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HomeMy WebLinkAboutSteve Bubalo Construction Company; 2001-02-08; 31821 Pt 2 of 2TECHNICAL SPECIFICATIONS FOR VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC4 IA. And SOUTH CARLSBAD STORM DRAIN PROJECTS Supplemental Provisions to Standard Specifications for Public Works Construction Part 1, General Requirements; Part 2, Construction Materials; and Part 3, Construction Methods DIVISION 1 - General Requirements 01025 Measurement and Payment DIVISION 2 - Site Work 02050 02140 02220 02230 02235 02300 02306 02310 02320 02330 02340 02350 02500 02529 02606 02843 Demolition Dewatering Excavation and Backfill Crushed Stone and Gravel Stone Riprap Tunneling Operations Microtunneling Jacking and Receiving Shafts Tunnel Support Systems Pipe Jacking Boring and Jacking (Steel Casing) Installation of Pipe in Tunnel Pavement Concrete Curbs, Gutters and Sidewalks Manholes and Drainage Structures Video Traffic Signal Detector Systems DIVISION 3 - Concrete 03100 Concrete Formwork 03200 Concrete Reinforcement 03251 Concrete Joints 03300 Cast-In-Place Concrete 03610 Contact Grouting 03620 Annular Low Density Cellular Concrete 03630 Compaction Grouting i DIVISION 5 - Metals 05540 Castings DIVISION 6 - Wood and Plastics 06651 Polyvinyl Chloride Liner for Concrete 06653 Filter Fabric DIVISION 15 - Mechanical 15051 Buried Piping Installation 15061 Ductile-Iron Fittings 15064 Reinforced Concrete Pipe 15073 Concrete Pressure Pipe 15074 PVC Pipe - AWWA C900 and C905 15075 PVC Pipe - SDR 35 15083 Fiberglass Mortar Pipe 15122 Piping Specialties VISTAKIARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS SECTION 01025 MEASUREMENT AND PAYMENT PART 1 - GENERAL 1.1 DESCRIPTION A. The bid items listed herein, beginning with Part 1.5, Measurement and Payment, refer to and are the same pay items listed in the Bid Form. They constitute all of the pay items for the completion of the Work. No direct or separate payment will be made for providing miscellaneous temporary or accessory works, services, CONTRACTORS field offices, site security, layout surveys, job signs, sanitary requirements, testing, safety devices, approval and record drawings, water supplies, power, removal of waste, security, bonds, insurance, and all other requirements of the General Conditions, Supplemental Provisions. and Contract Documents. Compensation for all such services, things and materials shall be included in the prices stipulated for the lump sum and unit price bid items listed herein. B. Each lump sum and unit bid price will be deemed to include an amount considered by CONTRACTOR to be adequate to cover CONTRACTORS overhead and profit for each separately identified item. 1.2 ENGINEERS ESTIMATE OF QUANTITIES A. ENGINEER’S estimated quantities for unit price pay items, as listed in the Bid Forms, are approximate only and are included solely for the purpose of comparison of Bids. The District does not expressly or by implication agree that the nature of the materials encountered below the surface of the ground or the actual quantities of material encountered or required will correspond therewith and reserves the right to increase or decrease any quantity, or to eliminate any quantity as the District may deem necessary. Except as provided in Part 1.3, CONTRACTOR or the District wiil not be entitled to any adjustment in a unit bid price as a result of any change in an estimated quantity and agrees to accept the aforesaid unit prices as complete and total compensation for any additions caused by changes or alterations in the Work ordered by the District. 1.3 PAYMENT A. The quantities listed in the Bid Forms will not govern final payment. Payment to the CONTRACTOR will be made only for actual quantities on Contract items constructed in accordance with the Contract Documents. Upon completion of construction, if the actual quantities show either an increase or decrease from the quantities listed in the Bid Forms, the Contract Unit Prices will prevail subject to the provisions of Section 3 of the Supplemental Provisions. B. Payment for each Bid Item shall be made at the applicable contract bid price which shall include full compensation to perform the Work. MEASUREMENT AND PAYMENT 01025-l VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC58 TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS C. Payment will not be made for materials wasted or disposed of in a manner not specified in the Contract Documents. This includes rejected material after it has been furnished. material rejected after it has been provided, and material provided outside the Plan lines. No compensation will be allowed for disposing of rejected or excess material. 1.4 RELATED PROVISIONS A. Payments to CONTRACTOR: Refer to Supplemental Provisions and Agreement. 6. Changes in Contract Price: Refer to Supplemental Provisions. 1.5 MEASUREMENT AND PAYMENT - SCHEDULE A A-l A-2 A-3 A-4 Bid Item: Mobilization 1. Measurement: The quantity to be paid for shall be a stipulated lump sum payment for the establishment and movement of preparatory work and operations for the Project. 2. Payment: Payment for bid item shall include but is not limited to the establishment and movement of preparatory work and operations including but not limited to personnel, equipment, supplies, and incidentals to the Project site; for the establishment of all offices and other facilities necessary for work on the Project; acquisition of a storage yard; project signs; and for all work and operations which must be performed, or costs incurred prior to commencing work, on the various items on the Project site to perform the work. Bid Item: Class “A” Field Office 1. Measurement: The quantity to be paid for shall be a monthly payment for providing a furnished Class “A” Field Otfice for the ENGINEER’s use. 2. Payment: Payment for bid item shall be as specified in Section 8-8, Basis of Payment, of the Supplemental Provisions. Bid Item: Construction Schedule 1. Measurement: The quantity to be paid for shall be a stipulated lump sum payment for preparation and updating of the project construction schedule. 2. Payment: Payment for bid item shall be as specified in Section 8-1.8, Measurement and Payment, of the Supplemental Provisions. Bid Item: Schedule A, Traffic Control 1. Measurement: The quantity to be paid for shall be a lump sum payment for traffic control. 2. Payment: Payment for bid item shall include but is not limited to provide and maintain construction signs, barricades, flashing arrow boards, cones, temporary and final striping, flagmen, temporary fencing and maintenance of access to private property. MEASUREMENT AND PAYMENT 010252 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS A-5 Bid Item: Traffic Signal Video Detection I. Measurement: The quantity to be paid for shall be a lump sum payment for traffic signal video detection system at the Jefferson Avenue intersections with Carlsbad Village Drive, Grand Avenue, Laguna Drive and Las Flores Drive, complete in place. 2. Payment: Payment for each bid item shall include but is not limited to furnishing and installing hardware, cameras, cable and appurtenances necessary for the operation of the video detection system during construction. The payment shall include reprogramming of the vehicle detection system to provide detection compatible with the existing vehicle detection system at each intersection. A-6 Bid Item: Schedule A, Construction Dewatering 1. Measurement: The quantity to be paid for shall be a lump sum payment for construction dewatering of excavations and shafts. 2. Payment: Payment for bid item shall include but is not limited to installation of ‘wells, sumps, vacuum well points or other approved methods of groundwater control for trench excavations and shaft construction; obtaining well permits; disposal of groundwater and related sampling and testing; removal of wells; surface restoration and incidental items necessary to perform the Work. A-7 Bid Item: North County Transit District Deposit (NCTD) 1. Measurement: The Contractor shall provide a stipulated cash deposit to the North County Transit District as specified. 2. Payment: The Contractor will not receive direct payment of any kind from the District or City. The cash deposit will be placed directly with the North County Transit District for costs associated with plan check of submittals, site inspection and repair of damage to railroad facilities caused by the Contractor’s Work. The amount remaining at the end of the project will be returned to the Contractor. A-6 Bid Item: Re-Establish Survey Monuments 1. Measurement: The quantity to be paid for shall be the number of each Street Survey Monuments as determined by actual account for each item constructed, complete in place. 2. Payment: Payment for bid item shall include but is not limited to restoration of existing street survey monuments, surveying to reset monument, adjustment to grade and control of surface waters to perform the Work. A-9 Bid Item: Temporary K-Rail Movable Barrier 1. Measurement: The quantity to be paid for shall be a lump sum payment for Temporary K-Rail Movable Barrier. 2. Payment: Payment for bid item shall include but is not limited to provide install temporary K-Rail Movable Barrier as necessary within the SDNR right- of-way as required by NCTD. MEASUREMENT AND PAYMENT 010253 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS A-IO Bid Item: Erosion Control 1. 2. Measurement: The quantity to be paid for shall be a lump sum payment for Erosion Control. Payment: Payment for bid item shall include but is not limited to provide erosion control systems in street areas in accordance with the plans, erosion control blankets on slopes, hydroseeding of slopes and control of surface waters to perform the Work. A-l 1 Bid Item: Hydroseeding 1. Measurement: The quantity to be paid for shall be a lump sum payment for site preparation and hydroseeding of all disturbed area within the railroad right-of-way. 2. Payment: Payment for bid item shall include but is not limited to soil preparation and amendment, mulch and hydroseeding. A-12 Bid Item: Trench Shoring 1. Measurement: The quantity to be paid for shall be a lump sum payment for shoring in open trenches required for construction of direct-bury pipelines. 2. Payment: Payment for the bid item shall include but is not limited to providing shoring for pipe trenches and manhole construction as necessary to perform the Work. A-13 Bid Item: Jacking Shafts 1. Measurement: The quantity to be paid for shall be the number of each jacking shaft shown on Plan Set 1 of 2. Additional payment shall not be provided for shafts constructed by the CONTRACTOR for the purpose of facilitating his Work except where specifically allowed by the Specifications and approved by the District. 2. Payment: Payment for the bid item shall include but is not limited to excavation; control of surface waters; shoring; preparation of shaft floor; thrust wall construction; set-up of above ground equipment, slurry separation system and generator; installation of jacking equipment and tunneling machine; safety equipment and railings; removal of shoring; backfill of shaft; noise attenuation; and all appurtenant activities necessary to perform the Work. A-14 Bid Item: Receiving Shafts 1. Measurement: The, quantity to be paid for shall be the number of each receiving shaft shown on Plan Set 1 of 2. Additional payment shall not be provided for shafts constructed by the CONTRACTOR for the purpose of facilitating his Work except where specifically allowed by the Specifications and approved by the District. 2. Payment: Payment for the bid item shall include but is not limited to excavation; shoring; breakout ring; control of surface waters; and backfill of shaft. MEASUREMENT AND PAYMENT 0102!5-4 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS A-l 5 Bid Item: 54” Interceptor Sewer - Open Trench Sta 8+13 to Sta 6+48 1. Measurement: The quantity to be paid for shall be the number of linear feet of 54” Interceptor Sewer pipeline installed in open trench construction as determined by actual measurements along the centerline of the pipeline, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide direct-bury pipe and specials; trench excavation; spoil disposal; preparation of subgrade; pipe bedding and compaction; trench backfill and compaction; joint grouting; liner welding; pipeline tests; and control of surface waters to perform the Work. A-16 Bid Item: 48” Interceptor Sewer - Open Trench Sta 6+48 to Sta 21 +I 7 1. Measurement: The quantity to be paid for shall be the number of linear feet of 48” Interceptor Sewer pipeline installed in open trench construction as determined by actual measurements along the centerline of the pipeline, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide direct-bury pipe and specials; trench excavation; spoil disposal; preparation of subgrade; pipe bedding and compaction; trench backfill and compaction; joint grouting; liner welding; pipeline tests; and control of surface waters to perform the Work. A-17 Bid Item: 48” Interceptor Sewer - Tamarack - Pipe Jacking or Tunnel Sta 21+17 to Sta 22*42 1. Measurement: The quantity to be paid for shall be a lump sum payment for 48” Interceptor Sewer pipeline installed by pipe jacking or tunneling method of construction of the pipeline, complete in place. 2. Payment: Payment for bid Item shall be for pipe jacking or tunnel only and shall include but is not limited to one of the following: a. For Pipe Jacking: Shafts construction; provide jacking pipe and specials; jacking the carrier pipe; spoil removal and disposal; shafts removal; shafts backfill and compaction; grouting; liner welding; pipeline testing; settlement surveys; and control of surface waters to perform the Work. b. For Tunnel: Shafts construction; tunnel construction; provide direct- bury pipe and specials; installing the carrier pipe; spoil removal and disposal; shafts removal; shafts backfill and compaction; grouting; liner welding; pipeline testing; settlement surveys; and control of surface waters to perform the Work. A-l 8 Bid Item: 48” Interceptor - Open Trench Sta 22+42 to Sta 49+02 1. Measurement: The quantity to be paid for shall be the number of linear feet of 48” Interceptor Sewer pipeline installed in open trench construction installation as determined by actual measurements along the centerline of the pipeline, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide direct-bury pipe and specials; trench excavation; spoil disposal; preparation of subgrade; pipe bedding and compaction; trench backfill and compaction; joint grouting; liner welding; pipeline tests; and control of surface waters to perform the Work. MEASUREMENT AND PAYMENT 01025-5 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS A-19 Bid Item: 42” Interceptor Sewer - Microtunnel or Open Trench Sta 49+02 to Sta 58+73- 1. Measurement: The quantity to be paid for shall be a lump sum payment for 42” Interceptor Sewer pipeline installed by microtunneling or open trench method of construction of the pipeline, complete in place. 2. Payment: Payment for bid item shall be for microtunnel or open trench only and shall include but is not limited to one of the following: a. For Microtunnel: Shafts construction; provide jacking pipe and specials; jacking the carrier pipe; pipe lubrication; muck removal and disposal; shafts removal; shafts backfill and compaction; grouting; liner welding; pipeline testing; settlement surveys; and control of surface waters to perform the Work. b. For Open Trench: Provide direct-bury pipe and specials; trench excavation; spoil disposal; preparation of subgrade; pipe bedding and compaction; trench backfill and compaction; joint grouting; liner welding; pipeline tests; and control of surface compaction; joint grouting; liner welding; pipeline tests; and control of surface waters to perform the Work. A-20 Bid Item: 42” Interceptor Sewer - Microtunnel Sta 144+24 to Sta 195+57 1. Measurement: The quantity to be paid for shall be the number of linear feet of 42” Interceptor Sewer pipeline installed by microtunneling as determined by actual measurements along the centerline of the pipeline, complete in place. Note: Shaft construction is not included in this item. 2. Payment: Payment for bid item shall include but is not limited to provide jacking pipe and specials; jacking the carrier pipe; pipe lubrication; muck removal and disposal; shafts removal, shaft backfill and compaction; grouting; liner welding; pipeline testing; settlement surveys; and control of surface waters to perform the Work. A-2 1 Bid Item: 36” Interceptor Sewer - Open Trench Sta 195+57 to Sta 198+72 1. Measurement: The quantity to be paid for shall be the number of linear feet of 36” Interceptor Sewer pipeline installed in open trench construction as determined by actual measurements along the centerline of the pipeline, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide direct-bury pipe and specials; trench excavation; spoil disposal; preparation of subgrade; pipe bedding and compaction; trench backfill and compaction; joint grouting; liner welding; pipeline tests; and control of surface waters to perform the Work. A-22 Bid Item: Typical Interceptor Sewer Manhole - 8 Ft. Dia. 1. Measurement: The quantity to be paid for shall be the number of typical Interceptor Sewer Manholes (8’-0” inside diameter) provided as determined by actual account for each item constructed, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide and construct cast-in-place concrete base with steel reinforcement; precast concrete manhole components; frame and cover castings; concrete collar; joint sealants; lining and coatings, excavation and spoil disposal, preparation of subgrade, backfill and compaction, capillary waterproofing, manhole tests, liner tests, and control of surface waters to perform the Work. MEASUREMENT AND PAYMENT 01025-6 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC58 TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS A-23 Bid Item: Typical Interceptor Sewer Manhole - 7 Ft. Dia. 1. Measurement: The quantity to be paid for shall be the number of typical Interceptor Sewer Manholes (7’-0” inside diameter) provided as determined by actual account for each item constructed, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide and construct cast-in-place concrete base with steel reinforcement; pre-cast concrete manhole components; frame and cover castings; concrete collar; joint sealants; lining and coatings, excavation and spoil disposal, preparation of subgrade, backfill and compaction, capillary waterproofing, manhole tests, liner tests, and control of surface waters to perform the Work. A-24. Bid Item: Sewer Manhole 1 - Cast-In-Place Structure 1. Measurement: The quantity to be paid for shall be a lump sum payment for construction of Sewer Manhole 1 on the existing interceptor sewer, complete in place. 2. Payment: Payment for bid item shall include but is not limited to by-pass existing sewage flow; construct reinforced cast-in-place concrete base; sawcutting and removal of existing 42” RCP sewer; concrete collar; frame and cover castings; joint sealants; excavation; preparation of subgrade; backfill and compaction; capillary waterproofing; manhole tests; and control of surface waters to perform the Work. A-25 Bid Item: Asphalt Concrete Pavement - 2-l/2” Base Course, Trench Excavation and Repair 1. Measurement: The quantity to be paid for shall be the number of tons of asphalt concrete pavement base course provided as determined by actual delivery tickets furnished to the District for each load of asphalt concrete delivered to the Project site. 2. Payment: Payment for bid item shall include but is not limited to provide and place asphalt base course; prime coat; and tack coat to perform the Work. A-26 Bid Item: Asphalt Concrete Pavement - 1 -l/2” Surface Course, Trench Excavation and Repair 1. Measurement: The quantity to be paid for shall be the number of tons of asphalt concrete pavement surface course provided as determined by actual delivery tickets furnished to the District for each load of asphalt concrete delivered to the Project site. 2. Payment: Payment for bid item shall include but is not limited to provide and place asphalt surface course; prime coat; and tack coat to perform the Work. A-27 Bid Item: Aggregate Base - 8” 1. Measurement: The quantity to be paid for shall be the number of cubic yards of aggregate base provided as determined by actual measurements complete in place. 2. Payment: Payment for bid item shall include but is not limited to furnish, place and compact aggregate base to perform the Work. A-28 Bid Item: Sawcut Pavement 1. Measurement: The quantity to be paid for shall be the number of linear feet of concrete pavement sawcut provided as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide pavement sawcutting as necessary to perform the Work. MEASUREMENT AND PAYMENT 010257 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS A-29 Bid Item: Remove Asphalt Concrete Pavement 1. Measurement: The quantity to be paid for shall be the number of square yards of 4” thick (* l/2”) asphalt concrete pavement removal provided as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to removal of asphalt pavement; and load, haul and dump asphalt to legal disposal/recycle as necessary to perform the Work. A-30 Bid Item: Remove and Replace Concrete Curb 1. Measurement: The quantity to be paid for shall be the number of linear feet of removal and replacement of concrete curb provided as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to construct concrete curb; sawcut concrete curb; removal of curb; and load, haul and dispose concrete to legal disposal as necessary to perform the Work. A-31 Bid Item: Remove and Replace Concrete Curb and Gutter 1. Measurement: The quantity to be paid for shall be the number of linear feet of removal and replacement of concrete curb and gutter provided as detemrined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to construct concrete curb and gutter; sawcut concrete curb and gutter; removal of curb and gutter; and load, haul and dispose concrete to legal disposal as necessary to perform the Work. A-32 Bid Item: Remove and Replace Concrete Cross Gutter 1. Measurement: The quantity to be paid for shall be the number of square feet of removal and replacement of concrete cross gutter provided as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to construct concrete cross gutter; removal of cross gutter; and load, haul and dispose concrete to legal disposal as necessary to perform the Work. A-33 Bid Item: Remove and Replace Concrete Sidewalk 1. Measurement: The quantity to be paid for shall be the number of square feet of removal and replacement of concrete sidewalk provided as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to construct concrete sidewalks; pedestrian ramps; driveways; removal of sidewalk; and load, haul and dispose concrete to legal disposal as necessary to perform the Work. A-34 Bid Item: Remove and Replace Landscape Irrigation 1. Measurement: The quantity to be paid for shall be a lump sum payment for removal and replacement of landscape and irrigation as shown on sheet 12 and at station 77+29, complete in place. 2. Payment: Payment for bid item shall include but is not limited to removal and disposal of landscaping, irrigation pipe and spray heads; removal and replacement of a 2” backflow prevention assembly for irrigation; replacement of landscape and irrigation materials in kind; and removal and disposal of a tree at station 77+29 as necessary to perform the Work. MEASUREMENT AND PAYMENT 010258 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS A-35 Bid Item: Abandon Manhole 1. Measurement: The quantity to be paid for shall be the number of each manhole to be abandoned as determined by actual account for each item, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide pre- cast concrete Rat top; joint sealant; permanent pipe plugs; fill sand; excavation; backfill and compaction; remove frame and cover; remove grade rings and cone; and provide legal disposal as necessary to perform the Work. A-36 Bid item: Abandon Interceptor Sewer 1. Measurement: The quantity to be paid for shall be the linear feet of existing interceptor sewer to be cleaned and video inspected as determined by actual measurement. 2. Payment: Payment for bid item shall include but is not limited to cleaning the existing interceptor; disposal of waste; and documentation of pipe condition with CCTV equipment. A-37 Bid Item: Sewage Flow Transfer at Manhole 1 1. Measurement: The quantity to be paid for shall be a lump sum payment for Work required to temporarily divert and permanently transfer flow from the existing collector and interceptor sewers to the new interceptor sewer at Manhole 1 complete in place. * 2 Payment: Payment for bid item shall include but is not limited to confined space entry of existing and new manholes; provide temporary and permanent pipe plugs, pumping equipment, and incidental items as necessary to perform the Work. A-38 Bid Item: Sewage Flow Transfer at Manhole 2 1. Measurement: The quantity to be paid for shall be a lump sum payment for Work required to temporarily divert and permanently transfer flow from the existing collector and interceptor sewers to the new interceptor sewer at Manhole 2 complete in place. 2. Payment: Payment for bid item shall include but is not limited to confined space entry of existing and new manholes; provide temporary and permanent pipe plugs, pumping equipment, and incidental items as necessary to perform the Work. A-39 Bid Item: Sewage Flow Transfer at Manhole 3 1. Measurement: The quantity to be paid for shall be a lump sum payment for Work required to temporarily divert and permanently transfer flow from the existing collector and interceptor sewers to the new interceptor sewer at Manhole 3 complete in place. 2. Payment: Payment for bid item shall include but is not limited to confined space entry of existing and new manholes; provide temporary and permanent pipe plugs, pumping equipment, and incidental items as necessary to perform the Work. MEASUREMENT AND PAYMENT 01025-Q VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS A-40 Bid Item: Sewage Flow Transfer at Manhole 4 1. Measurement: The quantity to be paid for shall be a lump sum payment for Work required to temporarily divert and permanently transfer flow from the existing collector and interceptor sewers to the new interceptor sewer at Manhole 4 complete in place. 2. Payment: Payment for bid item shall include but is not limited to confined space entry of existing and new manholes; provide temporary and permanent pipe plugs, pumping equipment, and incidental items as necessary to perfomr the Work. A-41 Bid Item: Sewage Flow Transfer at Manhole 6 1. Measurement: The quantity to be paid for shall be a lump sum payment for Work required to temporarily divert and permanently transfer flow from the existing collector and interceptor sewers to the new interceptor sewer at Manhole 6 complete in place. 2. Payment: Payment for bid item shall include but is not limited to confined space entry of existing and new manholes; provide temporary and permanent pipe plugs, pumping equipment, and incidental items as necessary to perform the Work. A-42 Bid Item: Sewage Flow Transfer at Manhole 8 1. Measurement: The quantity to be paid for shall be a lump sum payment for Work required to temporarily divert and permanently transfer flow from the existing collector and interceptor sewers to the new interceptor sewer at Manhole 8 complete in place. 2. Payment: Payment for bid item shall include but is not limited to confined space entry of existing and new manholes; provide temporary and permanent pipe plugs, pumping equipment, and incidental items as necessary to perform the Work. A-43 Bid Item: Sewage Flow Transfer at Manhole 10 1. Measurement: The quantity to be paid for shall be a lump sum payment for Work required to temporarily divert and permanently transfer flow from the existing collector and interceptor sewers to the new interceptor sewer at Manhole 10 complete in place. 2. Payment: Payment for bid item shall include but is not limited to confined space entry of existing and new manholes; provide temporary and permanent pipe plugs, pumping equipment, and incidental items as necessary to perform the Work. A-44 Bid Item: Sewage Flow Transfer at Manhole 11 1. Measurement: The quantity to be paid for shall be a lump sum payment for Work required to temporarily divert and permanently transfer flow from the existing collector and interceptor sewers to the new interceptor sewer at Manhole 11 complete in place. 2. Payment: Payment for bid item shall include but is not limited to confined space entry of existing and new manholes; provide temporary and permanent pipe plugs, pumping equipment, and incidental items as necessary to perform the Work. MEASUREMENT AND PAYMENT 01625-10 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS A-45 Bid Item: Sewage Flow Transfer at Manhole 15 1. Measurement: The quantity to be paid for shall be a lump sum payment for Work required to temporarily divert and penanently transfer flow from the existing collector and interceptor sewers to the new interceptor sewer at Manhole 15 complete in place. 2. Payment: Payment for bid item shall include but is not limited to confined space entry of existing and new manholes; provide temporary and permanent pipe plugs, pumping equipment, and incidental items as necessary to perform the Work. A-48 Bid Item: Sewage Flow Transfer at Manhole 17 1. Measurement: The quantity to be paid for shall be a lump sum payment for Work required to temporarily divert and permanently transfer flow from the existing collector and interceptor sewers to the new interceptor sewer at Manhole 17 complete in place. 2. Payment: Payment for bid item shall include but is not limited to confined space entry of existing and new manholes; provide temporary and permanent pipe plugs, pumping equipment, and incidental items as necessary to perform the Work. A-47 Bid Item: Sewage Flow Transfer- Exist. Accesshole 53 1. Measurement: The quantity to be paid for shall be a lump sum payment for Work required to enter Access Hole 53 and divert flow to the new interceptor, complete in place. 2. Payment: Payment for bid item shall include but is not limited to confined space entry of existing Access Hole 53 and removal of existing stop logs from the channel; remove existing wood bulkhead in the 36” interceptor sewer; install new pipe plug in existing 27” interceptor and install new 2”x8” stop logs in the existing fiberglass guide frame and incidental items as necessary to perform the Work. A-48 Bid Item: Sewage Flow Transfer - 2 Manholes at Grand Ave and Roosevelt St 1. Measurement: The quantity to be paid for shall be a lump sum payment for the diversion of remaining sewage flow from the existing interceptor sewer to the existing collector sewer as shown in the plans, complete in place. 2. Payment: Payment for bid item shall include but is not limited to excavation and backfill; removal and disposal of Manhole ‘H”; providing permanent pipe plugs; install 8” PVC sewer pipe with bedding; mechanical coupling; reshape channel bottoms in Manholes ‘J” & ‘K”; and provide temporary bypass of the sewage flow in the existing collector sewer as necessary to perform the Work. A-49 Bid Item: Televising New Sewer Pipelines 1. Measurement: The quantity to be paid for shall be a lump sum payment for televising new, completed interceptor sewer and collector sewer pipelines, upon final acceptance by the District. 2. Payment: Payment for bid item shall include but is not limited to providing televising services to provide and record on video tape completed portions of the interior of interceptor and collector sewer pipelines as those portions o pipelines are granted final acceptance by the District. The copies of video tape cassettes shall be submitted to the District. (continued on next page) MEASUREMENT AND PAYMENT 0102511 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS 1.6 MEASUREMENT ANB PAYMENT - SCHEDULE B B-l Bid Item: Schedule B, Traffic Control 1. Measurement: The quantity to be paid for shall be a lump sum payment for traffic control. 2. Payment: Payment for bid item shall include but is not limited to provide and maintain construction signs, barricades, flashing arrow boards, cones, temporary and final striping, flagmen, temporary fencing and maintenance of access to private property. B-2 Bid Item: Schedule B, Construction Dewatering 1. Measurement: The quantity to be paid for shall be a lump sum payment for construction dewatering of excavations and shafts. 2. Payment: Payment for bid item shall include but is not limited to installation of wells, sumps, vacuum well points or other approved methods of groundwater control for trench excavations and shaft construction; obtaining well permits; disposal of groundwater and related sampling and testing; removal of wells; surface restoration and incidental items necessary to perform the Work. B-3 Bid Item: 8” PVC Sewer Lateral and Cleanout 1. Measurement: The quantity to be paid for shall be the number of each 6” PVC sewer lateral and cleanout as determined by actual account for each item complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide sewer lateral piping, cleanouts, and appurtenances, connections to collector sewer, excavation, trench backfill and compaction, pipe bedding and compaction, trench resurfacing, and control of surface waters to perform the Work. B-4 Bid Item: 8” PVC Sewer 1. Measurement: The quantity to be paid for shall be the number of linear feet of 8” PVC Sewer pipeline installed in open trench construction as determined by actual measurements along the centerline of the pipeline, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide piping and appurtenances; trench excavation; spoil disposal; preparation of subgrade; pipe bedding and compaction; trench backfill and compaction; pipeline tests and control of surface waters to perform the Work. B-5 Bid Item: 10” PVC Sewer 1. Measurement: The quantity to be paid for shall be the number of linear feet of 10” PVC Sewer pipeline installed in open trench construction as determined by actual measurements along the centerline of the pipeline, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide piping and appurtenances; trench excavation; spoil disposal; preparation of subgrade; pipe bedding and compaction; trench backfill and compaction; pipeline tests and control of surface waters to perform the Work. . MEASUREMENT AND PAYMENT 0102512 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS B-6 Bid Item: 12” PVC Sewer 1. Measurement: The quantity to be paid for shall be the number of linear feet of 12” PVC Sewer pipeline installed in open trench construction as determined by actual measurements along the centerline of the pipeline, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide piping and appurtenances; trench excavation; spoil disposal; preparation of subgrade; pipe bedding and compaction; trench backfill and compaction; pipeline tests and control of surface waters to perform the Work. B-7 Bid Item: 15” PVC Sewer - Boring and Jacking 1. Measurement: The quantity to be paid for shall be the number of linear feet of 15” PVC Sewer pipeline installed by the boring and jacking method of installation as determined by actual measurements along the centerline of the pipeline, complete in place. 2. Payment: Payment for bid item shall include but is not limited to shaft construction and removal, provide piping, appurtenances, and steel casing, jacking the steel casing, muck removal and disposal, contact grout void space between casing and soil, compaction grouting, carrier pipe installation and blocking materials, grout annular space between pipe and casing, liner welding, pipeline testing, and settlement surveys. B-8 Bid Item: Modify Existing Manhole 1. Measurement: The quantity to be paid for shall be the number of each Modify Existing Manhole as determined by actual account for each item complete in place. 2. Payment: Payment for bid item shall include but is not limited to demolition of existing manhole channel, reforming of manhole channel, excavation, backfill and compaction, bedding, and control of surface workers to perform the Work. B-9 Bid Item: Remove Existing VCP Sewer (8” to 12”) 1. Measurement: The quantity to be paid for shall be the number of linear feet of removal of existing VCP sewer piping and appurtenances as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to removal of piping and appurtenances, excavation, backfill and compaction, control of surface waters, and haul and legally dispose piping as necessary to perform the Work. B-l 0 Bid Item: Reconstruct Sewer Lateral 1. Measurement: The quantity to be paid for shall be the number of each reconstruct sewer lateral as determined by actual account for each item complete in place. 2. Payment: Payment for bid item shall include but is not limited to removal of portions of existing sewer lateral, construction of new sewer lateral piping and fittings, connection to sewer main, excavation, trench backfill and compaction, pipe bedding and compaction, trench resurfacing, and control of surface waters to perform the Work. MEASUREMENT AND PAYMENT 0102513 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCBB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS B-l 1 Bid Item: Reconstruct Water Service 1. Measurement: The quantity to be paid for shall be the number of each reconstruct water service as determined by actual account for each item complete in place. 2. Payment: Payment for bid item shall include but is not limited to removal of portions of existing water service, construction of new water service piping and fittings, connection to water main, excavation, trench backfill and compaction, pipe bedding and compaction, trench resurfacing and control of surface waters to perform the Work. B-12 Bid Item: Remove Existing Sewer Manhole 1. Measurement: The quantity to be paid for shall be the number of each Remove Existing Sewer Manhole as determined by actual account for each item complete in place. 2. Payment: Payment for bid item shall include but is not limited to removal of concrete structure, excavation, backfill and compaction, control of surface waters to perform the work, and haul and disposal of pipe to legal disposal as necessary to perform the Work. B-13 Bid Item: Standard CMWD Manhole (Accesshole) 1. Measurement: The quantity to be paid for shall be the number of each Standard CMWD Sewer Manhole (Type Sl) provided as determined by actual account for each item constructed, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide and construct cast-in-place concrete base; pre-cast concrete manhole components; concrete collar; frame and cover castings; joint sealants; excavation; preparation of subgrade; backfill and compaction; manhole tests; and control of surface waters to perform the Work. B-14 Bid Item: Remove Exist. 18” DI Sewer 1. Measurement: The quantity to be paid for shall be the number of linear feet of removal of existing 18” ductile iron sewer piping and appurtenances as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to removal of piping and appurtenances, excavation, backfill and compaction, control of surface waters, and haul and legally dispose piping as necessary to perform the Work. B-15 Bid Item: Re-Establish Survey Monuments 1. Measurement: The quantity to be paid for shall be the number of each Street Survey Monuments as determined by actual account for each item constructed, complete in place. 2. Payment: Payment for bid item shall include but is not limited to restoration of existing street survey monuments, surveying to reset monument, adjustment to grade and control of surface waters to perform the Work. MEASUREMENT AND PAYMENT 0102514 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS B-16 Bid Item: Asphalt Concrete Pavement - 2-l/2” Base Course, Trench Excavation and Repair 1. Measurement: The quantity to be paid for shall be the number of tons of asphalt concrete pavement base course provided as determined by actual delivery tickets furnished to the District for each load of asphalt concrete delivered to the Project site. 2. Payment: Payment for bid item shall include but is not limited to provide and place asphalt base course; prime coat; and tack coat to perform the Work. B-17 Bid Item: Asphalt Concrete Pavement - 1 -I/2” Surface Course, Trench Excavation and Repair 1. Measurement: The quantity to be paid for shall be the number of tons of asphalt concrete pavement surface course provided as determined by actual delivery tickets furnished to the District for each load of asphalt concrete delivered to the Project site. 2. Payment: Payment for bid item shall include but is not limited to provide and place asphalt surface course; prime coat; and tack coat to perform the Work. B-18 Bid Item: : Aggregate Base - 8”. Trench Excavation and Repair 1. Measurement: The quantity to be paid for shall be the number of cubic yards of aggregate base provided as determined by actual measurements complete in place. 2. Payment: Payment for bid item shall include but is not limited to furnish, place and compact aggregate base to perform the Work. B-19 Bid Item: Sawcut Pavement 1. Measurement: The quantity to be paid for shall be the number of linear feet of concrete pavement sawcut provided as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide pavement sawcutting as necessary to perfom, the Work. B-20 Bid Item: Remove Asphalt Concrete Pavement 1. Measurement: The quantity to be paid for shall be the number of square yards of 4” thick (+ l/2”) asphalt concrete pavement removal provided as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to removal of asphalt pavement; and load, haul and dump asphalt to legal disposal/recycle as necessary to perform the Work. B-21 Bid Item: Remove and Replace Concrete Cross Gutter 1. Measurement: The quantity to be paid for shall be the number of square feet of removal and replacement of concrete cross gutter provided as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to construct concrete cross gutter; removal of cross gutter; and load, haul and dispose concrete to legal disposal as necessary to perform the Work. MEASUREMENT AND PAYMENT 0102515 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS B-22 Bid Item: Sewage Flow Transfer at Manhole 10-B .d 1. Measurement:-The quantity to be paid for shall be a lump sum payment for Work required to temporarily divert and permanently transfer flow from the existing collector and interceptor sewers to the new interceptor sewer at Manhole 1OB complete in place. 2. Payment: Payment for bid item shall include but is not limited to confined space entry of existing and new manholes; provide temporary and permanent pipe plugs, pumping equipment, and incidental items as necessary to perform the Work. B-23 Bid Item: Sewage Flow Transfer at Manhole 1 OC 1. Measurement: The quantity to be paid for shall be a lump sum payment for Work required to temporarily divert and permanently transfer flow from the existing collector and interceptor sewers to the new interceptor sewer at Manhole 1 OC complete in place. 2. Payment: Payment for bid item shall include but is not limited to confined space entry of existing and new manholes; provide temporary and permanent pipe plugs, pumping equipment, and incidental items as necessary to perform the Work. B-24 Bid Item: Sewage Flow Transfer at Manhole 1OE 1. Measurement: The quantity to be paid for shall be a lump sum payment for Work required to temporarily divert and permanently transfer flow from the existing collector and interceptor sewers to the new interceptor sewer at Manhole 1OE complete in place. 2. Payment: Payment for bid item shall include but is not limited to confined space entry of existing and new manholes; provide temporary and permanent pipe plugs, pumping equipment, and incidental items as necessary to perform the Work. B-25 Bid Item: Sewage Flow Transfer at Manhole 1OG 1. Measurement: The quantity to be paid for shall be a lump sum payment for Work required to temporarily divert and permanently transfer flow from the existing collector and interceptor sewers to the new interceptor sewer at Manhole 1OG complete in place. 2. Payment: Payment for bid item shall include but is not limited to confined space entry of existing and new manholes; provide temporary and permanent pipe plugs, pumping equipment, and incidental items as necessary to perform the Work. B-26 Bid Item: Connect From Exist. Manhole to New Manhole 1. Measurement: The quantity to be paid for shall be a lump sum payment for connecting new collector sewer piping from existing manholes to new manholes, complete in place. 2. Payment: Payment for bid item shall include but not limited to provide piping and appurtenances; connect to existing and new manholes; trench excavation; spoil disposal; preparation of’ subgrade; pipe bedding and compaction; trench backfill and compaction; pipeline tests and control of surface waters to perform the Work. (continued on next page) MEASUREMENT AND PAYMENT 0102516 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS 1.7 MEASUREMENT AND PAYMENT - SCHEDULE C C-l c-2 c-3 C-4 c-5 C-6 Bid Item: Mobilization 1. Measurement: The quantity to be paid for shall be a stipulated lump sum payment for the establishment and movement of preparatory work and operations for the Project. 2. Payment: Payment for bid item shall include but is not limited to the establishment and movement of preparatory work and operations including but not limited to personnel, equipment, supplies, and incidentals to the Project site; for the establishment of all offices and other facilities necessary for work on the Project; acquisition of a storage yard; project signs; and for all work and operations which must be performed, or costs incurred prior to commencing work, on the various items on the Project site to perform the Work. Bid Item: Construction Schedule 1. Measurement: The quantity to be paid for shall be a stipulated lump sum payment for preparation and updating of the project construction schedule. 2. Payment: Payment for bid item shall be as specified in Section 6-1.8, Measurement and Payment, of the Special Provisions. Bid Item: Schedule C, Traffic Control 1. Measurement: The quantity to be paid for shall be a lump sum payment for traffic control. 2. Payment: Payment for bid item shall include but is not limited to provide and maintain construction signs, barricades, flashing arrow boards, cones, temporary and final striping, flagmen, temporary fencing and maintenance of access to private property. Bid Item: Schedule C, Construction Dewatering 1. Measurement: The quantity to be paid for shall be a lump sum payment for construction dewatering of excavations and shafts. 2. Payment: Payment for bid item shall include but is not limited to installation of wells, sumps, vacuum well points or other approved methods of groundwater control for trench excavations and shaft construction; obtaining well permits; disposal of groundwater and related sampling and testing; removal of wells; surface restoration and incidental items necessary to perform the Work. Bid Item: Re-Establish Survey Monuments 1. Measurement: The quantity to be paid for shall be the number of each Street Survey Monuments as determined by actual account for each item constructed, complete in place. 2. Payment: Payment for bid item shall include but is not limited to restoration of existing street survey monuments,. surveying to reset monument, adjustment to grade and control of surface waters to perform the Work. Bid Item: Temporary K-Rail Movable Barrier 1. Measurement: The quantity to be paid for shall be a lump sum payment for Temporary K-Rail Movable Barrier. 2. Payment: Payment for bid item shall include but is not limited to provide install temporary K-Rail Movable Barrier as necessary within the SDNR right- of-way as required by NCTD. MEASUREMENT AND PAYMENT 0102517 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS c-7 Bid Item: Erosion Control 1. Measurement: The quantity to be paid for shall be a lump sum payment for Erosion Control. 2. Payment: Payment for bid item shall include but is not limited to provide erosion control systems in street areas In accordance with the plans, erosion control blankets on slopes, and control of surface waters to perform the work. C-8 Bid Item: Slope Grading 1. Measurement: The quantity to be paid for shall be a lump sum payment for the slope repair shown on sheet 28 of plan set 2, complete in place. 2. Payment: Payment for bid item shall include but is not limited to backcutting of existing slope, overexcavation and gravel backfill, filter fabric, placement and compaction of fill material, fine grading slope rounding, erosion control blanket and control of surface waters to perform the Work. c-9 Bid Item: Trench Shoring 1. Measurement: The quantity to be paid for shall be a lump sum payment for shoring in open trenches required for construction of direct-bury pipelines. 2. Payment: Payment for the bid item shall include but is not limited to providing shoring for pipe trenches and manhole construction as necessary to perform the Work. C-10 Bid Item: 18” Storm Drain 1. Measurement: The quantity to be paid for shall be the number of linear feet of 18” Storm Drain pipeline provided as determined by actual measurements along the centerline of the pipeline, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide pipe; trench excavation; preparation of subgrade; pipe bedding and compaction; trench backfill and compaction; pipeline tests; and control of surface waters to perform the Work. C-l 1 Bid Item: 24” Storm Drain I. Measurement: The quantity to be paid for shall be the number of linear feet of 24” Storm Drain pipeline provided as determined by actual measurements along the centerline of the pipeline, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide pipe; trench excavation; preparation of subgrade; pipe bedding and compaction; trench backfill and compaction; pipeline tests; and control of surface waters to perform the Work. C-12 Bid Item: 30” Storm Drain 1. Measurement: The quantity to be paid for shall be the number of linear feet of 30” Storm Drain pipeline provided as determined by actual measurements along the centerline of the pipeline, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide pipe; trench excavation; preparation of subgrade; pipe bedding and compaction; trench backfill and compaction; pipeline tests; and control of surface waters to perform the Work. MEASUREMENT AND PAYMENT 0102518 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS C-13 Bid Item: 38” Storm Drain 1. Measurement: The quantity to be paidfor shall be the number of linear feet of 36” Storm Drain pipeline provided as determined by actual measurements along the centerline of the pipeline, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide pipe; trench excavation; preparation of subgrade; pipe bedding and compaction; trench backfill and compaction; pipeline tests; and control of surface waters to perform the Work. C-14 Bid Item: 42” Storm Drain 1. Measurement: The quantity to be paid for shall be the number of linear feet of 42” Storm Drain pipeline provided as determined by actual measurements along the centerline of the pipeline, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide pipe; trench excavation; preparation of subgrade; pipe bedding and compaction; trench backfill and compaction; pipeline tests; and control of surface waters to perform the Work. C-15 Bid Item: 48” Storm Drain 1. Measurement: The quantity to be paid for shall be the number of linear feet of 48” Storm Drain pipeline provided as determined by actual measure along the centerline of the pipeline, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide pipe; trench excavation; preparation of subgrade; pipe bedding and compaction; trench backfill and compaction; pipeline tests; and control of surface waters to perform the Work. C-18 Bid Item: 54” Storm Drain 1. Measurement: The quantity to be paid for shall be the number of linear feet of 54” Storm Drain pipeline provided as determined by actual measure along the centerline of the pipeline, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide pipe; trench excavation; preparation of subgrade; pipe bedding and compaction; trench backfill and compaction; pipeline tests; and control of surface waters to perform the Work. C-17 Bid Item: 80” Storm Drain 1. Measurement: The quantity to be paid for shall be the number of linear feet of 60” Storm Drain pipeline provided as determined by actual measure along the centerline of the pipeline, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide pipe; trench excavation; preparation of subgrade; pipe bedding and compaction; trench backfill and compaction; pipeline tests; and control of surface waters to perform the Work. C-18 Bid Item: 72” Storm Drain 1. Measurement: The quantity to be paid for shall be the number of linear feet of 72” Storm Drain pipeline provided as determined by actual measure along the centerline of the pipeline, complete in place. 2. Payment: Payment for bid item shall include. but is not limited to provide pipe; trench excavation; preparation of subgrade; pipe bedding and compaction; trench backfill and compaction; pipeline tests; and control of surface waters to perform the Work. MEASUREMENT AND PAYMENT 01025-19 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS C-19 Bid Item: 84” Storm Drain - Open Trench Sta 4+44 to Sta 4+70 1. Measurement: The quantity to be paid for shall be the number of linear feet of 84” Storm Drain pipeline provided as determined by actual measure along the centerline of the pipeline, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide pipe; trench excavation; preparation of subgrade; pipe bedding and compaction; trench backfill and compaction; pipeline tests; and control of surface waters to perform the Work. C-20 Bid Item: 84” Storm Drain - Open Trench Sta 22+18 to Sta 44+13 1. Measurement: The quantity to be paid for shall be the number of linear feet of 84” Storm Drain pipeline provided as determined by actual measure along the centerline of the pipeline, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide pipe; trench excavation; preparation of subgrade; pipe bedding and compaction; trench backfill and compaction; pipeline tests; and control of surface waters to perform the Work. C-21 Bid Item: 24” Storm Drain - Boring and Jacking with Steel Casing 1. Measurement: The quantity to be paid for shall be the number of linear feet of 24” Storm Drain Pipe installed by the boring and jacking method of installation as determined by actual measurements along the centerline of the pipeline, complete in place. 2. Payment: Payment for bid item shall include but is not limited to shaft construction and removal, provide pipe, specials and steel casing; jacking the steel casing; muck removal and disposal; contact grout void space between casing and soil; compaction grouting; carrier pipe installation and blocking materials; grout annular space between pipe and casing; liner welding; pipeline testing and settlement surveys. C-22 Bid Item: 84” Storm Drain - Pipe Jacking or Open Trench Sta 4+70 to Sta 20+74 1. Measurement: The quantity to be paid for shall be a lump sum payment for 84” Storm Drain Pipe installed by the boring and jacking or open trench method of construction of the pipeline, complete in place. 2. Payment: Payment for bid item shall be for pipe jacking or open trench only and shall include but is not limited to on eof the following: a. For Pipe Jacking: Shafts construction; provide jacking pipe and specials; jacking the carrier pipe; spoil removal and disposal; shafts backfill and compaction; grouting; liner welding; pipeline testing; settlement surveys; and control of surface waters to perform the Work. b. For Open Trench: Provide direct-bury pipe and specials; trench excavation; spoil disposal; preparation of subgrade; pipe bedding and compaction; trench backfill and compaction; joint grouting; liner welding; pipeline tests; and control of surface waters to perform the Work. MEASUREMENT AND PAYMENT 0102520 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC58 TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS C-23 Bid Item: 84” Storm Drain - Pipe Jacking or Tunnel Sta 20+74 to Sta 22+16 1. Measurement: The quantity to be paid for shall be a lump sum payment for 84” Storm Drain Pipe installed by pipe jacking or tunneling method of construction of the pipeline, complete in place. 2. Payment: Payment for bid item shall be for pipe jacking or tunnel only and shall include but is not limited to one of the following: a. For Pipe Jacking: Shafts construction; provide jacking pipe and specials; jacking the carrier pipe; spoil removal and disposal; shafts backfill and compaction; grouting; liner welding; pipeline testing; settlement surveys; and control of surface waters to perform the Work. b. For Tunnel: Shafts construction; tunnel construction; provide direct- bury pipe and specials; installing the carrier pipe; spoil removal and disposal; shafts removal; shafts backfill and compaction; grouting; liner welding; pipeline testing; settlement surveys; and control of surface waters to perform the Work. C-24 Bid Item: 8’ x 3’ Reinforced Concrete Box Culvert 1. Measurement: The quantity to be paid for shall be the number of linear feet of 8’ x 3’ Reinforced Concrete Box Culvert provided as determined by actual measurements along the centerline of the Reinforced Concrete Box Culvert, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide and install pipe, trench excavation, preparation of subgrade, pipe bedding and compaction, trench backfill and compaction, forming, tests, and control of surface waters to perform the Work. C-25 Bid Item: 5’ x 3’ Reinforced Concrete Box Culvert 1. Measurement: The quantity to be paid for shall be the number of linear feet of 5’ x 3’ Reinforced Concrete Box Culvert, provided as determined by actual measurements along the centerline of the Reinforced Concrete Box Culvert, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide and install pipe, trench excavation, preparation of subgrade, pipe bedding and compaction, trench backfill and compaction, forming, tests, and control of surface waters to perform the Work. C-26 Bid Item: Curb Inlet - Type B, (L = 5’ to 10’) 1. Measurement: The quantity to be paid for shall be the number of each Curb Inlet, Type B, L = 5’ to 10’ including modified Type B curb inlets provided as determined by actual account for each item, complete in place. 2. Payment: Payment for bid item shall include but is not limited to construct reinforced cast-in-place concrete structure; frame and cover castings; manhole steps; protection bar; support bolts; steel angle; excavation; concrete inlet depression; preparation of subgrade; backfill and compaction; control of surface waters; and modifications to provide a Type F catch basin opening at back of inlet where shown to perform the Work. MEASUREMENT AND PAYMENT 01025-21 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS C-27 Bid Item: Curb Inlet - Type B-l, (L = 11’ to 15’) 1. Measurement: The quantity to be paid for shall be the number of each Curb Inlet, Type B-l, L = 11’ to 15’ provided as determined by actual account for each item, complete in place. 2. Payment: Payment for bid item shall include but is not limited to construct reinforced cast-in-place concrete structure; frame and cover castings; manhole steps; protection bar; support bolts; steel angle; excavation; concrete inlet depression; preparation of subgrade; backfill and compaction; and control of surface waters to perform the Work. C-28 Bid Item: Curb Inlet-Type B-1, (L = 16’ to 20’) 1. Measurement: The quantity to be paid for shall be the number of each Curb Inlet, Type B-l, L = 16’ to 20’ provided as determined by actual account for each item, complete in place. 2. Payment: Payment for bid item shall include but is not limited to construct reinforced cast-in-place concrete structure; frame and cover castings; manhole steps; protection bar; support bolts; steel angle; excavation; concrete inlet depression; preparation of subgrade; backfill and compaction; and control of surface waters to perform the Work. C-29 Bid Item: Curb Inlet - Type B-1, (L = 21’ to 25’) 1. Measurement: The quantity to be paid for shall be the number of each Curb Inlet, Type B-l, L = 21’ to 25’ provided as determined by actual account for each item, complete in place. 2. Payment: Payment for bid item shall include but is not limited to construct reinforced cast-in-place concrete structure; frame and cover castings; manhole steps; protection bar; support bolts; steel angle; excavation; concrete inlet depression; preparation of subgrade; backfill and compaction; and control of surface waters to perform the Work. C-30 Bid Item: Storm Drain Cleanout Type B-5 1. Measurement: The quantity to be paid for shall be the number of each Storm Drain Cleanout, Type B-5 provided as determined by actual account for each item, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide cast-in-place concrete base; concrete collar; frame and cover castings; precast concrete components; joint sealants; manhole steps; excavation; preparation of subgrade; backfill and compaction; and control of surface waters to perform the Work. C-31 Bid Item: Storm Drain Cleanout Type B-8 1. Measurement: The quantity to be paid for shall be the number of each Storm Drain Cleanout, Type B-6 provided as determined by actual account for each item, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide cast-in-place concrete base; concrete collar; frame and cover castings; precast concrete components; joint sealants; excavation; preparation of subgrade; backfill and compaction; and control of surface waters to perform the Work. MEASUREMENT AND PAYMENT 01025-22 C-32 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS Bid Item: Storm Drain Cleanout Type B-8 1. Measurement: The quantity to be paid for shall be the number of each Storm Drain Cleanout, Type B-8 provided as determined by actual account for each item, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide cast-in-place concrete base; concrete collar; frame and cover castings; precast concrete components; joint sealants; excavation; preparation of subgrade; backfill and compaction; and control of surface waters to perform the Work. C-33 Bid Item: Storm Drain Cleanout Type B-9 1. Measurement: The quantity to be paid for shall be the number of each Storm Drain Cleanout, Type B-9 provided as determined by actual account for each item, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide cast-in-place concrete base; concrete collar; frame and cover castings; precast concrete components; joint sealants; excavation; preparation of subgrade; backfill and compaction; and control of surface waters to perform the Work. C-34 Bid Item: Storm Drain Cleanout Modified Type B-8 1. Measurement: The quantity to be paid for shall be the number of each Storm Drain Cleanout, Modified Type B-8 provided as determined by actual account for each item, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide cast-in-place concrete base; concrete collar; frame and cover castings; precast concrete components; joint sealants; excavation; preparation of subgrade; backfill and compaction; and control of surface waters to perform the Work. C-35 Bid Item: Storm Drain Cleanout Modified Type B-9 (X = 9’, Y = 14’) 1. Measurement: The quantity to be paid for shall be the number of each Storm Drain Cleanout, Modified Type B-9 (X = 9’. Y = 14’) provided as determined by actual account for each item, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide cast-in-place concrete base; concrete collar; frame and cover castings; precast concrete components; joint sealants; excavation; preparation of subgrade; backfill and compaction; and control of surface waters to perform the Work. C-38 Bid Item: Storm Drain Cleanout Modified Type B-9 (X = 4’. Y = 11’) 1. Measurement: The quantity to be paid for shall be the number of each Storm Drain Cleanout, Modified Type B-9 (x = 4’, y = 11’) provided as determined by actual account for each item, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide cast-in-place concrete base; concrete collar; frame and cover castings; precast concrete components; joint sealants; excavation; preparation of subgrade; backfill and compaction; and control of surface waters to perform the Work. MEASUREMENT AND PAYMENT 01025-23 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS C-37 Bid Item: Storm Drain Cleanout Modified Type B-9 1. Measurement: The quantity to be paid for shall be the number of each Storm Drain Cleanout, Modifiid Type B-9 provided as determined by actual account for each item, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide cast-in-place concrete base; concrete collar; frame and cover castings; precast concrete components; joint sealants; excavation; preparation of subgrade; backfill and compaction; and control of surface waters to perform the Work. C-38 Bid Item: Storm Drain Cleanout Modifed Type B-5 1. Measurement: The quantity to be paid for shall be the number of each Storm Drain Cleanout, Modified Type B-5 provided as determined by actual account for each item, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide cast-in-place concrete base; concrete collar; frame and cover castings; precast concrete components; joint sealants; excavation; preparation of subgrade; backfill and compaction; and control of surface waters to perform the Work. C-39 Bid Item: Storm Drain Catch Basin Modified Type F 1. Measurement: The quantity to be paid for shall be the number of each Storm Drain Catch Basin Modified Type F provided as determined by actual account for each item complete in place. 2. Payment: Payment for bid item shall include but is not limited to construct reinforced cast-in-place concrete structure; frame and cover castings; excavation; grout and epoxy mortar to prepare existing retaining wall surface; preparation of subgrade; backfill and compaction; and control of surface waters to perform the Work. C-40 Bid Item: K -Ton Riprap, Energy Dissipater 1. Measurement: The quantity to be paid for shall be the number of tons of Yt- Ton Riprap provided as determined by actual measurements complete in place. 2. Payment: Payment for bid item shall include but is not limited to placement of %-Ton Riprap, Type 2 filter backing, geotextile fabric, excavation, preparation of subgrade, backfill, muck removal and disposal, control of surface waters to perform the Work. c-41 Bid Item: Headwall Modified Wing Type C-35 1. Measurement: The quantity to be paid for shall be the number of each Headwall, Modified Wing Type C-35 provided as determined by actual account for each item complete in place. 2. Payment: Payment for bid item shall include but is not limited to construct reinforced cast-in-place concrete structure, excavation, spoils disposal, preparation of subgrade, bedding, backfill and compaction, and control of surface waters to perform the Work. MEASUREMENT AND PAYMENT 0102524 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS C-42 Bid Item: Concrete Pipe Lug 1. -Measurement: The quantity to be paid for shall be the number of each Concrete Pipe Lug provided as determined by actual account for each item complete in place. 2. Payment: Payment for bid item shall include but is not limited to construct concrete collar, excavation, preparation of subgrade, backfill and compaction, and control of surface waters to perform the Work. C-43 Bid Item: Abandon Reinforced Concrete Pipe 1. Measurement: The quantity to be paid for shall be the linear feet of Abandon Reinforced Concrete Pipe as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include, but is not limited to, backfilling of pipe with sand or cement slurry and control of surface waters to perform the Work. C-44 Bid Item: Remove Reinforced Concrete Pipe (83” to 72”) 1. Measurement: The quantity to be paid for shall be the linear feet of Remove Reinforced Concrete Pipe (83” to 72”) as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include, but is not limited to, removal of pipe, excavation, backfill and compaction, control of surface waters perform the work, and haul and disposal of pipe to legal disposal as necessary to perform the Work. C-45 Bid Item: Remove Storm Drain Pipe (12” to 30”) 1. Measurement: The quantity to be paid for shall be the linear feet of Remove Storm Drain Pipe (12” to 30”) as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to removal of pipe, excavation, backfill and compaction, control of surface waters perform the work, and haul and disposal of pipe to legal disposal as necessary to perform the Work. C-46 Bid Item: Plug 4’ x 8’ Reinforced Concrete Box (RCB) 1. Measurement: The quantity to be paid for shall be the number of each Plug 4’ x 8’ Reinforced Concrete Box (RCB) as determined by actual account for each item complete in place. 2. Payment: Payment for bid item shall include but is not limited to pouring concrete plug, excavation, backfill and compaction, and control of surface waters to perform the Work. C-47 Bid Item: Relocate 3” PVC Water Line 1. Measurement: The quantity to be paid for shall be the number of linear feet of 3” PVC water line as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide piping and appurtenances, trench excavation, spoil disposal, preparation of subgrade, pipe bedding and compaction, trench backfill and compaction, high-lining existing water main, pipeline disinfection and tests, and control of surface waters to perform the Work. MEASUREMENT AND PAYMENT 0102525 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS C-48 Bid Item: Gate Valve - 3” 1. Measurement: The quantity to be paid for shall be the number of each 3” Gate Valve as determined by actual account for each item complete in place. 2. Payment: Payment for bid item shall include but is not limited to providing and installing 3-Inch Gate Valve, connection to water main, excavation, backfill and compaction, testing and control of surface waters to perform the Work. C-49 Bid Item: Reconstruct Sewer Lateral 1. Measurement: The quantity to be paid for shall be the number of each reconstruct sewer lateral as determined by actual account for each item complete in place. 2 Payment: Payment for bid item shall include but is not limited to removal of portions of existing sewer lateral, construction of new sewer lateral piping and fittings, connection to sewer main, excavation, trench backfill and compaction, pipe bedding and compaction, trench resurfacing and control of surface waters to perform the Work. C-50 Bid Item: Reconstruct Water Service 1. Measurement: The quantii to be paid for shall be the number of each reconstruct water service as determined by actual account for each item complete in place. 2. Payment: Payment for bid item shall include but is not limited to removal of portions of existing water service, construction of new water service piping and fittings, connection to water main, excavation, trench backfill and compaction, pipe bedding and compaction, trench resurfacing and control or surface waters to perform the Work. C-51 Bid Item: Connect Exist. Storm Drain Pipe to Storm Drain Cleanout 1. Measurement: The quantity to be paid for shall be the number of each Connect Exist. Storm Drain Pipe to Storm Drain Cleanout as determined by actual account for each item complete in place. 2. Payment: Payment for bid item shall include but is not limited to removal of portion of existing pipe, grout and mortar at structure, excavation, backfill and compaction, and control of surface waters to perform the Work. C-52 Bid Item: Low Flow Earthen Swale 1. Measurement: The quantity to be paid for shall be the cubic yards of Low Flow Earthen Swale as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include, but is not limited to, excavation of Low Flow Swale, backfill and compaction, and control surface waters to perform the Work. C-53 Bid Item: Connect Exist. Storm Drain Pipe to New Channel 1. Measurement: The quantity to be paid for shall be the number of each Connect Exist. Storm Drain Pipe to Channel as determined by actual account for each item complete in place. 2. Payment: Payment for bid item shall include but is not limited removal of portion of existing pipe, excavation, backfill and compaction, concrete apron, and control of surface waters to perform the Work. MEASUREMENT AND PAYMENT 0102526 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC58 TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS C-54 Bid Item: Concrete Pipe Collar 1. Measurement: The quantity to be paid for shall be the number of each concrete pipe collar as determined by actual account for each item complete in place. 2. Payment: Payment for bid item shall include but is not limited to pouring concrete pipe collar, excavation, backfill and compaction, bedding, and control of surface waters to perform the Work. C-55 Bid Item: Remove Curb Inlet 1. Measurement: The quantity to be paid for shall be the number of each remove curb inlet as determined by actual account for each item complete in place. 2. Payment: Payment for bid item shall include but is not limited to demolition of existing structure, excavation, backfill and compaction, control of surface waters to perform the work, haul and dispose concrete to legal disposal as necessary to perform the Work. C-56 Bid Item: Remove Storm Drain Cleanout 1. Measurement: The quantii to be paid for shall be the number of each remove curb inlet as determined by actual account for each item complete in place. 2. Payment: Payment for bid item shall include but is not limited to demolition of existing structure, excavation, backfill and compaction, control of surface waters to perform the work, haul and dispose concrete to legal disposal as necessary to perform the Work. C-57 Bid Item: Asphalt Concrete Pavement - 2-112” Base Course, Trench and Excavation Repair 1. Measurement: The quantity to be paid for shall be the number of tons of asphalt concrete pavement provided as determined by actual delivery tickets furnished to the District for each load of asphalt concrete delivered to the Project site. 2. Payment: Payment for bid item shall include but is not limited to provide and place asphalt concrete pavement; prime coat; and tack coat to perform the Work. C-58 Bid Item: Asphalt Concrete Pavement - l-1/2” Surface Course, Trench and Excavation Repair 1. Measurement: The quantity to be paid for shall be the number of tons of asphalt concrete pavement surface course provided as determined by actual delivery tickets furnished to the District for each load of asphalt concrete delivered to the Project site. 2. Payment: Payment for bid item shall include but is not limited to provide and place asphalt surface course; prime coat; and tack coat to perform the Work. C-59 Bid Item: Aggregate Base - 8”. Trench and Excavation Repair 1. Measurement: The quantity to be paid for shall be the number of cubic yards of aggregate base provided as determined by actual measurements complete in place. 2. Payment: Payment for bid item shall include but is not limited to furnish, place and compact aggregate base to perform the Work. MEASUREMENT AND PAYMENT 0102527 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS C-60 Bid Item: Concrete Cross Gutter 1. Measurement: The quantity to be paid for shall be the square feet of concrete cross gutter ad determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to construct concrete cross gutter, removal of concrete cross gutter and load, haul and dispose concrete to legal disposal as necessary to perform the Work. C-61 Bid Item: Sawcut Pavement 1. Measurement: The quantity to be paid for shall be the number of linear feet of concrete pavement sawcut provided as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide pavement sawcutting as necessary to perform the Work. C-62 Bid Item: Remove Asphalt Concrete Pavement 1. Measurement: The quantity to be paid for shall be the number of square yards of 4” thick (* l/2”) asphalt concrete pavement removal provided as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to removal of asphalt pavement; and load, haul and dump asphalt to legal disposal/recycle as necessary to perform the Work. C-63 Bid Item: Remove and Replace Concrete Curb and Gutter 1. Measurement: The quantity to be paid for shall be the number of linear feet of removal and replacement of concrete curb and gutter provided as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to construct concrete curb and gutter; sawcut concrete curb and gutter; removal of curb and gutter; and load, haul and dispose concrete to legal disposal as necessary to perform the Work. C-64 Bid Item: Remove and Replace Concrete Sidewalk 1. Measurement: The quantity to be paid for shall be the number of square feet of removal and replacement of concrete sidewalk provided as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to removal and replacement of concrete sidewalk and load, haul and dispose concrete to legal disposal as necessary to perform the Work. C-65 Bid Item: Replace Existing Chain Link Fence 1. Measurement: The quantity to be paid for shall be the linear feet of chain link fence to be removed and replaced in kind as determined by the actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to removal of existing 6’ high chain link fence and non-motor operated slide gate; provide and install chain link fabric; posts and post caps; concrete footings; top rails; intermediate rails; tension wire; slide gate and appurtenant materials as necessary to perform the Work. MEASUREMENT AND PAYMENT 0102528 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS C-66 Bid Item: 10” Water Line PVC C900 1. Measurement: The quantity to be paid for shall be the linear feet of 10” PVC water line as determined by the actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide piping and appurtenances, trench excavation, spoil disposal, preparation of subgrade, pipe bedding and compaction, trench backfill and compaction, high-lining existing water main, pipeline disinfection and tests, and control of surface waters to perform the Work. C-67 Bid Item: Removal and Replace Concrete Wall - 2’ High 1. Measurement: The quantity to be paid for shall be the number of linear feet of removal and replacement of concrete wall provided as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to construct concrete wall; sawcut concrete curb and gutter; removal of concrete wall; and load, haul and dispose concrete to legal disposal as necessary to perform the Work. C-68 Bid Item: Storm Drain Cleanout Type A-4 1. Measurement: The quantity to be paid for shall be the number of each Storm Drain Cleanout, Type A-4 provided as determined by actual account for each item, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide cast-in-place concrete base, walls, top slab; concrete collar; frame and cover casting; precast components; joints sealants; excavation; preparation of subgrade; backfill and compaction; and control of surface waters to perform the Work. C-69 Bid Item: Drain Inlet Oil-Water Separator Inserts 1. Measurement: The quantity to be paid for shall be the number of each catch basin and curb inlet insert provided in Chestnut Avenue and the westerly portion of Oak Avenue between Madison Street and the railroad right-of-way as determined by actual account for each item, complete in place. 2. Payment: Payment for bid item shall include, but is not limited to, installation of drain inlet inserts. (continued on next page) MEASUREMENT AND PAYMENT 0102529 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS 1.8 MEASUREMENT AND PAYMENT - SCHEDULE D D-l D-2 D-3 D-4 D-5 D-6 Bid Item: Cold Milling Asphalt Concrete Pavement 1. Measurement: The quantity to be paid for shall be the number of square feet of cold milling asphalt concrete pavement provided as determined by actual measurements, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide cold milling of asphalt concrete pavement and disposal as shown and specified to perform the Work. Bid Item: Asphalt Concrete Pavement - Leveling Course 1. Measurement: The quantity to be paid for shall be the number of tons of asphalt concrete leveling course provided as determined by actual delivery tickets furnished to the District for each load of asphalt concrete delivered to the Project site. 2. Payment: Payment for bid item shall include but is not limited to provide cleaning; asphalt concrete leveling course; and tack coat to perform the Work. Bid Item: Asphalt Concrete Pavement - l-1/2” Overlay 1. Measurement: The quantity to be paid for shall be the number of tons of asphalt concrete pavement overlay provided as determined by actual delivery tickets furnished to the District for each load of asphalt concrete delivered to the Project site. 2. Payment: Payment for bid item shall include but is not limited to street cleaning; tack coat; provide, place and compact pavement overlay (Asphalt- Rubber Hot Mix-Gap Graded) to perform the Work. Bid Item: Adjust Manhole Covers and Valve Boxes to Grade 1. Measurement: The quantity to be paid for shall be a lump sum payment to adjust all manhole covers and valve boxes raised to grade, complete in place. 2. Payment: Payment for bid item shall include but is not limited to the Work required to remove AC pavement and existing concrete collar; raise frame and cover to meet new grade; construct concrete collar; and place AC finish course to perform the Work. Bid Item: Pavement Striping and Markings 1. Measurement: The quantity to be paid for shall be a lump sum payment to provide permanent striping and markings, complete in place. 2. Payment: Payment for bid item shall include but is not limited to provide and apply final striping and markings as shown and specified. Bid Item: Traffic Signal Loop Detectors 1. Measurement: The quantity to be paid for shall be the number of each loop detector replaced, complete in place. 2. Payment: Payment for bid item shall include but is not limited to replacing loop detectors damaged by cold milling of the pavement at locations where video detection equipment is not used. MEASUREMENT AND PAYMENT 0102530 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS GENERAL REQUIREMENTS D-7 Bid Item: Schedule D, Traffic Control 1. Measurement: The quantity to be paid for shall be a lump sum payment for providing traffic control. 2. Payment: Payment for the bid item shall include but is not limited to provide and maintain construction signs; barricades; flashing arrow boards; cones; and flagmen. ++ ENDOFSECTION ++ MEASUREMENT AND PAYMENT 01025-31 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK SECTION 02050 DEMOLITION PART 1 - -NFfW. 1.1 DFSCRIPTION A. Scope: 1. Perform the work required to provide all clearing and grubbing, sawcutting, demolition, removal and disposal shown, specified and required for construction of pipelines, manholes structures and other facilities required to complete the Work. This shall include, but is not limited to, removal and disposal of existing fences, asphalt concrete and aggregate base, concrete curb and gutter, concrete sidewalk, existing gate, existing abandoned underground pipes and conduits, existing headwalls, rip-rap, traffic signs, and other existing features which interfere with the work, whether or not such items are called out on the Plans or in the Specifications for removal. 2. All materials and debris generated and not designated for salvage in the Contract Documents shall be legally disposed at the CONTRACTORS expense. B. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown or specified. Refer to Section 2-5.2 of the Supplemental Provisions. C. Related Sections: 1. Section 2-5.2, Precedence of Contract Documents. 2. I Section.2-5.3, Shop Drawings and Submittals. 3. Section 7-7, Cooperation and Collateral Work. - 4. Section 7-8, Project Maintenance. 5. Section 7-15, Connection to Existing Faciliies. 6. Section 7-9, Protection and Restoration of Existing Improvements. 7. Section 01025, Measurement and Payment. 8. Section 02220, Excavation and Backfill. 1.2 ~-LIP/ ASSURANCE A. Initial Survey of Existing Improvements: Prior to beginning demolition, excavation or shaft construction, perform a sufficient level of surveying of the area so that all existing improvements can be returned to their original location and elevation. B. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. DEMOLlTlON 02050-l VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 1.3 SlJRMl-lTAt S A. Submit the following in accordance with Section 2-5.3. B. Submit for approval proposed methods, equipment and operating sequences for demolition and removal of existing utilities and structures. The submittal shall reflect coordination with the District for shutdown, temporary services, re-instating utility service, and other applicable items to ensure continuous and safe operation of existing utilities affected by the Work. 3.4 MATERIAI S TRANSPORTATION. HANDLING AND STORAGE A. Refer to Section 4-2, Materials Transportation, Handling and Storage. A. Refer to Section 01025. PART 2 - PRODUCTS A. Part 2 not used. PART 3-Fx’=CUTlCN 3.1 A. The extent of demolition required shall be limited to that which is necessary to perform the work as shown and specified. B. Pollution Controls: Use water sprinkling, temporary enclosures, and other suitable methods to limit the amount of dust and dirt rising and scattering in the air to the lowest practical level. Comply with governing regulations pertaining to environmental protection. 1. Do not use water when it may create hazardous or objectionable conditions such as flooding and pollution. C. Sheeting, Shoring and Bracing: Refer to Section 02220, Excavation and Backfill. D. Underpinning: Refer to Section 02220, Excavation and Backfill. E. Protection: Protect all adjoining structures, pipelines, trees, lawns, landscaping, fencing, pavements, curbs, gutters and sidewalks not designated to be removed and not interfering with Work. F. Utilities: 1. Protect all existing utilities that are to remain during demolition. 2. Provide temporary protection for existing utilities that are temporarily relocated during demolition. DEMOLITION 02050-2 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 3.2 CLEARING AND GRU- A. Perform cleaning and grubbing in accordance with the requirements of Section 300-l .l of the SSPWC. B. During surface clearing operations, the Contractor shall not cover or bury any plant growth, or other objectionable materials. If the Contractor cannot successfully separate the plant growth from the surface soil and advertently or inadvertently mixes organic or other objectionable materials with the soil, the soil so contaminated shall be removed from the site by the Contractor. All costs, if any, associated with removing the soil mixed with organic or other objectionable materials and importing soil to replace said contaminated soil shall be borne by the Contractor and no additional payment therefor shall be made to the Contractor. C. If the Contractor stockpiles, or otherwise deposits soil or unclassified excavation materials, it shall clear and grub the area over which stockpiled soil or unclassified excavation materials are placed. 3.3 PAVFMENT.OVAND ,S A. Sawcut existing pavement, curb, gutter and sidewalk to be removed in straight lines. B. All pavement, curb, gutter and sidewalk demolitions shall be generally made to the limits shown, unless otherwise directed by the ENGINEER due to unforeseen field conditions, and as required for the construction of the complete project. 3.4 RFMOVAL OF SFW.LFTS AN2 . ? NOUTS A. Removal of existing structures shall include sawcutting adjacent pavement, excavation of existing structure, demolition of existing structures, and the removal and disposal of demolished structure to a licensed landfill where shown on the Plans. Work will include the transportation of disposal material and disposal fees. Work will also include backfill and compaction. 3.5 RFMOVAL OF EXISTING ! JNDFRGROUND PIPF A. Removal of drainage pipe shall include sawcutting of existing pavement, removal of pavement materials, excavation of existing pipe, demolition and removal of existing pipe materials where shown on the Plans. DEMOLITION 02050-3 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 33 DISPOSAL, A. All materials generated during clearing and grubbing and demolition shall be promptly removed from the site and legally disposed of. Recycling of materials where appropriate is encouraged. Recycled materials shall not be used on this project unless requested in writing and approved by the Engineer. 3.7 CJ EAN m UP A. Refer to Section 7-8, Project Maintenance. + + END OF SECTlON + + DEMOLITION 020504 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK SECTION 02140 DEWATERING PART I - GENERAL 1.1 DESCRIPTION A. Scope: 1. Perform the work required to provide all groundwater dewatering, specified and required for construction of pipelines, manholes, structures and other facilities required to complete the Work. 2. All temporary means required to prevent discharge of sediment to water courses from dewatering systems or erosion shall be induded. 3. All sampling and analytical testing of groundwater as required by permitting agencies. B. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. C. Related Sections: 1. Section 2-5.2, Precedence of Contract Documents. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 7-8.6, Water Pollution Control. 4. Section 7-16, Geologic Conditions. 5. Section 01025, Measurement and Payment. 6. Section 02220, Excavation and Backfill. ii- Section 02230, Crushed Stone and Gravel. 9: Section 02306, Microtunneling. Section 02340, Boring and Jacking. 10. Section 02310, Jacking and Receiving Shalts. II. Section 15051, Buried Piping Installation. 1.2 QUALITY ASSURANCE A. Permits and Regulations: I. Obtain all applicable permits for earthwork, dewatering, work in roads, rights-of-way, etc., as required by local, state and federal agencies. 2. Obtain well permits from the County of San Diego, Department of Health Services, as applicable to the Work. 3. Comply with the requirements of the Storm Water Pollution Prevention Plan and Monitoring Plan as specified in Section 7-8.6 of the Supplemental Provisions. DEWATERING 02140-l VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 4. 5. 6. Perform excavation work in compliance with applicable require- ments of governing authorities having jurisdiction, including but not limited to OSHA Standard 29 CFR 1926.650. Comply with the requirements of En&a Wastewater Authority Discharge Permit #98-SPl for discharge of groundwater to the sanitary sewer system. A copy of the permit is included as Appendix D. Comply with the requirements of California Regional Water Quality Control Board authorization for Groundwater Discharge issued on September 28, 1999. Compliance with General Discharge Order #96-41 and supplemental requirements of the September 28,1999 authoriration shall be the sole responsibility of the Contractor. B. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.3. 1.3 SUBMITTALS A. Submit the following in accordance with Section 2-5.3. B. Shop Drawings: Dewatering system analyses, design, and shop drawings prepared by and stamped with the seal of a Registered Professional Civil Engineer in the State of California with at least 8 years of experience in designing similar systems. Qualifications of the dewatering contractor, the Contractor’s Engineer, sampling service, and testing laboratory shall be included in the submittal. I. The analyses shall include an evaluation of the anticipated subsurface conditions, required well spacing, diameter, depth, screen interval, backfill and filter pack, pump size, drawdown duration, drawdown and steady state, flow rates, desilting tank and settlements which support the requirements of Section 3.1 .A. 2. Dewatering calculations shall include water drawdown curves for the portion of the pipeline to be installed using Rotary Cutter Head or Open Face Digger Shield methods. C. Well construction logs which include descriptions of actual materials encountered, construction details, well development procedures and results, and deviations from original submitted design. D. Laboratory test results and flow rate information in accordance to Paragraph 3.1 .C.6 of this Section. E. Dewatering analyses and design shall be fully coordinated with excavation and shoring design. The shoring and excavation design shall recognize the changes in groundwater conditions and earth pressures. I. Chart recorder readings in accordance with Paragraph 3.1 .C.6 of this section. DEWATERING 02140-2 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VC58 TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK F. Dewatering discharge plan as work progresses which identifies the proposed alignment of the discharge line and method for the conduit to enter the manhole. Provide typical details of the conduit entering the manhole. Open manholes will not be allowed for discharge piping. Approval of each discharge location must be obtained from the ENGINEER. 1.4 JOB CONDITIONS A. Subsurface Information: A geotechnical investigation has been performed by Woodward-Clyde. I. Refer to Section 7-16. I.5 MEASUREMENT AND PAYMENT A. Refer to Section 01025, Measurement and Payment. PART 2 - PRODUCTS Part 2 not used. PART 3 - EXECUTION 3.1 DRAINAGE AND DEWATERING A. General: I. Prevent surface and subsurface water from flowing into excava- tions and from flooding adjacent areas. 2. Remove water from excavation as fast as it collects. 3. Maintain the ground water level a minimum of 5 feet below the bottom of the excavation to provide a stable surface and slope conditions for construction operations, a stable subgrade for the permanent work, and to prevent damage to the Work during all stages of construction. 4. Provide and maintain pumps, sumps, suction and discharge lines, power supply and other dewatering system components necessary to convey water away from excavations. 5. Obtain DISTRICT’s approval before shutting down dewatering system for any reason. 6. Gas or diesel fuel generators shall be provided with a minimum residential silencer and acoustic enclosure capable of complying with the ambient noise requirements specified in Section 02306, Paragraph 3.5. B. Standby Requirements for Dewatering: Provide standby equipment and power supply to insure continuity of dewatering operations. C. Disposal of Water Removed by Dewatering System: I. The discharge location for the groundwater dewatering system shall be either the sanitary sewer system or storm drain system. DEWATERING 02140-3 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK I. The discharge location for the groundwater dewatering system shall be either the sanitary sewer system or storm drain system. 2. 3. 4. 5. 6. 7. Discharge groundwater to a settling tank and then by dosed conduit to the nearest manhole. Discharging to the existing sewer interceptor is preferred to discharging to the collector pipe. Monitor, sample and test all groundwater as required by Encina Wastewater Authority Permit #@8-SPl or the RWQCB authorization dated September 28, 1999. The maximum allowable discharge shall not be exceeded without approval from the permitting agency and the ENGINEER. Where the conduit crosses sidewalks, ramps shall be constructed over the conduit for pedestrian movement with a slope no steeper than 12:l. Where the conduit must enter the traveled portion of the roadway to discharge to the nearest manhole, it shall be placed below grade and covered with a trench plate, as approved by the ENGINEER. Provide flow meter and continuous 24-hour chart recorder for recording dewatering flow. Maintain the meter/recorder and provide continuous reading charts with a minimum capacity of 24 hours each. Calibrate flowmeter and recorder device to provide accuracy of *5%. Provide evidence of calibration of mater and recorder signed by a California Registered Professional Engineer. Recorder shall be portable (benchmount), dual scale, mounted in NEMA 4X enclosure with transparent plastic door and latch. Unit shall operate off 1 I5V, 60 Hz power supply. Provide M-Tek Model 310, or equal. a. Submit readings to the District on a weekly basis. Dispose of all water removed from the excavation in such a manner as not to endanger public health, property, or any portion of the Work under construction or completed and per the requirements of all permits. D. Dewatering within the Railroad Right-Of-Way: I. Dewatering wells shall not be located closer than 10 feet to the edge of the railroad tracks. 2. Settlement at the tracks shall not exceed that specified in Paragraph 3.4 of Section 02306, Microtunneling. E. Well Removal Procedures: 1. Dewatering wells shall be destroyed in accordance with California Department of Water Resources “California Well Standards - Bulletin 74-90”. Documentation of well destruction shall be submitted to the ENGINEER for review prior to submission to the local permitting agency. 2. The top 5 feet shall be concrete. The pavement surface shall match existing adjacent surface material. 3. Eight (8) groundwater monitoring wells are located throughout the project as identified in the geotechnical report. The Contractor shall remove these wells in accordance with the above requirements. + + END OF SECTION + + DEWATERING 02140-4 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK SECTION 02220 EXCAVATION AND BACKFILL PART I- GWEBAL A. B. C. D. E. Scope: 1. Perform the work required to provide all excavating, sheeting and shoring, backfilling, compacting and disposing of materials shown, specified and required for construction of pipelines, manholes, structures, slope repair grading, and other facilities required to complete the Work. 2. All temporary means needed to prevent discharge of sediment to water courses from erosion are included. 3. No classification of excavated materials will be made. Excavation includes all materials regardless of type, character, composition, moisture or condition thereof. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. Reference Standards: Comply with the applicable provisions of the latest edition of the following: 1. Cal OSHA Construction Safety Orders. 2. Cal OHSA California Trenching and Shoring Manual. 3. Refer to Subparagraphs 3 and 4 under Paragraph 1.2.A of this Section. Referenced Sections: SSPWC: 1. Section 300, Earthwork. 2. Section 306-l .1 , Trench Excavation. Related Sections: 1. Section 2-5.2, Precedence of Contract Documents. 2. Section 26.3, Shop Drawings and Submittals. 3. Section 4-2, Materials Transportation, Handling and Storage. 4. Section 5-2, Protection. 5. Section 7-9, Protection and Restoration of Existing Improvements. 6. Section 7-l 0, Public Convenience and Safety. 7. Section 01025, Measurement and Payment. 6. Section 02050, Demolition. 9. Section 02140, Dewatering. 10. Section 02230, Crushed Stone and Gravel. 11. Section 02235, Stone Riprap. 12. Section 02306, Microtunneling. EXCAVATION AND BACKFILL 02220-l VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 13. Section 02310, Jacking and Receiving Shafts. 14. Section 02340, Boring and Jacking (Steel Casing). 15. Section 15051, Buried Piping Installation. 17 QUALITY ASSURANCE A. Permits and Regulations: 1. Obtain all applicable permits for earthwork, work in roads, rights-of-way, SDNR right-of-way, as required by tocal, state and federal agencies. 2. Obtain a permit from the State of California, Department of industrial Relations, Division of Occupational Safety 81 Health by submitting a Permit AppIicafion and Job Notification Form. 3. Excavation Plans shall be in compliance with Cal OSHA, State of California Code Regulations Title 8 - Industrial Relations, Chapter 4 - Division of Industrial Safety, Subchapter 4 - Construction Safety Orders, Article 1 and Article 6 including Appendix A through F; and Labor Code of the State of California, Section 6705. 4. Conform to the requirements of Cai OSHA California Trenching and Shoring Manual. 5. Comply with all construction dewatering discharge requirements specified in Section 02140, Dewatering. 6. Comply with the requirements of the Storm Water Pollution Prevention Plan and Monitoring Plan. See Section 7-8.6, Water Pollution Control. B. Reference Standards Test Methods: Comply with applicable provisions and recommendations of the following except as othewise shown or specified. 1. ASTM A 36. Specification for Stnrctural Steel. 2. ASTM A 328, Specification for Steel Sheet Piling. 3. ASTM D 422, Standard Test Method for Particle-Size Analysis of Soils. 4. ASTM D 1557, Test Methods for Moisture-Density Rela_tions of Soils and Soil-Aggregate Mixtures Using lo-lb (4.54 kg) Rammer and 1 &in. (457 mm) Drop. 5. ASTM D 2922, Standard Test Methods for Density of Soil and Soil- Aggregate in place by Nuclear Methods (Shallow Depth). 6. ASTM D 3017, Standard Test Methods for Moisture Content of Soil and Soil-Aggregate in Place by Nuclear Methods (Shallow Depth). 7. AASHTO T 224, Standard Test Methods for Correction for Coarse Particles in the Soil Compaction Test. 8. OSHA Standard, Title 29, Code of Federal Regulations, Part 1926, Section .650 (Subpart P - Excavations). 9. ASTM D 4318, Standard Test Method for Liquid Limit, Plastic Limit, and Plasticity Index of Soils. 10. Uniform Building Code Standard No. 29-2, Expansion Index Test. C. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. EXCAVATION AND BACKFILL 02220-2 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 1.3 SURMlTTAl S A. Submit the following in accordance with Section 2-5.3. B. Permit: Copy of permit issued by State of California, Department of Industrial Relations, Division of Occupational Safety & Health. 1. Submittals made under this Section will not be reviewed until a copy of the permit is submitted. C. Excavation Plan: Excavation plan prepared and stamped by a California Registered Professional Geotechnical Engineer with at least 5 years experience to demonstrate compliance with Cal OSHA Construction Safety Orders-referenced in Subparagraph 1.2.A.3 of this Section. As a minimum, the excavation plan shall include: 1. Name and training experience of competent person as defined in Cal OSHA Construction Safety Orders, Article 2, Section 1504. 2. Narrative description of excavation methods and protective systems to be used. 3. Copies of manufacturers data, shop drawings, and other tabulated data of sheeting, shoring and bracing systems if protective systems are designed on the basis of such data. 4. Plans identifying locations for stockpiling excavated material, haul routes, and ingress/egress from excavations. 5. Excavation and compaction equipment and procedures. D. Samples - Select Fill Material: 1. Provide a sample of select fill material to District for testing and approval. Advise District of source and location. E. Storm Water Pollution Prevention and Monitoring Plans: Comply with the reqoiremenkof.Section 7-8.6, Water Pollution Control. F. Hydroseeding: Submit information on fertilizer, organic soil amendment, mulch, herbicides and pesticides, and seed mix. 1.4 JOB CONDITIONS A. Subsurface Information: A geotechnical investigation has bean perfomted by Woodward-Clyde. 1. Refer to Section 7-16. B. Existing Manhole Structures: Existing manhole structures adjacent to the Work are shown on the Plans. The location of these structures are approximate and are shown for reference only. Explore ahead of the required excavation to determine the exact location of all manhole structures. Support and protect manhole structures from damage. 1. If collector sewer and interceptor sewer manholes are damaged, they shall be restored immediately at CONTRACTOR’s expense. EXCAVATION AND BACKFILL 02220-3 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK C. D. Existing Utilities: Locate existing underground utilities in the areas of Work. If utilities are to remain in place, provide adequate means of protection during all operations. 1. For uncharted and incorrectly charted piping and other utilities encountered during excavation, consult District immediately for directions as to procedure. Cooperate with District and utility companies in keeping respective services and facilities in operation. a. The CONTRACTOR shall repair damaged piping and utilities by the CONTRACTOR. 2. Do not intermpt existing utilities serving facilities occupied and used by District or others, except when permitted in writing by District and then only afier acceptable temporary utility services have been provided. 3. Demolish and completely remove from site existing underground utilities indicated to be removed. Coordinate with utility companies for shut-off of services if lines are active. 4. A 1Zinch high pressure gas line exists in the railroad right-of-way adjacent to the work. The exact location and depth of the gas line shall be verified by the Contractor prior to his Work. a. Refer to Part 1.4.0 of this Section. Existing High Pressure Gas Line: An existing 12-inch high pressure gas transmission line is located in the railroad right-of-bay as shown on the Plans. The pipeline at the Agua Hedionda Lagoon is exposed due to a slope failure at the lagoon. 1. The earthwork for reconstructing the slope failure at the lagoon will restore the exposed pipeline to a buried condition. 2. The Gas Company will inspect and repair the pipeline prior to the CONTRACTOR backftlling the gas line. 3. The expedite the Gas Company’s inspection and repairs of their gas line, the CONTRACTOR shall backfill the slope to approximately 1 foot below the bottom of the pipeline to provide access for the Gas Company to execute their inspection and repairs. 4. The Gas Company will remove the sag from the pipeline and repair its coatings. 5. The Gas Company will require a minimum 2 working days to complete their work. 6. The CONTRACTOR shall complete the backfill of the gas line upon the Gas Company completing their inspection and repairs. 7. Backtill the pipe trench with trench backtill. a. Refer to Part 2.1 .B. 8. Refer to Section 5-2 and Section 15051, Part 3.5. E. Stockpiling: Stockpile materials as follows: 1. Within Roadways: Materials excavated from roadways shall not be stockpiled within the roadways. Remove excavated spoil from roadways and stock pile materials at an off-site location which shall be obtained by the CONTRACTOR. 2. Within Railroad Right-Of-Way: Excavated spoil may be stockpiled within the SDNR right-of-way. EXCAVATION AND BACKFILL 022204 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK F. Use of Explosives: The use of explosives are prohibited. G. Protection of Persons and Property: 1. Protect structures, utilities, pavements, and other facilities from damage caused by settlement, lateral movement, undermining, washout and other hazards created by excavation operations. 2. Comply with the requirements of Section 7-10, Public Convenience and Safety, of the Supplemental Provisions. H. Dust Control: Conduct all operations and maintain all areas of activity, including sweeping and sprinkling of roadways, to minimize creation and dispersion of dust. 1.5 MATERlALS TRANSPORTATION. HANDLING AND STOR- A. Refer to Section 4-2, Materials Transportation, Handling and Storage. A. Refer to Section 01025, Measurement and Payment. PART 2 PRODUCTS - A. Pipe Bedding: 1. Pipe bedding shall be defined as those materials supporting, surrounding and extending to 1 foot above top of pipe, comprising the pipe bedding zone as shown on the Plans. 2. Pipe Bedding Materials: a. Crushed Stone: Refer to Section 02230, Crushed Stone and Gravel. b. Select Fill: Refer to Paragraph 2.1 .C of this Section. 1) May be used in the pipe bedding zone where shown on the Plans. 2) The maximum size for rocks and hard lumps in any dimension shall be 2-inches. B. Trench Backfill: 1. Trench backfill shall be defined as the material backfilling the pipe trench from the top of pipe bedding zone to bottom of aggregate base for pavement as shown on the Plans. 2. Trench backfill materials shall be select fill per Paragraph 2.1 .C. a. Rocks greater than 2-inches in any dimension shall not be c. penitted within the top 1 foot of pavement subgrade. EXCAVATION AND BACKFILL 02220-5 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK C. Select Fill: 1. All imported soils shall consist of select fill material and shall be placed where shown for grading of the site or specified below, around structures, roads, backfills and other work. 2. Use granular material free from organic matter that has a UBC expansion index of 30 or less when tested in accordance with UBC Standard 29-2. 3. Select fill shall contain no rocks or hard lumps greater than 6 inches in maximum dimension, shall contain at least 40% of material smaller than l/4 inch in size. Material of a perishable, spongy, or otherwise improper nature shall not be used in fills. 4. Previously excavated materials meeting these requirements may be used for select fill. 5. Samples of materials to be used for select fill shall be tested in the laboratory in order to evaluate the maximum density, optimum moisture content, classification of the soil, and expansion index, as required. 6. During excavation, soil types other than those analyzed in the report of the geotechnical study may be encountered. Notify the ENGINEER to determine the suitability of these soils. PART 3 - WK!JTlON 3.1 FXCAVATlON A. General: 1. Perform all excavation required to complete the Work as shown and specified. Excavations shall include earth, sand, clay, gravel, hardpan, boulders, decomposed rock, pavements, rubbish and all other materials within the excavation limits. 2. Excavations for structures and pipelines shall be open excavations. Provide excavation protection systems required by _ ordinances, codes, law and regulations to prevent injury to workmen and to prevent damage to new and existing structures or pipelines. Protection systems shall be utilized under the following conditions, unless otherwise shown and specified: a. Excavation Less Than 5 Feet Deep: Excavations in soil conditions where there is no potential for a cave-in may be made with vertical sides. Under all other conditions, excavations shall be shielded, or shored and braced. b. Excavations Greater Than 5 Feet Deep: Under all conditions, excavations shall be shielded or shored and braced. C. Install and maintain excavation protection systems in accordance with approved drawings submitted under Part 1.3 of this Section. 3. When excavations are made below the required grades, they shall be backfilled with select fill at the CONTRACTOR’S expense . EXCAVATION AND BACKFILL 02220-6 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 4. 5. Material Storage: Stockpile satisfactory excavated materials at approved locations, until required for backfill or fill. Place, grade and shape stockpiles for proper drainage. a. Dispose of excess soil material and waste materials as specified herein. b. For Work within the railroad right-of-way, excavated material may be placed adjacent to the excavation at a minimum horizontal distance equal to the depth of the excavation. Perform demolition, clearing and grubbing in accordance with Section 02050 prior to performing the Work specified in this Section. B. Pipe Trench Excavations: 1. Maximum trench width shall be as shown on the Plans. Where the maximum width is not specifically detailed, the trench width shall be minimized to the greatest extent practical but shall conform to the following: a. Suffkzient to provide room for installing, jointing and inspecting piping, as shown on the Plans. b. Sufficient to allow thorough compaction of backfill to springline of pipeline. C. Do not use excavating equipment which requires the trench to be excavated to excessive width. d. The approved Traffic Control Drawings. 2. Depth of trench shall be as shown on the Plans. 3. Subgrades for trenches shall conform to the following: a. Firm, dense, compacted and consolidated. b. Free from mud, muck, and other soft and unsuitable materials. 4. 5. 6. 7. 8. Remain firm and intact under all construction operations. &arify trench subgrades to a depth of 120inches and compact to 90 percent relative compaction. The finished elevation of stabilited subgrades shall not be above subgrade elevations shown. a. Scarify trench subgrades for concrete sewer pipelines and concrete ston drain pipelines. b. Do not scarify trench subgrades for PVC sewer forcemain and collector sewer pipelines. In roadways no more than 200 feet of trench may be opened at any one time. In railroad right-of-way no more than 400 feet of trench may be opened at any one time. Unsuitable Material: Where existing material in the scarified trench subgrade is unsuitable, as determined by the ENGINEER, overexcarate 2 ft. minimum depth, place and compact select fill to 90% relative compaction. Material removed from the excavations which does not conform to the requirements for backfill or is in excess of that required for backfill shall be hauled away from the project site and disposed of in compliance with ordinances, codes, laws and regulations. The Work shall be paid for in accordance with Section 3 of the Supplemental Provisions. Trench excavation shall be maintained in a condition that is firm, clean and free from all debris and foreign matter. EXCAVATION AND BACKFILL 02220-7 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 9. 10. 11. Provide barricades, fencing and other protective measures at the end of each work day in accordance with OSHA regulations to prevent unauthorized access to the work. A K-rail barrier shall be provided as detailed on the drawings for Work performed within the railroad right-of-way. Pedestrian and vehicle access across trenches shall be provided in accordance with the requirements of 7-10, Public Convenience and Safety, of the Supplemental Provisions. C. Manhole Excavation: 1. Maximum excavation limits shall be as shown on the Plans. 2. Depth of excavation limits shall be as shown on the Plans. 3. Manhole bases and structures shall be founded on an encapsulated crushed stone base. a. Refer to Section 02230, Crushed Stone and Gravel and Section 06653, Filter Fabric. 4. Subgrades for manhole excavation shall conform to the following: ii: Firm, dense, compacted and consolidated. Free from mud, muck, and other soft and unsuitable materials C. Remain firm and intact under all construction operations. 5. Scarify manhole excavation subgrades to a depth of 12-inches and compact to 90 percent relative compaction. The finished elevation of stabilized subgrades shall not be above subgrade elevations shown. 6. Unsuitable Material: Where existing material in the scarified manhole excavation subgrade is unsuitable, as determined by the ENGINEER, overexcavate 2 ft. minimum depth, place select fill and wmpact to 90% relative compaction. UNAt JTHORITPD FXCAVATION A. All excavations outside the lines and grades shown, together with the removal ar&:disposal of the associated material shall be at CONTRACTOR’S expense. B. All unauthorized excavations shall be filled and compacted to at least 90% relative compaction with select backfill at CONTRACTOR’s expense. 3.3 DRAINAGF AND DEWATFRING A. General: 1. Prevent surface water from flowing into excavations. 2. Dewatering shall be performed in accordance with Section 02140. 3.4 SHFFTING. SHORING AND BRACING A. General: 1. All municipal, county, state and federal ordinances, codes, regulations and laws shall be observed. 2. Used material shall be in good condition and not damaged. New or used sheeting may be used for temporary work. EXCAVATION AND BACKFILL 02220.8 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 3. 4. 5. 6. 7. 8. All timber used for breast boards (lagging) shall be new or used, meeting the requirements for Douglas Fir Dense Construction grade with a bending strength not less than 1500 psi or Southern Pine No. 2 Dense. All steel work for sheeting, shoring and bracing shall be designed in accordance with the provisions of the “Specifications for the Design, Fabrication and Erection of Structural Steel for Buildings,” of the AISC except that field welding will be permitted. Steel sheet piling shall be manufactured from steel conforming to ASTM A 328. Steel for soldier piles, wales and braces shall be new or used and shall conform to ASTM A 36. Carry down shoring and bracing as excavation progresses. Maintain shoring and bracing in excavations regardless of time period excavations will be open. Safe and satisfactory sheeting, shoring and bracing shall be the entire responsibility of CONTRACTOR. 6. Removal of Sheeting, Shoring and Bracing: 1. Remove sheeting and bracing from excavations when complete. Removal shall be done so as to not cause injury to the Work, existing street, adjacent utilities or structures. Removal shall be equal on both sides of excavation to ensure no unequal loads on pipelines and manholes. 2. Defer removal of sheeting and bracing, where removal may cause soil to wme into contact with concrete, until concrete has cured a minimum of 7 days. 3.5 TRENCH SHIELDS AND HYDRAULIC SHORING A. Comply with the requirements of Section 306-l .1.6, Bracing Excavations, of the SSPWC. B. The method of trench shoring and shoring system design shall be the sole responsibility of the CONTRACTOR. The shoring system design shall be coordinated with the CONTRACTOR’s dewatering plan, proposed pipe lengths and shall consider the frequent crossings of existing utilities that will be encountered. C. Excavation of earth material below the bottom of a shield shall not exceed the limits established by ordinances, codes, laws and regulations. D. When using a shield for pipe installation, any portion of the shield that extends below the spring line of an installed rigid pipe, the shield shall be raised above this point prior to moving the shield ahead for the installation of the next length of pipe. E. When a shield is removed or moved ahead, extreme wre shall be taken to prevent the movement of pipe or structures or the disturbance of the bedding for pipe or structures. Pipe or structures that are disturbed shall be removed and reinstalled as specified and shown. EXCAVATION AND BACKFILL 02220-9 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK F. All surface and subsurface improvements adjacent to the Work shall be protected by the CONTRACTOR. Replacement or repair of existing utilities and surface improvements shall be performed at no additional cost to the DISTRICT. G. Sloughing or deterioration of the trench wall behind the shield or shoring shall be replaced and compacted in accordance with Paragraph 3.6 of this Section. The cost of this work shall be included in the CONTRACTOR’s unit price bid for pipe installation. Should pavement removal and replacement be necessary outside the limits shown on the drawings in order to achieve the required compaction, the cost of this work shall also be included in the CONTRACTOR’S unit price bid for pipe installation. 3.6 >I ACING AND COMPACTING TRENCH BACKFjl,.L A. General: Backfilling and compacting shall be in accordance with SSPWC Section 366-l .3. 1. Pipe Trenches Below Pavement: Compact the upper 124nches of backfill in pipe trenches below pavement subgrade to not less than 95 percent relative compaction. 2. Pipe Trenches Not Below Pavement: Compact backfill in pipe trenches not below pavement to not less than 90 percent relative compaction. 3. Jetting and flooding backfill will not be permitted. B. BackfIll excavations as promptly as Work permits, but not until completion of the following: 1. Acceptance by District of construction below finish grade. 2. Inspection, testing, approval, and recording of locations of under- ground utilities. 3. Removal of trash and debris. C. Keep excavations dry during backfilling operations. Bring backfill around pipelines and manholes up evenly on all sides. D. Place backfill in pipe trenches in 6-inch compacted layers. 3.7 SLOPF RFPAIR AND STAR11 IZATION A. Areas over which fills are to be placed shall first, be cleared and grubbed in accordance with Section 02050, Demolition. B. A slope shall be defined as any area equal to or steeper than three horizontal to one vertical. The hinge points (the top and bottom) of slopes shall be located within 3 inches of the locations shown on the Plans. C. Fill material shall be select fill as specified in Paragraph 2.1 .C. EXCAVATION AND BACKFILL 02220-l 0 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK D. Placing Fill Material: Fill material shall be placed in horizontal layers of depths compatible to the material being placed and the type of equipment being used. Each layer shall be evenly spread and moistened or aerated, as necessary. Unless otherwise approved by the Engineer, each layer spread for compaction shall not exceed 8 inches of compacted thickness. Unless otherwise permitted by the Engineer, each layer of fill material shall cover the length and width of the area to be filled before the next higher layer of material is placed. 1. All fill soil shall be placed at a moisture content no less than 1 percent below optimum moisture or 5% above as determined by ASTM test D-l 557-91. 2. When the moisture content of the fill material exceeds the optimum moisture content by more than 5% or is too wet to achieve proper compaction, the fill material shall be aerated by the CONTRACTOR by blading, mixing, or other satisfactory methods until the moisture content is as required to permit proper compaction. E. Compaction of fill material shall be performed in accordance with the requirements of Section 3004.7 of the SSPWC. 1. Compaction Feathering of fill over the tops of slopes will not be permitted. The face of fill slopes shall be compacted with a sheeps foot roller at vertical intervals no greater than 2’ or shall be built and cut back to finish grade. In addition, if not over built and cut back, the face of the slope shall be track walked upon completion. 3.8 RFSTORING AND RFSURFACING FXISTING ROADWAYS AND FACII ITIFS A. Pavement or roadways damaged by construction operations shall be restored. 3.9 FIFLD QUALITY CONTROI A. Field density tests shall be performed by the District on all compacted fill to provide a basis for determining whether the fill material has been compacted to the minimum relative compaction specified. Tests must shown that all compacted or recompacted areas indicate a relative compaction as specified. Density tests shall be made in the compacted material below any disturbed surface. B. The frequency of field density tests shall follow the minimum requirements listed below. The actual frequency of tests shall be based on the more stringent condition for trench backfill: 1 test every 50 cubic yards 1 test every 2 feet vertical 1 test every 100 feet horizontal EXCAVATION AND BACKFILL 02220-l 1 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK C. If the specifed densities are not obtained because of improper control of placement or compaction procedures, or because of inadequate or improperly functioning compaction equipment, the CONTRACTOR shall perform the work required to provide the required densities. This work shall include complete removal of unacceptable fill areas, and replacement and rewmpaction until acceptable fill is provided. 3.10 /FROSION CONTROL A. Erosion control shall be provided as detailed on the Contract Drawings and maintained during all phases of construction to minimize soil erosion. B. Minimize erosion, turbidity and siltation on the work site by proper scheduling of work and careful construction practices. Trap sedimentation in temporary debris basins where sediment is caused by construction operations. Employ erosion control measures and temporary site drainage structures where significant erosion would occur during the winter periods. C. Immediately restore all erosion control devices to working order after each rainfall. D. Silt and other debris shall be removed after each rainfall. E. Toe of reconstructed fill slope at lagoon outlet shall be protected with l/2 ton riprap. F. Filter Fabric shall be used below riprap. G. Newly graded fill slopes shall be protected with a biodegradable erosion control blanket with the approved seed mix. 3.11 HYDROSFDING A. Landscape Materials. 1. General: Revegitate disturbed areas in the railroad right&way caused by construction activities and any additional areas designated by the Engineer. 2. Commercial Fertilizer. Preplant fertilizer shall be granular commercial fertilizer 7-7-7 or approved equal. Postplant fertilizer shall be 124-6 or approved equal with Ca, Fe, Zn, and Mn and with the majority of nitrogen in nonammoniac form to prevent acidification of soil. Planting tablets shall be compressed fertilizer tablets with a 20-10-S analysis. Hyroseed fertilizer shall be long-lasting, controlled- release, plastic-coated, uniform in compostition, free-flowing, suitable for application with approved equipment, and shall contain the minimum available percentages of nitrogen, phosphoric acid, potash and suifur required by table in Paragraph C of this Section. 3. Organic Soil Amendment: For all types of Organic Soil Amendment mulch materials produced from pine trees grown in Alameda, Monterey, Santa Clara, Santa CNZ or San Mateo Counties shall not be used in the Work. Type 1 A Organic Soil Amendment shall EXCAVATION AND BACKFILL 02220-l 2 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK conform to the requirements for type 1 Organic Soil Amendment except as modified hereinafter. Type 1A Organic Soil Amendment shall be a wood or rice residual product derived from the bark of pine, white fir, or red fir or cedar or redwood shavings or rice hulls. Type 1A Organic Soil Amendment shall be manufactured from clean wood, free from clods coarse objects and rocks and shall conform to the following: Wettability I (1) I (1) I 4. For all types of Organic Soil Amendment submit a sample of the proposed amendment accompanied by an analytical analysis from an agricultural laboratory, Mary Matava of AgriServiws (7575451) shall certify compliance to the requirements herein. B. Mulch for Hydraulic Method Seed Lawn Planting: The terms hyroseeding and hydroseed shall be synonymous with hydraulic. Disturbed areas, and planting areas shall be mulched, fertilized and seeded using methods B. Mulch shall be manufactured from virgin wood cellulose fiber mulch and shall not contain growth or germination inhibitors. When mixed with water, the mulch shall remain in uniform suspension and when blended with the seed, fertilizer, and other approved additives, shall form homogeneous slurry. When applied, the fibers shall form a moisture absorbing membrane with adequate percolation properties sufficient to allow one hundred percent of water applied at the rate of 3.1 liters per minute per square meter (0.075 gallons per minute per square foot) onto a surface inclined at a 2:l (horizontal: vertical) slope to pass through the membrane. A non-phyto-toxic wetting agent shall be added to the slurry mixture. A water soluble, non-toxic green dye shall be added in sufficient quantii to clearly delineate the planted areas. When required, binder shall be added to the slurry mixture “CPA 4000”, “AZTAC”, “Ecology Control” M-Binder, or approved equal. EXCAVATION AND BACKFILL 02220-l 3 VISTNCARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK C. Disturbed Area Mulch Fertilizer and Additives: In addition to the seed mix shown in the table for Disturbed Areas the slurry mixture shall be applied at the rates as follows: Component Application Rate grams per sq. meter (pounds per acre) Virgina Wood Cellulose Fiber Mulch 225 (2000) Binder (1) 7 (60) Fettilizer (16-20) Ammonium Phosphate Sulfate, 35 (399) Plus 15% Soil Sulfur Wetting Agent Per Mfg. Recommendation Green Colorant Per Mfg. Recommendation (1) Required to be incorporated only when applied between the months of Nov. through Feb. D. Herbicides and Pesticides: Shall be used in their appropriate applications with strict adherence to manufacturer’s specifications and instructions. Postemergent herbicide for all areas shall be Roundup, Diquat, Montar, or approved equal. Preemergent herbicide for shrubs and groundwver areas planted from flats shall be Treflan, Surflan, Eptan, or approved equal. E. General Soil Conditioners: Agricultural-grade gypsum shall be a calcium sulfate (CaSO, H,O) product - 94.3 percent. 90 percent shall pass a 59-mesh screen. Control of dust during application is mandatory. Iron Sulfate shall be ferrous sulfate in pelletized or granular form containing not less than 20.0 percent iron expressed as metallic iron. Iron Sulfate pellets shall be of size and gradation such that 98 percent is retained on a lo-mesh screen. F. Stabilizing Emulsion: Stabilizing emulsion shall be a concentrated liquid chemical that forms a plastic film upon drying and allows water and air to penetrate. The film shall be nonflammable and shall have an effective life of at least one year. Stabilizing emulsion shall be nontoxic to plant and animal life and nonthinking to concrete or painted surfaces. In the cured state the stabilizing emulsion shall not be re-amulsifiable. The material shall be registered with, and licensed by the California, Department of Food and Agriculture, as an “auxiliary soil chemical”. Stabilizing emulsion shall be miscible with water at time of mixing and application. G. The quantity of pure live seed supplied shall meet or exceed the quantlty shown in the specified mixes. Seed shall not contain more than 0.5 percent weed seed by volume. All brand-name, patented seed must be received by Contractor in original manufacturer’s bag. Seed shall be received by Contractor in separate containers specifying kind, quantity, purity, and germination. Contractor shall provide the Engineer with each seed bag label used in the Work. EXCAVATION AND BACKFILL 02220-14 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK H. Seed for Disturbed Areas: Hydroseading mix for Disturbed Areas shall consist of no less than the seed varieties as follows: Seed Variety Application Rate Grams per sq. meter (pounds per acre) Rose Clover 2.5 20 0) Festuca Megalura, Zorro Fescue 2.5 20 Eschscholzia California 0.35 3 Achilles Millefolia 0.45 4 Alyssum (Carpet Of Snow) 0.35 3 Dimorpholeca 0.25 2 (1) Rose Clover shall be inoculated with nitrogen-fixing bacteria and be applied dry either by drilling or broadcasting immediately before hydraulic application of the remaining seed mix and mulch. 3.17 DISPOSAI OF FXCAVATFD MATERIAI S A. Material removed from the excavations which does not conform to the requirements for fill and excess excavated materials shall be hauled away from the project site and disposed of in compliance with ordinances, codes, laws and. regulations at no additional cost to the District. The CONTRACTOR shall utilize highway legal trucks for the export of material from the project site and to a site secured by the CONTRACTOR. No earth moving equipment or special construction equipment, as defined in Section 565, of the California Vehicle Code, will be allowed for hauling material on public streets. 8. In lieu of disposal, the CONTRACTOR may determine if excess material is suitable for local beach nourishment in accordance with the City’s Opportunistic Beach Sand Program. If the material is deemed acceptable by the City, then it shall be placed in the location designated by the City at no additional cost the DISTRICT. Contact Steve Jantz, City of Carlsbad at 760- 436-l 161, Ext. 4354. ++ ENDOFSECTION ++ EXCAVATION AND BACKFILL 02220-15 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK SECTION 02230 CRUSHED STONE AND GRAVEL PART 1 GFNWAL B lL1 DFSCRIPTIQN A. scope: 1. Perform the work required to provide all crushed stone, sand, and gravel of the types shown, specified and required for wnstnrction of pipelines, manholes, structures, pavement, slope buttress and other facilities required to complete the Work. B. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. C. Referenced Sections: SSPWC: 1. Section 200-l .l , Rock Products - General. 2. Section 200-1.2, Crushed Rock and Rock Dust. 3. Section 200-2.2, Crushed Aggregate Base. 4. Section 301-2, Untreated Base. 5. Section 306-l .2.1, Bedding. D. Related Sections: 1. Section 2-5.2, Precedence of Contract Drawings. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 4-2, Materials Transportation, Handling and Storage. 4. Section 01025, Measurement and Payment. 5. Section 02220, Excavation and Backfill. 6. Section 02500, Pavement. 7. Section 06653, Filter Fabric. 8. Section 15051, Buried Piping Installation. 1.2 QUALITY ASSURANCF A. Reference Specifications: Unless othenvise specified or shown on the Plans, all work specified herein shall conform to the requirements of SSPWC Sections 200-1, Rock Products. B. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section Z-5.2. CRUSHED STONE AND GRAVEL 02230-l VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 1.3 SUBMl7-fm A. Submit the following in accordance with Section 2-5.3. B. Representative samples of the crushed stone, sand, and gravel and the source location. C. Laboratory results of tests specified in SSPWC Section 200-l for crushed stone, sand, and gravel. 1. Laboratory tests shall be performed for each material used, when a change in material composition is observed, and when the supplier is changed. MATFRIAI ,S TRANSPORTATION. HANDLING AND STORAGF A. Refer to Section 4-2, Materials, Transportation, Handling and Storage. 1.5 MPASUWT AND PAYMFNT A. Refer to section 01025, Measurement and Payment. PART 2 PRODUCTS - A. General: Provide crushed stone for pipe bedding and aggregate base for pavement. B. Pipe Bedding: Provide pipe bedding materials as follows: 1. Concrete Sewer Pipe: Nominal rock size: 3/4-inch. 2. PVC-Pipe: Nominal rock size: 316inch. 3. Concrete Storm Drain Pipe: Nominal rock size: 3/4-inch. - 4. For pipe bedding conditions, see Typical Trench Details shown on the Plans. 5. Material gradation and quality requirements shall comply with SSPWC Section 200-l -2. C. Encapsulated Crushed Stone Base for Manhole Bases and Structures: Provide base material as follows: 1. Nominal rock size: 3/4-inch. 2. For base conditions, see Standard Sewer Manhole Details shown on the Plans. 3. Material gradation and quality requirements shall comply with SSPWC Section 200-l -2. 4. For encapsulating material, refer to Section 06653, Filter Fabric. CRUSHED STONE AND GRAVEL 02230-2 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK D. Aggregate Base for Pavement: Provide crushed aggregate base which shall conform to Section 200-2.2 or crushed miscellaneous base (CMB) which shall meet the requirements of Section 200-2.4 of the SSPWC. Gradation of CMB material shall conform to the requirements for “fine” grading per Section 200-2.4.2, Grading. E. Gravel for Buttress Fill Stabilization: 1. Nominal Rock Size: 1-l/2-inch. 2. Material .Gradation and quality requirements shall comply with SSPWC Section 200-l .2. F. Riprap Bedding: 1. Material used on slopes shall be angular crushed gravel or crushed stone. Screened rounded river gravel is not acceptable. 2. Nominal Rock Size: 1 -l/2-inch. 3. Material Gradation and quality requirements shall comply with SSPWC Section 200-l .2 4. Filter fabric shall be used as riprap underlayment. a. Refer to Section 06653. PART 3 - FXFcI JTION . 3.1 A. Pipe Bedding: Provide crushed stone and select fill material in the pipe bedding zone as shown on the Plans. 1. Spread in layers of uniform thickness not exceeding 6 inches. 2. Compact each lift with suitable power driven vibrating drum rollers, tampers, or other power driven equipment. Jetting and flooding is prohibited. 3. Compact crushed stone bedding material until firm and unyielding. 4. Place select fill material in the pipe bedding zone and compact to the relative compaction shown on the Plans and in accordance with Paragraph 3.6.A of Section 02220. B. Base: Provide crushed stone encapsulated in filter fabric as foundation bases for manhole bases and structures. 1. Spread in layers of uniform thickness not exceeding 6 inches. 2. Compact each lift with suitable power driven vibrating drum rollers, tamper, or other power driven equipment. Jetting and flooding is prohibited. 3. Compact crushed stone bedding material until firm and unyielding. 4. Refer to Section 06653, Filter Fabric. C. Aggregate Base for Pavement: The aggregate base for pavement shall be 8-inches in depth. 1. Pavement replacement section is shown on the Plans. 2. Comply with the requirements of Section 301-2 for placement of aggregate base. CRUSHED STONE AND GRAVEL 02230-3 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK D. Gravel for Buttress Fill Stabilization: 1. May be placed in a single lift to the depth shown on the Plans. 2. Compacted with a minimum of 4 passes with a heavy vibratory roller. E. Riprap Bedding: 1. Thickness: 12-inches. + + END OF SECTION + + - CRUSHED STONE AND GRAVEL 02230-4 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS . SITE WORK SECTION 02235 STONE RIPRAP PART- - 1.1 DFSCRIPTION A. Scope: 1. Perform the work required to provide all stone riprap of the types shown, specified and required for construction of slopes, - embankments and energy dissipators required to complete the Work. B. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. c. Referenced Sections: SSPWC: 1. Section 200-l .6, Stone for Riprap. 2. Section 300. Earthwork. D. Related Sections: 1. Section 2-5.2, Precedence of Contract Drawings. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 4-2, Materials Transportation, Handling and Storage. 4. Section 01025, Measurement and Payment. 5. Section 02220, Excavation and Backfill. 6. Section 02230, Crushed Stone and Gravel. 7. Section 06653, Filter Fabric. 17 QUALITY ASSURANCF A. Reference Specifications: Unless otherwise specified or shown on the Plans, all work specified herein shall conform to the requirements of SSPWC Sections 200-l. Rock Products. B. If them is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. 1.3 SUBMITTALS A. Submit the following in accordance with Section 2-5.3. B. Source location of riprap material and laboratory results of tests specified in Section 200-l .6.3 of the SSPWC. 1.4 MATFRl&S TRANSPORTATION, HANDI ING AND STORAGF A. Refer to Section 4-2, Materials, Transportation, Handling and Storage. STONE RIPRAP 02235-l VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK A. Refer to section 01025, Measurement and Payment. PART 2 - PROMSIS 71 RIPRAP A. General: Provide riprap material to the extent shown on the Plans. Riprap material shall conform to the requirements of SSPWC Section 200-1.6, Stone for Riprap. - B. The stones shall be free of dirt, debris, deleterious material, laminations, weak cleavages, and undesirable weathering. Stone shall be sound, durable, and hard. Stones salvaged from excavation and meeting the above requirements may be used for riprap. C. Riprap Gradation: Gradation shall conform to the requirements of SSPWC Section 200-l .6, of the SSPWC, Regional Supplemental Amendment. 1. l/2 Ton Riprap Gradation: Layer Thickness as shown on the Plans. 72 RIPRAP BEpDlNG A. Material shall conform to the requirements of Section 02230, Crushed Stone and Gravel. B. Filter fabric shall be used as riprap undenayment. 1. Refer to Section 06653. E. PART 3 - F,XECUTION 3.1 PI ACING A. Subgrade: Prepare subgrade for riprap bedding to the required lines and grades. Compact subgrade to 90 percent maximum density in accordance with ASTM D1557. B. Subgrade: Place filter fabric underlayment over prepared subgrade. 1. Refer to Section 06653. c. Riprap Bedding: 1. Refer to Section 02230, Part 3.1 .E. STONE RIPRAP 02235-2 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK D. Riprap: 1. Install riprap to the extent shown on the Plans. 2. Place the bottom layer of stones so that the weight of each stone is carried by the underlying material and not by the adjacent stones. On slopes, place the largest stones at the bottom. Riprap shall be of proper gradation to form a compact solid blanket to protect the slopes. Carefully fit and nudge each stone to achieve a solid three- point bearing and to lock solidly in place. Start placement at the bottom of the slope and work upward. In general, place the longitudinal axis of each outer rock perpendicular to the face of the slope. The top of the slope transitions shall be reasonably smooth. 3. Place riprap of the types specified such that the limits follow with reasonable variation the indicated lines and slopes without continuous underbuilding or overbuilding. Construct the tiprap to a full section so as to produce a stable revetment. Place all riprap from bottom of the slope upwards. Do not dump riprap from excessive heights or employ placement methods that may cause misplacement of stone. In order to achieve slope uniformity and solid seating, nudge all high-riding rocks with a normal-to-slope strike of the placement bucket, rock grab, or another rock held in a ;.mck grab. Nudging shall be carefully controlled to prevent dislodgement of more distant rocks with impact sufficient only to consolidate the immediate area around the riprap being nudged so as to bring it within tolerance limits and lock it firmly in place. Where nudging fails to achieve this purpose, the stone shall be ltfted and re-seated for better fit or replaced with a better fitting stone. Placement methods are subject to approval of the 3istrict. 4. Misplacement Material: Remove rock which is misplaced, laying beyond the limits of the construction indicated on the Plans, and unacceptable rocks prior to completion of the work. ++ ENDOFSECTION ++ STONE RIPRAP 02235-3 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK SECTION 02300 TUNNELING OPERATIONS PART 1 GF,NERAt - 1.1 DFSCRIPTION A. Scope: 1. Perform the work required to provide all excavating, sheeting, shoring and initial supports shown, specified and required for tunneling operations required to complete the Work. 2. The extent of tunnels is shown on the Plans. 3. This Section specifies the construction of tunnels by methods using man-entry tunneling operations to the alignments and grades shown. 4. This Section defines in general terms the Work to be completed. The CONTRACTOR shall have sole responsibility for the means and methods utilized to construct the tunnels to the lines and grades shown and for preventing settlement and heave, all within the tolerances specified and subject to review by the Engineer. The CONTRACTOR shall demonstrate to the Engineer that the proposed means and methods will complete the Work in accordance with the Contract Documents. 6. Definitions: 1. Mechanised Shield: Tunnel excavation using an open face shield tunneling machine with closeable doors and a digger boom for excavation. This machine shall be equipped for removal of boulders up to 20 inches in diameter. 2. Tunnel Initial Support: Elements designed, furnished, installed, monitored, and maintained in the tunnel for ground- support, excavation stability, and safety during construction. Pipes jacked into place may be used as initial suppoit as approved by the District. 3. Pipe: The pipe installed following tunnel excavation and initial support of the tunnel, or directly jacked into place. 4. Direct Jacking: Installation of the pipe by jacking it into the ground behind a tunnel shield with no initial support installation required. 5. Tunnel Shield: The structural full perimeter element at the front of the tunnel where excavation takes place. 6. Thrust Block: The structural/soil system which provides a reaction for loads associated with pipe jacking located at the back of the jacking pit. 7. Microtunneling: A remotely controlled, guided pipe jacking process that provides continuous support to the excavation face. The microtunneling process provides ability to control excavation face stability by applying mechanical or fluid pressure to counterbalance the earth and hydrostatic pressures. TUNNELING OPERATIONS 02300-l VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 8. 9. Surface Settlement Points: Survey control points established at the ground surface along the pipe alignment for monitoring surface settlement due to subsurface excavation. Auger, Boring Machine: An auger boring machine is the motor employed to drive an auger which carries out the excavation of soil material within a steel casing. The casing is driven forward into place and the auger segments are later removed. C. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. D. Referenced Sections: 1. SSPWC, Section 300, Earthwork. 2. SSPWC, Section 306-1, Open Trench Excavation. 3. SSPWC, Section 306-3, Tunneling Operations. E. Related Sections: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Section 2-5.2, Precedence of Contract Documents. Section 2-5.3, Shop Drawings and Submittals. Section 4-2, Materials Transportation, Handling and Storage. Section 7-9, Protection and Restoration of Existing Improvements. Section 7-10, Public Convenience and Safety. Section 01025, Measurement and Payment. Section 02140, Dewatering. Section 02220, Excavation and BacMill. Section 02306, Microtunneling. Section 02310, Jacking and Receiving Shafts. Section 02320, Tunnel Support Systems. Section 02340, Boring and Jacking (Steel Casing). Section 03610, Contact Grouting. - Section 03620, Low Density Cellular Concrete. Section 03630, Compaction Grouting. Section 15051, Buried Piping Installation. Section 15064, Reinforced Concrete Pipe. Section 15073, Concrete Pressure Pipe. Section 15083, Fiberglass Mortar Pipe. 1.2 A. Qualifications: The CONTRACTOR shall be qualified for tunneling operations as follows: TUNNELING OPERATIONS 02300-2 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 1. 2. 3. 4. All tunneling operations shall be performed by a qualified CONTRACTOR, approved by the Engineer, with at least 5 years, and 2000 LF experience using the tunneling methods that will be used for this project. At all times, perform the work under the direction of an experienced project superintendent with at least five years recent on- the-job supervision experience on similar projects involving tunnels of similar size constructed by similar methods. Safety Representative(s) shall have at least five years experience in tunnel construction and be certified by CAUOSHA. Personnel responsible for testing for underground gasses shall be certified by CAUOSHA as a Gas Tester. Tunnel surveying shall be done by a California licensed land surveyor who has at least three years recent experience in surveying for tunnels. B. Reference Standards and Codes: Comply with applicable provisions and recommendations of the following, except as otherwise shown or specified. 1. Standards: a. ASTM A53: Specification for Pipe, Steel, Black and Hot- Dipped, Zinc-Coated Welded and Seamless. b. ASTM C 443: Specification for Joints for Circular Concrete Sewer and Culvert Pipe Using Rubber Gaskets. 2. Codes: a. CAUOSHA, State of California Administrative Code, Title 8, Industrial Relations, Chapter 4. Division of Industrial Safety, Subchapter 20, Tunnel Safety Orders. b. Occupational Safety and Health Administration (OSHA) Regulations and Standards for Underground Construction (29 CFR Part 1926, Subpart S). C. Permits and Regulations: 1. Obtain all applicable permits for earthwork, work in toads, right-of- way, etc., as required by local, state and federal agencies. 2. Comply with all construction dewatering discharge requirements specified in Section 02140, Dewatering. 3. Comply with requirements of the Storm Water Pollution Prevention Plan and Monitoring Plan as indicated in Section 7-8.6. 4. Perform excavation work in compliance with applicable requirements of governing authorities having jurisdiction. 5. Work within the railroad right-of way shall be performed in accordance with the requirements of Paragraph 1.2.B of Section 02306, Microtunneling. D. Subsurface Information: A geotechniwl investigation has been performed by Woodward-Clyde. 1. Refer to Section 7-16. E. Notify the Enginer a minimum 3 workdays in advance of the start of tunneling operations. TUNNELING OPERATIONS 02300-3 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK F. Perform all work in the presence of the Engineer or District’s representative, unless the Engineer has granted prior approval to perform such work when absent. G. Alignment Tolerances: The following tolerances apply to the construction of tunnels. 1. Line Tolerance: 0.3 feet. 2. Grade Tolerance: 0.1 feet. H. Allowable Ground Surface Settlement and Heave Tolerances: Refer to Paragraph 1.4.8 of this Section. I. Surveys: Surveys shall be conducted by a professional surveyor licensed by the State of California. 1. Refer to Paragraph 3.5.B of this Section. J. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. K. General Requirements for NCTD/SDNR Railroad Crossing: 1. Contact Eric Hankinson at (714) 7568800 at least one week in advance of excavation to mark out SDNR’s underground signal cables. NCTD is not a member of Underground Service Alert (USA). 2. NCTD track inspectors will sight the track daily for settlement from excavation, jack and bore, and/or microtunneling activities. The CONTRACTOR shall be responsible for any track resurfacing costs from heaving or settlement caused as a result of construction activities. 3. NCTD flag protection is required at all times when the CONTRACTOR is on the railroad right-of-way. Contact Chip Willett at (760) 9666594 at least 72 hours in advance to schedule flag protection. 4. An SDNR Engineering Representative, in addition to a flagman, is required when jacking the casing under the track. Contact Eric Hankinson at least one week in advance to schedule the Engineering Representative. 1.3 SUBMITTALS A. Submit the following in accordance with Section 2-5.3. B. Submittals: Submit the following work plans, drawings, and details for review. These submittals shall be prepared and sealed by a Civil Engineer registered in the State of California. 1. Tunnel Work Plan: A detailed description of the tunneling equipment and procedures to be employed. Provide manufacturer’s literature describing, in detail, the shield tunneling system to be used. Describe the methods and capabilities for exerting pressure on the tunnel face and maintaining stability of the tunnel heading. Clearly TUNNELING OPERATIONS 023004 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 2. 3. 4. 5. 6. 7. tunnel face and maintaining stability of the tunnel heading. Clearly indicate the maximum size of boulder that wn be excavated and removed by the proposed tunneling system. The plan shall include details of proposed methods and procedures for excavating the tunnels, hauling and disposal of tunnel muck, ventilation, illumination, initial support procedures, supporting face if tunneling operations are interrupted, erosion control, procedures for handling, control, and disposal of surface water and groundwater. Settlement Control Plan: A plan to protect existing utilities, streets, residences, railroads, and other structures and improvements from damage resulting from settlement and heave caused by tunneling operations. Tunnel Shield: Shop drawings and details for a full-circle tunnel shield, including details of propulsion system, safety systems, breasting capabilities, and steering provisions for making line-and- grade corrections. Include details of provisions for supporting the face of the tunnel required by ground conditions when tunneling operations are interrupted. Clearly indicate the maximum size of boulder that can be excavated and processed by the proposed mtichine. a. The shield manufacturer’s product information, description, model number, details, working arrangement drawings, steering procedures, machine controls, specifications, and operating procedures. b. Drawings and details showing excavation and mucking systems and components: support erector details and other provisions for installing initial supports; and trailing equipment, including muck conveyors. C. Maintenance procedures and a list of spare parts to be maintained onsite. d. Description of procedures for shield demobilization and removal from the tunnel. Drawings and details for power, lighting, and ventilation_ systems; dust control system; air monitoring system; electrical system; and temporary and back-up power provisions. Tunnel safety plan accident prevention program, code of safe practices, emergency plan, and other CAUOSHA or OSHA safety requirements. Tunnel survey methods and procedures. Drawings and details for temporary muck stockpile and disposal plans. Provide a tunnel spoil handling plan, including anticipated daily production volume, layout and description of spoil handling equipment, details of stockpiling locations and procedures, and disposal procedures. TUNNELING OPERATIONS 023004 -e.- VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK C. D. 8. 9. 10. A description of the alignment control and steering system. Confirm that these systems are steerable and can maintain an accuracy within the tolerances specified in Paragraph 1.2.G. The laser guidance control system must be mounted such that it is isolated from the movements of the shaft walls, floor, and equipment. Include a description of the equipment and procedures to be used in checking the positioning of the alignment control system during tunneling operations, Layout of the access pit, including all major equipment and staging areas. This plan drawing shall show, at a minimum, the layout of the shaft equipment, crane, control cabin, and muck handling area, and staging areas. Details on how the proposed equipment and operations will prevent loss of ground and surface heave during tunneling operations. These methods shall include procedures to handle face stability and groundwater if required. Reports and Records: Submit weekly the following: 1. Daily Logs and Reports: Records of construction logs and reports shall include, at a minimum, the hours worked by the crew, the number of people on the crew. survey notes, records, thrust force, rate of advance, the excavation procedures, characterization of excavated material, the position of the equipment relative to the steering apparatus, steering corrections, and other pertinent information. 2. Survey records of tunnel excavation including deviations from design line and grade. Indicate how the deviation from design line and grade of the tunnel was determined. 3. Comply with all applicable health and safety reporting requirements. Provide reports as required by public authorities and provide a copy of each report to the District at the same time report is transmitted to the agency. Schedule: Submit a schedule for the tunneling work identifying all major construction activities as independent items. The schedule shall include, as a minimum, the following activities: mobilization, equipment set-up, tunneling activities, equipment teardown, and demobilization. The schedule shall also include planned working hours for each activity, and a written description of the construction method and equipment to be employed during each activity. The schedule shall be reviewed with the District and shall be updated and resubmitted by the CONTRACTOR every week or more frequently lf conditions warrant, as decided by the Owner. TUNNELING OPERATIONS 02300-6 _.- _ VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK E. Calculations: Submit the following calculations: 1. Design calculations demonstrating that the pipe is capable of sustaining the maximum stresses to be imposed during jacking with a factor of safety of at least three (3). The calculations shall take into account maximum ground loads, live loads, jacking forces, eccentric forces due to steering, external loads such as traffic, and other loads which may be reasonably anticipated. All loads shall be shown and described. 2. Calculations showing the hydraulic pressure which is required to develop the maximum allowable jacking pressure. A description of controls to ensure that this hydraulic pressure will not be exceeded during jacking operations. Calculations demonstrating that the soils behind the thrust Mock will sustain the maximum forces developed by the main jacks. F. Equipment and Procedures: Submit all that apply: 1. Lubrication System: Details of the bentonite injection/lubrication system used for lubrication during tunneling. Submit calculations on the volume of the annular space and the amount of lubrication material required to completely fill the annular space. A lubrication plan shall be submitted detailing the type of lubrication material to be used, including manufacturer’s literature on the lubrication product. 2. MuckfSlurry transport and Disposal: Details on the mucklsluny transport procedures. For slurry microtunneling, this will include the slurry separation procedures and planned slurrq! removal procedures. For the mechanized shield tunneiing, this will include the equipment used to transport, haul, and remove muck from the site. 3. Jacking Equipment: Details on the jacking equipment including the design capacity and drawings of the jacking frame, the jacking controls, and the location of the pressure measurement gages. 4. Thrust Block: Thrust block design and details, including dimensions, load capacity and thrust transfer calculations. 5. Compression Rings/Jacking Strips: Details of compression rings/jacking strips that will be used. 6. Launch Seals: Details on the launch seal, including a dimensioned drawing, to prevent lubrication, slurry, and groundwater inflows into the shaft during tunneling operations. G. Safety Plan: Submit a general and tunneling safety plans in compliance with all general OSHA regulations and those governed by the Cal/OSHA Mining and Tunneling Division. 1. Submit the name and experience of the site safety representative. 2. Submit the name of the designated on-site gas tester and documentation of CAUOHSA certification. H. CONTRACTOR’s Qualifications: In accordance with Paragraph 1.2.A of this Section. TUNNELING OPERATIONS 02300-7 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK I. Submittals for work to be performed within the railroad right-of-way require approval by NCTD. A. Tunneling Equipment: Use only tunneling equipment, approved by the Engineer, meeting the requirements specified in this Section for the tunneling work described. Equipment shall be designed to minimize loss of ground, and minimize settlement and heave of the ground surface. B. Allowable Ground Surface Settlement and Heave Tolerances: Control ground surface settlement and heave to the following tolerances: 1. 112 inch for roadways. 2. l/8 inch for railroad crossings. 3. 1 inch within railroad right-of-way, parallel to railroad tracks. C. Thrust Block: The thrust block shall be normal (square) with the proposed pipe alignment and shall be designed to withstand the maximum jacking pressure to be used with a factor of safety of at least 2.0, without excessive deflection and displacement. TRANSPORTATION. HANDLING AND STORAGE A. Refer to’section 4-2, Materials Transportation, Handling and Storage. NT AND PAYMFNT A. Refer to Section 01025, Measurement and Payment. PART 7 PRODUCTS - A. Tunnel Excavation: Tunnel excavation shall be carried out with the use of an open face shield tunneling machine with closeable flood doors, an open face digger shield with breasting capabilities, an auger boring machine, or a microtunneling machine. B. Tunnel Shield: The hrllcircie shield shall be designed to sustain ground loads which may be imposed upon it as well as loads imposed by the thrust jacks, steering mechanisms, and other appurtenances. The shield shall be capable of being controlled to the desired line and grade within the tolerances specified herein. Use a circular tunnel shield of design suitable for the work conforming to the shape of the tunnel having uniform exterior surface from the leading edge to the trailing edge, and free of projection, except beads. that will produce overexwvation or voids. The shield shall be continuous around its full perimeter. Ensure that the shield is sufficiently strong to maintain its true shape during use. The tunnel shield shall be TUNNELING OPERATIONS 02300-B VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK capable to address the anticipated geological conditions described in the Geotechniwl Report. The shield shall also satisfy the following requirements: 1. The shield shall be steerable in both vertical and horizontal directions to maintain line and grade within the specified tolerances. Provide steering jacks as required to correct line and grade deviations during jacking. If a rotary-type cutterhead is used, the cutterhead shall have a reversible drive system so that it can rotate in ether direction to minimize rotation or roll of the pipe during installation. 2. The shield shall be capable of advancing through the geologic conditions described in the Geotechniwl Report, and of excavating, handling, and removing cobbles up to 20-inches in diameter. 3. The tail of the shield shall have gaskets to prevent material from moving into the tunnel through the joint between the tail skin and the Pipe. 4. The maximum allowable overcut shall not be greater than 1 inch larger in diameter than the outside diameter of the jacked pipe. PART 3 FXECUTlON w 3.1 L TSMPNTS A. Tunnel Excavation: Tunnel excavation shall not begin until the following conditions have been met: 1. Required submittals have been made and the District has reviewed and accepted submittals. 2. Shaft excavation, stabilization and shoring have been satisfactorily completed in accordance with Section 306-3.2. 3. Survey control has been established for the tunnel and has been verified by the District. 4. A prejob safety conference has been conducted in accordance with CALIOSHA requirements. Arrange this conference and inform the District of the time and place of the conference at least 7 days in advance. B. Ground Movement: Conduct shaft and tunnel excavation in .a manner that will minimize ground movements and loss of ground and minimize settlement and heave of the ground surface, structures, and utilities above and adjacent to the tunnel. Use positive control methods to prevent loss of ground and surface settlement. 1. Immediately repair damaged ground resulting from surface settlement and heave caused by shatt and tunneling operations to the satisfaction of the Agency having jurisdiction, at no additional cost to the District. a. Refer to Paragraph 1.4.B of this Section. TUNNELING OPERATIONS 02300-g VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK C. Support: Support the ground continuously in accordance with the provisions of Section 306-3.4, and in a manner that will prevent loss of ground and maintain the stability of the tunnel perimeter and face. Support the tunnel face by positive means during all shut down periods. D. Air Quality: Provide, operate, and maintain for the duration of tunnel construction a temporary ventilation system and air quality monitoring system which conforms to the requirements of all federal, state, and local regulations. Ventilation fans shall be located at the access pit or inside the tunnel. No intermediate vent shafts will be permitted. Remove ventilation system from the site when the work is completed. Provide a silencer as needed to comply with noise restrictions, 1. Refer to Par& 3.7 of this Section. E. Temporary Lighting: Provide, operate, and maintain for the duration of construction operations temporary lighting systems which conform to the requirements of ail federal, state, and local taws. All construction areas shall have sufficient lighting and ventilation to ensure proper performance and inspection of the work. F. Housekeeping: Maintain clean working conditions at all times inside the tunnel, and remove all muck, grout spilk, unused timber, and all material not required for tunneling. G. Access: Provide access for the District to inspect and observe the work, to perform independent line and grade surveys, to perform geologic mapping, to monitor instrumentation, and to install additional instrumentation, as deemed necessary by the District. H. Delays: Prosecute tunneling work in accordance with the working hours established for the project. Notify the District at least 3 days in advance of a proposed change in working hours except in emergency conditions. When the work is interrupted for more than 4 hours, the tunnel face shall be fully supported in accordance with accepted submittals. I. Emergency Stoppage: In case of emergency or work stoppages likely to endanger the stability of the excavation or adjacent structures, maintain a full work force 24 hours per day, including weekends and holidays, until emergency or hazardous conditions no longer jeopardize stability and safety of the work. J. Safety: Tunneling operations shall be conducted in accordance with CAUOSHA Mining and Tunneling Division regulations. The designated gas tester shall be on site during operations when personnel are underground and occupying the confines of a tunnel. 1. Refer to Part 3.7 of this Section. TUNNELING OPERATIONS 02300-10 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK K. Alignment Control System: All steering corrections will be controlled to prevent problems that result form over-steering such as high jacking forces, point loading, broken pipe sections, and opening of joints. Steering corrections shall be made gradually to build a uniform tunnel with proper line and grade control. The laser shall be mounted such that it is isolated from any movements or vibrations of the shaft walls, floor or equipment. The path of the laser target shall not be obstructed by equipment or objects. The position of the laser shall be checked at the beginning, middle, and end of each shift. Adjustment of the laser position shall be under the explicit direction of the CONTRACTORS approved Surveyor in consultation with the District. If the laser is bumped or moved, the surveyor shall direct the Superintendent on repositioning techniques. The position and any modification or correction shall be recorded on the daily survey records. 1. Refer to Paragraph 1.3.G. L. Lubrication: Continuous lubrication of the annular space will be required during tunneling operations. Pumping will be sufficient to completely fill the annular space with lubrication material during tunneling operations. The lubrication materials shall be selected by the CONTRACTOR, in accordance with the geotechnical conditions. Preparation of the lubrication mixture and pumping schemes shall be controlled in the field based on jacking forces. Lubrication application through lube ports and valves shall be adjusted during tunneling according to jacking forces. Lubrication pumping pressures shall be controlled to minimize possibility of lubrication returns to the surface or at alternate undesirable locations. Lubrication materials shall be on site prior to launch of the tunneling operations. M. Compression Rings/Jacking Strips: Provide plywood compression rings/jacking strips between each pipe joint to evenly distribute load transfer across pipe joints. N. Launch Seals: Provide launch seals to prevent lubrication, slurry, and groundwater intlows into the shaft during tunneling. 0. Location of Jacking Frame/Guide Rails: Prior to starting tunneling operations, the location and orientation of the jacking frame shall be verified by survey to ensure that the equipment is in position in accordance to the design line and grade of the pipeline. P. Slurry: The CONTRACTOR shall select slurry mixtures. Viscosity and unit weights shall be checked 3 times per shift (at the beginning, middle, and end of each shift) and adjusted as necessary for proper performance, as determined by the CONTRACTOR. Drilling tluids shall be added to adjust the viscosity of the slurry depending on the materials encountered during excavation. Adjustments to the slurry composition shall be recorded in the daily logs. The slurry shall be controlled to prevent heave, settlement, face deterioration, and damage to equipment. The slurry flow rate shall be controlled to prevent over-excavation of material and blockage of slurry lines. TUNNELING OPERATIONS 02300-l 1 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 ‘IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK cl. Muck Removal Procedures for Slurry Separation Tanks: The muck shall be removed from the tanks at the direction of the on-site technical supervisor. Muck removal will be controlled to maintain appropriate slurry viscosity. Frequency of muck removal will be dependent on the percentage of fines encountered during the excavation procedures. R. Trouble Shooting: Based on the infom\ation gathered during the tunneling operations, CONTRACTOR shall develop and approve schemes for trouble shooting problems, such as mechanical problems, line and grade deviations, electrical malfunctions with the tunneling system, high jacking .forces, machines that become stuck, blocked slurry lines, locking of the tunneling head, and slow productivity/advance rates. 3.2 LINF AND GRADF TOI ERANCFS A. Tolerances: Refer to Paragraph 1.2.G of this Section. 6. No reverse grades shall be allowed. The grade over any ten-foot section of pipeline shall never exceed twice the design grade. C. Control tunnel excavation and construction of initial support to allow construction of the final lining elements in accordance with the specified tolerances. Monitor line and grade using an approved alignment control system and record the deviation from design line and grade following each shove. Laser supports should be independent of jacking frame and its supports. Do not continue to advance the tunnel if the laser system is not functioning properly. Stop pipe jacking operations and reset laser immediately if movement of laser occurs during the Work. Halt tunneling operations and reset laser, as approved by the District, prior to resuming tunneling. D. When excavation is off line and grade, return to design line and-grade at a rate not to exceed 2 inches per 100 feet. E. If the tunnel is sufficiently far off line and/or grade to require redesign of structures, acquisition of easements, or backfilling and m-excavation, the CONTRACTOR shall be responsible for doing so at no additional cost to the District. F. Survey the invert of the tunnel excavation at 50-foot intervals on at least a weekly basis, and compare survey data with design line and grade. Determine deviation from design line and grade. Determine deviation from design line and grade and provide survey report with a copy of survey notes indicating survey control established in the tunnel in accordance with Section 306-3.1.6. Survey shall be conducted by the approved tunnel surveyor. G. Establish benchmarks for establishing survey control, check benchmarks at the commencement of the tunneling operations. TUNNELING OPERATIONS 02300-12 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK H. When satisfied that all benchmarks are correct, use these benchmarks to furnish and maintain all reference lines and grades for the tunnel construction. Use these lines and grades to establish the exact location of the pipe using a laser guidance system on the tunneling machine. I. If the pipe installation exceeds the specified tolerance, correct the installation, including, if necessary, redesign of the pipelines and structures. All corrective work shall be performed at no additional cost to the District, and is subject to the approval of the CONTRACTOR. J. Provide access for the District to check the line and grade. The District’s checking shall not substitute for the CONTRACTORS own line and grade control responsibilities. 3.3 TUNNEL EXCAVATION A. General: Perform the tunnel excavation in accordance with Section 306-3 and the following requirements: 1. Anticipated geologic conditions are described in the Geotechnical Report. a. Refer to Paragraph 1.2-D of this Section. 2. Commence tunneling only after surface control points and other instrumentation have been established and surveyed, and preconstruction sun/eys have been completed. 3. On initial setup, support the tunnel shield on a cradle to provide the correct tunnel alignment and grade. 4. Excavate the materials in the heading using an acceptable tunnel shield. Limit over excavation beyond the shield outside diameter to less than 1 inch unless approved otherwise by the District. Blasting will not be permitted. 5. During forward movement of the shield provide sufficient support at the tunnel face to prevent loss of ground. Control the removal of material at the face using appropriate procedures and methods to only remove the materials that will be displaced by the shield in order to minimize loss of ground and surface settlement. Keep the shield hood buried and the machine pushed against the face firmly to support the ground in the heading at all times. 6. If access ahead of the face of the shield is necessary, completely support the tunnel face, as approved by the District, prior to accessing. 7. During shutdowns and other interruptions in tunnel excavation work, shove shield firmly against soil at tunnel face. Open face shields shall be fully breasted. Take all precautions necessary to prevent loss of ground at the tunnel heading during shutdown periods. a. Remove and dispose excavated materials from the tunnel in accordance with local, state and federal standards. Materials not removed from the site at the end of each work shift shall be stockpiled and covered with tarps or plastic sheeting to minimize dust and erosion. TUNNELING OPERATIONS 02300-13 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC? 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK CONTRQL A. Control Groundwater in accordance with Section 306-3.3. 3.5 A. General: Refer to Paragraph 3.4.A of Section 02306, Microtunneling. 6. Survey: Refer to Paragraph 3.4.6 of Section 02306, Microtunneling. A. Tunnel Access: Provide access to the tunnel for the District. The District will access the tunnel for inspection and observation of the work, and may elect to perform line and grade surveys, perform geologic mapping, and install and monitor instrumentation. A. Provide and operate a temporary ventilation system, and air monitoring system conforming to the requirements of CAUOSHA and OSHA. The ventilation system shall maintain a sufficient supply of fresh air and maintain an atmosphere free of toxic and flammable gasses in underground work areas when personnel are underground and occupying the confines of a tunnel. .I. Refer to Paragraph 3.1 .D of this Section. 2. Refer to Paragraph 3.1 .J of this Section. ++ END OF SECTION ++ TUNNELING OPERATIONS 02300-l 4 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK SECTION 02306 MICROTUNNELING PART I - GENERAL 1.1 DESCRIPTION A. Scope: 1. Perform the work required to install all piping shown, specified and required to provide for the construction of complete and operable pipelines using the microtunneling trenchless method of installation required to complete the Work. 2. The extent of microtunneling pipelines is shown on the Plans. 3. This Section specifies the construction of pipelines by using a single- pass, non-man entry pipe jacking method using a remote controlled tunneling operation to install pipelines to the alignments and grades shown. Remote controlled tunneting operations apply to the trenchless pipe installation method of microtunneling or remote controlled pipe jacking where the carrier pipe is installed directly behind the microtunneling boring machine (MTBM) and where the machine provides support to the excavation face at all times. 4. This Section defines in general terms the Work to be completed. The CONTRACTOR shall have sole responsibility for the means and methods utilized to install the pipelines to the lines and grades shown and for preventing settlement and heave, all within the tolerances specified herein and subject to review by the ENGINEER. The CONTRACTOR shall demonstrate to the ENGINEER that the proposed means and methods will complete the Work in accordance with the Contract Documents. 5. Provide all items required to complete the Work by microtunneling including but not timited to, the microtunneling system, jacking system, spoil transportation and separation, hoisting, lifting, safety and control equipment. 6. Jacking and receiving shafts are shown on the Plans considering overhead and underground utility conflicts, driveway access traffic impacts, a maximum manhole spacing of 1000 feet, and relationship to the geologic contact line. Alternate shaft locations may be allowed. a. Refer to Section 02310. Jacking and Receiving Shafts. B. Definitions: 1. Casing: A pipe to support a bore in which the product/carrier pipe is inserted. 2. Compression Ring/Jacking Strips: A wood ring fitted between the end bearing area of the bell and spigot to help distribute applied loads more uniformly. Jacking strips are also referred to as compression rings and spacers. 3. Controls: The system which synchronizes excavation, removal of excavated material, and jacking of pipe to maintain overall balance to provide complete and adequate ground support at all times. 4. Cutterhead: Any rotating tool or system of tools on a common support which excavates at the face of a bore. MICROTUNNELING 02306-l VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. MICROTUNNELING 02306-2 Earth Pressure Balance Machine: An earth pressure balance type of microtunneling or tunneling machine in which mechanical pressure is applied to the material at the face and controlled to provide the correct counter-balance to earth pressures in order to prevent heave or subsidence. Guidance System: Relates the actual position of the MTBM to a design reference by a laser beam transmitted from the jacking shaft along the centerline of the pipe to a target mounted in the shield. Intermediate Jacking Station: A fabricated steel cylinder fitted with hydraulic jacks that is incorporated into a pipeline between two pipe segments. Its function is to distribute the jacking load over the pipe string on long drives. Jacking Frame: A structural component that houses the hydraulic cylinders used to propel the microtunneling machine and pipeline. The jacking frame serves to distribute the thrust load to the pipeline and the reaction load to the shaft wall or thrust wall. Jacking/Access Shaft (Pit): Excavation from which trenchless technology equipment is launched. Jacking Shield: A fabricated steel cylinder from within which the excavation is carried out either by hand or machine. Incorporated within the shield are facilities to allow it to be adjusted to control line and grade. Laser: An optical system projecting a beam to a target to provide guidance reference for the excavation. Lubrication: A fluid, normally bentonite or polymers, used to reduce jacking loads on the jacking pipe. Microtunneling: A remotely controlled, guided pipe jacking process that provides continuous support to the excavation face. The microtunneling process provides ability to control excavation face stability by applying mechanical or fluid pressure to counterbalance the earth and hydrostatic pressures. Microtunnel Boring Machine (MTBM): A remotely controlled, steerable, laser guided microtunnel boring machine consisting of an articulated boring machine shield and a rotating cutting head. This machine shall be capable of removing cobbles up to 20-inches in diameter. Overcut: The annular space between the excavated hole (bit extension diameter) and the outside diameter of the jacking pipe. Product Pipe (Carrier Pipe): As it relates to this project, a pipe for conveyance of sewage. Receiving/Exit Shaft (Pit): Excavation pit into which the microtunneling equipment is driven and recovered. Slurry: A fluid, normally water, used in a closed loop system for the removal of spoil and to balance the groundwater pressure during microtunneling. Slurry Chamber: Located behind the cutting head of a slurry microtunneling machine. Excavated material is mixed with slurry in the chamber for transport to the surface. Slurry Line: A series of hoses or pipes that transport tunnel muck and slurry from the face of a slurry microtunneling machine to the ground surface for separation. VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 21. 22. 23. 24. 25. Slurry Pressure Balance Machine: A microtunneling system which uses a low pressure fluid to balance the ground and water pressure at the face of the tunnel and to transport the excavated spoil to the surface. Slurry Separation: A process where excavated material is separated from the circulation slurry. Spoil: Earth, rock, and other materials removed during installation. Thrust Ring: A fabricated ring that is mounted on the face of the jacking frame. It is intended to transfer the jacking load from the jacking frame to the thrust bearing area of the pipe section being jacked. Surface Settlement Points: Survey Control Points to be established at the ground surface along the pipe alignment for monitoring surface settlement due to subsurface excavation. C. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. D. Related Sections: :: Section 2-5.2, Precedence of Contract Documents. Section 2-5.3, Shop Drawings and Submittals. 3. Section 4-2, Materials Transportation, Handling and Storage. 4. Section 01025, Measurement and Payment. 5. Section 02140, Dewatering. 6. Section 02220, Excavation and Backfill. 7. Section 02310, Jacking and Receiving Shafts. 8. Section 06310, Contact Grouting. 9. Section 03620, Low Density Cellular Concrete. 10. Section 15064, Reinforced Concrete Pipe 11. Section 15073, Concrete Pressure Pipe. 12. Section 15083, Fiberglass Mortar Pipe. 1.2 QUALITY ASSURANCE A. Qualifications: The CONTRACTOR shall be qualified for microtunnleing operations as follows: 1. Microtunneling Construction: The CONTRACTOR shall have a California Contractor’s license and a minimum of 3 years experience in the installation of pipelines using microtunneling as the method of installation. 2. Microtunneling Projects: The CONTRACTOR shall have constructed and completed a minimum of 5 pipeline projects, each with a minimum of 1000 LF of installed pipe in excess of 30-inches in diameter using microtunneling as the method of installation. a. The installation experience shall be of the same type of piping material used in this Project. b. The projects constructed shall be of the same type of piping materials used in this Project. MICROTUNNELING 02306-3 VlSTA/CARLSBAD INTERCEPTOR SEWER REACHES VC56 TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 3. 4. 5. Project Superintendent: The microtunneling CONTRACTOR’s project superintendent shall have at least 5 years of tunneling/pipe jacking experience and shall have managed at least 2 microtunneling projects in similar ground conditions with similar equipment and with drive lengths exceeding 500 LF. MTBM Operator: The MTBM operator(s) shall have at least 2 years of tunneling experience as an operator and shall have operated a MTBM similar to the one proposed on this project on at least 1 other completed project. The operator(s) shall have successfully completed at least one drive in excess of 700 LF with pipe larger than 36-inches in inside diameter. For the above items, include addresses and telephone numbers and a contact person for each project Owner, as well as length, diameter, and pipe material used. B. Permits and Regulations: 1. Requirements for CONTRACTOR’s Work within the San Diego Northern Railroad/NCTD right-of-way: a. Provide the NCTD with a $30,000 deposit for NCTD submittal review, inspection costs, and for repair of track damage caused by the CONTRACTOR’s Work within the railroad right-of-way. The unused portion of the deposit amount, if any, will be returned to the CONTRACTOR upon final acceptance of the project. The specified deposit amount shall not limit the CONTRACTOR’s liability or responsibility for the. cost of track repair caused by the CONTRACTOR’s Work. b. Provide Liability Insurance in accordance with Section 7-3. 2. Obtain the applicable air permit from the Air Pollution Control District (APCD) for operation of on-site power generation equipment and comply with all permit requirements. C. Reference Codes: 1. CaVOSHA, State of California Administrative Code, Title 8, Industrial Relations, Chapter 4, Division of Industrial Safety, Subchapter 4, Construction Safety Orders; and Subchapter 20, Tunnel Safety Orders. 2. Occupational Safety and Health Administration (OSHA) Regulations and Standards for Underground Construction (29 CFR Part 1926, Subpart Section 1926.800, final rule dated June 9, 1989). 0. Subsurface Information: A geotechnical investigation has been performed by Woodward-Clyde. 1. Refer to Section 7-l 6. E. Alignment Tolerances: the following tolerances apply to the installationof the pipeline. 1. Line Tolerance: 0.3 feet. 2. Grade Tollerance: 0.1 feet. 3. Refer to Paragraph 3.3.8 of this Section. F. Allowable Ground Surface Settlement and Heave Tolerances: Refer to Paragraph 1.6.B of this Section. MICROTUNNELING 02306-4 VISTAXARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK G. Surveys: Surveys shall be conducted by a professional surveyor licensed by the State of California. 1. Refer to Paragraph 3.4.8 of this Section. s H. General Requirements for NCTDlSDNR Railroad Crossing: 1. Contact Eric Hankinson at (714) 756-6800 at least one week in advance of excavation to mark out SDNR’s underground signal cables. NCTD is not a member of Underground Service Alert (USA). 2. NCTD track inspectors will sight the track daily for settlement from excavation, jack and bore, and/or microtunneling activities. The CONTRACTOR shall be responsible for any track resurfacing costs from heaving or settlement caused as a result of construction activities. 3. NCTD flag protection is required at all times when the CONTRACTOR is on the railroad right of way. Contact Chip Willett at (760) 966-6504 at least 72 hours in advance to schedule flag protection. 4. An SDNR Engineering Representative, in addition to a flagman, is required when jacking the casing under the track. Contact Eric Hankinson at least one week in advance to schedule the Engineering Representative. I. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. 1.3 SUBMITTALS A. Submit the following in accordance with Section 2-5.3. All items required in this paragraph shall be provided as a single submittal. B. Submittals: Submit the proposed method of construction and the sequence of operations to be performed during construction including the following: 1. A general description and schedule of the microtunneling procedure including but not limited to, shaft construction, set-up, above ground equipment, method of spoil removal, spoil disposal, disposal location, methods of protection and maintenance of work area, and dewatering methods. 2. Certification by the machine manufacturer that the microtunneling machine, or one of similar design, has been successful in installing pipe in similar soil and groundwater conditions. The microtunneling equipment shall employ a soil removal system with a pressure balance system that is capable of equalizing pressures between the tunnel face and the microtunneling machine head in order to prevent caving beyond the outside diameters of the pipe. 3. Working Drawings/Work Plan: a. Layout of jack and receive shafts, jacking equipment within the shaft, and above ground equipment at each shaft location. Relationship of the manhole within the pit shall also be provided. b. Shop drawings of tunnel machine, including configuration of cutter head and overcut tolerances. C. Shaft ventilation system details. MICROTUNNELING 02306-5 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 4. 5. 6. 7. 8. 9. d. Pipe lubrication system details and proposed materials to be used for lubrication. e. Electrical system, lighting system, and onsite power generation. d. Grade and alignment control system details. 8. Groundwater control provisions of tunneling machine. Details of slurry system and soil separation methods including proposed slurry formulations and calculations of the system capacity to handle flows at all proposed distances and changes of elevations to and from the tunneling machine. Jacking system details, intermediate jacking stations and their proposed spacing, method of operation, thrust capacity and sleeve details. Describe method of control to prevent the maximum allowable jacking force from being exceeded. Description of lubrication mix equipment and procedure for lubricating the pipe during jacking operations. a. Submit Material Safety Data Sheets (MSDS). Description of grout mix, equipment and procedure for grouting the void space after the pipe has been installed and the requirements of Paragraphs 2.1 .D and 3.3.D of this Section. Theoretical jacking load calculations and pipe material calculations shall be prepared and submitted in accordance with the requirements of Sections 15073 or 15083, as applicable. Load calculations provided by the CONTRACTOR shall be stamped and signed by a licensed California civil engineer. It shall be the sole responsibility of the CONTRACTOR to determine the maximum anticipated construction loads, including jacking forces, and to ensure that the anticipated loads are implemented in the manufacturer’s design of the pipe, subject to ENGINEER’s review. A proposed contingency plan for potential situations that may occur during tunneling operations shall be provided for the following scenarios: it: Cuttings do not settle/separate with the equipment on site. The MTBM hits a small (less than 113 of the MTBM diameter) hard object or a large (greater than l/3 of the MTBM diameter) hard object located within the cutterhead of the MTBM or along the edge of the MTBM cutter-head. C. The target laser is distorted by heat and/or humidity or has been knocked out of alignment. Describe which operational parameters will be observed/measure recorded so that it can be determined if the above are occurring or have just occurred. d. The jacking pressures start to move up rapidly and there is reasonable concern for completing jacking operations to the reception pit. e. Tunneling operations cause the railroad track to settle or heave beyond the tolerance specified in Paragraph 1.6.B of this Section. f. The MTBM “freezes” within a typical pipe reach during jacking operations. The MTBM “freezes” beneath Carlsbad Village Drive. MICROTUNNELING 02306-6 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 10. A safety plan for personnel conducting the tunneling and jacking operations and appurtenance installation. 11. Submit all survey plans and data required by Part 3.4, Instrumentation and Monitoring, including but not limited to the following: a. Settlement Surveying and Monitoring Plan in accordance with Paragraph 3.4.A.2 of this Section. b. Building and Structures Assessment Plan in accordance with Paragraph 3.4.A.3 of this Section. c. Initial Survey in accordance with Paragraph 3.4.8.1 of this Section. d. Final Survey in accordance with Paragraph 3.4.8.4 of this Section. 12. Noise Abatement Plan and monitoring reports in accordance with Part 3.5.A of this Section. C. Jacking Operations Log: 1. Provide a sample of logging reports and daily reports prior to beginning microtunneling. 2. The jacking operations logs, if computer generated in digital format, shall be transcribed to paper and submitted to the ENGINEER once per day. 3. As a minimum, the jacking operations log shall consist of the following: a. The position of the tunneling machine in relation to design line and grade. b. Jacking forces exerted on the pipe at each section. The starting time and finish time for each crew shift each day. The position of steering jacks. E: i. Inclination and torque of cutter head. Face pressure of slurry. Hydraulic pressure. Volume of pipe lubricant used, its viscosity and pumping pressure. Evidence of settlement and heaving. D. CONTRACTOR’s Qualifications: In accordance with Paragraph 1.2.A of this Section. E. Review of the CONTRACTOR’s submittals by the ENGINEER shall not be construed in any way as relieving the CONTRACTOR of his responsibilities under this contract. F. The CONTRACTOR shall allow 27 Working days for the ENGINEER’s review of these submittals. G. Submittals for work to be performed within the railroad right-of-way require approval by NCTD. MICROTUNNELING 02306-7 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 1.4 PROJECT CONDITIONS A. Subsurface Information: A geotechnical investigation has been performed by Woodward-Clyde. :: Refer to Section 7-l 6. The MTBM will bore through at least two types of soils during the jacking operations as identified by the geologic interface contact line shown on the Plans. a. Refer to the geotechnical report. B. Provide adequate ventilation in the tunnel and shafts at all times. Air quality in the shaft shall be tested immediately prior to each change in shift. Air quality in the tunnel shall be tested prior to personnel entry and periodically thereafter as required by law. C. Provide adequate lighting in the tunnel shaft and around equipment being utilized. Power and lighting circuits shall be separated and thoroughly insulated. D. Existing groundwater monitoring wells with PVC casing are located throughout the project as shown in the geotechnical report prepared by Woodward-Clyde. Two (2) of the wells are located in Jefferson Street and two (2) other wells are located in the optional microtunneling reach in the railroad right-of-way. These wells are in the alignment of the microtunneling operation and shall be removed by the Contractor in accordance with the requirements of Paragraph 3.1 .E of Section 02140. 1.5 SAFETY A. The DISTRICT has obtained from the State of California, Department of Industrial Relations, Division of Occupational Safety and Health Administration (CallOSHA) an underground classification of ‘Potentiallv Gassv” for these crossings. Perform Work in conformance with all applicable federal, state, and local safety requirements. B. The CONTRACTOR shall submit his safety plan for the ENGINEER’s information only. Safety on the project site shall be the sole responsibility of the CONTRACTOR, therefore, the submitted plan will not be subject to approval by the ENGINEER. At a minimum, the plan shall include: 1. Safety plan for shaft access and exit, including ladders, stairs, walkways, and hoists. 2. Protection against improper mechanical and hydraulic equipment operations, and for lifting and hoisting equipment and material. 3. Ventilation and lighting details. 4. Monitoring for hazardous gases. 5. Protection against flooding and means for emergency evacuation. 6. Protection of shaft including traffic barriers, accidental or unauthorized entry, and falling objects. 7. Safety supervision responsibilities. 1.6 DESIGN CRITERIA A. Microtunneling Equipment: Use only microtunneling equipment approved by the Engineer, meeting the requirements specified in this Section for the microtunneling work described. Equipment shall be designed to minimize loss of ground, and minimize settlement and heave of the ground surface. MICROTUNNELING 02306-8 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK B. Allowable Ground Surface Settlement and Heave Tolerances: Control ground surface settlement and heave to the following tolerances: 1. l/2 inch for roadways. 2. l/8 inch for railroad crossings. 3. 1 inch within railroad right-of-way, parallel to railroad tracks. C. Thrust Block: The thrust block shall be normal (square) with the proposed pipe alignment and shall be designed to withstand the maximum jacking forces to be used with a factor of safety of at least 2.0, without excessive deflection and displacement. 1.7 MATERIALS TRANSPORTATION. HANDLING AND STORAGE A. Refer to Section 4-2, Materials Transportation, Handling and Storage. 1.8 MEASUREMENT AND PAYMENT A. Refer to Section 01025. Measurement and Payment. PART 2 - PRODUCTS 2.1 MATERIALS A. B. Jacking Pipe: Pipe shall be specifically designed for microtunneling and shall be either Concrete Pressure Pipe (CPP) or Fiberglass Mortar Pipe (FMP) as specified in Sections 15073 and 15075 respectively. 1. Refer to Section 15051. Jacking Strips: Concrete pressure pipe shall be fitted with jacking strips. 1. Refer to Section 15073. C. Lubrication: Lubricatin shall consist of bentonite or polymers and water. Water shall be obtained by the CONTRACTOR at its expense from a potable water source. Polymers shall be non toxic and shall not be used until the MSDS is submitted and approved. D. Grout: Grout for the void space between the piping and the soil shall conform to the following: 1. Cement: Type II or Type V conforming to ASTM Cl 50. 2. Grout: Grout shall contain at least 8 sacks of cement per cubic yard of mix. 3. Fineness Modulus: Between 1.50 and 2.00. Sieve Size % Passina bv Weiaht No. 8 100 No. 16 95-l 00 No. 30 60-85 No. 50 20-50 No. 100 1 O-30 No. 200 o-5 MICROTUNNELING 02306-g VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 4. 5. 6. Fluidifier: Use Celebex 209X manufactured by Celtite, Inc., or an equal approved by the ENGINEER. Admixtures: Other admixtures may be used subject to the approval of the Engineer. Compressive Strength: Minimum 100 psi in 24 hours, 2000 psi in 28 days. 2.2 EQUIPMENT A. General: The microtunneling system selected shall be specifically designed for excavating, transporting and separating the soil materials which could routinely be encountered or expected along the alignment of the proposed sewer. 6. Microtunnel Boring Machine (MTBM): The Contractor shall employ equipment that will be capable of handling the various anticipated ground conditions. In addition, the MTBM shall: 1. Be capable of maintaining the tunnel face under wet and adverse soil conditions and preventing loss of ground through the machine. The MTBM shall provide satisfactory support of the excavated face at all time. 2. Be articulated to allow steering. 3. Incorporate a suitable seal between the MTBM and the leading pipe. 4. Provide protection to the electric and hydraulic motors and operating controls against water damage. 5. Use bi-directional drive on the cutter head wheel, and/or adjustable fins or other means, to control roll. 6. Pressurized face tunneling machines shall be capable of exerting a controllable pressure against the face, during both excavation and shutdown periods, to support the excavation face, prevent groundwater inflows, and prevent loss of ground. A closed-face cutterhead designed to minimize loss of ground shall be provided. Pressurized face tunneling machines shall be capable of controlling the volume of excavated material removed at the tunnel face and coordinating the machine advance rate to avoid overexcavation. 7. MTBM conversion kits shall not increase the outside diameter more than 15Oh of the standard outside diameter of the machine without approval of the ENGINEER. C. Automated Spoil Transportation: Provide a MTBM which includes an automated spoil transportation slurry system which shall balance the ground water pressures by the use of a slurry pressure balance system. System shall be capable of adjustment required to maintain face stability for the particular soil condition to be encountered on the Project and shall monitor and continuously balance the ground water pressure to prevent loss of slurry or uncontrolled ground water inflow. 1. Manage the pressure at the excavation face by use of the slurry pumps (which may be of variable speeds), pressure control valves, and a flow meter. 2. Include a slurry bypass unit in the system to allow the direction of flow to be changed and isolated, as necessary. 3. Have a spoil transportation system that has the capability for removal of soil in balance with excavation and advance. MICROTUNNELING 02306-l 0 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK D. Slurry Separation Equipment: Provide a slurry separation system consisting of a shaker, screens, and hydro-cyclone capable of the following: 1. Provide adequate separation of the spoil from the slurry so that slurry with a sediment content within the limits set by the CONTRACTOR’s Work Plan can be returned to the cutting face for reuse. A centrifuge may be implemented as deemed necessary by the work plan. Appropriately contain spoil at the site prior to disposal. 2. Use the type of separation process suited to the size of the tunnel being constructed, the soil type being excavated, and the work space available at each work area for operating the plant. 3. Carefully monitor the composition of the slurry to maintain the slurry weight and viscosity limits defined by the CONTRACTOR’s Work Plan. E. Pipe Jacking Equipment: Provide a MTBM operation which includes a pipe jacking system with the following features: 1. Main jacks mounted in a jacking frame located in the jacking shaft. 2. Jacking system which successively pushes the MTBM along with a string of connected pipes toward a receiving shaft. 3. Sufficient jacking capacity to push the MTBM and the pipe string between the shaft locations identified on the Shop Drawings. 4. Hydraulic cylinder extension rates which are synchronited with the excavation rate of the MTBM, as determined by the soil conditions. 5. Develops a uniform distribution of jacking forces on the end of the pipe by use of spreader rings and packing. 6. Provides and maintains a pipe lubrication system at all times to lower the friction developed on the surface of the pipe during jacking. 7. Provides intermediate jacking stations as necessary. Steel sleeves for intermediate jacking stations shall be coated with fusion bonded epoxy. F. Remote Control System: Provide a MTBM which includes a remote control system with the following features: 1. Allows for operation of the system without the need for personnel to enter the tunnel. Have a display available to the operator, showing the position of the shield in relation to a design reference together with other information such as roll, pitch, complete guidance system, valve positions, thrust force, cutter head torque, rate of advance and installed length. 2. Integrates the system of excavation and removal of spoil and its simultaneous replacement by pipe. As each pipe section is jacked forward, the control system shall synchronize all of the operational functions of the system. G. Active Direction Control: Provide a MTBM which includes an active direction control system with the following features: 1. Controls tine and grade by a guidance system. 2. Is equipped with a high intensity laser (maximum legal limit). 3. Is capable of maintaining grade and line to the tolerances specified in Paragraph 3.3.8 of this Section. 4. Provides active steering information which shall be monitored and transmitted to the operating console. As a minimum, this information shall include location of the laser beam on the target, location of the cutter head. MICROTUNNELtNG 02306-11 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 5. 6. Provide positioning and operation information to the operator on the control console. Provide a reference laser, or other approved device, which will indicate visually in the jack shaft that the directional control laser has not been accidentally moved. H. All equipment shall be suitably insulated so as not to exceed the noise limitations stated in Paragraph 3.5, Environmental Controls, of this Specification. I. Provide all appropriate safety equipment as necessary for the CONTRACTOR’s method and operation of construction and as required by all applicable laws and regulations. PART 3 - EXECUTION 3.1 JACKING AND RECEIVING SHAFTS A. Jacking and receiving shafts for microtunneling shall be constructed in accordance with the requirements of Section 02310, Jacking and Receiving Shafts. 3.2 WORK AREA PREPARATION AND MAINTENANCE A. The CONTRACTOR shall be responsible for means and methods of tunneling and pipe jacking operations and shall ensure the safety of the work, the CONTRACTOR’s employees, the public, and adjacent property, whether public or private. B. Maintain clean working conditions inside the jacking operation area and remove spoil, debris, equipment, and other material not required for operations. C. Microtunneling surface equipment shall be organized for each drive in such a manner as to enable proper operation at all times, to minimize impacts to property owners, and to maintain traffic control patterns shown on the traffic control drawings and specified in the Contract Specifications. Refer to Section 7-10.1, Traffic and Access, for specific requirements. D. Power generation equipment and any other equipment operating on or with fuel or lubrication oils shall be provided with suitable barriers and safeguards to ensure no loss of oil to drains or water courses or to contaminate the ground. 3.3 INSTALLATION A. Alignment Establishment: 1. Surveying shall be performed in accordance with the requirements of Section 2-9 and utilizing the survey control identified on the Plans. Check baseline and benchmarks at the beginning of the work and report any errors or discrepancies to the ENGINEER. MICROTUNNELING 02306-12 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 2. 3. 4. 5. Use the baseline and benchmarks shown on the Plans to furnish and maintain reference control lines and grades for the sewer pipe construction. Use these lines and grades to establish the exact location of the pipeline excavation, and structures. Establish and be responsible for accuracy of control for the construction of the entire Project, including Access Shaft locations, structures, excavation, pipe alignment, and grade. Establish control points sufficiently far from the tunnel operation not to be affected by ground movement. Check the primary control for the Microtunneling system against an aboveground undisturbed reference at least once each week or not greater than 250-foot intervals of pipeline constructed. B. Tolerances: 1. For alignment tolerances, refer to Paragraph 1.2.E of this Section. 2. Record the exact position of the MTBM at 50-foot intervals or a minimum of once per shift to ensure the alignment is within the specified tolerances. Make the survey at the MTBM to allow immediate correction of misalignment before allowable tolerances are exceeded. The tunnel guidance system may be used, however, select times to measure and record this information after the air temperatures have stabilized throughout the pipe to ensure accurate readings. 3. When the excavation is off line or grade, return to the design line and/or grade at a rate of not more than l-inch per 25 feet. 4. If allowable tolerances are exceeded, the CONTRACTOR shall bear full responsibility and expense for correction (redesign, reconstruction, etc.). If the redesign is required, the CONTRACTOR shall obtain the services of a Professional Engineer registered in the State of California for the redesign. The installed pipe must be capable of meeting the design flow shown on the Plans. Plans showing the changes shall be submitted to the ENGINEER for review. 5. Perform a verification survey with a transit or total station of the installed pipe from shaft to shaft after removal of the MTBM. Document measured conformance to design line and grade of the pipe together with locations and deviation (distance and direction) of any out-of-tolerance locations. Comply with the requirements of Part 3.6, Quality Control. C. Tunneling and Jacking of Pipes: 1. Conduct microtunneling operations in accordance with applicable safety rules and regulations and use methods which include due regard for safety of workers, and protection for adjacent structures, utilities, and the public. 2. Keep tunnel excavation within the rights-of-way indicated on the Plans and to the lines and grades shown. 3. Locate equipment powered by combustible fuels at suitable distances from shafts and protect equipment to prevent the possibility of explosion and fire in shafts or the pipe. 4. The rate of advance of the MTBM shalt be matched with the rate of spoil removed to avoid over-excavating. MtCROTUNNELlNG 02306-l 3 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 5. 6. 7. 6. 9. Make the excavation of a minimum sufficient size to permit pipe installation by jacking with allowance for injection of the lubricant into the annular space. The overcut shall not exceed 1.5 inches. Cushion pipe joints with an approved jacking strip to transmit the jacking forces without damaging the pipe or pipe joints. Maintain an envelope of lubricating slurry around the exterior of the pipe during jacking and excavation operation to reduce the exterior friction and possibility of the pipe seizing in place. Water jetting of the ground to advance the pipe is not permitted without approval of the ENGINEER. lf the pipe Yreezes” and the CONTRACTOR is unable to move it again, the CONTRACTOR may be permitted to construct a recovery access shaft, with the location subject to review by the ENGINEER. A recovery access shaft will not be permitted in Carlsbad Village Drive and beneath the NCTD railroad tracks. The CONTRACTOR shall be responsible for all costs associated with recovery of the MTBM, including, but not limited to permits, shaft construction, demolition and replacement, and utility relocation. Recovery shafts shall be performed in accordance with the requirements of Section 02310, Jacking and Receiving Shafts. In the event a section of pipe is damaged during the jacking operation, or joint failure occurs, as evidenced by visible ground water inflow or other observations, use one of the following procedures to correct the damage, as directed by the ENGINEER, at no additional cost to the DISTRICT: a. Slightly damaged pipe which passes leakage test and maintains pipe barrel and joint structural integrity, may, if access is possible, be repaired in place with a method approved by the pipe supplier. b. Severely damaged pipe, or pipe where joint failure is evident, shall be removed from the excavation by surface excavation, except as noted above, or by jacking it through the excavation and removing it at the receiving shaft. D. Mixing and Injection of Grout: 1. All materials shall be free of lumps when put into the mixer and the grout mix shall be constantly agitated. Grout shall flow unimpeded and shall completely fill all voids. Grout not injected after 90 minutes of mixing shall be wasted. 2. The spacing of contact grout holes for the pipe and casing, as applicable, shall be as specified in these Contract Specifications. Drilling grout holes through pipe will not be permitted. 3. The grouting process shall be operated and controlled so that the grout will be delivered uniformly and steadily. 4. Grouting shall progress from grout hole to grout hole in the sequence indicated in the approved Shop Drawings. 5. In general, grouting will be considered completed when less than one cubic foot of grout of the accepted mix and consistency can be pumped in 15 minutes under the specified maximum pressure. After the grouting is finished, the pressure shall be maintained by means of a stopcock or other suitable device until the grout has set to the extent that it will be retained in the grout hole. Replace grout plugs in pipe or casing at the completion of grouting. MICROTUNNELING 02306-14 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 6. 7. 6. 9. 10. 11. 12. The minimum grouting pressure shall be 10 pounds per square inch (psi) at the grout hole collar connection, unless otherwise directed by the ENGINEER. The maximum sustained grouting pressure shall be 15 pounds per square inch (psi) at the grout hole collar connection. Provide means for bentonite slurry around exterior of the pipe to escape while it is being displaced by the grout. All grouting operations are to be performed in the presence of the ENGINEER. Notify the ENGINEER at least 24 hours in advance of starting grouting operations. Pipe grout fittings shall be sealed with screw type plugs upon completion of grouting. Dry pack mortar shall be used to fill any recesses, and to provide a smooth surface for patching the PVC lining inside the pipe as shown on the approved Shop Drawings. Take all necessary precautions to protect and preserve the interior surfaces of the pipe or casing from damage. Grout spills shall be minimized and clean-up shall proceed immediately after grouting. Any damage to the pipe caused by or occurring during the grouting operations shall be repaired by a method approved by the ENGINEER at no additional cost to the DISTRICT. During grouting work, provide for adequate disposal of all waste and wastewater. Remove and properly dispose of all waste grout resulting from grouting operations. E. Obstructions During Microtunneling: 1. Obstructions shall be defined as objects or portions of objects located within the cross sectional area to be excavated by the Microtunneling system that stops the forward progress of the Microtunneling system and is shown to be a particle with principle dimensions measuring at least one-third the external diameter of the pipe being installed. 2. Remove, clear or otherwise make it possible for the Microtunneling system and pipe to progress past through obstructions in accordance with the CONTRACTOR’s submitted contingency plan. 3. The CONTRACTOR shall receive no additional compensation for removing, clearing or otherwise making it possibie for the Microtunneling system to progress past obstructions of maximum lateral dimension less than one third the external diameter of the pipe. 4. The CONTRACTOR will receive payment for obstruction removal shafts, which shall include the removal of the obstruction, if the dimension or the obstruction is greater than described herein, and subject to the following requirements: a. Notify the ENGINEER immediately upon encountering an obstruction that stops the forward progress of the work. b. Upon written authorization by the ENGINEER, proceed with removal of the obstruction by means of obstruction removal procedures in accordance with the CONTRACTORS approved submittals and Section 02310, Jacking and Receiving Shafts. C. No excavation shall be carried out within 5 feet of the front of the boring head without the ENGINEERS knowledge. MICROTUNNELING 02306-l 5 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 5. The CONTRACTOR may propose alternative methods for removing, clearing or othewise making it possible for the Microtunneling system to progress past obstructions, however, any such method that does not allow visual observation of the nature of the obstruction to be made will not be considered for additional payment. 3.4 INSTRUMENTATlON AND MONITORING A. General: 1. Conduct construction operations to minimize ground surface settlement and heave. The CONTRACTOR shall be responsible for damage due to settlement and heave caused by construction operations. a. For allowable settlement and heave tolerances refer to Design Criteria in Part 1. 2. Submit a settlement surveying and monitoring plan for review prior to construction. The plan shall identify the location of settlement monitoring points, reference benchmarks, survey schedules and procedures and reporting formats. 3. Submit a Building and Structures Assessment Plan prior to construction. Pre-construction and post-construction assessment reports shall be provided for buildings and structures located within a distance of 100 feet from the proposed pipe centerline and shafts. Photographs or a video of existing damage to structures in the vicinity of the pipeline alignment shall be included in the assessment reports. 4. Install and maintain a system of instrumentation to monitor the underground excavation operation and to detect movement in the soil, adjacent structures and utilities. 5. In the event of movement of the ground surface, structure or utility being detected or damage recorded, the ENGINEER may order that the work be stopped and secured. Before proceeding, the CONTRACTOR shall correct any problems causing or resulting from such movement entirely at its own cost. It is the CONTRACTORS responsibility to monitor and immediately report to the ENGINEER ground settlement and heave which might affect the accuracy of temporary and permanent benchmarks. B. Survey: 1. Initial Survey: Record the horizontal coordinates and elevations (with accuracy of 0.01 feet) for each survey point location. Reference survey points so that they may be accurately re-established if lost or destroyed. 2. Unless otherwise directed, surface movement monitoring points shall be established along the pipe alignment and at 18foot offset each side of the centerline of each drive section located at not less than 30 foot intervals. Monitoring points shall be installed prior to the commencement of any underground operations, including shaft construction. MICROTUNNELING 02306-l 6 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 3. Submit readings from the various instruments and survey points to the ENGINEER on the same day the readings are taken. Reading shall commence at the commencement of microtunneling. Initial readings of surface points shall be taken before any weekly excavation or construction is started. Monitoring shall continue weekly for at least 4 weeks after completion of any drive section. Final Survey: At the end of all construction operations, make a final survey of all control points established for instrumentation and observation. The final readings shall be submitted to the ENGINEER. 3.5 ENVIRONMENTAL CONTROLS A. Noise Monitoring and Abatement: 1. Implement measures necessary to mitigate noise impacts caused by construction activity. The following noise monitoring and abatement requirements are specific to the microtunneling operation when the power generation and slurry separation equipment are operating. Shaft construction is exempt from the following requirements: a. Monitor the ambient noise at the corner of the occupied building closest to the generator and slurry separation equipment. b. Provide equipment with enclosures or construct portable sound barriers to maintain the following conditions: 1) Provide and maintain power generation and slurry separation equipment with sound attenuation enclosures to maintain existing environmental noise levels. Do not cause an increase of 3 dBA average above existing conditions. 2) Maintain an hourly Lave of 60 dBA or 3 dBA above ambient noise levels during the daytime 7 A.M. to 7 P.M. (60 dBA is 10 dBA above non-construction requirements). 3) Maintain an hourly Lave of 50 dBA or 3 dBA above ambient noise levels at night (7 P.M. to 7 A.M.) (50 dBA is 5 dBA above non-construction requirements). 4) Lave is not to be exceeded for more than 30 minutes on a rolling average and Lmax is not to be exceeded for more than 1 minute in any hour at the affected pwerty. C. Submit a noise abatement plan prior to shaft construction. The plan shall address each jacking pit location independently. The noise abatement plan and sound attenuation enclosure design shall be prepared by a licensed engineer specialized in acoustical engineering. d. The Contractor shall be responsible for monitoring noise levels during construction and submit reports to the ENGtNEER daily. Continuous noise levels in excess of allowable will be cause for the ENGINEER to stop CONTRACTOR’s operations until the problem is corrected. MICROTUNNELING 02306-l 7 VIST#CARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK e. Provide the generator with a minimum ‘residential” silencer and acoustic enclosure capable of complying with the ambient noise requirements stated above. B. Spoil from the slurry separation process shall be placed directly into containers and shall at no time be placed onto the ground prior to disposal. C. Disposal of Muck and Excess Material: 1. Muck and excavated material shall be removed from the job site in accordance with the requirements of Section 7-10, Public Convenience and Safety. 2. The CONTRACTOR shall be responsible for locating and acquiring a site for the legal disposal of muck and excess excavated material. Contractor shall provide a letter from owner/operator of disposal site which authorizes disposal. 0. Site Cleanup: Unless otherwise shown or specified, all existing surface improvements damaged or removed as a result of microtunneling operations shall be restored to their original condition. 3.6 QUALITY CONTROL A. Pipelines wilt be subject to visual inspection by the ENGINEER in addition to the testing requirements specified in Section 15051, Buried Pipe Installation and Section 15073, Concrete Pressure Pipe and Section 15051, Centrifugally Cast Fiberglass Mortar Pipe. 8. Perform a CCTV inspection of the completed interceptor sewer pipeline. 1. Refer to Section 15051. ++ E+lD OF SECTION ++ MICROTUNNELING 02306-l 6 VlSTA/CARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK SECTION 02310 JACKING AND RECEIVING SHAFTS PART I- GENERAL, 1.1 DESCRtPTtON A. Scope: I. 2. 3. 4. 5. Perform the work required to provide all excavating, sheeting, shoring and supports shown, specified and required for construction of jacking and receiving shafts, and other shafts as may be required to complete the Work. The CONTRACTOR shall design, furnish, install, and maintain a system of supports, including all bracing and associated items, to retain excavations in a safe manner and to control ground movements within tolerable limits. Upon completion of the required tunnel construction, the system of supports shall be completely removed, as specified, and the shaft and staging area sites restored. The Work shall include sawcut and pavement removal, fencing, and signing construction staging areas; design and construction of shaft excavations and excavation support systems; material disposal; control and disposal of surface water, ground water and construction water; and site restoration. The CONTRACTOR shall have sole responsibility for sizing the shaft excavations. The size of the shafts shall be adequate to construct all structures required. Shaft excavations shall be contained within the right-of-way and shall be limited in width by the allowable Work area provided by the Contract Traffic Control Drawings. Shaft excavation size shall be subject to the approval of the ENGINEER. Shafts shall be located where shown on the Plans unless otherwise approved by the ENGINEER. B. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. C. Referenced Sections: 1. SSPWC, Section 300. Earthwork. 2. SSPWC, Section 306-l .l , Trench Excavation. D. Related Sections: 1. Section 2-5.2, Precedence of Contract Documents. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 4-2, Materials Transportation, Handling and Storage. 4. Section 7-9, Protection and Restoration of Existing Improvements. 65: Section 7-10, Public Convenience and Safety. Section 01025, Measurement and Payment. JACKING AND RECEIVING SHAFTS 02310-l VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK ;: Section 02140, Dewatering. Section 02220, Excavation and Backfill. 9. Section 02300, Tunneling Operations. 10. Section 02306, Microtunneling. 11. Section 02320, Tunnel Support Systems. 12. Section 02330, Pipe Jacking. 13. Section 02340, Boring and Jacking (Steel Casing). 14. Section 02350, tnstallation of Pipe in Tunnel. 1.2 QUALITY ASSURANCE A. Permits and Regulations: I. Obtain all applicable permits for earthwork, work in roads, right-of- way, etc., as required by local, state and federal agencies. 2. CONTRACTOR shall comply with all construction dewatering discharge requirements specified in Section 02140, Dewatering. 3. CONTRACTOR shall comply with requirements of the Storm Water Pollution Prevention Plan and Monitoring Plan as indicated in Section 7-8.6. 4. Perform excavation work in compliance with applicable requirements of governing authorities having jurisdiction. B. Reference Standards: Comply with applicable provisions and recommendations of the following except as otherwise shown or specified. I. ASTM A 36, Specification for Structural Steel. 2. CSHA Standard, Title 29, Code of Federal Regulations, Part 1926, Section .650 (Subpart P - Excavations). 3. CALlOSHA State of California Administrative Code, Title 8, tndustriat Relations, Chapter 4, Subchapter 4, Construction Safety Orders. C. Subsurface Information: A geotechnical investigation has been performed by Woodward-Clyde: I. Refer to Section 7-l 6. D. Initial Survey of Existing Improvements: Prior to beginning demolition, excavation or shaft construction, the CONTRACTOR shall perform a sufficient level of surveying of the area so that all existing improvements can be returned to their original location and elevation. E. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. 1.3 SUBMITTALS A. Submit the following in accordance with Section 2-5.3. B. Submit shop drawings for shaft excavations, excavation support systems, and other related information as requested by the ENGINEER. The shop drawings shall be prepared and sealed by a Structural Engineer registered in the State of California who has a minimum of five years experience in the design of earth retaining structures. Submit the following in accordance with the requirements of Section 2-5.3, Shop Drawings and Submittals. JACKING AND RECEIVING SHAFTS 02310-2 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK I. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Name and qualifications of person responsible for excavation support system design. Construction method to be used for the installation for excavation support system design. Shaft locations and sizes. a. Refer to Part 3.1 of this Section. Shop drawings and design calculations indicating arrangements of supports and construction sequence for proposed support system(s). Show the elevation of struts, braces, or other supports as related to the depth of excavation at intermediate stages of construction. Provide details of working slab, drains, and sump construction. Indicate sizes, shapes, and materiel specifications for all support elements including lagging, if used. Calculations shall include estimates of likely deflections or deformations of the support system and shaft bottom along with maximum tolerable values. Design and calculations shall be coordinated with the requirements of he CONTRACTOR’S dewatering submittal. a. Refer to Paragraph 1.4.A.l .a of this Section. Breakout plans indicating support installed to transfer loads and maintain excavation support and stability of the excavation when commencing tunneling operations and when holing out in exit shafts. Thrust block design and details. Quality control procedures. Address materials testing requirements, proof-test and performance test requirements for tiebacks, and excavation monitoring provisions. A site plan for each excavation indicating the location, excavation dimensions, site grading, and site development details for the excavation and all work areas, and the proposed limits of disturbance surrounding each excavation. Provisions for protecting adjacent facilities and utilities. All utilities within 20 feet of excavations and all structures within 50 feet of excavations shall be addressed. Site drainage and groundwater control details. Show details of the measures to control, treat, handle, and dispose of surface water runoff, groundwater, and construction water. Provide details of working slab, subdrains, and sump construction. Details of materials handling, stockpiling, and disposal sites for excavated materials. Monitoring system to evaluate stability, safety, ground movements, and any nearby facilities and structures which could be affected by the work. a. Monitoring measurements in accordance with Paragraph 3.4.A of this Section. Plans indicating layout of guardrail barrier system around open shafts. Plans indicating removal of excavation supports and site restoration details. Plans for environmental controls. Copies of all documentation, releases, and permits required herein and necessary to complete the work. Documentation, releases, and permits shall include but not be limited to imported materials, material disposal, utility disturbances, and affected properties. JACKING AND RECEIVING SHAFTS 0231 O-3 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK C. Submittals for work to be performed within the railroad right-of-way require approval by NCTD. 1.4 DESIGN CRtTERtA A. Design shaft excavation support systems and working slabs to withstand earth pressures, unrelieved hydrostatic pressures, bottom heave, equipment loads, applicable traffic and construction loads, lateral loads from railroad, and other surcharge loads to allow the safe construction of the tunnel or jacked pipe without movement or settlement of the ground beyond specified tolerances, and to prevent damage to or movement of adjacent structures, streets, utilities or the newly installed pipeline or structures. Design excavation support systems to be compatible with the geologic conditions described in the Geotechnical Report including any adjacent slope support structures. Recommended lateral earth pressures are summarized in the Geotechnical Report. The CONTRACTOR shall: 1. Design the support system to minimize horizontal and vertical movements, and to protect adjacent utilities from damage. Design support system to maintain the stability of the excavation and provide a factor of safety of at least 1.5 against sliding and against bottom heave. a. Resubmittals in accordance with Paragraph 3.3.A.7 of this Section. 2. Design a working stab for each shaft bottom to provide stable support for guide rails, thrust blocks, and other construction operations. 3. Design, install, operate, and maintain groundwater control system for excavations to control any groundwater inflows, prevent piping or loss of ground, and maintain stability of the excavation. 4. Locate shafts where indicated on the Contract Drawings unless otherwise approved by the ENGINEER. 5. Provide temporary concrete safety K-railing and fencing around shaft excavations. Provide traffic control around working areas and shafts as shown on the Contract Traffic Control Drawings. 6. Design excavation support systems in accordance with all applicable CAL/OSHA and OSHA requirements. 7. Review of the CONTRACTOR’s plans and methods of construction by the DlSTRtCT does not relieve the CONTRACTOR of his responsibility to provide and maintain an adequate support system achieving the specified requirements. 1.5 MATERIALS TRANSPORTATION. HANDLING AND STORAGE A. Refer to Section 4-2, Materials Transportation, Handling and Storage. 1.6 MEASURMENT AND PAYMENT A. Refer to Section 01025, Measurement and Payment. JACKING AND RECEIVING SHAFTS 02310-4 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK PART 2 - PRODUCTS 2.1 MATERIALS A. All timber and structural steel used for the supporting systems, whether new or used, shall be sound and free from defects which may impair their strength. B. Structural Steel shall conform to ASTM A 36 or higher strength unless approved otherwise. C. All timber shall be structural grade with a minimum allowable flexural strength of 1,500 pounds per square inch (psi). D. Shotcrete shall conform to the requirements of ACI 506.2. Minimum design compressive strength shall be as required but not less than 4,000 psi. PART 3 - EXECUTION 3.1 SHAFT LOCATIONS AND SIZE A. Shaft Location: The shaft location and function shalt be as shown on the Plans unless otherwise approved by the ENGINEER. Proposed shafts at locations other than shown on the Plans shall comply with the following conditions: 1. Alternate Shaft Locations: Alternate or additional shaft locations shall be defined as alternate jacking/receiving shaft locations proposed by the CONTRACTOR, intermediate shafts, recovery shafts, and obstruction removal shafts as defined in Paragraph 3.3.E of Section 02306, Microtunneling. The CONTRACTOR shall be responsible for obtaining all approvals, permits and all costs related to the revised shaft location; including, but not limited to, traffic control, utility relocation, construction and restoration. Revised traffic control drawings, if necessary, must be signed by a licensed civil engineer in the State of California and submitted to the ENGINEER for approval. Utility relocation costs can be minimized if the CONTRACTOR complies with the requirements specified in Section 5-6 of the Supplemental Provisions. 2. Shaft construction will not be allowed in Carlsbad Village Drive, beneath the railroad tracks and at the intersection of Grand Avenue and Jefferson Street. Additionally, the shaft located at Station 77+29 shall remain as a receiving shaft and shall not be changed to a jacking shaft due to site constraints. Alternate shaft locations proposed by the CONTRACTOR shall not be located such that the sole vehicle access to the adjacent property is closed. Shafts shall be located to minimize public inconvenience and impacts to existing facilities. 3. Jacking and receiving shafts shall be located at least 50 feet from the railroad track centerline. JACKING AND RECEIVING SHAFTS 0231 O-5 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 ?A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK B. Shaft Size: The CONTRACTOR shall have sole responsibility for sizing the shafts. Shaft size shall be adequate for construction of any permanent structures indicated on the Plans and to provide adequate room to meet the CONTRACTOR’s operational requirements for tunnel construction and for backfill. Shaft excavations shall be contained within the public right-of-way and shall be limited in width by the allowable work area shown in the Contract Traffic Control Drawings. 1. For shafts longer than 25 feet in length, comply with the requirement of Paragraph 3.1 .A.1 of this Section. 3.2 UTtLlTY RELOCATION A. Utility relocation shall be in accordance with Section 5-8 of the Supplemental Provisions. 3.3 SHAFT CONSTRUCTtON A. General: 1. Provide shoring in accordance with the requirements of Paragraph 3.4.A of Section 02220, Excavation and Backfill and this Section. 2. Methods of construction for shafts shall be such as to ensure the safety of the work, CONTRACTOR’S employees, DtSTRlCTs employees and inspectors, the public, and adjacent property and improvements, whether public or private. 3. Provide shaft excavations with a gravel pad or concrete working slab equipped with a sump to pump out construction water and storm water. 4. Before beginning construction at any location of this project, adequately protect existing structures, utilities, trees, shrubs, and other existing facilities. Design excavation support systems to limit deformations that could damage adjacent facilities including utilities and structures. The repair of or compensation for damage to existing facilities shall be at no additional cost to DISTRICT. 5. All welding shall conform to the applicable provisions of ANSI/AWS Dl.l. 6. install support system monitoring provisions as necessary to assure proper performance of the work, to monitor the support system and the excavation, and as indicated in the Shop Drawings. Monitor performance of excavation support system for both horizontal and vertical deflections daily during excavation, and at intervals not to exceed seven days following the completion of excavation work. If monitoring data indicates that deflections have exceeded estimated values, CONTRACTOR shall notify ENGINEER immediately. 7. Install excavation support systems in accordance with approved Shop Drawings. a. If settlement and deflections of supports and shaft bottom indicate that support system requires modification to prevent excessive movements, the CONTRACTOR’s structural engineer shall redesign and resubmit revised shop drawings and calculations to the ENGINEER at no additional cost. JACKING AND RECEIVING SHAFTS 02310-6 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 8. 9. Excavations shalt be performed in accordance with the requirements of Section 02220, Excavation and Backfill. Stockpiling of excavated material within the public right-of-way is not permitted. The working slab may be left in place for manhole support, if the foundation has been approved by the ENGINEER prior to placement of the slab and no subsequent disturbance to the foundation has occurred. B. Soldier Beams and Plates/Wood Lagging: 1. Install soldier beams by pre-boring or other pre-excavating methods to the tip elevation shown on the Shop Drawings. Provide casing, drilling mud, or other method of support to prevent caving of holes and loss of ground. 2. After soldier pile has been seated plumb in the pre-bored hole. encase it with concrete from the tip to the bottom level of the final excavation. Encase the remaining portion of soldier pile with sand/cement slurry or other approved material. Concrete strength shall be in accordance with Shop Drawings and shall be placed by means of a tremie system. Apply vibration through the pile. 3. Provide steel plates or wood lagging of sufficient thickness to withstand lateral earth pressures. 4. Install steel plates using a vibro-mechanical method. tnstall to sufficient depth to avoid piping failures or bottom heave. 5. Install wood lagging with no gaps between adjacent pieces. As installation progresses, backfill the voids between the excavation face and the lagging with sand or pea gravel packed into place. Pack all gaps between lagging/lagging and tagging/pile interface with materials such as excelsior, hay, burlap or geotextile fabric where necessary to allow drainage of groundwater without the loss of fines. 6. The timber employed as lagging for shafts shall be of structural grade with a minimum allowable flexural stress of 1100 psi, Douglas Fir or equal approved by the ENGINEER. 7. Shotcrete, if used, shall be applied in accordance with ACI 506.2. C. Internal Bracing Support System: 1. The internal bracing support system shall include walls, struts, and/or shores. 2. Provide struts with intermediate bracing as needed to enable them to carry maximum design load without distortion or buckling. 3. tnclude web stiffeners, plates, or angles as needed to prevent rotation, crippling, or buckling of connections and points of bearing between structural steel members. Allow for eccentricities caused by field fabrication and assembly. 4. Install and maintain all bracing support members in tight contact with each other and with the surface being supported. 5. Preload bracing members by jacking struts to 50 percent of the design load if necessary to control shoring movement. Preload bracing members in accordance with methods, procedures, and sequence as described on the Shop Drawings. Coordinate excavation work with installation of bracing and preloading. Use steel shims and steel wedges welded or bolted in place to maintain the JACKING AND RECEIVING SHAFTS 02310-7 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 6. preloading force in the bracing after release of the jacking equipment pressure. ‘Install support and pretoad immediately after installation and prior to continuing excavation. Use procedures that produce uniform loading of bracing members without eccentricities or over stressing and distortion of members of system. D. Corrugated Metal Pipe Receiving Shaft: 1. The receiving pit shall be of sufficient size to facilitate the removal of the tunneling equipment employed for the Work, and construction of any manhole structures. 2. Dewatering shalt be required for all shaft construction below the water table. The dewatering system shall be implemented prior to beginning any Work on the shaft’s construction. 3. The shaft will be constructed using a mechanical auger with 6-inch maximum overcut when the CMP casing is placed. 4. The void between the CMP casing and receiving pit shall be filled with lean concrete backfill. 5. The CONTRACTOR has the option of placing a watertight invert working slab in the bottom of the shaft or leaving the dewatering system in place for the duration of the shaft’s existence. 6. The top 5 feet of the CMP casing shall be cut and removed prior to backfilling of the shaft. 3.4 INSTRUMENTATtON AND MONITORING A. tnstall excavation support system monitoring provisions as necessary to assure proper performance of the work, and to monitor the deflection of the excavation. Monitor performance of excavation support system for both horizontal and vertical deflections daily during excavation, and at intervals not to exceed seven days following the completion of excavation work. If monitoring data indicates that deflections have exceeded estimated values, increase frequency of monitoring as required by the Engineer. 1. Submit all monitoring measurements to the Engineer within one day from when the measurements are taken. 3.5 REMOVAL OF SUPPORT SYSTEM A. Remove all sheeting, shoring and bracing at the completion of work in accordance with the requirements of Paragraph 3.4, Section 02220, Excavation and Backfill, unless otherwise approved by the ENGINEER. 3.6 RESTORATION A. Backfill and Foundation: Furnish, place, compact, and backfill all shaft excavations in accordance with Section 02220, Excavation and Backfill and Section 15051, Buried Piping Installation. JACKING AND RECEIVING SHAFTS 02310-B VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK B. Site Restoration: Restore the work area disturbed by construction activities and repair any damage caused to existing utilities, to its original, or better, condition. Paved areas shall be restored in accordance with the Contract Documents. 3.7 ENVIRONMENTAL CONTROLS A. Ground Water Control: Provide ground water control and drainage from shafts while work is in progress and until adjacent pipe joints have been properly sealed and the shaft is properly backfilled. Ground water control shall conform to the requirements of Section 02140, Dewatering and Section 7-8.6, Water Pollution Control. B. Surface Water Control: Divert surface water runoff from the shaft and protect the shafts from infiltration or flooding by surface water, including discharge from any dewatering operation. Jacking shaft lining system shall at all locations be extended a minimum of 2 feet above existing, adjacent ground elevation. C. Launch seals for the microtunneling entrance ring must not be ripped or tom and shall be replaced if damaged to prevent the loss of fines into the jacking pit and possible subsequent ground settlement. D. CONTRACTOR shall comply with the requirements of Section 7-10.2, Storage of Equipment and Materials in Public Streets. 3.8 SAFETY A. Safety shall be the sole responsibility of the CONTRACTOR. Security fencing shall be placed around the CONTRACTOR’s work area with appropriate signage and lighting. Construct a concrete K-railing barrier around the periphery of the shaft, meeting applicable safety standards. The work area shall be fenced with a minimum 6’ high chain link fence provided with screening material as a visual barrier. Properly maintain the barrier throughout the period the shaft remains open. Repair broken boards, supports, and structural members. In addition, provide a full cover or other security barrier for each access shaft in which there is no construction activity or which is unattended by the CONTRACTOR’s personnel. + + END OF SECTION + + JACKING AND RECEIVING SHAFTS 02310-g VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK SECTION 02320 TUNNEL SUPPORT SYSTEMS PART 1-_GFNFRAL 3.1 DFSCRIPTION A. Scope: 1. Perform the work as shown, specified and required to provide all support systems for construction of tunnels required to complete the work. 8. Definitions: 1. Tunnel Shield: The structural perimeter element at the front of the tunnel where excavation takes place. 2. Thrust Block: The structural/soil system which provides a reaction for toads associated with pipe jacking which is usually located at the back of the jacking pit. 3. Tunnel Initial Support: Elements designed, furnished, installed, monitored, and maintained in the tunnel for ground support, excavation stability, and safety during construction. 4. Steel Ribs: Structural steel sets consisting of ribs, butt plates, tie rods, collar braces, blocking, dutchmen, shims, and other material as required to expand and erect the steel ribs in place. 5. Precast Concrete Segments: Precast concrete segments erected in a circumferential ring and expanded for support of the tunnel excavation. 6. Liner Plates: Thin, rectangular, curved steel plates with flanges projecting into the tunnel which are punched wlth oversized holes for bolting each plate to the adjacent plate with the annulus between the liner plate and the ground, grouted after erection. - 7. Pipe Jacking: Pipe installed by pushing it into the tunnel opening from a jacking pit using powerful hydraulic jacks. The pipe is lubricated during installation and the annulus between the pipe and- the ground is filled with contact grout after the pipe is installed. C. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. D. Referenced Sections: 1. SSPWC, Section 300, Earthwork. 2. SSPWC, Section 306-3, Tunneling Operations. TUNNEL SUPPORT SYSTEMS 02320-A VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC56 TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK E. Related Sections: 1. Section 2-5.2, Precedence of Contract Documents. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 4-2, Materials Transportation, Handling and Storage. 4. Section 7-9, Protection and Restoration of Existing Improvements. 5. Section 7-10, Public Convenience and Safety. 6. Section 01025, Measurement and Payment. 7. Section 02140, Dewatering. 8. Section 02220, Excavation and Backfill. 9. Section 02300, Tunneling Operations. 10. Section 02306, Microtunneling. 11. Section 02350, installation of Pipe in Tunnel. 12. Section 03610, Contact Grout. 13. Section 03620, Low Density Cellular Concrete. A. Qualifications: The CONTRACTOR shall be quaffied for tunnel support systems as follows: 1. All tunnel support systems shall be provided by a CONTRACTOR with at least 5 years experience, and having installed 3009 LF of similar support systems on at least 3 similar projects. The site superintendent shall have at least 10 years experience installing similar tunnel support systems. 2. Engineered Support System: All tunnel initial support systems shall be designed by a Civil or Structural Engineer registered in the State of California with at least 5 years recent, demonstrated experience designing the selected type of initial support for tunnels. 3. Support Fabrication: Precast concrete segment initial supports shall be fabricated by a firm with experience in the fabrication of precast concrete structural units with similar design and tolerance requirements to those specified in this Section. B. Reference Standards: Comply with applicable provisions and recommendations of the following, except as otherwise shown or specified. 1. Standards: :: ASTM A 36: Specification for Structural Steel. ASTM A 325: Specification for High Strength Bolts for Structural Steel Joints. C. ASTM A 569: Specification for Steel, Carbon (0.15 Maximum, Percent), Hot-Rolled Sheet and Strip, Commercial Quality. d. American Institute of Steel construction (AISC). e. Manual of Steel Construction. C. Subsurface Information: A geotechnicai investigation has been performed by Woodward-Clyde. 1. Refer to Section 7-16. TUNNEL SUPPORT SYSTEMS 02320-2 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK D. Notify the Enginer a minimum 3 workdays in advance of the start of tunneling operations. E. Perform ail work in the presence of the Engineer or District’s representative, unless the Engineer has granted prior approval to perform such work when absent. F. Tolerances: Refer to Paragraph 1.2-G of Section 02300. G. Allowable Ground Surface Settlement and Heave Tolerances: Refer to Paragraph 1.2.H of Section 02300. H. Surveys: Refer to Paragraph 1.2.1 of Section 02300. I. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. A. Submit the Following in accordance with Section 2-5.3. B. Submittals: Submit the following drawings and calculations for review. These submittals shall be prepared and sealed by a Civil Engineer registered in the State of California. 1. Structural design calculations and drawings for each initial support system proposed including assumed engineering parameters and design loading conditions and anticipated ground behavior. Indicate approximate areas where the proposed initial support systems will be installed. Design calculations shall aiso.include: a. Structural calculations indicating that initial supports selected can safety withstand handling and shield jacking loads, as applicable. If tunnel initial support systems will be overstressed by these forces, submit calculations and drawings of details to strengthen tunnel initial supports so as to withstand these loads. b. Calculations for connections: Design connections for tunnel initial supports to transfer the full structural capacity of th& - member. 2. Drawings and calculations for any modifications or alternatives to the details indicated on the Drawings. 3. Steel Ribs: Fabrication and assembly drawings indicating the details of the proposed steel rib supports. include the following information and any other additional details as requested by the Engineer. a. Sizes and shapes. b. Details, arrangements, and spacing of members, including tie rods and/or collar braces if applicable. C. Method of assembly, expansion procedures, and connection details. Submit calculations for all rib connections. d. Lists of materials. include certification stating that the steel ribs comply with the tolerances and material properties included herein. e. Lagging design and details, including steel lagging, if used. TUNNEL SUPPORT SYSTEMS 02320-3 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 4. 5. 6. 7. Precast Concrete Segments: Complete drawings and details indicating segment geometry, reinforcing, reinforcing supports, joints, bolt and dowel connectors, compression packing, expansion elements, inserts, and accessories. Include the following information: a. Provide design calculations indicating structural adequacy of segments. Address all ground, surcharge, live, and construction loads including loads due to fabrication, transportation, storage, handling, gripping, jacking and segment erection. Indicate method for transferring loads across expansion gap. b. A written description of procedures for fabricating, curing, handling, transporting, storing, erecting and expanding segments, including quality assurance provisions and calculations of stresses during handling and erecting. Describe procedure for fiiling expansion gap prior to instaliation of the final lining. Design of segment liiing systems. Include a description of the equipment to be used for erecting segments. Data sheets detailing the following items, if used: E: Compression packings. Expansion element& C. Connectors across longitudinal joints including bolts, washers, plates, sockets, and &eve assemblies. as applicable. d. Connectors across circumferential joints including locking dowels, embedded sleeves and accessories, as applicable. Quality assurance program, with schedules and sequences for checking segment dimensions and materials testing program. C. CONTRACTOR’S Qualifications: In accordance with Paragraph 1.2.A of this Section. D. Submittals for work to be performed within the railroad right-of-way require approval by NCTD. -- 1.4 RESlGN CRlTFRlA A. Ground Support: Support the ground to provide safety, to prevent loss of ground, and to keep the perimeters and faces of tunnel excavations stable until installation of the pipe. TUNNEL SUPPORT SYSTEMS 023204 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK B. Initial Support: lnitial support includes, precast concrete segments, steel support members, with timber or steel lagging liner plates, jacked pipe, and blocking, or combinations thereof: 1. Initial supports shall be designed for all expected loading conditions, including: handling, erection, installation, equipment, and jacking stresses: loads imposed by subsequent construction operations; ground pressures; estimated distortion ratios; live loads; ground convergence control; and other conditions of service. 2. Initial support systems shall be designed to support the ground safely, maintain the shape of the tunnel without encroaching inside the limits required for final lining construction or within the specified tolerances, and prevent loss of ground. Initial support systems shall be compatible with the anticipated geologic conditions and the selected method of tunnel excavation. Tunnel initial support systems shall be designed to withstand ground loads consistent with the Geotechnical Report. 3. Thrust Block: The thrust block shall be normal (square with the proposed pipe alignment and shall be designed to withstand the maximum jacking pressure to be used with a factor of safety of at least 2.0. Deflection of the thrust block shall be limited to a value which does not adversely affect the jacking system or create a safety hazard. In no case shall the deflections be allowed to exceed one inch without prior approval. 1.5 MATERIALS TRANSPORTATION. HAND1 ING AND STOME A. Refer to Section 4-2, Materials Transportation, Handling and Storage. A. Refer to Section 01025, Measurement and Payment. PART 2 - PRODUCTS -- 71 MATPW A. Steel Rib Supports: 1. Steel rib supports and other structural steel members shall be free of rust and defects which may impair or reduce their structural integrity. Ribs shall be accurately bent to approved circular shape for the proper radius of tunnel section. Rib segments shall fit closely for bolted joint connections. 2. Steel appurtenances required for the installation of the ribs such as tie rods, collar braces, bolts, butt plates, wedges, shims, and other necessary accessories shall be provided with the ribs. 3. Ribs, channels, plates, rods, and accessories shall be structural steel conforming to ASTM A 36. Bolts shall conform to ASTM A 325. 4. Steel lagging and steel channel supports shall be structural steel conforming to ASTM A 36. TUNNEL SUPPORT SYSTEMS 02320-5 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK B. C. Timber: 1. Timber for lagging shall be sound, well-seasoned lumber of rectangular cross section. 2. Timber lagging shall be structural grade or better. Liner Plates: Comply with the requirements of ASTM A 569. 1. Manufacturer: Provide one of the following for steel liner plates: a. Pantex, Sika Corp. b. Armco Steel Corp. ii: Dosco Corp. Or equal. PART 3 - EXECUTION 3.15ENTS A. B. C. D. E. F. Support System Requirements: Design, furnish, install, and maintain tunnel initial support systems in accordance with requirements specified herein. Design and install tunnel initial support systems to ensure stability and safety during construction. If ground movements indicate unstable conditions are developing, modify initial support system or provide additional support as required to maintain stability. Expanded Initial Supports: Install initial supports within the shield and expanded immediately against the ground as they exit the tail of the shield. Damaged and Displaced Supports: lmmediateiy remove and replace or repair damaged and displaced and improperly installed initial support in a manner acceptable to the Engineer, Support System Maintenance: Maintain elements of the initial support system in good condition until construction of the final lining js complete. Repair immediately defects which threaten the satisfactory performance of the initial support. -- Jacking Frame and Thrust Block: Jacking equipment and methods shall be compatible with anticipated geologic conditions identified in the Geotechnical Report. Provide a suitable jacking frame and thrust block to carry out the work. Procedures: Develop procedures to support the ground in a safe manner, for maintaining stability of the ground, and for safety during excavation and ground installation. TUNNEL SUPPORT SYSTEMS 02320-6 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK G. Unstable Ground: If unstable ground conditions occur and, in the Engineer’s opinion, the CONTRACTOR has not sufficiently stabilized the ground to provide safe working conditions and prevent ground loss, the Engineer will request that additional support be installed. If the Contractor and Engineer cannot agree on the use of additional support, the Engineer will suspend inspection of such areas until safe conditions are restored. Payment for work performed during any period of suspended inspection will not be made and no time extensions will be granted for completing the work in accordance with the requirements of the Contract Documents, t-l. On-Site Supports: Maintain an adequate supply of tunnel supports at the work site at all times. I. Access: Provide and facilitate safe access to the instruments at all times for the District. A. Erect liner plate rings within the tail of the tunnel shield. B. Erect liner plates with tight, clean joints, and in a manner which will not deform or overstress the completed rings. Flanges shall be clean and free from material that could interfere with proper bearing. Longitudinal joints in adjacent rings shall be staggered by one-half segment, but in no cases, less than two bolt spaces. C. Provide stiffeners, or other supports as required to allow thrusting of the shield off the liner plates without damage to the liner plates, and as required to maintain the liner plate ring in a true circle without buckling. D. The annular space between the liner plate and the excavated surface shall be promptly contact grouted in accordance with Section 03610, Contact Grouting. E. Inspect daily previously placed rings of liner plates for signs of damage an+ - distress. Where damage or distress is observed by the Engineer or the CONTRACTOR, promptly repair or replace such elements, as appropriate, at no additional cost to the District. 3.3 lNSTALLATlON OF FXPANDEDClRCULAR RIBS AND ’ AGGW A. Steel Ribs: All steel ribs used for initial support shall be expanded with full perimeter lagging installed between the flanges of the rib. B. Steel Rib and Lagging Erection: Erect steel ribs and lagging within the tail of the shield or tunneiing machine, and upon emerging from the tail, immediately expand the ribs with jacks of sufficient capacity to produce continuous full contact with the surrounding ground. TUNNEL SUPPORT SYSTEMS 02320-7 VISTA/CARLSBAD lNTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAlN PROJECTS SITE WORK C. Rib Expansion: Expand the ribs by jacking at two locations across the joints between adjoining rib segments. Upon completion of expansion, install steel shims, dutchmen, steel wedges or plates, and secure each joint before releasing the jacking load with bolts in a manner that will not allow relaxation or inward movement of the ribs. D. Rib Securing: Secure ribs against longitudinal movement and distortion by the use of steel tie rods or collar braces. Maximum circumferential tie rod or brace spacing shall be 4-feet measured along rib centertine. E. Lagging: Fit full-perimeter lagging between ribs so that no opening large enough to permit inflow of soil exists. install plywood backing, at least l/4- inch thick, at the point(s) of separation between lagging that occurs as the result of rib expansion, in such a manner as to provide continuous support at the outside circumference of the support system. F. Voids: Fill all voids behind the lagging with pea gravel, grout, geotextiie fabric, or other material of such consistency to prevent loosening of the ground and movement of the ground through the lagging 3.4 TOLERANCFS A. Deformation of Tunnel Initial Supports: Maintain allowable deformation of the tunnel initial support systems within the limits specified by the tunnel support ,design Engineer so as to not over-stress the support system, allow ground settlements to exceed the tolerable limits, and interfere with installation of the pipe. In no case shall the supports be allowed to deflect more than 2-inches without prior approval. B. Pipelines shall be positive draining between any two points. C. Steel Rib Fabrication Tolerances: 1. Chord, measured on centerline of rib: Theoretical length plus or minus l/16-inch. 2. Face of butt or foot plates: Within plus or minus l/%-inch of- - theoretical plane. 3. Gap between ends of ribs and butt or foot plates prior to welding not exceeding 1/18inch for at least 75 percent of the cross sectional area of the rib. Where gaps are in excess of l/16-inch, fill by additional welding. 4. Tie rod holes in rib webs: Within plus or minus 318inch of the locations shown in the submittals. 5. Width or length of shear plates: Within the theoretical dimensions plus or minus l/8-inch. 6. Center to center of bolt hole dimensions on butt or splice plates: Theoretical dimension plus or minus l/l&inch. 7. Bolt hole groups in butt or splice plates after fabrication: Within plus or minus l/16-inch of the theoretical location regardless of the variations in the rib resulting from other tolerances. TUNNEL SUPPORT SYSTEMS 02320-8 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAlN PROJECTS SITE WORK D. Steel Rib Bending Tolerances. 1. Conformance to true template: Plus or minus 3/8-inch between end plates and plus or minus l/&inch in 3-foot gauge depth. 2. Bending curvature: Uniform. 3. After bending: a. Outer flange will be pemritted to deflect l/&inch maximum toward the inner flange for radii of bend less than 14 times the rib depth. b. Buckling of the web for a distance of half the rib depth from either end will be permitted with deviation from the flat no greater than plus or minus l/8-inch for radii of bend equal to 14 times the rib depth or greater. C. Buckling of the web for a distance equal to the depth of the rib from either end will be permitted with deviation from the flat no greater #an plus or minus 3/1&inch for radii of bend less than 14 times the rib depth. 4. Rib depth at the web: ‘Not less than the theoretical depth minus l/4- inch. E.. Liner Plate Segment Tolerances: The designer shall develop liner plate tolerances based on design and installation requirements for adequate structural performance. Comply with the following minimum tolerance requirements. 1. Space drilled holes so that any two rings can be bolted in any relative position with same size bolts in every hole as used in field assembly. 2. Grout Holes: Plus or minus l/2-inch. 3. Fabricate segment within tolerances to ensure that lt will satisfy watertightness and airtightness requirements after application of gasket material along flanges as required. 4. Design details of segments and installation methods capable of limiting ground movement to a maximum of l-inch at a height of 3- feet above the highest point of the sleeted excavation dimension. 5. Design initial support to maintain the shape of the tunnel without exceeding the deflection limits specified by the manufacturer or 0.25 percent stresses so not exceed the specified allowable unit stress. -- 3.5 PIPF INSTAI 1 ATION IN TlJN A. Install all pipe in accordance with Section 02320, installation of Pipe in Tunnel. ++ END OF SECTION ++ TUNNEL SUPPORT SYSTEMS 02320-9 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SlTE WORK SECTION 02330 PlPE JACKlNG PART 1 - GWEBAL 1.1 DFSCRIPTION A. scope: 1. Perform the work required to install all piping shown, specified and required for the construction of complete and operable pipelines using the horizontal jacking trenchless method of installation required to complete the Work. 2. The extent of jacking reinforced concrete pipe is shown on the Plans. 3. This Section specifies the construction of pipelines by using a single- pass, man entry pipe jacking operation to install pipelines to the alignments and grades shown. B. Definition: Pipe jacking is a tunneling technique that involves installing a pipe by jacking it into place from a jacking pit or shaft, using hydraulic jacks. Excavation is canted out within a shield in front of the lead pipe segment using hand-mining or mechanical methods, or with mechanized equipment such as a tunnel boring machine. C. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. D. Related Sections: 1. Section 2-5.2, Precedence of Contract Documents. - 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 4-2, Materials Transportation, Handling and Storage. 4. Section 01025, Measurement and Payment. 5. Section 02140, Dewatering. 6. Section 02306, Microtunneling. 7. Section 02310, Jacking and Receiving Shafts. 8. Section 02340, Boring and Jacking (Steel Casing). 9. Section 03610, Contact Grouting. 10. Section 15051, Buried Piping Installation. 11. Section 15064, Reinforced Concrete Pipe. 12. Section 15073, Concrete Pressure Pipe. -- PIPE JACKING 02330-l VISTAXARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAlN PROJECTS SITE WORK 17 QUALITY ASSURU A. B. C. D. E. F. G. Qualifications: The CONTRACTOR shall be qualified for boring and jacking operations as follows: 1. Jacking Construction: The CONTRACTOR shall have a California Contractor’s license and a minimum of 3 years experience in the installation of pipelines using jacking as the method of installation. 2. Jacking Projects: The CONTRACTOR shall have constructed and completed a minimum of two similar pipe jacking projects. 3. Project Superintendent: The pipe jacking CONTRACTOR’s project superintendent shall have at least 5 years of pipe jacking experience involving pipe jacking construction. 4. Operators: The operators shall have technical training in the operation of the proposed equipment. Reference Standards and Codes: 1. Standards: a. ANSI/AWS Dl .l , Structural Welding Codes. 2. Codes: a. CAUOSHA, State of California Administrative Code, Title 8, industrial Relations, Chapter 4, Division of lndustrial Safety, Subchapter 4, Construction Safety Orders; and Subchapter 20, Tunnel Safety Orders. b. Occupational Safety and Health Administration (OSHA) Regulations and Standards for Underground Construction (29 CFR Part 1926, Subpart Section 1926.800, final rule dated June 9, 1989). Permits and Regulations: 1. Work within the railroad right-of-way shall be performed in accordance with the requirements of Paragraph 1.2.8 of Section 02306, Microtunneling. Subsurface Information: A geotechnical investigation has been performed by Woodward-Clyde. 1. Refer to Section 7-l 6. - Notify the ENGINEER a minimum of 3 work days in advance of the start of jacking operations. Perform all work in the presence of the ENGlNEER or DISTRICT’s Representative, unless the ENGINEER has granted prior approval to perform such work when absent. The thrust block shall be constructed normal (square) with the proposed pipeline alignment and shall be designed in accordance with allowable pressures indicated in the Geotechnical Report. The maximum jacking force to be used shall not exceed the force that can be safely transferred to the soil/rock behind the thrust block. PIPE JACKING 02330-Z VISTAICARLSBAD lNTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK H. Alignment Tolerances: The following tolerances apply to the installation of the pipeline: 1. Line Tolerance: 0.3 feet. 2. Grade Tolerance: 0.1 foot. I. Allowable Ground Surface Settlement and Heave Tolerances: Refer to Paragraph 1.5.B of this Section. J. Surveys: Surveys shall be conducted by a professional surveyor licensed by the State of California. 1. Refer to Paragraph 3.5.8 of this Section. K. General Requirements for NCTDISDNR Railroad Crossing: Refer to Paragraph 1.2.K of Section 02340, Boring and Jacking (Steel Casing). L. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. M. General Requirements for NCTD/SDNR railroad Crossing: 1. Contact Eric Hankinson at (714) 7566800 at least one week in advance of excavation to mark out SDNR’s underground signal cables. NCTD is not a member of Underground Service alert (USA). 2. NCTD track inspectors will sight the track daily for settlement from excavation, jack and bore, and/or microtunneling activities. The CONTRACTOR shall be responsible for any track resurfacing costs from heaving or settlement caused as a result of construction activies. 3. NCTD flag protection is required at all times when the CON?RACTOR is on the railroad right-of-way. Contact Chip Willett at (760) 966-6504 at least 72 hours in advance to schedule flag protection. 4. An SDNR Engineering Representative, in addition to flagman, is required when jacking the casing under the track. Contact Eric Hankinson at least one week in advance to schedule the Engineering Representative. -- 1.3 SUBMlTTAt S A. Submit the following in accordance with the Section 2-5.3. B. Provide sufficient detail to allow the Engineer to judge whether or not the proposed equipment, materials, and procedures will meet the Contract requirements. 1. Details of the methods to control loss of ground in the shafts when breaking out of the jacking pit and breaking into the receiving pit. 2. A description of the laser monitoring, alignment control, and steering systems. Confirm that these systems can achieve the required pipeline and grade within the specified tolerances. Provide manufacturer’s literature for laser and show details of laser supports in the jacking pit. PIPE JACKING 02330-3 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 3. 4. 5. 6. 7. 8. 9. 10. Arrangement and position of main jacks, thrust ring, jacking controls, and pressure gages. Thrust block and jacking frame design and details, including reaction transfer calculations. Details of pipe lubrication system and description of pipe lubricants to be used during pipe jacking, including manufacturer’s literature. Layout of jacking pit and details such as launching seals. Details of lighting, ventilation, and electrical systems. Muck Disposal Plan: Submit describing muck handling and hauling procedures, and the location and sequence for filling disposal site(s). Provide location of disposal site for slurry, if used. Submit a water control plan including temporary drainage provisions, and details for the control, treatment, and disposal of groundwater and construction water in order to comply with the requirements of local, state and federal laws. A safety plan for personnel conducting the pipe jacking operations, including provisions for lighting ventilation, and electrical system safeguards. C. Provide name of site safety representative and persons responsible for gas testing and evidence of Cal/OSHA certification for each, respectively. D. Calculations: Calculations demonstrating that the materials behind the thrust block will sustain the maximum planned forces developed by the main jacks. E. Submit all survey plans and data required by Paragraph 3.4, Instrumentation and Monitoring, including but not limited to the following: 1. Settlement Surveying and Monitoring Plan. 2. Building and Structures Assessment Plan. 3. lnitial Survey. 4. Final Survey. F. Reports and Records: 1. Submit results of instrumentation taken in accordance with Section 3063.11 - Instrumentation and Monitoring, within 24 hours of reading. C- 2. Survey notes, records, and shii reports indicating thrust force, rate of advance, line and grade deviation, and other pertinent information. Submit the following day for each shift worked. G. CONTRACTOR’s Qualifications: In accordance with Paragraph 1.2.A of this Section. H. Name of gas testing representative and evidence of CAUOSHA certification. I. Submittals for work to be performed within the railroad right-of-way require approval by NCTD. PIPE JACKING 023304 VlSTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SD-E WORK 1.4 SAFETY A. The DlSTRlCT has obtained from the State of California, Department of Industrial Relations, Division of Occupational Safety and Health Administration (Cal/OSHA) an underground classification of “Potentially && for these crossings. The classification is included in Section 02306, Microtunneling. B. Perform all work conformance with all current applicable regulations of the federal, state and local agencies. Comply with all applicable provisions of CAUOSHA’s Tunnel Safety Orders and OSHA’s Underground Construction regulations. in the event of conflict, comply with the more restrictive applicable requirements. 1. Refer to Paragraph 1.4.A of Section 02340; Boring and Jacking (Steel Casing). 1.5 DFSIGN CRITFRIA A. Pipe Jacking Equipment: Use only pipe jacking equipment approved by the engineer, meeting the requirements specified in this Section for the boring and jacking work described. Equipment shall be designed to minimize settlement and heave o the ground surface. B. Allowable Ground Surface Settlement and Heave Tolerances: Control ground surface settlement and heave to the following tolerances: 1. !12 inch for roadways. 2. 118 inch for railroad crossing. 3. 1 inch within railroad right-of-way, parallel to railroad tracks. C. Thrust Block: The thrust block shall be normal (square) with the proposed pipe alignment and shall be designed to withstand the maximum jacking forces to be used with a factor of safety of at least 2.0, without excessive deflection and displacement. 1.6 MATE- TRANSPORTATION. HAND1 ING AND STORAGE -- A. Refer to Section 4-2, Materials Transportation, Handling and Storage. T AND PAYMENT A. Refer to Section 01025, Measurement and Payment. PART 7 - PR0nUC-G A. Jacking Pipe: Pipe shall be specifically designed for jacking and shalt be Concrete Pressure Pipe (CPP). 1. Refer to Section 15064. 2. Refer to Section 15073. PIPE JACKING 023304 VISTNCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK PART 3 FXECUTlON s 3.1 GFNERAI RF- A. Use boring and jacking equipment that is compatible with the geologic conditions described in the Geotechniwl Report. 1. Refer to Paragraph 1.2.0 of this Section. B. Pipe jacking or horizontal boring shall not begin until the following conditions have been met: 1. Required submittals have been made and the Engineer has reviewed and accepted all submittals. 2. Jacking pit excavation has been completed and supported in accordance with Section 02310, Jacking and Receiving Shafts 3. A pre-job safety conference has been conducted in accordance with CAUOSHA requirements. Arrange this conference and inform the ENGINEER of the time and place of the conference not less #an 3 working days in advance. 4. The CONTRACTOR’s site safety representative shall prepare a code of safe practices and an emergency plan in accordance with CAUOSHA requirements. Provide the Engineer with a copy of each 7 calendar days prior to starting pipe jacking. Hold safety meetings and provide safety instruction for new employees as required by CAUOSHA. C. Pipe shall be installed between the limits indicated on the Plans to the specified lines and grades, and utilizing methods which include due regard for safety of workers, adjacent structures and improvements, utilities, and the public. Jacking and receiving pits shall be located as shown on the Plans, unless approved otherwise by the Engineer and shall be in accordance with Section 02310, Jacking and Receiving Shafts. D. All work shall comply to the requirements of CALIOSHA and -0SHA. Gas testing shall be performed by a certified gas tester in accordance with CAUOSHA requirements. E. -- Furnish all necessary equipment, power, water, and utilities for excavation, pipe jacking, bentonite mixing and pumping, removal and disposal of spoil, grouting, and other associated work consistent with the CONTRACTOR’S methods of construction. F. Jacking equipment and methods shall be compatible with the anticipated geologic conditions identified in the Geotechniwi Report. Provide a suitable jacking frame and thrust block to carry out the work. G. No gasoline powered equipment shall be permitted in jacking and receiving pits. PIPE JACKING 02330-6 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK H. Diesel, electrical, and air powered equipment are acceptable, subject to applicable local, state, and federal regulations. I. Conduct all operations such that trucks and other vehicles do not create a dust nuisance in the streets and adjacent properties. Promptly remove and dispose of any muck spillage at no additional cost to the District. J. Perform all work so as not to disturb adjacent structures, landscaped areas, and existing utilities. Damage shall be immediately repaired to the satisfaction of the agency or utility having jurisdiction, at no additional cost to the District. TEMPORAY VFNTILATION A. When personnel are underground, furnish and operate a temporary ventilation system, and air monitoring system conforming to the requirements of CAUOSHA and OSHA. Operate and maintain a ventilation system that provides a sufficient supply of fresh air and maintains an atmosphere free of toxic and flammable gasses in all underground work areas. 3.3 IWI 1 ATION A. Alignment Establishment: Refer to Paragraph 3.3.A of Section 02306, Microtunneling. B. Control of Line and Grade: 1. irse an acceptable laser system to monitor line and grade continuously during pipe jacking operations. Laser supports shall be independent of working slab, jacking frame and thrust block to avoid movement of the laser during jacking. Stop pipe jacking operations and reset laser immediately if movement of laser occurs during the Work. Monitor line and grade continuously during pipe jacking operations and record deviation with respect to design line and grade at least once per foot and submit records to the Engineer as requested. Control line and grade of the pipe to within the specified tolerances. C- a. Refer to Paragraph 1.2.H of this Section. 2. When the excavation is off line or grade, make the necessary corrections, and return to the plan alignment at a rate of not more than 1 inch per 25 feet. 3. If the pipe installation exceeds the specified tolerances, correct the installation, including, if necessary, redesign of the pipeline. Corrective work shall be performed at no additional cost to the District, and is subject to the approval of the Engineer. 3.4 AKAGF TFSTINQ A. Repair leakage observed after completing the pipe installation using methods reviewed and approved by the Engineer. PIPE JACKING 02330-7 VISTAKZARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 3.5 INSTRUMFNTATION ANnjklDNITORlNG A. General: Refer to Paragraph 3.4.A of Section 02340, Boring and Jacking (Steel Casing). B. Survey: Refer to Paragraph 3.4.B of Section 02340, Boring and Jacking (Steel Casing). + + END OF SECTION + -+ PIPE JACKING 02330-e -- VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC58 TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK SECTION 02340 BORING AND JACKING (STEEL CASING) 1.1 DFSCRIPTION A. scope: 1. Perform the work required to provide all steel casing shown, specified and required for the construction of complete and operable casings using the horizontal boring and jacking trenchless method of installation required to complete the Work. 2. The extent of boring and jacking steel casing is shown on the Plans. 3. This Section specifies the construction of steel casing by using a single-pass, non-man entry boring and jacking operation to install pipe casings to the alignments and grades shown. 4. Installation of the carrier/product pipe within the steel casing shall be in accordance with the requirements contained in this Section. 5. Microtunneling requirements for the installation of interceptor sewer piping are addressed in Section 02306, Microtunneling. B. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. C. Related Sections: 1. Section 2-5.2, Precedence of Contract Documents. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 4-2, Materials Transportation, Handling and Storage. 4. Section 01025, Measurement and Payment. 5. Section 02140, Dewatering. 6. Section 02306, Microtunneling. 7. Section 02310, Jacking and Receiving Shafts. a. Section 03610, Contact Grouting. 9. Section 03620, Low Density Cellular Concrete. 10. Section 03630, Compaction Grouting. 11. Section 15051, Buried Piping Installation. 12. Section 15064, Reinforced Concrete Pipe. 13. Section 15075, PVC Pipe - SDR 35. -- BORING AND JACKING (STEEL CASING) 02340-l VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 17 C&&l ITY ASSURANCF A. B. C. D. E. F. Qualifications: The CONTRACTOR shall be qualified for boring and jacking operations as follows: 1. Boring and Jacking Construction: The CONTRACTOR shall have a California Contractor’s license and a minimum of 3 years experience in construction of pipelines in steel casing using the boring and jacking method of installation. 2. Boring and Jacking Projects: The CONTRACTOR shall have constructed and completed a minimum of 1,000 LF of installed pipelines in steel casing in excess of 30-inches in diameter using a similar boring and jacking method of installation. a. The installation experience shall be of the same type of steel casing used in this Project. b. The projects constructed shall be of the same type and size of steel casing used in this Project. Reference Standards and Codes: 1. Standards: a. ASTM A 283, Specification for Low and Intermediate Tensile Strength Carbon Steel Plates, Shapes, and Bars. b. ANSI/AWS Dl .l , Structural Welding Code. 2. Codes: a. CAUOSHA, State of California Administrative Code, Title 8, Industrial Relations, Chapter 4, Division of Industrial Safety, Subchapter 4, Construction Safety Orders: and Subchapter 20, Tunnel Safety Orders. b. Occupational Safety and Health Administratlon (OSHA) Regulations and Standards for Underground Construction (29 CFR Part 1926, Subpart Section 1926.800, final rule dated June 9, 1989). Permits and Regulations: 1. Work within the railroad right-of-way shall be performed in accordance with the requirements of Paragraph 1.2.8 of Section 02306, Microtunneling. c- Subsurface Information: A geotechnical investigation has been performed by Woodward-Clyde. 1. Refer to Section 7-16. Notify the ENGINEER a minimum of 3 work days in advance of the start of boring operations. Perform all work in the presence of the ENGINEER or DISTRICT’S Representative, unless the ENGINEER has granted prior approval to perform such work when absent. BORING AND JACKING (STEEL CASING) 02340-2 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK G. H. I. J. K. L. Welding Requirements: All welding procedures used to fabricate steel casings shall be prequalified under the provisions of ANSI/AWS D1.l. Welding procedures shall be required for, but not necessarily limited to, longitudinal and girth or special welds for pipe cylinders, casing joint welds, reinforcing plates, and grout coupling connections. 1. All welding shall be performed by qualified welders, welding operators, and tackers who have had prior experience with the type of materials used. Welders shall be qualified under the provisions of ANSI/AWS D1.l by an independent local, approved testing agency not more than 6 months prior to commencing work on the casing of pipeline. Machines and electrodes similar to those used in the work shall be used in qualification tests. The Contractor shall bear the full expense of qualifying welders. Alignment Tolerances: The following tolerances apply to the installation of the casing and the carrier/product pipeline: 1. Line Tolerance: 0.3 feet 2. Grade Tolerance: 0.1 foot Allowable Ground Surface Settlement and Heave Tolerances: Refer to Paragraph 1.58 of this Section. Surveys: Surveys shall be conducted by a professional surveyor licensed by the State of California. 1. Refer to Paragraph 3.4.8 of this Section. General Requirements for NCTD/SDNR Railroad Crossing: 1. Contact Eric Hankinson at (714) 766-6800 at least one week in advance of excavation to mark out SDNR’s underground signal cables. NCTD is not a member of Underground Senrice Alert (USA). 2. NCTD track inspectors will sight the track daily for settlement from excavation, boring and jacking, jacking and microtunneling operations. CONTRACTOR shall be responsible fer any track resurfacing costs from heaving or settlement caused as a result of construction activities. 3. NCTD flag protection is required at all times when the CONTRACTOR is on the railroad right of way. Contact Chip Willett at (760) 9666594 at least 72 hours in advance to schedule flag protection. 4. An SDNR Engineering Representative, in addition to a flagman, is required when jacking the casing under the track. Contact Eric Hankinson at least one week in advance to schedule the Engineering Representative. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. BORING AND JACKING (STEEL CASING) 02340-3 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK BMllTqLS A. Submit the following in accordance with the Section 2-5.3. B. Shop Drawings: 1. Material list and casing details including diameter, thickness, class of steel and joint welds. Provide fabrication drawings from casing supplier. 2. Locations and details showing sizes of all jacking and receiving shafts. C. Provide name of site safety representative and persons responsible for gas testing and evidence of Cal/OSHA certification for each, respectively. D. Description of boring methods, procedures, and equipment to be used to jack the casing. Provide a description of the method to be used for controlling and correcting the boring operation in order to maintain the line and grade shown within the specified tolerances. Provide description of methods used for providing temporary ventilation and for checking line-and-grade of the casing. Indicate the location of muck disposal sites that will be utilized. E. Casing installation schedules which address excavation, casing and carrier pipe installation, and backfill operations. F. Calculations demonstrating that the casing selected has been designed to support,the maximum anticipated earth loads, superimposed live loads (Cooper E80 Railroad Loads and H20 Highway Loads), buckling stresses and the additional stresses imposed by the jacking operation. Calculations shall be stamped and signed by a licensed civil engineer in the State of California. G. Confirmation that steel casing inside diameter has been coordinated with the sewer pipe outside diameter to provide an annular space specified in Paragraph 2.1 .A. H. Groundwater control methods and supporting information for the shafts an& - sewer line crossings shall be submitted with Section 02140, Dewatering. I. Procedures and methods to be used to install the carrier pipe including loading and blocking details and spacing of blocking points. J. Submit details of compaction grouting program at the NCTD Railroad Crossing which can be implemented during or after boring and jacking to mitigate settlement which exceeds the l/&inch tolerance at this location. K. Submit details of chemical grouting program for use with open face rotary cutterhead (without flood door) or digger shield, in lieu of dewatering, subject to approval by the ENGINEER. BORING AND JACKING (STEEL CASING) 02340-4 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK L. Submit all survey plans and data requited by Paragraph 3.4, Instrumentation and Monitoring, including but not limited to the following: 1. Settlement Surveying and Monitoring Plan in accordance with Paragraph 3.4.A.2 of this Section. 2. Building and Structures Assessment Plan in accordance with Paragraph 3.4.A.3 of this Section. ,3. Initial Survey in accordance with Paragraph 3.4.8.1 of this Section. 4. Final Survey in accordance with Paragraph 3.4.8.4 of this Section. M. Certifications: Submit certified affidavits of compliance for all pipe and other products or materials furnished under this Section and the following supplemental requirements: 1. Physical and chemical properties of all steel. 2. Welder certifications in accordance with the requirements specified in Paragraph 1.2 of this Section. 3. All expenses incurred in making samples for certification of tests shall be borne by the Contractor. N. CONTRACTOR’s Qualifications: In accordance with Paragraph 1.2.A of this Section. 0. Name of gas testing representative and evidence of CAUOSHA certification. P. Submittals for work to be performed within the railroad right-of-way require approval by NCTD. 1.4 SAFETY A. The DISTRICT has obtained from the State of California, Department of Industrial Relations, Division of Occupational Safety and Health Administration (Cal/OSHA) an underground classlfiwtion of ‘Pote&8& w for these crossings. The classification is included in Section 02308, Microtunneling. Perform work in conformance with all applicable federal, state, and local safety requirements. 1.5 DESIGN CRI- -- A. Boring and 3acking Equipment: Use only boring and jacking equipment approved by the Engineer, meeting the requirements specified in this Section for the boring and jacking steel casing work described. Equipment shall be designed to minimize loss of ground, and minimize settlement and heave of the ground surface. B. Allowable Ground Surface Settlement and Heave Tolerances: Control ground surface settlement and heave to the following tolerances: 1. l/2 inch for roadways. 2. l/8 inch for railroad crossings. 3. 1 inch within railroad right-of-way, parallel to railroad tracks. BORING AND JACKING (STEEL CASING) 02340-5 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK C. Thrust Block: The thrust block shall be normal (square) with the proposed pipe alignment and shall be designed to withstand the maximum jacking forces to be used with a factor of safety of at least 2.0, without excessive deflection and displacement. 1.6 MATERIAI S TRANSPORTATION. HANDWG AND STORAGE A. Refer to Section 4-2, Materials Transportation, Handling and Storage. 1.7FNT AND PAYMFNT A. Refer to Section 01025, Measurement Andy Payment. PART 7 - PRODUCTS 2.1 GFNERAl A. Steel casings shall be welded steel pipe of size and thickness specified herein. The CONTRACTOR may select a greater casing diameter or thickness for the method of work, loadings involved, and site conditions, at no additional cost to the DISTRICT, subject to the review and additional requirements of the ENGINEER. Such increases of the casing diameter shall not interfere with existing utilities. B. The annular space between the inside diameter of the steel casing and the outside diameter of the sewer and storm drain pipe shall be 5 to 6-inches all around the pipe. C. Anoular.spaces between the carrier pipe and the casing shall be filled with Low Density Cellular Concrete backfill grout. 77 MATERIAI B A. Steel Casing: The steel casing pipe shall be in accordance with ASTM A283, Grade C. Casing sections shall be butt welded, lap welded, or welded= - using butt straps in the field. If butt welded, each end of the casing shall be prepared by providing a 45degree chamfer on the outside edges. Steel casing shall have a specified minimum yield strength (SMYS) of at least 35,000 psi. Minimum casing thicknesses for specific diameters are: . . Caslna 12-3t4” and under 14 16 18” 20” and 22 24” 30” 36 Min. Thim 0.188” 0.250” 0.281” 0.312” 0.344” 0.375” 0.469” 0.531” BORING AND JACKING (STEEL CASING) 02340-6 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK Casings larger than 36inches in diameter shall have at least one grout coupling every 8 feet longitudinally along the casing for contact grouting the annular void outside the casing due to over-cutting. B. Grout: 1. Voids between casing and soil shall conform to the following: i: Cement: Type II or Type V conforming to ASTM Cl50. Grout: Grout shall contain at least 8 sacks of cement per cubic yard of mix. C. Fineness Modulus: Between 1.50 and 2.00. Sieve No. 8 100 No. 16 95-100 No. 30 60-85 No. 50 20-50 No. 100 lo-30 No. 200 O-5 d. Fluidifier: Use Celebex 209X manufactured by Celtite, Inc., or an equal approved by the ENGINEER. e. Admixtures: Other admixtures may be used subject to the approval of the Engineer. f. Compressive Strength: Minimum 100 psi in 24 hours, 2000 psi in 28 days. 2. Annular space between casing and carrier pipe shall conform to the following: a. Low Density Cellular Concrete: b. Cement: Conform to ASTM Cl 50 C. Foaming Agent: Comply with ASTM C869, when tested in accordance with ASTM C796. d. Strength: Minimum 7 day/28 day ASTM C495 compressive strength of 300 / 500 psi. C. Blocking or Centralizers: The pipe shall be blocked to grade inside the casing using an approved blocking system. -- PART 3 FX-XJTION - . A. Comply with all of the requirements of Section 02306, Microtunneling, if Microtunneling is employed as the method of installing the casings. B. Use boring and jacking equipment that is compatible with the geologic conditions described in the Geotechnical Report. BORING AND JACKING (STEEL CASING) 02340-7 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 3.2 INSTaLLATlON OF STFFt CASING A. B. C. D. Microtunneling Machine in accordance with Section 02366. 1. The NCTD Railroad Crossing: If the CONTRACTOR chooses the Auger Boring option, then the gmundwater must be controlled by means of dewatering or chemical grouting at the CONTRACTOR’s discretion. Jacking and Receiving Shafts: Shoring systems for excavations for the boring and jacking operations shall be designed and constructed in accordance with Section 02310, Jacking and Receiving Shafts. Heavy guide timber, structural steel, or concrete cradles of sufficient length shall be provided to assure accurate control of the boring alignment. Provide adequate space within the excavation to permit the insertion of the lengths of casing to be installed. Anchor or brace timbers and structural steel sections to maintain orientation of the jacks in line with the axis of the casing. A thrust block, consisting of a timber, concrete, or structural steel framework, shall be constructed between the jacks and the end of the casing to provide uniform end bearing over the perimeter of the casing and to distribute the jacking pressure evenly. Control of Line and Grade: Control the application of the jacking pressure and excavation of materials ahead of the casing as it advances to prevent the casing from becoming earthbound or from deviating from the required line and grade. Check line and grade using surveying methods from inside the casing, or other methods approved by the ENGINEER, at least every 60 feet unless permitted otherwise by the ENGINEER. Installation: The installation of the casing shall be in accordance with the Plans and shop drawings, and shall be subject to the approval of the District The shop drawings and calculations pertaining to the railroad crossing will also be subject to review and approval by the NCTD. Provide dewatering wells or other methods of groundwater control in accordance-with Section 02310, Jacking and Receiving Shafts, and Section 02140, Dewatering. 1. Provide jacks of adequate capacity to push the casing through the soil as required to complete the crossing. Provide a suitable jacking- frame and thrust block to carry out the work. 2. Set the casing to be jacked on guide rails, properly braced to support the casing, and direct it in the proper line and grade. Line up the jacking assembly in the direction and grade of the tunnel. Weld all casing joints completely prior to jacking. 3. Provide temporary ventilation when personnel are working inside the casing. BORING AND JACKtNG (STEEL CASING) 02340-8 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 ?A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 4. 5. 6. To minimire voids outside the casing, excavation shall be carried out entirely within the jacking head and not in advance of the head. Coordinate the advance of the casing and boring rate to avoid over- excavation. Restrict the excavation of the materials to the least clearance necessary to prevent binding in order to avoid loss of ground and consequent settlement or possible damage to overlying pavements, utilities, structures or railroad tracks. Excavated materials shall be removed from the casing as the boring and jacking operation progresses. No accumulation of excavated materials within the casing shall be permitted. Contact grout the annular space outside the casing in accordance with the procedures contained in Specification Section 02306, Microtunneling. E. Muck disposal and settlement monitoring shall conform to the requirements of Section 02306, Microtunneling. F. The CONTRACTOR shall be fully responsible for correcting all roadway and railroad track settlement and any other damage that occurs as a result of installation of the casing at no additional cost to the DISTRICT. The CONTRACTOR shall install and implement a compaction grouting program in accordance with approved Shop Drawings for use at the NCTD Railroad Crossing to immediately mitigate ground/track settlement which exceeds the l/&inch tolerance. The CONTRACTOR shall demonstrate, prior to encroaching beneath the railroad track influence zone, that settlements can be maintained within the specified tolerances. 3.3 INST Al LATION OF CAqBlER PIPE A. Pipe Installation: Install carrier pipe as shown on the Plans in accordance with specified tolerances. Remove all loose soil from casing. Provide timber skids and blocking or other approved devices as required to prevent flotation, movement and damage to the pipe during installation and grout backflll placement. Every individual pipe length or section should be supported by at least two skids or blocking points that are at least three feet long. B. Joints: All joints of the carrier pipe within the casing shall be completed i; accordance with the appropriate Section of pipe material. C. Pipeline Test of the Carrier Pipe: Pipeline test of the wnier pipe shall be completed prior to the filling of the annular space between the casing and carrier pipe with grout 1. Refer to Section 15051, Buried Piping Installation. BORING AND JACKING (STEEL CASING) 02340-g VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 ?A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK D. Grout Backfill for Annular Space in Jacked Casing: Provide the necessary grout, equipment, hoses, valves, and fittings for the backftlling operation. Grouting materials and grout mixes shall conform to the requirements of this Section. Protect and preserve the interior surfaces of the steel casing from damage. Grout shall be pumped through a pipe or hose. The grout shall be proportioned to flow and to completely fill all voids between the carrier pipe and the casing. Provide bulkheads at each end of the casing to contain the grout backfill. Pump the grout from the low elevation end of the tunnel to the high elevation end. Install a blow plug at the top high elevation end of the tunnel to verify communication of the grout through the tunnel alignment. Grout backfilt will be considered completed when grout is communicating through the blow plug at the top high ,elevation end of the tunnel. E. Closing of Shafts: After jacking equipment and excavated materials from the boring or jacking operations have been removed from the jacking and receiving shahs, prepare the bottom of the shafts as a pipe foundation. Backfill excavations, compact backfill materials, and restore the jacking and receiving shaft sites in accordance with Section 02310, Jacking and Receiving Shafts. 3.4 A. General: 1. Conduct Construction operations to minimize settlement and heave of the ground. The CONTRACTOR shall be responsible for damage due to settlement and heave caused by construction operations. Settlement and heave shall not exceed those limits specified under Design Criteria in Part 1. 2. Submit a settlement surveying and monitoring plan for review prior to construction. The plan shall identify the location of settlement monitoring points, reference benchmarks, survey schedules and procedures and reporting formats. 3. Submit a Building and Structures Assessment Plan prior to construction. Pre-construction and post-construction assessment reports shall be provided for buildings and structures located within a distance of 100 feet from the proposed pipe centerline and shaft& - Photographs or a video of existing damage to structures in the vicinity of the pipeline alignment shall be included in the assessment reports. 4. Install and maintain a system of instrumentation to monitor the underground excavation operation and to detect movement in the soil, adjacent structures and utilities. 5. In the event of movement of the ground surface, structure or utility being detected or damage recorded, the ENGINEER may order that the work be stopped and secured. Before proceeding, the CONTRACTOR shall correct any problems causing or resulting from such movement entirely at its own cost. It is the CONTRACTORS responsibility to monitor and immediately report to the ENGINEER ground settlement and heave which might affect the accuracy of temporary and permanent benchmarks. BORING AND JACKING (STEEL CASING) 02340-10 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK B. Survey: 1. Initial Survey: Record the horizontal coordinates and elevations (with accuracy of 0.01 feet) for each survey point location. Reference surrey points so that they may be accurately reestablished if lost or destroyed. 2. Unless otherwise directed, surface movement monitoring points shall be. established along the pipe alignment and at 15-foot offset each side of the wnterline of each drive section located at not less than 30 foot intervals. Monitoring points shall be installed prior to the commencement of any underground operations, including shaft construction. 3. Submit readings from the various instruments and survey points to the ENGINEER on the same day the readings are taken. Reading shall wmmence at the commencement of microtunneling. Initial readings of surface points shall be taken before any weekly excavation or construction is started. Monitoring shall continue weekly for at least 4 weeks after completion of any drive section. 4. Final Survey: At the end of all construction operations, make a final survey of all control points established for instrumentation and observation. The final readings shall be submitted to the ENGINEER. + + END OF SECTION + + -- BORING AND JACKING (STEEL CASING) 02340-11 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK SECTION 02350 INSTALLATION OF PIPE IN TUNNEL PART 1 MNFFW - 1.1 DESCRIPTION A. scope: 1. Perform the work required to install all piping shown, specified and required to provide for the construction of complete and operable pipeline in tunnels required to complete the Work. B. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. C. Referenced Sections: 1. SSPWC, Section 300, Earthwork. 2. SSPWC, Section 306-3, Tunneling Operations. D. Related Sections: 1. Section 2-5.2, Precedence of Contract Documents, 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 4-2, Materials Transportation, Handling and Storage. 4. Section 7-9, Protection and Restoration of Existing Improvements. 5. Section 7-10, Public Convenience and Safety. 6. Section 01025, Measurement and Payment. 7. Section 02140, Dewatering. 8. Section 02220, Excavation and Backfill. 9. Section 02300, Tunneling Operations. 10. Section 02306, Microtunneling. 11. Section 02320, Tunnel Support Systems. 12. Section 03610, Contact Grouting. 13. Section 03620, Low Density Cellular Concrete. -- 1.2 OyPl ITY ASSURAU A. Reference Standards: Comply with applicable provisions and recommendations of the following, except as otherwise shown or specified: 1. Standards: a. American Society of Mechanical Engineers (ASME). b. Boiler and Pressure Vessel Code (BPVC). C. Section VIII, Rules for Construction of Pressure Vessels, Division 1. B. Subsurface Information: A geotechniwl investigation has been performed by Woodward-Clyde. 1. Refer to Section 7-16. INSTALLATION OF PIPE IN TUNNEL 02350-l VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK C. Notify the Engineer a minimum 3 workdays in advance of the start of tunneling operations. 0. Perform all work in the presence of the Engineer or District’s representative, unless the Engineer has granted prior approval to perform such work when absent. E. Tolerances: Refer to Paragraph 1.2.G of Section 02300. F. Allowable Ground Surface Settlement and Heave Tolerances Refer to Paragraph l.2.H of Section 02300. G. Surveys: Refer to Paragraph 1.2.1 of Section 02300. H. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. IL3 SUBMIT-TM A. Submit the following in accordance with Section 2-5.3. B. Submittals: Submit the following shop drawings and details for review. These drawings shall be prepared and sealed by a Civil Engineer registered in the State of California. 1. Shop Drawings: Detailed fabrication shop drawings of pipe to be installed. Include the following installation information: a. Methods of controlling groundwater inflows in the tunnel including b. panning, drainage, vent pipe, and drain pipe details. Design calculation and details of pipe carriers, tie-downs, blocking, support brackets, or other measures to support pipe and prevent floatation. ii: Details of proposed cradles and other support details. Design and details of internal pipe supports, bracing, and stulling to maintain pipe roundness. F’ Methods of grade control. Pipe laying schedule for the tunnels showing pipe lengths, deflections, and fittings to meet the actual excavated tunnel alignment. Demonstrate those proper clearances for pipe installation exists. 9. Submit details for installing the pipe in the tunnel. Provide d<wings indicating centraliser details; rails, stiffeners, concrete placement pipes; and drain lines. Describe methods and equipment for welding and testing pipe, installing pipe in shaft securing it in place, and placing backflll concrete around pipe. h. For procedures of installing the carder pipe utilizing metal guide rails, the rails shall be cathodically isolated from the initial support system. Methods involving the welding of the metal rails to the initial support to achieve line and grade will not be allowed. i. For casing centralizers, submit calculations from the centralizer manufacturer certifying that the centralizers are designed and arranged in a manner capable of supporting the unit weight of the pipe per linear foot without failure, under the project conditions. INSTALLATION OF PIPE IN TUNNEL 02350-2 C. VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PR’OJECTS SITE WORK Equipment and Procedures: 1. Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR), and Welding Operator Performance Qualifications (WPQ) for each welding process and each welder proposed for use in the steel-plate pipe work. 2. Welder’s certifications demonstrating certification by an independent testing laboratory within the past six months, or documentation proving continuous employment from last certification date. 0. Quality Control Submittals: 1. Installer’s Qualifications:. Description of experience demonstrating required qualifications for installing similar type of pipe in tunnel. Submit project name and details, contract, and telephone number for three projects completed within the last 5 years. 1.4 QUAI ITY ASSURANCF A. Tolerances: 1. Centeriine Variation From Design Line: 1 inch except at shafts. l/2 inch at shafts. 2. Variation From Design Grade: in-inch from indicated invert elevations. 3. Allowable rate of change: a. Horizontal: 1 inch in 30 feet. b. Vertical: 1 inch in 40 feet. 1.5 MATFRlAf ,S TRANSPORTATION. HANDI ING AND STORAGE A. Refer to Section 4-2, Materials Transportation, Handling and Storage. 1.6 ME B. Refer to Section 01025, Measurement and Payment. A. Timber: Timber for stulls, braces, and blocking shall be Construction Grade 00~~~s Fir, and especially selected for straightness. Timber need not be new but used lumber shall be of the same grade and species specified for new lumber and shall be sound, free from defects, which might impair the serviceability of the piece. Timber shall be stored where it can be easily inspected. Timber with excessive knots, bark, holes, splits or other defects shall not be used. B. Blocking: Precast concrete, treated timber, or other nondegradable material. C. Redwood Skids: Redwood skids will not be allowed on this project. INSTALLATION OF PIPE IN TUNNEL 02350-3 D. VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK Casing Centralizers: Provide non-conductive spacers in tunnel with a conductive initial support system, and maintain separation of the carrier pipes, as shown on the Drawings. Spacers shall hold the carrier pipes securely within the tunnel and shall be fully restrained with runners and/or wheels to support the pipes and facilitate carrier pipe installation. Spacers shall be fabricated of materials compatible with the cathodic protection system. The spacers shall be designed and arranged in a manner, certified by the piping manufacturer, that will be capable of supporting the pipe without failure during installation. PART 3 - FXFCUTION 3.1 WORK =FPARATION A. Tunnel and shaft initial support systems shall be inspected and accepted ‘by the Engineer prior to installation of pipe. B. A special inspection shall be required before the installation of pipe by means of casing centralizers to ensure the casing is free from irregularities in roundness, casing welding irregularities, and misaligned casing joints. These deficiencies shall be corrected and approved by the Engineer prior to the installation of the carrier pipe. C. Pipe installation shall not commence until the Engineer indicates that the tunnel and shaft excavation has been stabilized and that all deformations of the initial supports have been successfully controlled. D. Install temporary drainage pipes and panning to control water infiltration that will be detrimental to the placement of cellular concrete or backfill concrete and any piping required for contact grouting and air vents for the drainage and panning elements. When no longer needed, these drains shall be grouted after the installation of pipe and cellular concrete or backfill concrete. E. All rock, soil, nonessential timber blocking, and other wood or degradable materials shall be removed to provide the minimum thickness of cellular wncrete or backfill aencrete indicated on the Plans. F. All voids outside the tunnel or shaft supports that will not be filled properly during placement of cellular or backfill concrete shall be filled with shotcrete or grout prior to installation of the pipelines in the tunnel as required by the Engineer. The Engineer will inspect the tunnel and identify areas where voids shall be filled. G. Clean up of the tunnel and shaft shall be complete prior to pipe installation. Clean up shall include the removal of the following: 1. All loose, disturbed soil or rock and standing water in the tunnel invert and along the tunnel and shaft sidewalls. INSTALLATION OF PIPE IN TUNNEL 023504 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 2. 3. Timber blocking or other timber supports, which are not load carrying supports, shall be replaced with steel or concrete. Timber lagging, timber blocking, and timber wedges shall be removed as much as practical without endangering the stability of the excavation. All blocking and lagging shall be checked and made tight. Structural steel spreaders, steel pipe spreaders, and steel tie rods used to brace the structural steel supports may be left in place and the backfill concrete placed about them as accepted by the Engineer. H. All timber left in place as part of the initial tunnel support system and which is not fire retardant shall be covered with a 2-inch layer of shotcrete prior to installation of steel pipe which requires field welded joints to be welded in the field. I. All utilities shall be removed prior to the installation of pipe in tunnel except for drainage facilities and other provisions to control groundwater inflows. J. Pipe installation shall not wmmence until the Engineer confirms in writing that tunnel preparation and clean-up have been property completed. 37 GFNERAI RFQU- A. Temporary ventilation, lighting, and other utilities in the tunnel shall be maintained throughout the tunnel during installation of the pipes and all subsequent operations. - B. Tunnel groundwater inflows shall be controlled by means of cutoff grouting, installing drain pipes,, panning, backdrains, underdrains, invert drains, channeling, pumping, or other means approved by the Engineer. Any drains installed shall be connected to grout pipes so that they can be contact grouted after placement of cellular or backfill concrete. Tunnel groundwater inflows shall be handled, treated, and disposed of in accordance with Section 02140, Dewatering. C. The pipe shall be installed in the tunnel and shaft as indicated on the Plans and accepted submittals for pipe installation. The pipe shall be installed without sliding or dragging in a manner that would damage the pipe or its coatings and linings. Any damage to the pipe or its coatings and linings during transport and installation, for any reason, shall be repaired to the satisfaction of the Engineer or replaced witba new section of pipe at no additional expense to the District 0. The pipe in the tunnel and shaft shall be supported, blocked, stulled, tied off, and braced to prevent buckling, ovalling, misalignment, and flotation in accordance with the recommendations of the pipe manufacturer, and accepted submittals. E. Each section of pipe shall be blocked to the required line and grade without encroaching on the minimum annular space indicated on the Plans. The blocking spacing shall be sufficient to preclude damage to the pipe due to excessive deflection or misalignment of pipe. F. The Contractor shall ensure that each pipe section is firmly secured, by providing tiedowns or blocking or by other means to prevent flotation, settlement, or lateral or axial movement of the pipe during placement of cellular or concrete backfill. INSTALLATION OF PIPE IN TUNNEL 02350-5 3.3 INSTAI 1 ATION OF PIPF IN TUNNELS AND SHAFTS VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK G. The pipe shall be securely held in position by blocking between field joints in such manner as not to interfere with the required work at the joints. Blocking shall be placed near the ends of the section as indicated on accepted submittals. A. Cleaning: Before installation of any section of pipe, any foreign matter shall be removed from all joint.surfaces and the entire outer surface of the pipe to leave thoroughly clean surfaces for metal-to-metal contact in field joints and for bond of cellular or backfill concrete. B. The use of sledges for driving or hammering in such a manner as to injure any joint will not be allowed. Care shall be taken to prevent the pipe from being in any way subjected to heavy shocks. Sharp kinks, scars, bends, or other injuries from hammering or other causes shall be cause for rejection wherever, in the opinion of the Engineer, the presence of such deformation will cause damage to the pipe or pipe joints. C. The use of dogs or equivalent devices welded to the pipe for the purpose of forcing it into position will not be permitted. D. Field Joints: 1. 2. 3. 4. 5. 6. 7. a. 9. 10. 11. Welding shall be done by skilled welders who have demonstrated adequate experience in the methods and materials to be used. Welders shall be qualified in the procedure and positions for the work to be done. All welders shall be certified by an independent laboratory within the last six months. Weld procedures shall be in accordance with the approved welding procedures submitted in this Section. , The Engineer may call for additional test specimens as the work progresses and maydernandthe. removal of a welder whose work is not satisfactory, regardless of the quality of the test welds. After assembly, the joints shall be thoroughly cleaned by wire-brushing a minimum of 5 inches each side of root opening. The steel pipe shall be welded with a full penetration lap weld. The lap weld shall be performed on the outside of the pipe, as shown in the welding details. Weld area shall be maintained free of moisture during the welding and subsequent cooling cycle to the extent necessary to assure weld quality.- - After the pipe has been welded at the joint, flash rusting shall be removed by mechanical means such as a wire brush. Burrs and weld slag shall be removed to achieve a smooth surface. After the weld has cooled, cement mortar shall be hand placed, or placed with a pig or pull ball, into the joint gap inside the pipe, as shown on the drawings. The exposed steel pipe joint shall then be tape wrapped with a minimum 50 mil thickness of joint tape and shall overlap the exposed steel pipe joint by a minimum of 2 inches on both sides of the joint as shown in the joint detail. The pipe shall then be jacked into the tunnel on casing centralizers, or a method approved by the Engineer. Line and grade deficiencies or damage to the carrier pipe resulting from the failure of casing centralizers shall be corrected by the Contractor, in a method approved by the Engineer, at no cost to the District. INSTALLATION OF PIPE IN TUNNEL 02350-6 VISTkVCARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK E. After pipe installation, backfilling, and contact grouting is complete, inspect pipe for damage and repair any damage to the pipe and its lining at no additional cost to the District. Repair methods shall be submitted to the Engineer for review prior to performing the repairs. ++ END OF SECTION ++ INSTALLATION OF PIPE IN TUNNEL 02350-T -- VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK SECTION 02500 PAVEMENT 1.1 DESCRIPTION A. Scope: 1. Perform the work as shown, specified and required to provide for construction of all pavement required to complete the Work. 2. The extent of pavement to be constructed shall be that which is required to reconstruct existing improvements removed and damaged by the CONTRACTOR8 operations. 3. The extent of street pavement resurfacing and striping is specified and shown on the Plans required to complete the Work under Schedule D. B. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. C. Referenced Sections: SSPWC: 1. Section 4-1.4, Test of Materials. 2. Section 200, Rock Materials. 3. Section 201, Concrete, Mortar and Related Materials. 4. Section 203, Bituminous Materials. 5. Section 210-I -6, Paint for Traffic Striping, etc. 6. Section 302-5, Asphalt Concrete Pavement. 7. . Section 302-5.4, Tack Coat. - 8. Section 3026, Portland Cement Concrete Pavement. 9. Section 400-4, Asphalt Concrete. 10. Section 600-2.6, Asphalt Rubber Hot Mix - Gap Graded. c- D. Related Sections: 1. Section 2-5.2, Precedence of Contract Documents. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 4-2, Materials Transportation, Handling and Storage. 4. Section 01025, Measurement and Payment. 5. Section 02220, Excavation and Backfill. 6. Section 02230, Crushed Stone and Gravel. 7. Section 02529, Concrete Curbs, Gutters and Sidewalks. PAVEMENT 02500-l VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK A. Materials incorporated in the Work shall be obtained from the same source of supply throughout the life of the project unless the CONTRACTOR is otherwise granted written permission by the District. B. Tests: 1. Perform in accordance with Section’4-1.4, Test of Materials. 2. Perform tests as specified in SSPWC Sections 200, 201, 203 and 211. C. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. 1.3 SUBMITTAt ,S A. Submit the following in accordance with Section 2-5.3. B. Proposed mix design of each class of Portland cement concrete, asphalt concrete, tack coat, and fog seal to be used in the Work. C. Certified Delivery Tickets: Provide certified weighmaster delivery tickets at the time of delivery. Each certification shall show the public weighmaster’s signature, the total quantities by weight of all components of the specific design mix. Each certificate shall, in addition, state the mix number, total yield in cubic yards or tons and the time 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. D. Test Results: In accordance with Paragraph 1.2.8 of this Section. E. Traffic Control Plan for asphalt pavement overlay in accordance with Part 3.4Cof this Section. PART 2 MATERIALS m c- 71 UOFATFD BASF MATERIAI ,S A. Untreated base material for paving shall be Aggregate Base as specified in Section 02230, Crushed Stone and Gravel. ASPHAI .T CONC- A. Asphalt Concrete (AC) shall be as specified in SSPWC Section 203-I or 400-4. PAVEMENT 02500-2 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 8. Asphalt Concrete shall be designated as follows: 1. Base Course: Ill-B-AR-4000 2. Surface Course: Ill-C2-AR-4000 3. Leveling Course: ill-D-AR-4000 C. Asphalt Concrete Overlay: AC Overlay shall be provided in accordance with the requirements of Section 600-2.6 of the SSPWC, Asphalt Rubber Hot Mix - Gap Graded. 23 PRlME COAT A. Prime coat shall be slow curing, Type X-250, in accordance with SSPWC Section 203-2. 24 TACK COAT A. Tack coat shall be either paving asphalt or an emulsified asphalt in accor- dance with SSPWC Section 302-5.4. 75 PORTI AND CFMENT CONCRETF PAVING A. Concrete paving and related work shall be as specified in SSPWC Section 201 unless otherwise shown or specified. 26 P-NT STRIPING AND MARKING A. Pavement striping shall conform to the applicable requirements of SSPWC Section 21 O-l .6. B. Type of Paint: Fast Dry. PART 3 - FyECUTION 3.1 FXAMjNATlQjj A. Crushed aggregate base shall be free of ponded water prior to placement o?- pavement. Verify that gradients and elevations of subgrade and granular base are correct prior to placement of pavement. Subgrade preparation shall be as shown on the Plans and specified in SSPWC Section 301-1, Treated Soil, Subgrade Preparation and Placement of Base Materials. PAVEMENT 02500-3 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 3.3 CRysLjFD qGGpFGATF BASF A. Crushed aggregate base shall be placed to the lines and grades shown on the Plans in accordance with Section 02230, Crushed Stone and Gravel. 3.4 ASPHAI T C0NCRjZJ-F PAVEMFNT OVERI AY A. Asphalt concrete pavement overlay under Schedule D shall be provided for the entire width of the streets as shown on the Plans. The pavement overlay shall be transitioned into the street intersections of crossing streets as shown and specified. 1. The limits of AC pavement overlay shall be the same limits for cold milling existing pavement. 2. Refer to Paragraph 3.4.D of this Section. B. Pavement shall not be provided in the intersection of Jefferson Street and Cansbad Village Drive. C. Submit a traffic control plan for the AC pavement overlay under Schedule D for approval. The plans shall be stamped and signed by a licensed California civil engineer. All costs associated with preparation of the traffic control plans and obtaining approval shall be included in the CONTRACTOR’s bid for AC pavement overtay. D. Cold Milling: Cold milling existing pavement shall be performed prior to AC pavement overlay in accordance with the requirements of Section 302-5.2 of ‘the SSPWC and the following: 1. Cold mill pavement adjacent to concrete curbs and gutters at a minimum width of 6 feet. The depth of milling shall be l-inch adjacent to the gutter and tapered outward. 2. Cold mill pavement adjacent to concrete cross gutters which parallel the street shall be performed to the same requirements of Item D.l . 3. Cold mill pavement adjacent to concrete cross gutters which are transverse to the street shall be milled at a minimum width of 12 feet each side of the cross gutter. The depth of milling shall be l-inch adjacent to the cross gutter and tapered outward. 4. Cold mill pavement at street intersections shall be contained within- the existing concrete cross gutters. Where the crossing street does not have a cross gutter, the AC overlay and milling shall extend 18 feet beyond the curb return into the cross street. The pavement shall be milled to a depth of l-inch at the limit of overlay and tapered toward the intersection. The width of taper shall be 16-feet. 5. Cold mill pavement adjacent to manhole covers and valve boxes at a minimum width of 2 feet. The depth of milling shall be l-inch adjacent to the casting and tapered outward. 6. Replace damaged traffic signal loop detectors at Laguna Drive. Other loop detectors will be replaced with video detection equipment as required in Section 02643. , PAVEMENT 02500-4 VISTNCARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 ?A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK E. Preparation of existing AC pavement prior to receiving the overlay shall be as be as specified in Part 3.5 of this Section. F. The material for asphalt concrete overlay shall be a specified in Part 2 and shall be placed in accordance with Sections 600-2.6 and 302-5 of the SSPWC. G. Manhole Covers and Valve Boxes: Sewer and storm drain manhole covers and water valve boxes and covers shall be adjusted to meet new finish grade in accordance with the requirements of Section 302-5.8 of the SSPWC. H. Additional Adjustments: Telephone manholes electric vaults and gas valves shall be adjusted to meet new finish grade in accordance with the requirements of Section 302-5.8 of the SSPWC. 3.5 ASPHALT CONCRETF PAVFMENT A. Preparation - Primer: Prior to placing AC pavement base course, a prime coat of liquid asphalt shall be applied to the compacted base at a rate between 0.10 and 0.25 gallons per square yard per Section 302-5.3 of the SSPWC. B. Preparation - Cleaning of Existing Surfaces: Where new AC pavement is to be placed upon existing pavement, the surface to be paved shall be cleaned of all dust, loose material, and vegetation by sweeping with power brooms, or other approved method. Remove scrap and dispose of all dirt and loose material’ collected during the surface cleaning operations. After washing, all standing water shall be removed and the prepared surfaces shall be dry before applying the tack coat. C. Preparation - Filling of Cracks: Where new AC pavement is to be placed upon existing pavement, fill all cracks between l/6- and l&inch with crack filler consisting of liquid asphalt and clean, dust-free sand. Repair larger cracks and holes with a leveling course and compacted in accordance with these specifications. D. Preparation - Tack Coat: - 1. Apply a tack coat to prepared surfaces where new AC pavement is to be placed upon existing pavement and leveling courses, and where it abuts existing pavement along sawcut trench edges. 2. After the surface has been thoroughly cleaned and dry, apply a thin asphalt emulsion tack coat to the surface at a rate not to exceed 0.10 gallons per square yard. 3. Coat surfaces of manholes and storm drainage structures with oil to prevent bond with asphalt pavement. Do not tack coat these surfaces. PAVEMENT 02500-5 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 4. 5. Refer to SSPWC Section 302-5.4. Tack coat will be required when in the opinion of the engineer, the Contractor has failed to maintain or prepare each existing or previously laid course of asphalt receiving the subsequent course of asphalt in a sufficiently clean state and the asphalt receiving the new pavement wurse is dirty enough to impair bonding between the next lift of asphalt. E. Preparation - Leveling Course: 1. Where new AC pavement is to be placed upon existing pavement, prior to placement of the AC pavement, a leveling course of asphalt concrete may be required. 2. Ptace leveling courses in localized areas under the following conditions: a. Where the final placement of AC pavement base wurse and surface wurse exceeds 4-inches in depth, b. To level irregularities and fill in holes and depressions in the existing pavement. C. A tack coat shall be applied prior to the leveling course. F. Placing Asphalt Concrete Base and Surface Courses: 1. Place AC pavement on an aggregate base as specified in Section 02230. The pavement shall be Cinches in depth and placed in two separate paving courses as follows: a. Base Course 2-l/2 inches thick - III - B- AR - 4000 b. Surface Course I-112 inches thick - 111 - C2 -AR - 4000 2. Place and strike off AC base and surface courses with a self- propelled paving machine utilizing a power driven vibrating screen. Correct irregularities in the surface of the pavement course directly behind the paver. Remove excess material forming high spots with a shovel,=lute or edge of a shovel being pulled over the surface. Casting of mix over such areas will not be pen-nit&cl. 3. Provide proper surface drainage and maintain existing drainage patterns during placing AC pavement. 4. Spreading: The spreading and finishing machine used to construct the asphalt concrete surface course shall be equipped with an automatic screed control for surface wurse paving. The automatic- screed control shall be 30’ minimum length. The paving machine shall be operated by an operator and two full-time screed men during all paving. A backup asphalt windrow pickup machine (ASPWP) will be required at all times when a ASPWP is used. Additionally, a front end loader will be required during all ASPWP paving. G. Compaction of Asphalt Concrete Surface Course: 1. Start rolling as soon as the hot mix material can be compacted without displacement. Rolling shall continue until all compaction requirements have been met and all roller marks have disappeared. In areas too small for the roller, a vibrating plate shall be used for compaction. Compacting equipment and compaction requirements are provided in SSPWC Section 302-5.6. PAVEMENT 02500-6 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 2. 3. The Asphalt concrete shall be placed to the lines and grades shown on the plans or as otherwise specified herein. Total compacted thickness shall not be less than 3 inches, nor shall the thickness of any one lift exceed 4 inches. Asphalt wncrete shall be compacted to 95 percent relative compaction in accordance with ASTM D 1557. Pinched joint rolling procedures shall be required, and vibratory rollers shall be limited to breakdown, unless otherwise directed by the Engineer. Unless directed otherwise by the Engineer, the initial breakdown rolling shall be followed by a pneumatic-tired roller as described in SSPWC Section 302-5.6. H. Protection of Pavement: After final compaction rolling, no vehicular traffic of any kind shall be permitted until it has cooled and hardened. The minimum time between completion of final compaction rolling and exposure of new pavement to vehicular traffic shall be 6 hours. 3.6 PORTLAND CFMENT CONCRETE PAVING A. Concrete paving shall conform to the requirements of SSPWC Section 302- 6. 3.7 PAV_EMENT AND CURR MARKINGS A. Pavement striping, parking stalls and curb markings shall be provided where shown and shall conform to the applicable requirements of SSPWC Section 31 O-5.6 with the following exceptions: 1. Section 310-5.6.1, General: Remove existing and temporary traffic markings and lines, other than tape, by wet grinding methods. a. Sandblasting is prohibited. 2. Section 310-5.6.3, Equipment: Removal equipment shall be a wet grinding machine. The surface produced by grinding the existing or temporary traffic striping or markings on pavement shall not exceed variations from a uniform plane more than 118 inch in j0 feet when measured parallel to the centerline of the street or more than l/4 inch in 10 feet when measured perpendicular to the centeriine of the street Ridges, indentations and other objectionable marks shall not be made. Equipment shall meet all requirements of the air polluttoni control district having jurisdiction. Removal of striping by high velocity water jet may be permitted when there is neither potential of the water and detritus from the high velocity water jetting to damage vehicles or private property not to flow from the street into any storm drain or water course and when approved by the ENGINEER. All water from high velocity water jet striping removal shall be vacuumed from the pavement immediately after the water jetting and shall not be allowed to flow in the gutter, enter the storm drain system or to leave the pavement surface. Surface variation limitations for high velocity water jet striping removal shall be the same as for grinding. PAVEMENT 02500.7 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 3. Section 310-5.6.6, Preparation of Existing Surfaces: Modify the first paragraph as follows: Existing markings and striping, either permanent or temporary, which are to be abandoned, obliterated or that conflict with the plans shall be removed by grinding methods. Dry or wet sandblasting may not be used in any areas. Alternate methods of paint removal require prior approval of the ENGINEER. Obliteration of traffic striping with black paint, light emulsion oil and other masking methods other than a minimum 30mm (0.125ft.) thick asphalt concrete overlay is prohibited. 4. Section 310-5.6.7, Layout, Alignment, and Spotting: Establish the necessary control points for all required pavement striping and markings by surveying methods. No layout of traffic striping shall be performed before establishment of the necessary control points. Establish all traffic striping between these points by stringline or other method to provide striping that will vary less than l/2-inch in 50 feet from the specified alignment. Straight stripes deviating more than l/2-inch in 50 feet shall be obliterated by grinding, and the markings corrected. Lay out (cat track) immediately behind installation of surface course asphalt and as the Work progresses. 5. Section 310-5.6.6, Application of Paint: The first coat of paint shall be done immediately upon approval of striping layout by the ENGINEER. Ten days shall elapse between the application of a bituminous seal coat where required and the permanent traffic marking. The paint shall not bleed, curt or diswlor when applied to bituminous surfaces. If bleeding or discoloring occurs, the unsatisfactory areas shall be given an additional coat of paint. This additional painting will be paid for as work incidental to the preparation of final and temporary pavement striping and marking and shall be applied in two coats, a minimum of seven days apart, and all streets shall include raised pavement markers. Paint end of median noses yellow. ++ ENDOFSECTION ++ PAVEMENT 02500-8 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK SECTION 02529 CONCRETE CURBS, GUTTERS AND SIDEWALKS PART 1 (-N-AL e 1.1 DFSCRIPTION A. B. C. D. scope: 1. Perform the work as shown, specified and required to provide for construction of all curbs, gutters and sidewalks required to complete the Work. 2. The extent of concrete curbs, gutters and sidewalks to be constructed shall be that which is necessary to reconstruct existing improvements removed and damaged by the Contractor’s operations. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. Referenced Sections SSPWC: 1. Section 201-1, Portland Cement Concrete. 2. Section 302-6, Portland Cement Concrete Pavement 3. Section 303-5, Concrete Curbs, Walks, etc. Related Sections: 1. Section 2-5.2. Precedence of Contract Documents. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 4-2, Materials Transportation, Handling and Storage. 4. Section 01025, Measurement and Payment. 5. Section 02220, Excavation and Backftll. 6. Section 02230, Crushed Stone and Gravel. 7. Section 02500, Pavement. a. Section 03100, Concrete Formwork. - Qt.jAl D-Y ASSWNCE 17 A. Reference Standards: Comply with applicable provisions and recommendations of the following, except as otherwise shown or specified. 1. ASTM D 1190, Specification for Concrete Joint Sealer, Hot Poured Elastic type. B. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. CONCRETE CURBS, GUTTERS AND SIDEWALKS 02529-l VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC56 TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 1.3 SUBMll7Aj.S A. B. Submit the following in accordance with Section 2-5.3. Manufacturer’s product data, test reports and material certifications as required in this section for concrete Work. 1.4 MATERIAI S TRANSPORTATION. HAND1 ING AND STORAGE A. Refer to Section 4-2, Materials Transportation, Handling and Storage. 1.5 A. Refer to Section 01025, Measurement and Payment. PART 2 - PRODUCTS 31 MAT- A. Concrete Materials: Concrete and related materials for curbs, gutters and sidewalks shall be as shown on the San Diego Regional Standard Drawings and shall comply with the requirements of SSPWC Section 201, except that the minimum concrete mix shall be 560-C-3250. B. Reinforcing Bars and Welded Wire Fabric: Deformed steel bars and smooth wire fabric shall comply with the requirements of SSPWC Section 201-2 except as noted below. 1. Furnish wire fabric in flat sheets, not rolls. C. Expansion Joint Material: Comply with requirements of SSPWC Section 201-3 for pm-formed expansion joint fillers. PART 3 - EXECUTlCN 3.1 INSPECTION A. Examine the substrate and the conditions under .which Work is to be performed and notify District of unsatisfactory conditions. Do not proceed with the Work until unsatisfactory conditions have been corrected. B. Verify that earthwork is completed to correct line and grade. C. Check that subgrade is smooth, compacted, and free of frost and excessive moisture. 0. Do not commence work until conditions are satisfactory, and approved by District. CONCRETE CURBS, GUTTERS AND SIDEWALKS 02529-2 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 37 FORM CONSTRUCTION A. Set forms to line and grade. install forms over full length of curb, gutter and sidewalk. B. Curb height shall match existing curb heights unless otherwise directed by the ENGINEER. A. Locate, place, and support reinforcement as specified in SSPWC Section 302-6. Size of reinforcement shall be as shown, otherwise use welded wire fabric 4 x 4 - w4 x w4 each way. 3.4 CONCRETF PLAC- A. General: Comply with the requirements of SSPWC Sections 302-6 and 303 5 for mixing and placing concrete, and as specified. B. Place concrete for curbs and gutters using methods which prevent segregation of the mix. Consolidate concrete along the face of forms with an internal vibrator. C. For sidewalks, place concrete in one course, monolithic construction, to the full width and depth of walks. 0. Machine Formed: Automatic curb, gutter and sidewalk machine may be used for forming, as an option and with approval of the District Concrete shall have properties as specified in SSPWC Section 201-1.1.2. Machine forming shall produce curbs, gutters and sidewalks to the required cross-section, lines, grades, finish, and jointing, as specified for conventionally formed concrete. If results do not conform to requirements remove and replace. 3.5 JOW A. General: Comply with the requirements of SSPWC Section 3035. 3.6 CONCRPTE FINISHING A. General: Comply with the requirements of SSPWC Section 303-5. 1. Stamp curb tops with YV” and *G” at locations for water and gas laterals. 3.7 cuw A. General: Comply with the requirements of SSPWC Section 303-5.6. CONCRETE CURBS, GUITERS AND SIDEWALKS 025294 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK SECTION 02606 MANHOLES AND DRAINAGE STRUCTURES PART 1 -GENERAL 1.1 DESCRIPTION A. Scope: 1. Perform the work as shown, specified and required to provide for construction of all precast and cast-in-place manholes and drainage structures required to complete the Work. 2. The types of manholes and structures include the following items: a. Interceptor Sewer Manholes and Special Sewer Structures. b. Existing Interceptor Sewer Manholes. ii: Collector Sewer Manholes. Storm Drain Cleanouts. i? Curb Inlets. Catch Basins. 3. Refer to Appendix B for copies of applicable standard drawings. The drawings provided are for convenience and are not necessarily all inclusive. B. General: Manholes shall conform in shape, size, dimensions, material, and other respects to the details shown on the Plans. 1. Manhole bases shall be cast-in-place concrete. 2. Manhole risers, top slabs, cones and grade rings shall be precast concrete. 3. Concrete for cast-in-place manhole bases shall conform to the requirements specified under Section 03300, Cast-In-Place Concrete. 4. Inverts shall conform accurately to the size and elevation of the adjoining pipes. Side inverts shall be curved and main inverts, where direction changes, shall be laid out in smooth curves of the longest possible radius which is tangent to the centerlines of adjoining pipelines. C. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. D. Referenced Sections: SSPWC: :: Section 201-1, Portland Cement Concrete. Section 203-6, Asphalt Paint. 3. Section 206-3, Gray Iron Castings. MANHOLES AND DRAINAGE STRUCTURES 02606-l VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK E. Related Sections: 1. Section 2-5.2 Precedence of Contract Documents. z* Section 2-5.3, Shop Drawings and Submittals. 4: Section 4-2, Materials Transportation, Handling and Storage. Section 01025, Measurement and Payment. 5. Section 02220, Excavation and Backfill. 6. Section 03100, Concrete Formwork. 7. Section 03200, Concrete Reinforcement. ii- Section 03251, Concrete Joints. lb. Section 03300, Cast-In-Place Concrete. Section 05540, Castings. 11. Section 06651, Polyvinyl Chloride Liner for Concrete. 12. Section 15051, Buried Piping Installation. 13. Section 15122, Piping Specialties. 1.2 QUALITY ASSURANCE A. Reference Standards: 1. ASTM C476, Specification for Precast Reinforced Concrete Manhole Sections. B. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. 1.3 SUBMITTALS A. Submit the following in accordance with Section 2-5.3. B. Shop Drawings: 1. Drawings showing design and construction details of all precast concrete and cast-in-place manholes including details of joints between the manhole bases and riser sections, and openings for the connection of pipes. 2. Procedure for conducting watertightness testing. 3. Details of channel layouts for manholes. 4. Details and catalog cut sheets of stop log channels. 5. Details and manufacturer’s catalog cut sheets of items listed under appurtenances. 1.4 MATERIALS TRANSPORTATION, HANDLING AND STORAGE A. Refer to Section 4-2, Materials Transportation, Handling and Storage. 1.5 MEASUREMENT AND PAYMENT A. Refer to Section 01025, Measurement and Payment. MANHOLES AND DRAINAGE STRUCTURES 02606-2 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK PART 2 - PRODUCTS 2.1 CAST-IN-PLACE CONCRETE MANHOLE BASES A. Cast-in-place manhole bases shall confomt to the details shown on the Plans and in the SDRS Drawings. 1. Cast-in-place manhole bases shall be used for the following items: It: Interceptor Sewer Manholes. Storm Drain Cleanouts Type B. B. Manhole bases shall be constructed with Class A, 4000 psi minimum cast-in- place concrete in accordance with Section 03300, Cast-In-Place Concrete and SSPWC Section 201-l. unless otherwise specified. C. Pipe connections to manhole bases shall be as shown on the Plans and in the SDRS Drawings. D. Interceptor Sewer manhole bases shall be interior lined with PVC plain sheet liner. The areas to be covered are all interior concrete surfaces including the base walls, channels and shelves. 1. The bottom 90 degrees of the channels shall not be lined. 2. Refer to Section 06651, Polyvinyl Chloride Liner for Concrete. 2.2 PRECAST CONCRETE MANHOLE COMPONENTS A. Precast manhole components shall consist of reinforced concrete sections especially designed for manhole construction and manufactured in accordance with ASTM C 478 except as modified herein. 1. Precast concrete manhole components shall be used for the following items: a. Interceptor Sewer Manholes. b. Collector Sewer Manholes. Storm Drain Cleanouts Type B. Existing Interceptor Sewer Manholes to be abandoned. B. Precast risers, cones, flat top slabs, abandonment slabs, grade rings and other components shall be manufactured by wet cast methods only, using forms which will provide smooth surfaces free from irregularities, honeycombing or other imperfections. C. Eccentric cones and openings in flat top slabs shall be oriented as shown on the Plans. D. Joints between manhole components shall be the tongue and groove type. Joints shall be sealed with a joint sealant. The circumferential and longitudinal steel reinforcement shall extend into the tongue and groove ends of the joint without breaking the continuity of the steel. MANHOLES AND DRAINAGE STRUCTURES 02606-3 VISTIVCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK E. Precast manhole components shall be of approved design and of sufficient strength to withstand the loads imposed upon them. They shall be designed for a minimum earth cover loads and an AASHTO H-20 wheel loading. Manholes located within the railroad right-of-way shall be designed for lateral loading of E-80 railroad loads. F. Lifting holes, if used in manhole components, shall be tapered, and no more than two shall be cast in each section. Tapered, solid rubber plugs shall be furnished to seal the lifting holes. The lifting holes shall be made to be sealed by plugs driven from the outside face of the section only. G. Mark date of manufacture and name or trademark of manufacturer on inside of barrel. H. The barrel of the manhole shall be constructed of various lengths of riser pipe manufactured in increments of one foot to provide the correct height with the fewest joints. Openings in the barrel of the manholes for sewers or drop connections will not be permitted closer than one foot from the nearest joint. Special manhole base or riser sections shall be furnished as necessary to meet this requirement. I. Precast manhole components, except for abandonment slabs shall be interior lined with a polyvinyl chloride (PVC) T-lock liner. 1. Refer to Section 06851, Polyvinyl Chloride Liner for Concrete. J. Precast manhole components shall be exterior coated with a concrete coating after installation. 1. Refer to Section 03300, Cast-In-Place Concrete, Paragraph 2.7. K. Manhole steps: 1. Sewer Manholes shall not contain steps. 2. Storm drain structures shall not contain steps. L. Manufacturer: Provide precast manhole components as manufactured by one of the following: 1. B&W Precast Construction, Inc. 2. Associated Concrete Products, Inc. 3. Mar-Con Products. 4. Or equal. 2.3 CAST-IN-PLACE SEWER MANHOLE STRUCTURES AND STORM DRAIN STRUCTURES A. Cast-in-place manholes and storm drain structures shall conform to the details shown on the Plans and in the SDRS Drawings. 1. Cast-in-place manhole structures and storm drain structures shall be used for the following items: ;: Sewer Manhole 1. Curb Inlets Type B. :: Catch Basin Type F. Modified Storm Drain Cleanouts. i?- Concrete Headwall. Storm Drain Box Culverts. MANHOLES AND DRAINAGE STRUCTURES 02606-4 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK B. C. D. For cast-in-place concrete, refer to Section 03300, Cast-In-Place Concrete. Pipe connections to cast-in-place structures shall be as shown on the Plans. Cast-in-place sewer manhole structures shall be interior lined with polyvinyl chloride (PVC) plain sheet liner. 1. Refer to Section 06651, Polyvinyl Chloride Liner for Concrete. E. F. G. Cast-in-place structures shall be exterior coated with a concrete coating. 1. Refer to Section 03300, Cast-In-Place Concrete, Paragraph 2.7. Storm drain catch basins and curb inlets shall have the phrase “No Dumping- Drains to the Ocean” labeled on a marker and affixed to the inlet. 1. Product and Manufacturer: Duracast style marker, das Manufacturing, Inc. 2. Or equal. Storm drain catch basins and curb inlets constructed in Chestnut Avenue and the westerly portion of Oak Avenue between Madison Street and the railroad right-of-way shall be provided with an oil/water separator insert filtering system which removes oil and grease from water flows entering the drain. 1. Product and Manufacturer: Provide one of the following: E: Fossile Filter Drop in Units, KriStar Enterprises, Inc. Or equal. ; 2.4 A. Reinforced concrete pipe shall connect to manhole bases as shown on the Plans. 1. Refer to Section 15122, Piping Specialties. 2.5 JOINT SEALANTS A. Polymer joint sealant shall be used to seal the joints of precast concrete manhole components to create water-tight joints to resist infiltration. 1. Joint sealant shall be placed on the outside of the joint. B. C. D. Polymer joint sealant shall be used at pipe connections to manholes to create water-tight joints to resist infiltration. 1. Joint sealant shall be placed at the center of the penetration. Product and Manufacturer: Provide one of the following for precast concrete manhole components: 1. Pro-Stik Butyl Gasket (rope form) or CPS-20 Butyl Gasket (rope form) or EZ-Stik Butyl Gasket (rope form), Press Seal Gasket Corporation. 2. CS-102 Butyl Gasket (rope form), Concrete Sealants. 3. Or equal. Product and Manufacturer: Provide one of the following for pipe connections to manholes: 1. 490 Epoxy Putty or 498 Underwater Epoxy Putty, Engard Coatings. Sikadur 31 Hi-Mod Gel or Sikadur 32 Hi-Mod Gel, Sika Corporation. FP1212 Polyurethane Sealant, Fluid Polymer or RAM NEK. Or equal. MANHOLES AND DRAINAGE STRUCTURES 02606-5 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 2.6 JOINT GROUT A. Field mortar shall be used to grout the joints of precast concrete manhole components after the manhole vacuum test and before field jointing the PVC liner. 1. Joint grout shall be placed on the inside of all joints. 2. Field mortar shall be a cement-sand mix at a ratio of 1 to 2. 2.7 DROP CONNECTIONS A. Drop connections for sewer manholes shall be constructed where shown on the Plans. 2.8 APPURTENANCES A. Manhole Chimney Rings: Manhole chimney rings shall be used to stop manhole frame-chimney water inflow. 1. The ring shall seal off inflow through the frame-chimney area joints between the frame, grade rings and top slab or cone. 2. Installation: Internal. 3. Material: Rubber. 4. Compression Ring: Stainless Steel. 5. Product and Manufacturer: Provide one of the following: a. Manhole Chimney Seal, Cretex Specialty Products. b. Or equal. B. Manhole Lid Gasket: Manhole lid gaskets shall be used to stop inflow around the manhole cover. 1. The gasket shall seal off inflow through the frame and cover. 2. Material: Rubber. 3. Product and Manufacturer: Provide one of the following: a. Manhole Lid Gasket, Cretex Specialty Products. b. Or equal. C. Manhole Lid Plugs: Manhole lid plugs shall be used to stop inflow through the manhole cover vent holes and pick holes. 1. The plugs shall seal off inflow through the manhole cover vent holes and pick holes. 2. Material: Rubber. 3. Product and Manufacturer: Provide one of the following: a. Manhole Lid Plugs, Style 1, Cretex Specialty Products. b. Or equal. MANHOLES AND DRAINAGE STRUCTURES 026066 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK PART 3 - EXECUTION 3.1 MANHOLE BASES A. Cast-in-place bases shall be placed on suitable foundations. They shall be cast monolithically unless otherwise shown, to an elevation 12-inches minimum above the top of the highest pipe. Base, walls and bottom shall be at least the thickness shown and reinforced as shown. Connections for sewer pipes shall conform to the details shown on the Plans. 3.2 PRECAST MANHOLE SECTIONS A. Set vertical sections with all sections in true alignment. The base of the bell or groove end at joints between components shall be sealed with joint sealant to provide a uniform bearing between components. B. Install sections and joints in accordance with manufacturers recommendations. C. Lifting holes shall be sealed tight with a solid rubber plug driven into the hole from the outside of the barrel and the remaining void filled with 1 to 2 cement- sand mortar. D. Abandonment Slabs shall be used at each abandonment of existing interceptor sewer manhole as shown on the Plans. 3.3 SEWER MANHOLE CHANNELS A. All invert channels through interceptor sewer manholes shall be constructed of Class A, 4000 psi concrete. Channels shall be properly formed to the sizes, cross sections, grades and shapes shown or as ordered. Shelves shall be built up to full pipe depth and given a uniform wood float finish. Care shall be taken to slope all shelves for proper drainage to the invert channel. 3.4 GRADE RINGS A. Grade rings shall be used for all precast manholes. Grade rings shall be a maximum of 18-inches in height, constructed on the roof slab or cone section on which the manhole frame and cover shall be placed. The height of the grade rings shall be as necessary to bring the manhole frames to meet existing pavement grades. 3.5 GRADING AT MANHOLES A. Manholes in paved areas shall be constructed to meet existing pavement grades. 8. Manholes located in unpaved areas within the railroad right-of-way shall be constructed 6-inches above grade. MANHOLES AND DRAINAGE STRUCTURES 02606-7 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 3.6 APPURTENANCES A. Manhole Chimney Rings: Install chimney rings on the following manholes: :: All interceptor sewer manholes constructed under this Contract. All collector sewer manholes constructed under this Contract. B. Manhole Lid Gaskets: Install lid gaskets on the following manholes: 1. All interceptor sewer manholes constructed under this Contract. 2. All collector sewer manholes constructed under this Contract. C. Manhole Lid Plugs: Install lid plugs on the following manholes: 1. All interceptor sewer manholes constructed under this Contract. 2. All collector sewer manholes constructed under this Contract. 3.7 SEWER MANHOLE TESTS A. Tests shall be conducted prior to backfilling of manholes. 8. A water-tightness test shall be conducted on each interceptor sewer manhole as follows: 1. Each manhole shall be tested immediately after placement of risers and cones. It is important that no joints are grouted with mortar prior to test. This will interfere with the repair of any leaks that may be detected by this test. 2. All lift holes shall be sealed from the outside with joint sealant compressed at the O.D. of the section. Mortar neatly pointed on the I.D. shall be placed after infiltration test is complete. 3. All pipes entering the manhole shall be plugged, taking care to securely brace the plugs from being drawn into the manhole during the test. 4. The test head shall be placed at the inside of the top of the cone, prior to the installation of grade rings, and the seal inflated in accordance with manufacturer’s recommendations. 5. A vacuum of IO inches of mercury shall be drawn and the vacuum pump shut off. With the valves closed, the time shall be measured for the vacuum to drop to 9 inches. The manhole shall pass if the time is greater than 90 seconds for 84-inch I.D. manhole. 6. If the manhole fails the initial test, necessary repairs shall be made with non-shrink grout while the vacuum is still being drawn. Retesting shall proceed until a satisfactory test is obtained. 3.8 STORM DRAIN STRUCTURE TESTS A. All storm drain structures shall be free of visible leakage. Each structure shall be inspected, and all cracks shall be repaired in a manner subject to DISTRICT’s approval. B. Refer to Section 15051, Buried Piping Installation. MANHOLES AND DRAINAGE STRUCTURES 02606-6 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 3.9 MANHOLE ABANDONMENT A. Existing interceptor sewer manholes shall be abandoned where shown and detailed on the plans. Manholes shall be pressure washed prior to abandoning. + + END OFSECTION + + MANHOLES AND DRAINAGE STRUCTURES 02606-g VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK SECTION 02843 VIDEO TRAFFIC SIGNAL DETECTOR SYSTEMS A. scope: 1. Perform the work as shown, specified and required to provide all video traffic signal detector systems in place, complete and ready for intended use, required to complete the Work. 2. Video traffic signal detector systems shall be located at the following intersections: a. Jefferson Avenue at Cartsbad Village Drive. b. Jefferson Avenue at Grand Avenue. ii: Jefferson Avenue at Laguna Drive. Jefferson Avenue at Las Flares Drive. B. Related Sections: 1. Section 2-5.2, Precedence of Contract Documents. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 01025, Measurement and Payment. 1.2 QUALITY ASSURANCE A. All system controls and components shall be supplied as a complete system from one manufacturer. 6. The manufacturer of the system shall be ISO- certified. - C. The supplier of the video detection system shall supervise the installation and testing of the video detection system and computer equipment. A factory certified representative from the supplier shall be on-site during installation. D. The video detection system shall be warranted by the supplier for a minimum of two years. E. Ongoing software support by the supplier shall include updates of the MVP and supervisor software. These updates shall be provided free of charge during the warranty period. F. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. VIDEO TRAFFIC SIGNAL DETECTOR SYSTEMS 02043-I VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK A. Submit the following in accordance with Section 2-5.3. B. Shop Drawings: 1. Shop drawings, specifications and equipment lists. C. Instructions: Manufacturer’s instructions for installation of video traffic signed detector system. D. Operation Manual: Manufacturer’s operation manual for video traffic signal detector systems. 1.4 MATER&?&S TRANSPORTATION. HAND1 ING AND STORAGF A. Refer to Section 4-2, Materials Transportation, Handling and Storage. 1.5 MFASU_BFMFNT AND PAYMFNT A. Refer to Section 01025, Measurement and Payment. PART 2 PRCDJCTS w 2.1 FUNCTIONAI SPFCIFICATIONS A. The video traffic signal detector systems shall comply with the following functional specifications: 1. This specification sets forth the minimum requirements for a system that monitors vehicles on a roadway via processing of video images and provides detector outputs to a traffic controller. 2. The system shall consist of one to four image sensor(s) or other video source, a Machine Vision Processor (MVP) and a supervisor computer. 3. The system shall be able to detect either approaching or receding vehicles in multiple traffic lanes. With a MVP capable of handling four image sensors and a minimum of 100 detection zones that can be user defined and user assigned through the use of the supervisor computer. 4. The MVP and components supplied under this specification shall be thoroughly tested and proven in a minimum of 30 actual non-beta California installations in a 332 cabinet. A list of actual field uses shall be submitted. 5. The MVP shall be capable of simultaneously processing information from up to four image sensors. The video shall be digitized and analyzed at a rate of 30 times per second; A fifth image sensor input shall be provided on four camera units as a surveillance video input to be switched as one of five live video sources. VIDEO TRAFFIC SIGNAL DETECTOR SYSTEMS 02843-2 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 6. 7. 8. 9. 10. 11. 12. 13. A MVP capable of handling four image sensors shall be able to detect the presence of vehicles in a minimum of 100 detection zones within the combined field of view of the image sensors. Different detector types shall be selectable via software. Detector types shall include count detectors, presence detectors, directional presence detectors, speed detectors, station detectors, input detectors and detector logical functions. The MVP shall provide the ability to compensate for minor camera movement. At a minimum, image stabilization detectors shall minimize the effects of image sensor movement. The MVP shall provide the capability to link the analog video image to the detector layout as reference information for stabilization. Stabilization shall only be required if there is a motion problem observed by the user. The video detection system shall provide flexible detection zone placement anywhere and at any orientation within the combined field of view of the image sensors. Preferred presence detector configurations shall be lines placed across lanes of traffic or lines placed in-line with lanes of traffic. A single detector line shall be able to replace one or more conventional detector loops connected in a series. Detection zones shall be able to be overlapped. In addition, detection zones shall have the capability of implementing logical functions including AND, OR, NAND, N of M and delay/extend timing. The detection zones shall be capable of being sized, shaped and overlapped to provide optimal road coverage and detection. It shall be possible to save the detector configurations on disk, to download detector configurations to the MVP and to retrieve the detector configuration that is currently running on the MVP. When a vehicle is within a detection zone, the detection zone shall change wlor on a VGA monitor verifying the proper operation of the detection system. Color changes shall also indicate detection delay and extension timing. The video detection system shall reliably detect vehicle presence when the image sensor is mounted 30 feet or higher above the roadway, when the image sensor is adjacent to the desired coverage area, and when the length of the detection area or field of view is not greater than ten times the mounting height of the image sensor. The image sensor shall be able to view both approaching and departing traffic. A single image sensor placed at a proper mounting height which minimizes vehicle occlusion and equipped to match the road width shall be able to monitor six to eight traffic lanes simultaneously. The MVP shall be designed to operate reliably in the adverse environment found in the typical roadside traffic cabinet. It shall meet the environmental requirements set forth by NEMA TSl and TS2 standards as well as the environmental standards for Type 170 and 179 controllers. The MVP shall be equipped with a NEMA TSl detector interface with 32 detector outputs. Output level shall be compatible with NEMA TSl, NEMA TS2, Type 170 and Type 179 standards. A 37 pin ‘D’ subminiature connector on the front of the MVP shall be used for interfacing these outputs. VIDEO TRAFFIC SIGNAL DETECTOR SYSTEMS 02043-3 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS SITE WORK 14. 15. 16. 17. 18. NEMA Red and Green inputs for all 16 phases shall be available as inputs to provide controller state information for detection and extend/delay timing functions. A 37 pin ‘D’ subminiature connector on the front of the MVP shall be used for these inputs. The video detection system shall use medium resolution, monochrome image sensors as the source for real time video detection. Each image sensor shall provide the following as a minimum: a. Images shall be produced with a CCD sensing element with horizontal resolution of at least 500 lines and a vertical resolution of at least 350 lines. b. Useable video and resolvable features shall be produced when those features have luminance levels as low as 0.1 lux at night. C. Useable video and resolvable features shall be produced when those features have luminance levels as low as 10,000 lux during the day. The image sensor shall have automatic gain, automatic iris and absolute black reference controls, the automatic iris shall operate in a damped manner with a time constant of 0.25 seconds or longer, the automatic gain shall operate in a damped manner with a time constant of one second and automatic gain shall not be applied to the video signal until the lens aperture is’ fully opened by the automatic ins control and the black level control shall be adjusted to 0 IRE units. The image sensor shall be crystal synchronized. The image sensor and lens assembly shall be housed in an environmental enclosure which shall be waterproof and dust-tight to NEMA 4 specifications and shall be pressurized with an inert gas to 5 plus or minus 1 psi. B. Product and Manufacturer: Provide one of the following: 1. Autoscope. 2. Or equal. PART 3 - FXECUTION 3.1 GFW A. Installation: Installation of the video traffic signal detector system shall be in accordance with the manufacturer’s recommendations. + + END OF SECTION + + VIDEO TRAFFIC SIGNAL DETECTOR SYSTEMS 02843-4 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE SECTION 03100 CONCRETE FORMWORK PART 1 GENf=RAL M 1.1 DFSCRIPTION A. scope: 1. Perform the work as shown, specified and required to provide all formwork for construction of all concrete required to complete the work. 2. The Work also includes providing openings in formwork to accommodate the Work under this and other Sections and building into the formwork all items such as sleeves, anchor bolts, inserts and all other specialty items to be embedded in concrete for which placement is not specifically provided under other Sections. B. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. C. Referenced Sections: SSPWC: 1. Section 303-l .3, Forms. 2. Section 303-l .4, Removal of Forms. 3. Section 303-l -6, Falsework. 4. Section 303-l .8, Placing Concrete. 5. Section 303-2.6, Placement. 6. Section 303-5.2, Forms. D. Related Sections: 1. Section 2-5.2, Precedence of Contract Documents. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 4-2, Materials Transportation, Handling, and Storage. 4. Section 01025, Measurement and Payment. 5. Section 02529, Concrete Curbs, Gutters and Sidewalks. 6. Section 03200, Concrete Reinforcement. 7. Section 03251, Concrete Joints. 8. Section 03300, Cast-In-Place Concrete. 17 Ql JAI D-Y ASSURANCE A. Reference Standards: Comply with applicable provisions and recommenda- tions of the following, except as otherwise shown or specified: 1. ACI 117, Standard Tolerances for Concrete Construction and Materials. 2. ACI 301, Specifications for Structural Concrete for Buildings. CONCRETE FORMWORK 03100-l VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 3. 4. 5. ACI 347, Recommended Practice for Concrete Formwork. US Product Standard, PS-1. Construction Safety Orders, Division of Industrial Safety, State of California. B. Allowable Tolerances: 1. Construct formwork to provide completed concrete surfaces complying with tolerances specified in ACI 347, Chapter 3.3, except as otherwise specified. C. All items for permanent or temporary facilities shall be used in accordance with manufacturer’s instructions. D. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. 1.3 SUBMI-ITAI S A. Submit the following in accordance wlth Section 2-5.3. B. Shop Drawings: 1. Submii for information purposes copies of manufacturer’s data and installation instructions for proprietary materials, including form coatings, manufactured form systems, architectural formliners, ties and accessories. 1.4 MMFRIAI .S TRANSPORTATION. HANDLING AND STORAGE A. On delivery to job site, place materials in area protected from weather. B. Store materials above ground on framework or blocking. Cover wood for forms with protective waterproof covering. Provide for adequate air circulation or ventilation. C. Handle materials to prevent damage. D. Refer to Section 4-2, Materials Transportation, Handling and Storage. -MEASUREMFNT AND PAYMENT A. Refer to Section 01025, Measurement and Payment. CONCRETE FORMWORK 03100-2 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE PART 2 - PRODUCTS 71 FORM MATEW A. B. C. D. Forms for Unexposed Finish Concrete: 1. Form concrete surfaces that will be unexposed in the finished struc- ture with plywood, lumber, metal, or other acceptable material. Provide lumber that is dressed on at least two edges and one side. Forms shall not be required for pipe encasements and electrical duct banks provided that concrete wverages are provided as shown in the Contract Documents. Formwork Accessories: 1. Provide chamfer and rustication strips in sizes and locations shown on the Contract Drawings and as specified herein. 2. Product and Manufacturer: Provide the following: a. Chamfer strip, 3/4-inch by 3/4-l&, Cat. No. 622, l-inch by l- inch, Cat. No. 623; Rustication strip, Cat No. 322, as manufactured by Greenstreak Plastic Products co., Inc. b. Or equal. Form Ties: 1. Provide factory-fabricated, removable or snapoff metal form ties, designed to prevent form deflection, and to prevent spalling of concrete surfaces upon removal. Materials used for tying forms will be subject to approval of COR. 2. Unless otherwise shown, provide ties so that portion remaining within concrete after removal of exterior parts is at least 1 inch from the outer concrete surface. Unless otherwise shown, provide form ties that will leave a hole no larger than l-inch diameter in the concrete surface. 3. Ties for exterior walls and walls subject to hydrostatic pressure shall have waterstops. A pm-formed neoprene or polyurethane tapered plug, sized to seat at the center of the wall, shall be inserted in the hole left by the removal of the taper tie. 4. Provide wood or plastic wnes for ties, where concrete is exposed in the finished structure and in the interior of tanks. Forms Coatings: 1. Provide commercial formulation form-coating compounds that will not bond with, stain, nor adversely affect concrete surfaces, and will not impair subsequent treatment of concrete surfaces requiring bond or adhesion, nor impede the wetting of surfaces to be cured with water or curing compounds. For concrete surfaces which will be in contact with potable water, the form coating shall be a mineral oil base coating. CONCRETE FORMWORK 03100-3 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE PFSIGN OF FORMWORK A. Design, erect, support, brace and maintain formwork so that it shall safely support vertical and lateral loads that might be applied, until such loads can be supported by the concrete structure. Carry vertical and lateral loads to ground by formwork system or in-place construction that has attained adequate strength for this purpose. Construct fonnwork so that concrete members and structures are of correct size, shape, alignment, elevation and position. B. Design forms and falsework to include values of live load, dead load, weight of moving equipment operated on formwork, concrete mix, height of concrete drop, vibrator frequency, ambient temperature, foundation pressures, stresses, lateral stability, and other factors pertinent to safety of structure during construction. C. Provide shores and struts with positive means of adjustment capable of taking up formwork sefflement during concrete placing operations, using wedges or jacks or a combination thereof. Provide trussed supports when adequate foundations for shores and struts cannot be secured. D. Support form facing materials by structural members spaced sufficiently close to prevent significant deflection. Fit forms placed in successive units for continuous surfaces to accurate alignment, free from irregularities and within allowable tolerances. For long span members without intermediate supports, provide camber in formwork as required for anticipated deflections resulting from weight and pressure of fresh concrete and construction loads. E. Design formwork to be readily removable without impact, shock or damage to concrete surfaces and adjacent materials. F. Provide formwork sufficiently tight to prevent leakage of cement paste during concrete placement. Solidly butt joints and provide backup material at joints as required to prevent leakage and fins. CUTION 51 GFNFRAL A. Concrete forms shall conform to the shape, lines and dimensions of structures as shown on the Contract Drawings. Forms shall confine the concrete and shape it to the required lines. A sufficient number of forms of each kind shall be provided to permit the required rate of progress to be maintained. The design and inspection of concrete forms, falsework, and shoring shall comply with applicable local, state and Federal regulations. Plumb and string lines shall be installed before concrete placement and shall be maintained during placement. During concrete placement, continually monitor plumb and string line form positions and immediately correct deficiencies. CONCRETE FORMWORK 03100-4 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 1. 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 its expense. B. Concrete forms 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. C. Examine the substrate and the conditions under which Work is to be performed and notify the District of unsatisfactory conditions. Do not proceed with the Work until unsatisfactory conditions have been corrected. A. General:. Construct forms complying with ACI 347; to the exact sizes, shapes, lines and dimensions shown; as required to obtain accurate alignment, location and grades; to tolerances specified; and to obtain level and plumb work in finish structures. Provide for openings, offsets, keyways, recesses, moldings, rustications, reglets, chamfers, blocking, screeds, bulkheads, anchorages and inserts, and other features required. Use selected materials to obtain required finishes. Finish shall be as determined by approved sample panel. B. Fabricate forms for easy removal without damaging concrete surfaces. Provide crush plates or wrecking plates where stripping may damage cast concrete surfaces. Provide top forms for inclined surfaces where the slope is too steep to place concrete with bottom forms only. Kerf wood inserts for forming keyways, reglets, recesses, and the like, to prevent swelling and assure ease of removal. C. Provide temporary openings where interior area of fotmwork is inaccessible for cleanout, for inspection before concrete placement, and for placement of concrete. Brace temporary closures and set tightly to forms to prevent loss of concrete mortar. Locate temporary openings on forms in locations as inconspicuous as possible, consistent with requirements of the Work. Form intersecting planes of openings to provide true, clean-cut comers, with edge grain of plywood not exposed as form for concrete. D. Falsework: 1. Erect falsework and support, brace and maintain it to safely support vertical, lateral and asymmetrical loads applied until such loads can be supported by in-place concrete structures. Construct falsework so that adjustments can be made for take-up and settlement. 2. Provide wedges, jacks or camber strips to facilitate vertical adjustments. Carefully inspect falsework and fonnwork during and after concrete placement operations to determine abnormal deflec- tion or signs of failure; make necessary adjustments to produce finished Work of required dimensions. CONCRETE FORMWORK 03100-5 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE E. Forms for Exposed To View Concrete: 1. Do not use metal cover plates for patching holes or defects in forms. 2. Provide sharp, clean wmers at intersecting planes, without visible edges or offsets. Back joints with extra studs or girts to maintain true, square intersections. 3. Use extra studs, walers and bracing to prevent bowing of forms between studs and to avoid bowed appearance in concrete. Do not use narrow strips of form material that will allow bowing. 4. Assemble forms so they may be readily removed without damage to exposed wncrete surfaces. 5. Form molding shapes, recesses, mstication joints and projections with smooth-finish materials, and install in forms with sealed joints to prevent displacement. F. Comer Treatment: 1. Form exposed wmers of beams, walls, foundations, bases and columns to produce smooth, solid, unbroken lines, except as otherwise shown. Except as specified below for reentrant or internal comers, exterior wmers shall be chamfered. 2. Form chamfers with 3/4-inch by 314inch, or l-inch by l-inch strips, where shown on the Contract Drawings, accurately formed and surfaced to produce uniformly straight lines and tight edge joints. Extend terminal edges to required limit and miter chamfer strips at changes in direction. G. Joints: 1. See Section 03251, Concrete Joints, for treatment of joints. Locate as shown on the Contract Drawings and as specified herein. H. Openings and Built-In Work: 1. Provide openings in concrete fonnwork shown or required by other Sections or other contracts. Refer to Paragraph 1.l.B herein for the requirements of coordination. 2. Accurately place and securely support items to be built into forms. 3. Where it is not possible to pour concrete from the top through the use of “elephant trunks” or tremies, pouring of walls may be done only through pouring openings on one of the wall sides. 4. Erect the complete form on one side of the wall then erect the form panels on the other side of the wall between construction joints for concrete placement. 5. The horizontal centerline distance between such openings shall not exceed 8 ft - 0 in. nor shall the distance between the nearest opening and the bulkhead for the vertical joint exceed 3 ft - 0 in. 6. The vertical centerline distance between horizontal rows of openings shall not exceed 4 ft - 0 in. 7. The minimum pouring opening size shall be 24” x 18”. 8. The bottom of the lower openings shall be no more than 48 inches from the top of the wall-footing. 9. Under no circumstances shall forming be such that the drop of concrete in the forms will exceed 4 feet in any one place. CONCRETE FORMWORK 03100-6 VISTAKZARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE I. Cleaning and Tightening: 1. Thoroughty clean forms and adjacent surfaces to receive concrete. Remove chips, wood, sawdust, dirt or other debris just before concrete is to be placed. Retighten forms immediately after concrete placement as required to eliminate mortar leaks. J. Full Height Pours: 1. The wall form design shall be such that wall sections can be poured full height without creating horizontal cold joints and without causing snapping of form ties which shall be of sufficient strength and number to prevent spreading of the forms during the placement of concrete and which shall permit ready removal of the forms without spalling or damaging the concrete. 3.3 FORM COATINGS A. Coat form contact surfaces with a non-staining form-coating compound before reinforcement is placed. Do not allow excess form coating material to accumulate in the forms or to come into contact with surfaces which will be bonded to fresh concrete. Apply in compliance with manufacturer’s instructions. B. Coat steel forms with a non-staining, rust-preventative form oil or otherwise protect against rusting. Rust-stained steel formwotk is not acceptable. 3.4 INSTALl ATION OFBEDDED ITEMS A. General: Set and build into the formwork, anchorage devices and other embedded items, shown, specified or required by other Sections. Refer to Paragraph 1.1.8 herein for the requirements of coordination. Use necessary setting drawings, diagrams, instructions and directions. B. Edge Forms and Screeds Strips for Slabs: 1. Set edge forms or bulkheads and intermediate screed strips for slabs to obtain required elevations and contours in the finished slab surface. Provide and secure units to support screeds. 3.5 FlELDQUAl ITY CONTROt A. Before concrete placement, check formwork, including tolerances, lines, ties, tie cones, and form coatings. He shall make corrections and adjustments to ensure proper size and location of concrete members and stability of forming systems. B. During concrete placement, check formwork and related supports to ensure that forms are not displaced and that completed Work shall be within specified tolerances. C. If the forms are unsatisfactory in any way, either before or during placing Of concrete, placement of concrete shall be postponed or stopped until the defects have been corrected, and reviewed by the District. CONCRETE FORMWORK 03100-7 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE RFMOVAI OF FOR@& A. B. C. D. E. Conform to the requirements of ACI 301, Chapter 4 and ACI 347R, Chapter 3.7, except as specified below. Careful procedures for the removal of forms shall be strictly followed, and this work shall be done with care so as to avoid injury to the concrete. No heavy loading on green concrete will be permitted. In the case of roof slabs, above-ground floor slabs, box culvert slabs and other above grade slabs forms shall remain in place until test cylinders for the roof concrete attain a minimum compressive strength of 75 percent of the 28day strength specified in Section 03300, Cast-In-Place Concrete; that no forms shall be disturbed or removed under an individual panel or unit before the wncrete 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. Forms for all vertical walls and columns shall remain in place at least 2 days after the concrete has been placed. Forms for all parts of the Work not specifkally mentioned herein shall remain in place for periods of time as determined by the District When high-early strength concrete is specified, a schedule for removal of forms will be developed in the field from the age/strength relationships estabkhed for the materials and proportions used by tests in accordance with ACI-301, Section 3.8. Do not remove supporting forms or shoring until the members have acquired sufficient strength to safely support their weight and the load upon them. Results of suitable control tests may be used as evidence that the concrete has attained sufficient strength. The time for removal of all forms will be subject to the District’s approval. 3.7 PFRMANENT SHW A. Provide permanent shores as defined in ACI 347R Chapter 7.4. B. Reshores will not be permitted. 38 - OF FOR& A. Clean and repair surfaces of forms to be re-used in the Work. Split, frayed, delaminated or otherwise damaged form facing material will not be acceptable. Apply new form coating compound material to concrete contact surfaces as specified for new formwork. B. When forms are extended for successive concrete placement, thoroughly clean surfaces, remove fins and laitance, and tighten forms to close all joints. Align and secure joints to avoid offsets. Do not use “patched” forms for exposed concrete surfaces. Form surfaces shall be subject to the Districts approval. CONCRETE FORMWORK 03100-8 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 3.9 INSPFCTION OF FORMWORK A. Concrete shall not be placed until the formwork is inspected by the District. 1. The District shall be allowed a sufficient period of time to properly inspect all formwork prior to the placement of concrete. + + END OF SECTION + + CONCRETE FORMWORK 03100-g VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE SECTION 03200 CONCRETE REINFORCEMENT PART 1 - GE= 1.1 DFSCRIPTION A. Scope: 1. Perform the work required to provide all reinforcement shown, specified and required for construction of all concrete required to complete the Work. 2. The extent of concrete reinforcement is shown on the Plans. 3. The Work includes fabrication and placement of reinforcement in- cluding bars, ties and supports, and welded wire fabric for concrete . and encasements. B. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specifted. Refer to Section 2-5.2 of the Supplemental Provisions. C. Related Sections: 1. Section 2-5.2, Precedence of Contract Documents. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 4-2, Materials Transportation, Handling and Storage. 4. Section 01025, Measurement and Payment. 5. Section 02529, Concrete Curbs, Gutters and Sidewalks. 6. Section 03100, Formwork. 7. Section 03300, Cast in Place Concrete. j7 QUALITY ASSURANCE A. Reference Standards: Comply with applicable provisions and recommen- dations of the following, except as othewise shown or specified: 1. Concrete Reinforcing Steel Institute, Manual of Standard Practice, including ASTM standards referred to herein. 2. ACI 318, Building Code Requirements for Reinforced Concrete. 3. ACI 315, Manual of Standard Practice for Detailing Reinforced Concrete Structures. 4. The Building Code, as referenced herein, shall be the Uniform Building Code (UBC) of the International Conference of Building Officials (ICBO). B. Allowable Placing Tolerances: Comply with ACI 318, Chapter 7 - Details of Reinforcement except as specified below: 1. Concrete surfaces which are in contact with sewage: 2 inches coverage. CONCRETE REINFORCEMENT 03200-l VlSTAlCARLSBAD tNTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE C. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. 1.3 SURMlTTqlS A. Submit the following in accordance with Section 2-5.3. B. Shop Drawings: 1. Manufacturer’s specifications and installation instructions for all materials and reinforcement accessories. 2. Drawings for fabrication, bending, and placement of wncrete rein- forcement. Comply with ACI 315, Parts A and B. For walls, show elevations to a minimum scale of l/4 inch to 1 foot. For foundations and slabs, show top and bottom reinforcing on separate plan views. Show bar schedules, stirrup spacing, diagrams of bent bars, arrangements and assemblies, as required for the fabrication and placement of concrete reinforcement unless otherwise noted. Splices shall be kept to a minimum. Splices in regions of maximum tension stresses shall be avoided whenever possible. 3. Drawings detailing the location of all construction and expansion joints as required under Section 03251, Concrete Joints, shall be submitted and approved before Shop Drawings for reinforcing steel are submitted. C. Certificates: 1. Submit 1 copy of steel producer’s certificates of mill analysis, tensile and bend tests for reinforcing steel. 1.4 MATERIAI S TRANSPORTATION. HANDI ING AND STORAGE A. Deliver concrete reinforcement materials to the site bundled, tagged and marked. Use metal tags indicating bar size, lengths, and other information corresponding to markings shown on placement diagrams. B. Store concrete reinforcement material at the site to prevent damage and accumulation of dirt or excessive rust. Store on heavy wood blocking to avoid contact with the ground. C. Refer to Section 4-2, Materials Transportation, Handling and Storage. PART 7 PRODUCTS s 21 MATFR1Aj.S A. Reinforcing Bars: ASTM A 615, and as follows: 1. Provide Grade 60 for all bars. 2. Provide Grade 40 for all stirrups and ties. B. Steel Wire: ASTM A 82. CONCRETE REINFORCEMENT 03200-2 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE C. Welded Smooth Wire Fabric: ASTM A 185. Furnish in flat sheets, not rolls. D. Column Spirals: Hot-rolled rods for spirals, ASTM A 815. E. Supports for Reinforcement: Bolsters, chairs, spacers and other devices for spacing, supporting and fastening reinforcement in place. 1. Use wire bar type supports complying with CRSI recommendations, except as specified below. Do not use wood, brick, or other un- acceptable materials. 2. For slabs on grade, use supports with sand plates or horizontal run- ners where base material will not support chair legs. Precast concrete bar supports will be acceptable for supporting reinforcing steel off the ground only. 3. For all concrete surfaces, where legs of supports are in contact with forms, provide supports complying with CRSI “Manual of Standard Practice” as follows: a. Either hotdip galvanized, plastic protected or stainless steel legs. 4. Over waterproof membranes, use precast concrete chairs. 5. For all polyvinyl chloride (PVC) lined concrete surfaces, where legs of supports are in contact with forms, provide supports complying with CRSI “Manual of Standard Practice’ as follows: a. Either plastic or metal plastic protectedlegs. FARRICATION A. General: Fabricate reinforcing bars to conform to required shapes and dimensions, with fabrication tolerances complying with CRSI, Manual of Standard Practice. In case of fabricating errors, do not re-bend or straighten reinforcement in a manner that will injure or weaken the material. B. Unacceptable Materials: Reinforcement with any of the following defects will not be permitted in the Work: 1. Bar lengths, bends, and other dimensions exceeding specified fabrication tolerances. 2. Bends or kinks not shown on approved Shop Drawings. 3. Bars with reduced cross-section due to excessive rusting or other cause. UTION A. Examine the substrate and the conditions under which concrete reinforcement is to be placed, and notify District in writing of unsatisfactory conditions. Do not proceed with the, Work until unsatisfactory conditions have been corrected. CONCRETE REINFORCEMENT 03200-3 VISTAXARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 37 IN=1 1 ATION A. Comply with the applicable recommendations of specified codes and stan- dards, and CRSI, Manual of Standard Practice, for details and methods of reinforcement placement and supports. B. Clean reinforcement to remove loose rust and mill scale, earth, ice, and other materials which reduce or destroy bond with concrete. C. Position, support, and secure reinforcement against displacement during formwork construction or concrete placement operations. Locate and sup- port reinforcing by metal chairs, runners, bolsters, spacers and hangers, as required: 1. Place reinforcement to obtain the concrete cover-ages as shown and as specified in ACI 318. Arrange, space, and securely tie bars and bar supports together with 16 gage wire to hold reinforcement accurately in position during concrete placement operations. Set wire ties so that twisted ends are directed away from exposed concrete surfaces. 2. Reinforcing steel shall not be secured to forms with wire, nails or other ferrous metal. Metal supports subject to corrosion shall not touch formed or exposed concrete surfaces. D. Install welded wire fabric In as long lengths as practical. Lap adjoining pieces at least one full mesh and lace splices with 16 gage wire. Do not make end laps midway between supporting beams, or directly over beams of continuous structures. Offset end laps in adjacent widths to prevent continuous laps. E. Provide sufficient numbers of supports of strength required to carry reinforcement. Do not place reinforcing bars more than 2 inches beyond the last leg of any continuous bar support. Do not use supports as bases for runways for concrete conveying equipment and similar construction loads. F. Provide standard reinforcement splices by lapping ends, placing bars in contact, and tying tightly with wire. Comply with requirements shown for minimum lap of spliced bars. NFORCFMW A. Concrete shall not be placed until the reinforcing steel is inspected by the District. All concrete placed in violation of this provision will be rejected. 1. The District shall be allowed a sufficient period of time to properly inspect all reinforcement prior to the placement of concrete. ++ ENDOFSECTION ++ CONCRETE REINFORCEMENT 03200-4 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE SECTION 03251 CONCRETE JOINTS PART I- GENERAL 1.1 DFSCRIPTION A. scope: 1. Perform the work as shown, specified and required to provide all concrete joints for the construction of all concrete required to complete the Work. 2. The types of concrete joints required include the following: a. Construction joints. b. Expansion joints and fillers. B Waterstops. Control joints. B. General: All joints subject to hydrostatic pressure shall be provided with continuous waterstops. C. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. D. Related Sections: .I. Section 2-5.2, Precedence of Contract Documents. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 4-1, Materials and Workmanship. 4. Section 4-2, Materials Transportation, Handling and Storage. 5. Section 01025, Measurement and Payment. 6. Section 03100, Concrete Formwork. 7. Section 03300, Cast-In-Place Concrete. 1.2 Q!JAI ITY ASSURANCE A. Reference Standards: Comply with applicable provisions and rewmmen- dations of the following, except as otherwise shown or specified: 1. ACI 301, Specifications for Structural Concrete for Buildings, Chapter 6, Joints and Embedded Items. 2. ASTM D 1752, Preformed Expansion Joint Fillers for Concrete Paving and Structural Construction. 3. CRD-C572, Corps of Engineers Specifications for Polyvinyl- Chloride Waterstop. B. All manufactured items shall be installed in accordance with manufacturer’s instructions. CONCRETE JOINTS. 03251-l VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE C. If there is a conflict between contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. 1.3 CUBMITTAI S A. Submit the following in accordance with Section 25.3. B. Samples: 1. Polyvinyl chloride (PVC) waterstops for joints. 2. Cork expansion joint fillers. C. Shop Drawings: 1. Manufacturer’s specifications and installation instructions for all materials required. 2. Layout of all construction joint locations prior to the submittal of steel reinforcing drawings. 3. Detail for joining polyvinyl chloride (PVC) to steel waterstops. 1.4 MATERIAI ,S TRANSPORTATION. HANDLING AND STORAGE A. Refer to Section 4-2, Materials Transportation, Handling and Storage. A. Refer to Section 01025, Measurement and Payment. PART 7 - PRODUCTS 71 WATERSTOPS A. Polyvinyl Chloride: 1. Reference Standard: CRD-C572. 2. Construction Joints: Minimum of 3/8-inch thick. a. Width shall be 8” unless otherwise shown or unless more stringent requirements are recommended by the manufacturer. 3. Expansion Joints: Uniform minimum thickness of 3/8 inch by 9 inches minimum width. Center bulb shall be “0” or “U” shaped. The “0” shall have an outside diameter of 3/4-inch minimum. The top of the “U” shall be jointed by a membrane which will tear when the expansion occurs. 4. Manufacturer: Provide waterstops as manufactured by one of the following: ii W .R. Meadows, Incorporated. AC. Horn, Inwrporated. ii: Vulcan Metal Products, Incorporated. Or equal. CONCRETE JOINTS 03251-2 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 77 PRFFORMW EXPANSION JOINT FII 1 FR A. Provide performed expansion joint filler complying with ASTM D 1752, Type II. cork. 23 CONCRFTF CONSTRUCTION JOINT ROUGHEC!ER A. Provide a water soluble non-flammable, surface-retardant roughener. B. Product and Manufacturer: Provide one of the following: 1. Rugasol-S by Sika Corporation for horizontal joints only. 2. EAC-S by Preco Industries, Ltd. for horizontal joints only. 3. Tuf-Cote (Deep Etch) by Prew Industries Ltd. for vertical joints. 4. Or equal. 34 EPOXY BONDING AGEfQ A. Provide an epoxy-resin bonding agent, two component type. B. Product and Manufacturer: Provide one of the following: 1. Sikadur 32 Hi-Mod LPL by Sika Corporation. 2. Eucopoxy LPL by the Euclid Chemical Company. 3. Or equal. 25 JOINT SE&&U A. Joint sealant shall be polyurethane polymer designed for bonding to concrete which is continuously submerged in water. No material will be acceptable which has an unsatisfactory history as to bond or durability when used in the joints of water retaining structures. B. Joint sealant material shall meet the following requirements: _ Work Life 45 - 90 minutes 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 CONCRETE JOINTS 03251-3 24 hours, maximum 30 - 40 Shore “A” 250 psi, minimum 400 percent, minimum 75 pounds per inch of thickness, minimum Light Gray VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE C. 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 ANSI/ASTM C920 or Federal Specification IT-S-00227 E(3) for 2- part materials, as applicable. 2. For vertical joints and overhead horizontal joints, only “non-sag” compounds shall be used; all such compounds shall conform to the requirements of ANSI/ASTM C920 Class B, or Federal Specification l-T-D-0027 E(3), Type II. 3. For plane horizontal joints, the self-leveling compounds which meet the requirements of ANSI/ASTM C920 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. Primary materials, if recommended by the sealant manufacturer, shall conform to the printed recommendations of the sealant manufacturer. D. All sealants, wherever shown on the Plans or required hereunder, shall be Rubbercalk 2101 or 220 as manufactured by Products Research Company; GS 102 or GS 1102 as manufactured by Federal Sealants Corp.: Pacific Polymer Elasto-Thane Type 227R: or equal. 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 l/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. 27 ROND RR- A. Bond breaker shall be Super Bond Breaker as manufactured by Burke Company, San Mateo, California; Hunt Process 225TU as manufactured by Hunt Process Company, 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. CONCRETE JOINTS 03251-4 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 3.1 INSPFCTION A. CONTRACTOR shall examine the substrate and the conditions under which Work is to be performed and notify District of unsatisfactory conditions. The Work shall not proceed until unsatisfactory conditions have been corrected. 3.2 CONSTRUCTION JOINTS A. Comply with ACI 301, Chapter 6, and as specified below. B. Locate and install construction joints as shown. Additional construction joints shall be located as follows: 1. In walls locate joints at a spacing of 40 feet maximum and ap- proximately 12 feet from comers, unless otherwise shown on the Plans. 2. In foundation slabs and slabs on grade locate joints at a spacing of approximately 40 feet, unless othewise shown on the Plans. Place concrete in a checkerboard pattern. 3. Inmats and structural slabs and beams, at a spacing of approxi- mately 40 feet, unless otherwise shown on the Plans. Locate joints in compliance with ACI 301, Chapter 6. . C. Horizontal Joints: 1. Roughen concrete at the interface of construction joints by sand- blasting or high pressure waterblasting to expose the aggregate and remove accumulated concrete on rebar immediately subsequent to form stripping unless otherwise approved by the District. Immediately before placing fresh concrete, thoroughly clean the existing contact surface using a stiff brush or other tools and a stream of water under pressure. The surface shall be c!ean and wet, but free from pools of water at the moment the fresh concrete is placed. 2. Remove laitanw, waste mortar or other substance which may pre- vent complete adhesion. 3. Place a 2-inch thick coat of mortar, of similar proportions to the mortar in the concrete, over the contact surface of the old concrete. Place fresh concrete before the mortar has attained its initial set. D. Vertical Joints: 1. Apply roughener to the form in a thin, even film by brush, spray or roller in accordance with the manufacturer’s instructions. After roughener is dry, concrete may be placed. 2. When concrete has been placed and the form removed, wash loosened material off with high pressure water spray to obtain roughened surface subject to approval by Distrfct. CONCRETE JOINTS 03251-5 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE A. Comply with ACI 301, Chapter 6, and as specified below. B. Locate and install expansion joints as shown. Install cork filler in accordance with manufacturer’s instructions. Caulking and sealants shall be installed as specified in Section 07920, Caulking and Sealants. 3.4 WATERSTOPS A. General: 1. Comply with ACI 301, Chapter 6, and as specified below. All joints shall be made in accordance with manufacturer’s instructions. 2. Obtain District’s approval for waterstop locations not shown. 3. Provide waterstops in all foundations, tanks and other substructures up to an elevation at least 12 inches above grade or to an elevation at least 12 inches above liquid level in tanks, whichever is higher, except where otherwise shown or noted. B. Polyvinyl Chloride Waterstop: 1. Tie waterstop to reinforcement so that it is securely and rigidly supported in the proper position during concrete placement. Vertical waterstops shall be held in place with light wire ties on 12-inch wnters which shall be passed through the edge of the waterstop and tied to the curtain of the reinforcing steel. Continuously inspect waterstops during concrete placement to insure their proper positioning. 2. Waterstops shall be fused using equipment as supplied by or rec- ommended by the manufacturer. 3.5 RONDING WITH EPOXY AD- A. Use adhesive for the following: 1. Bonding of fresh wncrete to concrete cured at least 45 days or to existing concrete. B. Handle and store epoxy adhesive in compliance wlth the manufacturer’s printed instructions, including safety precautions. C. Mix the epoxy adhesive in complete accordance with the instructions of the manufacturer. D. Before placing fresh concrete, thoroughly roughen and clean hardened concrete surfaces and coat with epoxy grout not less than l/%-inch thick. Place fresh concrete while the epoxy material is still tacky, without removing the in place grout coat, and as directed by the instructions provided by the epoxy manufacturer. + + END OF SECTION * + CONCRETE JOINTS 03251-6 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE SECTION 03300 CAST-IN-PLACE CONCRETE PART 1 - GENERAL 1.1 DFSCRIPTION A. scope: 1. Perform the work as shown, specified and required to provide all concrete for the construction of all cast-in-place structures required to complete the Work. 2. The Work includes providing concrete consisting of portland cement, fine and coarse aggregate, water, and approved admixtures; combined, mixed, transported, placed, finished and cured. 3. The Work also includes providing openings in concrete to accommodate the Work under this and other Sections and building into the concrete all items such as sleeves, frames, anchor bolts, inserts and all other items to be embedded. 4. Requirements for Portland cement concrete pavement, curb, gutters, and sidewalks shall be as specified in Sections 02500 and 02529. B. Classes of Concrete: 1. Class “A” concrete shall be steel reinforced and includes the following: a. Cast-In-Place Sewer Manhole Structures. b. Drainage Structures. :: Manhole Bases. Headwalls. 2. Class “B” concrete shall be placed without forms or- with simple forms, with little or no reinforcing, and includes the following: a. Concrete fill. C. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as othennrise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. D. Related Sections: 1. Section 2-5.2, Precedence of Contract Drawings. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 4-1, Materials and Workmanship. 4. Section 4-2, Materials Transportation, Handling and Storage. 5. Section 01025, Measurement and Payment. 6. Section 02606, Manholes and Drainage Structures. 7. Section 03100, Concrete Formwork. CAST-IN-PLACE CONCRETE 03300-l VISTNCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 8. Section 03200, Concrete Reinforcement. 9. Section 03251, Concrete Joints. 10. Section 06651, Polyvinyl chloride Liner for Concrete. 11. Section 09930, Protective Coating of Concrete. 17 Qt 1sLR-Y ASSURANCE A. Reference Standards: Comply with the applicable provisions and recom- mendations of the following, except as otherwise shown or specified. 1. 2. 3. 4. 5. 6. 7. 0. 9. 10. 11. 12. 13. 14. 15. AASHTO M 182, Burlap Cloth Made From Jute or Kenaf. ACI 211.1, Recommended Practice for Selecting Proportions for. Normal and Heavyweight Concrete. ACI 214, Recommended Practice for Evaluation of Compression Test Results of Field Concrete. ACI 224 R, Control of Cracking in Concrete Structures. ACI 301, Specification for Structural Concrete for Buildings, (includes ASTM Standards referred to herein). ACI 304, Recommended Practice for Measuring, Mixing, Transport- ing and Placing Concrete. ACI 305, Recommended Practice for Hot Weather Concreting. ACI 306, Recommended Practice for Cold Weather Concreting. ACI 309, Recommended Practice for Consolidation of Concrete. ACI 31 I, Recommended Practice for Concrete Inspection. ACI 315, Details and Detailing of Concrete Reinforcement. ACI 318, Building Code Requirements for Reinforced Concrete. ACI 347, Rewmmended Practice for Concrete Formwork. ACI 350R, Environmental Engineering Concrete Structures. The Uniform Building Code (UBC) of the International Conference of Building Officials (ICBO). B. Not Used. C. Qualifications of Water-Reducing Admixture Manufacturer. - 1. Water-reducing admixtures shall be manufactured under strict quality control in facilities operated under a quality assurance program. Manufacturer shall maintain a concrete testing laboratory which has been approved by the Cement and Concrete Reference Laboratory at the Bureau of Standards, Washington, D.C. a. Submit a copy of manufacture& quality assurance handbook to document the existence of the program. 2. When requested by the District provide a qualified concrete technician employed by the admixture manufacturer to assist in proportioning the concrete for optimum use of the admixture. The concrete technician, when requested, shall advise on proper addition of the admixture to the concrete and on adjustment of the concrete mix proportions to meet changing jobsite conditions. CAST-IN-PLACE CONCRETE 03300-2 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE D. Tests for Concrete Materials: 1. Submit written reports to the District, for each material sampled and tested, prior to the start of Work. Provide the Project identification name and number, date of report, name of CONTRACTOR, name of concrete testing service, source of concrete aggregates, material manufacturer and brand name for manufactured .materials, values specified in the referenced specification for each material, and test results. Indicate whether or not material is acceptable for intended use. E. Fly Ash: Fly ash shall not be used. F. Qualifications of Cement Supplier: Submit the qualifications of a cement supplier who is qualified per PCA requirements, and who has a minimum of five years of experience in producing cement. G. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. 1.3 SUBMIT-TA& A. B. Submit the following in accordance with Section 25.3. Samples: Submit samples of materials including names, sources and descriptions. C. Submit the following: 1. Manufacturer’s specifications with application and installation instructions for proprietary materials and items, including admixtures and bonding agents. 2. Concrete Mix Reports for concrete mix designs including list of materials. Include the results of all tests performed to qualify the materials and to establish the mix designs. 3. The following information, if ready-mixed concrete is used: E: Physical capacity of mixing plant. Trucking facilities available. C. Estimated average amount which can be produced and delivered to the site during a normal 8 hour day, excluding the output to other customers. D. Adjustment-to Concrete Mixes: In accordance with Paragraph 2.3.8 of this Section. E. Submit notanzed certification of conformance to referenced standards when requested by the District. F. Delivery Tickets: Furnish to the District copies of all delivery tickets for each load of concrete delivered to the site. Provide items of information as specified in ASTM C94, Section 15. CAST-IN-PLACE CONCRETE 03300-3 VISTAGARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE G. Qualifications of Admixture Manufacturer: In accordance with Paragraph 1.2.C of this Section. H. Qualifications of Cement Supplier: In accordance with Paragraph 1.2.F of this Section. 1.4 MATERIAI ,S TRANSPORTATION. HANDLING AND STORAGF A. All materials used for concrete must be kept clean and free from all foreign matter during transportation and handling and kept separate until measured and placed in the mixer. Bins or platforms having hard clean surfaces shall be provided for storage. Suitable means shall be taken during hauling, piling and handling to insure that segregation of the coarse and fine aggregate particles does not occur and the grading is not affected. B. Refer to Section 4-2, Materials Transportation, Handling and Storage. C. Refer-to Part3.3 of this Section. 1.5 MEASURFMFNT AND PAY- A. Refer to Section 01025, Measurement and Payment. PART 7 PRODUCTS - 2.1 CONCRFTF MATERIM A. Cement: 1. Portland cement, ASTM Cl50, Type II. 2. Use Portland cement produced by not more than one plant. A single brand of cement shall be used throughout the Work. 3. Do not use cement which has deteriorated because-of improper storage or handling. B. Aggregates: ASTM C33 and as herein specified. 1. Do not use aggregates containing soluble salts or other substances such as iron sulfides, pyrite, marcasite, ochre, or other materials that can cause stains on exposed concrete surfaces. 2. Fine Aggregate: Clean, sharp, natural sand free from loam, clay, lumps or other deleterious substances. Dune sand, bank run sand and manufactured sand are not acceptable. 3. Coarse Aggregate: Clean, uncoated, processed aggregate contain- ing no clay, mud, loam, or foreign matter, as follows: a. Crushed stone, processed from natural rock or stone. b. Washed gravel, either natural or crushed. Use of slag and pit or bank run gravel is not permitted. C. Water: Clean, free from injurious amounts of oils, acids, alkalis, organic materials or other substances that may be deleterious to concrete or steel. CAST-IN-PLACE CONCRETE 03300-4 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE TURFS A. Provide and use admixtures in compliance with the manufacturer’s printed instruction. Do not use admixtures which have not been incorporated and tested in the accepted mixes, unless otherwise authorized in writing by the District. B. Air-Entraining Admixtures: ASTM C260. I. Product and Manufacturer: Provide one of the following: a. SIKA AER by Sika Chemical Corporation. b. MB-VR by Master Builders Company. C. Or equal. 2. Sufficient air-entraining agent shall be used to provide a total air content of 3 to 5 percent; provided that, when the mean daily temperature in the vicinity of the worksite falls below 40 degrees Fahrenheit for more than one day, the total air content provided shall be 5 to 7 percent. 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 hatcher capable of accurate measurement. C. D. Water-Reducing High Range Admixture: ASTM 0494, Type F/G. 1. At the Contractor’s option, high range water-reducer may be used in Class “A” concrete. If it is used in concrete mix design, the admixture shall not contain more chloride ions than are contained in municipal drinking water. It shall be added only at the job site to concrete in compliance with the manufacturer’s printed instruction. Provide one of the following: a. Duracem 100 by W.R. Grace & Company. b. Sikament 320 by Sika Corporation. C. Or equal. Water-Reducing Admixture: ASTM C494, Type A. 1. Proportion all Class B concrete with non-air entraining, normal setting, water-reducing, aqueous solution of a modification of the salt of polyhydroxylated organic acids. The admixture shall not contain any lignin, nitrates, or chlorides added during manufacture. 2. Product and Manufacturer: Provide one of the following: :: Eucon WR-75 by The Euclid Chemical Company. Pozzolith by Master Builders Company. C. Or equal. E. Calcium Chloride: Do not use calcium chloride in concrete, unless specifically authorized in writing by District. Do not use admixtures containing calcium chloride where concrete is placed against galvanized steel. CAST-IN-PLACE CONCRETE 03300-5 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 23 PROPORTIONING AND DFSIGN OF MIXFS A. Proportioning: 1. 2. Concrete shall comprise cement, admixtures, aggregates and water; these materials shall be of the qualities specified in Parts 2.1 and 2.2. The mix shall be designed to produce a concrete capable of being placed so as to obtain maximum density and minimum shrinkage and, where placed in forms, to have maximum smoothness of surface. 3. 4. 5. Mix designs shall not have more than 41 percent of sand of the total weight of fine and coarse aggregate. The exact proportions of these materials for the mix design of each different type of concrete shall be determined prior to production. The minimum compressive strength and cement content of concrete shall be not less than that shown in the following tabulation. The District may order the cement content for any class of concrete to be increased over the quantity specified in the tabulation if he determines that such increase is necessary to attain the required strength. Such increased quantities of cement, if so ordered, shall be furnished by the CONTRACTOR at no additional cost to the District. Class of Type of Max. Size Min. Cement Max. W/C Concrete Wok Aggregate per cu’yd Ratio Min. 28day ALL -(saaL (bv Compr. 4,000 Class A - I-112 6.0 0.45 2.500 Class B l-112 4.0 0.49 Note: One sack of cement equals 94 Ibs. B. Adjustment to Design of Mix: Concrete mix may require adjustment when characteristics of materials, job conditions. weather, test results, or other circumstances warrant revision of design of mix. 1. Submit laboratory test data, strength results and revised mix design for adjustments to design of mix. C. The independent concrete testing laboratory shall prepare the concrete mix reports. D. Concrete production shall not begin until submitted concrete mix designs have been approved. E. Proportion mixes by either laboratory trial batch or field experience methods, using materials to be employed on the Project for concrete required. Comply with ACI 211 .l and report to the District the following data: 1. Complete identification of aggregate source of supply. 2. Tests of aggregates for compliance with specified requirements. 3. Scale weight of each aggregate. CAST-IN-PLACE CONCRETE 033006 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 4. 5. 6. 7. 8. 9. 10. 11. 12. Absorbed water in each aggregate. Brand, type and composition of cement. Brand, type and amount of each admixture. Amounts of water used in trial mixes. Proportions of each material per cubic yard. Gross weight and yield per cubic yard of trial mixtures. Measured slump. Measured air content. Compressive strength developed at 7 days and 28 days, from not less than 3 test cylinders cast for each 7day and 28day test, and for each design mix. F. Laboratory Trial Batches: When laboratory trial batches are used to select concrete proportions, prepare test specimens and conduct strength tests as specified in ACI 301, Chapter 3 - Proportioning. However, 4,000 psi concrete mixes need not be designed for greater than 4,600 psi regardless of the production facilities standard deviation. 1. The trial batch shall be prepared using the aggregates, cement and admixture proposed for the project The trial batch shall be of a quantity such that the testing laboratory can obtain 3 drying shrinkage and 6 compression test specimens from each batch. 2. Three compression test cylinders shall be tested at 7 days and 3 at 28 days. The average compressive strength for the 3 cylinders prepared for any given trial batch shall be not less than 125 percent of the specified compressive strength. G. Shrinkage Tests: 1. Drying shrinkage tests will be made for the trial batch and during construction to ensure continued compliance with these Specifications. One set of 3 specimens shall be taken from the first pour of each class of concrete having a 28day strength of 4,000 psi or higher, and additional set of 3 specimens for 4000 psi or higher strength concrete shall be taken during construction, in accordance with Paragraph 3.8.B of this Section. 2. The maximum concrete shrinkage for specimens cast in the laboratory from the trial batch, as measured at 21day drying age or at 28day 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. 3. If the required shrinkage limitation is not met during construction, take any or all of the following actions, at no additional cost to the District, for securing the specified required 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. CAST-IN-PLACE CONCRETE 03300-7 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE H. Field Experience Method: When field experience methods are used to select concrete proportions, establish proportions as specified in ACI 301, Chapter 3. I. Admixtures: . 1. Use air-entraining admixture in all concrete, except interior slabs subject to abrasion, unless otherwise shown or specified. Add air-entraining admixture at the manufacturer’s prescribed rate to result in concrete at the point of placement having air content within the prescribed limits. 2. Use amounts of admixtures as recommended by the manufacturer and approved by the District for climatic conditions prevailing at the time of placing. Adjust quantities and types of admixtures as required to maintain quality control. J. Slump Limits: 1. ‘Class A Concrete: .Proportion and design mixes to result in concrete slump: a. Not more than 3 inches prior to adding high range water reducer. b. Not more than 8 inches at point of placement after adding high range water-reducer. 2. Class B Concrete: Proportion and design mixes to result in concrete slump at point of placement of not less than 1 inch and not more than 4 inches. 2.4 EPOXY RONDING AGFNT A. Provide an epoxy-resin bonding agent, two component, polysulfide type for bonding freshly mixed concrete to hardened concrete. B. Product and Manufacturer: Provide one of the following: - 1. Sikadur 32 Hi-Mod LPL by Sika Chemical Corporation. 2. Epoxtite Binder (Code #2390) by A.C. Horn, Incorporated. 3. Or equal. CONCRFTF CURING fyJ.&TERIAI S A. Absorptive Cover: Burlap cloth made from jute or kenaf, weighing approximately 10 ounces per square yard and complying with AASHTO M 182, Class 3. B. Moisture-Retaining Cover: One of the following, complying with ASTM Clfl. 1. Waterproof paper. 2. Polyethylene film. 3. White burlap-polyethylene sheet. CAST-IN-PLACE CONCRETE 03300-B VISTIUCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE C. Curing Compound: ASTM C309 Type 1-D (water retention requirements). 1. Product and Manufacturer: Provide one of the following: :: Super Aqua Cure VOX by The Euclid Chemical Company. Mastercure by Master Builders. C. Or equal. 2. Provide fugitive dye when requested by the District- 2.6 FMBWED ITFMS A. Items such as plates, angles, inserts, bolts and similar items not specified elsewhere shall be provided and installed under this Section. All embedded steel items shall be hot dip galvanized after fabrication. Stainless steel items shall not be galvanized. 2.7 CAP11 r ARY WATFRPROOFING A. Below grade concrete structures shall be exterior coated with capillary waterproofing system. The waterproofing is a brush or spray applied cement based system to protect against hydrostatic water pressure. 1. The following structures shall be treated with capillary waterproofing: ;: Cast-in-place sewer manhole structures including bases. Precast sewer manhole structures including cast-in-place bases. 2. New concrete and masonry surfaces shall cure for 7 days prior to applying capillary waterproofing system. B. Composition and Material: A formulation of cements and chemical additives mixed with water and bonding agent to penetrate into the capillaries of the substrate and form a crystalline structure. 1. Color: Gray. 2. Bonding Agent: Latex formulation added to cementitious mixes to increase the cohesive, adhesive, flexural, tensile, bond and waterproofing properties of the mix. C. Product and Manufacturer. Provide one of the following: 1. HEY’DI K-II Cement Based Waterproofing: and HEY’DI SB Inetgral Latex Bonding Agent, Tamms Industries Co. 2. Or equal. PART 3 - F=CUTION 3.1 INSPFCTION A. Exanke the subgrade substrate and the conditions under which Work is to be performed and notify District of unsatisfactory conditions. Do not proceed with the Work until unsatisfactory conditions have been. CAST-IN-PLACE CONCRETE 03300-g VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 37 CONCRFTF MI= A. General: I. Concrete may be produced at batch plants or it may be produced by the ready-mixed process. Batch plants shall comply with the recommendations of ACI 304, and shall have sufficient capacity to produce concrete of the qualities specified, in quantities required to meet the construction schedule. All plant facilities are subject to testing laboratory inspection and acceptance by the District. 2. Mixing: a. Mix concrete with an approved rotating type batch machine, except where hand mixing of very small quantities may be permitted. b. Remove tiardened accumulations of cement and concrete frequently from drum and blades to assure acceptable mixing action. C. Replace mixer blades when they have lost 10 percent of their original height. d. Use quantities such that a whole number of bags of cement is required, unless otherwise permitted. B. Ready-Mix Concrete: 1. Comply with the requirements of ASTM C&I, and as herein specified. Proposed changes in mixing procedures, other than herein specified, must be accepted by the District before implementation. a. Plant equipment and facilities: Conform to National Ready- Mix Concrete Association “Plant and Delivery Equipment speclflwtion”. b. Mix wncrete in revolving type truck mixers which are in good condition and which produce thoroughly mixed concrete of the specified consistency and strength. :: Do not exceed the proper capacity of the mixer. Mix concrete for a minimum of two minutes after arrival at the . job site, or as recommended by the mixer manufacturer. 2’ Mix at proper speed until concrete is discharged. Maintain adequate facilities at the job site for continuous delivery. of concrete at the required rates. 9* Provide access to the mixing plant to the District at all times. C. Maintain equipment in proper operating condition, with drums cleaned before charging each batch. Schedule rates of delivery in order to prevent delay of placing the concrete after mixing, or holding dry- mixed materials too long in the mixer before the addition of water and admixtures. 3.3 TRANSPORTING CONCRFTE A. Transport and place concrete not more than 60 minutes after water has been added to the dry ingredients. B. Take care to avoid spilling and separation of the mixture during transportation. CAST-IN-PLACE CONCRETE 03300-l 0 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE C. D. Placing Concrete into Forms: 1. Deposit concrete in forms in horizontal layers not deeper than 18 inches and in a manner to avoid inclined construction joints. Where placement consists of several layers, place concrete at such a rate that concrete which is being integrated with fresh concrete is still plastic. 2. Do not permit concrete to free fall within the form from a distance exceeding 4 feet. Use “elephant trunks” or openings in formwork to prevent free fall, aggregate segregation, and excessive splashing on forms and reinforcement. 3. Remove temporary spreaders in forms when concrete placing has reached the elevation of such spreaders. 4. Consolidate concrete placed in forms by mechanical vibrating equip ment supplemented by hand-spading, rodding or tamping. Use equipment and procedures for consolidation of concrete in accord- ance with the applicable recommended practices of ACI 309. Vibration of forms and reinforcing will not be permitted, unless approved in writing by the District. 5. Do not use vibrators to transport wncrete inside of forms. Insert and withdraw vibrators vertically at uniformly spaced locations not farther than the visible effectiveness of the machine. Place vibrators to rapidly penetrate the layer of concrete and at least 6 inches into the preceding layer. Do not insert vibrators into imer layers of concrete that have begun to set. At each insertion, limit the duration of vibration to the time necessary to consolidate the wncrete and complete embedment of reinforcement and other embedded items without causing segregation of the mix. 6. Do not place concrete in beam and slab forms until the concrete previously placed in columns and walls is no longer plastic. 7. Force concrete under pipes, sleeves, openings and inserts from one side until visible from the other side to prevent voids. Placing Concrete Slabs: 1. Deposit and consolidate concrete slabs in a continuous operation, within the limits of construction joints, until the placing of a panel or section is completed. 2. Consolidate concrete during placing operations using mechanical vibrating equipment, so that concrete is thoroughly worked around reinforcement and other embedded items and into comers. 3. Consolidate concrete placed in beams and girders of supported slabs, and against bulkheads of slabs on ground, as specified for formed concrete structures. 4. Bring slab surfaces to the correct level. Smooth the surface, leaving it free of humps or hollows. Do not sprinkle water on the plastic surface. Do not disturb the slab surfaces prior to beginning finishing operations. CAST-IN-PLACE CONCRETE 03300-12 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE E. Bonding for Next Concrete Pour: Roughen surfaces of set concrete at all joints, except where bonding is obtained by use of a concrete bonding agent. Construction joints are as shown on the Contract Drawings and as specified in Section 03251, Concrete Joints, of these Specifications. Clean surfaces of laitance, coatings, loose particles, and foreign matter. Roughen surfaces in a manner to expose bonded aggregate uniformly and to not leave laitance, loose particles of aggregate, or damaged concrete at the surface. 1. Prepare for bonding of fresh concrete to new concrete that has set but is not fully cured, as follows: a. Thoroughly wet the surface but allow no free standing water. b. For horizontal surfaces place a 2-inch layer of mortar, one part sand and one part cement with water, over the hardened concrete surface. C. Place fresh concrete before the mortar has attained its initial set. 2. Bonding of fresh concrete to fully-cured hardened concrete or existing concrete shall be accomplished by using an epoxy-resin bonding agent as specified in Section 03251, Concrete Joints. F. Quality of Concrete Work: 1. Make all concrete solid, compact and smooth, and free of laitance, cracks and cold joints. 2. Ail concrete for liquid retaining structures, and all concrete in contact with earth, water, or exposed directly to the elements shall be watertight. 3. Cut out and properly replace to the extent ordered by the District, or repair to the satisfaction of the District, surfaces which contain cracks or voids, are unduly rough, or are in any way defective. Thin patches or plastering will not be acceptable. 4. All leaks through concrete, and cracks, holes or other defective concrete in areas of potential leakage, shall be repaired and made watertight. 5. Repair, removal, and replacement of defective concrete as ordered by District shall be at no additional cost to the District. - G. Cold Weather Placing: Not Used. H. Hot Weather Placing: 1. When hot weather conditions exist that would seriously impair the quality and strength of concrete, place concrete in compliance with AC1 305 and as herein specified. 2. Cool ingredients before mixing to maintain concrete temperature at time of placement below 80EF when the temperature is rising and below 85EF when the temperature is falling. Mixing water may be chilled, or chopped ice may be used to control the concrete temperature provided the water equivalent of the ice is calculated in the total amount of mixing water. 3. Cover reinforcing steel with water-soaked burlap if it becomes too hot, so that the steel temperature will not exceed the ambient air temperature immediately before embedment in concrete. 4. Wet forms thoroughly before placing concrete. CAST-IN-PUCE CONCRETE 03300-13 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 5. 6. 7. Do not place concrete at a temperature so as to cause difficulty from loss of slump, flash set, or cold joints. Do not use set-control admixtures unless approved by District in mix designs. Obtain the District’s approval of other methods and materials pro- posed for use. 3.5 FINISH OF FORMED SURFACFS A. B. Smooth Form Finish: 1. Produce smooth form finish by selecting form materials which will impart a smooth, hard, uniform texture. Arrange panels in an orderly and symmetrical manner with a minimum of seams. Repair and patch defective areas as above with all fins or other projections completely removed and smoothed. 2. Use smooth form finish for surfaces to be covered with a protective coating material. The material shall be applied directly to the concrete such as waterproofing. Surface preparation and repair of concrete surfaces to receive protective coatings shall be as specified herein and in accordance with the recommendations of the protective coating manufacturer. b Related Unformed Surfaces: 1. At tops of walls, horizontal offsets, and similar unformed surfaces occurring adjacent to formed surfaces, strike off smooth and finish with a texture matching the adjacent formed surfaces. Continue the final surface treatment of formed surfaces uniformly across the adjacent unformed surfaces. A. Float Finish: 1. After placing concrete slabs, do not work the surface further until ready for floating. Begin floating when the surface water has disappeared or when the concrete has stiffened sufficiently. Use a wood float only. Check and level the surface plane to a tolerance not exceeding l/4 inch in 10 feet when tested with a 10 foot straightedge placed on the surface at not less than 2 different angles. Cut down high spots and fill all low spots. Uniformly slope surfaces to drains. Immediately after leveling, refloat the surface to a uniform, smooth, granular texture. 2. Use float finish for the following: a. Interior exposed horizontal surfaces of liquid containers. b. Exterior below grade horizontal surfaces. C. Surfaces to receive additional finishes, except as shown or specified. ’ CAST-IN-PLACE CONCRETE 03300-14 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 8. Trowel Finish: 1. After floating, begin the first trowel finish operation using a power-driven trowel. Begin final troweling when the surface pro- duces a ringing sound as the trowel is moved over the surface. 2. Consolidate the concrete surface by the final hand troweling opera- tion. Finish shall be free of trowel marks, uniform in texture and appearance, and with a surface plane tolerance not exceeding l/8 inch in 10 feet when tested with a 10 foot straight edge. Grind smooth surface defects which would telegraph through applied floor covering system. 3. Use trowel finish for the following: :: Interior exposed slabs unless otherwise shown or specified. Slabs to receive resilient floor finishes. C. Non-Slip Broom Finish: 1. Apply non-slip broom finish to exterior concrete surfaces subject to light foot traffic, steps, and ramps, and in other areas where shown on the Contract Drawings. 2. Immediately after trowel finishing, slightly toughen the concrete surface by brooming in the direction perpendicular to the main traffic route. Use fiber-bristle broom unless otherwise directed. Coordinate the required final finish with District before application. D. Scratch Finish: Not Used. E. Trowel and Fine Broom Finish: Not Used. 3.7 CONCRFTF CURING AND PROTFCTION A. General: 1. Protect freshly placed concrete from premature drying and excessive cold or hot temperature, and maintain without drying at a relatively constant temperature for the period of time necessary for hydration of the cement and proper hardening of the concrete. - 2. Start ihitial curing after placing and finishing concrete as soon as free moisture has disappeared from the concrete surface. Keep wn- tinuously moist for not less than 72 hours. 3. Begin final curing procedures immediately following initial curing and before the concrete has dried. Continue final curing for at least 7 days and in accordance with ACI 301 procedures. For concrete sections over 30 inches thick, continue final curing for an additional 7 days, minimum. Avoid rapid drying at the end of the final curing period. CAST-IN-PLACE CONCRETE 03300-l 5 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE B. Curing Methods: 1. Perform curing of concrete by moist curing, or by moisture-retaining cover curing. Use curing compound only in cold weather and only when permitted by the District. a. For curing, use water that is free of impurities which could etch or discolor exposed, natural concrete surfaces. 2. Provide moisture curing by any of the following methods: a. Keeping the surface of the concrete continuously wet by covering with water. b. Continuous water-fog spray. C. Covering the concrete surface with the speci)ied absorptive cover, thoroughly saturating the cover with water, and keep- ing the absorptive cover continuously wet with sprinklers or porous hoses. Place absorptive cover so as to provide coverage of the concrete surfaces and edges, with a 4-inch lap over adjacent absorptive covers. 3. Provide moisture-retaining cover curing as follows: a. Cover the concrete surfaces with the specified moisture- retaining cover for curing concrete, placed in the widest practical width with sides and ends lapped at least 3 inches and sealed by waterproof tape or adhesive. Immediately repair any holes or tears during the curing period using cover material and waterproof tape. 4. Provide liquid curing compound as follows: a. Apply the specified curing compound to all concrete surfaces when permitted by the District. The compounds shall be applied immediately after final finishing in a continuous operation by power spray equipment in accordance with the manufacturet’s directions. Rewat areas which are subjected to heavy rainfall within 3 hours after initial application. Maintain the continuity of the coating and repair damage to the coat during the entire curing period. C. Curing Formed Surfaces: 1. Cure formed concrete surfaces, including the undersides of supported slabs and other similar surfaces by moist curing with the forms in place for the full curing period or until forms are removed. lf forms are removed, continue curing by methods specified above, as applicable. D. Curing Unformed Surfaces: 1. initially cure unformed surfaces, such as slabs, floor topping, and other flat surfaces by using the appropriate method specified above. 2. Final cure unformed surfaces, unless otherwise specified, by utilizing methods specified above, as applicable. CAST-IN-PLACE CONCRETE 03300-l 6 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE E. Temperature of Concrete During Curing: 1. When the atmospheric temperature is 40EF and below, maintain the concrete temperature between 50EF and 70EF continuously through- out the curing period. When necessary, make arrangement before concrete placing for heating, covering, insulation or housing as required to maintain the specified temperature and moisture con- ditions continuously for the concrete curing period. Provide cold weather protection complying with the requirements of ACI 306. 2. When the. atmospheric temperature is 80EF and above, or during other climatic conditions which will cause too rapid drying of the concrete, make arrangements before the start of concrete placing for the installation of wind breaks or shading, and for fog spraying, wet sprinkling, or moisture-retaining covering. Protect the concrete continuously for the concrete curing period. Provide hot weather protection complying with the requirements of ACI 305, unless otherwise specified. 3. Maintain concrete temperature as uniformly as possible, and protect from rapid atmospheric temperature changes. Avoid temperature changes in concrete which exceed 5EF in any one hour and 50EF in any 24 hour period. F. Protection from Mechanical Injury: 1. During the curing period, protect concrete from damaging mechanical disturbances including load stresses, heavy shock, excessive vibration, and from damage caused by rain or flowing water. Protect all finished concrete surfaces from damage by subsequent construction operations. 3.8 FlELDQUALLT-Y CONTROL A. Concrete Sampling and testing will be performed by the District. The CONTRACTOR shall provide the ENGINEER with reasonable access for the procurement of samples of fresh concrete at time of placement. B. Quality Control Testing During Construction: 1. Sampling and testing for field quality control during the placement of concrete to be performed by,the ENGINEER as follows: a. Sampling Fresh Concrete: ASTM C172. b. Slump: ASTM C143; one test for each concrete load at point of discharge: and one for each set of compressive strength test specimens. C. Air Content: ASTM C231; one for every other concrete load at point of discharge, or when required by an indication of change. VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 ?A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE d. e. f. cl- Compressive Strength Tests: ASTM C39; one set of compression cylinders for each 50 cubic yards or fraction thereof, of each mix design placed in any one day or for each 2,500 square feet of surface area placed; 1 specimen tested at 7 days, and 2 specimens tested at 28 days, 1 specimen tested at 56 days. 1) Adjust mix if test results are unsatisfactory and resub- mit for Districts approval. 2) Concrete which does not meet the strength requirements is subject to rejection and removal from the Work, or to other such corrective measures as directed by District, at the expense of CONTRACTOR. Compression Test Specimens: ASTM C31; make one set of 4 standard cylinders for each compressive strength test, unless otherwise directed. 1) Cast, store and cure specimens as specified in ASTM c31. Concrete Temperature: Test hourly when air temperature is 40EF and below, and when 80EF and above: and each time a set of compression test specimens is made. Shrinkage Test Specimens: ASTM C157; 3 specimens for each 250 cubic yards or fraction thereof. C. Evaluation of Quality Control Tests: 1. Do not use concrete delivered to the final point of placement which has slump or total air content outside the specified values. 2. Compressive strength tests for laboratorycured cylinders will be considered satisfactory if the averages of all sets of three consecutive compressive strength tests results equal or exceed the 28 day design compressive strength of the type or class of concrete; and, no individual strength test falls below the required compressive strength by more than 500 psi. a. Where questionable field conditions may exist during placing concrete or immediately thereafter, strength tests of speci- mens cured under field conditions will be required by the District to check the adequacy of curing and protecting of the concrete placed. Specimens shall be molded at the same time and from the same samples as the laboratory cured specimens. 1) Provide improved means and procedures for protecting concrete when the 28 day compressive strength of fieldcured cylinders is less than 85 percent of companion laboratorycured cylinders. 2) When laboratory-cured cylinder strengths are appreciably higher than the minimum required compressive strength, field-cured cylinder strengths need not exceed the minimum required compressive strength by more than 500 psi even though the 85 percent criterion is not met. VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC58 TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE b. 3) If individual tests of laboratory-cured specimens produce strengths more than 500 psi below the required minimum compressive strength, or if tests of field-cured cylinders indicate deficiencies in protection and curing, provide additional measures to assure that the load- bearing capacity of the structure is not jeopardized. If the likelihood of low-strength concrete is confirmed and computations indicate the load-bearing capacity may have been significantly reduced, tests of cores drilled from the area in question will be required .at CONTRACTOR’S expense. If the compressive strength tests fail to meet the minimum requirements specified, the concrete represented by such tests will be considered deficient in strength and subject to replacement, reconstruction or to other action approved by the District. D. Testing Concrete Structure for Strength: 1. When there is evidence that the strength of the in-place concrete does not meet specification requirements, CONTRACTOR shall employ at his expense the services of a concrete testing service to take cores drilled from hardened concrete for compressive strength determination. Tests shall comply with ASTM C42 and the following: a. Take at least 3 representative cores from each member or suspect area at locations directed by the District. b. Strength of concrete for each series of cores will be con- sidered satisfactory if their average compressive strength is at least 85 percent and no single core is less than 75 percent of the 28 day required compressive strength. C. Report test results in writing to the District on the same day that tests are made. Include in test reports the Project identi- fication name and number, date, name of CONTRACTOR, name of concrete testing service, location of test core in the structure, type or class of wncrete represented by core sample, nominal maximum size aggregate, design compressive strength, compression breaking strength and type of break (corrected for length-diameter ratio), direction of applied load to core with respect to horizontal plane of the concrete as placed, and the moisture condition of the core at time of testing. 2. Fill core holes solid with patching mortar, and finish to match adjacent concrete surfaces. 3. Conduct static load test and evaluations complying with ACI 318 if the results of the core tests are unsatisfactory, or if core tests are impractical to obtain, as directed by the District. VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE E. Testing for Shrinkage: 1. The maximum concrete shrinkage for specimens cast in the field shall not exceed the trial batch maximum shrinkage requirement by more than 25 percent. 2. If the required shrinkage limitation is not met during construction, take any or all of the following required actions, at no additional cost to the District, for securing the indicated 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. 3.9 CONCRETF REPAIRS A. Repair of Formed surfaces: 1. Repair exposed-to-view formed concrete surfaces, that contain defects which adversely affect the appearance of the finish. Surface defects that require repair include wtor and texture irregularities, cracks, spalls, air bubbles, honeycomb, rock pockets, and holes left by the rods and bolts; fins and other projections on the surface; and stains and other discolorations that cannot be removed by cleaning. 2. Repair concealed formed concrete surfaces that may contain defects that adversely affect the durability of the concrete. Surface defects that require repair include cracks in excess of 0.01 inch wide, cracks of any width and other surface deficiencies which penetrate to the reinforcement or completely through non-reinforced sections, honeycomb, rock pockets, holes left by tie rods and bolts, and spalls except minor breakage at comer. 3. Repair structural cracks and cracks in water-holding structures. B. Method of Repair of Formed Surfaces: 1. Repair and patch defective areas with cement mortar_ immediately after removal of forms and as directed by District. 2. Cut out honeycomb, rock pockets, voids over l/2-inch diameter, and holes left by tie rods and bolts, down to solid concrete but, in no case, to a depth of less than 1 inch. Make edges of cuts perpendicular to the concrete surface. Before placing the cement mortar, thoroughly clean, dampen with water, and brushcoat the area to be patched with the specified bonding agent. a. For exposed-to-view surfaces, blend white portland cement and standard portland cement so that, when dry, the patching mortar wlor will match the wlor of the surrounding concrete. CONTRACTOR shall impart texture to repaired surfaces to match texture of existing adjacent surfaces. Provide test areas at inconspicuous locations to verify mixture, texture and color match before proceeding with the patching. Compact mortar in place and strike off slightly higher than the surrounding surface. VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 3. 4. 5. Cracks which require repair shall be pressure grouted using one of the following. Apply in accordance with the manufacturer’s directions and recommendations: :: Sikadur Hi-Mod L.V. and Gel by Sika Chemical Company. Euw Epoxy #452 Epoxy System by The Euclid Chemical Company. C. Or equal. Fill holes extending through concrete by means of a plunger-type gun or other suitable device from the least exposed face, using a flush stop held at the exposed face to ensure completely filling. Sandblast exposed-to-view surfaces that require removal of stains, grout accumulations, sealing compounds, and other substances marring the surfaces. Use sand finer than No. 30 and air pressure from 15 to 25 psi. C. D. Repair of Unformed Surfaces: 1. Test unformed surfaces, such as monolithic slabs, for smoothness and to verify surface plane to the tolerances specified for each surface and finish. Correct low and high areas as herein specified. 2. Test unformed surfaces sloped to drain for trueness of slope, in addition to smoothness, using .a template having the required slope. Correct high and low areas as herein specified. 3. Repair finish of unformed surfaces that contain defects which adversely affect the durability of the concrete. Surface defects, as such, include crazing, cracks in excess of 0.0%inch wide or which penetrate to the reinforcement or completely through non- reinfoiced sections regardless of width, spalling, popouts, honeycomb, rock pockets, and other objectionable conditions. 4. Repair structural cracks and cracks in water-holding structures. Methods of Repair of Unformed Surfaces: 1. Correct high areas in unformed surfaces by grinding, after the concrete has cured sufficiently so that repairs can be made without damage to adjacent areas. 2. Correct low areas in unformed surfaces during, or immediately after completion of surface finishing operations by cutting out the low areas and replacing with fresh concrete. Finish repaired areas to blend into adjacent concrete. Use one of the following and apply in accordance with the manufacturer’s directions and rewm- mendations: a. Poly-Patch by The Euclid Chemical Company. b. Sikatop by Sika Chemical Company. C. Or equal. 3. Repair defective areas, except random cracks and single holes not exceeding l-inch diameter, by cutting out and replacing with fresh concrete. Remove defective areas to sound concrete with clean, square cuts, and expose reinforcing steel with at least 3/4-inch clearance all around. Dampen all concrete surfaces in contact with patching concrete and brush with the specified bonding agent. Place patching concrete before grout takes its initial set. Mix patching VISTAXARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 4. 5. of the same type or class as the original adjacent concrete. Place, compact and finish as required to blend with adjacent finished con- crete. Cure in the same manner as adjacent concrete. Repair isolated random cracks, and single holes not over l-inch diameter, by the dry-pack method. Groove the top of cracks, and cut out holes to sound concrete and clean of dust, dirt and loose particles. Dampen all cleaned concrete surfaces and brush with the specified bonding agent. Place dry-pack before the cement grout takes its initial set. Mix dry-pack, consisting of 1 part portland cement to 2-l/2 parts fine aggregate passing a No. 16 mesh sieve, using only enough water as required for handling and placing. Compact dry-pack mixture in place and finish to match adjacent concrete. Keep patched areas continuously moist for not less than 72 hours. Cracks which require repair shall be pressure grouted using one of the following. Apply in accordance with the manufacturer’s directions and recommendations. a. Sikadur Hi-Mod L.V. and Gel by Sika Chemical Company. b. Euco Epoxy #452 Epoxy System by The Euclid Chemical Company. 6. C. Or equal. Assure that surface is acceptable for flooring material to be installed in accordance with manufacturets recommendations. E. Other Methods of Repair. 1. Repair methods not specified above may be used and will be subject to approval and at CONTRACTOR’s expense. 3.10 ~APUJARY WATERPROOFING A. Application: Apply capillary waterproofing system in accordance with the manufacturer’s recommendations. 1. Additional Surface Preparation Requirements: Surfaces shall be clean, structurally sound and free from dust, dirt, loose particles, cracks, grease, oil and other foreign matter that might affect the bond of the material to the concrete. a. Cleaning solutions shall be thoroughly removed before starting the Work. b. Unsatisfactory surfaces shall be etched and rinsed B. Environmental Conditions: 1. Proceed with capillary waterproofing Work only when temperature and moisture conditions are favorable within the capillary waterproofing manufacturer’s written recommendations. 2. Proceed with capillary waterproofing Work only when the curing techniques recommended by the capillary waterproofing manufacturer for the conditions of installation encountered can be successfully performed. VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 3. 4. 5. 6. Surface and surrounding air temperature shall not be less than 35°F for a minimum period of 48 hours before, during and after the capillary waterproofing Work. Protect Work from precipitation, frost, and direct sunlight. During hot weather use wet mats or constant mist spray to prevent premature drying. Provide air circulation to assure setting of the capillary waterproofing. C. Application: Following completion of surface preparation, apply the capillary waterproofing at the rate of 2-l/2 pounds/square yard, and vertical and horizontal intersections and construction joints at the rate of 2 pounds/square yard. D. Curing: Moisture-cure all capillary waterproofing for a minimum period of 2 days, starting with a fine water fog spraying the day following completion of the application unless other recommendations are made by the manufacturer of because of weather conditions as specified herein. Allow 14 days for curing. ++ ENDOFSECTION ++ VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE SECTION 03610 CONTACT GROUTING PART I- GFNFRAL 1.1 DFSCRIPTION A. Scope: 1. Perform the work required to provide all contact grouting shown, specified and required for construction of pipelines required to complete the Work. 2. The Work specified in this section includes requirements for contact grouting the annular space outside the initial tunnel support if steel liner plates, precast concrete segments, steel ribs and lagging, jacked pipe, steel casing or any other groutable initial support system is used. 3. Voids. All voids between the outside of the Pipe and the excavation surface shall be completely filled with grout. B. Definitions: 1. Initial Support. As defined in Section 02320, Tunnel Support Systems. 2 Contact Grouting: Grouting outside structural members such as pipe and initial support to fill voids and obtain good contact between the member and the material outside that member. C. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, and the SSPWC except as othenrvise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. D. Related Sections: 1. Section 2-5.2, Precedence of Contract Documents. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 02300, Tunneling Operations. 4. Section 02306, Microtunneling. 5. Section 02320, Tunnel Support Systems. 6. Section 02330, Compaction Grouting. 7. Section 02340, Boring and Jacking (Steel Casing). E. Standards: 1. ASTM C 31: Practice for Making and Curing Concrete Test Specimens in the Field. 2. ASTM C 39: Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens. 3. ASTM C 94: Specifications for Ready Mixed Concrete. VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 4. 5. 6. 7. ASTM C 109: Standard Test Method for Compressive Strength of Hydraulic Cement Mortars (using 2-inch or 50-mm cube specimens). ASTM C 144: Specification for Aggregate for Masonry Mortar. ASTM C 150: Specification for Portland Cement. ASTM C 937: Standard Specification for Grout Fluidifier for Preplaced Aggregate Concrete. 1.2 QUA1 ITY ASSURANCE A. Grout Strength Tests: Prepare samples for 24 hours and 28 days compressive strength tests according to ASTM C 31 for cylinders or ASTM C 109 for cubes. Cylinder molds shall be at least two inches in diameter and four inches long. Grout cubes shall be either hvo inches or 50 millimeters square. Test samples according to ASTM C 39 or C 109 as applicable. Grout for the cylinders or cubes shall be taken from the nozzle of the grout injection line. Provide at least one set of four (4) samples for each 100 cubic feet that grout is injected but not less than one set for each grouting shift, unless directed otherwise by the Owner. B. If there is a conflict beheen Contract Documents, the document highest n precedence shall control. Refer to Section 2-5.2. 1.3 SUBMITTALS A. Submit the following in accordance with Section 2-5.3. B. Work Plan and Methods: 1. Work Plan including contact grouting methods and details of equipment and grouting procedures and sequences including injection pressures, monitoring and recording equipment, pressure gauge calibration data, methods of controlling grout pressure, method of transporting grouting equipment and materials within the Pipe, and provisions to protect Pipe lining, for each type of contact grouting required. 2. Details of grout mix proportions: admixtures, including manufacturers literature, and laboratory test data verifying the strength of the proposed grout mix. C. Reports and Records: 1. Maintain and submit daily logs of grouting operations, including pressures, volumes, and grout mix pumped, and time of pumping. PART 7 - PR0nUC-G 2.1 MATFBj&Y.S A. Cement: Cement shall be Type II or Type V Portland cement conforming to ASTM C 150. Type II cement shall meet Table 4 false set requirements of ASTM C 150. B. VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE Bentonite shall be a commercially processed powdered bentonite, Wyoming type, such as Imacco-gel, Black Hills, or equal. C. Sand: Conform to ASTM C 144 except where modlfied in the following subparagraphs. 1. Fineness modulus: Between 1.50 and 2.00. 2. Grading requirements: Sieve Sizes No. 8 No. 16 No. 30 No. 50 No. 100 No. 200 Percentage Passing by Weight 100 95- 100 60-85 20-50 10-30 o-5 D. Fluidifier: 1. 2. Fluidifiers shall hold the solid constituents of the grout in colloidal suspension, be compatible with the cement and water used in the grouting work, contain an expansive shrinkage compensator, and comply with the requirements of ASTM C 937. Use CELEBEX 209X manufactured by CELTITE, Inc. or approved equal. E. Admixtures: Other admixtures may be used subject to the approval of the Owner to improve the pumpability, to control set time, to hold sand in suspension, and to prevent segregation and bleeding. F. Compressive Strength: Minimum strength of 100 pounds per square inch (psi) in 24 hours, and 2,000 psi in 28 days. 2.2 A. Equipment for. mixing and injecting grout shall be adequate to satisfactorily mix and agitate the grout-and force it into the grout holes, in a continuous flow at the desired pressure. Pumps shall be capable of continuously developing a sustained pressure of 15 psi at the grout hole connection. B. Two pressure gauges shall be provided, one at the grout pump and one at the collar of each hole being grouted. The accuracy of the gauges shall be periodically checked with an accurately calibrated pressure gauge. An adequate supply of spare pressure gauges shall be available on site at all times. C. Suitable stop valves shall be provided at the collar of each hole for use in maintaining pressure as required until the grout has set. D. The grouting equipment shall be provided with a meter to determine the volume of grout injected. The meter shall be calibrated in cubic feet to the nearest one-tenth of a cubic foot. E. VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE The grouting equipment shall be maintained in satisfactory operating condition throughout the course of the work to ensure continuous and efficient performance during grouting operations. F. Grouting hoses shall have an inside diameter not less than l-112 inches or greater than 2 inches and capable of withstanding the maximum water and grout pressures to be used. PART 3 - FXFCI ITION 3.1 GFNFRAI REQUIREMFNTS A. Commence contact grouting following the completion of tunnel support installations performed in accordance with Section 02320 - Tunnel Support Systems. B. Contact grout shall be used to fill any voids between the tunnel Initial Supports and the ground. An attempt shall be made to hook-up and pump grout at every grout hole or coupling unless approval is granted by the Owner to skip selected holes. C. Inject grout through the grout connections in such a manner as to completely fill all voids outside the tunnel supports resulting from tunneling or pipe jacking operations. Where liner plates or precast concrete segments are used for support, contact grouting shall take place immediately after the supports have exited the tail shield. Where pipe jacking is used as the tunnel support, contact grouting shall wmmence after the Pipe has been jacked into place and before the Pipe is installed in the tunnel. Grout pressure shall be controlled so as to avoid damaging the pipe, and to avoid movement of the surrounding ground or improvements. D. Grout mixes: Develop one or more grout mixes designed to completely fill the voids outside the Pipe and to provide acceptable strength. Make four samples of each proposed grout mix and determine 24 hour and 28 day strength in accordance with ASTM C 39 or C 109. All grout mix proportions shall be subject to review and acceptance by the Owner. E. Grout Composition: Grout shall consist of Portland cement, not more than two percent bentonite by weight of cement, fluidifier as necessary, and water in the proportions specified herein or as approved by the Owner. Sand may be added to the grout mix in instances of very high grout takes as approved by the Owner, but in no case shall the grout mix contain less than six sacks of cement per cubic yard of grout. The addition of sand may require additional water or fluidifier to be added to the grout mix. F. Grout mix (water/cement) ratios shall be expressed in cubic feet of water per cubic foot of cement (94 pound bag). The water-cement ratio by volume shall be varied as needed to fill the voids outside the Pipe. The range of water-cement ratios shall be between 1:l and 2:l by volume. G. Recirculate grout mixes when any new mix is batched or after adding water, fiuidifier, or sand to mix. Recirculate mix for at least 2 minutes prior to pumping grout into grout hole. VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 37 MIXING AND INJFCTION OF GROUT A. All materials shall be free of lumps when put into the mixer and the grout mix shall be constantly agitated. Grout shall flow unimpeded and shall completely fill all voids. Grout not injected after 90 minutes of mixing shall not be used for contact grouting. 6. The locations of contact grout holes in the Pipe or Initial Support are shown on the Drawings. Drilling grout holes through Pipe will not be permitted. C. The grouting processes shall be operated and controlled so that the grout will be delivered uniformly and steadily. D. Grouting shall generally progress sequentially in a constant upgradient direction from one grout hole to the next grout hole in the sequence indicated in the approved submittals. E. At any time during the grouting operations, sufficient contact grouting holes ahead of the hole to be grouted shall be cleaned. Valves or other suitable devices shall be attached and placed in the fully open position on all ungrouted holes within the maximum grout communication distance, as determined by the Contractor and accepted by the Owner. F. In general, grouting shall be considered completed when less than one cubic foot of grout of the accepted mix and consistency can be pumped in five minutes under the specified maximum pressure. After the grouting is finished, the valve shall be closed before the grout header is removed and remain closed until grout has set. For any hole ahead of the grouting operation, with a valve attached, and the valve in the open position; such hole shall be considered. grouted if grout issues forth of the same consistency; and at the same rate as that being pumped, and the valve closed. Replace grout plugs in Pipe and Initial Support at the completion of grouting. G. The maximum sustained grouting pressure shall be 15 psi at the grout hole collar connection. H. All grouting operations are to be performed in the presence of the Owner. Notify the Owner at least 24 hours in advance of starting contact grouting operations. I. Pipe grout fittings shall be sealed with screw type plugs upon completion of grouting. Dry pack mortar shall be used to fill any recesses in concrete pipes, and to provide a smooth surface for patching the PVC lining inside the Pipe as shown on the Drawings. Seal and patch holes in alternative lining and pipe materials as appropriate to those materials and as approved by the Owner. VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 3.3 12 FAN-UP A. Take .all the necessary precautions to protect and preserve the interior surfaces of the Pipeline from damage. Grout spills shall be minimited and clean-up shall proceed immediately after grouting. Any damage to the Pipe caused by or occurring during the grouting operations shall be repaired by a method approved by the Owner at no additional cost to the Owner. 6. During grouting work, provide for adequate disposal of all waste and wastewater. Remove and properly dispose of all waste grout resulting from grouting operations. Grout spills shall be minimized and all clean up of grout and waste materials shall be performed immediately to avoid damage to the Pipe or lining. The contents of grout lines shall not be discharged into the tunnel. ++ END OF SECTION ++ VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE SECTION 03620 ANNULAR LOW DENSITY CELLULAR CONCRETE PART 1 - Gf=NFRAL 1.1 DFSCRIPTION A. Scope: 1. Perform the work required to provide all annular low density cellular concrete shown, specified and required for construction of pipelines required to complete the Work. 2. The Work specified in this Section includes backfilling the annular space between the interceptor pipe and the tunnel initial support system with low density cellular concrete. B. Definitions: 1. Low Density Cellular Concrete. Light weight hardened cementious material made from the combination of concrete and a foaming agent with an oven-dried weight and compressive strength as specified herein. 2. Tunnel Initial Support System. As defined in Section 02320, Tunnel Support Systems. 3. Manufacturer. Cellular concrete foaming agent manufacture’s representative. 4. Initial Support. Elements designed, furnished, installed, monitored and maintained in the tunnel for ground support, excavation, stability and safety during construction. C. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and the SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. D. Related Sections: 1. Section 2-5.2, Precedence of Contract Documents. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 02300, Tunneling Operations. 4. Section 02306, Microtunneling. 5. Section 02320, Tunnel Support Systems. 6. Section 02340, Boring and Jacking (Steel Casing). 7. Section 02350, Installation of Pipe in Tunnel. E. Standards: 1. ACI 523.1R: Guide for Cast-In-Place Low Density Concrete. 2. ACI 523.3R: Guide for Cellular Concretes Above 50 pcf and for Aggregate. Concretes Above 50 pcf with Compressive Strengths Less Than 2,500 psi. 3. ASTM C 94: Standard Methods for Ready Mixed Concrete. 4. ASTM C 138: Standard Test Method for Unit Weight, Yield, and Air Content (G&metric) of Concrete. VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 5. 6. 7. 8. 9. 10. ASTM C 150: Specifications for Portland Cement. ASTM C 495: Standard Test Method for Compressive Strength of Lightweight Insulating Concrete. ASTM C 567: Standard Test Method for Unit Weight of Structural Lightweight Concrete. ASTM C 618: Specifications for Fly Ash and Raw or Calcified Natural Pouolan for Use as a Mineral Admixture in Portland Cement Concrete. ASTM C 796: Standard Method of Testing Foaming Agents for Use in Producing Cellular Concrete Using Preformed Foam. ASTM C 869: Standard Specification for Foaming Agents Used in Making Preformed Foam for Cellular Concrete. 1.7 QUALITY ASSURAN(;E A. Qualifications: 1. The Contractor shall be capable of developing a mix design, and batching, mixing, handling and placing low density cellular concrete under tunnel conditions. The Contractor shall have furnished and placed low density cellular concrete on at least three tunnels of the general type and the size specified herein which have been in successful operation and shall have a record of experience and quality of work using low density cellular concrete that is satisfactory to the Owner. 2. As an alternative, the Contractor may employ a manufacturer’s representative to supervise supplying and placing of cellular concrete. The manufacturer’s representative shall be capable of complying with the qualifications specified for the Contractor and shall be acceptable to the Owner. The manufacturer s representative shall supervise all cellular concrete operations including training the Contractor’s personnel, mixing designs, and placement of cellular concrete in the tunnel. 3. Personnel Qualifications: The Contractor’s or subcontractor’s superintendent responsible for installation .of cellular concrete shall have had previous experience on at least three similar previous projects under similar ground and tunnel conditions or the cellular concrete supplying and placing shall be under the supervision of the Manufacturer. 4. Field Services: The Manufacturer shall provide engineering field services to review the project and the material application prior to any preparation to approve the applicator, the material used, the equipment, and the procedures to be used; to approve setup before production of cellular concrete; and to observe during initial application. The Manufacturer shall submit, in writing, approvals of proposed material, equipment, application procedures, applicator, and setup before production. B. Trial Mix Test: A tentative mix shall be designed and tested in accordance with ASTM C 796 for each consistency intended for use. These results will be compared with field test results to confirm consistent properties are obtained in the field. Preliminary testing for each mix shall be as follows: C. VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 1. 2. 3. Two sets of compression test cylinders (three inches by six inches), three cylinders per set, shall be made from each proposed cellular concrete mix. One set of three cylinders shall be tested at an age of seven days and the other set shall be tested at an age of 28 days. Cellular concrete test specimens shall be made, cured, stored, and tested in accordance with ASTM C 495. Determine total air content of each proposed cellular concrete mix in accordance with ASTM C 796. Determine unit weight of each proposed cellular concrete mix in accordance with ASTM C 567. Field Tests: 1. General: Field control tests, including unit weight (wet density), air content test, and making compressions test cylinders, shall be performed by the Contractor. The Owner may, at the Owner’s option, perform similar tests. 2. The frequency specified herein for each field control test is approximate. A greater or lesser number of tests may be made, as required by the Owner. 3. Test specimens shall be collected within the tunnel at or near the connection where the cellular concrete is being injected. 4. Provide at or very near the point of injection, a system of valves in the’ line transporting the cellular concrete, which will allow easy access for collection of test specimens without disconnecting the line from the outlet. 5. Unit Weight: Unit weight (wet density) test shall be made from the first batch mixed each day, after a change in mix design, from each batch of cellular concrete from which compression test cylinders are made, and at a frequency at not less than one per hour. Unit weight shall be determined in accordance with ASTM C 567. Unit weight at the point of placement shall be within plus or minus five ‘percent of the unit weight established for the mix design being placed. Adjust mix as required to obtain the specified unit weight. 6. Air Content: An air content test shall be made from the first batch mixed each day and from each batch of cellular concrete from which concrete compression test cylinders are made. Air content at the point of placement shall be the difference between the wet density at the point of placement less the wet density at the point immediately before the addition of preformed foam. Air content shall be determined in accordance with ASTM C 138 except there shall. be no vibration or rodding of the sample. D. Compression Tests: One set of four test cylinders (three inches by six inches) shall be made for each shift when cellular concrete is placed. One additional set shall be made from each additional 100 cubic yards or major fraction thereof, placed in any one shift. Two cylinders from each set shall be tested at an age of 28 days; one-cylinder shall be tested at an age of seven days. 1. Compressive strength of cellular concrete shall be considered satisfactory if both of the following requirements are met: 2. Average of three consecutive compressive strength tests equal or exceed the specified unconfined compressive strength. 3. No individual compressive strength test (average of two cylinders) is below the specified unconfined compressive strength by more than 20 percent. 4. The 28-day strength test shall be the average of the compressive strengths of two cylinders made from the same concrete sample and tested at 28 days. ANNULAR LOW DENSITY CELLULAR CONCRETE 03620-3 1.3 SUBMITTALS VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 5. 6. Test cylinders shall be cast in the field, cured and stored in the laboratory, and tested in accordance with ASTM C 495. Each set of compression test cylinders shall be marked or tagged with the date and time of day the cylinders were made, the location in the work where the cellular concrete represented by the cylinders was placed, batch number, wet density unit weight, and the air content. E. If there is a conflict between Contract Document, the document highest in precedence shall control. Refer to Section 2-5.2. A. Submit the following in accordance with Section 2-5.3. B. Qualifications: Submit Qualifications of the grout Contractor and Manufacturer. The Contractor should have a minimum of 5 years of experience in similar type of grouting work. The Manufacturer should provide letters of recommendation from three previously successful jobs of a similar nature. c. Product Data: 1. Mix designs for each type of cellular concrete proposed for use. Each mix design shall show the ingredients of the mix and shall include: a. Type, brand, source, and amounts of cement, ponolans, admixtures, and other additives. b. Source and amount of water. C. Representative samples of materials for materials testing and mix proportion testing. d. Combined grading of each mix design. F’ Specific gravity of all materials. Results of required tests. D. A certificate of compliance signed by the supplier identifying the type of fly ash and stating that the fly ash is in accordance with ASTM C 618 and these specifications. Supporting test data shall be furnished when requested by the Owner. 1. Water / Cement Ratio vs. compressive strength test results. 2. Concrete Admixtures: Material specifications and instructions for use. 3. Air content, unit weight, and compressive strength test results for proposed mix design. E. Equipment: 1. Manufacturer’s specifications and operation instructions for conveyance equipment. 2. Pumps. 3. Foam generators and ancillary equipment. ANNULAR LOW DENSITY CELLULAR CONCRETE 03620-4 F. G. H. I. J. K. L. M. VISTIXARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE Work Plan: 1. For placing low density cellular concrete including sequence of work, type(s) of equipment, location of equipment, placing procedures (i.e., batching, mixing, and pumping procedures), concrete conveyance provisions, pump line arrangement (including moving and breaking), communications provision, methods for monitoring mix, testing procedures, and cleanup procedures. The work plan shall include pumping pressures, pumping rates, volumes to be placed per day, injection locations, and sequence of placement and pumping. Drawings: 1. Submit drawings showing the method of preventing pipe floatation along with certification from the pipe supplier that proposed blocking details to prevent floatation are in accordance with their recommendations and will not damage me pipe. Submit shop drawings showing how the cellular concrete backfill will be terminated at the ends of the tunnel. Trial Mix: Details and testing results for cellular concrete backfill trial mixes. 1. Written documentation from the Manufacturer indicating that they have reviewed the project requirements, materials, equipment, procedures, trial mix tests, and final mix design, and approve the proposed procedures for final mixing and placement. Proposed method to determine the limits of cellular concrete backfill to verify as a minimum that the invert and crown are filled and to determine the limits of each successive backfill lift. Test Reports and Certifications: 1. Mill test reports for cement. 2. Certificates of compliance for each load of cement and pozzolan. ’ 3. Certifications of compliance for all admixtures. 4. A delivery ticket with the information stated in Section 16 of ASTM C 94; excepting actual scale weights of materials shall be furnished to the Owner with each batch of concrete before unloading at the site. 5. A printout of the actual scale weights for all loads batched shall be submitted to the Owner at the end of each working day. Daily reports and records of concrete placement, including but not limited to, volumes placed, stationing of placement, injection locations, pressures, unit weight and air content testing results, time of placement, and designation of cylinder samples prepared that day. Valve Arrangement. Submit to the Owner for review at least 15 days prior to commencing cellular concrete backfilling operations. Results at Trial Mixes and Field Trials. Results shall include batch proportions of aIt components, test results, and field measurements. ANNULAR LOW DENSITY CELLULAR CONCRETE 03620-5 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 71 MATFRIALS A. Cement: Conform to the requirements of ASTM C 150. B. Water: Potable water free from deleterious amounts of alkali, acid, organic materials, or other impurities which would adversely affect the setting time, strength, durability, or other quality of the cellular concrete. If warm water is used to prefonn the foam, it shall not exceed 80 degrees Fahrenheit (“F). C. Admixtures: Admixtures may only be used when specifically approved by foaming agent supplier in writing. D. Foaming Agent: 1. Foaming agent shall comply with ASTM C 869 when tested in Accordance with ASTM C 796. 2. Product and Manufacturer: Provide one of the following: a. Mearl Geofoam Liquid Concentrate, The Mean Corporaration. b. Foam Liquid Concentrate, Cellufoam Concrete Systems. C. Or equal. 37 MIX DFSIGN A. General: Low density cellular concrete mix shall be designed in accordance with the requirements of this Section, ACI 523.1R and ACI 523.3R. Mixes shall be adjusted in the field as necessary to meet the requirements of these specifications. The Manufacturer shall approve all changes to the mix designs. B. Strength: Minimum sevenday and .28day compressive strength (ASTM C 495): 300 and 500 pounds per square inch (psi), respectively. C. Limiting Requirements: Unless otherwise specified, each cellular concrete mix shall be designed and controlled within the following limits: 1. Wet Density: As the point of placement, the wet density unit weight of the cellular concrete shall be not less than 50 pcf and shall be within 5 pcf plus or minus of the density of the approved cellular concrete mix. 2. Preformed Foam: Preformed foam shall be generated by combining controlled quantities of air, water, and foaming agent under pressure. Foam shall retain its stability until the cement sets to form a self-supporting matrix. The resulting cellular concrete shall have essentially closed cell and low water absorptive characteristics. The concentration of foam agent shall be in accordance with the Manufacturer s recommendations. ANNULAR LOW DENSITY CELLULAR CONCRETE 03620-6 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 3. 4. Admixtures: The admixture content, batching method, and time of introduction to the mix shall be in accordance with the manufacturer s recommendations for minimum shrinkage and for compliance with these specifications. Admixtures may be used when specifically approved by foaming agent material manufacturer and shall be in accordance with their recommendations. No calcium chloride or admixture containing chloride other than impurities from admixture ingredients will be acceptable. All proposed changes to the mix design shall be submitted to the Owner for approval prior to implementation. 73 FQUIPMENT A. Foam Generator: A foam generator shall be used to produce a predetermined quantity of preformed foam which shall be injected into the mixer and blended with the cement slurry. Two types of foam generating systems, batch and continuous generating, are acceptable. 1. The batch system shall consist of a tank in which the foam liquid concentrate and water are first premixed. This dilute solution shall be discharged from either a pressurized tank or by means of a mechanical pump through a foam-making nozzle in which this solution is blended with compressed air in fixed proportions. 2. The continuous generating system shall consist of a container, which continuously draws the concentrate directly from its shipping container, automatically blends it with water and compressed air in fixed proportions, and forms the stable micro-bubbled foam. 3. Both types shall utilize a foam refining column or nozzle calibrated for foam qual,ity and discharge rate. The foam nozzles shall be timer-controlled to repetitively discharge any preselected quantities or to discharge continuously at a fixed rate. 4. Specially designed batch mixers may also be used in conjunction wi surge hopper equipped pumps. The rates of mixing and pumping shall be property adjusted and a continuous flow of cellular wncrete shall be obtained at the point of-placement. UTION 3.1 GENE&&. A. Requirements. 1. Following placement of the pipeline within the tunnel, completely fill the annular space between the pipe and the Initial Support with cellular concrete backfill in accordance with these specifications. 2. Low density cellular concrete shall bs placed as specified herein. Cellular concrete shall be made using preformed foam process equipment approved by the Manufacturer. 3. Methods for completely filling the annular space between pipe and the initial support shall be subject to approval by the Manufacturer and the District. 4. Inform the District at least 72 hours in advance of the times and places where placement of cellular concrete is anticipated. ANNULAR LOW DENSITY CELLULAR CONCRETE 03620-7 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 5. No standing water shall be allowed where low density cellular concrete is to be placed. 37 BATCHING AND MIXING A. General: Conform to the requirements of approved submittals and the Manufacturer’s recommendations. B. Mixing: 1. Cellular concrete shall be mechanically mixed to produce a uniform distribution of the materials with a suitable consistency and the specified limiting requirements. Avoid excessive mixing in order to reduce the possibility of changes in unit weight and consistency and separation. 2. In batch mixing operations, follow the manufacturer’s recommendations concerning the order of charging the mixer with the various ingredients. The as- cast unit weight shall be monitored, the method of placement, such as mechanical or pneumatic pumping, and for any unit weight changes that may result from these methods. 3. For continuous mixing operations, provisions shall be made for reasonably uniform and continuous rate of addition of all mix components at appropriate positions in the mixing machine and in the correct ratio, to assure uniformity and the specified limiting requirements at the point of placement. 4. Alternative methods for batching and mixing cellular concrete will be considered by District. 3.3 PI AQNG CPt t UI AR CONCRETF A. General Requirements: All void space outside of the pipeline shall be completely filled with low density cellular concrete. Force cellular concrete into all irregularities around the tunnel to completely fill the tunnel arch and annulus with low density cellular concrete to the maximum extent possible. Place cellular concrete in accordance with approved submittals. B. Use vertical construction joints at bulkheads unless approved otherwise by the Owner. C. At the start of cellular concrete backfilling operations, extend the discharge pipe from the placing equipment to the point of lowest elevation of the section of interceptor pipe being backfilled. D. Backftlling of the annular space between the Interceptor Pipeline and the Initial Support shall be accomplished by placing cellular concrete in multiple lii. Monolithic placements will be acceptable, provided the Contractor can demonstrate that the placement techniques will not induce movement of the pipe. E. Pressure gauges of appropriate range for monitoring the low density cellular concrete injection pressures shall be located in the line transporting the cellular concrete at the point of injection. Pressure shall not exceed 15 psi at the point of injection unless lower pressures are required to prevent pipe movement. ANNULAR LOW DENSITY CELLULAR CONCRETE 03620-6 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE F. Volume of cellular concrete injected shall be measured, recorded, and compared with the anticipated volume per foot of pipe backfilled. G. Provide a means of direct communication between the injection point and the pump operator. 3.4 PROTECTION AND Cl FAN UP A. Take all necessary precautions to protect and preserve the pipe from damage. Spills shall be minimired and shall be cleaned up immediately. Any damage to the pipe caused by or occurring during the backfilling operations shall be repaired by a method approved by the Owner at no additional cost. B. During backftlling work, provide for adequate disposal of all waste and wastewater. Minimize cellular concrete spills and clean-up immediately after backfilling. Remove and property dispose of all waste resulting from backftlling operations. ++ END OF SECTION ++ ANNULAR LOW DENSITY CELLULAR CONCRETE 03620-g VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE SECTION 03630 COMPACTION GROUTING A. Scope: 1. 2. Perform the work required to provide all compaction grouting shown, specified and required for construction of pipelines required to complete the Work. 2.The work specified in this section shall include setting up a compaction grouting system at all NCTD Railroad Crossings for the purpose of reversing any settlement caused by tunneling activities at the crossing locations. The compaction grouting system shall be installed prior to any work associated with the NCTD crossings. The ground surface above the tunnel at the NCTD track shall be continuously monitored during tunneling operations and if settlement exceeds l/8 of an inch, positive measures using the installed compaction grouting system shall be used to counteract the induced settlement. B. Definitions: 1. Compaction Grouted Soil: Existing soil which has been treated by compaction grouting in order to increase its relative density to meet the requirements specified herein. 2. Compaction Grouting: The process of creating compaction grouted soil which is accomplished by pressure grouting the existing underlying soil by virtue of pressure injecting a series of low-slump, soil-cement grout bulbs into the ground. Such grouting is to increase the relative existing soil densities. through compaction by the introduction of additional material. The grout does not penetrate the soil pores, but it displaces the subsurface soils. 3. Monitoring System: A ground movement monitoring system installed and operated by the Contractor at the surface of the ground to determine if their movement exceeds specified criteria. C. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. D. Related Sections: 1. Section 25.2, Precedence of Contract Documents. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 4-2, Materials Transportation, Handling and Storage. 4. Section 01025, Measurement and Payment. 5. Section 02140, Dewatering. 6. Section 02306, Microtunneling. 7. Section 02310, Jacking and Receiving Shafts. 8. Section 02340, Boring and Jacking (Steel Casing). 9. Section 15064, Reinforced Concrete Pipe. 10. Section 15075, PVC Pipe - SDR 35. COMPACTION GROUTING 03630-l VISTAXARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 37 QUALITY ASSt IRANCF A. Reference Standards: Comply with applicable provisions and recommendations of the following, except as otherwise shown or specified. 1. ASTM C 150: 1992 Standard Specification for Portland Cement. 2. ASTM D 3441: 1994 Test Method for Deep, Quasi-Static, Cone and Friction- Cone Penetration Tests of Soil. B. Compaction Grouting Expertise: Compaction grouting shall be performed by an approved Contractor expert with an established record of at least five years experience in performing compaction grouting operations. The Contractor shall furnish supervision, equipment, labor and materials as necessary. C. Qualifications: The Contractor shall be regularly engaged in compaction grouting work and shall be specifically qualified to perform the work as indicated. The Contractor shall document that they have successfully completed a minimum of the following work in the United States: 1. Six compaction grouting projects in the last five years, on which they provided all supervision, labor, materials and equipment. 2. Two of the six documented, successfuliy completed projects shall have involved compaction grouting to depths equal to or greater than those specified in this contract. 3. Two of the six completed projects were of a combined value of at least $1 ,ooo,ooo.oo. D. Supervisor Qualifications: All work shall be continuously supervised by an experienced individual who has been in responsible charge of supervising compaction grouting for at least two years (total cumulative supervisory experience). E. Inspection and Inspector (QC Specialist) Qualifications: Continuous inspection is required for compaction grouting. Employ a qualified compaction grouting inspector approved by the Engineer to perform continuous inspection of this work. Compaction grouting inspector shall have at least two years of experience in the inspection and/or supervision of this type of work. F. Testing: Provide the necessary testing as required herein. G. If there is a conflict between Contract Documents, the document highest in precedence shall control. 1. Refer to Section 2-5.2. 1.3 SUBMITTALS A. Submit the following in accordance with Section 2-5.3. B. Qualification Submittals: 1. Submit Contractor qualifications in accordance with Paragraph 1.2.C of this Section. COMPACTION GROUTING 03630-2 VISTAKZARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE 2. 3. Submit Supervisor qualifications in accordance with Paragraph 1.2.C of this Section. Submit Inspector qualifications in accordance with Paragraph 1.2.D of this Section. C. Qualifications: 1. Detailed compaction grouting program to achieve required soil compaction. 2. Plant, equipment and material descriptions. 3. Arrangement of grout plant, mixer and injection equipment, and other necessary details. 4. Methods for drilling and driving. 5. Arrangement and spacing of grout pipes, including pressure and volumes of grout required. 6. Sequence of grouting. 7. Layout and procedures for monitoring program to determine ground movement. D. Test Reports: 1. Grout mix design demonstrating compliance for slump and materials. E. Field Test Reports: Submit daily: 1. Grout hole geometry (length and location). 2. Time and date of beginning and completion of each grouted hole. 3. Grout mix data, including mix proportions. 4. Pressures and grout volumes used to construct each grouted hole. 5. Grout rates and takes for each grouted hole. 6. Slump of grout 7. Records of ground and top of seawall movement based on monitoring system. 8. Other pertinent observations, such as: grout escapes, ground. heave, or other unusual behavior. 1.4 DFSIGN CRITERIA A. Surface and subsurface elevations as shown on the Plans. B. No pipes, steel tie rods, structures or other man-made obstructions, except those indicated, will be encountered. C. The character of the soil material is as indicated in the Geotechnical Report. 1. Refer to Section 7-16. PART 2 - PRODUCTS 21 MATFRIAI S A. Cement shall be Portland Cement conforming to ASTM C 5, Type II. B. Water shall be potable. COMPACTION GROUTING 03630-3 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE C. Fine aggregate shall be silty sand with a fines content (percent passing No. 200 sieve) of not less than 10 percent and not more than 25 percent. This may be supplemented by flyash, bentonite or aggregate washings. D. Grout shall be a pumpable mixture of three to six sacks of cement per bulk cubic yard of fine aggregate. Add water to limit slump to a maximum of 2 inches. 72 F,QUIPMFNT A. Mixer shall be of a type that ensures complete and uniform mixing of the materials used for grout. It shall have sufficient capacity to continuously feed the grout pump at its normal pumping rate. B. Grout pump shall be capable of injecting grout at a rate of up to 5 cubic feet per minute at a pressure of up to 500 psi at the point of injection. It shall be controllable down to 0.2 cubic feet per minute. Grout pump shall have a volume measurement system that will measure volumes pumped down to 0.5 cubic feet. Pressure gages at the injection point shall measure grout pressure to within 10 psi. C. Grout pipes shall be of steel of adequate strength to withstand the required driving and pumping pressures. The grout pipes shall be at least 2.0 inches in diameter in order to handle the low slump grout without plugging. D. Monitoring devices shall be capable of continuously measuring: (1) the vertical movement of the top surface of the ground in the area of the compaction grouting and (2) the vertical and lateral movement of the top of the gravity and tied back seawall adjacent to the compaction grouting. E. Drilling and/or driving equipment shall be of a type and capacity suitable for performing the compaction grouting as shown on the Contract Drawings and as specified herein. 3.1 INJFCTION OF GROUT A. Installation of Monitoring Devices and Measurements: 1. Install monitoring devices, and then continuously measure during the compaction grouting installation and for two days thereafter the following items: 2. The vertical movement of the top surface of the ground in the area of the compaction grouting. COMPACTION GROUTING 036304 B. VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS CONCRETE Grout Pipe installation: Install grout pipes at locations indicated on approved layout drawings. Maximum spacing of grout pipes shall not exceed 8 foot spacing each way. Install grout pipes by driving and/or drilling. The methods of installation shall insure intimate contact with the hole in order to prevent grout return outside the casing. Stage lengths shall not exceed 5 feet. All grout pipes shall be removed at completion of the work. C. Grouting shall continue without intemrption until the ground surface has been displaced to within the tolerances defined in this Section. D. Perform monitoring as specified. Verify that the ground is within allowable tolerances defined in this Section. 3,2BD QUALITY CONTROL A. Provide both inspection and testing as defined herein for compaction grouting. B. Field Inspection and Daily Records: 1. Continuous field inspection shall be provided by a qualified inspector. 2. The inspector shall record and submit daily the data obtained in the field. 3.3 A. Clean and then dispose of all debris to an off-site location. However, all granular soil spoil materials shall be disposed of at a site on Naval Air Station North Island which is located a maximum of three miles from the construction site. The exact location will be determined by the Engineer. All materials shall be allowed to dry out on site prior to their removal from site. 3.4 FINISH GRADING A. At the conclusion of all compaction grouting operations,. finish grade site to approximately the existing grades, unless othenrvise directed by the Engineer. ++ END OF SECTION ++ COMPACTION GROUTING 03630-S VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS METALS SECTION 05540 CASTINGS PART 1- GENI=FM A. scope: 1. Perform the work as shown, specified and required to provide all castings, in place, complete and ready for intended use, required to complete the Work. 2. The types of castings shall include the following items: a. Sewer manhole frames and covers. b. Sewer cleanouts, frames and covers. :1 Catch basin frame and cover. Storm drain curb inlet frames and covers. e. Storm drain cleanout frames and covers. 3. Refer to Appendix B for copies of applicable standard drawings. The drawings provided are for the convenience of the CONTRACTOR and are not necessarily all inclusive. B. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. C. Related Sections: 1. Section 2-5.2, Precedence of Contract Documents. 2. Section-2-5.3, Shop Drawings and Submittals. 3. Section 4-2, Materials Transportation, Handling and Storage. 4. Section 01025, Measurement and Payment. 5. Section 02606, Manholes and Drainage Structures. 1.2 QUALITY ASSURANCF A. Reference Standards: Comply with applicable provisions and recommendations of the following, except as otherwise shown or specified. 1. ASTM A 46, Gray Iron Castings. 2. ASTM A 536, Ductile Iron Castings. B. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. CASTINGS 05540-l VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS METALS 1.3 SURMIITAI S A. Submit the following in accordance with Section 2-5.3. 6. Shop Drawings: 1. Shop drawings for the fabrication and erection of all casting assemblies. Include plans, elevations, and details of sections. 2. Copies of manufacturer’s specifications, load tables, dimension diagrams, anchor details and installation instructions. 1.4 MATERIALS TRANSPORTATICN. HANDLING AND STCRACF A. Refer to Section 4-2, Materials Transportation, Handling and Storage. 1.5 MFASURFMFNT AND PAYMFNT A. Refer to Section 01025, Measurement and Payment. PART 7 - PRODUCTS 2.1 MATERIAL S A. Sewer Manhole Frames and Covers: 38-inch diameter manhole frame and two concentric covers shall be used as shown on the Plans. 1. Frame and cover shall conform to Carfsbad Standard Drawing S4, Accesshole Frame and Cover. 2. Covers shall be furnished with designation: “CITY OF CARLSBAD” and “SEWER’. 3. Clear Opening: 38inches. 4. Product and Manufacturer. Provide one of the following: a. A-l 325, Alhambra Foundry Company. b. SBF 1325, South Bay Foundry. C. Or equal. 8. Sewer Cleanout Frame and Cover: Sewer cleanouts shall have a frame and cover as shown on the Plans. 1. Frames and covers shall be cast iron suitable for traffic. 2. Clear Opening: +&inches. 3. Frame Height: 8 inches. 4. Covers shall be furnished with designation “SEWER.” 5. Product and Manufacturer: Provide one of the following: it: A-1244, Alhambra Foundry Co. Or equal. C. Catch Basin Type F Frame and Cover: 24-inch diameter (nominal) frame and cover shall be used. 1. Frame and cover shall conform to SDRS Drawing M-2. 2. Clear Opening: 22-inches. 3. Covers shall be furnished with designation: “STORM DRAIN”. CASTINGS 05540-2 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS METALS 4. Product and Manufacturer: Provide one of the following: 2 A-l 530, Alhambra Foundry Company. SBF 1535, South Bay Foundry. C. Or equal. D. Storm Drain Cleanout Frame and Cover. 36-inch diameter frame and two concentric covers shall be used. 1. Frame and cover shall conform to SDRS Drawing M-3. 2. Clear Opening: 36-inches. 3. Covers shall be furnished with designation: “STORM DRAIN”, 4. Product and Manufacturer: Provide one of the following: a. A-l 325, Alhambra Foundry Company. b. SBF 1325, South Bay Foundry. C. Or equal. E. Curb Inlet Frame and Cover: 24-inch diameter (nominal) frame and cover shall be used. 1. Frame and cover shall conform to SDRS Drawing M-2. 2. Clear Opening: 22-inches. 3. Covers shall be furnished with designation: “STORM DRAIN”. 4. Product and Manufacturer: Provide one of the following: a. A-l 530, Alhambra Foundry Company. b. SBF 1535, South Bay Foundry. C. Or equal. 72 DFSIGN AND FABRICATION A. Design frames and covers to prevent rocking and raffling under traffic. B. Fabricate castings true to pattern so that component parts fit together. 73 FINISH A. Iron: Coat with asphattic paint standard with the manufacturer. - PART 3 - EX’=CUTW 3.1 INSIiIt 1 ATION A. Follow manufacturer’s instructions and approved shop drawings. + + END OF SECTION + + CASTINGS 05540-3 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VCllA AND SOUTH CARLSBAD STORM DRAIN PROJECTS WOOD AND PLASTICS SECTION 06651 POLWINYL CHLORIDE LINER FOR CONCRETE PART A- GEN=Wl. 1.1 DFSCRIPTION A. Scope: 1. Perform the work as shown, specified and required to provide all polyvinyl chloride (PVC) liner for concrete in place, complete and ready for intended use, required to complete the Work. 2. Concrete items and structures to be interior lined with PVC T-lock liner shall be as follows: a. Precast concrete sewer manhole components, except for abandonment slabs. e.g.: risers and cones. b. Interceptor sewer piping. C. Cast-in-place sewer manhole structures above the shelves. 3. Concrete items to be interior lined with PVC plain sheet liner shall be as follows: a. Shelves and channels in cast-in-place sewer manhole structures. b. Shelves and channels in cast-in place sewer manhole bases. B. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. C. Referenced Sections: SSPWC: 1. Section 216-2, Plastic Liner. 2. Section 31 l-1, Plastic Liner Installation. D. Related Sections: 1. Section 2-5.2, Precedence of Contract Documents. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 01025, Measurement and Payment. 4. Section 02606, Manholes and Drainage Structures. 5. Section 03100, Concrete Formwork. 6. Section 03251, Concrete Joints. 7. Section 03300, Cast-In-Place Concrete. 8. Section 15051, Buried Piping Installation. 9. Section 15073, Concrete Pressure Pipe. POLYVINYL CHLORIDE LINER FOR CONCRETE 06651-l VISTAKZARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS WOOD AND PLASTICS J.2 QUALITY ASSURANCF A. Manufacturers’ Qualifications: Manufacturer of each type of liner system shall have a minimum of 5 years experience in the production of PVC lined concrete products, and shall show evidence with his submittal of satisfactory service in at least 5 similar applications. 8. Manufacturer’s Warranty: Provide a manufacturer’s warranty for materials. C. Contractor’s Warranty: Provide a Contractor’s warranty for installation of materials for a period of one year. D. Reference Standards: Comply with applicable provisions and recommendations of the following except as otherwise shown or specified. 1. ASTM C 794, Standard Test Method for Adhesion-in-Peel of Elastomeric Joint Sealants. E. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. 1.3 SUBMITTALS A. Submit the following in accordance with Section 2-5.3. B. Shop Drawings: 1. Manufacturer’s literature, illustrations, recommendations, engineering data, product data, and specifications for each type of lining system including performance criteria, surface preparation and applications, volatii&organic compound (V.O.C.) data, and safety requirements. 2. Layout drawings of all liner sheets at the locations shown or specified within structures. 3. Locations and types of all shop joints and field joints. a. Identify type of field joint to be used: Type C-l, C-2 or C-3. 4. Samples - T-lock: Samples of liner materials and liner systems required to perform the Work, including but not limited to, the following: a. One 5-inch square sample of liner with at least two rows of T- shaped ribs. b. Two 6-inch by 6-inch pieces of liner connected together by a weld strip. Ei 1 Z-inch long weld. Comer, termination, patching and all other strips expected to be utilized in the Work. F’ “Heels” for interior comers. Outside comers. 9. Inside comers. POLYVINYL CHLORIDE LINER FOR CONCRETE 06651-2 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS WOOD AND PLASTICS 5. 6. 7. 6. 9. 10. Samples - Plain Sheet Linen A sample of the liner system required to perform the Work, including but not limited to the following: b”: One liner-mastic-substrate sample. One premolded comer sample. Manufacturer’s standard details including but not limited to the following conditions: comers, liner edges, liner joints, pipa ends, manhole openings, and channels. Detail showing tenination of PVC liner at the pipe to manhole connections. Letter from manufacturer of each type of liner approving the installer of the liner. Material Safety Data Sheets (MSDS) for materials brought on site including lining system materials, solvents, cleaners, and abrasive blast media. Installer’s List: A list of the names of installers who will perform the work covered by this specification including certificates of completion of training (as applicable) by the manufacturer. C. Manufacturer’s Qualifications: In accordance with Paragraph 1.2.A of this Section. D. Manufacturer’s Warranty: In accordance with Paragraph 1.2.8 of this Section. E. Contractor’s Warranty: In accordance with Paragraph 1.2C of this Section. F. Certifications: In accordance with Paragraph 3.5.A.2 of this Section. 1.4 A. Deliver materials to the manhole manufacturing plant and concrete pipe manufacturing plant to ensure uninterrupted progress of the Work. B. Store materials out of sunlight and to permit easy access for inspection and identification. Keep materials off the ground using pallets, platforms, or other supports. C. Refer to Section 4-2, Materials Transportation, Handling and Storage. %5 NT AND PAYMENT A. Refer to Section 01025, Measurement and Payment. POLWINYL CHLORIDE LINER FOR CONCRETE 06651-3 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS WOOD AND PLASTICS PART 7 - PRODUCTS 21 T-l OCK LINFR A. Plastic liner material shall be made from high polymer vinyl chloride resin, pigments and plasticizers, extruded under high temperature and pressure to form a dense, flexible and impervious sheet. PVC resin shall constitute not less than 99 percent, by weight, of the resin used in the formulation. Copolymer resins are not permitted. Its surface shall not absorb or retain precipitated or crystalline materials. Liner system shall be impermeable to sewage gases and liquids and shall be non-conducive to bacterial or fungus growth. Liner shall easily clean and easily maintain in a sanitary condition. Liner shall be resistant to oxidizing agents, sulfuric, phosphoric, nitric, chromic, oleic, and stearic acids; sodium and calcium hydroxides: ammonia, sodium, calcium, magnesium, and ferric sulfate, petroleum oils and greases, vegetable and animal oils, fats, greases and soaps. Liner shall have good impact resistance and shall have an elongation sufficient to bridge up to l/4-inch settling cracks, which may occur after installation, without damage to the liner 1. Color of liner: White. B. Liner shall have rows of T-shaped ribs (T-lock) which protrude from the liner to mechanically bond (lock) the liner to the concrete being lined. Once cast into the structure, lining shall be permanently and physically attached to the concrete by the T-shaped ribs and shall not rely on an adhesive bond. T- shaped ribs shall have a minimum height of 0.375 inches not including the liner sheet. Rows of T-shaped ribs shall have an approximate spacing of 2-l/2 inches measured center to center. T-shaped ribs shall be of the same material as the liner and shall be integrally extruded with the sheet.. Unsecured terminal edges of the liner sheet shall not extend beyond the base of the final row of T-shaped ribs by more than 3/&inch. Liner sheets shall have a nominal width of 48 inches and shall be supplied in lengths which minimize the number of joints. C. Inside comers, outside comers, “heels” for interior comers, and L-shaped terminal strips fabricated of plastic material similar to the plastic liner material shall be provided at all comers, and changes in direction of walls and slabs, and at terminations to provide a neat, gas tight installation. All joint, comer edge and other required strips shall be fabricated of the same material as the liner. Joint strips and exposed welding strips shall have minimum widths of 3-3/4 inches and 7/8-inch, respectively. Joint and exposed welding strips shall both have beveled edges. All terminal bottom edges of the liner in walls of structures shall be sealed with a termination strip or other means approved by the District. POLYVINYL CHLORIDE LINER FOR CONCRETE 06651-4 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS WOOD AND PLASTICS D. E. Minimum thickness of liner sheet and strips shall be as follows: Thickness Materiel Sheet wlth integral 0.065 T-Shaped ribs Joint strip 0.075 Weld Strip 0.094 Cleaners used in the liner installation shall be approved by the District prior to use. Cleaners shall be water soluble and non- detrimental to the liner. F. Product and Manufacturer: Provide one of the following: 1. T-Lock Amer-Plate, Amaron. 2. Poly-Tee PVC T-Ribbed Liner, Poly-Tee, Inc. 3. Or equal. 2-m A. B. C. D. The plain sheet liner system shall be the product of one manufacturer. The liner system shall consist of the following major components: 1. Primer to bond the mastic to the concrete substrate. 2. Surface activator to cross-link the mastic with the PVC. 3. Mastic coating applied to the primer to provide a fully-adhered anchoring mechanism and chemical resistance. 4. PVC plain sheet liner. 5. Mastic seam material. 6. Top coat for non-skid surfaces. Product and Manufacturer: Provide one of the following: 1. Linabond Mastic System, Linabond, Inc. 2. Or equal. Primer: Epoxy/urethane primer shall be two component high solids primer with a relatively fast cure time. 1. Product and Manufacturer. Provide one of the following: ;: EP36-HS Primer, Linabond, Inc. Or equal. Surface Activator: Surface activator shall be a catalytic polyurethane providing cross-linking of the polyurethane mastic with the polyvinyl chloride lining. 1. Product and Manufacturer: Provide one of the following: a. CLA-2 Activator, Linabond, Inc. b. Or equal. POLWINYL CHLORIDE LINER FOR CONCRETE 06651-5 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS WOOD AND PLASTICS E. Mastic: Mastic shall be a high solids polyurethane mastic/joint sealant. The mastic shall be permanently flexible, non-flow, and shall be resistant to weathering, aging, dilute acids (10% sulfunc acid solution, or acid conditions generating pH levels of 1.0) and dilute alkalis. The material shall exhibit excellent adhesion to the activated polyvinyl chloride (PVC) liner and to the primed concrete substrate. 1. Product and Manufacturer: Provide one of the following: a. Mastic, Linabond, Inc. b. Or equal. F. PVC Liner: PVC lining material shall be a homogenous thermoplastic polyvinyl chloride sheet material conforming to the following: 1. Thickness: 30 mils. 2. Colon White. 3. Premolded comer units shall be used at comers. a. Maximum thickness shall be 100 mils. 4. Product and Manufacturer: Provide one of the following: a. PVC plain sheet liner and preformed PVC comers, Linabond, Inc. b. Or equal. G. Mastic Seam Material: Mastic seam material shall be a two component high strength, high solids polyurethane material. It shall be non-flow, and shall be resistant to wearthering, aging, dilute (10 percent) solutions of sulfuric acid and intermittent wetting by raw sewage. 1. Product and Manufacturer: Provide one of the following: a. Mastic Seam Material, Linabond, Inc. b. Or equal. H. Top Coat: Top coat shall be a liquid aliphatic material used for providing a non-skid surface to the PVC liner. 1. Product and Manufacturer: Provide one of the following: a. 1755 UV Topcoat, Linabond, Inc. b. Or equal. PART 3 F-C ITION s 3.1 INSlY I ATION OF PVC T LOCK I INFR - A. General: Install liner in accordance with the recommendations of the manufacturer and approved Shop Drawings. 1. Do not install when the ambient temperature is outside the acceptable installation range specified by the manufacturer, but under no condition shall the liner be installed when the ambient temperature is below 60 F. 2. All concrete liner sheets and strips shall be free of cracks, cleavages or other defects adversely affecting the protective characteristics Of the material. Remove all defective liner material from the job site. POLWINYL CHLORIDE LINER FOR CONCRETE 06651-6 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC58 TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS WOOD AND PLASTICS 6. Coverage: Coverage of the liner shall be as shown on the Plans and as follows: 1. Precast Concrete: Refer to Paragraph 1 .l .A.2 of this Section. 2. Concrete Pressure Pipe: Refer to Paragraph 2.4.A of Section 15073. C. Positioning Liner: 1. Liner installed in walls shall have the T-shaped ribs running vertically. In areas requiring termination strips, the bottom elevation of the liner shall be considered to be the lower edge of the termination strip. 0. Securing Liner: 1. Liner sheets shall be closely fitted and property secured to the liner side of the forms. Nailing through the liner shall be minimized and nails shall be placed no greater than l/&inch from each liner sheet edge. Adjacent sheets shall be butted with not more than an l/&inch opening between the sheets using approved joint type. Where the liner must be bonded to metal, the metal shall be sandblasted to white metal (SSPGSPS) before application of the material. 2. Welding or cutting of reinforcing with welding torches. shall not be performed within 10 feet of any liner sheet prior to placement or securing of forms. Torch cutting and welding around liner secured to forms shall only be permitted after protection for the liner is in place and approved by the District. E. Concrete Placement: 1. Carefully vibrate concrete poured against lining so as to protect the lining and produce a dense, homogeneous concrete, securely anchoring the locking extensions into the concrete. F. Removing Forms: 1. Protect the lining from damage when removing forms. Do not use sharp instruments to pry forms from lined surfaces. When forms are removed, pull any remaining nails without tearing the lining. Clearly mark nail holes, form tie holes, all areas of serious- abrasion or damage for repair. 2. Remove banding strips used in securing liir to forms within the limits of the unlined concrete. Fill voids left in the concrete with cement mortar or other approved material. G. Field Jointing: Field jointing shall be done after the joints are grouted with field mortar. 1. Manholes shall be grouted and vacuum tested before PVC jointing the liner. 2. Sewer piping shall be routed and pressure tested before PVC jointing the liner. POLWINYL CHLORIDE LINER FOR CONCRETE 06651-7 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS WOOD AND PLASTICS H. Field Joint Types: Field joints in the liner shall, be one or a combination of the following types: 1. Type C-l : a. Use this type of joint at concrete expansion joints, and concrete construction joints where the space between adjacent sheets is greater than l&inch, but does not exceed 2 inches. b. Make joint with a separate 4-inch joint strip and two welding strips. Center the 4-inch strip over the joint, and secure to the liner by an approved adhesive, tackwelding or other approved means, and weld along each edge to adjacent liner sheets with a l-inch weld strip. Space between adjacent sheets shall not exceed l-inch in width. Lap the 4-inch joint strip over each sheet a minimum of l-inch. 2. Type C-2: a. Use this type of joint at concrete construction joints, where the space between adjacent sheets is greater than l/8 inch, but does not exceed l/Z-inch. b. Make joint by overlapping sheets by at least one inch and securing the overlap to the adjacent liner by means of a welding strip. Upstream sheet shall overlap the downstream sheet. Overlapping sheets shall not extend more than four inches beyond the T-shaped ribs. Secure the lap in place prior to welding using the same means utilized for Type C-l joint. Apply a welding strip to the back of the joint. 3. Type C-3: a. Use this type of joint at concrete construction joints where the space between adjacent sheets is not more than 1Knch. b. Make joint by applying one welding strip on the back of the butt joint, or other approved method, to prevent wet concrete from flowing around the edges. Apply a second welding strip over the butt joint on the face of the sheet after the forms have been stripped. I. Hot Air Welding: Perform all hot air liner welding by qualified welders in strict conformance with the Specifications and instructions of the liner manufac- turer. Clean all liner surfaces before welding commences. Provide adequate ventilation in confined spaces during welding operations. Incomplete fusion, charred, or blistered welds will be rejected. Hot air welding guns shall provide clean effluent air at constant pressure to the surfaces to be joined within a temperature range between 500EF and 600EF. Welding shall fuse liner material together to provide a continuous joint equal in corrosion resistance and impermeability to the liner sheets. Supply all equipment required to power the welding guns. POLWINYL CHLORIDE LINER FOR CONCRETE 06651-6 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS WOOD AND PLASTICS ATION OF PVC PLAIN SHFFT LINER A. General: Install liner in accordance with the recommendations of the Manufacturer and approved Shop Drawings. B. Coverage: Coverage of the liner shall be as shown on the Plans and as follows: 1. Cast-In-Place concrete: Refer to Paragraph 1 .l .A.3 of this Section. C. Application of Plain Sheet Liner Concrete Surfaces: 1. PVC plain liner sheets shall be installed using the Linabond Mastic System. 2. Prepare surfaces in accordance with the manufacturer’s recommendations. 3. Obtain the services of a qualified and authorized representative of the manufacturer of the protective lining system as required in Paragraph 3.5 of this Section. 4. Install the lining system in accordance with the procedures identified by the lining system manufacturer. Apply the mastic at a minimum thickness of 60 mils over the entire area that will receive the PVC liner. 5. Protect the finished lining from damage during curing and shall be cured as recommended by the lining manufacturer but in all cases no less than three (3) days of curing time must elapse before the lined area can be returned to senrice. D. Application of Non-Skid Surfaces: 1. Clean and mask off areas to be covered with non-skid surface. . a. Use only manufacturer-approved cleaning solution. 2. Apply surface activator to the liner in the areas for non-skid surface: 3. Apply top coat material with a brush or roller in the same area as the surface activator at a rate of 250 sq. ft. par gallon. 4. Distribute clean sand evenly across the surface to be non-skid. 5. Or mix sand into the top coat before application, then apply top coat. TING OF LINER A. Weld Test: Each hot air welding strip shall be tested by the liner installer in the presence of the District. Welding strips shall extend two inches below the liner to provide a tab. Apply a 10 pound pull to each tab. Apply the force normal to the face of the lining by means of a spring balance Liner adjoining the welding strip shall be held against the concrete during application of the force. The lo- pound pull shall be maintained if a weld failure develops, until no further separation occurs. Defective welds shall be retested after repairs have been made. Tabs shall be trimmed away neatly from the liner after the welding strips have been successfully tested. Testing shall be made within two days after the joint has been completed. Provide all labor and equipment required to test liner joints in the manner recommended by the manufacturer and as specified above. POLWINYL CHLORIDE LINER FOR CONCRETE 06651-g VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS WOOD AND PLASTICS 8. Spark Test: After the welds have been tested and defective welds repaired, the liner shall be completely cleaned to permit visual inspection and spark testing by personnel provided by liner manufacturer in the presence of the District. Spark testing shall be performed with an approved electrical holiday detector with the instrument set at 20,000 volts minimum. Provide ventilation, power, lighting, ladders, labor, and scaffolding. Liner areas failing to meet the field test shall be properly repaired and retested. 3.4 PROTFCTION AND RFPAIR A. Take all necessary measures to prevent damage to installed lining from equipment and materials used in or taken through the Work. CON- TRACTOR shall be responsible for repairing all damage. B. Patch all nail and tie holes and all cut, tom, and seriously abraded areas in the liner. Fuse welding strip patches to the liner over the entire patch area. The use of parallel, overlapping, or adjoining welding strips will not be permitted. Large patches may consist of plain liner over the damaged area, with an adhesive bond and all edges covered with welding strips fused to the patch and the sound liner adjoining the damaged area. C. Whenever liner is not property anchored to concrete, the repair of liner and restoration of anchorage shall be as directed by the manufacturer and approved by the District. 3.5 , MANUFACTURER S SERVI- A. Manufacturer’s Field Services: Provide the following services in addition to any other services specified herein, and required by these Specifications. 1. Provide a factory trained manufacturer’s representative for each type of liner system for a minimum of two (2) visits to the site. Each visit shall be for a minimum period of one 8 hour day to provide installation supervision and field testing services. Coordinate the installation services with the manufacturer. The field testing services shall be coordinated with the District. 2. The manufacturer’s representative for the plain sheet liner shall inspect surface preparation for all installations on the first field visit, and shall inspect final installation and conduct field tests on the second visit. The second visit shall consist of visual inspection, and adhesion and peeling tests. 3. After installation supervision and field testing services by the manufacturer, submit a certification letter on the Manufacturer’s letterhead and signed by the Manufacturer certifying that the liner was installed per the manufacturer’s recommendations and requirements and shall furnish all field test data. B. All costs, including travel, lodging, meals and incidentals for manufacturer services shall be included in the CONTRACTORS bid. + + END OF SECTION + + POLWINYL CHLORIDE LINER FOR CONCRETE 06651-10 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS WOOD AND PLASTICS SECTION 06653 FILTER FABRIC PART I- GFNEfWI. 1.1 DFSCRIPTION A. Scope: 1. Perform the work as shown, specified and required to provide all filter fabric (geotextile material) in place, compete and ready for intended use, required to complete the Work. 2. The extent of filter fabric is shown in the Plans, and specified in Section 02235, Stone Riprap; and Section 15051, Buried Piping Installation. 3. Filter fabric shall be utilized for the following: ii: Riprap underlayment for slope stabilization. Trench liner for bedding zone wrap in pipe trenches. C. Encapsulating material for manhole bases and structures. B. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. C. Related Sections: 1. Section 2-5.2, Precedence of Control Documents. 2. Section Z-5.3, Shop Drawings and Submittals. 3. Section 4-2, Materials, Transportation, Handling and Storage. 4. Section 01025, Measurement and Payment. 5. Section 02220, Excavation and Backfill. 6. Section 02230, Crushed Stone and Gravel. 7. Section 02235, Stone Riprap. 8. Section 15051, Buried Piping Installation. 17 QUALITY ASSURANCE A. Each type of fitter fabric shall be the product of one manufacturer. B. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. 1.3 SUBMll-TqlS A. Submit the following in accordance with Section 2-5.3. B. Shop Drawings: 1. Manufacturer’s data on each type of filter fabric. 2. Manufacturer’s instructions for installing each type of filter fabric for type of installation specified. FILTER FABRIC 06653- 1 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS WOOD AND PLASTICS C. Submit one 5-inch square sample of each type of filter fabric for approval. D. Mill certificates or affidavits signed by a company official of the manufacturer of the fabrics. The mill certificates or affidavits shall attest that the fabrics meet chemical, physical and manufacturing requirements specified in this Section, 1. No fabric shall be shippad until the certificates are submitted. 1.4 MATFRIAI US TRANSPORTATION. HANDLING AND STORAGE Refer to Section 4-2, Materials Transportation, Handling and Storage. Refer to Section 01025, Measurement and Payment. PART 2 - PRODUCTS 2.1 RIPRAP UNQFRt AYhdEIy7: A. Filter fabric shall be used as a geotextile material for riprap underlayment. 1. The geotextile material shall be a woven fabric of monofilament and multifiliment yam construction which is highly UV stabilized. 2. The geotextile material shall have high strength for durability and survivability; consistent, measurable pore sizes; and high percent open area for high flow rates. B. Properties: 1. Wide Width Tensile Strength: 2. Grab Tensile Strength: 3. Elongation: 4. Burst Strength: 5. Puncture Strength: 6. Apparent Opening Size: 7. Flow Rate: 210 lb&t, ASTM D 4595 . 370 Ibs, ASTM D 4632 16 percent, ASTM D 4632 480 psi, ASTM D 3786 100 Ibs, ASTM D 4833 70 US Sieve, ASTM D 4751 18 gallminkf, ASTM D 4491 C. Product and Manufacturer: Provide one of the following: 1. Mirafi Filter Weave Woven Geotextile FW 700, TC Mirafi. 2. Or equal. D. Securing Pins: Securing pins shall be 3/16-inch diameter steel, pointed at one end and fabricated with a head to retain a steel washer having an outside diameter no less than 1.5 inches. The lengths of the pins shall be no less than 24 inches. 1. Pins shall not be removed once in place or reused if removed. FILTER FABRIC 06653- 2 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS WOOD AND PLASTICS 72 TRFNCH LINFR A. Filter fabric shall be used as a geotextile material for a trench liner to wrap the bedding zone in pipe trenches as shown on the Plans. 1. The geotextile material shall be a nonwoven fabric of polypropylene stable fibers. 2. The geotextile material shall provide reinforcement for soil separation, filtration and protection. B. Properties: 1. Grab Tensile Strength: 2. Elongation: 3. Burst Strength: 4. Puncture Strength: 5. Apparent Opening Size: 6. Permittivity: 7. Flow Rate: 120 Ibs, ASTM D 4632 55 percent, ASTM D 4632 240 psi, ASTM D 3786 70 Ibs, ASTM D 4833 70 US Sieve, ASTM D 4751 1.5 set, ASTM D 4491 120 gal/min/sf, ASTM D 4491 C. Product and Manufacturer: Provide one of the following: 1. Mirafi 140N. TC Mirafi. 2. Or equal. 23 FNCAPSUI ATING MATFRIAI. A. Filter fabric shall be used as a geotextile material for encapsulating crushed stone bases for manhole bases and structures as shown on the Plans. 1. The geotextile material shall be a nonwoven fabric of polypropylene stable fibers. 2. The geotextile material shall provide reinforcement for soil separation, filtration and protection. B. Propertiesl . 1. Grab.Tensile Strength: 2. Elongation: 3. Burst Strength: 4. Puncture Strength: 5. Apparent Opening Size: 6. Permit&&y: 7. Flow Rate: 120 lbs, ASTM D 4632 55 percent, ASTM D 4632 240 psi, ASTM D-3786 70 Ibs, ASTM D 4833 70 US Sieve, ASTM D 4751 1.5 set, ASTM D 4491 120 gaWmin/sf, ASTM ‘D 4491 C. Product and Manufacturer: Provide one of the following: 1. Mirafi 140N, TC Mirafi. 2. Or equal. FILTER FABRIC 06653- 3 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS WOOD AND PLASTICS PART 3 - FXFCUTION 3.1 lNSI&J.ATlON m m A. The geotextile shall be placed in the manner and at the locations shown on the Plans. At the time of installation, fabric shall be rejected if it has defects, rips, holes, flaws, deterioration or damage incurred during manufacture, transportation or storage. The surface to receive fabric shall be prepared to a relatively smooth condition free of obstructions, depressions, debris and soft or low density pockets of material. The fabric shall be placed with the long dimension perpendicular to the slope and shall be laid smooth and free of tension, stress, folds, wrinkles or creases. The fabric shall be placed loosely, not in a stretched condition. The fabric strips shall be placed to provide a minimum width of 24 inches of overlap for each joint. B. Securing pins with washers, where necessary to maintain fabric location, shall be inserted through both strips of overlapped fabric at not greater than 2 foot intervals along a line through the midpoint of the overlap. Additional pins shall be installed as necessary, regardless of location, to prevent any slippage of the filter fabric. Each securing pin shall be pushed through the fabric until the washer bears against the fabric and secures it firmly to the underlying soils. C. D. The fabric shall be protected at all times during construction from contamination by surface runoff and all fabric so contaminated shatl be removed and replaced with uncontaminated fabric. Any damage to the fabric during its installation or during placement of rock shall be repaired or replaced by the CONTRACTOR. The work shall be scheduled so that the covering of the fabric with a layer of the specified bedding material is accomplished within 5 working days after placement of the fabric. Failure to comply shall require replacement of fabric. Before placement of rock, the CONTRACTOR shall demonstrate to the DISTRICT that the placement technique will not damage the fabric. Preparation of Subgrade: Prior to placing energy dissipater and rock slope protection fabric, the surfaces upon or against which rock slope protection fabric is to be placed shall be free of loose or extraneous material and sharp objects that may damage the fabric during installation. Equipment or vehicles shall not be operated or driven directly on the rock slope protection fabric. Energy Dissipater and Rock slope protection fabric damaged during placement shall be replaced or repaired, by the Contractor at its expense, as directed by the Engineer. A. Holes and tears in the fabric shall be repaired as follows: 1. On slopes: A fabric patch shall be sewn into place using a double sewn lock stitch (l/4 to 314 inches apart and no closer than 1 inch from any edge). All tears exceeding 10 percent of the width of the roll of the tom section shall be removed from the slope and replaced. 2. Non-Slopes: A fabric patch shall be spot-seamed in place with a minimum of 24 inches of overlap in all directions. FILTER FABRIC 066% 4 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS WOOD AND PLASTICS A. Place all cover materials in such a manner to ensure: the filter fabric is not damaged; minimal slippage of the filter fabric on underlying layers; and no excess tensile stresses in the filter fabric. + + END OF SECTION + + FILTER FABRIC 06653- 5 . VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC56 TO VC1 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL SECTION 15051 BURIED PIPING INSTALLATION PART kGENFm’ 1.1 DESCRIPTION A. B. C. D. E. scope: 1. Perform the work required to provide all buried piping, fittings, specials and appurtenances shown, specified and required for construction of complete and operable pipelines required to complete the Work. 2. The Work includes but is not limited to the following: a. All types and sizes of buried pipelines, specified herein and in other Sections of these Contract Documents, and shown on the Plans. b. Connections to existing sewer systems. :: Sewer flow transfers. Sewer transfer sequences. F’ Testing. Abandonment of existing interceptor sewer. 9 Abandonment of existing storm drain. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. Referenced Section: SSPWC: 1. 500-I .1.5. Television Inspection. Related Sections: 1. Section 2-l .l , Bid Schedules. 2. Section 2-5.2, Precedence of Contract Documents. 3. Section 2-5.3, Shop Drawings and Submittals. 4. Section 4-2, Materials Transportation and Handling. 5. Section 5, Utilities. 6. Section 01025, Measurement and Payment. 7. Section 02140, Dewatering. 8. Section 02220, Excavation and Backfill. 9. Section 02230, Crushed Stone and Gravel. 10. Section 02300, Tunneling Operations. 11. Section 02306, Microtunneling. 12. Section 02330, Pipe Jacking. 13. Section 02340, Boring and Jacking (Steel Casing). 14. Section 06653, Filter Fabric. 15. Division 15. Mechanical. Geotechnical Report: Refer to Section 7-16.1. BURIED PIPING INSTALLATION 15051-l VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 3.2 QUA1 ,ITY ASSURANCE A. Qualifications: The CONTRACTOR shall be qualified for the method of selected pipeline construction, as applicable, as follows: 1. Schedule A consists of four methods of pipeline installation: Tunneling, Microtunneling, Pipe Jacking, and Open Trench. a. Tunneling Operations: For CONTRACTORS qualifications, refer to Section 02300, Paragraph 1.2.A. b. Microtunneling: For CONTRACTORS qualifications, refer to Section 02306, Paragraph 1.2.A. C. Pipe Jacking: For CONTRACTORS qualifications, refer to Section 02330, Paragraph 1.2.A. d. Open Trench Construction: The CONTRACTOR shall have a minimum of 5 years experience in the construction of pipelines of approximately equal extent as this Project using the open trench method of installation. 8. Open Trench Projects: The CONTRACTOR shall have constructed and completed a minimum of 3 separate pipeline projects in urban areas. The qualifying projects shall consist of similar scope and diameter as this Project, each with a minimum 1000 ft. length, using the open trench method of installation. 1) Submit evidence showing the 3 open trench pipeline projects in satisfactory operation. B. Reference Standards: Comply with applicable provisions and recommendations of the following, except as othewise shown or specified. 1. ASTM D 2321, Practice for Underground Installation of Flexible Thermoplastic Sewer Pipe. 2. ASTM D 2774, Practice for Underground installation of Them&- plastic Pressure Piping. 3. AWWA ClO5, Polyethylene Encasement for Ductile-Iron Piping for Water and Other Liquids. 4. AWWA C900, Polyvinyl Chloride (PVC) Pressure Pipe, 4 In. Through 12 In., for Water Distribution. 5. AWWA M9, Concrete Pressure Pipe. 6. AWWA M23, PVC Pipe - Design and Installation. 7. ASCE MOP No. 37, Design and Construction of Sanitary and Storm Sewers. 8. Concrete Pipe Handbook, American Concrete Pipe Association. C. Manufacturer’s Installation Specialists: 1. CONTRACTOR shall provide at its expense the services of a competent manufacturer’s installation specialist for each type of pipe installation and each method of installation when pipe installation commences. 2. Retain the specialists on the job for a minimum of 8 hours or until a sufficient amount of pipe has been installed and joined to demonstrate to the specialist and the District the competency of the pipe installation crew. BURIED PIPING INSTALLATION 15051-2 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL D. Perform a CCTV inspection of the completed interceptor sewer pipeline prior to placing the sewer in service and receiving sewage flow. The CCTV inspection shall be performed in accordance with the requirements of SSPWC Section 500-I .I .5. E. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section Z-5.2. 1.3 SUBMlTTqlS A. Submit the following in accordance with Section 2-5.3. B. Shop Drawings: 1. Laying schedules and detailed layout drawings for pipelines reflecting the CONTRACTOR’S construction schedule and installa- tion methods. Reference laying schedules and layout drawings to the stationing and elevations or coordinates as shown on the Plans. Designate each pipe joint, length, fitting and special on the layout drawings and in the laying schedules. Include pipe closures in the layout drawings. Pipe, fittings and specials delivered to the job site shall be marked with the same letter or number designation appearing on the layout drawings and in the laying schedules. a. Include locations of restrained joints in the layout schedules and layout drawings. b. Submittals for reinforced concrete pipe shall be submitted under Section 15664. c. Submittals for concrete pressure pipe shall be submitted under Section 15073. d. Submittals for fiberglass mortar pipe shall be submitted under Section 15083. 2. Full details of connections to existing manholes, sewer pipelines, and pipe closures, including dimensions, sizes, classes, etc. 3. A detailed description of the order of sewer flow transfers to be conducted in accordance with Part 3.6 of this Section. - 4. A detailed description of the methods of sewer transfer sequences for each permanent diversion and each temporary bypass in accordance with Part 3.7 of this Section. C. Detailed description of the proposed pipe handling and installation methods. Copies of these descriptions shall be furnished to the pipe manufacturer for use in pipe design. D. Pipeline Tests: In accordance with Part 3.8 of this Section. E. CCTV Inspection Documentation: Documentation of the CClV inspection as follows: 1. Video tapes of the inspected pipelines as required by Paragraph I .2.D of this Section. 2. Video tapes of the existing interceptor sewer as required by Part 3.10 of this Section. BURIED PIPING INSTALLATION 15051-3 VISTAZARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL + F. Certificates: Submit certificates of compliance with referenced standards. G. Record Drawings: During progress of the Work, keep an uptodate set of drawings showing field and shop drawing modifications. The drawings shall show all piping on plans and in sections, with all reference dimensions and elevations required for complete record drawings regardless whether the piping was shown on the Plans. H. CONTRACTOR’S Qualifications: In accordance with Paragraph 1.2.A of this Section. I. Description of abandonment procedures and equipment required in Paragraph 3.10 of this Section for abandonment of the existing interceptor. I.4 MATWI S TRANSPORTATION. HANDLING AND STORAGF A. Deliver materials to the site to ensure uninterrupted progress of the Work. B. Handle all pipe, fittings, specials and accessories carefully with approved handling devices. Do not drop or roll material off trucks. Do not otherwise drop, roll or skid piping. C. Store pipes and flttings on heavy wood blocking or platforms so they are not in contact with the ground. D. Unload pipe, fittings and specials opposite to or as close to the place where they are to be installed as is practical to avoid unnecessary handling. Keep pipe interiors completely free from dirt and foreign matter. E. Store thermoplastic so as to prevent-sagging and bending. F. Store thermoplastic pipe, fittings and specials under cover and not stored in direct sunlight. G. Materials cracked, gouged, chipped, dented or otherwise damaged shall be subject to acceptance. Damaged products that can be repaired shall be done in a manner acceptable to the manufacturer and District. All repairs shall be at the CONTRACTOR’S expense. Any unaccepted damaged products shall be removed and replaced at the CONTRACTORS expense. H. Refer to Section 4-2, Materials Transportation, Handling and Storage. 3.5 NT AND PAYMENT A. Refer to Section 01025, Measurement and Payment. BURIED PIPING INSTALLATION 15051-4 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL PART 7 - f’RODUmS 71 MATE&!,LS A. Piping materials are listed in the Piping Schedule at the end of this Section. B. Refer to applicable Sections for material specifications. OPTIONAL PIPING MATERIALS - SCHFW A. Pipe material for the interceptor sewer under Schedule A shall be an option of either concrete pressure pipe (CPP) or fiberglass mortar pipe (FMP) as an alternate, as listed in the Buried Piping Schedule. A. The Buried Piping Schedule is included with this Section listing service, pipe material, lining, coating, pressure class, joint type, test pressure and minimum cover. PART 3 - FXECUTION 51 INSTAI 1 ATION A. Delivery: 1. All pipe, fittings, structures,. appurtenances and materials shall be subject to inspection and acceptance by the District upon delivery. 2. The District’s inspection will not relieve CONTRACTOR or manufacturer from responsibility for damage to products incurred during transportation. B. General: 1. All pipe, fittings, structures, appurtenances and materials shall be subject to inspection and acceptance by the District prior to installation. 2. The District’s inspection will not relieve CONTRACTOR or manufacturer from responsibility for damage to products incurred during handling and installation. 3. All products shall be carefully examined for damage and defects before installation. Any product that is damaged or defective shall be subject to rejection by the District. Any product found to be unacceptable by the District after it has been installed shall be removed and replaced at the CONTRACTOR’S expense. 4. Install piping as shown, specified and as recommended by the manufacturer and in conformance with referenced standards and approved Shop Drawings. 5. Take field measurements where required prior to construction to ensure proper installation of the Work. BURIED PIPING INSTALLATION 15051-5 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TC VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 6. 7. a. 9. Present all conflicts between pipelines and existing utilities to the District for determination of corrective measures before proceeding as soon as practicable but not more than 7 calendar days. Where unforeseen conditions will not permit the installation of piping as shown or specified, no piping shall be installed without approval of the District. Do not modify structures or facilities without approval of the District. All piping and structures shall be cleaned from all dirt, gravel, sand, debris or other foreign material before installation. Measures shall be taken to maintain the interior of all piping clean until acceptance of the completed Work. Care shall be taken to prevent foreign matter from entering pipe joint. Install piping accurately to line and grade as shown or specified, unless otherwise approved by the District. Accurate means of determining and checking the alignment and grade. shall be used, which shall be subject to the approval of the District. A. Open I. 2. 3. 4. 5. 6. 7. 8. 9. Trench Pipe Laying: Conform to manufacturer’s instructions and requirements of the following standards where applicable: a. Concrete Pressure Pipe: AWWA Manual of Practice M9. b. Ductile Iron Pipe: AWWA C600, AWWA Cl 05. i. Thermoplastic Pipe: ASTM D 2774. ASCE Manual of Practice No. 37. Start laying piping at low point and proceed toward the high point, unless othennrise approved by the District. Slope piping uniformly between elevations shown on the Plans. Place pipes so that the bells face the direction of laying. Install pipes so that the barrels, and not the joints, bear the weight ‘of the pipe. No pipe shall be brought into position until the preceding pipe or fitting has been bedded and secured in place. Place PVC lined concrete pipe with the unlined section located at the invert of the pipeline. When pipe laying is not actively in progress, the open ends of the piping shall be closed by a temporary plug or cap to prevent soil, water and other foreign matter from entering the piping. Field cutting of metallic piping, where required for inserting fittings and closures, shall be made with a machine specially designed for. cutting such pipes, and in accordance with the manufacturer’s instructions. Cuts shall be carefully done, without damage to piping, so as to leave a smooth end at right angles to the axis of the piping. Cut end shall be tapered and sharp edges filed off smooth. Flame cutting shall not be permitted. Piping damaged by the CONTRACTOR by improper or careless methods of cutting shall be replaced or repaired at the CONTRACTORS expense. Blocking under piping will not be permitted unless specifically approved by the District for Supplemental Provisions. BURIED PIPING INSTALLATION 15051-6 VlSTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 10. Temporarily plug new sewers connecting to existing sewers until the District authorizes its use. a. Refer to Section 7-I 5. B. Separation of Sewers and Potable and Fire Waterlines: 1. Comply with the requirements of the San Diego Health Department Guidelines. C. Plugs: I. Temporarily plug installed pipe at the end of each day’s work, or interruption or delay to construction. Plugs shall be adequate to prevent entry of animals, persons, water and deleterious materials. 2. Plugs installed for pressure testing shall be fully secured and blocked to withstand the test pressure. D. Excavation and Backfill: Excavation and backfill shall conform with Section 02220 and as shown on the Plans. E. Pipe Bedding shall conform with Section 02230, Crushed Stone and Gravel, and as shown on the Plans. F. Polyethylene Encasement: 1. Wrap buried ductile iron piping in polyethylene encasement to prevent contact between the pipe and surrounding bedding material and backfill. 2. Polyethylene may be supplied in tubes or in sheet material. 3. Polyethylene encasement materials and installation shall be in accordance with the requirements of AWWA C105. Materials shall be in accordance with Paragraph 4.1.2. of AWWA C105. For tubes, use Method A installation. G. Joining Pipe: I. Reinforced Concrete Pipe: Refer to Section 15064, Part 3. 2. Concrete Pressure Pipe: Refer to Section 15073, Part 3; 3. Ductile Iron Mechanical Joint Fittings: a. Wipe clean the socket, plain end and adjacent areas immediately before making joint. Make certain that cut ends are tapered and sharp edges are filed off smooth. b. Lubricate the plain ends and gasket with soapy water or an approved pipe lubricant, in accordance with AWWA Cl 1 I, just prior to slipping the gasket onto the plain end of the joint assembly. C. Place the gland on the plain end with the lip extension toward the plain end, followed by the gasket with the narrow edge of the gasket toward the plain end. d. Insert the pipe into the socket and press the gasket firmly and evenly into the gasket recess. Keep the joint straight during assembly. e. Push gland toward socket and center it around pipe with the gland lip against the gasket. BURIED PIPING INSTALLATION 15051-7 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 4. f. Insert bolts and hand tighten nuts. 9. Make deflection after joint assembly, if required, but prior to tightening bolts. Alternately tighten bolts 180 degrees apart to seat the gasket evenly. PVC Pipe: a. Gasketed Push-On Joints: 1) Bevel all field-cut pipe, remove all burrs and provide a reference mark the correct distance from the pipe end. 2) Clean the pipe end and the bell thoroughly before making the joint. Insert the O-ring gasket, making certain it is property oriented. Lubricate the spigot well with an approved lubricant; do not lubricate the bell or O-ring. Insert the spigot end of the pipe carefully into the bell until the reference mark on the spigot is flush with the bell. H. Transitions from One Type of Pipe to Another: 1. Provide all necessary couplings when connecting different types and sizes of pipe or connecting pipe made by different manufacturers, or of different material. 2. Refer to Section 15122, Piping Specialties. I. Pipe Closures: 1. Provide pipe closures only where specified in other Division 15 Sections. A. Boring and Jacking: Refer to Section 02340. B. Microtunneling: Refer to Section 02306. 3.4 THRUST RESTRAINT A. Provide thrust restraint on all pressure piping systems where specified and shown on the Plans. 1. For pipelines with restrained joints, refer to the Burled Piping Schedule. B. Thrust restraint shall be accomplished by means of restrained pipe joints as specified. Thrust restraints shall be designed for the axial thrust exerted by the test pressure specified in the Buried Piping Schedule. C. Concrete thrust blocks will not be permitted except where specifically shown on the plans. BURIED PIPING INSTALLATION 15051-8 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL D. Restrained Pipe Joints: Pipe joints shall be restrained by means suitable for the type of pipeline being installed. I. PVC C900 and C905 pipe, with ductile iron mechanical joint fittings and valves utllizing restrained joint retainer glands, refer to Section 15074, PVC Pipe - AWWA C900 and C905. 2. PVC C900 and C905 bell and spigot pipe joints utilizing restraint harnesses, refer to Section 15074, PVC Pipe - AWWA C900 and C905 Pipe. E. Restrained Pipe Joints Locations: Restrained pipe joints shall be located in pipelines as follows: 1. Retainer glands for ductile iron mechanical joint fittings with PVC C900 and C905 piping: Refer to Section 15074, Part 3.1 .B. 2. Restraint harnesses for PVC C900 and C905 pipe joints: Refer to Section 15074, Part 3.1 .C. 3.5 WORK AFFFCTING FXISTING UTII ITIFS A. Refer to Section 5 of the Supplemental Provisions. B. Existing High Pressure Gas Line: An existing IZ-inch high pressure gas transmission line owned by the Southern California Gas Company is located in the railroad right-of-way as shown on the Plans. The pipeline is exposed due to a slope failure at the Agua Hedionda Lagoon. 1. The earthwork for reconstructing the slope failure at the lagoon will restore the exposed pipeline to a buried condition. 2. Prior to completing the bacldlll around the gas line, the Gas Company will remove the sag in the pipeline and repair its coating. 3. Contact the Gas Company’s field representative to coordinate work efforts. 4. Refer to Section 02220, Part 1.4.D. 3.6 SFQl lPNCF OF CONSTRUCTION A. General: The Work will commence at the downstream end of the project within the railroad right-of-way at the Agua Hedionda Lagoon, proceed upstream sequenced in phases, and finish at various upstream termination points as shown on the Plans. 1. The Work includes, but is not limited to, construction of the interceptor sewer and storm drain pipelines, relocation of existing utilities, and demolition and removal of existing sewer and storm drain facilities. 2. Refer to Section 6-2.2, Sequence of Construction. B. Railroad Right-of Way: The general sequence of construction within the railroad right-of-way from Agua Hedionda Lagoon to Oak Avenue shall be sequenced in the following stages: I. Remove the existing 63 and 72-inch RCP storm drain pipeline from Station 5+80 to Station 20+73. BURIED PIPING INSTALLATION 15051-g VISTFGARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 2. 3. 4. 5. 6. 7. a. 9. 10. Relocate the existing 3-inch water line from Station 6+75 to Station 13+40. Waterline shall be constructed, tested and accepted prior to storm drain construction or a temporary high-line installed. Water service shall not be out of service more than 2 hours. Construct the 84-inch storm drain from Station 4+40 to Station 20+74 including the energy dissipator and its appurtenances. Construct the tunnel or jack the 84-inch storm drain under Tamarack Avenue from Station 20+74 to Station 22+16. This construction shall be completed including the 36-inch storm drain between the existing 4’ x 8’ reinforced concrete box culvert and the new storm drain cleanout at Station 20+74. Construct Manhole 1 at Station 6+13. This structure shall be complete including the 54-inch sewer pipe stub-out to the southwest. The stop logs and pipe plug shall be in place and tested. Construct Manhole 2 at Station 6+48 and the 54-inch sewer between Manholes 1 and 2. Construct the 48inch storm drain form Station 6+85 to Station 19+00 with a temporary pipe plug installed in the end of the pipe at Station 19+00. Construct stub-outs and temporary plugs at Manholes 3 and 4 for future connections to Date Street and Chinquapin Avenue Stage 10. Construction for Stages 5 and 6 shall be tested and inspected for acceptance prior to commencing Stage 7. Construct the tunnel or jack pipe under Tamarack Avenue between approximate Stations 21+05 to 22+55. The jacking or tunneling operations may be accomplished concurrently with Stages 5 or 6; however, the tunneling shall be completed prior to beginning Stage 8. Set up temporary bypass pumps and piping from the existing sewer manholes in the vicinity of Station 19+80. Bypass pump from the existing manhole at Station 19+80 to the existing manhole at Station 18+95. Open the outlet in Sewer Manhole 2 to allow future flow to the southwest to flow into the existing 36”-inch sewer. Plug the downstream side to the existing manhole at Station 19+80. The temporary bypass piping will be approximately 85 feet long, laid on the ground within the railroad right-of-way. The peak flow is estimated to be approximately 24 mgd; therefore the temporary pumps will require a combined capacity of approximately 18,000 gpm. It is estimated that six or seven lO-inch trash pumps will be needed during the bypass pumping operations to accommodate peak flow conditions. A failsafe ditch lined with a 8 mil plastic liner shall be constructed along the bypass to facilitate surface flow to existing manhole at Station la+95 and channel this flow to the proposed pipe should pump failure occur. Construct new 48-inch sewer from Station 19+00 to Manhole 5 at Station 20+00 and from Manhole 5 to approximate Station 21+00 to connect to the end of the jacked pipe station. Construct 48inch sewer from Station 22+55 at end of jacked pipe station to Manhole 6, to be constructed in Stage 10. This stage will include removal of a portion of the 36-inch main in the area near Station 19+25. Plug the existing sewer with permanent plugs at both ends. All work of Stages 5 through 9 shall be tested, inspected and accepted before Stage 10. BURIED PIPING INSTALLATtON 15051-10 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 IA AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL Il. 12. 13. 14. 15. Construct Manhole 6 at Station 22+97. The manhole shall be constructed with benches and channel bottom to divert the flow from the existing 36-inch to the new 48-inch sewer. Cut the top off the existing 36-inch sewer and provide a 48-inch inflatable plug per Section 15122-2.1.C on the upstream side of manhole. Final channeling of Manhole 1 shall occur at this point, channelize flow from 48” sewer from Manhole 2 to I through Manhole I to connect to the exist 36” sewer to the south. Block channel from existing 36” sewer to the north as flow is transferred. to the 48” sewer. Connection from Date Avenue to Manhole 3 and Chinguapin Avenue to Manhole 4 shall be established at this time prior to abandonment of the exist 36” sewer. Plug 36-inch pipe on downstream side of manhole. At this point the flow in the existing 36-inch sewer will be diverted into the new 48inch interceptor. The bypass pumps can now be removed. Major portions of the proposed pipeline north of Manhole 6 shall be constructed concurrently with Stages 5 through 10. Final connections at Manhole 8 at Station 33+60; Manhole 10 at Station 44+26; and Manhole II at Station 49+01 shall be delayed until the completion of the pipelines and Manhole 6. The end of the pipeline at Station 58+72 connects to Manhole 12 as shown on the Plans. This work shall be inspected, tested, and accepted prior to Stage 8. The 1 5-inch PVC sewer at Walnut Avenue also shall be jacked from Manhole 11 to the existing manhole on the west side of the SDNR railroad tracks adjacent to Walnut Avenue. The final connection of Walnut Avenue shall be delayed until flows from the existing northerly 36inch sewer have been directed through the upstream connection at Oak Avenue. At Manhole 6 remove 4&inch inflatable plug, shape channel bottom for through flow before making final connections north of the manhole. Make final connection at Manhole 8, the Village Connection. The existing 8” VCP sewer from Manhole 8 to the west, connecting to the existing IO” VCP sewer along the west side of the SDNR right-of-way shall be plugged and abandoned in place. Make final connection to Manhole 12 at Station 58+72 and accept flows from the new pipeline concurrently being constructed in Oak Avenue. Make final connection in Walnut Avenue at Manhole 11 and Chestnut Avenue proceed with pipeline and the final connection at Manhole IO as outlined in Stage 14. Construct Manhole 1 I as shown on the Plans. Jack and bore 15 inch PVC sewer with casing pipe under SDNR tracks. The receiving pit shall not interfere within the operation of the existing 36” interceptor sewer, east of Walnut Street. Complete construction testing and acceptance of all downstream interceptor sewer. Make final connection of sewer laterals at Manhole II and plug existing interceptor sewer as indicated on the plans. Construct Manhole IO as shown on the Plans. Construct IZ-inch PVC sewer between Manhole 10 and Manhole IOA after the completion of the RCB storm drain section of the intersection of Chestnut Avenue and the SDNR right-of-way. The storm drain south of Manhole IO shall be constructed to the connection to the end of the jacked pipe section at . BURIED PlPtNG INSTALLATION 15051-l 1 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAlN PROJECTS MECHANICAL 16. Station 22+16. The storm drain construction north of Manhole 10 to the connection to the SDCO at Oak Avenue at Station 58+42.33 as shown on the Plans shall also be competed prior to installation of the 12-inch PVS sewer between Manhole 10 and Manhole 1OA. Storm drain construction may proceed concurrently within sewer construction between Tamarack Avenue and Oak Avenue in the SDNR right-of-way, the CONTRACTOR may opt to install both pipes in a common trench. The flow from 8” PVC sewer to the south, which discharges into the existing sewer manhole at the location of Manhole lOA, shall be temporarily bypassed and discharged into Manhole 10 until the construction of Manhole 1OA is complete and the existing 8” PVC sewer has been connected to Manhole 1OA. The existing 8” VCP sewer from Manhole 10A to the west shall be plugged and abandoned within the SDNR right-of-way. Plug all cut existing sewers and fill existing manholes where appropriate. Set manhole cover rims to proper elevations. 3.7 SFWFR FI OW TRANSFFqS A. Refer to Section 7-15 of the Supplemental Provisions: B. Order of Sewer Flow Transfers: Sewer flows shall be transferred from the existing sewer to the new interceptor sewer, as shown on the Plans, through a series of transfer sequences. The following is a suggested outline for the order of sewer flow transfers for Schedule A, and is offered for consideration only. The transfers are located at the following connections to the existing and new sewers: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Downstream Connection: Connect new sewer at Manhole 1. Railroad Right-of-Way: Connect existing sewer to Manhole 3. Railroad Right-of-Way: Connect existing sewer to Manhole 4. Chestnut Avenue: connect new collector sewer to Manhole 10. Walnut Street: Connect existing sewer railroad crossing extension to Manhole 11. Tyler Street: Connect existing sewer to Manhole 2A. Roosevelt Street: Connect existing sewer to Manhole 3A. Madison street: Connect existing sewer to Manhole 5A. Grand Avenue: Connect existing sewer to Manhole 15 Access Hole 53: Transfer flow within the manhole. a. Note: Access Hole 53, an existing manhole is located approximately 300 feet north of Las Flores Drive in Jefferson Street. Laguna Drive: Connect existing sewers to Manhole 17. Grand Avenue and Roosevelt Street: Modifications to 4 existing manholes in Grand Avenue at Roosevelt Street and the alley. BURIED PIPING INSTALLATION 15051-12 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL A. General: The CONTRACTOR shall be responsible for assuring that all sewers and laterals shall remain in continuous and full operation throughout the duration of the contract. 1. Prior to commencement of work, submit for approval a detailed plan showing and describing the methods of bypassing sewage, types and sizes of pipes and hoses, types of connections, types of plugs, type and sizes of pumps, type of generator that will power the pumps, and engineering specifications of pumps to be used during bypass operations. a. When pumping is required to maintain sewage flows through bypass operations, provide a complete set of stand-by pumps and generator at the job site. B. Maintaining Sewage Flows and Sewage Bypass: Provide all piping, pumps generators, ptugs, stand-by equipment and appurtenances required to remove and bypass sewage from the existing sewer systems, and legally dispose the sewage into the downstream sewage system. Bypassing sewage to surface water and drainage course, and within pipe trenches is prohibited. 1. Temporary connections are required to maintain lateral flows. Pumping will be allowed only during working hours. At the end of the work day restore sewage flows by placing temporary gravity piping 2. between the new sewer and the existing sewer. The CONTRACTOR shall be responsible for notifying property owners, residents and businesses a minimum 48 hours notice’ regarding the usage of facilities during temporary disconnection of their laterals. C. Sewage Flows: Sewage flows range from 2 to 24 mgd in the interceptor sewer. D. Details of Sewer Transfer Sequences: The following are detailed step-by- step methods of conducting the sewer transfer sequences at each location listed in Parts 3.6 and 3.7 of this Section. 1. The CONTRACTOR may submit alternate methods of providing temporary bypasses for conducting the sewer transfer sequences. E. Downstream Connection Sewer Transfer Sequence at Manholes 1 and 2: See Part 3.6.8 of this Section. F. Railroad Right-of-Way Sewer Transfer Sequence at Manhole 3: See Part 3.6.B of this Section. G. Railroad Right-of-Way Sewer Transfer Sequence at Manhole 4: See Part 3.6.8 of this Section. H. Chestnut Avenue Sewer Transfer Sequence: See Part 3.6.B of this Section. I. Walnut Street Sewer Transfer Sequence: See Part 3.6-B of this Section. BURIED PIPING INSTALLATION 15051-13 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL J. Tyler Street Sewer Transfer Sequence: See Part 3.6.8 of this Section. K. Roosevelt Street Sewer Transfer Sequence: See Part 3.6.8 of this Section. L. Madison Street Sewer Transfer Sequence: See Part 3.6.6 of this Section. M. Grand Avenue Sewer Transfer Sequence: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. During a low flow period, provide sandbags in Manhole C to collect sewage flow from the three collectors, but does not drain out through the its 10” outlet. Provide a temporary high-line and pump sewage from Manhole C to Manhole A. Remove the existing 10” sewer piping between Manhole C and Manhole A and provide a permanent plug in the existing 10” inlet in Manhole A and existing 10” outlet in Manhole C. Temporarily plug the outlet of the nearest upstream manhole south of Manhole C and pump sewage into a tanker truck. Complete the new 12” collector sewer pipeline from Manhole C to Manhole 15 including the Accesshole. Remove the temporary high-line between Manholes A and C, and remove sandbags from Manhole C. During a low flow period, temporarily plug the outlets of the nearest upstream manholes and pump sewage into tanker trucks to stop flows into Manhole C. Demolish and remove the channel in Manhole C. Provide a temporary flow-through, 3-way bypass plug to pick up the two inlets and discharge through the outlet in Manhole C. Remove the plugs in upstream manholes and cease pumping to trucks. Construct the new channel in Manhole C. The new 12” collector sewer pipeline from Manhole C to Manhole i 5 ison line and in service. N. Access Hole 53 Sewer Transfer Sequence: 1. Remove stop logs from the new 36” outlet. 2. Install stop logs over the existing 24” outlet. 3. The new interceptor sewer is on line and in service over its entire length. 0. Laguna Drive Sewer Transfer Sequence: The sewer force main has a flow rate of 1.4 mgd. 1. Provide a permanent plug in the 30” outlet in Manhole B. 2. Provide a temporary high-line and pump sewage from Manhole B to Manhole 17. 3. Complete the new 12” collector sewer pipeline from Manhole D to Manhole 17 including Accesshole. BURIED PIPING INSTALLATION 15051-14 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. During a low flow period, the Home Plant Pump Station will be shut down by the District to stop flow in the 10” sewer force main and allow connection to it. Sawcut and remove a portion of the existing 10” sewer force main and connect the new sewer force main to complete the pipeline to Manhole 17. The Home Plant Pump Station can only be shut down for approximately 40 minutes during low flow periods. During a low flow period, temporarily plug the outlets of the nearest upstream manholes and pump sewage into tanker trucks to stop flows into Manho1e.D. Remove the temporary high-line between Manholes B and 17. Demolish and remove the channel in Manhole D. Provide a temporary flow-through, 3-way bypass plug to pick up the two inlets and discharge through the outlet in Manhole D. Remove plugs in upstream manholes and cease pumping to trucks. Provide two permanent plugs, one at each end of the 10” pipe between Manholes B and D. Construct new channel in Manhole 0. Remove the 3-way bypass in Manhole D and provide temporary plugs in the two 8” inlets and a permanent plug in the 10” outlet in Manhole D. The new 12” collector sewer from Manhole D to Manhole 17 and the sewer force main to Manhole 17 are on line and in service. P. CL Grand Avenue and Roosevelt Street: 1. During a low flow period, temporarily plug the outlets of the nearest upstream manholes from Manholes J and K, and pump sewage into a tanker truck. 2. Demolish and remove the channels in Manholes J and K. 3. Construct new channels in Manholes J and K. 4. Provide two permanent plugs, one at each pipe end of the 10” pipe between Manholes G and J. 5. Remove plugs in upstream manholes and cease pumping to trucks. 6. Manhole J is in service and Manhole K is partially in service. 7. During a low flow period, temporarily plug the outlet of the nearest upstream manhole from Manhole H in the alley in the 8” collector sewer, and pump sewage into a tanker truck. 8. Demolish and remove Manhole H. 9. Connect permanent sewer piping between existing 8” collector sewer pipe and Manhole K, 10. Remove plug in upstream manhole and cease pumping to truck. 11. Manhole K is now fully in service. Refer to Section 7-l 5 for connection to existing sewer systems. BURIED PIPING INSTALLATION 15051-15 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 ?A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 3.9 +IFr r) TFSTING A. Pipeline Water Test: Conduct water pressure tests on the following completed pipelines: 1. Allowable Leakage Rates (gallons per hour per 1,000 feet per inch diameter): a. PVC AWWA C900: 0.0. b. PVC SDR 35: 0.0. C. Reinforced Concrete Pipe: 1 .O. B. For testing concrete pressure pipelines, refer to Section 15073, Part 3. C. For testing fiberglass mortar pipelines, refer to Section 15075, Part 3. D. Prior to conducting tests, submit details of testing procedures with a description of methods and equipment proposed to be used for approval. E. Test Pressure: Refer to Buried Piping Schedule in this Section. 3.10 DI.SPOSAI OF WATFR A. Provide suitable means for disposal of test water so that no damage results to private and public property and waterways. B. Means of disposal of test water shall be subject to the approval of the District, local governing authorities and regulatory agencies. C. All test water shall be disposed to the storm drain. D. CONTRACTOR shall be responsible for any damage caused by water disposal operations. 3.11 ARAtQONMENT OF EXISTING INTERCFPTOR SEWER PlPELlNES A. Upon complete installation of the new interceptor sewer and the successful transfer of all sewage flows out of the existing interceptor, the existing interceptor sewer shall be abandoned in place. 8. The existing interceptor sewer shall be abandoned from the connection point of the new interceptor at approximately station 43+00 to the flow diversion structure (Access Hole 53) at the north end of the project. The pipe ranges in size from 27- to 36-inches in diameter. C. The existing interceptor sewer shall be pressure washed and adequately cleaned of debris and sediment so that it can be inspected by CClV equipment. D. The existing interceptor sewer shall be inspected by CCTV per the requirements of Section 500-l .1.5 of the SSPWC to document the condition of the pipeline. BURIED PIPING INSTALLATION 15051-16 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC58 TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL E. The CONTRACTOR shall submit a plan describing the equipment and methods to be used for cleaning and inspecting the pipeline. F. Manhole abandonment shall be performed in accordance with Section 02606, Manholes and Drainage Structures. 512 PIPING SCHEDUI F The following abbreviations are used in the piping schedule: A. Material Abbreviations Fiberglass Mortar Pipe Ductile Iron Polyvinyl Chloride Concrete Pressure Pipe Reinforced Concrete Pipe B. Interior Linings/Exterior Coatings Abbreviations Asphaltic Coated Cement Mortar Lined Plastic Lined (PVC) Polyethylene or Polyurethane C. Schedule or Pressure Class Abbreviations Pressure Class Pressure Rating Standard Dimension Ratio D. Joint Abbreviations Bell and Spigot Mechanical Joint E. [x] Refer to notes following Buried Piping Schedule. FMP DI PVC CPP RCP AC CML PVC PE PC PR SDR B&S - ., MJ BURIED PIPING INSTALLATION 15051-17 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN MECHANICAL SECTION 15061 DUCTILE-IRON FITTINGS PART 1 - GFNERql 1.1 DFSCRIPTION A. Scope: 1. Perform the work as shown, specified and required to furnish and all ductile-iron fittings in place, for complete and operable pipelines ready for intended use, required to complete the Work. 2. The extent of piping is shown on the Plans and in the schedule included in Section 15051, Buried Piping Installation. B. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2. C. Related Sections: 1. Section 2-5.2, Precedence of Contract Documents. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 4-2, Materials Transportation, Handling and Storage. 4. Section 01025, Measurement and Payment. 5. Section 02220, Excavation and Backfill. 6. Section 15051, Buried Piping Installation. 7. Section 15074, PVC Pipe - C900 and C905. A. Manufacturer’s Qualifications: Manufacturer shall have a minimum of 5 years of experience producing ductile iron fittings. 1. Submit evidence of experience and production of fitting manufacture. B. Ductile iron fittings shall each be the product of one manufacturer. C. Reference Standards: Comply with applicable provisions and recommendations of the following unless otherwise shown or specified. 1. AWWA C104, Cement-Mortar Lining for Ductile-Iron Pipe and Fittings for Water. 2. AWWA C105, Polyethylene Encasement for Ductile-Iron Piping for Water and Other Liquids. 3. AWWA Cl 10, Ductile-Iron and Gray-Iron Fittings, 3 in. through 48 in., for Water and Other Liquids. 4. AWWA Cl 11, Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings. DUCTILE-IRON FllTlNGS 15061-i VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN MECHANICAL 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. AWWA Cl50, American National Standard for the Thickness Design of Ductile-Iron Pipe. AWWA C151, Ductile-Iron Pipe, Centrifugally Cast, for Water or Other Liquids. AWWA C153, Ductile-Iron Compact Fittings, 3 in. through 24 inches and 54 inches through 64 inches for Water Service. AWWA C600, Installation of Ductile-Iron Water Mains and Their Appurtenances. ANSI B16.1, Cast Iron Pipe Flanges and Flanged Fittings. ANSI 818.2.1, Square and Hex Bolts and Screws Inch Series, Including Hex Cap Screws and Lag Screws. ANSI B18.2.2, Square and Hex Nuts. ASTM A 307, Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength. ASTM A 354, Specification for Quenched and Tempered Alloy Steel Bolts, Studs and Other Externally Threaded Fasteners. ASTM A 746, Standard Specifications for Ductile Iron Gravity Sewer Pipe. D. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. 1.3 SUBMIT-I-AI S A. Submit the following in accordance with Section 2-5.3. B. Shop Drawings: 1. Detailed drawings and data on fittings, joints, gaskets, coatings, linings, and polyethylene encasement. 2. Restrained joint retainer glads for mechanical joint fittings shall be submitted under Section 15074. a. Refer to Section 15074, PVC Pipe - AWWA C900 and C905. C. Certificates: Submit certificates of compliance with referenced standards. D. Manufacturer’s Qualifications: In accordance with Paragraph 1.2.A of this Section. E. Instructions: Manufacturets instructions for installation of fittings. 1.4 A. Refer to Section 15051. B. Handle all fittings and appurtenances carefully with proper handling devices: web slings, padded slings and clean, padded forks. C. Store fittings and appurtenances on heavy wood block or platforms so they are not in contact with the ground. DUCTILE-IRON FllTlNGS 15061-2 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN MECHANICAL D. Materials cracked, gouged, chipped, dented or otherwise damaged will not be accepted. Minor defects in the pipe or coatings may be repaired at the site by a method approved by the manufacturer and the ENGINEER. Damaged pipe, fittings and appurtenances shall be repaired or replaced at CONTRACTOR’s expense. E. Refer to Section 4-2, Materials Transportation, Handling and Storage. 1.5 MFASURFMFNT AND PAYMFM A. Refer to Section 01025, Measurement and Payment. PART 2 PRODUCTS - 71 MATE- A. Mechanical Joint Fiings: Mechanical joint fittings shall be used with PVC AWVVA C900 and C905 pipe as specified in the Buried Piping Schedule and shown on the Plans. Fittings shall conform to AWWA Cl 10. 1. Material: Ductile iron. 2. Maximum Working Pressure: 350 psi. 3. Joints: Joints shall conform to AWWA Cl 11. 4. Glands: Ductile iron. 5. Gaskets: Vulcanized styrene butadiene rubber (SBR). 6. Bolts, Studs and Nuts: 316 SS tee-head bolts and hexagon nuts. 7. Restrained Joints: Fittings shall have restrained joints with retainer glands for cast-iron-pipe-equivalent outside diameters which conform toAWWACll1. a. Refer to Section 15074, PVC Pipe - C900 and C905. 8. Wyes: Welded-on lateral outlets shall not be permitted in place of w=. 9. Manticturer: Provide one of the following for mechanical joint fittings: a. American Cast Iron Pipe Company. b. U.S. Pipe and Foundry Company. C. Or equal. B. Coatings: 1. Ductile iron fittings shall be exterior coated with 1 mil asphaltic coating in accordance with AWWA Cl 51. DUCTILE-IRON FITTINGS 15061-3 C. VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN MECHANICAL Linings: Ductile iron fittings shall be interior lined by the manufacturer with one of the following linings: 1. Polyethylene lining shall be as follows: a. Materials: The lining material for fittings shall be virgin polyethylene complying with ASTM D 1248, compounded with an inert filler and with sufficient carbon black to resist ultraviolet rays during aboveground storage of the fittings. The polyethylene shall be bonded to the interior of the fitting by heat. b. Surface Preparation: All surface areas to be lined shall be blast cleaned comparable to the requirements of SSPC-SP6. C. Applications: Polyethyiene linings shall cover all inner surface of fittings. In mechanical joints the lining shall cover the interior surfaces including the socket areas as defined above. d. Lining Thickness: Lining in fittings shall be 40 mils nominal thickness. Minimum lining thickness shall be 30 mils. e. Holiday Test: Holiday inspection shall be conducted using a 2000 volt spark test. Holiday testing shall be conducted after the lining has reached sufficient cure. f. Repair and Field Touchup: Repairs and touchup shall be performed in accordance with the manufacturer’s recommended repair and touchup procedures. 9. Product and Manufacturer: Polybond Lining, American Cast Iron Pipe Company. 2. Polyurethane lining shall be as follows: a. Materials: The lining material for fittings shall consist of a polyisocyanate resin and polyol resin which are mixed in a 1 to 1 ratio at the time of application complying with ASTM D ‘I’6 Type V system. b. Surface Preparation: All surface areas to be lined shall be blast cleaned comparable to the requirements of SSPC- SPl 0. C. Applications: Polyurethane linings shall cover all inner surface of fmings. In mechanical joints the lining shall cover the interior surfaces including the socket areas as defined above. d. Lining Thickness: Lining in fittings shall ba 40 mils nominal thickness. Minimum lining thickness shall be 30 mils. e. Holiday Test: Holiday inspection shall be conducted using a 2000 volt spark test. Holiday testing shall be conducted after the lining has reached sufficient cure. f. Repair and Field Touchup: Repairs and touchup shall be performed in accordance with the manufacturers recommended repair and touchup procedures. 9. Product and Manufacturer: Polythane Lining, U.S. Pipe and Foundry Company. DUCTILE-IRON FllTlNGS 15061-4 D. VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN MECHANICAL Polyethylene Encasement: 1. All buried ductile iron fittings shall be wrapped in polyethylene encasement to prevent contact between the fitting and surrounding bedding material and backfill. 2. Polyethylene encasement materials and installation shall be in accordance with the requirements of AWWA C105. Materials shall be in accordance with Paragraph 4.1.2 of AWWA C105. Tube installation shall be per Method C of AWWA C105. E. Restrained Joint Retainer Glands: Refer to Section 15074, Part 2.1 .C. 72 IDFNTIFICATION A. All flings shall be marked in accordance with the following: 7. Mechanical Joint Fittings: AVVWA C153. A. Refer to Section 15051, Buried Piping Installation. A. Refer toSection 15051, Buried Piping Installation. + + END OF SECTION + + DUCTILE-IRON FllTlNGS 15061-5 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL SECTION 15064 REINFORCED CONCRETE PIPE PART 1 - GENERA1 1.1 DESCRIPTION A. scope: 1. Perform the work as shown, specified and required to provide all reinforced concrete piping in place, for complete and operable pipelines ready for intended use, required to complete the Work. 2. The extent of piping is shown on the Plans and in the schedule included in Section 15051, Buried Piping Installation. B. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. C. Related Sections: 1. Section 2-5.3, Shop Drawings and Submittals. 2. Section 4-2, Materials, Transportation, Handling and Storage. 3. Section 01025, Measurement and Payment. 4. Section 02220, Excavation and Backfill. 5. section 02230, Crushed Stone and Gravel. 6. Section 02300, Tunneling Operations. 7. Section 02330, Pipe Jacking. 8. Section 02340, Boring and Jacking (Steel Casing). 9. Section 15051, Buried Piping Installation. A. Manufacturer’s Qualifications: 1. Manufacturer shall have a minimum of 5 years of experience producing reinforced concrete pipe and have produced a minimum 20,000 feet of reinforced concrete pipe ranging in sizes from 18 to 84-inches in diameter. a. Submit evidence of experience and production of pipe manufacture. B. Reinforced concrete pipe shall be the product of one manufacturer. C. Design Responsibility: The design and layout of pipe shall meet the service conditions and the criteria specified in this Section and as shown on the Plans and are the responsibility of the CONTRACTOR. This design shall be performed by or under the supervision of a Professional Engineer licensed by the State of California. REINFORCED CONCRETE PIPE 15064-l VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 1. Allowable Jacking Capacity: Jacking pipe shall be manufactured to provide an allowable jacking capacity capable of withstanding the maximum jacking forces imposed by jacking operations. a. The allowable jacking capacity of the pipe shall be 3.0 times greater than the maximum jacking forces imposed on the pipe by jacking operations as identified by theoretical calculations. D. Marking for Identification: Pipe shall be marked in accordance to ASTM C 76. E. Reference Standards: Comply with applicable provisions and recommendations of the following, except as otherwise shown or specified. 1. ASTM A 82, Specification for Cold-Drawn Steel Wire for Concrete Reinforcement. 2. ASTM A 615, Specification for Deformed and Plain Billet Steel Bars for Concrete Reinforcement. 3. ASTM A 185, Specification for Welded Steel Wire Fabric for Concrete Reinforcement. 4. ASTM C 14, Specification for Concrete Sewer, Storm Drain and Culvert Pipe. 5. ASTM C 33, Specification for Concrete Aggregates. 6. ASTM C 76, Standard Specification for Reinforced Concrete Culvert, Storm Drain and Sewer Pipe. 7. ASTM C 150, Specification for Portland Cement. 8. ASTM C 655, Specification for Reinforced Concrete D-Load Culvert, Storm Drain and Sewer Pipe. 9. ASTM c 497M, Absorption Test. 10. ASCE Manuals and Reports on Engineering Practice No. 37, WPCF Manual of Practice No. 9. F. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. 1.3 SUBMITTALS A. Submit the following in accordance with Section 2-5.3. B. Shop Drawings: 1. Fabrication Drawings: Manufacturer’s drawings shall include the following details: a. Details of the pipe including wall thickness, bells and pipe joints. b. Reinforcement details including circular or elliptical reinforcement, location of the cages in the pipe wall, size and spacing of circumferential and longitudinal reinforcing steel, reinforcement for joints, and the cross-sectional area of reinforcing steel in each cage per lineal foot of pipe. :: Dimensions of pipe. Pipe D-loads: As shown on the Plans. e. Revised Pipe D-loads: In accordance to Part 1.4.A.4. REINFORCED CONCRETE PIPE 15064-2 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 2. Layout Schedule: A tabulated layout schedule for each reach of pipeline. C. Certificates: Submit certificates of compliance with referenced standards. D. Manufacturer’s Qualifications: In accordance with Paragraph 1.2.A of this Section. E. Instructions: Manufacturer’s instructions for installation of pipe. 1.4 SFRVICF, CONDITIONS A. Design Parameters: 1. Classification of Construction Condition: Singie trench, see Item 4 below. 2. Fill Height: As shown on the Plans. 3. Test Pressures: Refer to Section 15051, Buried Piping Installation. 4. The CONTRACTOR may elect to construct storm drain pipelines in a wmmon trench with sewer pipelines, which may place the loading on the pipe in another classification on construction conditions, such as negative projecting or positive projecting, as depicted in Fig. 43 in reference standard listed under Part 1.2.E.10. a. Under this option, submit calculations substantiating the D- loads selected for the storm drain piping based on the revised classification of construction condition. b. Under this option, submit manufacturer’s certifications in accordance with Part 1.3.C. B. External Loads for Buried Pipelines. Minimum external loads imposed on pipelines include earth load plus live load. 1. Earth Load: 130 lb&u. ft. 2. Ku’ = 0.165. 3. Piping shall be designed for an external loading, including impact, for the following conditions: a. Under roadways: AASHTO H20 truck loading with earth wver. b. Under Railroads and Within Railroad Right-of-Way: Cooper E80 live loading with earth cover. C. Service Lines: Refer to piping schedule in Section 15051, Buried Piping Installation. A. Refer to Section 4-2, Materials Transportation, Handling and Storage. 1.6 MFASURFMENT AND PAYMFNT A. Refer to Section 01025, Measurement and Payment. REINFORCED CONCRETE PIPE 15064-3 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL PART 2 PRODUCTS - 71 PIPF A. Reinforced concrete pipe shall conform to ASTM C 76: . 1. Pipe shall be minimum Class Ill. a. Wall thickness shall be determined by D-load. 2. Minimum D-loads: 1350 Ib/LF/inch diameter. 3. Joints: Concrete joint, gasketed. a. Interior Pipe joints shall be grouted with mortar. 4. Pipe shall w be manufactured with an interior polyvinyl chloride (PVC) liner. B. Pipe Materials: 1. Cement: Cement shall conform to ASTM C 150. a. Concrete strength for jacking and tunneling pipe: 5000 psi at 28 days. b. Concrete strength for open trench pipe: 4500 psi at 28 days. 2. Aggregates: Fine and warse aggregates shall conform to ASTM c 33. 3. Steel wire bar reitiforcement, ASTM A 82 or ASTM A 496. 4. Steel wire fabric reinforcement. ASTM A 185 or ASTM A 997. C. Jacking Pipe: Conform to minimum requirements as follows: 1. Grout Fittings and Plugs: Grout fittings and plugs shall be installed at an &foot maximum spacing in the crown of the pipe and shall meet the requirements of ASTM A 53, Type E or S, Grade B. a. Plugs shall be recessed to maintain a smooth interior pipe surface. 2. Pipe Tolerances: Pipe shall be manufactured with fabrication tolerances conforming to industry standards such that pipe jacking shall not be hindered during installation and the limit of allowable overcut is not exceeded. a. Pipe tolerances include, but not limited to, wall thickness, pipe roundness, length of two opposite sides, and end squareness. 3. Joints: Joints shall be configured to accommodate 3/4-inch thick plywood jacking strips. a. Pipe spigots shall be 0.125 inch shorter than pipe bells to eliminate forces on the spigots. b. Refer to Paragraph 3.2.A of this Section. D. Manufacturer: Provide one of the following: 1. Ameron International Concrete and Steel Pipe Group. 2. CSR Hydra Conduit Corporation. 3. Or equal. REINFORCED CONCRETE PIPE 15064-4 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL PIPF Cl OSUR& A. Storm drain piping shall not have pipe closures. 23 MARKING FOR lDFNTIFICATION A. All pipeline materials shall be marked in accordance with ASTM C76. PART 3 W=CUTloN s 3.1 INSTaLl ATION A. General: 1. Install piping as shown, specified and as recommended by the manufacturer. 2. If there is a conflict between manufacturers recommendations and the Contract Documents, request instructions from District before proceeding. 3. All trench excavations shall be inspected prior to laying pipe. Notify the ENGINEER in advance of excavating, bedding and pipe laying operations. 4. For trench excavation and backfill refer to Section 02220. B. Plugs: 1. Temporarily plug installed pipe at the end of each day’s work and other interruptions to the installation of pipelines. Plugging shall prevent the entry of animals, liquids or persons into the pipe or the entrance or insertion of foreign materials. 2. Where plugging is required for phasing of the Work and for subsequent connection of piping, install temporary type plugs. C. Bedding Pipe: Bed pipe as shown and specified, 1. Trench excavation and backfill, and bedding materials shall conform to the requirements of Section 02220, Excavation and Backfill; and Section 02230, Crushed Stone and Gravel, as applicable. 2. Excavate trenches below the pipe bottom by an amount shown and specified. Remove all loose and unsuitable material from the trench bottom. 3. Carefully and thoroughly compact all pipe bedding with hand held mechanical or pneumatic compactors. 4. Do not lay pipe until the ENGINEER approves the bedding condition. If a conflict exists, obtain clarification from the ENGINEER before proceeding. 5. No pipe shall be brought into position until the preceding length has been bedded and secured in its final position. REINFORCED CONCRETE PIPE 15064-5 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 0. Laying Pipe: 1. 2. 3. 4. 5. 6. 7. 0. 9. 10. Confomr to manufacturer’s instructions and to ASCE Manual of Practice No. 37. Install all pipe to line and grade shown unless othennrise approved by the ENGINEER. Remove and relay pipes that are not laid correctly. Slope pipe uniformty between elevations shown. Start laying pipe at lowest point and proceed towards the higher elevations, unless otherwise approved by the ENGINEER. Place bell and spigot pipe so that bells face the direction of laying. Deflections at joints shall not exceed 75 percent of the amount allowed by the pipe manufacturer. Carefully examine all pipe, fittings and specials for cracks, damage and other defects installation. Immediately remove defective materials from site. Inspect interior of all pipe and fittings and completely clean all dirt, gravel, sand, debris or other foreign material from pipe interior and joint recesses before it is moved into the trench. Bell and spigot mating surfaces shall be thoroughly wire brushed, and wiped clean and dry immediately before the pipe is laid. Blocking under piping will not be permitted. Notify the ENGINEER in advance of backfilling operations. E. Jointing Pipe: Pipe shall be jointed in accordance with the requirements of SSPWC Section 306-1.2.4(b), except that no jetting or flooding of the bedding material will be allowed. F. Refer to’section 15051, Buried Piping Installation. 37 JACKING PIPF A. Pipe Joints: Pipe joints for jacking pipe shall be fitted with 3&inch thick plywood jacking strips covering the full circumference of the pipe. 1. Interior pipe joints shall be grouted. 3.3 FACTORY INSPECTION AND TESTING A. Inspection and testing at the manufacturer’s plant shall bein accordance with ASTM C 76. A. Refer to Section 15051, Buried Piping Installation. REINFORCED CONCRETE PIPE 15064-6 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 3.5 CONNF CTIONS TO FXISW PIPFS A. Connections to existing pipes within the SDNR and street right-of-ways shall be accomplished by use of either a concrete pipe collar per CSSD OS-5 or concrete lug per CSSD DS-7 or SDRSD D-63 as shown on the Plans. Existing CMP shall be cut off at a point where the pipe is not corroded and structurally sound, and a new pipe section shall be installed to the point of connection with the new RCP. + + END OF SECTION + + REINFORCED CONCRETE PIPE 15064-7 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC56 TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL SECTION 15073 CONCRETE PRESSURE PIPE PART I- GFNF& A. Scope: 1. Perform the work as shown, specified and required to provide all concrete pressure piping in place, for complete and operable pipelines ready for intended use, required to complete the Work. 2. The extent of piping is shown on the Plans and in the schedule included in Section 15051, Buried Piping Installation. 3. This section identities the requirements for reinforced concrete pressure pipe, noncylinder type, to be installed by open trench and trenchless methods of construction. B. Reference Specifications: Compty with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otheMilse shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. C. Related Sections: 1. Section 2-5.2, Precedence of Contract Documents. 2. Section 4-2, Materials, Transportation, Handling and Storage. 3. Section 01025, Measurement and Payment. 4. Section 02220, Excavation and Backfill. 5. Section 02223, Trench Excavation. 6. Section 02230, Crushed Stone and Gravel. 7. Section 02300 Tunneling Operations. a. Section 02306, Microtunneling. 9. Section 02330, Pipe Jacking. 10. Section 02350, Installation of Pipe in Tunnel. 11. Section 02340, Boring and Jacking (Steel Casing). 12. Section 06651, Polyvinyl Chloride Liner for Concrete. 13. Section 15051, Buried Piping Installation. 14. Section 15122, Piping Specialties. A. Manufacturer’s Qualifications: 1. The piping specified in this Section shall be manufactured by a single manufacturer that has supplied at least three miles of similar size and type of this pipe, fittings and appurtenances in the last five years. ’ 2. Concrete pressure pipe and fittings shall be the product of one manufacturer. B. Concrete pressure pipe shall be the product of one manufacturer. CONCRETE PRESSURE PIPE 15073-l VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC58 TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL C. Design Responsibility: The design and layout of pipe shall meet the service conditions and the criteria specified in this Section and as shown on the Plans are the responsibility of the CONTRACTOR. This design shall be performed by or under the supervision of a Professional Engineer licensed by the State of California. 1. Allowable Jacking Capacity: Jacking pipe shall be manufactured with an allowable jacking capacity capable of withstanding the maximum jacking forces imposed by jacking operations. a. The allowable safe jacking capacity of the pipe shall be 3.0 times greater than. the maximum jacking forces imposed on the pipe by jacking operations as identified by theoretical calculations. b. Refer to Part 1.4 of this Section. D. Marking for Identification: Pipe shall be marked in accordance AWWA C302. E. Reference Standards: Comply with applicable provisions and recommendations of the following except as otherwise shown or specified. 1. ACPA Concrete Pipe Design Manual. 2. ACPA Concrete Pipe Handbook. 3. AWWA C302, Reinforced Concrete Pressure Pipe, Non-cylinder Type. 4. ASTM C 1103, Standard Practice for Joint Acceptance Testing of Installed Precast Concrete Pipe Sewer Lines. 5. AWWA M9, Concrete Pressure Pipe. F. Quality Assurance Inspection and Testing: 1. General: Manufacturer shall have a permanent quality control department and laboratory facilities capable of performing the inspections and testing required by the Contract Documents. All material testing, inspection procedures and process of manufacture shall be subject to inspection by the District. 2. Manufacturer shall perform all tests and inspections -requited by AWWA C302. G. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. 1.3 SUBMIT-r&S A. Submit the following in accordance with Section 2-5.3. B. Shop Drawings: 1. Specifications, and product data sheets as necessary to fully describe all materials, components, and finished products and to show conformance with the Contract Documents. Calculations are for record purposes only. CONCRETE PRESSURE PIPE 15073-2 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 2. Include the following information: a. Detailed drawings showing dimensions of pipes including inside diameter and wall thicknesses. b. Pipe classes. C. Details of pipe joints and gaskets including plywood jacking strips. d. Circular or elliptical pipe reinforcement. F‘ Coverage of PVC pipe liner. Pipe Closure Details. C. Marking Schedule: Marks to be used on the finished products to identify pipes, specials, and accessories shown on shop drawings and laying schedules. D. Laying Schedules: 1. Tabulated schedules designating each pipe, special, and accessory item necessary to complete the Work in sequence of installation. Coordinate identification of each piece with shop drawings, product data, and marking schedule. a. Each piece shall be identified to show its proper location within its pipeline by reference to the Laying Schedules and Shop Drawings. 2. Include the following information: t : Quantities and laying lengths of each piece. Invert stations with respect to the Project baseline. C. Invert grade with respect to horizontal between each change of grade. d. Invert elevations referenced to Project vertical datum at each change in horizontal geometry and vertical grade. e. Joint opening dimensions other than zero (0) for each joint, to nearest l/8-inch; top or bottom, left or right. f. Areas requiring special embedment conditions. Z: Details of pipe closures. Details of specials. E. Design Calculations: Design calculations demonstrating that the pipe is capable of sustaining the total maximum loads to be imposed during installation including jacking loads. The calculations shall take into account maximum earth loads, live loads (traffic and railroad), jacking forces, eccentric forces due to steering (0.5 degree joint deflection), and other loads which may be reasonably anticipated. 1. All loads, the factor of safety and allowable jacking capacities, shall be shown and described. 2. Design calculations shall be signed and sealed by a professional engineer licensed by the State of California. 3. Refer to Part 1.4 of this Section. F. Jacking Pipe: In accordance with Paragraph 1.2.C of this Section. CONCRETE PRESSURE PIPE 15073-3 VISTNCARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL G. Joint Testing Procedures: Pipe joint test procedures describing method of joint testing. H. Joint Repair Procedures: Pipe joint repair procedures describing method of joint repair in accordance to pipe manufacturer’s recommendations. I. Affidavit of Compliance: Affidavit of compliance in accordance with AWWA C302. J. Manufacturer’s Qualifications: In accordance with Paragraph 1.2.A of this Section. K. Instructions: Manufacturets instructions for installation of pipe. 1.4 SERVICF CONDITIONS A. Design Criteria: Minimum criteria for design and layout of concrete pressure pipelines. 1. Sewice Conditions: a. Liquid Service: Sewage. b. Flow Conditions: Gravity flow. :: Maximum Operating Pressure: Zero psi. Maximum Operating Plus Surge Pressures: Zero psi. e. Test Pressure: Refer to Section 15051. 2. Design Responsibility: Refer to Paragraph 1.2.8 of this Section. B. External Loads for Buried Pipelines: Minimum external loads imposed on pipelines include earth load plus live load. 1. Earth Load: 130 lb&u. ft. 2. Ku’ = 0.165. 3. Piping shall be designed for an external loading, including impact, for the following conditions: a. Under Roadways: AASHTO H20 truck loading with earth cover. b. Under Railroads and Within Railrod Rightsf-Way: Cooper E80 live loading with earth cover. 4. Criteria for minimum external loads to be used for design of pipe shall be as follows: 150734 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 ?A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 1 Diameter Station Station Cover Load 54 6+13 6+48 15 2.750 lbift 48” 6+48 11+06 15 21950 Ib/ft 48 11+06 15+61 15 2,950 Ib/ft 48” 15+61 49+02 15 3,300 Ib/ft 4T 49+02 58+73 15 3,500 lb/ft 42 144+24 157+55 15 1,800 IbIft 42 157+55 166+50 18 2,000 Ib/ft 42”’ 166+50 178+59 14 3,400 Ib/tt 42” 178+59 195+57 18’ 2,000 Ib/ft 36” 195+57 198+72 20 15.150 lb/ft TABLE 1.5-A Minimum Pipe From To Max. Earth External Installation Method Open Trench Open Trench O.T. or MT O.T. or MT O.T. or MT Microtunnel Microtunnel Microtunnel Microtunnel Ooen Trench Vote: O.T. = Open Trench MT = Microtunnel 4. 5. External load calculations shall use the maximum trench width or the transition width as applicable. Piping installed within casing shall be designed for 100% of the external load; no allowance shall be taken for pipe casing. C. Service lines: Refer to piping schedule in Section 15051, Buried Piping Installation. 3.5 MATERIAI S TRANSPORTATION. HANDLING AND STORAGF A. B. Refer to Section 15051. Handle-all pipe; fittings, and appurtenances carefully with proper handling devices: web slings, padded slings and clean, padded forks. C. Store pipe, fittings and appurtenances on heavy wood blocking or platforms so they are not in contact with the ground. D. Materials cracked, gouged, chipped, and otherwise damaged will not be accepted. Minor defects in the pipe or coatings may be repaired at the site by a method approved by the manufacturer and the ENGINEER. Damaged pipe, fittings and appurtenances shall be repaired or replaced at CONTRACTOR’s expense. E. Refer to Section 4-2. Materials Transportation, Handling and Storage. 1.6 M-AND A. Refer to Section 01025, Measurement and Payment. CONCRETE PRESSURE PIPE 15073-5 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL PART 7 PRODUCTS m 31 PIPE MATPRlAl $ A. Portland Cement: Type II. 1. Concrete strength for microtunneling, jacking and tunneling pipe: 5000 psi at 28 days. 2. Concrete strength for open trench pipe: 4500 psi at 28 days. 3. Cement Content: 560 Ibs/cu. yd. 6. Coarse and Fine Aggregate: Shall contain no more than trace amounts of limestone. C. Reinforcing Steel: No more than 0.25 percent carbon content. 27 PIPF A. Reinforced Concrete Pressure Pipe, Non-cylinder Type: 1. Pipe shall conform to AWWA C302. 2. The reinforcement of the pipe shall consist of one or mom cages of welded steel hoops, helically wound steel bar or wire, or welded wire fabric properly spaced and supported with longitudinal reinforcing. 3. Pipe design shall be in conformance with AWWA M9. Design pressures and external loads shall meet or exceed that given in the Contract Documents. B. Manufacture: 1. The nominal laying length of pipe shall be selected by the CONTRACTOR. a. For lengths of specials, refer to Paragraph 2.5.B of this Section. 2. Cast Method: West cast. 3. Cover Over Steel: l-114 inches or l-1/3 times the largest aggregate. 4. Forms shall not be removed until 12 hours after the completion of concrete placement. C. Microtunneling and Jacking Pipe: Conform to minimum requirements as follows: 1. Portland Cement: Refer to Paragraph 2.1 .A.1 of this Section. 2. Grout Fittings and Plugs: Grout fittings and plugs shall be installed at an 8-foot maximum spacing in the crown of the pipe and shall meet the requirements of ASTM A 53, Type E or S, Grade B. a. Plugs shall be recessed to maintain a smooth interior pipe surface. CONCRETE PRESSURE PIPE 15073-6 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 3. 4. 5. Pipe Tolerances: Pipe shall be manufactured with fabrication tolerances conforming to industry standards such that pipe jacking shall not be hindered during installation and the limit of allowable overcut is not exceeded. Dimensional Characteristics: a. Circumference: No greater than 0.5% deviation. b. Exterior Roundness: No greater than 0.5% deviation. i. End Squareness: 42” dia. pipe, +/-0.06 inches. End Squareness: 48” dia. pipe and larger, +/-0.12 inches. ;- Straightness (per lO-ft. length): Within 0.12 inches. Pipe Length: +I-0.25 inches. Pipe Liner: Refer to Part 2.4 of this Section. D. Open Trench Pipe: Conform to minimum requirements as follows: 1. Portland Cement: Refer to Paragraph 2.1 .A.2 of this Section. 2. Pipe Liner: Refer to Part 2.4 of this Section. E. Manufacturer Provide one of the following: 1. Ameron International Concrete and Steel Pipe Group. 2. CSR Hydro Conduit. 3. Or equal. JOINTS A. General: 1. Pipe joints shall be doubled-gasketed, flush bell, steel camegie bell and spigot joint rings. 2. Joints shall use two identical gaskets. 3. Gaskets shall be continuous C-ring solid circular rubber cross section. 4. The joints shall be designed and fabricated so that: a. When the pipe is laid, the gaskets shall not be required to support the weight of the pipes, but shall keep the joint tight under all conditions of service, including expansion, construction, and normal earth settlement. b. When the outer surface of each spigot and the inner surface of each bell are in contact at a point on their periphery, the deformation in the stretched gasket shall not exceed 50 percent at the point of contact and at a point diametrically opposite the point of contact, the deformation of the stretched gasket shall not be less than 15 percent. 5. Joints shall be configured to accommodate 3/4-inch thick plywood jacking strips. a. Pipe spigots shall be 0.125 inch shorter than pipe bells to eliminate forces on the spigots. b. Refer to Paragraph 3.4.A of this Section. CONCRETE PRESSURE PIPE 15073-7 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL B. Joint Rings: 1. Joint rings shall be checked for size and shape on accurate templates before being incorporated in the pipe. Templates shall be a minimum of 16 inches in length. On the finished pipe,. the circumference of the inside bell ring contact surface shall not exceed the circumference of the outside spigot ring contact surface by more than 3/l 6-inch. 2. The minimum thicknesses of the completed bell ring and spigot ring shall conform to AWWA C302 except that the minimum section beneath the spigot groove of the spigot ring which shall be 3/16 inch. 3. The contact surfaces shall be smooth to prevent cutting of the rubber gasket during installation. 4. Joint ring surfaces which are exposed after manufacture shall be galvanized metal to a thickness of not less than 0.0025 inch. C. D. Double Gasket Testable Joints: 1. Each pipe spigot shall be fitted with 2 test ports to test the annular space between the 2 gaskets. 2. The test ports shall be 3&inch female thread opening located between the gaskets for testing from pipe interior after joining. 3. The test ports shall be located 45 degrees from the pipe invert, 90 degrees from each other. 4. The PVC T-lock lining shall be blocked out at each test port. Grout Bands, Polyethylene Lined: Pipe joints shall be grouted on the exterior in pipelines installed in open trenches. 1. The polyethylene foam liner shall be 100 percent closed call, chemically inert, insoluble in water, and resistant to acids, alkalies, and solvents. Polyethylene foam liner shall be Dow Chemical Co.. Ethafoam 222 or equal. 2. The fabric backing of the polyethylene foam-lined bands shall be bf sufficient strength to hold the fresh mortar and of a type that will allow excess water to escape. 3. The fabric backing shall be cut and sewn into strips with slots for the steel strapping on the outer edges. The polyethylene foam shall be cut into strips and slit to a thickness of % inch which will expose a hollow or open cell surface on one side. The foam liner shall be attached to the fabric backing with the open or hollow cells facing towards the pipe. The foam strip shall cover the full interior circumference of the grout band with sufficient length to pemtit an 8- inch overlap of the foam at or near the top of the pipe joint. Splices to provide continuity of the material will be permitted and shall be heat welded or made with a waterproof adhesive which is compatible with the polyethylene foam. The polyethylene foam material shall be protected from direct sunlight. 4. Steel Strapping: The steel strapping used to hold the grout band in place shall be equal to class 1, type 1, heavyduty steel strapping par Federal Specification QQ-S-781 H. E. Grout: Field Mixed Grout for Pipe Joints: 2-112 parts sand, 1 part Portland Cement and water only as necessary for proper consistency. CONCRETE PRESSURE PIPE 15073-a VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VCllA AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 24 PIPF LINER A. PVC Liner: Pipe shall be manufactured with an interior polyvinyl chloride (PVC) liner. The PVC liner shall conform to Section 06651, Polyvinyl Chloride Liner for Concrete: 1. Coverage of Microtunneling and Jacking Pipe: The liner shall cover the upper 300 degrees of the pipe; the bottom 60 degrees at the invert of the pipe shall not be lined. 2. Coverage of Open Trench Pipe: The liner shall cover the upper 270 degrees of the pipe: the bottom 90 degrees at the invert of the pipe shall not be lined. 3. Pipe Manufacture: No welding or torch cutting of pipe reinforcement will be permitted, unless in such a manner as to protect the liner from damage, as approved by the DISTRICT. 4. Joints: Shop joint and field joint types shall be submitted under this Section 06651. 5. Refer to Section 06651. 7.5 APPURTENANCES A. Pipe Closures: 1. Pipe closure shall be delivered complete with gaskets, follower rings, long bells, and any other items necessary for a complete installation. 2. Pipe closures shall be submitted under this Section. 3. No extra payment will be made for closures, including the cost of any concrete required for closure joints. 8. Specials: 1. Manhole Specials: All interceptor sewer connections shall have ‘a special 4-foot pipe piece at each manhole connection. a. The end of the specials connecting to manholes shall be plain end, except for the special connecting to Manhole 17. 1) Refer to Paragraph 2.5.8.2. 2. Manhole 17 shall have a special 5.35foot break-out pipe section with its midpoint at the center of the manhole. a. The special shall be demolished and removed after pipe jacking is wmpleted to allow for construction of the manhole. b. The special shall not be PVC lined. 3. The interceptor sewer shall connect to an existing pipe stub at the upstream terminus of the pipeline at Station 198+72 as shown in the Plans. a. The connection shall be made with a pipe special. b. Field verify the type of pipe joint required to connect the interceptor sewer to the existing pipe stub. C. Refer to Section 7-7.1. 76 MARKING FOR IDENTIFICATION A. Refer to Paragraph 1.2.C of this Section. CONCRETE PRESSURE PIPE 15073-g VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL PART 3 FXFCUTIW e 3.1 A. Provisions of this Part of the Specifications are in addition to the provisions of Section 15051. 3.2 JOINTING OPEN TRENCH PIP- A. Keep a sufficient quantity of joint lubricant, gaskets, diapers and, where required, joint fillers on hand at all times. 8. Gaskets which have been scoured or otherwise damaged shall not be used. C. Joints shall be prepared and made in the following manner: 1. Wtpe gasket, spigot groove and bell ring clean. 2. Apply joint lubricant liberally and thoroughly to entire circumference of gasket, spigot groove, and bell ring. Lubricate bell ring from bell seat to end of flare. Keep lubricated surfaces clean. 3. Place gasket in spigot groove. Place screwdriver or hammer handle between gasket and groove and pull around circumference of spigot. Ensure even gasket tension and seating. 4. Advance spigot into bell until gasket butts evenly against bell flare. If lubricated surfaces become soiled, clean, m-lubricate and repeat the process. 5. Ensure proper orientation of outlets and bevels. 6. Make joint rings parallel and force joint home. 7. Check for proper position of gasket. D. Place pipe into position and check joint opening. Joint opening shall not exceed 1 -inch for ordinary joints. E. F. Interior pipe joints shall be grouted. Exterior pipe joints shall be grouted: 1. The polyethylene foam-lined grout bands shall be centered over the joint space with approximately equal widths extending over each pipe end and securely attached to the pipe with the steel straps. 2. Cement grout shall be placed into one side of the grout band and placement shall continue into that side only until grout has completely encircled the pipe, assuring full joint coverage. Outside joint grouting shall be completed before assuring full joint coverage. 3. Outside joint grouting shall be completed before backfilling. 4. After filling the exterior joint space with cement grout, the foam flaps shall be closed and overlapped in a manner that fully encloses the grout with polyethylene foam. 5. The grout band shall remain in position on the pipe joint. CONCRETE PRESSURE PIPE 15073-10 ViSTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 ?A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 3.3 PIPF TO MANHOLE CONNECTIONS A. All interceptor sewer pipes connecting to manholes shall be fitted with a waterstop grout ring. 1. Refer to Section 15122. 3.4 JACKING PIPE A. Pipe Joints: Pipe joints for jacking pipe shall be fitted with %-inch thick plywood jacking strips covering the full circumference of the pipe. 1. Interior pipe joints shall be grouted. B. The special 5.35-foot break-out pipe section jacked into position of Manhole 17 shall be demolished and removed after pipe jacking is complete to allow for construction of the manhole. C. Refer to Section 02306. 3.5 FACTORY INSPFCTION AND TFSTING A. The CONTRACTOR shall be responsible for all costs associated with inspection and testing of materials, products, or equipment at the place of manufacture. This shall include costs for travel, meals, lodging, and car rental for District-designated inspectors for such inspections or observations exclusive of travel days, if the place of manufacture, fabrication and factory testing is more than fifty (50) miles outside the geographical limit of the City of Carlsbad. The CONTRACTOR shall not be responsible for salary or salary-related costs of the inspectors. B. Inspection and testing at the manufacturer’s plant shall be in accordance with AWWA C302 and the following supplemental requirements: 1. General: The District shall be notified of the place and time of testing two weeks prior to the commencement of testing. 2. Concrete Compression Tests: Compression tests shall comply with AWWA C302. 3. Hydrostatic Tests: Pipe and joint shall be tested in accordance with AWWA C302. The number of pipe section to be tested shall be not more than 1 percent of the total number of sections of each size and class, except that at least one test of each size and class of pipe shall be made. TFSTING A. Field testing shall conform to the requirements of Part 3 of Section 15051. B. Joint Tests: 1. Conduct joint water tests in accordance with Part 8.3 of ASTM C 1103. 2. Joint Repair: If a pipe joint fails the joint test, the joint shall be repaired in accordance with Paragraph 1.3.H of this Section. CONCRETE PRESSURE PIPE + + END OF SECTION + + 15073-l 1 VlSTAlCARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL SECTION 15074 PVC PIPE - AWWA C900 AND C905 1.1 DFSCRIPTION A. Scope: 1. Perform the work as shown, specified and required to provide all PVC Pipe - AWWA C900 and C905 in place, for complete and operable pipelines ready for intended use, required to complete the work. 2. The extent of piping is shown on the Plans, and in the schedule included in Section 15051, Buried Piping Installation. B. Reference Specifications: Comply with applicabte provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. C. Related Sections: 1. Section 2-5.2, Precedence of Control Documents. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 4-2, Materials Transportation, Handling and Storage. 4. Section 01025, Measurement and Payment. 5. Section 02220, Excavation and Backfill. 6. Section 02230, Crushed Stone and Gravel. 7. Section 15051, Buried Piping Installation. 8. Section 15061, Ductile-Iron Pipe Fittings. 9. Section 15122, Piping Specialties. 37 Qt JALITY ASSURANCE A. Manufacturer’s Qualifications: Manufacturer shall have at least 5 years experience in producing similar type products. B. PVC pipe shall be the product of one manufacturer. C. Reference Standards: Comply with application provisions and rewmmen- dations of the following. 1. ASTM F 477, Standard Specifications for Elastomeric Seals (Gaskets) for Joining Plastic Pipe. 2. AWWA C900, Polyvinyl Chloride (PVC) Pressure Pipe, 4 in. through 12 in., for Water Distribution. 3. AWWA C905, Polyvinyl Chloride (PVC) Water Transmission Pipe, Nominal Diameters 14” through 36”. PVC PIPE - AWVA C900 & C905 15074-l VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL D. If there is conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. 1.3 . MITTAt S A. Submit the following in accordance with Section 2-5.3. B. Shop Drawings: 1. Detailed procedures to be used in jointing and installing piping system including manufacturer’s recommendations. 2. Detail requirements for burial, restrained joints, restraint harnesses and all accessories required for a satisfactory piping system. 3. Bill of materials, indicating material composition of pipe, pressure rating, class, dimension ratio, and nominal sizes with wall dimensions. 4. Maximum allowable pipe joint deflection. 5. Certificates of compliance with referenced standards. C. Manufacturer’s Qualifications: In accordance with Paragraph 1.2.A of this Section. 1.4 =VlCF CONDITIONS A. Refer to piping schedule in Section 15051, Buried Piping installation. 1.5 A. Refer to Section 15051. B. Handle all pipe, fittings, and appurtenances wrefully with proper handling devices: web slings, padded slings and clean, padded forks. C. Store pipe, fittings and appurtenances on heavy wood blocking- or platforms so they are not in contact with the ground. 0. Materials cracked, gouged, chipped, dented or otherwise damaged will not be accepted. Minor defects in the pipe or coatings may be repaired at the site by a method approved by the manufacturer and the ENGINEER. Damaged pipe, fittings and appurtenances shall be repaired or replaced at CONTRACTOR’s expense. E. Refer to Section 4-2, Materials Transportation, Handling and Storage. A. Refer to Section 01025, Measurement and Payment. PVC PIPE - AWWA C900 8 C905 15074-2 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL PART 2 PRODUCTS s A. PVC C900 Pipe: 1. Pipe shall conform to AWVVA C900 with cast-iron-pipe-equivalent outside diameters. a. Pipe Sizes: 4 through 12 inches. 2. Class: 150. 3. Dimension Ratio: 18. 4. Pipe Joints: Gasketed bell and spigots. 5. Gaskets: Gasket material shall be a flexible elastomeric ring and conform to ASTM F 477. a. Gaskets shall be factory installed. 6. Fittings: Fittings shall be ductile iron. a. Refer to Section 15061, Ductile-Iron Pipe. 7. Repair Coupler: Repair Couplers shall be PVC and shall conform to AWWA C900 and shall be bell by bell with no center stop. 8. Product and Manufacturer: Provide one of the following: a. Blue Brute PVC Class Water Pipe, J-M Pipe. b. PVC C900 High Pressure Water Pipe, Pacific Western Extruded Plastics Co. C. Or equal. B. PVC C905 Pipe: 1. Pipe shall conform to AWWA C905 with cast-iron-equivalent outside diameters. a. Pipe sizes 14 through 36 inches. 2. Pressure Rating: 185 psi. 3. Dimension Ratio: 25. 4. Joints: Gasketed bell and spigots. 5. Gaskets: Gasket material shall be a flexible elastomeric ring and conform to ASTM F 477. Gaskets shall be factory installed. 6. Fittings: Fittings shall be ductile iron. a. Joints shall be mechanical joints. b. Refer to Section 15061, Ductile-Iron Pipe. 7. Repair Coupler. Repair Couplers shall conform to AWWA C905 and shall be bell by bell with no center stop. a. Product and Manufacturer: Provide one of the following: a. Big Blue Large Diameter PVC Pressure Pipe, J-M Pipe. b. PVC C905 Large-Diameter Transmission Pipe, Pacific Western Extruded Plastics Co. C. Or equal. PVC PIPE - AWWA C900 8 C905 15074-3 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL C. D. Restrained Joint Retainer Glands: Ductile iron fittings with mechanical joints used with PVC AVVWA C900 and C905 pipelines shall have restrained joints where shown in the Contract Drawings. Mechanical joint restraint shall incorporate restrained joint retainer glands and shall conform to AWWA Cl 11. The restraint mechanism shall consist of numerous individually activated gripping surfaces to grip onto the outside wall of the PVC pipe to maximize restraint capability. Dimensions of the retainer gland shall be such that it can be used with standard mechanical joint bells. 1. Material: Ductile iron. 2. Nuts: 316 SS twist-off nuts, sized same as tee-head bolts, shall be used to ensure proper activating of restraining devices. 3. Product and Manufacturer: a. Provide one of the following for 4- through 12-inch diameter PVC C900 pipes: 1) Megalug Retainer Gland for PVC Pipe, Series 2000 PV, EBAA Iron Sales, Inc. 2) Or equal. b. Provide one of the following for 14- through 24-inch diameter PVC C905 pipes: 1) Megalug Retainer Gland for PVC Pipe, Series 1100 PV. EBAA Iron Sales, Inc. 2) Or Equal. Restraint Harnesses: PVC AWWA C900 and C905 pipelines shall be restrained using restraint harnesses at the bell and spigot pipe joints where specified in Section 15051. The restraint mechanism shall consist of numerous activated gripping surfaces to m&mite restraint capability. The harness shall conform to ASTM A 536. 1. Material: Ductile iron. 2. Product and Manufacturer: a. Provide one of the following for 4- through 12-inch diameter PVC AVVWA C900 pipes: 1) Restraint Harness, Series 1600, EBAA Iron Sales, Inc. 2) Or equal. b. Provide one of the following for 14 through 24-inch diameter PVC AWWA C905 pipes: 1) Restraint Harness, Series 2800, EBAA Iron Sales, Inc. 2) Or equal. 77 IDFNTIFICATIQhl A. All pipe sections shall be marked in accordance to AWWA C900 and C905. PVC PIPE - AM/WA C900 8 C905 150744 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL PART 3 - FXFCUTIW 3.1 INsL_AI t ATION A. Refer to Section 15051, Buried Piping Installation, Part 3.4. B. Provide restrained joint retainer glands on new 10” sewer force main pipe fittings at Laguna Drive. C. Provide restraint harnesses on new 10” sewer force main pipe joints at Laguna Drive. 3.2 PIPE TO MANHOLF CONNFCTIONS A. All sewer force main pipelines connecting to manholes shall be fitted with a waterstop grout ring. 1. Refer to Section 15122. A. Refer to Section 15051, Buried Piping Installation. ++ ENDOFSECTION ++ PVC PIPE - AWWA C900 8 C905 15074-S VISTNCARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL SECTION 15075 PVC PIPE - SDR 35 PART 1 - GF”J’=RAL 1.1 DFSCRIPTION A. scope: 1. Perform the work as shown, specified and required to furnish and install all PVC Pipe - SDR 35 in place, for complete and operable pipelines ready for intended use, required to complete the Wok 2. The extent of piping is shown on the Plans, and in the schedule included in Section 15051, Buried Piping Installation. B. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. C. Referenced Sections SSPWC: 1. Section 207-17, PVC Plastic Pipe. D. Related Sections: 1. Section 2i5.2, Precedence of Control Documents. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 4-2, Materials Transportation, Handling and Storage. . 4. Section 01025, Measurement and Payment. 5. Section.02220; Excavation and Backfill. 6. Section 02230, Crushed Stone and Gravel. 7. Section 15051, Buried Piping Installation. 8. Section 15122, Piping Specialties. 1’ QUALITY ASSUM A. Manufacturer’s Qualifications: Manufacturer shall have at least 5 years experience in producing similar type products. B. PVC Pipe SDR 35 shall be the product of one manufacturer. C. Reference Standards: Comply with application provisions and recommen- dations of the following. 1. ASTM D 1784, Rigid Poly (Vinyl Chloride) PVC Compounds and Chlorinated Poly (Vinyl Chloride) CPVC Compounds. 2. ASTM D 2321, Standard Practice for Underground Installation of Thermoplastic Pipe for Sewers and Other Gravity-Flow Applications. 3. ASTM D 2412, Test Method for External Loading Properties of Plastic Pipe by Parallel Plate Loading. PVC PIPE - SDR 35 150751 VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 4. 5. 6. 7. 8. 9. ASTM D 2444, Test Method for Impact Resistance of Thermoplastic Pipe and Fittings by Means of a Tup (Falling Weight).ASTM D 3034, Standard Specification for Type PSM Poly (Vinyl Chloride) (PVC) Sewer Pipe and Fittings. ASTM D 3212, Standard Specification for Joints for Drain and Sewer and Plastic Pipes Using Flexible Elastomeric Seals. ASTM F 477, Standard Specifications for Elastomeric Seals (Gaskets) for Joining Plastic Pipe. ASTM F 679, Standard Specification for Poly (Vinyl Chloride) (PVC) Large-Diameter Plastic Gravity Sewer Pipe and Fittings. Standard No. 14, National Sanitation Foundation. American National Standards Institute. D. If there is conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. 3.3 SUBMITTALS A. Submit the following in accordance with Section 2-5.3. B. Shop Drawings: 1. Detailed procedures to be used in jointing and installing piping system including manufacturets recommendations. 2. Detail requirements for burial, and all accessories required for a satisfactory piping system. 3. Bill of materials, indicating material composition of pipe, pressure rating, class, dimension ratio, and nominal sizes with wall dimensions. 4. Maximum allowable pipe joint deflection. 5. Certificates of compliance with referenced standards. C. Manufacturer’s Qualifications: In accordance with Paragraph 1.2.A of this Section. l.4 SERVICE CONDlTlONS A. Refer to piping schedule in Section 15051, Buried Piping Installation. J.5 MATERlAl S TRANSPORTATION. HANDLING AND STORAGF A. Refer to Section 15051. B. Handle all pipe, fittings, and appurtenances carefully with proper handling devices: web slings, padded slings and clean, padded forks. C. Store pipe, fittings and appurtenances on heavy wood blocking or platforms so they are not in contact with the ground. PVC PIPE - SDR 35 150752 VISTAXARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL D. Materials cracked, gouged, chipped, dented or otherwise damaged will not be accepted. Minor defects in the pipe or coatings may be repaired at the site by a method approved by the manufacturer and the ENGINEER. Damaged pipe, fittings and appurtenances shall be repaired or replaced at CONTRACTOR’s expense. E. Refer to Section 4-2, Materials Transportation, Handling and Storage. 1.6 MEASUREMENT AND PAYMFNT A. Refer to Section 01025, Measurement and Payment. PART 7 - PRODUCTS 31 MATFR1AJ.S A. PVC SDR 35 Pipe and Fittings: 1. Pipe: Pipe shall conform to the following: It: Sizes 4- through 15inches: ASTM D 3034. Sizes 1& through 24-inches: ASTM F 679. 2. Standard Dimension Ratio: SDR 35. 3. Joints: Gasketed bell and spigots. 4. Gaskets: Gasket material shall be a flexible elastomeric ring and conform to ASTM F 477. a. Gaskets shall be factory installed. 5. Fittings: Fiings shall not be fabricated from pipe sections. 6. Product and Manufacturer: Provide one of the following for pipe: . a. Ring-The (Green-Tite) Sewer Pipe, J-M Pipe. b. PVC Gravity Sewer Pipe, CertainTeed. C. TwinSeal PVC Sewer Pipe Pacific Western Extruded Plastics Co. d. Or equal. 7. Product and Manufacturer. Provide one of the following for fittings: a. Ring-Tite (Green Tii) Sewer Fittings, J-M Pipe. b. Gasketed Sewer Fittings, SDR 35, Head Manufacturing, Inc. C. Or equal. IDENTIFICATIQN A. All pipe sections shall be marked in accordance with ASTM D 3034. PVC PIPE - SDR 35 150753 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL PART 3 - FXFCUTION 3.1 INSTAI I m A. Refer to Section 15051, Buried Piping Installation. 3’ PIPE TO MANHOLE CONNECTIONS A. All collector sewer pipelines connecting to manholes shall be fitted with a waterstop grout ring. 1. Refer to Section 15122. 53 PlPFt INF TFSTS A. Refer to Section 15051, Buried Piping Installation. ++ ENDOFSECTION ++ PVC PIPE - SDR 35 1507% VlSTAiCARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL SECTION 15083 FIBERGLASS MORTAR PIPE PART 1 GFNFRAL s 1.1 DESCRIPTION A. scope: 1. Perform the work as shown, specified and required to provide all fiberglass mortar pipe in place, for complete and operable pipelines ready for intended use, required to complete the Work. 2. The extent of piping is shown on the Plans and in the schedule included in Section 15051, Buried Piping Installation. B. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. Refer to Section 2-5.2 of the Supplemental Provisions. C. Referenced Sections: SSPWC: 1. Section 207-22, Centrifugally Cast Fiberglass Reinforced Plastic Mortar (CCFRPM) Microtunneling Pipe. D. Related Sections: 1. Section 2-5.3, Shop Drawings and Submittals. 2. Section 4-2, Materials Transportation, Handling and Storage. 3. Section 02306, Micmtunneling. 4. Section 15051, Buried Piping Installation. 5. Section 15122, Piping Specialties. Qt IAl IlY ASSURANCE A. Manufacturer’s Qualifications: Manufacturer shall have at least 5 years experience in producing similar type products. B. Centrifugally cast ftberglass mortar pipe shall be the product of one manufacturer. 1. Refer to SSPWC Section 207-22. C. Design Responsibility: The design and layout of pipe shall meet the service conditions and the criteria specified in this Section and are the responsibility of the CONTRACTOR. This design shall be performed by or under the supervision of a professional engineer licensed by the State of California. 1. Allowable Jacking Capacity: Jacking pipe shall be manufactured to provide an allowable jacking capacity of the pipe capable of withstanding the maximum jacking forces imposed by the microtunneling process of installation. a. Refer to Paragraph 1.5 of this Section. FIBERGIASS MORTAR PIPE 15083-l VISTAICARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL b. The allowable safe jacking capacity of the pipe shall be 3.0 times greater than the maximum jacking forces which may be imposed on the pipe by the microtunneling process of installation as identified by theoretical calculations. D. Reference Standards: Comply with applicable provisions and recommendations of the following. 1. ASTM D 2412, Standard Test Method for Determination of External Loading Characteristics of Plastic Pipe by Parallel-Plate Loading. 2. ASTM D 3262, Standard Specification for AFiberglass@ (Glass- Fiber-Reinforced Thermosetting-Resin) Sewer Pipe. 3. ASTM D 4161, Standard Specification for AFiberglas@ (Glass- Fiber-Reinforced Thermosetting-Resin) Pipe Joints Using Flexible Elastomeric Seals. 4. ASTM F 447, Standard Specifications for Elastomeric Seals (Gaskets) for Joining Plastic Pipe. E. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. 1.3 SUBMIT-I-As A. Submit the following in accordance with Section 2-5.3. B. Shop Drawings: 1. Design calculations (including estimates of pipe compression during installation), specifications, and product data sheets as necessary to fully describe all materials, components, and finished products and to show conformance with the Contract Documents. Calculations are for record purposes only. 2. Include the following information: a. Detailed drawings showing dimensions of pipes including inside diameter and wall thicknesses. b. Details of pipe joints and gaskets. C. Marking Schedule: Marks to be used on the finished products to identify pipes, specials and accessories shown on shop drawings and laying schedules. D. Laying Schedules: 1. Tabulated schedules designating each pipe, special, and accessory item necessary to complete the Work in sequence of installation. Coordinate identification of each piece with shop drawings, product data, and marking schedule. a. Each piece shall be identified to show its proper location within its pipeline by reference to the Laying Schedules and Shop Drawings. FIBERGLASS MORTAR PIPE 15083-2 VISTA/CARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 2. Include the following information: it: Quantities and laying lengths of each piece. Invert stations with respect to the Project baseline. C. Invert grade with respect to horizontal between each change of grade. d. Invert elevations referenced to Project vertical datum at each change in horizontal geometry and vertical grade. e. Maximum allowable joint deflections for each type of joint to nearest l/8 inch: top or bottom, left or right. E. Design Calculations: Design calculations demonstrating that the pipe is capable of sustaining the maximum stresses to be imposed during jacking. The calculations shall take into account maximum ground loads, live loads, jacking forces, estimated pip8 string compression, eccentric forces due to steering (0.5 degree joint deflection), external loads such as traffic and railroad, and any other loads which may be reasonably anticipated. I. All loads, the factor of safety and allowable jacking capacities shall be shown and described. 2. Design calculations shall be signed and sealed by a professional engineer licensed by the State of California. F. Joint Testing Procedures: Pip8 joint test procedures describing method of joint testing. G. Manufacturer’s Qualifications: In accordance with Paragraph 1.2.A of this Section. RVICE CONDITIOI\IS A. B. General: The following contains certain minimum acceptable criteria for layout and design of centrifugally cast fiberglass mortar pipelines for microtunneling. 1. Refer to Paragraph I .2.C. Design Criteria: Minimum criteria for layout and design of centrifugally cast fiberglass mortar piping systems. 1. Service Conditions: a. Liquid Service: Sewage. b. Flow Conditions: Gravity. iii Maximum Operating Pressure: Zero. ’ Maximum Operating Plus Surge Pressure: Zero. e. Test Pressure: Refer to Section 15051. 2. Refer to Paragraph 1.2.C of this section. C. External Loads for Buried Pipelines: External loads imposed on pipelines include earth load plus live load in Ib/ft of pipe. 1. Minimum earth ioad for design of pipe shall be a unit weight of soil of 130 pounds per cubic foot. 2. Ku’ = 0.165. FIBERGLASS MORTAR PIPE 15083-3 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 3. 4. The piping systems shall be designed for an external loading, including impact, for the following conditions: a. Under Roadways: AASHTO H20 truck loading with earth cover. b. Under Railroads and Within Railroad Right-of-Way: Cooper E80 live loading with earth cover. External loads to be used for design of microtunneling pipe shall be as follows: TABLE 1.5 Max. Pipe From To Earth Diameter Station Station Cover 42 49+02 58+73 15 42 144+24 157+55 15 42 157+55 166+50 18 42 166+50 178+59 14 42 178+59 195+57 18 Minimum External Installation Load Method 3,500 Ib/ft Microtunnel 1,800 IbIft Microtunnel 2,000 lb/h Microtunnel 3,400 Ib/ft Microtunnel 2.000 lb/ft Microtunnel J.5 MATERIAI S TRANSPORTATION. HANDI ING AND STORAGE A. Refer to Section 15051. B. Handle all pipe, fittings, and appurtenances carefully with proper handling devices: web slings, padded slings and clean, padded forks. C. Store pipe, fittings and appurtenances on heavy wood blocking or platforms so they are not in contact with the ground. D. Materials cracked, gouged, chipped, dented or otherwise damaged will not be accepted. Minor defects in the pipe or coatings may be repaired at the site by a method approved by the manufacturer and the ENGINEER. Damaged pipe, fittings and appurtenances shall be repaired or replaced at CONTRACTOR’s expense. E. Refer to Section 4-2, Materials Transpoltation, Handling and Storage. A. Refer to Section 01025, Measurement and Payment. PART 7 PROnUCTS m 2.1 MATEM A. Resin Systems: The manufacturer shall use only polyester resin systems with a proven history of performance in this particular application. The historical data shall have been acquired from a composite material of similar construction and composition as the proposed product. FIBERGLASS MORTAR PIPE 150834 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL B. Glass Reinforcements: The reinforcing glass fibers used to manufacture the components shall be of highest quality commercial grade E-glass filaments with binder and sizing compatible with impregnating resins. C. Silica Sand: Sand shall be minimum 98% silica with a maximum moisture content of 0.2%. D. Additives: Resin additives, such as curing agents, pigments, dyes, fillers, thixotropic agents, etc., when used, shall not detrimentally effect the performance of the product E. Elastomeric Gaskets: Gaskets shall be supplied by approved gasket manufacturers and be suitable for the service intended. A. Pipes: Pipes shall be manufactured by the centrifugal casting process to result in a dense, non-porous, corrosion-resistant, consistent WmpOSite structure. 1. Diameters: The actual outside diameter of the pipes shall be in accordance with ASTM D3262. 2. Lengths: Pipe shall be supplied in nominal lengths of 10 or 20 feet. Actual laying length shall be nominal +l, -4 inches. At least 90% of the total footage of each size and class of pipe, excluding special order length sections. 3. Wall thickness: The minimum wall thickness, measured at the bottom of the spigot gasket groove where the wall cross-section has been reduced, is determined from the maximum jacking load. a. Refer to Paragraph 1.2.C of this Section. 4. End Squareness: Pipe ends shall be square to the pipe axis with, a maximum tolerance of l/16-inch. 5. A minimum compressive strength of 10,000 psi. B. Joints: Flush bell and spigot. 1. Joints shall conform to ASTM D4161. C. Gasket: Elastomeric sealing gasket. D. Manufacturer: Provide one of the following: 1. Hobas Pipe USA, Inc. 2. Or equal. . 2.3 APPURTFNANCFS A. Closure Pieces: Closure pieces shall not be used. B. Specials: 1. All interceptor sewer connections shall have a special 4-foot pipe piece at each manhole. FIBERGIASS MORTAR PIPE 15083-S VISTAICARLSBAD INTERCEPTOR SEWER REACHES VC5B TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 2. Manhole 17 shall have a special 5.35-foot break-out piece with its midpoint at the center of the manhole. a. The special shall be demolished and removed after pipe jacking is completed to allow for construction of the manhole. A. Installation: The installation of pip8 and fittings shall be in accordance with the manufacturer’s recommendations. B. Pipe Handling: Use textile slings, other suitable materials or a forklift. Use of chains or cables shall not be permitted. C. Joining: 1. Clean ends of pipe and joint components. 2. Apply joint lubricant to the bell interior surface and the elastomeric seals. Use only lubricants approved by the pip8 manufacturer. 3. Use suitable equipment and end protection to push the pipes together. 4. Do not 8XCmd forces recommended by the manufacturer for jointing or pushing pipe. TIONS A. All interceptor sewer pipes connecting to manholes shall be fitted with a waterstop grout ring. 1. Refer to Section 15122. A. Air Pressure Test: The air test shall comply with SSPWC Subsection 305- 1.4.4. Joints may be air tested individually with the use of specialized equipment provided the joint testing procedure is submitted for the ENGINEER’s review prior to testing. Prior to each test, the pipe at the joint shall be wetted with water. The maximum test pressure shall be 3.0 psi. The maximum allowable pressure drop shall be 1.0 psi over a 30-second test period. + + END OF SECTION + + FIBERGLASS MORTAR PIPE 15083-6 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1 A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL SECTION I5122 PIPING SPECIALTIES PART 1 - GENERAI 1.1 DESCRIPTION A. SCOp8: 1. Perform the work as shown, specified and required to provide all piping specialties in place, complete and ready for intended use. required to complete the Work. 2. Piping specialties shall include but not limited to the following items: E: Mechanical couplings. Permanent pipe plugs. :: Mechanical link seals. Waterstop grout rings. B. Reference Specifications: Comply with applicable provisions of the Supplemental Provisions, CMWD Standard Specifications, and SSPWC except as otherwise shown and specified. c. Related Sections: 1. Section 2-5.2, Precedence of Contract Documents. 2. Section 2-5.3, Shop Drawings and Submittals. 3. Section 4-2, Materials Transportation, Handling and Storage. 4. Section 01025, Measurement and Payment. 5. Section 15051, Buried Piping Installation. 6. S8ctlon 15061, Ductile Iron Pipe Fittings. 7. Section .15073, Concrete Pressure Pipe. 8. Section 15074, PVC Pipe - AWWA C900 and C905. 9. Section 15075, PVC Pipe - SDR 35. 10. Section 15083, Fiberglass Mortar Pipe. A. Manufacturers’ Qualifications: I. Manufacturer shall have a minimum of 5 years of experience in the production of substantially similar types of piping specialties specified and shall shown evidence of satisfactory se&e in at least 5 similar installations. 2. Each type of piping specialty shall be the product of one manufacturer. B. If there is a conflict between Contract Documents, the document highest in precedence shall control. Refer to Section 2-5.2. PIPING SPECIALTIES 15122-I VISTAKARLSBAD INTERCEPTOR SEWER REACHES VC56 TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL 1.3 SURMll-TAl S A. Submit the following in accordance with Section 25.3. B. Shop Drawings: Submit for approval the following: 1. Shop drawings, data and manufacturers’ cut sheets for each type of piping specialty item. C. Manufacturers’ Qualifications: In accordance with Paragraph 1.2.A of this Section. 1.4 MATFRIALS TRANSPORTATION. HANtiLING AND STORAGE A. Refer to Section 4-2, Materials Transportation, Handling and Storage. 1.5 MFASUREMENT AND PAYMENT A. Refer to section 01025, Measurement and Payment PART 7 PRODUCTS s 31 MATERIALS A. Mechanical Coupling: Use couplings to flexibly join plain-end pipes with same outside diameters. 1. Pressure: Zero (0) psi, gravity flow. 2. Service: Collector sewers as shown on the Plans. 3. Material for Center and End Rings: Manufacturer’s standard. ’ 4. Gaskets: Manufacturer’s standard; 5. Bolts and Nuts: 316 stainless steel. 6. Product and Manufacturer: Provide one of the following: a. Style 411, Smith-Blair, Inc. b. Style 38, Dresser Industries, Inc. ii: Style 400, Romac Industries, Inc. Or equal. B. Transition Mechanical Coupling: Couplings to flexibly join pipes of different outside diameters. 1. Pressure: Zero (0) psi, gravity flow. 2. Service: Collector sewers as shown on the Plans. 3. Material for Center and End Rings: Manufacturer’s standard. 4. Gaskets: Manufacturers standard. 5. Bolts and Nuts: 316 stainless steel. 6. Product and Manufacturer: Provide one of the following: ;: Style 413, Smith-Blair, Inc. Style 162, Dresser Industries, Inc. :: Style TC400 Romac Industries, Inc. Or equal. PIPING SPECIALTIES 15122-2 VISTAKARLSBAD INTERCEPTOR SEWER REACHES VCSB TO VC1 1A AND SOUTH CARLSBAD STORM DRAIN PROJECTS MECHANICAL C. D. Permanent Pipe Plugs for Sewer Transfer and Abandonment: Use permanent pipe plugs for conducting sewer transfer sequences and the abandonment of the existing interceptor sewer. 1. Plugs Larger Than l&inches: Refer to Abandon Manhole detail shown on the Plans. 2. Plugs Smaller Than 184nches: Concrete plugs shall be poured in place. 2 Place concrete in pipes. Backup concrete by installing sandbags in pipes. C. Trowel finish concrete plug with smooth finish. 3. Prior to installing plugs, sandblast pipe to remove loose material and roughen surface. Waterstop Grout Rings: Sewer pipes connecting to manholes shall be fitted with a waterstop grout ring. 1. Waterstop Ring Material: Polyisoprene compounds conforming to ASTM C 923. 2. Take-Up Clamp: Stainless steel. 3. Product and Manufacturer: Provide one of the following: a. WS Series Waterstop Grout Ring, Press-Seal Gasket Corporation. b. Or equal. PART 3 s FXECl JTW 3.1 INSTAI 1 ATION A. Install piping specialties in accordance with manufacturer’s instructions. 8. Mechanical couplings shall be wrapped in a polyethylene encasement. 1. Refer to Section 15051, Buried Piping Installation. ++ ENDOFSECTION ++ PIPING SPECIALTIES 15122-3