Loading...
HomeMy WebLinkAboutVadnais Corporation; 2007-05-14; PWS07-12ENG Part 2 or 2TECHNICAL SPECIFICATIONS SECTION 01026 SCHEDULE OF VALUES PART 1 - GENERAL 1.01 REQUIREMENTS A. Within thirty (30) days of the Notice to Proceed, the CONTRACTOR shall submit a Schedule of Values for the OWNER'S approval. The Schedule of Values is a detailed itemized breakdown of all lump sum bid items. B. The Schedule of Values shall be used as a basis for determining progress payments on a lump sum contract or any designated lump sum bid item. The Schedule of Values shall be a schedule of cost loaded construction activities equal, in total, to the lump sum bid and shall be in such form and sufficient detail to correctly represent a reasonable apportionment of the lump sum. Prior to submitting a monthly payment request, the CONTRACTOR shall have submitted a detailed Schedule of Values and obtained approval from the OWNER. C. Each lump sum bid item on the Bid Schedule(s), as set forth in the Contractor's Bid Proposal must be broken down separately. The breakdown of each lump sum bid item must cover the cost of construction required by the Contract Drawings and Specifications for that item. The sum of the values for the construction activities, within a bid item, must equal the total bid amount for that item. The breakdown shall include subcontract amounts, which shall not deviate from the amounts submitted in the Bid Proposal. The CONTRACTOR shall provide certification from the Subcontractors certifying the subcontract amounts. D. Each activity in the Schedule of Values shall delineate one construction activity. For example, the placement of concrete between construction joints, the construction of an electrical duct bank or pipeline between points A & B. The costing for each activity should include all costs for the labor and materials or equipment required to complete the activity. For example, concrete construction activities should include all costs for the forming, placing of reinforcement, placing concrete, and curing. The cost for pipeline construction activities should include materials, equipment and installation including pipeline supports or thrust blocks. The excavation and backfill for a pipeline or structure may be separate activities. The Bid Proposal breakdown shall include the itemized costs for the plant startup and testing to be performed before the final project acceptance is made. No non-construction activity shall be cost loaded. E. Where Contract Documents require a CPM Construction Schedule, the CONTRACTOR shall use cost loaded construction activities from the Construction Schedule as a Schedule of Values. Each construction activity shall be encoded to its bid item and a sort provided for each bid item totaling the cost loaded amount. The total of the Cost Loaded amounts for each bid item shall equal the amount bid for that item. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01026-1 F. The total of the Schedule of Values shall equal the current Contract value at all C J times. At any time during the progress of the Contract Work, the OWNER ^ -^ reserves the right to review the cost loading of the Schedules of Values and direct necessary revisions. When requested by the OWNER, the CONTRACTOR shall provide all information necessary to substantiate the cost loading. **END OF SECTION** CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01026-2 SECTION 01505 GENERAL REQUIREMENTS PART 1—GENERAL 1.1 REFERENCES The publications listed below form a part of this section to the extent referenced. The publications are referred to within the text by the basic designation only. NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) NFPA 70 (2005) National Electrical Code NATIONAL ARCHIVES AND RECORDS ADMINISTRATION 29 CFR 1910 Occupational Safety and Health Standards 29 CFR 1926 Safety and Health Regulations for Construction 1.2 SCRAP MATERIAL Materials specified to be removed and become the property of the Contractor are designated as scrap, and the Contractor, by signing this contract, hereby acknowledges that he has made due allowance for value, if any, of such scrap in the contract price. This shall include, but not be limited to, the steel cofferdam. 1.3 TEMPORARY ELECTRIC WIRING A. Temporary Power and Lighting The Contractor shall provide construction power facilities in accordance with the safety requirements of NFPA 70. The Contractor, or his delegated subcontractor, shall enforce all the safety requirements of electrical extensions for the work of all subcontractors. All work shall be accomplished by skilled electrical tradesmen in a workmanlike manner, as approved by the Project Manager. B. Construction Equipment All temporary wiring conductors installed for operation of construction tools and equipment shall be either Type TW or THW contained in metal raceways, or may be multiconductor cord. Temporary wiring shall be 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01505 - 1 secured above the ground or floor in a workmanlike manner and shall not present an obstacle to persons or equipment. Open wiring may only be used outside of buildings, and then only in strict accordance with the provisions of the NFPA 70. C. Circuit Protection In addition to the present requirements in NFPA 70, all 15 and 20-ampere receptacle outlets used for obtaining power during construction shall have ground fault circuit interrupters (GFCI) for personnel protection. Block and brick saws shall also be equipped with GFCI. The Project Manager may allow an exception to this requirement for circuits for concrete vibrators or circuits operating at other than 60 Hertz normal (in both cases an assured grounding program as described in NFPA 70, except utilizing the daily inspection frequency of the grounding means of such equipment, may be permitted). The assured grounding program will not be permitted as a substitute for usage of GFCI'S except as described above. All generator-powered 15- and 20-ampere, 60 Hertz receptacle outlets shall have GFCI'S, and shall be properly grounded. A testing means shall be provided which will impose a measured fault of 5 milliamperes, plus or minus 1 milliamperes, and result in tripping the GFCI unit. 1.4 GENERAL SAFETY REQUIREMENTS A. General The Occupational Safety and Health Act (OSHA) Standards for Construction (Title 29, Code of Federal Regulations Part 1926 as revised from time to time); General Industry Standards (Title 29, Code of Federal Regulations Part 1910 as revised from time to time); and the National Fire Protection Association Codes are applicable to this contract. B. The Prime Contractor's Superintendent The Prime Contractor's superintendent shall take an active role in enforcing the safety requirements by participation in safety conferences, hazard analysis (see below), tool box meetings, walk-through inspections, correction of violations, etc., and including that of the subcontractor's work. C. Job Hazard Analysis (JHA) Based on the construction schedule, the Contractor shall submit a job hazard analysis of each major phase of work prior to entering that phase of activity. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01505 - 2 1. Analysis Content The analysis shall include major or high risk hazards, as well as commonly recurring deficiencies that might possibly be encountered for that operation, and shall identify proposed methods and techniques of accomplishing each phase in a safe manner. The Prime Contractor's superintendent shall take active participation in the Job Hazard Analysis, including the subcontractors' work. Prior to start of actual work a meeting shall be held with Prime Contractor, Government, and affected subcontractor to review the Job Hazard Analysis. In addition, job site meetings shall be held to indoctrinate foreman and workers on details of this analysis. 2. Analysis Review The JHA will be reviewed and approved by the Project Manager, and a copy of the JHA will be provided to the Project Manager before the start of each activity. A meeting shall be held with Contractor, Project Manager, and affected subcontractor to review and critique the JHA at all preparatory and initial inspection meetings prior to the start of actual work. 3. JHA for Marine Construction The Contractor must adhere to lockout and tagout procedures whenever entering the outlet tower area, during assembly and disassembly of the marine construction floating plant and equipment, during refueling operations, fuel or crew transfer, during diving operations (a separate dive operation plan is required in addition), and assembly and installation of the steel cofferdam. The JHA must also address the protection and evacuation of marine construction personnel in the event of rising lake elevation due to runoff. D. Violations If recurring violations and/or gross violation indicate that the safety performance is unsatisfactory, corrective action shall be taken as directed, and at the discretion of the Project Manager the retention or some part thereof will be withheld from the progress payment until corrective action has been completed. |7(F4 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01505 - 3 E. Elevated Work Areas Workers in elevated work areas in excess of 6 feet above an adjoining surface require special safety attention. In addition to any safety regulations, including OSHA requirements, the following safety measures are required to be submitted to the Project Manager. Prior to commencement of work in elevated work areas, the Contractor shall submit drawings depicting all provisions of his positive protection system including, but not limited to, all details of guard rails. 1. Protection Positive protection for workmen engaged in the installation of structural steel shall be provided by safety nets, tie-off s, hydraulic man lifts, scaffolds, or other required means. (a) Regulations The construction shall be in accordance with the Occupational Safety and Health Act (OSHA) Public Law 91-596. Contractor shall comply with OSHA safety standards. (b) Inspections All construction sites are subject to fire and safety inspections without notice. Any violation of fire and safety standards may result in a work stoppage at the expense of the Contractor. F. Recordkeeping/Reporting Requirements On all contract operations, the Prime Contractor shall be responsible for recording and reporting all accident exposure and experience incident work. (This includes exposure and experience of the prime contractor and his/her sub-contractor(s)). As a minimum these records shall include exposure work-hours and a log of occupational injuries and illnesses. (CaUOSHA Form 300 as prescribed by 29 CFR 1904.5). G. Accident Reporting The Prime Contractor will submit at the 50% point and 100% of project completion, a written summary of worker's compensation claims filed by workers on the project. The report will include all subcontractors. The main report covering the Prime Contractor claims will be certified as "correct and true" by the Contractor's compensation insurance carrier. The same certification will be required for subcontractor reports. See Accident CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01505-4 Reports in SECTION 01525 SAFETY AND OCCUPATIONAL HEALTH REQUIREMENTS for reference to Cal/OSHA Form 300A. 1.5 OTHER CONSTRUCTION A. Machinery and Mechanized Equipment Machinery and mechanized equipment used under this contract shall comply with the following: 1. When a rubber-tired front end loader, bulldozer, etc., is operated on a floating plant, either a bumper or curb with a minimum height of one-third of the outside diameter of the largest tire on the equipment, a barge tied alongside, or other means approved in writing by the Project Manager shall be used to prevent equipment from moving or falling into the water. 2. The stability of crawler, truck, and wheel-mounted cranes shall be assured. (a) The manufacturer's load-rating chart may be used to determine the maximum allowable working load for each particular crane's boom angle provided a test load, with a boom angle of 0.35 rads, confirms the manufacturer's load- rating table. (b) Stability tests are required if: (1) there is no manufacturer's load-rating chart securely fixed to the operator's cab; (2) there has been a change in boom or other structural members; or, (3) there has been a change in the counterweight. The test shall consist of lifting a load with the boom in the least stable undercarriage position and at an angle of 0.35 rads above the horizontal. The test shall be conducted under close supervision on a firm, level surface. The load that tilts the machine shall be identified as the test load. The test load moment (in N.m) shall then be calculated by multiplying the horizontal distance (in m) from the center of rotation of the machine to the test load, times the test load (in N). Three-fourths of this test-load moment shall then be used to compute the maximum allowable operating loads for the boom at 0.35, 0.70, 1.05, and 1.40 rads above horizontal. From these maximum allowable operating loads, a curve shall be plotted and posted in the cab of the machine in sight of the operator. These values shall not be 17u"4 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01505 - 5 exceeded except in the performance test described below. The test load shall never exceed 100 percent of the manufacturer's maximum rated ( j capacity. ^ (c) In lieu of the test and computations above, the crane may be load tested for stability at each of the four boom positions listed above. 3. Performance tests shall be performed in accordance with U.S. Army Corps of Engineers, Section 16 of EM 385-1-1, except as specified below. Performance tests shall be conducted after each stability test, when the crane is placed in service on a project, and at least every 12 months. (a) When conducting performance load test which is required of a new crane or a crane in which load sustaining parts have been altered, replaced, or repaired (excluding replacement of the rope), the test load shall be as specified in ASME/ANSI B30 series. That is, for overhead, gantry, portal, pillar, tower, monorail, and underhung cranes, the test load shall not exceed 125 percent of the manufacturer's load rating capacity chart at the configuration of the test for hammerhead tower, mobile, and floating cranes and boom trucks, the test load shall not exceed 110 percent of the manufacturer's load rating capacity chart at the configuration of the test. (b) When conducting a performance load test which is required because a crane is reconfigured, or reassembled after disassembly, or because the crane requires an annual load test, the test loads shall not exceed 100 percent of the manufacturer's load rating capacity chart at the configuration of the test. (c) All load tests are required to be conducted in accordance with the manufacturer's recommendations. 4. Inspections shall be made which will ensure a safe and economical operation of cranes with inspection document. Copies of the inspections and tests shall be available at the jobsite for review. All stability and performance tests on cranes shall be witnessed by the Project Manager or his authorized representative. 5. All heavy equipment moved on to the worksite shall be inspected using the appropriate Inspection Forms (available upon request). All requests, including abatement schedule of any violations, shall 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01505 - 6 be maintained at the jobsite for continued review and update as needed. 6. On-site fuel storage shall be limited to a weekly consumption amount and will be located in an area subject to the Project Manager's approval. A fuel spill containment system is required to prevent environmental impacts. 1.6 SPECIAL CONSTRUCTION PROCEDURES A. Work Within Reservoir The Contractor shall establish his own buoy or log boom demarcation to restrict public access from his work area for safety purposes and shall be responsible for its maintenance and upkeep. The Contractor shall be responsible to notify the Project Manager a minimum of 48 hours in advance of any water-bome construction activities. Fishing from the marine plant is prohibited. Upon the completion of the work, the Contractor shall promptly remove his plant, including ranges, anchoring devices, temporary buoys, and piles and other markers placed by him under the contract within the reservoir or on shore. B. Work Within Outlet Tower 1. Ventilation The Contractor shall design and install a construction ventilation system for use during all construction activities inside the outlet tower, in accordance with OSHA or other applicable requirements, codes, and regulations for working in a confined space. A Ventilation System Design Plan along with an Air-borne Particle Containment Plan shall be submitted to the Project Manager for approval prior to beginning work inside the tower. The submittal shall be updated and resubmitted as the system changes to suit the changing phases of the work. Monitoring of the ventilation system shall be as described below. 2. Monitoring The Contractor shall perform daily air monitoring. Monitoring shall include checking the fan to assure it is running and ventilation checks with breakable smoke tubes to check for air movement at all work locations. Air monitoring shall include testing for carbon monoxide. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01505-7 3. Reporting The Contractor shall include observations of the ventilation system operation and smoke tube tests, along with all air monitoring test results, in the daily QC reports. C. Lockout/Tagout Procedures The Contractor shall employ lockout/tagout procedures whenever the sequence of work requires that sources of hazardous energy be isolated. Work activities requiring lockout/tagout procedures include, but are not limited to, marine activities or plant performed and/or located within the outlet tower, and diving operations. The Contractor shall follow the Hazard Energy Control Procedure as detailed in the "Hazardous Energy Control Program," FIST Volume 1-1, Bureau of Reclamation, March 2002 and the Supplement to FIST Volume 1-1, Bureau of Reclamation, Winter 2001. The above documents will be provided by the Project Manager. The Contractor shall coordinate with the Project Manager to ensure that all procedures are followed precisely. D. Operational Constraints on Construction 1. Construction Activity Restrictions and Coordination All construction activities that could potentially interfere with the operation of either the spillway or discharge operations shall be fully coordinated sufficiently in advance with the Project Manager. The timing of such activities shall be subject to the Project Manager's approval. Such activities shall include all activities on both the upstream and downstream faces of the dam. No construction activity shall interfere with any outlet or spillway releases. No construction activities upstream or downstream of the dam shall be permitted while outlet or spillway releases are being made. 2. Construction and Staging Equipment Storage The Contractor shall not store or otherwise not actively employ equipment either within the outlet tower area, or on the dam without the approval of the Project Manager. 17tp4 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01505 - 8 E. Protection and Repair of Existing Features 1. General Existing features inside the outlet tower that are not scheduled for demolition or removal must be protected during construction from dust, vibration and any other source of damage. The Contractor shall be responsible at no expense to the City for the immediate repair of any project facilities and equipment that he damages during the course of construction. The Contractor shall take all necessary precautions when performing any work in the vicinity of any newly installed equipment. The Contractor shall not damage the existing dam. The Contractor shall submit anchoring device types and an anchorage plan to the Project Manager for approval prior to mobilization at the site. 2. Concrete Repairs Upon final removal of any cofferdam supports and/or anchorage into the concrete, the Contractor shall make all necessary repairs to return the facility to its pre-construction condition at his own expense. F. Weekly Coordination Meetings The Contractor shall schedule and administer weekly coordination meetings between himself and the Project Inspector. Such meetings may also require attendance by subcontractors and suppliers. G. Underwater Video Monitoring The Contractor shall monitor underwater work with videotape in real time during construction. Of particular concern will be underwater connections, assembly, and placement of the cofferdam, piping, and conduits. Videotapes shall be provided to the Project Inspector. H. Approval of Marine Work The Contractor shall obtain approval of marine construction by the Project Inspector and the DSOD Field Inspector, prior to demobilization of the underwater divers and marine construction equipment. 1.7 CITY RETAINED ARCHITECT-ENGINEER (A/E) The City may retain the services of an A/E to increase the level of confidence that the construction Contractor has complied with the requirements of the |-()74 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01505 - 9 construction contract. The A/E's role in observing, monitoring or inspecting the ^_ activities of the construction Contractor is not intended in any way to require the ( J A/E to assume any responsibility for the construction methods, means, techniques ^ or procedures, including any health or safety requirements, be subjected to nonmeritorious litigation relating to site accidents or other circumstances associated with the construction Contractor's activities. The A/E shall be named as an additional insured on all comprehensive general liability insurance policies carried by the construction Contractor. 1.8 DISPOSAL OF MATERIAL The Contractor shall remove and dispose of all excess material, waste, concrete and steel material and muck removed from the tower or reservoir, and any other material unsuitable for use in the project from the City's property, all at no expense to the City. 1.9 WATER REMOVAL / CONTROL OF WATER LEVEL A. The Contractor shall design, furnish, install, operate, monitor, maintain, and remove all necessary pumping and other equipment for removing water from the various parts of the work. The Contractor shall maintain the work area free from water to allow required excavation, concrete removal, concrete placement, grouting and other construction operations to be performed in dry conditions. The water removal system shall include required pumps, sumps, pipelines, flumes, channels, sand bags, filters and other facilities. The system shall be of sufficient capacity to perform the work. The Contractor shall be responsible for the performance and adequacy of the water removal system. B. Water removed from the worksites may be approved by the Project Inspector for discharge in the spillway exit channel, subject to water quality standards as approved by the Project Inspector and other restrictions, codes, or regulations, or at alternative locations approved by the Project Inspector. C. The Contractor shall temporarily seal leakage sources as needed to maintain dry working conditions. Sealing methods and materials shall be subject to the approval of the Project Inspector. D. The Contractor shall submit a water removal plan for approval by the Project Engineer. The plan shall describe equipment and methods to be used for water removal and shall include specific plans for removing water from work areas. I~(P4 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01505 - 10 E. The outlet tower is the primary source of water level control. When in place, the cofferdam will restrict water flows from Lake Calavera to the downstream Calavera Creek. The Contractor is responsible for maintaining the lake level throughout the project and will control the levels during rainfall events. Contractor shall submit a Water Control Plan for approval by the Project Engineer. 1.10 HAUL ROUTE PLAN This plan shall include offices, material storage areas and structures and the access routes to these areas. Haul routes from the sites to major highways shall be indicated. 1.11 CONTRACTOR SAFETY PERSONNEL REQUIREMENTS A. Full-time, on-site, safety coverage by contractors shall be required for the life of the contract. B. The following conditions shall be met: 1. The Contractor shall employ, to cover all hours of work at the project site(s), at least one safety and health person to manage the Contractor's safety program; duties which are not germane to the safety program shall not be assigned to this person(s). The principal safety and health person shall report to and work directly for the Contractor's top on-site manager, corporate safety office, or other high-level official of equivalent position. The safety and health person(s) shall have the authority to take immediate steps to correct unsafe or unhealthful conditions. The employment of a safety and health person(s) shall not abrogate the safety and health responsibilities of other personnel. 2. Qualifications for Safety and Health Person(s). See Section 01525 SAFETY AND OCCUPATIONAL HEALTH REQUIREMENTS, Personnel Qualifications. NOTE: The Contractor shall have one or more Safety and Health Persons, each of whom meets the qualifications of (B)(2) Qualifications for Safety and Health Person(s), physically present on the actual site of the work whenever work of any sort is being performed by a Contractor, subcontractor, or supplier personnel on the work site. The foregoing clause language shall not be interpreted to contravene this note. I "0~4 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01505- 11 1.12 EMERENGENCY ALARMS AND SIGNALS A. Alarms Emergency alarms shall be installed and maintained on all floating plant requiring a crew where it is possible for either a passenger or crewman to be out of sight or hearing from any other person. The alarm system shall be operated from the primary electrical system with standby batteries on trickle charge that will automatically furnish the required energy during an electrical-system failure. A sufficient number of signaling devices shall be placed so that the sound can be heard distinctly at any point above the usual background noise. All signaling devices shall be so interconnected that actuation can occur from at least one strategic point. B. Signals 1. Fire Alarm Signals. The general fire alarm signal shall be in accordance with para. 97.13-15b of the Coast Guard Rules and Regulations for Cargo and Miscellaneous Vessels, Sub-Chapter 1, 1 SEP 77 (CG 257). 2. Abandon Ship Signals. The signal for abandon ship shall be in accordance with para. 97.13-15c of reference cited in b.(l) above. 3. Man-Overboard Signal. Hail and pass the word to the bridge. All personnel and vessels capable of rendering assistance shall respond. 1.13 EMERGENCY EVACUATION A detailed plan for protection and evacuation of personnel and plant, in the event of an impending storm, flood, or other emergency is required as an enclosure to the Contractor's Job Hazard Analysis. The Emergency Evacuation Plan shall include at least the following: A. The time each phase of the plan will be put into effect. The time shall be the number of hours remaining for the storm or flood to reach the worksite if it continues at the predicted speed and direction. B. The safe anchorage for plant specifically identified. C. Identify the boat which will be used to move the plant, its type, capacity, and speed. D. The estimated time necessary to move the plant to the safe anchorage after movement is started. 17U74 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01505 - 12 1.14 COAST GUARD MOTORBOAT OPERATOR'S LICENSE A Coast Guard Motorboat Operator's License shall be required for the operator of any motorboat 26 feet long or longer. 1.15 OUTBOARD BOATS All boats less than 26 feet in length shall meet either the Boating Industry Association (BIA) Standards for minimum' flotation and capacity, or the certification requirements of the U.S. Coast Guard. The Contractor shall be required to provide satisfactory evidence of compliance. Such evidence should be a certification by the boat manufacturer, combined with an inspection to ensure that the boat had not been altered in a manner that reduced the safety features, or sufficient tests that would indicate the actual compliance with the BIA Standards. 1.16 MANDATORY CONDITIONS FOR WORK INVOLVING MARINE PLANT All floating plant and quarter boats not subject to USCG inspection and certification or not having a current American Bureau of Shipping (ABS) classification shall be inspected in the working mode prior to commencement of physical work at the job site and annually thereafter by a marine surveyor accredited by the National Association of Marine Surveyors (NAMS) or Society of Accredited Marine Surveyors (SAMS) and having at least 5 years experience in commercial marine plant and equipment. A copy of the most recent inspection report shall be posted in a public area on board the vessel and a copy shall be furnished to the Project Inspector. 1.17 MISPLACED MATERIALS Should the Contractor during the progress of the work, lose, dump, throw overboard, sink, or misplace any material, plant, machinery, or appliance, which in the opinion of the Project Manager may be dangerous to or adversely impact current or future reservoir releases, or cause pollution, the Contractor shall recover and remove the same with the utmost dispatch. The Contractor shall give immediate notice, with description and location of such obstructions, to the Project Manager or inspector, and when required mark or buoy such obstructions until the same are removed. Should he refuse, neglect, or delay compliance with the above requirements, such obstruction may be removed by the Project Manager, and the cost of such removal may be deducted from any money due or to become due the Contractor, or may be recovered under his bond. The liability of the Contractor of the removal of a vessel wrecked or sunk without fault or negligence shall be limited to that provided in Sections 15, 19, and 20 of the River and Harbor Act of 3 March 1899 (33 U.S.C. 410, et seq.) 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01505 - 13 1.18 FUEL TRANSFER When marine plant and equipment are in use, a safe means of fuel transfer shall be used. This fuel transfer shall meet the Coast Guard Regulations 33 CFR 155.120 regarding fuel/oil transfer operations and 33 CFR 155.320 fuel/oil discharge containment. The marine plant will be checked for compliance before such plant is allowed to be used on the contract. PART 2—PRODUCTS Not used. PART 3—EXECUTION Not used. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01505 - 14 SECTION 01525 SAFETY AND OCCUPATIONAL HEALTH REQUIREMENTS PART 1—GENERAL 1.1 REFERENCES The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI) ANSIZ359.1 (1991) Safety Requirements for Personal Fall Arrest Systems, Subsystems and Components ASME INTERNATIONAL (ASME) ASME B30.5 (2000) Mobile and Locomotive Cranes ASME B30.8 (2000) Floating Cranes and Floating Derricks ASME B30.22 (2000) Articulating Boom Cranes U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION 29 CFR 1910 Occupational Safety and Health Standards 29 CFR 1910.94 Ventilation 29 CFR 1910.120 Hazardous Waste Operations and Emergency Response 29 CFR 1910.146 Permit-required Confined Spaces 29 CFR 1926 Safety and Health Regulations for Construction 29 CFR 1926.65 Hazardous Waste Operations and Emergency Response 29 CFR 1926.500 Fall Protection 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525 - 1 46 CFR 197-SUBPART B Commercial Diving Operations 46 CFR 197.462 Pressure Vessels and Pressure Piping 29 CFR 1910-SUBPART T Commercial Diving Operations 29 CFR 1926-SUBPART Y Diving U. S. ARMY CORPS OF ENGINEERS (USAGE) EM 385-1-1 (2003) Safety and Health Requirements Manual NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) NFPA 10 (1998) Portable Fire Extinguishers NFPA 70 (2002) National Electrical Code NFPA 241 (2000) Safeguarding Construction, Alteration, and Demolition Operations CALIFORNIA CODE OF REGULATIONS (CCR) 8 CCR Title 8, Safety Orders 8 CCR 5157 Title 8, Section 5157 Permit-Required Confined Spaces 8 CCR Art 152 Title 8, Chapter 4, Subchapter 7, Group 26, Article 152 Diving Operations 8 CCR 339 Title 8, Section 339 Hazardous Substances List 8 CCR 1538 Title 8, Section 1538 Rock Drilling Operations 8 CCR 3203 Title 8, Section 3203 Injury and Illness Prevention Program 1.2 SUBMITTALS City approval is required for submittals with a "C" designation; submittals not having a "C" designation are for information only or as otherwise designated. The following shall be submitted: 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525 - 2 SD-01 Preconstruction Submittals Accident Prevention Plan (APP)/Injury and Illness Prevention Program (IIPP); C Activity Hazard Analysis (AHA); C Crane Critical Lift Plan; C Contractor's Safe Practices Manual Emergency Management Plan; C Confined Space Entry Plan; C Dive Operations and Dive Plan; C Scaffolding Plan; C SD-06 Test Reports Reports Submit reports as their incidence occurs, in accordance with the requirements of the paragraph entitled, "Reports." Accident Reports Monthly Exposure Reports Regulatory Citations and Violations Crane Reports Certificate of Compliance (Crane) SD-07 Certificates Dive Personnel Qualifications; C Dive Team certification Provide certification in CPR, first aid, and use of emergency oxygen systems for each dive team member. Also certify that each diver has been medically examined within the previous 12 months and has been determined fit and approved to dive. Confined Space Entry Permit Submit one copy of each permit attached to each Daily Quality Control Report. 1.3 DEFINITIONS A. Certified Industrial Hygienist (CIH). An individual who is currently certified by the American Board of Industrial Hygiene. B. Certified Safety Professional (CSP). An individual who is currently certified by the Board of Certified Safety Professionals. C. Certified Safety Trained Supervisor (STS). An individual who is currently certified by the Board of Certified Safety Professionals. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525 - 3 D. High Visibility Accident. Any mishap which may generate publicity and/or high visibility. E. Medical Treatment. Treatment administered by a physician or by registered professional personnel under the standing orders of a physician. Medical treatment does not include first aid treatment even through provided by a physician or registered personnel. F. Multi-Employer Work Site (MEWS). A multi-employer work site, as defined by OSHA, is one in which many employers occupy the same site. The City considers the Prime Contractor to be the "controlling authority" for all work site safety and health of the subcontractors. G. Operating Envelope. The area surrounding any crane. Inside this "envelope" is the crane, the operator, riggers, rigging gear between the hook and the load, the load and the crane's supporting structure (ground, rail, etc.). H. Recordable Injuries or Illnesses. Any work-related injury or illness that results in: 1. Death, regardless of the time between the injury and death, or the length of the illness; 2. Days away from work; 3. Restricted work; 4. Transfer to another job; 5. Medical treatment beyond first aid; 6. Loss of consciousness; or 7. A significant injury or illness diagnosed by a physician or other licensed health care professional, even if it did not result in (1) through (6) above. I. Site Safety and Health Officer (SSHO). The qualified or competent person who is responsible for the on-site safety and health required for the project. The Contractor quality control (QC) person cannot be the SSHO, even though the QC has safety inspection responsibilities as part of the QC duties. 17074 CUY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525 - 4 J. Weight Handling Equipment (WHE) Accident. A WHE accident occurs when any one or more of the six elements in the operating envelope fails to perform correctly during operation, including operation during maintenance or testing resulting in personnel injury or death; material or equipment damage; dropped load; derailment; two-blocking; overload; and collision, including unplanned contact between the load, crane, and/or other objects. A dropped load, derailment, two-blocking, overload and collision are considered accidents even though no material damage or injury occurs. A component failure (e.g., motor burnout, gear tooth failure, bearing failure) is not considered an accident solely due to material or equipment damage unless the component failure results in damage to other components (e.g., dropped boom, dropped load, roll over, etc.). 1.4 REGULATORY REQUIREMENTS In addition to the detailed requirements included in the provisions of this contract, work performed shall comply with the following federal, state, and local, laws, ordinances, criteria, rules and regulations especially 8 CCR. Submit matters of interpretation of standards to the appropriate administrative agency for resolution before starting work. Where the requirements of this specification, applicable laws, criteria, ordinances, regulations, and referenced documents vary, the most stringent requirements shall apply. 1.5 SITE QUALIFICATIONS, DUTIES AND MEETINGS A. Personnel Qualifications 1. Site Safety and Health Officer (SSHO) Site Safety and Health Officer (SSHO) shall be provided at the work site at all times to perform safety and occupational health management, surveillance, inspections, and safety enforcement for the Contractor. The SSHO shall meet the following requirements: Level 6: A Certified Safety Professional (CSP) and/or Certified Industrial Hygienist (Cffl). • A minimum of 10 years safety work of a progressive nature with at least 5 years of experience on similar projects. • 30-hour OSHA construction safety class or equivalent within the last 5 years. • An average of at least 24 hours of formal safety training each year for the past 5 years with training for competent person status for at least the following 8 areas of competency: Excavation; Scaffolding; Fall protection; Hazardous energy; Confined space; Health hazard 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525 - 5 recognition, evaluation and control of chemical, physical ~^ and biological agents; Personal protective equipment and f J clothing to include selection, use and maintenance; Diving; ^ and Crane Safety. 2. Competent Person for Confined Space Entry Provide a competent person meeting the requirements of EM 385- 1-1 who is assigned in writing by the Designated Authority to assess confined spaces and who possesses demonstrated knowledge, skill and ability to: (a) Identify the structure, location, and designation of confined and permit-required confined spaces where work is done; (b) Calibrate and use testing equipment including but not limited to, oxygen indicators, combustible gas indicators, carbon monoxide indicators, and carbon dioxide indicators, and to interpret accurately the test results of that equipment; (c) Perform all required tests and inspections specified in 29 CFR 1910.146; (d) Assess hazardous conditions including atmospheric hazards f j in confined space and adjacent spaces and specify the necessary protection and precautions to be taken; (e) Determine ventilation requirements for confined space entries and operations; (f) Assess hazards associated with hot work in confined and adjacent space and determine fire watch requirements; and, (g) Maintain records required. Much of the work within the outlet tower is confined space entry, and these safety requirements will apply. 3. Competent Person for the Health Hazard Control and Respiratory Protection Program Provide a competent person meeting the requirements of EM 385- 1-1 who is: 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525-6 (a) Capable by education, specialized training and/or experience of anticipating, recognizing, and evaluating employee exposure to hazardous chemical, physical and biological agents in accordance with USAGE EM 385-1-1, Section 6. (b) Capable of specifying necessary controls and protective actions to ensure worker health. 4. Crane Operators Crane operators shall meet the requirements in USAGE EM 385-1-1, Appendix G. 5. Dive Personnel Qualifications Surface-supplied Air Diving Supervisor, Surface-supplied Air Divers, Mixed-gas Divers, Bell/Saturation Divers, Bell/Saturation Diving Supervisor and Tenders qualifications shall be as follows: (a) The diving supervisor, is that employee designated by the employer, at the dive location, in charge of all aspects of the diving operation that affect the safety and health of dive team members. Depending on type of diving operation being conducted this maybe either the surface-supplied air diving supervisor or the bell/saturation diving supervisor. (b) The surface-supplied air diving supervisor, surface- supplied air divers, mixed-gas divers, bell/saturation divers, bell/saturation diving supervisor and tenders shall have the experience or training necessary to perform assigned tasks in a safe and healthful manner. (c) Any employed diver/team member may substitute a training certificate with a valid "Association of Diving Contractors (ADC) Commercial Diver Certification Card" for the appropriate training level. Otherwise, the contractors shall provide evidence that each dive team member has training and experience consistent with the performance requirements of the scope of work. (d) Documentation of training and experience shall be kept on file at the project site. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525-7 (e) Each dive team member shall have current certification in .—. CPR, first aid, and use of emergency oxygen systems. ( J Evidence of this will be a photocopy of the certificates. Each dive team member shall be fit and approved to dive. B. Personnel Duties 1. Site Safety and Health Officer (SSHO) (a) Conduct daily safety and health inspections and maintain a written log which includes area/operation inspected, date of inspection, identified hazards, recommended corrective actions, estimated and actual dates of corrections. Safety inspection logs shall be attached to the Contractors' daily quality control report. (b) Conduct mishap investigations and complete required reports. Maintain the Cal/OSHA Form 300 and Daily Production reports for prime and sub-contractors. (c) Maintain applicable safety reference material on the job site. (d) Attend the pre-construction conference, pre-work meetings including preparatory inspection meeting, and periodic in- progress meetings. (e) Implement and enforce accepted APP/UPPs and AHAs. (f) Maintain a safety and health deficiency tracking system that monitors outstanding deficiencies until resolution. A list of unresolved safety and health deficiencies shall be posted on the safety bulletin board. (g) Ensure sub-contractor compliance with safety and health requirements. Failure to perform the above duties will result in dismissal of the superintendent and/or SSHO, and a project work stoppage. The project work stoppage will remain in effect pending approval of a suitable replacement. 2. Certified Safety Professional (CSP) (a) Perform safety and occupational health management, surveillance, inspections, and safety enforcement for the project. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525 - 8 (b) Perform as the safety and occupational health "competent person" as defined by USAGE EM 385-1-1. (c) Be on site at least weekly whenever work or testing is being performed. (d) Conduct and document safety inspections. (e) Shall have no other duties other than safety and occupational health management, inspections, and enforcement on this contract. If the CSP is appointed as the SSHO all duties of that position shall also be preformed. C. Meetings 1. Preconstruction Conference (a) The Contractor will be informed, in writing, of the date of the preconstruction conference. The purpose of the preconstruction conference is for the Contractor and the City's representatives to become acquainted and explain the functions and operating procedures of their respective organizations and to reach mutual understanding relative to the administration of the overall project's APP/IIPP before the initiation of work. (b) Contractor representatives who have a responsibility or significant role in accident prevention on the project shall attend the preconstruction conference. This includes the project superintendent, site safety and health officer, quality control supervisor, or any other assigned safety and health professionals who participated in the development of the APP/IIPP (including the AHAs and special plans, program and procedures associated with it). (c) The Contractor shall discuss the details of the submitted APP/IIPP to include incorporated plans, programs, procedures and a listing of anticipated activity hazard analyses (AHAs) that will be developed and implemented during the performance of the contract. This list of proposed AHAs will be reviewed at the conference and an agreement will be reached between the Contractor and the City's representative as to which phases will require an analysis. In addition, a schedule for the preparation, ] 7074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525-9 submittal, review, and acceptance of AHAs shall be established to preclude project delays. (d) Deficiencies in the submitted APP/nPP will be brought to the attention of the Contractor at the preconstruction conference, and the Contractor shall revise the plan to correct deficiencies and re-submit it for acceptance. Work shall not begin until there is an accepted APP/IIPP. 2. Weekly Safety Meetings Conduct weekly safety meetings at the project site for all employees. The City's Representative will be informed of the meeting in advance and be allowed attendance. Minutes showing contract title, signatures of attendees and a list of topics discussed shall be attached to the Contractors' daily quality control report. 3. Work Phase Meetings The appropriate AHA shall be reviewed and attendance documented by the Contractor at the preparatory, initial, and follow-up phases of quality control inspection. The analysis should be used during daily inspections to ensure the implementation and effectiveness of safety and health controls. 1.6 TRAINING A. New Employee Indoctrination New employees (prime and sub-contractor) will be informed of specific site hazards before they begin work. Documentation of this orientation shall be kept on file at the project site. B. Periodic Training Provide Safety and Health Training in accordance with USAGE EM 385-1- 1 and the accepted APP/IIPP. Ensure all required training has been accomplished for all onsite employees. C. Training on Activity Hazard Analysis (AHA) Prior to beginning a new phase, training will be provided to all affected employees to include a review of the AHA to be implemented. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525 - 10 1.7 ACCIDENT PREVENTION PLAN (APP)/INJURY AND ILLNESS PREVENTION PROGRAM (IIPP) The Contractor shall use a qualified person to prepare the written site-specific APP/IIPP. Prepare the APP/IIPP in accordance with the format and requirements of USAGE EM 385-1-1 and 8 CCR 3203and as supplemented herein. Cover all paragraph and subparagraph elements in USAGE EM 385-1-1, Appendix A, "Minimum Basic Outline for Preparation of Accident Prevention Plan". Where a paragraph or subparagraph element is not applicable to the work to be performed indicate "Not Applicable" next to the heading. Specific requirements for some of the APP/IIPP elements are described below at paragraph 1.8.1. The APP/IIPP shall be job-specific and shall address any unusual or unique aspects of the project or activity for which it is written. The APP/IIPP shall interface with the Contractor's overall safety and health program. Any portions of the Contractor's overall safety and health program referenced in the APP/IIPP shall be included in the applicable APP/UPP element and made site-specific. The City considers the Prime Contractor to be the "controlling authority" for all work site safety and health of the subcontractors. Contractors are responsible for informing their subcontractors of the safety provisions under the terms of the contract and the penalties for noncompliance, coordinating the work to prevent one craft from interfering with or creating hazardous working conditions for other crafts, and inspecting subcontractor operations to ensure that accident prevention responsibilities are being carried out. The APP/IIPP shall be signed by the person and firm (senior person) preparing the APP/IIPP, the Contractor, the on-site superintendent, the designated site safety and health officer and any designated CSP and/or CIH. Submit the APP/IIPP to the City's Representative 15 calendar days prior to the date of the preconstruction conference for acceptance. Work cannot proceed without an accepted APP/IIPP. The City reviews and comments on the Contractor's submitted APP/IIPP and accepts it when it meets the requirements of the contract provisions. Once accepted by the City, the APP/IIPP and attachments will be enforced as part of the contract. Disregarding the provisions of this contract or the accepted APP/IIPP will be cause for stopping of work, at the discretion of the City, until the matter has been rectified. Once work begins, changes to the accepted APP/IIPP shall be made with the knowledge and concurrence of the City's Representative, project superintendent, SSHO and quality control manager. Should any unforeseen hazard become evident during the performance of work, the project superintendent shall inform the City's Representative, both verbally and in writing, for resolution as soon as possible. In the interim, all necessary action shall be taken by the Contractor to restore and maintain safe working conditions in order to safeguard onsite personnel, visitors, the public, and the environment. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525-11 Copies of the accepted plan will be maintained at the resident engineer's office and _^ at the job site. The APP/IIPP shall be continuously reviewed and amended, as ( j necessary, throughout the life of the contract. Unusual or high-hazard activities not identified in the original APP/IIPP shall be incorporated in the plan as they are discovered. A. EM 385-1-1 Contents In addition to the requirements outlines in Appendix A of USAGE EM 385-1-1, the following is required: 1. Names and qualifications (resumes including education, training, experience and certifications) of all site safety and health personnel designated to perform work on this project to include the designated site safety and health officer and other competent and qualified personnel to be used such as CSPs, CIHs, STSs, CHSTs. The duties of each position shall be specified. 2. Qualifications of competent and of qualified persons. As a minimum, competent persons shall be designated and qualifications submitted for each of the following major areas: excavation; scaffolding; fall protection; hazardous energy; confined space; health hazard recognition, evaluation and control of chemical, physical and biological agents; personal protective equipment and clothing to include selection, use and maintenance. 3. Confined Space Entry Plan. Develop a confined space entry plan in accordance with USAGE EM 385-1-1, applicable Cal/OSHA standards 29 CFR 1910, and 29 CFR 1926, and any other federal, state and local regulatory requirements identified in this contract, especially 8 CCR 5157. Identify the qualified person's name and qualifications, training, and experience. Delineate the qualified person's authority to direct work stoppage in the event of hazardous conditions. Include procedure for rescue by contractor personnel and the coordination with emergency responders. Confined Space Plan must be submitted fifteen (15) days prior to start of work. It must be approved and accepted by the COR prior to start of work. It has been ascertained that there are no local emergency responders available through the Carlsbad Fire Department. Submit the Confined Space Entry Plan to the City's Representative 15 calendar days prior to the start of work for acceptance. Work cannot proceed without an approved Confined Space Entry Plan. If there is no confined space work, include a statement that no confined space work exists and none will be created. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525-12 4. Health Hazard Control Program. The Contractor shall designate a competent and qualified person to establish and oversee a Health Hazard Control Program in accordance with USAGE EM 385-1-1, Section 6. The program shall ensure that employees, on-site City representatives, and others, are not adversely exposed to chemical, physical and biological agents and that necessary controls and protective actions are instituted to ensure health. Of particular concern is exposure to crystalline silica during the following construction activities: (a) Chipping, hammering, and drilling in rock or concrete or brick; (b) Crushing, loading, hauling, and dumping of rock and concrete; (c) Abrasive blasting using silica sand or from the materials being blasted (concrete); (d) Sawing, hammering, drilling, grinding, and/or chipping on masonry or concrete; (e) Demolition of brick, concrete, or masonry; (f) Dry sweeping concrete, sand, or rock dust; (g) Trenching and excavation; (h) Tile and grout work. 5. Crane Critical Lift Plan. Prepare and sign weight handling critical lift plans for lifts over 75 percent of crane hoist's maximum load limit; lifts involving more than one crane or hoist; lifts of personnel; and technically difficult lifts involving non-routine rigging or operation, sensitive equipment, or unusual safety risks in accordance with USAGE EM 385-1-1, paragraph 16.C.18. and submit 15 calendar days prior to on-site work. 6. Lead Work Plan. The safety and health aspects of lead work, prepared in accordance with Section 13282N, "Lead in Construction". 7. Site Demolition Plan. The safety and health aspects prepared in accordance with Section 02050, Demolition and Alterations. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525-13 8. Training Records and Requirements. List of mandatory training and certifications which are applicable to this project (e.g. C j explosive actuated tools, confined space entry, fall protection, crane ^ operation, vehicle operator, forklift operators, diving personnel, personal protective equipment); list of requirements for periodic retraining/certification; outline requirements for supervisory and employee safety meetings. 9. Dive Operations and Dive Plan. The contractor's diving operations to include preparation of required documentation, including a dive plan, shall be in accordance with the more stringent of the following requirements: Section 30 of USAGE EM 385-1-1; 29 CFR 1910-SUBPART T, Commercial Diving Operations; 29 CFR 1926-SUBPART Y, Diving; 46 CFR 197-SUBPART B, Commercial Diving Operations; 8 CCR Art 152; and any other, federal, state and local regulatory requirements identified in this contract. Submit the Dive Operations and Dive Plan to the City's Representative 30 calendar days prior to the start of work for acceptance. Work cannot proceed without an approved Dive Operations and Dive Plan. Dive logs shall be maintained at the diving location. The Safety Inspection Checklist for Contract Diving Operations shall be completed and submitted to the City's Representative. 1.8 ACTIVITY HAZARD ANALYSIS (AHA) The Activity Hazard Analysis (AHA) format shall be in accordance with USAGE EM 385-1-1. Submit the AHA for review at least 15calendar days prior to the start of each phase. Format subsequent AHA as amendments to the APP/IIPP. An AHA will be developed by the Contractor for every operation involving a type of work presenting hazards not experienced in previous project operations or where a new work crew or subcontractor is to perform work. The analysis must identify and evaluate hazards and outline the proposed methods and techniques for the safe completion of each phase of work. At a minimum, define activity being performed, sequence of work, specific safety and health hazards anticipated, control measures (to include personal protective equipment) to eliminate or reduce each hazard to acceptable levels, equipment to be used, inspection requirements, training requirements for all involved, and the competent person in charge of that phase of work. For work with fall hazards, including fall hazards associated with scaffold erection and removal, identify the appropriate fall arrest systems. For work with materials handling equipment, address safeguarding measures related to materials handling equipment. For work requiring excavations, include requirements for safeguarding excavations. An activity requiring an AHA shall not proceed until the AHA has been accepted by the City's representative and a meeting has been conducted by the Contractor to discuss its contents with everyone engaged in the activity, including on-site City 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525 - 14 representatives. The Contractor shall document meeting attendance at the preparatory, initial, and follow-up phases of quality control inspection. The AHA shall be continuously reviewed and, when appropriate, modified to address changing site conditions or operations. The analysis should be used during daily inspections to ensure the implementation and effectiveness of the activity's safety and health controls. The AHA list will be reviewed periodically (at least monthly) at the Contractor supervisory safety meeting and updated as necessary when procedures, scheduling, or hazards change. Activity hazard analyses shall be updated as necessary to provide an effective response to changing work conditions and activities. The on-site superintendent, site safety and health officer and competent persons used to develop the AHAs, including updates, shall sign and date the AHAs before they are implemented. 1.9 DISPLAY OF SAFETY INFORMATION Within 10 calendar days after commencement of work, erect a safety bulletin board at the job site. The following information shall be displayed on the safety bulletin board in clear view of the on-site construction personnel, maintained current, and protected against the elements and unauthorized removal: A. Map denoting the route to the nearest emergency care facility. B. Emergency phone numbers. C. Copy of the most up-to-date APP/HPP. D. AHA(s). E. Cal/OSHA 300A Form. F. Confined space entry permit. G. OSHA Safety and Health Protection-On-The-Job Poster. H. Proposition 65 notification. 1.10 SITE SAFETY REFERENCE MATERIALS Maintain safety-related references applicable to the project, including those listed in the article "References." Maintain applicable equipment manufacturer's manuals. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525 - 15 1.11 EMERGENCY MEDICAL TREATMENT Contractors will arrange for their own emergency medical treatment. City has no responsibility to provide emergency medical treatment. 1.12 REPORTS A. Accident Reports 1. For recordable injuries and illnesses, and property damage accidents resulting in at least $2,000 in damages, the Prime Contractor shall conduct an accident investigation to establish the root cause(s) of the accident, complete the USAGE Accident Investigation Report Form, ENG Form 3394, and provide the report to the City's Representative within 1 calendar day(s) of the accident. The City's Representative will provide copies of any required or special forms. 2. For a weight handling equipment accident the Prime Contractor shall conduct an accident investigation to establish the root cause(s) of the accident, complete the WHE Accident Report form and provide the report to the City's Representative within 30 calendar days of the accident. The City's Representative will provide a blank copy of the accident report form. 3. For a dive in which decompression sickness and/or pulmonary barotraumas is suspected or symptoms are evident, complete the ENG Form 3394 and provide the report to the City's Representative within 1 calendar day(s) of the incident. B. Accident Notification Notify the City's Representative as soon as practical, but not later than four hours, after any accident meeting the definition of Recordable Injuries or Illnesses or High Visibility Accidents, to include decompression sickness and/or pulmonary barotraumas, property damage equal to or greater than $2,000, or any weight handling equipment accident involving a overturned crane, collapsed boom, or any other major damage to the crane or adjacent property. Information shall include contractor name; contract title; type of contract; name of activity, installation or location where accident occurred; date and time of accident; names of personnel injured; extent of property damage, if any; extent of injury, if known, and brief description of accident (to include type of construction equipment used, PPE used, etc.). Preserve the conditions and evidence on the accident site until the City investigation team arrives on site and City investigation is conducted. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525 -16 C. Monthly Exposure Reports Monthly exposure reporting to the City is required to be attached to the monthly billing request. This report is a compilation of employee-hours worked each month for all site workers, both prime and subcontractor. The City's Representative will provide copies of any special forms. D. Regulatory Citations and Violations Contact the City's Representative immediately of any Cal/OSHA or other regulatory agency inspection or visit, and provide the City's Representative with a copy of each citation, report, and contractor response. Correct violations and citations promptly and provide written corrective actions to the City's Representative. E. Crane Reports Submit crane inspection reports required in accordance with USAGE EM 385-1-1, Appendix H and as specified herein with Daily Reports of Inspections. F. Certificate of Compliance The Contractor shall provide a Certificate of Compliance for each crane entering an activity under this contract (see City's Representative for a blank certificate). Certificate shall state that the crane and rigging gear meet applicable Cal/OSHA regulations (with the Contractor citing which Cal/OSHA regulations are applicable, e.g., cranes used in construction, demolition, or maintenance shall comply with 29 CFR 1926 and USAGE EM 385-1-1 Section 16 and Appendix H. Certify on the Certificate of Compliance that the crane operators) is qualified and trained in the operation of the crane to be used. The Contractor shall also certify that all of its crane operators working on the DOD activity have been trained in the proper use of all safety devices (e.g., anti-two block devices). These certifications shall be posted on the crane. 1.13 HOT WORK Prior to performing "Hot Work" (welding, etc.) or operating other flame- producing devices, a written permit shall be requested from the Carlsbad Fire Department. CONTRACTORS ARE REQUIRED TO MEET ALL CRITERIA BEFORE A PERMIT IS ISSUED. The Contractor will provide at least two (2) twenty (20) pound 4A:20 BC rated extinguishers for normal "Hot Work". All extinguishers shall be current inspection tagged, approved safety pin and tamper resistant seal. It is also mandatory to have a designated FIRE WATCH for any "Hot Work" done at this activity. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525 - 17 A. Oil painting materials (paint, brushes, empty paint cans, etc.), and all flammable liquids shall be removed from the facility at quitting time. All painting materials and flammable liquids shall be stored outside in a suitable metal locker or box and will require re-submittal with non- hazardous materials. B. Accumulation of trays, paper, shavings, sawdust, boxes and other packing materials shall be removed from the facility at the close of each workday and such material disposed of in the proper containers located away from the facility. C. The storage of combustible supplies shall be a safe distance from structures. D. Area outside the facility undergoing work shall be cleaned of trash, paper, or other discarded combustibles at the close of each workday. E. All portable electric devices (saws, sanders, compressors, extension chord, lights, etc.) shall be disconnected at the close of each workday. When possible, the main electric switch in the facility shall be deactivated. F. When starting work in the facility, Contractors shall require their personnel to familiarize themselves with the location of the nearest fire alarm boxes and place in memory the emergency Carlsbad Fire Department phone number. ANY FIRE, NO MATTER HOW SMALL, SHALL BE REPORTED TO THE RESPONSIBLE FIRE DEPARTMENT IMMEDIATELY. PART 2—PRODUCTS 2.1 FALL PROTECTION ANCHORAGE Fall protection anchorage, conforming to ANSI Z359.1, will be left in place and so identified for continued customer use. 2.2 CONFINED SPACE SIGNAGE The Contractor shall provide permanent signs integral to or securely attached to access covers for new permit-required confined spaces. Signs wording: "DANGER-PERMIT-REQUIRED CONFINED SPACE - DO NOT ENTER -" in bold letters a minimum of 25 mm(one inch) in height and constructed to be clearly legible with all paint removed. The signal word "DANGER" shall be red and readable from 1.52 m(5 feet). 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525 -18 PART 3—EXECUTION 3.1 CONSTRUCTION AND/OR OTHER WORK The Contractor shall comply with USAGE EM 385-1-1, NFPA 241, the APP/HPP, the AHA, and other related submittals and activity fire and safety regulations. A. Hazardous Material Use Any work or storage involving hazardous chemicals or materials must be done in a manner that will not expose City or Contractor employees to any unsafe or unhealthful conditions. Adequate protective measures must be taken to prevent City or Contractor employees from being exposed to any hazardous condition that could result from the work or storage. The Prime Contractor shall keep a complete inventory of hazardous materials brought onto the work-site. Approval by the City of protective measures and storage area is required prior to the start of the work. B. Hazardous Material Exclusions Notwithstanding any other hazardous material used in this contract, radioactive materials or instruments capable of producing ionizing/non- ionizing radiation (with the exception of radioactive material and devices used in accordance with EM 385-1-1 such as nuclear density meters for compaction testing and laboratory equipment with radioactive sources) as well as materials which contain asbestos, mercury or polychlorinated biphenyls, di-isocynates, lead-based paint are prohibited. The City, upon written request by the Contractor, may consider exceptions to the use of any of the above excluded materials. C. Unforeseen Hazardous Material The design should have identified materials such as PCB, lead paint, and friable and non-friable asbestos. If additional material, not indicated, that may be hazardous to human health upon disturbance during construction operations is encountered, stop that portion of work and notify the City's Representative immediately. Within 14 calendar days the City will determine if the material is hazardous. If material is not hazardous or poses no danger, the City's Representative will direct the Contractor to proceed without change. If material is hazardous and handling of the material is necessary to accomplish the work, the City will issue a modification pursuant to "FAR 52.243-4, Changes" and "FAR 52.236-2, Differing Site Conditions." It should also be noted that the cleanup and disposal of pre-existing hazardous material does not make the contractor the generator of the hazardous material. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525 - 19 3.2 FALL HAZARD PROTECTION AND PREVENTION The Contractor shall establish a fall protection and prevention program, for the protection of all employees exposed to fall hazards. The program shall include company policy, identify responsibilities, education and training requirements, fall hazard identification, prevention and control measures, inspection, storage, care and maintenance of fall protection equipment and rescue and escape procedures. A. Training The Contractor shall institute a fall protection training program. As part of the Fall Hazard Protection and Prevention Program, the Contractor shall provide training for each employee who might be exposed to fall hazards. Training requirements shall be in accordance with USAGE EM 385-1-1, Section 21.A. 16. B. Fall Protection Equipment The Contractor shall enforce use of the fall protection equipment designated for each specific work activity in the Fall Protection and Prevention Plan and/or AHA at all times when an employee is on a surface 1.8 m(6 feet) or more above lower levels. Fall protection systems such as guardrails, personnel fall arrest system, safety nets, etc., are required when working within 1.8m (6 feet) of any leading edge. In addition to the required fall protection systems, safety skiff, personal floatation devices, life rings etc., are required when working above or next to water in accordance with USAGE EM 385-1-1, paragraphs 05.1. and 05.J. Personal fall arrest systems are required when working from an articulating or extendible boom, swing stages, or suspended platform. In addition, personal fall arrest systems may be required when operating other equipment such as scissor lifts if the work platform is capable of being positioned outside the wheelbase. Fall protection must comply with 29 CFR 1926.500, Subpart M and USAGE EM 385-1-1. 1. Personal Fall Arrest Equipment Personal fall arrest equipment, systems, subsystems, and components shall meet ANSI Z359.1. Only a full-body harness with a shock-absorbing lanyard or self-retracting lanyard is an acceptable personal fall arrest device. Body belts may only be used as a positioning device system (for uses such as steel reinforcing assembly and in addition to an approved fall arrest system). Harnesses shall have a fall arrest attachment affixed to the body support (usually a Dorsal D-ring) and specifically designated for attachment to the rest of the system. Only locking snap hooks and carabiners shall be used. Webbing, straps, and ropes shall be made 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525 - 20 of synthetic fiber. The maximum fee fall distance when using fall arrest equipment shall not exceed 1.8m (6 feet). The total fall distance shall always be taken into consideration when attaching a person to a fall arrest system. C. Safety Nets If safety nets are used as the selected fall protection system on the project, they shall be provided at unguarded workplaces, over water, machinery, dangerous operations and leading edge work. Safety nets shall be tested immediately after installation with a drop test of 181.4 kg (400 pounds) and every six months thereafter. D. Existing Anchorage Existing anchorages, to be used for attachment of personal fall arrest equipment, shall be certified (or re-certified) by a qualified person in accordance with ANSI Z359.1. E. Horizontal Lifelines Horizontal lifelines shall be designed, installed, certified and used under the supervision of a qualified person as part of a complete fall arrest system (29 CFR 1926.500). 3.3 SCAFFOLDING Scaffolding Plan shall be submitted for City's Representative acceptance prior to the start of the project. Employees shall be provided with a safe means of access to the work area on the scaffold. Climbing of any scaffold braces or supports not specifically designed for access is prohibited. Access to scaffold platforms greater than 6 m (20 feet) in height shall be accessed by use of a scaffold stair system. Vertical ladders commonly provided by scaffold system manufacturers shall not be used for accessing scaffold platforms greater than 6 m (20 feet) in height. The use of an adequate gate is required. Contractor shall ensure that employees are qualified to perform scaffold erection and dismantling. Do not use scaffold without the capability of supporting at least four times the maximum intended load or without appropriate fall protection as delineated in the accepted fall protection and prevention plan. Stationary scaffolds must be attached to structural components to safeguard against tipping forward or backward. Special care shall be given to ensure scaffold systems are not overloaded. Side brackets used to extend scaffold platforms on self-supported scaffold systems for the storage of material is prohibited. The first tie-in shall be at the height equal to 4 times the width of the smallest dimension of the scaffold base. Work platforms shall be placed on mud sills, where applicable. Scaffold or work platform erectors shall have fall protection during the erection and dismantling of scaffolding or work 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525 - 21 platforms that are more than six feet. Delineate fall protection requirements when working above six feet or above dangerous operations in the Fall Protection and C j Prevention (FP&P) Plan and Activity Hazard Analysis (AHA) for the phase of ^- -^ work. 3.4 EQUIPMENT A. Weight Handling Equipment 1. The Contractor shall notify the City's Representative 15 days in advance of any cranes entering the activity so that necessary quality assurance spot checks can be coordinated. Contractor's operator shall remain with the crane during the spot check. 2. The Contractor shall comply with the crane manufacturer's specifications and limitations for erection and operation of cranes and hoists used in support of the work. Erection shall be performed under the supervision of a designated person (as defined in ASME B30.5). All testing shall be performed in accordance with the manufacturer's recommended procedures. 3. The Contractor shall comply with ASME B30.5 for mobile and locomotive cranes, ASME B30.22 for articulating boom cranes and ASME B30.8 for floating cranes and floating derricks. 4. The presence of City personnel does not relieve the Contractor of an obligation to comply with all applicable safety regulations. The City's Representative will investigate all complaints of unsafe or unhealthful working conditions received in writing from contractor employees, or city employees or their agents. 5. Each load shall be rigged/attached independently to the hook/master-link in such a fashion that the load cannot slide or otherwise become detached. Christmas-tree lifting (multiple rigged materials) is not allowed. 6. A critical lift plan will be prepared in conjunction with the lifting and placement of "pressure vessel for human occupancy" or diving bell. 7. When operating in the vicinity of overhead transmission lines, operators and riggers shall be alert to this special hazard and shall follow the requirements of USAGE EM 385-1-1 Section 11 and ASME B30.5 or ASME B30.22 as applicable. 8. Crane suspended personnel work platforms (baskets) shall not be used unless the Contractor proves that using any other access to the 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525 - 22 work location would provide a greater hazard to the workers or is impossible. Personnel shall not be lifted with a line hoist or friction crane. 9. A fire extinguisher having a minimum rating of 10BC and a minimum nominal capacity of 51b of extinguishing agent shall be available at all operator stations or crane cabs. Portable fire extinguishers shall be inspected, maintained, and recharged as specified in NFPA 10, Standard for Portable Fire Extinguishers. 10. All employees shall be kept clear of loads about to be lifted and of suspended loads. 11. A weight handling equipment operator shall not leave his position at the controls while a load is suspended. 12. Only Contractor crane operators who have met the requirements of 29 CFR 1910.94, 29 CFR 1910.120, 29 CFR 1926.65, 29 CFR 1926.500, USAGE EM 385-1-1, ASME B30.5, and ASME B30.22 and other local and state requirements shall be authorized to operate the crane. 13. The Contractor shall use cribbing when performing lifts on outriggers. 14. The crane hook/block must be positioned directly over the load. Side loading of the crane is prohibited. 15. A physical barricade must be positioned to prevent personnel from entering the counterweight swing (tail swing) area of the crane. 16. A substantial and durable rating chart containing legible letters and figures shall be provided with each crane and securely mounted onto the crane cab in a location allowing easy reading by the operator while seated in the control station. 17. Certification records which include the date of inspection, signature of the person performing the inspection, and the serial number or other identifier of the crane that was inspected shall always be available for review by City personnel. 18. Written reports listing the load test procedures used along with any repairs or alterations performed on the crane shall be available for review by City personnel. 19. The Contractor shall certify that all crane operators have been trained in proper use of all safety devices (e.g. anti-two block devices). 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525 - 23 B. Equipment and Mechanized Equipment 1. Equipment shall be operated by designated qualified operators. Proof of qualifications shall be kept on the project site for review. 2. Manufacture specifications or owner's manual for the equipment shall be on site and reviewed for additional safety precautions or requirements that are sometimes not identified by Cal/OSHA or USAGE EM 385-1-1. Such additional safety precautions or requirements shall be incorporated into the AHAs. 3. Equipment and mechanized equipment shall be inspected in accordance with manufacturer's recommendations for safe operation by a competent person prior to being placed into use. 4. Daily checks or tests shall be conducted and documented on equipment and mechanized equipment by designated competent persons. C. Diving Systems 1. The diving supervisor shall ensure proper function of all diving systems prior to diver entry. 2. The diving supervisor shall ensure the PVHO or diving bell is examined and tested as required by 46 CFR 197.462. 3.5 WORK IN CONFINED SPACES The Contractor shall comply with the requirements in Section 06.1 of USAGE EM 385-1-1 OSHA 29 CFR 1910.146 and Cal/OSHA 8 CCR 5157. Any potential for a hazard in the confined space requires a permit system to be used. Much of the work within the outlet tower is confined space entry and these safety requirements will apply. A. Entry Procedures. Prohibit entry into a confined space by personnel for any purpose, including hot work, until the qualified person has conducted appropriate tests to ensure the confined or enclosed space is safe for the work intended and that all potential hazards are controlled or eliminated and documented. (See Section 06.1.05 of USAGE EM 385-1-1 for entry procedures.) All hazards pertaining to the space shall be reviewed with each employee during review of the AHA. B. Forced air ventilation is required for all confined space entry operations and the minimum air exchange requirements must be maintained to ensure exposure to any hazardous atmosphere is kept below its' action level. ] 7074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525 - 24 C. Ensure the use of rescue and retrieval devices in confined spaces greater than 1.5 m (5 feet) in depth. Conform to Sections 06.1.09, 06.1.10 and 06.1.11 of US ACE EM 385-1-1. D. Include training information for employees who will be involved as entrants and attendants for the work. Conform to Section 06.1.06 of USAGE EM 385-1-1. E. Daily Entry Permit. Post the permit in a conspicuous place close to the confined space entrance. 3.6 HOUSEKEEPING A. Clean-Up All debris in work areas shall be cleaned up daily or more frequently if necessary. Construction debris may be temporarily located in an approved location; however, garbage accumulation must be removed each day. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01525 - 25 SECTION 01730 OPERATION AND MAINTENANCE 1.0 SCOPE Operation and maintenance (O&M) instructions shall be provided in accordance with this section and as required in the technical sections of this project manual. O&M information shall be provided for each maintainable piece of equipment, equipment assembly or subassembly, and material provided or modified under this contract. O&M instructions must be submitted and accepted before on-site training may start. 2.0 TYPES OF INFORMATION REQUIRED A. GENERAL: O&M information shall contain the names, addresses, and telephone numbers of the manufacturer, the nearest representative of the manufacturer, and the nearest supplier of the manufacturer's equipment and parts. In addition, one or more of the following items of information shall be provided as applicable. B. OPERATING INSTRUCTIONS: Specific instructions, procedures, and illustrations shall be provided for the following phases of operations: 1. SAFETY PRECAUTIONS: List personnel hazards for equipment and list safety precautions for all operating conditions. 2. OPERATOR PRESTART: Provide requirements to set up and prepare each system for use. 3. STARTUP, SHUTDOWN, AND POSTSHUTDOWN PROCEDURES: Provide a control sequence for each of these operations. 4. NORMAL OPERATIONS: Provide control diagrams with data to explain operation and control of systems and specific equipment. 5. EMERGENCY OPERATIONS: Provide emergency procedures for equipment malfunctions to permit a short period of continued operation or to shut down the equipment to prevent further damage to systems and equipment. Include emergency shutdown instructions 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01730 - 1 for fire, explosion, spills, or other foreseeable contingencies. Provide guidance on emergency operations of all utility systems including valve locations and portions of systems controlled. 6. OPERATOR SERVICE REQUIREMENTS: Provide instructions for services to be performed by the operator such as lubrication, adjustments, and inspection. 7. ENVIRONMENTAL CONDITIONS: Provide a list of environ- mental conditions (temperature, humidity, and other relevant data) which are best suited for each product or piece of equipment and describe conditions under which equipment should not be allowed to run. 8. Provide Material Safety Data Sheets (MSDS) for all chemicals, greases and oils that are required to operate each piece of equipment. All MSDS shall be supplied with each piece of equipment by the manufacturer. C. PREVENTIVE MAINTENANCE: The following information shall be provided for preventive and scheduled maintenance to minimize corrective maintenance and repair: 1. LUBRICATION DATA: Provide lubrication data, other than instructions for lubrication in accordance with paragraph 2.0-B6. a. A table showing recommended lubricants for specific temperature ranges and applications; b. Charts with a schematic diagram of the equipment showing lubrication points, recommended types and grades of lubricants, and capacities; and c. A lubrication schedule showing service interval frequency. 2. PREVENTIVE MAINTENANCE PLAN AND SCHEDULE: Provide manufacturer's schedule for routine preventive maintenance, inspections, tests, and adjustments required to ensure proper and economical operation and to minimize corrective maintenance and repair. Provide manufacturer's projection of preventive maintenance manhours on a daily, weekly, monthly, and annual basis including craft requirements by type of craft. 17074 CUY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01730 - 2 D. CORRECTIVE MAINTENANCE: Manufacturer's recommendations shall be provided on procedures and instructions for correcting problems and making repairs. 1. TROUBLESHOOTING GUIDES AND DIAGNOSTIC TECHNIQUES: Provide step-by-step procedures to promptly isolate the cause of typical malfunctions. Describe clearly why the checkout is performed and what conditions are to be sought. Identify tests or inspections and test equipment required to determine whether parts and equipment may be reused or require replacement. 2. WIRING DIAGRAMS AND CONTROL DIAGRAMS: Wiring diagrams and control diagrams shall be point-to-point drawings of wiring and control circuits including factory-field interfaces. Provide a complete and accurate depiction of the actual job-specific wiring and control work. On diagrams, number electrical and electronic wiring and pneumatic control tubing and the terminals for each type identically to actual installation numbering. 3. MAINTENANCE AND REPAIR PROCEDURES: Provide instruc- tions and list tools required to restore product or equipment to proper condition or operating standards. 4. REMOVAL AND REPLACEMENT INSTRUCTIONS: Provide step-by-step procedures and list required tools and supplies for removal, replacement, disassembly, and assembly of components, assemblies, subassemblies, accessories, and attachments. Provide tolerances, dimensions, settings, and adjustments required. Instructions shall include a combination of test and illustrations. 5. SPARE PARTS AND SUPPLY LISTS: Provide lists of spare parts and supplies required for maintenance and repair to ensure continued service or operation without unreasonably delays. Special consideration is required for facilities at remote locations. List spare parts and supplies that have a long lead time to obtain. 6. CORRECTIVE MAINTENANCE MANHOURS: Provide manufacturer's projection of corrective maintenance manhours including craft requirements by type of craft. Corrective maintenance that requires participation of the equipment manufacturer shall be identified and tabulated separately. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01730 - 3 E. APPENDICES: The following information shall be provided; include information not specified in the preceding paragraphs but pertinent to the maintenance or operation of the product or equipment. 1. PARTS IDENTIFICATION: Provide identification and coverage for all parts of each component, assembly, subassembly, and accessory of the end items subject to replacement. Include special hardware requirements, such as requirement to use high-strength bolts and nuts. Identify parts by make, model, serial number, and source of supply to allow reordering without further identification. Provide clear and legible illustrations, drawings, and exploded views to enable easy identification of the items. When illustrations omit the part numbers and description, both the illustrations and separate listing shall show the index, reference, or key number which will cross-reference the illustrated part to the listed part. Parts shown in the listings shall be grouped by components, assemblies, and subassemblies. 2. WARRANTY INFORMATION: List and explain the various warranties and include the servicing and technical precautions prescribed by the manufacturers or contract documents to keep warranties in force. 3. PERSONNEL TRAINING REQUIREMENTS: Provide information available from the manufacturers to use in training designated personnel to operate and maintain the equipment and systems properly. 4. TESTING EQUIPMENT AND SPECIAL TOOL INFORMATION: Provide information on test equipment required to perform specified tests and on special tools needed for the operation, maintenance, and repair of components. 3.0 TRANSMTTTAL PROCEDURE Only complete sets of O&M instructions will be reviewed for acceptance. 5 copies of the specified O&M information shall be provided. For ease of identification, each manufacturer's brochure and manual shall be appropriately labeled with the equipment name and equipment number as it appears in the project manual. The information shall be organized in the binders in numerical order by the equipment numbers assigned in the project manual. The binders shall be provided with a table of contents and tab sheets to permit easy location of desired information. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01730 - 4 If manufacturers' standard brochures and manuals are used to describe O&M procedures, such brochures and manuals shall be modified to reflect only the model or series of equipment used on this project. Extraneous material shall be crossed out neatly or otherwise annotated or eliminated. 4.0 PAYMENT Acceptable O&M information for the project must be delivered to the Construction Manager prior to the project being 65 percent complete. Progress payments for work in excess of 65 percent completion will not be made until the specified acceptable O&M information has been delivered to the Construction Manager. 5.0 FIELD CHANGES Following the acceptable installation and operation of an equipment item, the item's instructions and procedures shall be modified and supplemented by the Contractor to reflect any field changes or information requiring field data. **END OF SECTION** CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 01730 - 5 SECTION 02050 DEMOLITION AND ALTERATIONS PART 1 - GENERAL 1.1 DESCRIPTION: A. Demolish and alter existing facilities as indicated on drawings, as specified, and as directed by Engineer. B. Remove, salvage, or otherwise dispose of minor site improvements as specified in Section 02100, Site Preparation. 1.2 RELATED WORK: PART 1 - SECTION 02100: SITE PREPARATION PART2- SECTION02200: EARTHWORK 1.3 QUALITY ASSURANCE: A. Demolish and remove existing construction, utilities, equipment, and appurtenances without damaging integrity of existing structures, equipment, and appurtenances that are to remain. B. Store equipment to be salvaged for relocation where directed by Engineer, and if necessary, protect from damage during work. C. Repair or remove items that are damaged. Repair and install damaged items at no additional compensation and to condition at least equal to that which existed prior to start of work. D. Exercise all necessary precautions for fire prevention. Make acceptable fire extinguishers available at all times in areas where demolition work by burning torches is being done. Do not burn demolition debris on or near site. E. Protect persons and property throughout progress of work. Proceed in such manner as to minimize spread of dust and flying particles and to provide safe working conditions for personnel. F. Maintain circulation of traffic within area at all times during demolition operations. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02050 - 1 Obtain permission from Engineer before abandoning or removing any existing structures, materials, equipment and appurtenances. PART 2 - PRODUCTS (NOT APPLICABLE) PART 3 - EXECUTION 3.1 REFERENCES: A. Provide three reference points for each survey marker and monument removed, established by a licensed civil engineer or land surveyor and record locations and designations of survey markers and monuments prior to removal. B. Store removed markers and monuments during demolition work, and replace upon completion of work. Reestablish survey markers and monuments in conformance with recorded reference points. Forward letter to Engineer signed by licensed civil engineer or land surveyor verifying reestablishment of survey markers and monuments. 3.2 DEMOLITION: A. Confine apparatus, storage of material, demolition work, new construction, and operations of workmen to areas that will not interfere with continued use and operation of entire facility. Provide and maintain lights, barriers, and temporary passageways for free and safe access. 3.3 SALVAGE: A. Materials, equipment, and appurtenances removed, that are not designated for relocation, become property of Contractor. Haul from site and dispose of at no additional compensation. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02050 - 2 SECTION 02100 SITE PREPARATION PART 1 - GENERAL 1.1 DESCRIPTION A. Scope: This section specifies site preparation, which consists of clearing, grabbing and demolition. B. Existing Conditions: 1. The Contractor shall determine the actual condition of the site as it affects this portion of work. C. Protection: 1. Site preparation shall not damage structures, landscaping or vegetation adjacent to the site. The Contractor shall repair or replace any damaged property. 1.2 RELATED SECTIONS Section 02050 Demolition and Alteration Section 02110 Clearing, Grubbing and Stripping PART2-PRODUCTS A. No products are included in this section. PART 3 - EXECUTION 3.1 CLEARING AND GRUBBING A. Unless otherwise specified, the Contractor shall remove obstructions such as brush, trees, logs, stumps, roots, heavy sod, vegetation, rock, stones larger than 6 inches in any dimension, broken or old concrete and pavement, debris, and structures where the completion of the work require their removal. B. Material that is removed and is not to be incorporated in the work shall be disposed of off the site. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02100 - 1 3.2 DEMOLITION AND REMOVAL A. Structures 1. Demolition and removal of structures consist of removal of abandoned superstructures, foundation walls, footings, slabs and any other structures. Excavations caused by existing foundations shall be cleared of waste, debris and loose soil, and refilled. B. Salvage 1. The Owner has the right to salvage any items scheduled for removal. The Contractor shall notify the Construction Manager 5 days prior to any salvage or demolition work to determine the disposition of items to be removed. The Construction Manager will mark items to be salvaged. Such items shall be properly disconnected, removed from their foundations, cleaned, and stored at a location on the plant site as specified. 3.3 UTILITY INTERFERENCE A. Where existing utilities interfere with the prosecution of the work, the Contractor shall relocate them. **END OF SECTION*31 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02100 - 2 SECTION 02110 CLEARING, GRUBBING AND STRIPPING 1.1 GENERAL A. THE REQUIREMENT 1. CONTRACTOR shall furnish all tools, equipment, materials and supplies and shall perform all labor to complete the work associated with removal of all natural and artificial objectionable material from the designated areas of work as indicated in the Contract Documents. 2. This work shall also include the protection from injury and preservation of existing improvements, adjacent property, utility vegetation and existing objects designated to remain. 3. Prior to commencing the work, obtain acceptance from the ENGINEER regarding methods to be used and disposal of removed materials. B. RELATED WORK SPECIFIED ELSEWHERE 1. Section 02200 Earthwork C. REFERENCE SPECIFICATIONS, CODES AND STANDARDS 1. Comply with the applicable reference specifications of the GENERAL REQUIREMENTS. 2. Comply with SSPWC 7-8; Project Site Maintenance, and as modified by CMWD. D. CONTRACTOR SUBMITTALS 1. Submit schedule of clearing, grubbing, and erosion control measures to be put in place for all work permits during the rainy season (October 1 - April 30). E. QUALITY ASSURANCE 1. Comply with the applicable reference specifications of the General Requirements. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02110- 1 1.2 PRODUCTS A. CLEARING 1. Clearing shall consist of removing all vegetable growth such as trees, roots, stumps, shrubs, brush, limbs, and other vegetative growth. Remove all evidence of their presence from the growth surface. Clearing shall also include the removal and disposal of trash piles, rubbish, and fencing. B. PRESERVATION OF TREES, SHRUBS, AND OTHER VEGETATION 1. Protect trees, shrubbery, and other vegetation not designated for removal from damage resulting from the work. Cut and remove tree branches only where, in the opinion of the Project Manager, such cutting is necessary to affect construction. Scars resulting from the removal of branches shall be treated with an approved tree sealant. C. GRUBBING 1. Grubbing shall consist of the removal and disposal of wood, stumps or root matter a minimum of 36 inches below existing spillway channel ground surface or bottom of subgrade, whichever is deeper, unless otherwise shown on the Drawings. Clearing shall include stumps, logs, roots, or root systems greater than 1.5 inches in diameter or thickness. D. CLEARING AND GRUBBING FOR TRENCHING 1. The CONTRACTOR shall obtain ENGINEER'S approval before beginning excavation. The CONTRACTOR shall complete clearing and grubbing prior to the start of trenching. The CONTRACTOR shall not permit excavated materials to cover vegetation prior to disposal. E. REMOVAL AND DISPOSAL OF CLEARING AND GRUBBING DEBRIS 1. General: All materials removed shall be disposed of daily in a manner allowed by law. No accumulation of flammable material shall remain on site. The roadway and adjacent areas shall be left with a neat and finished appearance. 2. Bituminous Pavement: Bituminous pavement removal shall be in conformance with SSPWC Section 300-1.3, and as modified by CMWD. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02110-2 3. Concrete Pavement: Concrete pavement removal shall be in conformance with SSPWC Section 300-1.3, and as modified by CMWD. 4. Concrete Curb, Walk, Gutters, Cross Gutters, Driveways, and Alley Intersections: Concrete removal shall be in conformance with SSPWC Section 300-1.3, and as modified by CMWD. F. STRIPPING 1. Stopping shall include the removal and disposal of all organic sod, topsoil, grass and grass roots, and other objectionable material remaining after clearing and grubbing from the areas designated to be stripped. The depth of stripping shall be as shown on the Drawings and specified herein. 2. Topsoil from the stoppings shall be stockpiled and used for the- finished site grading. G. BACKFILL 1. Holes or depressions in the ground remaining after demolition of structures, existing gunite surface, or equipment shall be filled with compacted backfill material as specified in Section 02200. 1.3 EXECUTION A. CLEARING AND GRUBBING 1. Clearing and grubbing shall be in conformance with the CMWD's modified version of SSPWC Section 300-1. B. STRIPPING 1. Prior to beginning any excavation or fill, strip the topsoil to a depth sufficient to remove all organic material. In general, topsoil shall be removed where structures are to be built, trenches dug, and roads, parking lots, walks, and similar improvements constructed within the areas presently covered with topsoil. Topsoil shall be stored clear of the construction area. Take reasonable care to prevent the topsoil from becoming mixed with subsoil. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02110-3 SECTION 02200 EARTHWORK PART 1 - GENERAL 1.1 THE REQUIREMENT A. The CONTRACTOR shall perform all earthwork indicated and required for construction of the WORK, complete and in place, in accordance with the Contract Documents. 1.2 CONTRACTOR SUBMITTALS A. Submittals shall be in accordance with Section 2 - 5.3 of General Provisions. 1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Work under this section shall comply to CMWD's modified version of standard specification, Part 2 section 200-2.7 PART 2 - PRODUCTS 2.1 SUITABLE FILL AND BACKFILL MATERIAL REQUIREMENTS A. General: Fill, backfill, and embankment materials shall be selected or processed clean, fine earth, rock, or sand, free from grass, roots, brush, or other vegetation. B. Fill and backfill materials to be placed within 6 inches of any structure or pipe shall be free of rocks or unbroken masses of earth materials having a maximum dimension larger than 3 inches. C. Suitable Materials: Materials not defined as unsuitable below are defined as suitable materials and may be used in fills, backfilling, and embankment construction subject to the indicated limitations. In addition, when acceptable to the ENGINEER, some of the material listed as unsuitable may be used when thoroughly mixed with suitable material to form a stable composite. D. Suitable materials may be obtained from on-site excavations, may be processed on-site materials, or may be imported. If imported materials are required by this Section or to meet the quantity requirements of the project, the CONTRACTOR shall provide the imported materials at no CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02200 -1 additional expense to the OWNER, unless a unit price item is included for imported materials in the bidding schedule. E. The following types of suitable materials are defined: 1. Type A (three-quarters inch minus granular backfill): Crushed rock or gravel, and sand with the gradation requirements below. The material shall have a minimum sand equivalent value of 28 and a minimum R-value of 78. If the sand equivalent value exceeds 35 the R-value requirement is waived. Sieve Size Percentage Passing 3/4-inch 100 No. 4 30-50 No. 200 0 -12 2. Type B (Class I crushed stone): Manufactured angular, crushed stone or crushed rock with the following gradation requirements. The material shall have a minimum sand equivalent value of 75. Sieve Size Percentage Passing 3/4-inch 100 No. 4 30-50 No. 200 0-5 3. Type C (sand backfill): Sand with 100 percent passing a 3/8-inch sieve, at least. 90 percent passing a Number 4 sieve, and a sand equivalent value not less than 30, or a coefficient of permeability greater than 35mm per hour (1.4 inches/hour). 4. TypeD: Not used 5. Type E (pea gravel backfill): Crushed rock or gravel the size gradation for Size Number 8 in ASTM C 33 - Concrete Aggregates. 6. Type F (coarse drainrock): Crushed rock or gravel with the size gradation for Size Number 4 in ASTM C 33 7. Type G (class 2 aggregate base): Crushed rock aggregate base material of such nature that it can be compacted readily by watering and rolling to form a firm, stable base for pavements. At the option of the CONTRACTOR, the grading for either the 1 1/2 inch maximum size or 3/4-inch maximum size gradation shall be CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02200 - 2 used. The sand equivalent value shall be not less than 22, and the material shall meet the following gradation requirements. Percentage Passing 1 1/2-mch Max. 3/4-inch Max. Sieve Size Gradation Gradation 2-inch IQQ 1-1/2-inch 90 100 1-inch - 100 3/4-inch 50 85 90-100 No. 4 2S-4S 35 - 60 No. 30 10 25 10-30 No. 200 2—9 2 - 9 Type H (graded dramrock): Drainrock shall be crushed rock or gravel, durable and free from slaking or decomposition under the action of alternate wetting or drying The material shall be uniformly graded and shall meet the gradation requirements for Size Number 57 in ASTM C 33 The drainrock shall have a sand equivalent value not less than 75. The finish graded surface of the drainrock immediately beneath hydraulic structures shall be stabilized to provide a firm, smooth surface upon which to construct reinforced concrete floor slabs The CONTRACTOR shall use, at its option, one of the asphalt types listed below: Type 2 Type 3 Designation SC-800 SC-250 RS-1 Spray Temperature (°F) 175-255 165-200 70-120 Coverage (gal/sq yd) 0.50 0.50 0.50 If the surface remains tacky, sufficient sand shall be applied to absorb the excess asphalt. 2. Type I: Any other suitable material as defined herein. 3. Type J (cement-treated backfill): Material which consists of Type H material, or any mixture of Types B, C, G, and H materials which has been cement-treated so that the cement content of the material is not less than 5 percent by weight when tested in accordance with ASTM D 2901 - Standard Test Method for Cement Content of Freshly Mixed Soil Cement. The ultimate compressive strength at 28 days shall be not less than 400 psi when tested m accordance with ASTM D 1633 - Standard Test Method for Compressive Strength of Molded Soil - Cement Cylinders. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02200 - 3 4 Type K (topsoil): Stockpiled topsoil material which has been obtained at .—^ the site by removing soil to a depth not exceeding 2 feet. Removal of the ( J topsoil shall be done after the area has been stopped of vegetation and debris. 5. Type L (controlled low strength material): Not used. 6 Type M (aggregate subbase): Crushed rock aggregate subbase material that can be compacted readily by watering and rolling to form a firm stable base. The sand equivalent value shall be not less than 18 and the material shall meet the following gradation requirements Sieve Size Percentage Passing 3-mch 100 2-1/2 inch 87-100 No. 4 35-95 No. 200 0 - 29 7. Type N (trench plug)- Low permeable fill matenal, a non-dispersible clay material having a minimum plasticity index of 10. 2.2 UNSUITABLE MATERIAL A. Unsuitable materials include the materials listed below. 1 Soils which, when classified under ASTM D 2487 - Standard Classification of Soils for Engineering Purposes (Unified Soil Classification System), fall in the classifications of Pt, OH, CH, MH, or OL. 2. Soils which cannot be compacted sufficiently to achieve the density specified for the intended use. 3. Materials that contain hazardous or designated waste materials including petroleum hydrocarbons, pesticides, heavy metals, and any matenal which may be classified as hazardous or toxic according to applicable regulations. 4. Topsoil, except as allowed below. 5. Soil with expansion index > 50. 6. Oversize material > 6". CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02200 - 4 2.3 USE OF FILL, BACKFILL, AND EMBANKMENT MATERIAL TYPES A. The CONTRACTOR shall use the types of materials as designated herein for all required fill, backfill, and embankment construction hereunder. B. Where these Specifications conflict with the requirements of any local agency having jurisdiction or with the requirements of a pipe material manufacturer, the ENGINEER shall be immediately notified In case of conflict between types of pipe embedment backfills, the CONTRACTOR shall use the agency-specified backfill material if that material provides a greater degree of structural support to the pipe, as determined by the ENGINEER. In case of conflict between types of trench or final backfill types, the CONTRACTOR shall use the agency-specified backfill material if that material provides the greater in-place density after compaction C. Fill and backfill types shall be used in accordance with the following provisions 1. Embankment fill for the upstream face of the dam shall be compacted rock backfill. 2 Pipe zone backfill, as defined under "Pipe and Utility Trench Backfill" below, shall consist of the following materials for each pipe material listed below. 3 Embankment fills for dam crest surrounding the pull boxes shall be 1-sack cement slurry. D. Mortar coated pipe, concrete pipe, and un-coated ductile iron pipe shall be provided with Type A or B material in the pipe zone. E. Coal tar enamel coated pipe, polyethylene encased pipe, tape wrapped pipe, and other non-mortar-coated pipe shall be provided with Type C material in the pipe zone F. Plastic pipe and vitrified clay pipe shall be provided with Type B material in the pipe zone. G Where pipelines are installed on grades exceeding 4 percent, and where backfill materials are graded such that there is less than 10 percent passing a Number 4 sieve, trench plugs of Type J, L, or N material shall be provided at maximum intervals of 200 feet unless indicated otherwise. 1. Trench zone backfill for pipelines as defined under "Pipe and Utility Trench Backfill" shall be Type I backfill material or any of Types A through H backfill materials or any mixture thereof, except: CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02200 - 5 a. Type K material may be used for trench zone backfill in agricultural areas unless otherwise shown or specified 2. Final backfill material for pipelines under paved areas, as defined under "Pipe and Utility Trench Backfill" shall be Type G backfill material Final backfill under areas not paved shall be the same material as that used for trench backfill, except that Type K material shall be used for final backfill in agricultural areas unless otherwise indicated. 3 Trench backfill and final backfill for pipelines under structures shall be the same material as used in the pipe zone, except where concrete encasement is required by the Contract Documents 4 Aggregate base materials under pavements shall be Type G material constructed to the thicknesses indicated Aggregate subbase shall be Type M material. 5 Backfill around structures shall be Type I material, or Types A through Type H materials, or any mixture thereof, except as shown. 6 Backfill materials beneath structures shall be as follows 7. Dramrock materials under hydraulic structures or other water retaining structures with underdram systems shall be Type H material. 8. Under concrete hydraulic structures or other water retaining structures without underdram systems, Types G or H materials shall be used. 9. Under structures where groundwater must be removed to allow placement of concrete, Type F material shall be used. Before the Type F material is placed, filter fabric shall be placed over the exposed foundation. 10 Under all other structures, Type G or H material shall be used. 11. Backfill used to replace pipeline trench over-excavation shall be a layer of Type F material with a 6-inch top filter layer of Type E material or filter fabric to prevent migration of fines for wet trench conditions or the same material as used for the pipe zone backfill if the trench conditions are not wet. 12 The top 6 inches of fill on reservoir roofs, embankment fills around hydraulic structures, and all other embankment fills shall consist of Type K material, topsoil. 13. Filter fabric shall be Mirafi 140 N, Mirafi 700X, or equal. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02200 - 6 2.4 MATERIALS TESTING A All soils testing of samples submitted by the CONTRACTOR will be done by a testing laboratory of the OWNER'S choice and at the OWNER'S expense At its discretion, the ENGINEER may request that the CONTRACTOR supply samples for testing of any material used in the work. B. Particle size analysis of soils and aggregates will be performed using ASTM D 422 - Standard Test Method for Particle-Size Analysis of Soils C Determination of sand equivalent value will be performed using ASTM D 2419 - Standard Test Method for Sand Equivalent Value of Soils and Fine Aggregate D Unified Soil Classification System: References in this Section to soil classification types and standards shall have the meanings and definitions indicated in ASTM D 2487. The CONTRACTOR shall be bound by all applicable provisions of said ASTM D 2487 in the interpretation of soil classifications. E The testing for chloride, sulfate, resistively, and pH will be done in accordance with California Test Methods 532 and 643 of the California Department of Transportation. 2.5 IDENTIFICATION TAPE A Unless indicated otherwise, identification tape shall comply with CMWD modified version of the standard specification section 207-25. 2.6 SOIL STERILANT A Soil stenlant or chemical weed control agent shall be a commercial product manufactured specifically to sterilize subgrade soil against growth of weeds, plants, or any type of vegetation. PART 3 -- EXECUTION 3.1 EXCAVATION - GENERAL A General: Except when specifically provided to the contrary, excavation shall include the removal of all materials of whatever nature encountered, including all obstructions of any nature that would interfere with the proper execution and completion of the WORK The removal of said materials shall conform to the lines and grades indicated or ordered. Unless otherwise indicated, the entire construction site shall be stopped of all vegetation and debris, and such material shall be removed from the site CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02200 - 7 prior to performing any excavation or placing any fill The CONTRACTOR shall furnish, place, and maintain all supports and C J shoring that may be required for the sides of the excavations. Excavations ^~ ^ shall be sloped or otherwise supported in a safe manner in accordance with applicable State safety requirements and the requirements of OSHA Safety and Health Standards for Construction (29CFR1926). B. Removal and Exclusion of Water: The CONTRACTOR shall remove and exclude water, including stormwater, groundwater, irrigation water, and wastewater, from all excavations. Dewatenng wells, wellpomts, sump pumps, or other means shall be used to remove water and continuously maintain groundwater at a level at least two feet below the bottom of excavations before the excavation work begins at each location. Water shall be removed and excluded until backfilling is complete and all field soils testing has been completed. 3 2 STRUCTURE, ROADWAY, AND EMBANKMENT EXCAVATION A Excavation Beneath Structures and Embankments: Except where otherwise indicated for a particular structure or ordered by the Project Manager, excavation shall be earned to the grade of the bottom of the footing or slab Where indicated or ordered, areas beneath structures or fills shall be over-excavated The subgrade areas beneath embankments shall be excavated to remove not less than the top 6 inches of native _^ material and where such subgrade is sloped, the native material shall be ( j benched. When such over-excavation is indicated, both over-excavation and subsequent backfill to the required grade shall be performed by the CONTRACTOR. When such over-excavation is not indicated but is ordered by the ENGINEER, such over-excavation and any resulting backfill will be paid for under a separate unit price bid item if such bid item has been established; otherwise payment will be made in accordance with a negotiated price. After the required excavation or over-excavation has been completed, the exposed surface shall be scarified to a depth of 6 inches, brought to optimum moisture content, and compacted as defined under "Compaction of fill, backfill and embankment materials". B Excavation Beneath Paved Areas: Excavation under areas to be paved shall extend to the bottom of the aggregate base or subbase, if such base is called for; otherwise it shall extend to the paving thickness. After the required excavation has been completed, the top 12 inches of exposed surface shall be scarified, brought to optimum moisture content, and compacted as defined under "Compaction of fill, backfill, and embankment materials". The finished subgrade shall be even, self- draining, and in conformance with the slope of the finished pavement Areas that could accumulate standing water shall be regraded to provide a self-draining subgrade. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02200 - 8 C Notification of ENGINEER. The CONTRACTOR shall notify the ENGINEER at least 3 days in advance of completion of any structure excavation and shall allow the ENGINEER a review period of at least one day before the exposed foundation is scarified and compacted or is covered with backfill or with any construction materials. 3 3 PIPELINE AND UTILITY TRENCH EXCAVATION A Exploratory Excavation 1. The CONTRACTOR shall excavate and expose buried points of connection to existing utilities where indicated on the Drawings Excavation shall be performed prior to preparation of Shop Drawings for connections and before fabrication of pipe, and the data obtained shall be used in prepanng Shop Drawings. 2. Data, including dates, locations excavated, and sketches, shall be submitted to the ENGINEER within one week of excavation. 3. Damage to utilities from excavation activities shall be repaired by the CONTRACTOR. B. General: Unless otherwise indicated or ordered, excavation for pipelines and utilities shall be open-cut trenches with widths as indicated on construction drawings. C. Trench Bottom: Except when pipe bedding is required, the bottom of the trench shall be excavated uniformly to the grade of the bottom of the pipe bedding Excavations for pipe bells and welding shall be made as required D. Open Trench- Except by the permission of the Engineer, the maximum amount of open trench permitted in any one location shall be 500 feet, or the length necessary to accommodate the amount of pipe installed in a single day, whichever is greater. All trenches shall be fully backfilled at the end of each day or, in lieu thereof, shall be covered by heavy steel plates adequately braced and capable of supporting vehicular traffic in those locations where it is impractical to backfill at the end of each day. E Indicated Trench Over-Excavation: Where trenches are indicated to be over-excavated, excavation shall be to the depth indicated, and backfill shall be installed to the grade of the bottom of the pipe bedding F. Over-Excavation (Not Indicated) 1. When ordered by the OWNER to over-excavate trenches deeper and/or wider than required by the Contract Documents, the CONTRACTOR shall over-excavate to the dimensions ordered CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02200 - 9 and backfill to the indicated grade of the bottom of the pipe bedding. 2 Payment 3 Over-excavation less than 6-inches more than the indicated trench depth and/or width shall be done at no increase in cost. Additional payment will be made for over-excavation 6 inches or more than the indicated depth and/or width. 4 Additional payment will be based on unit price bid items for over- excavation if such bid items were established, otherwise payment will be based on a negotiated price Volumes of material will be based on survey measurements of the over-excavated area G. Where pipelines are to be installed in embankments, fills, or structure backfills, the fill shall be constructed to a level at least one foot above the top of the pipe before the trench is excavated. H. If a moveable trench shield is used during excavation operations, the trench width shall be wider than the shield so that the shield is free to be lifted and then moved horizontally without binding against the trench sidewalls If the trench walls cave in or slough, the trench shall be excavated as an open excavation with sloped sidewalls or with trench shoring, as indicated and as required by the pipe structural design 3 4 OVER-EXCAVATION NOT ORDERED OR INDICATED A. Any over-excavation carried below the grade ordered or indicated, shall be backfilled and compacted to the required grade with the indicated material. 3.5 EXCAVATION IN VICINITY OF TREES A. Except where trees are indicated to be removed, trees shall be protected from injury during construction operations No tree roots over 2 inches in diameter shall be cut without express permission of the Project Manager Trees shall be supported during excavation by any means previously reviewed by the Project Manager. 3.6 ROCK EXCAVATION A. Rock excavation shall include removal and disposal of the following (1) all boulders measuring 1/3 of a cubic yard or more in volume; (2) all rock material in ledges, bedding deposits, and un-stratified masses which cannot be removed without systematic drilling and blasting; (3) concrete or masonry structures which have been abandoned, and (4) conglomerate deposits which are so firmly cemented that they possess the characteristics l-.i-.. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02200- 10 of solid rock and which cannot be removed without systematic drilling and blasting. B. Rock excavation shall be performed by the CONTRACTOR; provided, that should the quantity of rock excavation be affected by any change in the scope of the work, an appropriate adjustment of the contract price will be made under a separate bid item if such bid item has been established; otherwise payment will be made m accordance with a negotiated price 3.7 DISPOSAL OF EXCESS EXCAVATED MATERIAL A The CONTRACTOR shall remove and dispose of all excess excavated material at a site selected by the CONTRACTOR and reviewed by the ENGINEER All incurred expenses shall be borne by the CONTRACTOR B. Unsuitable material shall be defined as material containing excessive amounts of organic matter, peat, blue clay, trash or debris; or as designated by the ENGINEER; or debris produced by clearing, grubbing, and demolition of existing structures, pavement, or pipe; or soil classified by test method ASTM D2486 as groups OL, CH, MH, OH or PT; or not meeting the grading or classification specified for the work. C. All unsuitable and surplus material remaining after the completion of the work shall be disposed of in a legal manner by the CONTRACTOR and all costs associated with disposal shall be borne by the CONTRACTOR. No unsuitable or surplus material shall be dumped on private property unless written permission is furnished by the OWNER of the property and unless a grading permit is issued from the local jurisdiction. D Unsuitable and surplus material within the confines of the project site shall be disposed of by the CONTRACTOR as specified above. E. Excess unsuitable and surplus materials shall be kept separated from materials of other CONTRACTORS working in the same area. 3 8 BACKFILL - GENERAL A. Backfill shall not be dropped directly upon any structure or pipe Backfill shall not be placed around or upon any structure until the concrete has attained sufficient strength to withstand the loads imposed. Backfill around water retaining structures shall not be placed until the structures have been tested, and the structures shall be full of water while backfill is being placed. B Except for drainrock materials being placed in over-excavated areas or trenches, backfill shall be placed after all water is removed from the CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02200 - 11 excavation, and the trench sidewalls and bottom have been dried to a moisture content suitable for compaction. C. If a moveable trench shield is used during excavation, pipe installation, and backfill operations, the shield shall be moved by lifting the shield free of the trench bottom or backfill and then moving the shield horizontally, The CONTRACTOR shall not drag trench shields along the trench causing damage or displacement to the trench sidewalls, the pipe, or the bedding and backfill. D Immediately prior to placement of backfill materials, the bottoms and sidewalls of trenches and structure excavations shall have all loose sloughing, or caving soil and rock materials removed. Trench sidewalls shall consist of excavated surfaces that are in a relatively undisturbed condition before placement of backfill materials. E Soil Stenlant. Apply soil stenlant or chemical weed control agent under all roads and as indicated, in strict compliance with the manufacturer's dosage and application instructions and with applicable laws, ordinances, and regulations governing use of such chemicals. 3 9 PLACING AND SPREADING OF BACKFILL MATERIALS A. Backfill materials shall be placed and spread evenly in layers. When compaction is achieved using mechanical equipment, the layers shall be evenly spread in 4-inches loose lifts pnor to compaction B Dunng spreading, each layer shall be thoroughly mixed as necessary to promote uniformity of material in each layer. Pipe zone backfill matenals shall be manually spread around the pipe so that when compacted the pipe zone backfill will provide uniform bearing and side support. C Where the backfill matenal moisture content is below the optimum moisture content as specified in ASTM D3017 - Moisture Content. Water shall be added before or dunng spreading until the proper moisture content is achieved. D. Where the backfill matenal moisture content is too high to permit the specified degree of compaction the matenal shall be dned until the moisture content is satisfactory. 3.10 COMPACTION OF FILL, BACKFILL, AND EMBANKMENT MATERIALS A. Each layer of Types A, B, C, G, H, I, and K backfill matenals as defined herein, where the material is graded such that 10 percent or more passes a No 4 sieve, shall be mechanically compacted to the indicated percentage of density. Equipment that is consistently capable of achieving the required degree of compaction shall be used and each layer shall be C j n>'- CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02200-12 compacted over its entire area while the material is at the required moisture content. B. Each layer of Type E, F, and J backfill materials shall be compacted by means of at least 2 passes from a flat plate vibratory compactor. When such materials are used for pipe zone backfill, vibratory compaction shall be used at vertical intervals of 24-mches, measured in the uncompacted state In addition, these materials shall be subjected to vibratory compaction at the spnngline of the pipe and the top of the pipe zone backfill, regardless of whether that dimension is less than 24-mches or not. C Equipment weighing more than 10,000 pounds shall not be used within 4 feet of concrete walls, encasements, and footing. Hand operated power compaction equipment shall be used where use of heavier equipment is impractical or restricted due to weight limitations. D Backfill around and over pipelines that is mechanically compacted shall be compacted using light, hand operated, vibratory compactors and rollers. After completion of at least two feet of compacted backfill over the top of pipeline, compaction equipment weighing no more than 8,000 pounds may be used to complete the trench backfill. E Compaction Requirements: The following compaction test requirements shall be in accordance with ASTM D 1557 - Test Method for Laboratory Compaction Characteristics of Soils Using Modified Effort (56,000 ft - lbf/ft3) (2,700 kN-m/m3) for Type A, B, C, G, H, I, K, M, and N materials and in accordance with ASTM D 4253 - Standard Test Method for Maximum Index Density and Unit Weight of Soils Using a Vibratory Table, and D 4254 - Standard Test Method for Minimum Index Density and Unit Weight of Soils and Calculation of Relative Density, for Type B, E, F, and J materials. Where agency or utility company requirements govern, the highest compaction standards shall apply Percentage of Percentage of Location or Use of Fill Maximum Density Relative Density Pipe embedment backfill for flexible pipe. 95 70 Pipe bedding and over-excavated zones under bedding for flexible pipe, including trench plugs. 95 70 Pipe embedment backfill for Steel Yard Piping — 70 Pipe zone backfill portion above embedment for flexible pipe 90 70 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02200- 13 Pipe embedment backfill for rigid pipe 90 55 Pipe zone backfill portion above embedment for rigid pipe. 90 70 Pipe bedding and over-excavated zones under bedding for rigid pipe. 95 70 Final backfill, beneath paved areas or structures. 95 70 Final backfill, not beneath paved areas or structures. 90 55 Trench zone backfill, beneath paved 95 70 areas and structures, including trench plugs. Trench zone backfill, not beneath paved areas or structures, including trench plugs. 90 70 Embankments and fills 90 55 Embankments and fills beneath paved areas or structures 95 70 Backfill beneath structures and hydraulic structures. 95 70 Backfill and fill around structures on reservoir or structure roof 90 55 Topsoil (Type K material) 80 N.A. Aggregate base or subbase (Type G or M material) 95 N.A. 3 11 PIPE AND UTILITY TRENCH BACKFILL A. Pipe Zone Backfill 1. The pipe zone is defined as that portion of the vertical trench cross- section lying between a plane below the bottom surface of the pipe and a plane at a point above the top surface of the pipe as indicated. The bedding is defined as that portion of pipe zone ; -1 ' - CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02200-14 backfill material between the trench subgrade and the bottom of the pipe. The embedment is defined as that portion of the pipe zone backfill material between the bedding and a level line as indicated. 2. After compacting the bedding the CONTRACTOR shall perform a final trim using a stnngline for establishing grade, such that each pipe section when first laid will be continually in contact with the bedding along the extreme bottom of the pipe. Excavation for pipe bells and welding shall be made as required. 3. The pipe zone shall be backfilled with the indicated backfill material. The CONTRACTOR shall exercise care to prevent damage to the pipeline coating, cathodic bonds, and the pipe itself during the installation and backfill operations 4. If a moveable trench shield is used during backfill operations the shield shall be lifted to a location above each layer of backfill material prior to compaction of the layer. The CONTRACTOR shall not displace the pipe or backfill while the shield is being moved. B. Trench Zone Backfill: After the pipe zone backfills have been placed, backfilling of the trench zone may proceed. The trench zone is defined as that portion of the vertical trench cross-section lying as indicated between a plane above the top surface of the pipe and a plane at a point 18 inches below the finished surface grade, or if the trench is under pavement, 18 inches below the roadway subgrade C. Final Backfill- Final backfill is all backfill in the trench cross-sectional area within 18 inches of finished grade, or if the trench is under pavement, all backfill within 18 inches of the roadway subgrade. D Identification Tape: Install identification tape as indicated. 3.12 FILL AND EMBANKMENT CONSTRUCTION A. The area where a fill or embankment is to be constructed shall be cleared of all vegetation, roots and foreign material. Following this, the surface shall be moistened, scarified to a depth of 6 inches, and rolled or otherwise mechanically compacted. Embankment and fill material shall be placed and spread evenly in approximately horizontal layers. Each layer shall be moistened or aerated, as necessary. Unless otherwise approved by the ENGINEER, each layer shall not exceed 6 inches of compacted thickness. B. Where embankment or structure fills are constructed over pipelines, the first 4 feet of fill over the pipe shall be constructed using light placement and compaction equipment that does not damage the pipe. Heavy i"H-- CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02200-15 construction equipment shall maintain a minimum distance from the edge of the trench equal to the depth of the trench until at least 4 feet of fill over the pipe has been completed. 3.13 FIELD TESTING A. General- All field soils testing will be done by a testing laboratory of the OWNER'S choice at the OWNER'S expense except as indicated below. B Where soil material is required to be compacted to a percentage of maximum density, the maximum density at optimum moisture content will be determined in accordance with Method C of ASTM D 1557 Where cohesionless, free draining soil material is required to be compacted to a percentage of relative density, the calculation of relative density will be determined in accordance with ASTM D 4253 and D 4254 Field density m-place tests will be performed in accordance with ASTM D 1556 - Standard Test Method for Density and Unit Weight of Soil in Place by the Sand-Cone Method, ASTM D 2922 - Standard Test Methods for Density of Soil and Soil-Aggregate in Place By Nuclear Methods (Shallow Depth), or by such other means acceptable to the ENGINEER. C In case the test of the fill or backfill show non-compliance with the required density, the CONTRACTOR shall accomplish such remedy as may be required to insure compliance. Subsequent testing to show compliance shall be by a testing laboratory selected by the OWNER and paid by the CONTRACTOR. D The CONTRACTOR shall provide test trenches and excavations including excavation, trench support, and groundwater removal for the OWNER'S field soils testing operations The trenches and excavations shall be provided at the locations and to the depths required by the OWNER **END OF SECTION** CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02200- 16 SECTION 02372 STORM WATER POLLUTION PREVENTION PART 1 - GENERAL 1 1 SECTION INCLUDES A Preparation, implementation and monitoring of Storm Water Pollution Prevention Plan (SWPPP) for the purpose of preventing the discharge of pollutants from the Project site into receiving waters This includes the elimination of pollution discharges such as improper dumping, spills or leakage from storage tanks or transfer areas B Compliance with local, state, and federal regulations. C Payment of application and annual fees required by the State Water Resources Control Board (SWRCB) until the date of Substantial Completion D Certification that the Project has met all of the conditions of the General Construction Activity Storm Water Permit (GCASP) 1 2 RELATED SECTIONS A GENERAL PROVISIONS Section 2-5 3. Submittals B GENERAL PROVISIONS Section 8 Facilities for Agency Personnel C GENERAL PROVISIONS Section 9 Measurement and Payment PART 2 - PRODUCTS 2.1 MATERIALS A. Provide the quality, grade, and type of materials as specified in the City of Carlsbad Department of Public Works - Development Best Management Practices - Part A - Construction Activities 6. ^ Utilize California Stormwater Quality Association Stprmwater Best Management Practice Handbook for Construction. Download template from ~www. cabmphandbooks. com. PART 3 - EXECUTION 3 1 QUALITY ASSURANCE A Comply with the following as a minimum requirement. 1 The City of Carlsbad Department of Public Works - Development Best Management Practices in accordance with Order no. 2001-01 SUSMP and General Provisions Section 7-8 6. 3.2 PREPARATION AND SUBMITTAL 01/19/06 STORM WATER POLLUTION PREVENTION CARLSBAD MASTER SPECIFICATIONS 02372-1 A Prepare and submit to the OWNER, within fourteen (14) days after the Effective Date of the Contract, four (4) copies of the Storm Water Pollution Prevention Plan (SWPPP) as required to comply with storm water pollution regulations for the Project site B Prepare Notice of Intent application Submit application and application fee made payable to State Water Resources Control Board. Instructions for completing the application can be found on the State Water Resources Control Board web site http //www swrcb ca gov/stormwtr/qen const htmlffconst permit C Prepare SWPPP by downloading instructions from the State Water Resources Control Board web site" http //www swrcb ca gov/stormwtr/qen const html#const permit Download template from www:cabmphandbooks. com. D Where land disturbance is less than one (1) acre, a SWPPP is not required, however, any BMP's indicated in the BMP required to prevent or minimize storm water pollution shall be implemented at no cost to OWNER 3 3 IMPLEMENTATION A. Install perimeter controls prior to starting Work at the Project site B Certain on-site storm water on the Project site. Do not dram on-site water directly into the storm dram C. Designate trained personnel for the proper implementation of the SWPPP. V^ _) D Revise SWPPP to suit changing Project site conditions and also when properly installed systems are ineffective E Upon Substantial Completion. 1 Leave storm water pollution prevention controls in place when required for post- construction storm water management and remove those that are not needed as determined by OWNER OWNER will maintain prevention controls left in place 2 Provide Site Monitoring Reports, SWPPP revisions, Compliance Certifications and related documents to OWNER Post-construction storm water operation and the management plan as mentioned in the compliance certifications are considered to be in place at Final Completion. 34 MONITORING A Conduct examination of pollution prevention controls on a monthly basis, as well as before and after each storm and each day during extended storm events Prepare and maintain, at the Project site, a log of each inspection using Site Monitoring Report forms Notify to RWQCB within 30 days if there is any noncompliance 01/19/06 STORM WATER POLLUTION PREVENTION CARLSBAD MASTER SPECIFICATIONS 02372-2 3 5 LIABILITIES AND PENALTIES A Review of the SWPPP and inspection log by OWNER shall not relive CONTRACTOR from liabilities arising from non-compliance of storm water pollution regulations. B Payment of penalties for non-compliance by CONTRACTOR shall be the sole responsibility of CONTRACTOR C Compliance with the Clean Water Act pertaining is the sole responsibility of CONTRACTOR Any fine against OWNER due to non-compliance by CONTRACTOR, OWNER shall recover all costs of the fine by appropriate assessment 3 6 CHANGE OF INFORMATION A Submit to OWNER completed NOI Form for change of information (Construction Site Information and Material Handling/Management Practices) 3:7 ATTACHMENTS A- '" Attachment "A - Compliance Certification. B , Attachments - Site Monitoring-Report 01/19/06 CARLSBAD MASTER SPECIFICATIONS STORM WATER POLLUTION PREVENTION 02372-3 ATTACHMENT "A" GENERAL CONSTRUCTION ACTIVITY STORM WATER PERMIT COMPLIANCE Name of Project Project Description Contract Number ANNUAL CERTIFICATION I certify the Project has met the following conditions All elements of the Storm Water Pollution Prevention Plan are in place, construction materials and equipment maintenance waste have been disposed of properly, and the Project site is in compliance with all local storm water management requirements including erosion/sediment control requirements, and the appropriate use permits have been obtained CONTRACTOR Print Name Title Signature Date' FINAL COMPLETION CERTIFICATION I certify the Project has been completed and the following conditions have been met All elements of the Storm Water Pollution Prevention Plan have been completed, construction materials and equipment maintenance waste have been disposed of properly, the Project site is in compliance with all local storm water management requirements including erosion/sediment control requirements and the appropriate use permits have been obtained, and a post- construction storm water operation, and management plan is in place. CONTRACTOR Print Name. Title: Signature: Date: 01/19/06 STORM WATER POLLUTION PREVENTION CARLSBAD MASTER SPECIFICATIONS 02372-4 ATTACHMENT "A" STORM WATER POLLUTION PREVENTION SITE MONITORING REPORT Name of Project" Project Description1 Contract Number I Type of Examination: (Use one form for each type of examination) D Prior to Anticipated Storm Event D After Actual Storm Event G Monthly Event Date Examined. II Check the response for each SWPPP question below: NO YES 1 Do you have an approved Storm Water Pollution Prevention Plan (SWPPP) and a BMP Handbook on the Project site7 G Q 2 Does your SWPPP incorporate an up-to-date erosion control plan7 G G 3 Is the erosion control installed per plan7 G G 4 Is the Work at a stage where the erosion control plan cannot be constructed, is the erosion control at the Maximum Extent Practicable for the stage you are in7 G G 5 Did you observe the presence of any floating materials such as oil, grease, pieces of wood, paper, etc , odor, toxics, and/or sediments7 G G 6 If yes, what is that you observed7 III. Check the status of the following items as observed: Not Repairs Date Repairs SWPPP Items Acceptable Acceptable Required Completed 1 De-silting Basins (Cleaned) G Q G 2 Water Quality Basin Q Q Q 3 Silt Fences G G G 4 Hay bales/Check dams/Sandbags G G G 5 Berms and Dikes G Q Q 6 Sand/Gravel Inlet Q G Q 01/19/06 STORM WATER POLLUTION PREVENTION CARLSBAD MASTER SPECIFICATIONS 02372-5 C Contingency to Drill, Case, Set and Pour the Piles If the compacted dam materials cause refusal driving conditions on the initial and two relocation attempts, then the Contractor shall change the installation method to drill, case, set and pour. The HP 12x53 piles shall be installed using a 24-inch conductor and drilling casing that can be drilled in 14 ft and then extracted after the piles are set and while the tremie concrete is placed. It is recognized the bottom template may not be usable in this condition, so GBS surface surveying and a setup that can hold the pile in-place, while the casing is extracted will be required. Should a pile need to be installed by the contingent method, the per lineal foot shall be adjusted by the amount bid per pile for "Piles Install by Drilling" multiplied by the actual number of pile installed by the drill, case, set and tremie pour method. D. Payment The Contractor shall furnish a price which includes all necessary equipment, tools, material, labor, and supervision required to: deliver, handle, install, and cut off the piles; furnish and install the pile top connection plates and bolts, and meet the applicable contract requirements and per the assumed dnvable and refusal driving contingency conditions Payment for piles will be on the basis of the lengths of the piles measured from cut off elevations to final tip elevations No additional payment will be made for: damaged, rejected, or misplaced piles; withdrawn piles other than additional piles withdrawn as directed, any portion of a pile remaining above the cut off elevation; back driving base bid withdrawn piles; cutting off piles; splicing, build-ups; or any cut off length of piles. The contingency to drill, case, set and pour the HP 12x53 will be paid for on a per pile basis, with mobilization pre or post driving attempt, of the drill rig, casing and all associated equipment items, to be included in the per lineal foot, so no additional payment will be made for contingency equipment mobilization therefore. E Splices Splices will not be allowed. 1.3 SUBMITTALS All submittals shall be in accordance with General Provisions, Section 2-5.3. Engineer approval is required for the following submittals: Shop Drawings Pile Driving CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02456 - 2 SECTION 02456 STEEL H-PILES PART I—GENERAL 1.1 REFERENCES The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. Reference Title AWS D1.1 (2004) Structural Welding Code - Steel ASTMA572 (2004) High-Strength Low-Alloy Columbium- Vanadium Structural Steel, Grade 50ksi (HP12x63 Piles & Bearing Plates) ASTMA27 Steel Castings, Carbon, for General Application, Grade 65/35 (H-Pile tip protection, APF Model HP- 7780-B, Versa Steel VS-312-N or equal) ASTMA490 Heat-Treated Steel Structural Bolts, ISOksi Minimum Tensile Strength (7/8" Bolts & Nuts) 1.2 BASIS FOR BIDS AND PAYMENT A Principal Lump Sum The bid price for piling shall be a "Per Lineal Foot" based on TABLE 1 having a total aggregate length of 138 feet (this does not include 9 feet of HP 12x53 for the 3 cross beams between piles). TABLE 1. PILE SCHEDULE FOR BIDDING Location Number Item Length #1 2 HP12x53 23ft #2 2 HP12x53 23 ft #3 2 HP12x53 23ft B. Variations in Pile Quantities The Owner reserves the right to increase or decrease the aggregate length of piles to be furnished and installed by changing the pile locations or elevations, requiring the installation of additional piles, and/or directing the omission of piles from the requirements shown and specified. PI I'M CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02456 -1 A complete and accurate record of each driven pile, within 3 days of completion of driving The record shall indicate the pile location (as driven), size, driven length, embedded length, final elevations of tip and top, pile weight, blows required and hammer energy (fuel setting or readouts) for each foot of penetration throughout the entire length of the pile and for the final 6 inches of penetration, and the total driving time. The record shall also include the type and size of the hammer used, the rate of operation, and the type and dimensions of driving helmet and cushion block used Vibratory hammers may be used. The dynamic force and penetration rates shall be recorded for each foot of H-pile penetration. Any unusual conditions encountered during pile installation shall be recorded and immediately reported to the Project Inspector. Product Data Equipment Description of pile driving equipment to be employed in the work, prior to commencement of pile installations; including details of the pile hammer, power plant, leads, cushion material, and helmet. Driving System Impact hammer shall have an H-pile helmet and a rated energy greater than 15,000 Ib-ft but less than 26,000 Ib-ft. The vibro hammer shall have a minimum rated drive force of 150 tons. Submit a WEAP (Wave Equation Analysis Program) analysis that shows the driving system can install the pile without damage, to the Engineer for approval prior to procurement and at least 2 work-weeks before the driving. Mudhne Template & Construction Sequence Due to the tight tolerances needed to fit the pipe rack beam, between the plumb and aligned HP12x53 pile pairs, either a reinforced concrete or steel template shall be designed and submitted for approval prior to commencement of the work. The shop drawing showing the template design, shall also include sequence diagrams of the rip-rap removals, bottom screeding as needed and the anchoring of the template at the mudhne level, to assure the pile are plumb, with webs in-line in the transverse direction to the pipe line. Barge and/or Flexi-Float Equipment Support CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02456 - 3 The pile driving and contingent drilling & casing equipment work shall be performed from a construction barge, with mooring anchors and spud piles capacity sufficient to support both the base bid and contingent operations. No pile work from the dam crest or a trestle will be allowed. Submit construction sequence drawings that indicate the barge launching and moonng requirements and the orientation of said equipment needed to complete the works safely without damage to existing facilities. Test Reports Field Tests and Inspections Provide driving records as required in paragraph on Pile Driving. Certificates Materials Certified copies of mill test reports for structural steel and tremie concrete prior to commencement of pile installations. Tremie concrete mix for drilled in piles shall have a 28 day compressive strength of 3000 psi, an 8-9 inch slump, 1/2" maximum aggregate and a set retarder as needed to be compatible with the necessary transport time The mix components shall meet the requirements of sections 5 1 and 90 of the Caltran's standard specifications. 1.4 EXPERIENCE The work shall be performed by a general contractor or a specialty subcontractor specializing in marine pile driving and having experience installing piles under similar subsurface and underwater conditions 1 .5 SUBSURFACE DATA & DRIVING REFUSAL CONTINGENCY There are no relevant boring logs in the upstream slope of the dam near where the HP12x53 will be driven. There are records and notes on the old dam drawings, indicating the dam fill below the rip-rap is compacted fill taken from nearby borrow areas. For the purpose of bidding the piling installation, assume the fill is penetrable with the minimum hammer sizes specified Contractor shall make a site visit at low water and provide photos of both the pile installation and the borrow areas as evidence of a pre-bid site visit, and document the observed dam materials along with the name of the recon person and photos of the same at the sites, along with his bid. The bid will be rejected if this evidence of site visit is not provided along with the bid documents on the due date. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02456 - 4 The np-rap shall be completely removed in the area of the six piles The piles and templates shall be stabbed into position, and then driving shall commence. If refusal as defined by 90 bpf penetration resistance, with the minimum impact hammer or greater than 60 seconds per foot for three feet with the vibro-hammer is encountered, then the pile bent pairs shall be extracted and relocated +/- l'-6" uphill or down hill of the locations shown on the plans If that first relocation attempt does not work, then an attempt on the other side shall be made If after the two attempts with any one pile in a bent, the pile continues to hit refusal, then both piles in the bent shall be installed by drilled and cased methods. PART 2—PRODUCTS 2 1 MATERIALS H-pile and bearing plate steel shall conform to ASTM A 572, Grade 50. Piles shall be HP12x53 and no substitutions will be allowed. H-Piles and cross beams shall be coated with an approved high-solids epoxy coating system, in accordance with the manufacturer's recommendations for achieving a 40-year life. Coating of the H-Piles is not required at a depth greater than 4 feet below the base of the 3-ft. rock blanket. Manufacturer's recommendations for surface preparation, as well as coating application and mil thickness shall be submitted for approval and followed by the Contractor. 2 2 EQUIPMENT A. Pile Hammers The hammer used shall have a delivered energy suitable for the total weight of the pile, the character of subsurface material to be encountered, and the pile capacity to be developed. The impact hammer rated energy shall not be less than 15,000 ft-lb, nor greater than 26,000 ft-lb. The dynamic force output for vibratory hammers shall not be less than 100 tons. CITY OF CARLSBADLAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02456 - 5 B Driving Helmets and Pile Cushions A driving helmet or cap, including a hammer cushion, shall be used between the top of the pile and the ram to prevent impact damage to the pile. The driving helmet, or cap and hammer cushion combination, shall be capable of protecting the head of the steel pile, minimizing energy absorption and dissipation, and transmitting hammer energy uniformly over the top of the pile The driving helmet or cap shall fit loosely around the top of the pile so that the pile is not restrained by the driving cap if the pile tends to rotate during driving Clamps for the vibratory hammers shall have sufficient clamping force to transfer all the driving force to the pile without damaging the H-pile One flange may be coped as needed to allow the clamp to fit the web. PART 3—EXECUTION 3 1 INSTALLATION A Pile Driving and Drilling Piles shall be driven to tip elevation. Each pile shall be driven continuously and without interruption until the required depth of penetration is attained. If a pile fails to reach the tip elevation the Contractor shall perform the specified contingency measures, and the .—^ Project Inspector shall be present at all times to verify the specified ( j procedures are needed and followed. See Subsurface Data and Driving Refusal Criteria in conjunction with Driving System for definition of when to change from driven to drilled, cased, set and pour methods. If the drilled, cased, set and pout method is needed, the tremie concrete shall be placed through a sealed tube from the bottom upwards to 5 ft above the top of mudhne, simultaneously with the casing extraction, in such a manner as to always maintain the top of the tremie concrete a minimum of 5 ft above the bottom of the casing. The casing shall be filled with water maintain an inside water level of at least 1 ft above the reservoir level at all times so as not to promote bottom instability during drilling and/or tremie concrete placement. B. Clearing of Rock Blanket The rock blanket (rip-rap) on the dam embankment shall be removed locally to allow for, template setting and pile driving operations. The H- piles shall not be driven or drilled through this layer. Following installation of the H-piles, this layer shall be replaced adjacent to the piles. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02456 - 6 C. Jetting of Piles Jetting of piles will not be permitted. D Splices Splices will not be allowed. E. Welding Shop and field welding, qualification of welding procedures, welders, and welding operators shall be in accordance with AWS D1.1/D1.1M. F Tolerances in Driving Top of pile at elevation of cut off shall be within +37-'/2-inch vertically, +/- 1-inch horizontally, relative to each other, +/- !/2-mch relative to the centerlme between adjacent pile webs both transversely oriented. Rotation of the pile at the connection level shall be less than 1 degree. Pile bents may be moved as needed +/-1 ft - 6-inch global up or down slope along pipe longitudinal centerlme. Piles shall be plumb +7-0.25%. Manipulation of piles to force them into position is permitted. Piles may also be pulled and rednven to attain tolerance. If a gap exists between the pile and soil as a result of redriving, gap shall be filled with a flowable cementitious grout. Contractor shall use a steel or precast concrete template on the slope surface to attain these tolerances Piles damaged or driven outside the above tolerances shall be replaced or additional piles driven at locations specified by the Owner's representative at no expense to the Owner. G. Cutting of Piles Piles shall be cut off at the elevations indicated by a method approved by the Engineer. **END OF SECTION** CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02456 - 7 SECTION 02780 CELLULAR CONCRETE MAT PART 1 - GENERAL 1 1. SCOPE OF WORK The contractor shall furnish all labor, matenals, equipment, and incidentals required and perform all operations in connection with the installation of cellular concrete erosion control mats in accordance with the fines, grades, design and dimensions shown on the Contract Drawings and as specified herein. 1.2. SUBMITTAL. The contractor shall submit to the engineer all manufacturer's performance research results and calculations in support of the cellular concrete mat system and geotextile proposed for use. All calculations must be made in accordance with PART 2.A. of this specification utilizing a windows based computer program developed specifically for the cellular concrete mat. The contractor shall furnish manufacturer's certificates of compliance for cellular concrete blocks/mats, revetment cable, and any revetment cable fittings and connectors to the engineer prior to the start of mat fabrication The contractor shall furnish to the engineer all manufacturer's specifications, literature, shop drawings for the fabrication of the mats, and recommendations, if applicable, that are specifically related to this project, 28 days prior to assembly of the cellular concrete mats. 1.3 RELATED SECTIONS Section 02200 - Earthwork Section 03200 - Concrete Reinforcement Section 03360 - Pneumatically Placed Concrete 1 4 QUALITY ASSURANCE A. Qualifications 1. Each manufacturing firm shall demonstrate 5 years continuous experience, including a minimum of 1,000,000 SF installation in the past 5 years. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02780 - 1 B. Test Sections 1. Prior to production placement of the protective cover soil on the side slopes, the Contractor shall demonstrate with the use of a test section that the proposed placement techniques will not damage the underlying geosynthetics C Manufacturer's Representative' 1 A qualified and experienced manufacturer representative shall be available for a minimum of one day of site assistance at the start of installation, to assist the Contractor in the proper construction/ installation techniques. 2. Thereafter, the representative shall be available on an on call basis during the construction of the remainder of the project. After the installation is completed by the Contractor the manufacturer representative shall inspect the installation and provide notes to the Contractor with any repairs required The representative will issue certificate that the worker was performed according to manufacturer recommendations and it was inspected to confirm that. 1 5 SUBMITTALS A See Section 2-5.3 of the General Provisions. B. Shop Drawings for Engineer's approval: i. Manufacturer's certification that materials comply with required physical properties 11. Manufacturer quality control manuals iii. Original test results iv. Documentation of Partial Factors of Safety in accordance with GRLGG-4. v. Layout plan with proposed size, number, position and direction of all field joints, vi. Proposed details of anchor trench and the interferences with the other lined and unhned sections of the channel, vii. Proposed method of placing protective cover soil on anchor trenches and side trenches. Include documentation that equipment will not damage geogrid. o CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02780 - 2 1 6 Delivery, Storage and Handling A. Cellular concrete mats shall be labeled, handled, and stored in accordance with ASTM D4873 and as specified herein B. Each roll of underlying fabric shall be wrapped in an opaque and waterproof layer of plastic during shipment and storage C. The plastic wrapping shall not be removed until deployment D No hooks, tongs or other sharp instruments shall be used for handling underlying fabric E. Rolls shall not be lifted by use of cables or chains in contact with the underlying fabric. F Underlying fabric shall not be dragged along the ground. PART 2 - PRODUCTS 2 1 GENERAL All cellular concrete mats shall be Sand colored and pre-manufactured of individual concrete blocks with specific hydraulic capacities, bound into mats by the use of revetment cables The mats shall arrive at the jobsite assembled according to lengths and widths as specified on the shop drawings. Individual blocks in the cellular concrete mats shall be interlocked for enhanced stability. The open cell blocks shall sufficient wall thickness to resist breakage dunng shipping and installation. Parallel strands of cable shall extend through two (2) ducts in each block in a manner which provides for longitudinal binding of the blocks within the mats Each row of blocks shall be laterally offset by one-half block width from the adjacent row so that any given block is cabled to four other blocks (two in the row above and two in the row below). Each block shall incorporate interlocking surfaces that prevent lateral displacement of the blocks within the mats when they are lifted by the longitudinal revetment cables The interlocking surfaces must not protrude beyond the perimeter of the blocks to such an extent that they reduce the flexibility or cellular capability of the cellular concrete mats or become damaged or broken when the mats are lifted dunng shipment or placement. Once the mats are in place, the interlocking surfaces shall prevent the lateral displacement of the blocks even if the cables should become damaged or removed. The mats must be able to flex a minimum of 25 degrees between any given row or column of blocks in the uplift direction and a minimum of 45 degrees in the downward direction. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02780 - 3 The cables shall be inserted into the mats in such a manner to form lifting loops at one end of the mat with the corresponding cable ends spliced together to form a lifting loop at the other end of the mat with sleeves approved by the engineer Certification (Open-Channel Flow)- Cellular concrete mats will only be accepted when accompanied by documented hydraulic performance characteristics, derived from tests under controlled flow conditions. Test conditions shall conform to U.S. Federal Highway Administration and U.S Bureau of Reclamation Testing protocol as documented in "Minimizing Embankment Damage During Overtopping Flow", Report No. FHWA-RD-88-181 Performance (Open-Channel Flow): The design of the cellular concrete mats shall be in accordance with the Factor-of-Safety design methodology as described in "Sediment Transport Technology" by D B Simons and F. Senturk, Water Resource Publication, 1977. The cellular concrete mats shall be designed to a minimum safety factor of 1.5. The analysis shall be performed based upon the stability of the mat due to gravity forces alone, neglecting forces which may be due to cabling, mechanical anchorage, contact with adjacent blocks, or other restraint not attributable to gravity based forces The analysis must account for a 0 5 inch block projection. The individual blocks comprising the mat shall have an open area of not more than 20%. All calculations must be based on the following hydraulic parameters: Channel Hydraulic Parameter, Mannings Constant, n = 0.036 Channel Bottom Station Liner Material Grade jSide Slope Discharge Wjdth ' Sta. # to Sta. _# "" " J~ " ~ "ft/ft~" " H:V " " ~" cfs^ _ " ~_~& 0+00 to 0+50i " Shotcrete0~05 Dwg C-5 ' 2,900 "_" 12 0+50tol+00~ Shotcrete ~"~~ 005 "" Dwg C-5 ~ *~_~ 2,900 " 20 ' 1+00 to" 1+50" " Shotcrete"" "" 005 ' '' Dwg C-5 2,90023 "" 1+50 to 1+66.46 " Shotcrete" ~" ~ '~_005 Dwg C-5~ ~_'~2,90Q_~_ __ 23 1+66.46 to 2+00 Cellular Concrete' 0.05 ]5~wg C-5~ __ 2,900 "_" 12 2+OOjto 2+50> ~ Cellular Concrete'"~ 005 ^Dwg C-5[ '." 2,900 '" 12 2+5pJo3+00 CellularConcrete " "_p"._Q5 Dwg cT_". "2,90{j"_""~"_"l2"" 3+00 to 3+50" .Cellular Concrete" " p'.OS" " "Dwg"C-5~ "" 2,900 " "" 12 3"+50~to4+00" ~ Cellular"Concretef" 0 05~"_"'" Owg C-5 ^ ~2~900_"_'_" 12 " If manning constant "n" value used is different than specified, contractor shall submit calculations with substituted n value for Engineers approval prior to any construction work. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02780 - 4 2.2 CELLULAR CONCRETE BLOCKS A Scope 1. This specification covers concrete blocks for erosion control mats used in revetments, storm channels, etc. and for soil stabilization. B Materials 1 Cementitious Materials - Materials shall conform to the following applicable ASTM specifications. a. Portland Cements - Specification C 150, for Portland Cement. b. Blended Cements - Specification C 595, for Blended Hydraulic Cements. c. Hydrated Lime Types - Specification C 207, for Hydrated Lime Types. d Pozzolans - Specifications C 618, for Fly Ash and Raw or Calcinated Natural Pozzolans for use in Portland Cement Concrete. 2. Aggregates shall conform to the following ASTM specifications, except that grading requirements shall not necessarily apply 22.1 Normal Weight - Specification C 33, for Concrete Aggregates. C Physical Requirements 1. At the time of delivery to the work site, the units shall conform to the following physical requirements : Compressive Strength (average of 3 units) • Mm. psi = 4000, mpa = 27.6 Water Absorption (average of 3 units) • Max lb/ft3 = 10, kg/m3 = 160 2. Durability The manufacturer shall satisfy the purchaser by proven field performance that the concrete units have adequate durability even if they are to be subjected to a freeze-thaw environment. 1 "f '•: CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02780 - 5 3 Sample and test units in accordance with ASTM Methods C 140, Sampling and Testing Concrete Masonry Units. D. Visual Inspection 1. All units shall be sound and free of defects that would interfere with the proper placing of the unit or impair the strength or permanence of the construction Surface cracks incidental to the usual methods of manufacture, or surface chipping resulting from customary methods of handling in shipment and delivery, shall not be deemed grounds for rejection 2 Cracks exceeding 0 25 inches in width and/or 1.0 inch in depth shall be deemed grounds for rejection 3. Chipping resulting in a weight loss exceeding 10% of the average weight of the blocks shall be deemed grounds for rejection. 4 Blocks rejected prior to delivery from the point of manufacture shall be replaced at the manufacturer's expense Blocks rejected at the job site shall be repaired with structural grout at the expense of the contractor E Sampling and Testing The purchaser or his authorized representative shall be accorded proper access to the manufacturer to inspect and sample the concrete blocks at the place of manufacture from lots ready for delivery F Expense of Tests Additional testing, other than that provided by the manufacturer, shall be bome by the purchaser. G. Manufacturer Cellular concrete mats shall be ARMOKFLEXR 60-T or approved equal The cellular concrete mats shall be Sand colored and have the following nominal characteristics. Cellular Concrete Mat Physical Properties CLASS TYPE ~" """" _"~BLOCK~WmGHT " OPEN AREA ~_ " ~" _ " Lbs./Sq J[t ~ " ~_' '__ %" ~~ ~ ' 60-T or approved Open 67-73 ' 20 equal i' i >•- CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02780 - 6 2.3 REVETMENT CABLE AND FITTINGS Galvanized Steel Revetment Cable. Revetment cable shall be constructed of preformed galvanized steel aircraft cable. The cable shall be made from individual wires and strands that have been formed during the manufacturing process into the shape they have in finished cable. Cable shall exhibit resistance to concentrations of acids, alkalis, and solvents. Fittings such as sleeves and stops shall be aluminum, washers shall be galvanized steel. The revetment cable shall have the following physical properties. Nominal Approx. Ave Weight/100 ft Cable Diam Strength Lbs. Mm Ibs. Max Lbs. 1/8" 3,700 2.47 2.74 3/16" 7,000 399 4.42 1/4" 10,000 4.75 5.26 3/8" 15,000 8.93 9.90 2 4 FILTER FABRIC A high strength (mm. 200 Ibs of Grab Tensile) woven mono-filament filter fabric with a minimum 10% open area is to be utilized on top of a 4-inch Type H graded dram rock base. The following filter fabrics shall be used: 1) Armortec, Filterweave 70/20 2) Mirafi, Filterweave 500 3) Approved Equal During all periods, of shipment and storage, the filter fabric shall be protected from direct sunlight, ultraviolet rays and temperatures greater than 140 degrees Fahrenheit To the extent possible, the fabric shall be maintained and wrapped in its protective covering. 2 5 SIZE OF CELLULAR CONCRETE MATS The cellular concrete blocks, cables and fittings shall be fabricated at the manufacturer or another approved location into mats with a width of up to eight (8) feet and a length of up to forty (40) feet or approved by the Engineer CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02780 - 7 PART 3 - FOUNDATION PREPARATION, FILTER FABRIC AND MAT PLACEMENT 3 1 FOUNDATION AND PREPARATION General Areas on which filter fabric and cellular concrete mats are to be placed shall be constructed to the lines and grades shown on the Contract Drawings and to the tolerances specified in the Contract Documents, and approved by the Engineer. Grading. The slope shall be graded to a smooth plane surface to ensure that intimate contact is achieved between the slope face and the filter fabric, and between the filter fabric and the entire bottom surface of the cellular concrete mats. All slope deformities, roots, grade stakes, and stones which project normal to the local slope face must be regraded or removed NO holes, "pockmarks", slope board teeth marks, footprints, or other voids greater than 1 0 inch in depth normal to the local slope face shall be permitted NO grooves or depressions greater than 0.5 inches in depth normal to the local slope face with a dimension exceeding 1 0 foot in any direction shall be permitted. Where such areas are evident, they shall be brought to grade by placing compacted homogenous matenal. The slope and slope face shall be uniformly graded, compacted, and the depth of layers, homogeneity of soil, and amount of compaction shall be as specified in Section 02200, Earthwork. Excavation and preparation for anchor trenches, side trenches, and toe trenches or aprons shall be done m accordance to the lines, grades and dimensions shown in the Contract Drawings. The anchor trench hinge-point at the top of the slope shall be uniformly graded so that no dips or bumps greater than 0.5 inches over or under the local grade occur The width of the anchor trench hinge-point shall also be graded uniformly to assure intimate contact between all cellular concrete blocks and the underlying grade at the hinge-point. Inspection Immediately prior to placing the filter fabric and cellular concrete mats the prepared area shall be inspected by the Engineer, the owner's representative, and or by the manufacturer's representative. No fabric or blocks shall be placed thereon until that area has been approved by one of these parties. 3.2. PLACEMENT OF FILTER FABRIC General Filter fabric, as specified elsewhere, shall be placed within the limits shown on the Contract Drawings CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02780 - 8 Placement. The filter fabric shall be placed directly on the prepared area, in intimate contact with the subgrade, and free of folds or wrinkles The filter fabric shall not be walked on or disturbed when the result is a loss of intimate contact between the cellular concrete mats and the filter fabric or between the filter fabric and the subgrade. The filter fabric shall be placed so that the upstream strip of fabric overlaps the downstream strip. The longitudinal and transverse joints shall be overlapped at least two (2) feet. The filter fabric shall extend at least one foot beyond the top and bottom revetment termination points. When the cellular concrete mats are placed as large mattress, the top lap edge of the filter fabric should not occur in the same location as a joint between cellular concrete mats unless the space is rilled with concrete. 3 3 PLACEMENT OF CELLULAR CONCRETE BLOCKS/MATS General. Cellular concrete block/mats, shall be constructed within the specified lines and grades shown on the contract drawings. Placement The cellular concrete mats shall be placed on the filter fabric in such a manner as to produce a smooth plane surface in intimate contact with the filter fabric. No individual block within the plane of placed cellular concrete mats shall protrude more than one-half inch or as otherwise specified by the Engineer. The equipment used to lay the concrete mats shall have adequate capacity to place the mats without bumping, dragging, tearing or otherwise damaging the underlying filter fabric. The mats shall be placed side by side, so that the mats abut each other. Mat seams or openings between mats greater than two (2)inches shall be filled with grout. Distinct changes in grade will result in a discontinuous revetment surface in the direction of flow shall require a grout seam at the grade change location so as to produce a continuous surface Anchor trenches and side trenches shall be back filled and compacted flush with the top of the blocks. The integrity of a soil trench back fill must be maintained so as to insure a surface that is flush with the top surface of the cellular concrete mats for its entire service life. Toe trenches shall be back filled as shown on the Contract Drawings. Back filling and compaction of trenches shall be completed in a timely fashion. No more than 500 lineal feet of placed cellular concrete mats with non-completed anchor and/or toe trenches shall be permitted at any time. Consultation. The manufacturer of the cellular concrete blocks/mats shall provide design and construction advice during the design and installation phases of the project. **END OF SECTION** CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02780 - 9 SECTION 02830 CHAIN LINK FENCE AND GATES 1 1 GENERAL A. THE REQUIREMENT 1 The CONTRACTOR shall furnish all tools, equipment, materials, and supplies and shall perform all labor required to complete the work as indicated on the Drawings and specified herein. 2. This section covers the work necessary for the chain link fence and gate(s), including removal of a portion of existing fence and reinstalling the chain link fence and gate(s) as shown on the Drawings and specified in the Contract Documents B REFERENCE SPECIFICATIONS, CODES AND STANDARDS 1. SSPWC Section 206-6 Chain Link Fence & Section 304-3 Cham Link Fence. C. CONTRACTOR SUBMITTALS 1. Submittals shall be made in accordance with Section 2-5.3 of the General Provisions D QUALITY ASSURANCE 1. Comply with the applicable Reference Specifications of the GENERAL REQUIREMENTS. 1.2 PRODUCTS A. GENERAL 1. All materials and fittings shall be in conformance with SSPWC Section 206-6 Chain Link Fence or as otherwise shown on the Drawings. Chain link fabric shall be black Polyvmyl Chloride (PVC) coated fabric 9-guage wire with 1-inch mesh pattern. 2. Salvaged material from the existing fence shall be undamaged and acceptable to the Construction Manager prior to reuse or remstallation. Any material not reused shall be removed as directed by the Project Manager. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02830 -1 3. Like items of materials provided hereunder shall be the end products of one manufacturer in order to achieve standardization for appearance, maintenance, and replacement. B POSTS, RAILS AND BRACES 1. The materials for posts, rails and braces shall be m conformance with SSPWC Section 206-6.2. C. CHAIN LINK FABRIC 1 All chain link fabric shall be PVC coated per SSPWC 206-6 3.2 and black in color 9-guage wire with 1 -inch mesh pattern. D. TRUSS OR TENSION RODS 1. Truss or tension rod used m construction shall be m conformance with SSPWC Section 206-6.5. E. FITTINGS 1 All required fittings and hardware shall be galvanized and in conformance with SSPWC Section 206-6.6. F BARBED WERE 1. Barbed wire shall be m conformance with SSPWC Section 206- 6.7. G. REPAIR OF DAMAGED COATINGS 1. Repairs to abraded or otherwise damaged zinc coating shall be made in conformance with SSPWC Section 206-6.8. H GATES 1. Gates shall be swing or sliding as indicated, complete with latches, stops, keepers, hinges, or rollers and roller tracks. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02830 - 2 2. Gate frames shall be constructed of tubular members welded at all corners or assembled with fittings On steel, welds shall be painted with zinc-based paint. Where corner fittings are used, gates shall have truss rods of 5/16-mch minimum nominal diameter to prevent sag or twist. Gate leaves shall have vertical intermediate bracing as required, spaced so that no members are more than 8 feet apart. Gate leaves 10 feet or over shall have a horizontal brace or one 5/16-inch minimum diagonal truss rod When fence has barbed wire top, the end members of the gate frames shall be extended 1 foot above the top horizontal member to which three strands of barbed wire, uniformly spaced, shall be attached by use of bands, clips, or hook bolts. 3. Fabricate frames of standard weight pipe 1.90-inch outside diameter, weight 2.72 pounds per linear foot. 4 Gate hinges shall be of adequate strength for gate and with large bearing surfaces for clamping in position. The hinges shall not twist or turn under the action of the gate. The gates shall be capable of being opened and closed easily by one person 5 Gate latches, stops, and keepers shall be provided for all gates. Latches shall have a plunger-bar arranged to engage the center stop, except that for single gates of openings less than 10 feet wide a forked latch may be provided. Latches shall be arranged for locking with padlocks. Center stops shall consist of a device arranged to be set in concrete and to engage a plunger-bar of the latch of double gates. No stop is required for single gates. Keepers shall consist of a mechanical device for securing the free end of the gate when in the full open position. a. Double Gates- Size and configuration shall be as indicated. Provide gate stops for all double gates, consisting of mushroom type or flush plate with anchors. Set in concrete to engage the center drop rod or plunger bar. Provide locking device and padlock eyes as an integral part of the latch, requiring one padlock for locking both gate leaves b Sliding Gates: Provide manufacturer's standard heavy-duty track, ball-bearing hanger sheaves, overhead framing and supports, guides, stays, bracing, and accessories as required. All sliding gates shall be rolling, cantilever slide, or overhead (top) suspended, as indicated on Drawings. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02830 - 3 6. Rolling gate track rollers shall be malleable iron or heavy pressed steel construction, with provision for regular grease lubncation Ground rollers shall have malleable iron or heavy pressed steel hubs with similar provision for lubncation. Gate track shall be Schedule 40 pipe, firmly attached to support posts on 7-foot maximum centers. Gates more than 8 feet in height shall have three tracks. Rolling gate frames shall be constructed similar to swing gates except diagonal bracing shall reflect different support type. 7. Cantilever gate rollers shall have heavy malleable rollers, needle or ball bearings with fittings for regular lubncation Maximum spacing of support posts is 10 feet. Additional weight supporting posts with lower roller shall be provided on 10-foot maximum centers. Support posts shall be 4-mch diameter, Schedule 40, set 36-mch minimum depth. Top and lower rails of gate shall be 2- 3/8-inch OD, Schedule 40 pipe. Vertical support posts shall be on 6 foot maximum spacing, 1-7/8-inch OD, Schedule 40 pipe, all diagonal bracing 1-5/8-inch OD, Schedule 40 pipe, all connections welded and painted. 8 Keeper. Provide keeper for all vehicle gates, which automatically engages the gate leaf and holds it in the OPEN position until manually released. I. CONCRETE 1. Matenals as specified in Section 03300; 03300 Cast-In-Place Concrete. Proportions shall be 1:2:4. Compressive strength shall not be less than 2,500 psi at 28 days. 1.3 EXECUTION A INSTALLATION 1 Installation of fencing shall meet the requirements of ASTM F 567. 2 Fence Construction shall be in conformance with SSPWC Section 304-3.2. 3 Installation of Gates shall be in conformance with SSPWC Section 304-3.3. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02830-4 B. REMOVAL AND RESETTING OF EXISTING FENCE 1. All accessories shall be removed carefully and all materials stored in a safe place until required for resetting The CONTRACTOR shall provide all new material necessary to replace lost or damaged material and as required for a complete and satisfactory installation. In general, the salvaged fencing shall be reinstalled as specified for new material. All concrete shall be removed from posts before they are reset. The CONTRACTOR may furnish all new materials, rather than salvage and reuse the existing fence. C CLEANUP 1. Upon completion of the fence installation, clean up all waste material resulting from the operation to the satisfaction of the Project Manager. **END OF SECTION** CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 02830 - 5 SECTION 03200 CONCRETE REINFORCEMENT PART 1—GENERAL 1.1 DESCRIPTION This section specifies reinforcing steel for use in reinforced concrete. 1.2 QUALITY ASSURANCE A. QUALITY CONTROL BY CONTRACTOR: To demonstrate conformance with the specified requirements for cast-in- place concrete, the Contractor shall provide the services of an independent testing laboratory which complies with the requirements of ASTM E329. The testing laboratory shall sample and test concrete related materials as required in Section 03300, Cast-m-Place Concrete. Costs of testing laboratory services shall be borne by the Contractor. B. REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified. In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Reference Title ACI315-80 Details and Detailing of Concrete Reinforcement ASTM A82-90 Steel Wire, Plain, for Concrete Reinforcement ASTM A185-90 Steel Welded Wire, Fabric, Plain for Concrete Reinforcement ASTM A615/A615M Deformed and Plain Billet-Steel Bars REV B-92 for Concrete Reinforcement ASTM A616/A616M-92 Rail-Steel Deformed and Plain Bars for Concrete Reinforcement 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03200 - 1 ASTM A617/A617M-92 ASTM A706/A706M Axle-Steel Deformed and Plain Bars for Concrete Reinforcement Low-Alloy Steel Deformed Bars for REV B-92 Concrete Reinforcement ASTM A775/A775M-92 Epoxy-Coated Reinforcing Steel Bars ASTM E329-93 AWSD 1.4-92 CRSI-PRB-86 CRSI-MSP 1-86 FEDSPEC QQ-W-461H-78 Inspection and Testing Agencies for Concrete, Steel, and Bituminous Materials as Used in Construction Structural Welding Code—Reinforcing Steel Placing Reinforcing Bars Manual of Standard Practice Wire, Steel, Carbon (Round, Bare, and Coated) 1.3 PLACING DRAWINGS The Contractor shall prepare reinforcement placing drawings conforming to the requirements of ACI 315. Placing drawings shall include bar lists, schedules, bending details, placing details, and placing plans and elevations as required to fully delineate this portion of the work. PART 2—PRODUCTS 2.1 BAR REINFORCEMENT Reinforcing bars shall be deformed billet steel in conformance with ASTM A615, including supplementary requirements. Bars shall be Grade 60, except ties or field-bent bars where specified shall be Grade 40. Bars to be welded shall be Grade 40 or shall be deformed billet steel conforming to ASTM A706. ASTM A616 or ASTM A617 steel shall not be used. Bars provided as dowels for future construction and bars where specified shall be epoxy-coated in conformance with ASTM A775. 2.2 WIRE FABRIC Wire fabric shall be welded steel mesh conforming to ASTM A185. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03200 - 2 2.3 WIRE AND PLAIN BARS Wire used as reinforcement and bars used as spiral reinforcement in structures shall be cold drawn steel conforming to ASTM A82. 2.4 TEE WIRE The wire shall be minimum 16 gage annealed steel conforming to FEDSPEC QQ.W-461H 2.5 BAR SUPPORTS Bar supports coming into contact with forms shall be CRSI Class 1 plastic protected or Class 2 stainless steel protected and shall be located in accordance with CRSI MSP-1 and placed in accordance with CRSI PRB. Concrete block supports shall be provided for footing and slabs on grade. Stainless steel or plastic protected plain steel supports shall be provided for other work. 2.6 PRODUCT DATA The following information shall be provided prior to installation in accordance with Section 01300, Submittals: 1. Certified mill test reports 2. Welder qualification certificate in accordance with AWS D1.4. PART 3—EXECUTION 3.1 FABRICATION Reinforcing steel shall not be bent or straightened in a manner which will injure the material. Bars with kinks or with bends not shown shall not be used. Heating or welding bars shall be performed in accordance with AWS D1.4 and shall only be permitted where specified or approved by the Construction Manager. Bars shall not be welded at the bend. 3.2 PLACEMENT Reinforcing steel shall be placed in accordance with CRSI PRB and CRSI MSP-1. Reinforcing steel shall be positioned accurately and secured against displacement by using annealed iron wire at intersections and shall be supported by concrete or metal chairs, spacers or metal hangers. Tack welding of cross bars is not acceptable. Bars shown on the drawings shall not be repositioned (buried) to act as support bars. Additional bars shall be provided as required for supports. Steel 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03200 - 3 rods and pegs may be used to support reinforcing steel on rock foundations. Reinforcing steel shall be placed in such a manner as to not damage waterproofing membrane or plastic lining which has been previously applied or constructed. Reinforcing steel shall be shop-bent or slightly relocated where necessary to clear waterstop. Reinforcing steel shall not be placed on fresh concrete or forced into fresh concrete. Supports for embedded items shall not be welded to the reinforcement. Additional reinforcement may be provided for this purpose. 3.3 SPLICING Reinforcing steel shall be spliced as shown. Additional splices may be provided where approved by the Construction Manager. In slabs, beams, girders and walls, reinforcing steel shall not be spliced in areas of maximum stress. Splices of adjacent bars shall be staggered at least one splice length, unless otherwise specified. Splices in welded wire fabric shall be at least 1 1/2 meshes wide. 3.4 CLEANING Reinforcing steel shall be cleaned of mill rust scale, dried concrete, or other coatings that may reduce bond. Reinforcement reduced in section is not acceptable. When concrete placement is delayed, reinforcement shall be cleaned by sandblasting if directed by the Construction Manager. 3.5 REPAIR OF EPOXY COATING Epoxy coating damage need not be repaired in cases where the damaged area is 0.1 square inch or smaller. All damaged areas larger than 0.1 square inch shall be repaired in conformance with ASTM A775. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03200 - 4 SECTION 03300 CAST-IN-PLACE CONCRETE PART 1—GENERAL 1 1 DESCRIPTION A. This section specifies cast-in-place concrete for footings, slabs, floors, walls, piers, channels, pavements, sidewalks, curbs, pipe bedding encasement, electrical conduit encasement, and miscellaneous structures. 1.2 QUALITY ASSURANCE A. Quality Control by Contractor 1. To demonstrate conformance with the specified requirements for cast-in-place concrete, the Contractor shall provide the services of an independent testing laboratory, which complies, with the requirements of ASTM E329 Costs of testing laboratory services shall be borne by the Contractor B. Basis for Quality 1. Cast-in-place concrete shall conform to the requirements of ACI 301, except as modified. Unless specified otherwise, all formwork shall conform to ACI 347. C. References 1. This section contains references to the following documents. They are a part of this section as specified and modified. In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Reference Title ACI 211.1-89 Recommended Practice for Selecting Proportions for Normal and Heavy Weight Concrete ACI 301-89 Specifications for Structural Concrete for Buildings ACI 305R-89 Hot Weather Concreting CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03300 - 1 Reference ACI 306R-88 ACI 347-89 ASTMC31-90 ASTM C33-90 ASTM C39-86 ASTM C42-87 ASTM C94-90 ASTM C136-84a ASTM C143-90 Title Cold Weather Concreting Concrete Form-work Standard Method of Making and Curing Concrete Test Specimens in the Field Concrete Aggregates Standard Test for Compressive Strength of Cylindrical Concrete Specimens Obtaining and Testing Drilled Cores and Sawed Beams of Concrete Ready-Mixed Concrete Sieve Analysis of Fine and Coarse Aggregates Standard Test for Slump of Portland Cement Concrete ASTM Cl 50-89 Portland Cement ASTM C172-82 ASTM C260-86 ASTM C309-89 ASTM C494-90 ASTM E329-90 Sampling Fresh Concrete Air-Entraining Admixtures for Concrete Liquid Membrane-Forming Compounds for Curing Concrete Chemical Admixtures for Concrete Inspection and Testing Agencies for Concrete, Steel, and Bituminous Materials as Used in Construction 1.3 SUBMITTALS A. Reports of concrete mix designs shall be provided to the Construction Manager. Requirements for the reports are specified in paragraph 03300-2.08. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03300 - 2 PART 2—PRODUCTS 2.1 MATERIALS A. Cement 1. Portland cement shall be ASTM C150, Type II or Type V, low alkali, containing less than 0.60 percent alkalies. B. Aggregates 1. General' Fine and coarse aggregates shall conform to ASTM C33. Fine and coarse aggregates shall be tested in accordance with ASTM C136. Aggregates shall be nonreactive and shall be washed before use. When sources of aggregates are changed, test reports shall be provided for the new material. The tests specified shall be performed prior to commencing concrete work. 2. Fine Aggregate: Fine aggregate shall be hard, dense, durable particles of either sand or crushed stone regularly graded from coarse to fine Gradation shall conform to ASTM C33. 3. Coarse Aggregate: Coarse aggregate shall be hard, dense and durable gravel or crushed rock free from injurious amounts of soft and friable particles, alkali, organic matter and other deleterious substances. Gradation of each coarse aggregate size specified in paragraph 03300-2.02 A shall conform to ASTM C33-Table 2. C. Admixtures 1. General: Admixtures shall be compatible with the concrete. Calcium chloride or admixtures containing calcium chloride are not acceptable. Admixtures shall be used in accordance with the manufacturer's recommendations and shall be added separately to the concrete mix. 2. Water Reducing Retarder: Water reducing retarder shall be ASTM C494, Type D, and shall be Master Builders, Pozzolith 300-R; Sika Chemical Corp., Plastiment; or equal. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03300 - 3 Air Entraining Agent Air entraining agent shall be Master Builders, MB-AE10, W. R. Grace and Co, DaraVair; or equal The air entraining agent added shall produce, in accordance with ASTM C260, an entrained air content specified in paragraph 03300-2.02 A for each class of concrete. D. Water 1. Water for washing aggregate, for mixing and for curing shall be free from oil and deleterious amounts of acids, alkalies, and organic materials. 2 2 CONCRETE CHARACTERISTICS A. Mix Proportioning 1 Concrete shall be normal weight concrete composed of specified cement, admixtures, aggregates and water proportioned and mixed to produce a workable, strong, dense, and impermeable concrete. Concrete shall be provided in accordance with the following Concrete class B C Eb ASTM coarse aggregate size 467 67 467 Min. cement content, sacks/cu yd concrete 5.25 5.25 3.25 Maximum water/cement ratio by weight 045 0.50 0.55 Minimum percent air content 2.5 3.5 2.5 Maximum slump in inches 4 41/2 6 Minimum3 28-day ( compressive strength, psi 4,000 4,000 2,000 Notes for table: a Compressive strength shall be determined at the end of 28 days based on test cylinders made and tested in accordance with ASTM D39 b Concrete encasement for electrical conduit shall contain 3 pounds of red oxide per sack of cement. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03300 - 4 1-Sack Cement Slurry Cement slurry shall consist of 5.2 to 60 gallons per 94-pound sack of Portland cement. Cement shall conform to ASTM C150, type II. Cement slurry shall not exceed 17.0 pounds per gallon. Cement weight shall be measured prior to installation as an indicator of water-cement ratio The slurry may contain sand, not to exceed 50 percent by volume of cement. Sand shall be equivalent of 30 Water used for the slurry shall be potable. B. Use 1. Concrete shall be provided by class for the corresponding use listed as follows: Class of Type of Use Concrete Concrete 12 inches thick and greater B Concrete less than 12 inches thick C Pipe bedding and encasement, E electrical conduit encasement (duct banks) and concrete fill C. Control 1. Before beginning concrete work, the Contractor shall determine the proper proportions of materials for class of concrete B and C. Methods for selecting and adjusting proportions of the ingredients shall be in accordance with ACI 211.1 Reports from the concrete supplier of each mix design shall state whether the items reported comply with the specifications and shall show (1) the expected strength, (2) corresponding slump, (3) expected drying shrinkage, (4) weights and test results of the ingredients, and (5) other physical properties necessary to check each mix design. Copies of the reports shall be submitted in accordance with paragraph 03300-1.03. 2.3 WATERSTOPS A Waterstops in construction joints shall be The Burke Company's Vinylbck Type RB316-6; Water Seals, Inc., 6-inch Flex-Bulb; or equal. Waterstops 17n'- CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03300 - 5 m expansion joints shall be The Burke Company's Vmylock Type ^-^ RB38-9; Water Seals, Lie , 9-inch heavy-duty Flex-Bulb; or equal. ( J 2 4 SEALANTS AND JOINT FILLERS A Sealants and preformed joint fillers shall be as per construction drawings 2.5 BONDING COMPOUNDS A Epoxy resin bonding compounds shall be used for wet areas and shall be Adhesive Engineering, Concresive Nos. 1001, 1001-LPL or 1180 as applicable; Sika Chemical Corporation, Sikadur 35, Hi-Mod LV, Sikadur 32, Hi-Mod, or Sikadur 31, Hi-Mod Gel as applicable; Burke Company 881 LPL Epoxy; or equal. Nonepoxy bonding compounds shall be used for dry areas and shall be Burke Company, Acrylic Bondcrete; Imperial Chemical Industrial, Inc., Thoro System Products, Acryl 60; Thorobond; or equal. Bonding compounds shall be applied in accordance with the manufacturer's instructions. 2.6 RETARDANT A. Retardant for exposing aggregates for nonformed surfaces in construction joints shall be Sika Rugasol-S, Horn Aggretex-H, Burke Company True Etch Surface Retarder, or equal. Retardant shall be applied in accordance with manufacturer's instructions sufficient to assure a minimum penetration of 1/8 inch. 2.7 CURING AND SEALING COMPOUNDS A. Curing and sealing compound shall be Master Builders, Masterseal; A. C. Horn Inc., Horn Clearseal EMI 80; Burke Company Spartan-Cote WB Cure Seal Hardner; or equal; conforming to ASTM C309. Curing compounds shall be clear and shall be applied in accordance with the manufacturer's instructions, except as otherwise specified. 2.8 PRODUCT DATA The following information shall be provided in accordance with Section 1.3: A. Manufacturer's Data Copies of manufacturer's data shall be provided for the following: 1. Waterstops 2. Retardants 3. Curing compounds C j no-- CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03300 - 6 4 Bonding compounds 5. Admixtures B. Test Reports 1. Three copies of reports from the concrete supplier shall be provided certifying that all concrete materials comply with the specifications and all test requirements. C Ready-Mixed Concrete Truck Delivery Tickets 1. Each load of ready-mixed concrete delivered to the job site shall be accompanied by a delivery ticket showing the information listed in ASTMC94, Section 16 PART 3—EXECUTION 3.1 GENERAL A. Construction of cast-m-place concrete shall be in accordance with the pertinent recommendations contained in ACI Manual of Concrete Practice of 300 Group. 3.2 CONCRETE A. Concrete shall be truck-mixed, ready-mixed concrete conforming to the applicable portions of ASTM C94. Materials shall be proportioned by weighing The Contractor shall be responsible for producing concrete of the specified characteristics. B Concrete shall be delivered to the site of work, and discharge shall be completed within 1-1/2 hours after introduction of the water to the mixture. 3.3 CONVEYING AND PLACING CONCRETE A. Conveying Concrete Concrete shall be conveyed from the mixer to the forms in accordance with ACI 301, Chapter 8. Concrete which has segregated in conveying shall be removed from the site of the work. B. Placing Concrete 17i r~ CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03300 - 7 1 General- Concrete shall be placed in accordance with ACI 301, Chapter 8, and ACI 304, Chapter 6. Pumped concrete shall be the class and consistency specified in paragraph 03300-2.02. 2. Placing Concrete in Hot Weather: In hot weather (above 85 degrees F), concrete shall be placed in accordance with ACI 305R. 3. Placing Concrete in Cold Weather: In cold weather (below 45 degrees F), concrete shall be placed in accordance with ACI 306R 3 4 CONCRETE FORMWORK Formwork shall be installed in accordance with ACI 347. 3 5 CURING AND SEALING A. General 1. Concrete curing shall be completed by water curing or by using a clear membrane curing compound or by a combination of both methods. Repairs or treatment of concrete surfaces shall be coordinated so that interruption of the curing will not be necessary 2. Concrete surface temperature shall be maintained between 50 degrees F and 80 degrees F for at least 5 days. Curing concrete in hot weather (above 85 degrees F) shall be in accordance with ACI 305 R. Curing concrete in cold weather (below 45 degrees F) shall be in accordance with ACI 306 F. B. Water Curing 1. When water curing is used, concrete shall be kept wet continuously for a minimum of 10 days after placement. Absorptive mats or fabric may be used to retain moisture during the curing period. C. Curing Compound 1. When curing compound is used, it shall be applied as soon as the concrete has set sufficiently so as not to be marred by the application or immediately following form removal for vertical and other formed surfaces. Preparation of surfaces, quantities used, application procedures, and installation precautions shall be followed in strict compliance with the manufacturer's instructions. 2. Curing compound shall not be used on concrete surfaces to be coated, waterproofed, or moisture proofed. ! 7(j-.l CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03300 - 8 3.6 PROTECTION A. Concrete shall be protected from injurious action by sun, ram, flowing water, frost and mechanical injury. 3.7 CONSTRUCTION JOINTS A. Construction joints shall be located and formed as specified. A rough surface of exposed concrete aggregates shall be produced using a surface retardant at construction joints. The limit of the treated surfaces shall be 1 inch away from the joint edges. Within 24 hours after placing, retarded surface mortar shall be removed either by high pressure water jetting or stiff brushing or combination of both so as to expose coarse aggregates. A rough surface of exposed aggregate may also be produced by sandblasting followed by high pressure water jetting. Sandblasting, if used, shall remove 1/8 inch of laitance film and shall expose coarse aggregate to insure adequate bond. B. Reinforcing steel and welded wire fabric shall be continued across construction joints. Waterstops shall be provided in construction joints at locations as specified 3.8 INSERTS AND EMBEDMENTS A. , Inserts 1 Where pipes, castings or conduits are to pass through structures, the Contractor shall place such pipes or castings in the forms before placing the concrete, or he may provide openings in the concrete for subsequent insertion of such pipes, castings or conduits. Such openings shall be provided with waterstops and V-shaped construction joint as shown and shall have a slight flare to facilitate grouting and permit the escape of entrained air during grouting. 2. Additional reinforcement shall be provided around large openings as shown. The grout shall be nonshrink grout. B. Embedments 1. Gate frames, gate thimbles, special castings, channels or other miscellaneous metal parts that are to be embedded m the concrete shall be set and secured in the forms prior to concrete placement. Unless otherwise specified, anchor bolts and inserts shall be embedded in concrete as shown. The Contractor shall provide CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03300 - 9 inserts, anchors or other bolts necessary for the attachment of _^ piping, valves, metal parts and equipment Operators or sleeves ( j for gate or valve stems shall be positioned to clear reinforcing steel, conduit and other embedments, and to align accurately with equipment. 3.9 EXPANSION JOINTS A. Expansion joints shall be as specified. Reinforcement or other embedded metal items bonded to the concrete shall not extend through expansion joints. Waterstops shall be provided m expansion joints as specified in paragraph 03300-3.10. 3.10 WATERSTOPS A. Waterstops shall be provided at the specified locations. Waterstops shall be securely held in position during placing of concrete. If, after placing concrete, Waterstops are materially out of position or shape, the surrounding concrete shall be removed, the waterstop reset, and concrete replaced in accordance with paragraph 03300-3.11. 3.11 MODIFICATION OF EXISTING CONCRETE A. Existing concrete shall be removed and the remaining surfaces resurfaced as specified. The remaining concrete shall be protected from damage. Clean lines shall be made by sawing through the existing concrete. The concrete may be broken out after initial saw cuts in the event thickness prevents cutting through Where it is not possible to use a saw, the initial cuts shall be made with chipping hammers. These cuts shall be sufficient to prevent damage to the remaining concrete In general, an opening in existing concrete shall be oversized 1 inch on all sides and built back to the correct dimension with an epoxy grout Where oversized openings cannot be made, the concrete shall be cut to the correct dimension, with the exposed reinforcing cut back an additional 1 inch and the resulting hole filled with epoxy grout. Cut or broken concrete surfaces shall be resurfaced with an epoxy grout. Concrete surfaces to be coated shall be dry. Where new concrete adjoins existing concrete surfaces or surfaces which have been cut, such surfaces shall be cleaned by sandblasting to remove laitance, loose coatings and foreign materials, and coated with the bonding compound just prior to the placement of the new concrete Bonding compounds shall be as specified in paragraph 03300-2 05. Unless otherwise specified, continuity of reinforcing steel shall be obtained across the joint either by exposing existing bars to provide sufficient laps with new bars or by welding existing bars with new bars. Dowels shall be drilled and set with epoxy grout into existing concrete. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03300-10 3.12 FORMED SURFACE FINISHES A. Repair of Surface Defects Surface defects, including tie holes, minor honeycombing or otherwise defective concrete shall be repaired in accordance with ACI301, Chapter 9 Areas to be patched shall be cleaned Patches on exposed surfaces shall be finished to match the adjoining surfaces after they have set. Patches shall be cured as specified for the concrete. B Finishing 1. Finish A' Finish A shall be a grout clean finish in accordance with ACI 301, Section 10.3.2. Surfaces shall be lightly sandblasted prior to sacking. For interior areas not exposed to moisture or weather, water used m the mortar shall be mixed with a PVA bonding compound as recommended by the manufacturer. Unless otherwise specified, Finish A shall be provided for all surfaces exposed to view, both painted and unpainted. 2. Finish B Finish B shall be the same as Finish A, except that the final burlap rubbing may be omitted, providing the steel trowel scraping removes the loose buildup from the surface. Finish B shall be provided for waterproof and moisture proof coated surfaces. 3. Finish C: Finish C shall be a finish which has surface imperfections less than 3/8 inch in any dimension. Surface imper- fections greater than 3/8 inch shall be repaired or removed and the affected areas neatly patched. Finish C or smoother shall be provided for interior surfaces of tanks and channels from 1 foot below minimum water surfaces and down and otherwise unfinished interior surfaces. 4. Finish D. Unless otherwise specified, Finish D shall be the finish for surfaces not exposed to view in the finish work or by other construction, which may be left as they come from the forms, except that tie holes shall be plugged and defects greater than 1/2 inch in any dimension shall be repaired. 313 SLAB FINISHES A. General CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03300 -11 1 Where finish is not specified, floor slabs shall receive steel troweling Dry cement shall not be used on new concrete surfaces to absorb excess moisture. Edges shall be rounded to a radius of 1/2 inch Joints shall be grooved to a radius and depth of 1/4 inch each. B Float Finish 1. Float finish shall conform to ACI 301, Section 1172. Floating shall be performed with a hand or power-driven float. Floating of any one area shall be the minimum necessary to produce the finish specified Floating shall compact and smooth the surface and close any cracks and checking of surfaces Float finish shall be applied to surfaces of channel and tank bottom slabs and to footings. C. Steel Trowel Finish 1. Steel trowel finish shall conform to ACI 301, Section 11.7.3. Immediately after final troweling, the surface shall be cured and protected as specified in paragraphs 03300-3.05 and 03300-3.06. Steel trowel finish shall be provided on floors unless specified otherwise D. Broomed Finish 1. Broomed finish shall conform to ACI 301, Section 11.7.4. Broomed finish shall be provided for walks, tops of walls, slabs on grade exposed to atmosphere, and where otherwise specified. 3.14 FIELD SAMPLING AND TESTING OF CONCRETE A General 1. Field sampling and testing shall be performed by the independent testing laboratory specified in paragraph 03300-1.02 A. Samples of concrete shall be taken at random locations and at such times to represent the quality of the materials and work throughout the project. The laboratory shall provide the necessary labor, materials and facilities for sampling, casting, handling and storing the concrete samples at the site of work. The minimum number of samples and tests are specified in paragraph 03300-3.14 C. B. Sampling CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03300 -12 1 Concrete shall be sampled as follows and tested in accordance with paragraph 03300-3.14 C. Samples of plastic concrete shall be obtained in accordance with ASTM C172. Samples for pumped concrete shall be taken at the hose discharge point. Samples for other concrete shall be taken at the hopper of transit mix truck. Testing 1. Strength Tests: The strengths specified for the design mix shall be verified by the testing laboratory during placement of the concrete. Verification shall be accomplished by testing standard cylinders of concrete samples taken at the job site. Standard cylinders shall represent the concrete placed in the forms. One set of three standard cylinders shall be cast for each 50 cubic yards, or fraction thereof, for concrete placed in structures, building slabs and footings, but at least three cylinders shall be taken from any one batch. Casting, handling and curing of cylinders shall be in accordance with ASTM C31. Additional cylinders shall be provided when an error in batching is suspected. For the first 24 hours after casting, the cylinders shall be kept moist in a storage box constructed and located so that its interior air temperature will be between 60 and 80 degrees F. At the end of 24 hours, the cylinders shall be transported to the testing laboratory. Testing of specimens for compressive strength shall be in accordance with ASTM C39. Tests shall be made at 7 and 28 days from time of casting. One test cylinder from each group of three shall be tested at the end of 7 days, and two shall be tested at the end of 28 days. Each strength test result shall be the average of the strengths of two test cylinders at 28 days, except that if one cylinder in a set of two shows evidence of low strength due to improper sampling, casting, handling or curing, the result of the remaining one cylinder shall be used. The average of any three consecutive 28-day strength test results of the cylinders representing each class of concrete shall be equal to or greater than the specified strength and not more than 10 percent of the strength test results shall have values less than the specified 28-day strength for the total job concrete. No individual strength test results shall be less than the specified strength by more than 500 pounds per square inch. Certified reports of the test results shall be provided directly to the Construction Manager. Test reports shall include sufficient CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03300-13 information to identify the mix used, the stationing or location of the concrete placement, and the quantity placed. Slump and ambient temperature shall be noted. If the 28-day test results fall below the specified compressive strength for the class of concrete required for any portion of the work, adjustment in the proportions, water content, or both, shall be made as necessary at the Contractor's expense. Changes and adjustments shall be reported in writing to the Construction Manager. If compressive test results indicate concrete in place may not meet structural requirements, tests shall be made to determine if the structure or portion thereof is structurally sound. Tests may include, but not be limited to, cores in accordance with ASTM C42 and any other analyses or load tests acceptable to the Construction Manager. Costs of such tests shall be borne by the Contractor. 2. Tests for Consistency of Concrete: The slump shall be as specified when measured in accordance with ASTM C143 Samples for slump determination shall be taken from the concrete during placing. Slump tests shall be performed whenever standard cylinders are cast. D. Final Laboratory Report 1 A final report, prepared by the testing laboratory, shall be provided at the completion of all concreting. This report shall summarize the findings concerning concrete used in the project and provide totals of concrete used by class and structure. 3.15 CLEANUP 1. Upon completion of the work and prior to final inspection, the Contractor shall clean all concrete surfaces, except outside sidewalks or paved areas and those having curing and sealing compound. **END OF SECTION** CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03300 -14 SECTION 03360 PNEUMATICALLY PLACED CONCRETE 1 1 GENERAL A. THE REQUIREMENT 1 The CONTRACTOR shall furnish, place, finish, cure, and protect all pneumatically-placed concrete and shall furnish and install all appurtenant work, in accordance with the requirements of the Contract Documents. 2. Pneumatically-placed concrete "Gunite" or "Shotcrete" as referred to herein shall mean any mixture of portland cement, sand and aggregate which is dry mixed in a machine, conveyed by air through a hose, hydrated at the discharge nozzle, and deposited by air pressure to its final position in the construction. B RELATED WORK SPECIFIED ELSEWHERE 1. Section 03200, Concrete Reinforcement. 2 Section 03300, Cast-m-Place Concrete. C. REFERENCE SPECIFICATIONS, CODES, AND STANDARDS 1 Comply with the current provisions of the following Codes and Standards. ANSI/ACI 506 Practice for Shotcreting ASTM C 31 Practices for Making and Curing Concrete Test Specimens in the Field ASTM C 40 Test Method for Organic Impurities in Fine Aggregates for Concrete ASTM C 42 Methods of Obtaining and Testing Drilled Cores and Sawed Beams of Concrete ASTM C 87 Test Method for Effect of Organic Impurities in Fine Aggregate on Strength of Mortar CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03360 -1 ASTMC136 Method for Sieve Analysis of Fine and Coarse Aggregates ASTM C 150 Specification for Portland Cement D. CONTRACTOR SUBMITTALS 1 Submittals shall be made in accordance with Section 2-5 3 of the General Provisions. 2. The following subrmttals and specific information shall be provided a. Shop Drawings The CONTRACTOR shall provide shop drawings of all steel reinforcing. b. Report of concrete mix design shall be provided to the Project Manager. E. QUALITY ASSURANCE 1. The concrete test specimen shall be made for each 150 cubic yard or fraction thereof. Three specimens shall be cut from each concrete block 7 days after its placing. The samples shall be cured as specified in ASTM C 31 One cylinder will be tested for the 7- day strength, the other 2 will be tested at 28 days in accordance with ACI 506 The remainder of the concrete blocks shall be cured and stored until after the 28-day test has been made and until the ENGINEER has informed the CONTRACTOR, m writing, that no additional specimens have to be cut and tested. All concrete specimens shall be properly numbered and dated and a record shall be made by the CONTRACTOR as to the relative location of the work for which these samples were prepared. 2. Special Inspection: It is required that all pneumatically-placed concrete work specified herein shall be subject to inspection by a special INSPECTOR approved by the DISTRICT, and no such work shall be scheduled or performed without making prior arrangements to have said special INSPECTOR present during all such construction operations hereunder. 1.2 PRODUCTS A. MATERIALS 1. Cement: Cement shall comply with the requirements of ASTM C 150 Type II, low alkali. The CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03360 - 2 Sand: Sand shall consist of natural sand obtained from a source acceptable to the ENGINEER and shall in all cases be washed. The control of the washing of sand shall be such that the finer particles are retained or removed as required. Washed or saturated sand shall be allowed to dram at least 24 hours to a uniform moisture content before batching. Dry sand shall be moistened before handling when necessary to prevent segregation. The sand shall be screened through a horizontal vibrating screen having square openings, and the grading as determined in accordance with the methods prescribed by ASTM C 136 shall be within the following limits: Passing a 3/8-mch square sieve Passing a No. 4 sieve Passing a No. 8 sieve Passing a No. 16 sieve Passing a No. 30 sieve Passing a No. 50 sieve Passing a No. 100 sieve Passing a No. 200 sieve PERCENT 100 90 to 100 65 to 90 45 to 75 30 to 50 30 to 50 2 to 8 Oto4 The difference between the percentages passing the No. 30 and the No. 50 sieves shall not exceed 32. Sand shall be composed of clean, hard, strong, durable, uncoated grains, free from shale, lumps, and soft or flaky particles and from injurious amounts of dust, alkali, organic matter, loam, mica, or other deleterious substances. When tested in accordance with the methods prescribed by ASTM C 40, the color of the supernatant liquid shall not be darker than the standard specified therein and shall not contain more than a total of 3 percent by volume of clay, silt, mica, or other objectionable inorganic materials, as determined by settlement after thoroughly mixing and shaking the sample with 2-1/2 times its volume of a 3 percent (by weight) solution of sodium hydroxide in a graduated column. Sand which in any respect varies from the foregoing requirements shall not be used in the work, and the CONTRACTOR shall do all sorting, crushing, screening, blending, washing, and other operations necessary to make the available material conform to said requirements, and shall receive no extra compensation 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03360 - 3 therefore, nor for the necessity of separating and wasting any part ^-^ of the natural materials. In case the finer particles from the ( j crushed coarse aggregate are permitted or required to be mixed with the sand from natural deposits, the 2 products shall be uniformly blended before washing or screening to insure a combined product of constant composition. 5. Sand as prepared for use shall be of such quality that 2-inch by 4- inch test cylinders made with a mixture of cement and the sand under test shall develop compressive strengths at 7 and 28 days of not less than 90 percent of those developed by a concrete mix prepared in the same manner with the same cement and graded Ottawa testing sand, all in accordance with the method prescribed in ASTM C 87. 6. Water: Water for pneumatically-applied concrete shall be furnished by the CONTRACTOR. All water shall be clean and free from objectionable quantities of organic matter, alkali, salts, and other impurities which might reduce the strength, durability, or other quality of the pneumatically-applied concrete. 7. Reinforcement: Pneumatically-applied concrete shall be reinforced with welded wire fabric. Welded wire fabric reinforcement shall conform to the requirements of ASTM A185 — welded steel wire fabric plain, for concrete reinforcement, and the details indicated. Welded wire fabric with longitudinal wire of W4 size wire and smaller shall be in flat sheets or in rolls with a core diameter of not less than 10 inches. Welded wire fabric with longitudinal wires larger than W4 size shall be in flat sheets only. 8. Pigments: Commercial colorants suitably compounded for use in gumte mixes. Do not exceed manufacturer's recommended pigment-to-cement ratio. Appropriate colorants shall be added to produce a "Sand" colored final product. B. EQUIPMENT 1. Mixers: Mixers shall be of a type and size which is sufficient to supply all materials required by the nozzles used while providing a mixing time of not less than 1-1/2 minutes after all the cement and aggregate have been placed in the mixer. 2. Placing Machines: For pneumatically-applied concrete placed by the dry-mix process, the minimum air pressure shall be 45 psi on the gun tank when 100 feet or less of hose is used and the pressure shall be increased 5 psi for each additional 50 feet of hose. The pressure shall also be increased 5 psi for each 25 feet that the 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03360 - 4 nozzle is located above the elevation of the gun tank. The maximum nozzle diameter shall be 1-5/8 inches unless the otherwise permitted by the Project Manager. Water pressure at the nozzle shall be at least 15 psi above the air pressure at the nozzle. Discharge nozzle shall be equipped with a manually operated water-injection system for directing an even distribution of water through the sand-cement mixture. The water valve shall be capable of ready adjustment to vary the quantity of water, and shall be convenient to the nozzleman. A properly operated air compressor of ample capacity to maintain a supply of clean, dry air adequate for maintaining sufficient nozzle velocity for the application to be performed and at the same time operate a blow pipe for clearing rebound shall be used. C. PROPORTIONING 1. Pneumatically-placed concrete shall ordinarily be mixed in the proportions of one sack of cement (94 pounds) to 4-1/2 cubic feet of sand, but the relative proportions of sand and cement shall be subject to change acceptable to the Project Manager as the materials used or results obtained indicated to be desirable at any time during the progress of the work. Appropriate colorants shall be added to produce a "Sand" colored final product. 1.3 EXECUTION A. GENERAL 1. Pneumatically-placed concrete shall be used on the work where shown; and, where not shown, may be used only with written approval of the Construction Manager. Pneumatically-placed concrete shall consist of dry-mixed fine aggregate and portland cement pneumatically-placed by a suitable mechanism, to which mixture the water is added immediately previous to its expulsion from the nozzle. B. RESTRICTIONS ON PLACING PNEUMATICALLY-PLACED CONCRETE 1. Wind: Pneumatically-placed concrete shall not be applied under strong wind conditions, as evidenced by the removal of a considerable amount of cement and moisture from the concrete spray. In areas where strong winds prevail and work must proceed, a richer mix than specified, and is acceptable to the Construction Manager, shall be used. The nozzleman shall work against the direction of the wind to avoid concrete being applied on rebound that has been carried with the wind. Shields shall be 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03360 - 5 placed around the nozzleman to prevent the loss of cement earned away by the wind. 2. Cold Weather: Pneumatically-placed concrete may be applied in cold weather, provided, that the surfaces are not frozen, the temperature during the day is expected to rise at least to 40 degrees F, and the night temperature of the first night after application is not predicted to drop below 27 degrees F. The CONTRACTOR shall apply concrete under these conditions solely at his own nsk. In order to gain quicker setting-up times, Type III high-early- strength portland cement would be considered subject to approval by the Engineer. 3. Ram: Whenever rain has damaged newly-placed concrete, the Project Manager may order such concrete to be removed when it has been determined that a significant amount of cement has been washed out. The CONTRACTOR prior to placing any new layers shall consult with the Construction Manager as to whether or not the concrete damaged by rain is acceptable to the Construction Manager or must be replaced. 4. Low Humidity: Under low humidity conditions (below 50 percent) in conjunction with wind, the CONTRACTOR shall immediately cease placing operations until there has been an improvement in the wind and humidity conditions as determined by the Construction Manager. Continuous water-curing shall be started as soon as the concrete has hardened sufficiently to prevent a washout of cement. C. PROTECTION OF ADJACENT WORK 1. The CONTRACTOR shall take every possible precaution to protect adjacent work, concrete surfaces, vehicles, equipment, etc., from being damaged by overshooting concrete and by materials earned by the wind. Overshot concrete and rebound concrete shall be removed before it adheres. D. PROPORTIONING 1. Structural, pneumatically-placed concrete shall be proportioned by volume on the basis of one part of cement to vanous parts of sand, according to the following table for the stated compressive strengths at 28 days: PRESUMPTIVE COMPRESSIVE STRENGTH IN psi AT 28 DAYS 4000 CEMENT / SAND RATIO BY VOLUME 1:4 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03360-6 The relative proportions of sand and cement shall be subject to adjustment by the Construction Manager as the materials used or results obtained indicate the desirability at any time during the progress of the work. 2. Compressive Strength: Unless otherwise specified, the minimum 28-day compressive strength of the pneumatically-placed concrete shall be 4,000 psi. E. MIXING 1. Mixing and placing of pneumatically-placed concrete shall conform to the requirements specified herein and to the applicable recommendations given in ANSI/Ad 506. 2. The sand and cement shall be thoroughly mixed in a dry state before being deposited in the placing machine or its hopper. Machine mixing will be required unless specific authority to use hand mixing is given by the Project Manager. The machine and its operation shall be acceptable to the Project Manager. The mixing operation shall continue for a period of not less than 1-1/2 minutes after all sand and cement has been placed in the mixer. The sand shall contain or be moistened with 6 to 10 percent of water by volume and shall not be mixed with the cement until just before placing in the hopper in order to insure against partial setting of the cement. Dry-mixed materials shall be used promptly after mixing. Any materials that remain in the hopper longer than 45 minutes after mixing shall be discarded. Rebound, recovered clean and free of foreign matter and otherwise in acceptable condition for reuse, may be reused as sand in a quantity not to exceed 20 percent of the total sand requirements. F. PREPARATION OF FOUNDATION 1. The foundation for areas to receive pneumatically-placed concrete shall be brought to line and grade as indicated on the Contract Documents or as otherwise acceptable to the Project Manager. The areas shall be thoroughly compacted and tested as specified in Section 02200, Earthwork. Sufficient moisture shall be added to provide a firm foundation and to prevent absorption of water from the concrete, but the foundation shall not contain free surface water. When indicated in the Contract Documents, joints, side forms, and shooting strips shall be provided for backing or paneling. Ground or gaging wires shall be used where necessary to establish thicknesses, surface planes, and finish lines. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03360 - 7 mud, dirt, mortar droppings, or other objectionable material by means of a bush hammer or sandblasting, before application. Concrete bonding agents shall be applied to all concrete surfaces to which pneumatically-placed concrete is to be applied. 3. Where shown on the Contract Documents, studs shall be used to anchor pneumatically-placed concrete to existing concrete. G. JOINTS 1. Contraction control joints shall be provided in the locations shown; where not shown, such joints shall be provided at approximately 15 ft spacing each direction in the case of unremforced pneumatically-placed concrete, and at approximately 30 ft spacing each direction in the case of reinforced pneumatically-placed concrete. Construction joints shall be provided as shown, or if not shown, as placing stops at locations selected by the CONTRACTOR and acceptable to the Project Manager. 2. Construction joints, or a day's work joints, shall be sloped off to a thin, clean, regular edge. Before placing the adjoining work, the sloped portion and adjacent gunite shall be thoroughly cleaned as necessary, then wetted and scoured with an air jet. H. PLACING WHERE NO FORMS ARE USED 1. Preparation of Subgrade: All cleaning, excavation, fill, backfill, grading of compacted fill, and disposal of excess earth shall be done prior to the application of pneumatically-placed concrete. The surfaces against which pneumatically-placed concrete are to be applied shall be left in a thoroughly compacted condition, and shall be neatly trimmed to line and grade. All surfaces shall be wetted before application, but pneumatically-placed concrete shall not be placed on any surface on which free water exists. 2. Thickness: Minimum thickness shall be 4 inches unless otherwise indicated in the Contract Documents. Pneumatically-placed concrete shall be installed to the full thickness of the lining in one application, unless the limit of thickness, as described above, is attained. 3. Reinforcement: Reinforcement shall be as shown; provided, that where welded wire fabric is indicated it shall be spliced as follows: (1) side splices of sheets or roll shall be spliced a minimum of one mesh plus 2 inches; (2) longitudinal splices, or direction of principal stress, shall be spliced a minimum of 2 mesh plus 2 inches. Tie wires shall only be used on cross wires on side splices and on longitudinal wires on end splices. 17()74 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03360 - 8 4. Ground Wires: Ground wires shall be installed in channels or ditches in such a manner that they accurately outline the finished surface of the lining as shown. They shall be located at intervals sufficient to insure proper thickness throughout. Wires shall be stretched tight and shall not be removed prior to application of the finish coat. 5. Headers: Headers shall be installed along the channel where shown. Headers shall be securely fastened to line and grade. 6. Placing a. Pneumatically-placed concrete shall be placed in the most expeditious manner as determined by the location of the work. There shall be a nozzleman's helper in attendance at the nozzle whose duty shall be to raise the reinforcement mat sufficiently to permit placing of concrete beneath the mat at frequent intervals to insure proper location of reinforcement. The reinforcing mat shall not be pulled through already placed concrete. Where sides of the channel do not terminate against headers, concrete shall be earned over the side in a berm of not less than the lining thickness, and/or a cut-off wall to prevent moisture seeping under the lining. b. Whenever possible the nozzle shall be held at right angles to the surface and at a distance of 2-1/2 to 3-1/2 feet. Gunite shall emerge from the nozzle in a steady, uninterrupted flow. When the flow becomes intermittent for any cause, the nozzle shall be diverted from the work until the stream again becomes constant. Hydration shall be thorough and uniform without the use of excessive water. c. In shooting banks, application shall begin at the bottom. The limit of thickness and the height shall be determined when the material begins to sag. d. In shooting slabs, the nozzle shall be held at a slight angle so that rebound is blown onto the finished portion where it shall be removed. The air blowout jet shall be constantly employed to keep the work free of rebound. The limit of material to be placed in one layer shall be reached when it begins to show evidence of too much moisture. e. Rebound pockets, sags, or other defects shall be carefully cut out and replaced with new gunite. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03360 - 9 f. The use of "puddled" gunite to facilitate placing of gunite in difficult places shall not be allowed. g. No work shall be done without the permission of the ENGINEER when the temperature is lower than 40°F. After placing, the pneumatically-placed concrete shall be protected from freezing or quick drying. 7. Finishing: After the concrete has been placed as nearly as practicable to the required depth, the surface shall be checked with a straight edge and any low spots or depressions shall be brought up to proper grade by placing additional pneumatically-placed concrete in such a manner that the finished surface is reasonably smooth. Following this, the surface shall receive a wood float finish. 8- Weep Holes: Where weep holes are shown, they shall be installed so that they are flush with the surface of the lining, and open. I. PLACING AGAINST FORMS 1- Forms: Forms shall be of plywood or sheathing and shall be true to line and level. They shall be substantially braced to insure against excessive vibration. Forms shall be built so as to permit the escape of air and rebound and to facilitate the placing of pneumatically-placed concrete. Wall intersections shall be formed in such a manner as to afford a minimum loss of time in pneumatically placing the concrete at the intersection. This may be accomplished by the installation of short removable bulkheads at these points. Columns shall be formed on 2 adjacent sides only where practicable. Forms for beams shall be constructed of a soffit and one side. Where acceptable to the Project Manager, such forms may be constructed of a soffit form only and a vertical backing of fine wire mesh near the center. Wood beams and shores shall be provided below the soffit in such a manner that no deflection will occur under the load to be superimposed. 2. Sufficient time shall be allowed for installing such of the work which must be attached to forms. Forms shall be thoroughly wetted with water prior to application of the concrete. 3. Reinforcement: Reinforcement shall be of the sizes and configuration specified or shown in the Contract Documents. Adequate chairs, ties, or other supports shall be used to maintain the reinforcing in the position required. 4. Ground Wires: Adequate ground wires to be used as screeds shall be installed to establish the thickness and surface planes of the 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03360 - 10 work. Both horizontal and vertical ground wires shall be installed at corners and offsets not clearly established by the form work. In general these will occur at exterior corners, one column or beam comer, water tables, sills, belt courses, etc. Ground wires shall be placed so that they are tight and true to line and in such a manner that they may be easily tightened up. Ground wires shall not be removed until application of the finish coat. 5. Placing: Whenever possible, except when enclosing reinforcing steel, the nozzle shall be held at right angles to the surface and at a distance of 2.5 to 3.5 ft. When enclosing steel, the nozzle shall be held so as to direct the material behind the bars. Each side of each bar shall be shot separately. When enclosing reinforcing steel, a nozzleman's helper equipped with an air blow-out jet shall precede the nozzleman and blow out all rebound, sand, etc., which may have lodged behind the bars. Pneumatically-placed concrete shall emerge from the nozzle in a steady, uninterrupted flow. When flow becomes intermittent for any cause, the nozzle shall be diverted from the work until the stream again becomes constant. Hydration shall be thorough and uniform without the use of excessive water. 6. In shooting walls or columns, application shall begin at the bottom and the first coat shall completely embed the reinforcement adjacent to the form. The limit of thickness and height shall be determined when the materials begin to sag. 7. In shooting beams, a surface at right angles to the nozzle shall be maintained. Beams, in general, shall not be shot from the top. Where beams are formed of a soffit and a mesh backing at the centerlme, they shall be shot from both sides in such a manner that no sags occur. 8. In shooting slabs, the nozzle shall be held at a slight angle to the work so that rebound is blown on to the finished portion where it shall be removed. The air blow-out jet shall be constantly used to keep the work free of rebound. The limit of material to be placed in one layer shall be reached when it begins to show evidence of too much moisture. All loose material or rebound shall be removed from the surface being concreted before placing the next layer. Reinforcement shall be cleaned of any previously deposited concrete which might prevent proper bond to it. Sufficient time shall be allowed between layers for the material to set. Before set has taken place and before placing any succeeding layer, laitance shall be removed by wire brushing. Any laitance which has set shall be removed by sandblasting. Surfaces shall be damp at all 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03360- 11 times. Rebound pockets, sags, or other defects shall be carefully cut out and replaced with new pneumatically-placed concrete. 9. Finishing: Upon reaching the thickness and planes outlined by forms and ground wires, the surface shall be rodded off to true lines. Low spots shall be built out to proper thickness. Upon completion of rodding, ground wires shall be removed. The finish coat shall be applied starting from the top of walls and working down so that pneumatically-placed concrete is not shot over the finished work. All exposed surfaces shall be finished to straight and true lines, as shown. 10. Finish shall be a wood float finish. J. JOINTS 1. Construction Joints: Particular care shall be given to formation of construction joints. They shall be sloped to a thin, clean edge. No square joints will be allowed. The location of all construction joints in structural members shall be acceptable to the ENGINEER. Before placing the adjoining work, the sloped portion and adjacent pneumatically-placed concrete shall be thoroughly cleaned as necessary, then wetted and scoured with an air jet. 2. Formed Joints: All formed joints shall be constructed as detailed, at the locations shown. K. CURING 1. Pneumatically-placed concrete shall be damp cured for at least 14 days after placing. Curing shall conform to the applicable requirements of Section 03300, Cast-m-Place Concrete, except as otherwise specified herein. No concrete shall be placed during freezing weather except when proper protective measures are taken as with ordinary concrete work. Concrete shall not be placed against frosted surfaces. 2. When required by the Project Manager the CONTRACTOR shall provide longer curing times or supplemental methods for curing concrete in structural members, and no additional payment will be allowed therefore. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03360 - 12 SECTION 03400 PRECAST CONCRETE VAULTS PART 1—GENERAL 1 1 DESCRIPTION A. SCOPE This section specifies the materials and labor required for the manufacture and erection of precast concrete vaults. Coordinate with specification 02200 regarding additional requirements. B. TYPE Precast concrete includes vaults. C. Related Section The work of the following section applies to the work of this section. Other sections of the specifications not referenced below shall also apply to the extent required for proper performance of this work. Section 02200- Earth Work Section 03300- Cast-in-Place Concrete 1.2 QUALITY ASSURANCE A. GENERAL The Contractor shall provide certification from the precast concrete manufacturer that the materials and manufacture of precast work supplied conforms to these specifications. The certification shall be signed by an officer of the manufacturer's corporation. The responsibility for furnishing and installing precast concrete conforming to the specifications is solely that of the Contractor. B. TESTING LABORATORY All testing shall be performed by recognized independent laboratories specializing in the particular test to be performed, and conforming to the requirements of the National Bureau of Standards and ASTM E329. r<V4 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03400- 1 C. REFERENCES This section contains references to the following documents. They are part of this section as specified and modified. In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Reference (Latest Edition) Title ACI318 Building Code Requirements for Reinforced Concrete AWS D1.1 Structural Welding Code - Steel AASHTO Standard Specification for Highway Bridges MNL-116 Prestressed Concrete Institute's Manual for Quality Control for Plants and Production of Precast and Prestressed Concrete Products, third edition 1.3 SUBMITTALS The following submittals shall be provided: A. CONCRETE MIX Prior to casting any precast elements, concrete mix design shall be submitted to the Construction Manager for acceptance. B. SHOP DRAWINGS Shop drawings shall be provided showing product location, fabrication details, number identification marks, reinforcement, connection details including field installed anchor sizes and locations, if required, openings, loose or embedded items and inserts, dimensions and relationship to adjacent materials in sufficient detail to cover manufacture, handling, and erection. C. LABORATORY TEST REPORTS Before delivery of materials, three copies of the reports of the tests specified herein shall be provided. Test reports on previously tested materials shall be accompanied by the manufacturer's statement that the previously tested material is the same type, quality, manufacture, and make as that proposed for use in this project. Test reports are required for the following: 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03400-2 1. Cement 2. Aggregates 3. Pozzolan 4. Admixtures 5. Curing compounds 6. Waterstops 7. Concrete mix designs 1.4 LABELING Each panel or member shall have an identification mark indicating its location in the structure as shown on the placing diagrams and date of casting. 1.5 HANDLING AND STORAGE Unless specified otherwise herein, fabrication, handling and erection of precast elements shall be in accordance with the recommendations made by ACI 318 and ACI Committee 533. Precast elements shall be properly supported off the ground to avoid damage during curing, storage, handling and transporting. Lateral support shall be sufficient to prevent bowing, warping, or permanent set due to creep. Edges of the units shall be adequately protected by padding or other means to prevent staining, chipping or spalhng of concrete. Lifting devices shall have a minimum safety factor of 4. PART 2—PRODUCTS 2.1 PERFORMANCE AND DESIGN REQUIREMENTS A. Unless otherwise indicated or specified, the minimum compressive strength of the concrete at end of 28 days shall be 4,000 psi. B. Design live loads for structural precast units shall comply with H-20 loading. 2.2 PRECAST CONCRETE MATERIALS A. CEMENT Concrete in contact with soil or liquids shall be formulated using Type II or Type V portland cement conforming to ASTM C150. Concrete not in contact with soil or liquids may be formulated using Type I or Type HI ] 7074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03400-3 Portland cement. Cement shall contain less than .60 percent alkalies and shall be from one source throughout the entire project. B. AGGREGATES Aggregates for normal weight concrete shall conform to ASTM C33 with a maximum size of 3/4 inch C WATER Water shall be clean, potable, free from injurious amounts of oil, alkalies, organic materials and other deleterious substances. D. ADMIXTURE Admixture shall be Pozzohth 300-R manufactured by Master Builders, Plastiment manufactured by Sika Chemical Corp., or equal. Admixture shall be used in strict accordance with manufacturer's recommendations. Calcium chloride or any admixture containing calcium chloride shall not be used. E. REINFORCING STEEL Reinforcing steel shall conform to ASTM A615, including supplementary requirements, and shall be Grade 60 except that bars to be welded shall be Grade 40 or ASTM A706. Reinforcing steel details shall be in accordance with Manual of Standard Practice for Detailing Reinforced Concrete Structure (ACI-315). F. EMBEDDED ITEMS AND ANCHORAGE DEVICES All embedded items, inserts, and anchorage devices exposed to view, moisture or weather shall be hot-dipped galvanized steel. Anchorage devices shall be fabricated from ASTM A36 steel. G. PENETRATIONS All required penetrations and openings larger than 6-mches in diameter or 6-inches square shall be formed in place at the time of casting. Additional reinforcing shall be added where required to meet loading requirements. Openings and penetrations smaller than 6-inches may be core drilled. H. MOLDS Material from which molds are to be fabricated shall be steel, concrete, fiberglass, reinforced plastic or wood. The selection of materials for molds shall be at the manufacturer's option, except that wood shall not be S 7074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03400-4 used without the express approval of the Construction Manager. All elements shall be cast in molds of rigid construction, accurate in detail with precise corners and arises, and designed to provide a close control of dimensions and details as indicated on the drawings. Prior to casting of precast elements, molds shall have all surface joints, radii, corners, etc., filled, ground, filed, straightened or otherwise removed to provide a finished concrete surface that is smooth and dense, free of honeycombing, large air pockets, offsets, sinkages, or other irregularities. I. PARTING COMPOUND All molds shall be coated with parting compound to facilitate removal of elements from molds. Parting compound shall be non-petroleum, nonstaining and shall be of a nature and composition not deleterious to concrete. J. JOINT SEALING COMPOUND A preformed, rope-like, ready to use, cold applied, permanently adhesive flexible plastic joint seal compound shall be applied over interior and exterior boundary of joint surfaces. K. ACCEPTABLE PRODUCTS Precast concrete vaults shall be by Jensen Concrete Products, New Basis Concrete Products, or equal. PART 3—EXECUTION 3.1 INSTALLATION A. CASTING Casting shall be accomplished by methods and equipment that are in conformance with generally acceptable systems for this type of Work. All precast concrete shall be manufactured by a plant thoroughly experienced in this type of Work. The manufacturer shall meet all production schedules. Surfaces on which units are cast shall be level and free from any imperfections detrimental to the surface appearance of the finished units. Parting compound shall be applied evenly as per manufacturer's recommendations. Concrete shall be so handled as to prevent segregation of materials and shall be continuously vibrated during casting, either internally or externally, to achieve proper compaction, finish and distribution of concrete. All precautions must be taken to keep the reinforcing steel in the 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03400-5 proper location during placing and consolidation of the concrete. Unless shown otherwise and except at concrete faces exposed to soil or liquids, all reinforcing steel shall have a minimum cover of 3/4 inch. At concrete faces exposed to soil or liquids, cover shall be 1-1/2 inches minimum. Embedded items shall be accurately placed and maintained in their proper location during the casting operation. Special inserts or other devices for handling of panels for the convenience of the manufacturer shall not be exposed to view after members are erected. Embedded anchors, inserts, plates, angles and other cast-in items shall have sufficient anchorage and embedment for design requirements. Casting, bowing, warpage and dimensional tolerances shall be in accordance with MNL-116, third edition. B. CURING All precast units shall be steam cured for a period of at least 12 hours. Fog spraying may be used when reviewed by the Construction Manager. Precast elements shall not be removed from molds for a minimum period of 12 hours after casting, or until concrete has attained a minimum compressive strength of 3500 pounds per square inch, whichever governs. After removal from the forms, curing by steam or fog spraying shall be continued until concrete has attained specified strength and confirmed by standard tests. Curing procedures shall be consistent and uniform throughout the entire project. C. WELDING The quality of material and fabrication of all welded connections shall conform to the latest AISC "Specification for the Design, Fabrication and Erection of Structural Steel for Buildings." All weldments shall be made in accordance with the applicable provisions of AWS. All welding, other than tacks, shall be done by certified welders. All units shall be protected from damage by field welding or cutting operations. Noncombustible shields shall be provided as necessary for this purpose. D. JOINTS AND JOINT COMPOUND In all instances, the edges of precast concrete units and of adjacent material shall be sound, smooth, clean and free of all contaminants prior to joint treatment. Joint compound and primer shall be supplied by the same manufacturer and the primer, when required, shall be as recommended for the particular sealant used. All joint compounds shall be delivered to the job in the manufacturer's original sealed containers with labels intact and shall be applied in strict accordance with the manufacturer's recommendations. ( j 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03400-6 3.2 ERECTION Any errors or misalignment in the structure which would prevent the proper setting of the elements shall be corrected by the Contractor before the erection is commenced. Erection shall be supervised and performed by workmen skilled in this type of Work. Each element shall be set in the proper position, carefully plumbed and anchored securely to the structural frame. Adjustments or changes in connections which could involve additional stresses in the products or connections shall not be permitted without approval of the Construction Manager. All bearing surfaces shall be true to line and grade. Erection tolerances shall be in accordance with MNL-116. All joints shall be uniform and watertight. 3.3 LEAKAGE TEST 1 General: Water tightness of precast concrete vaults shall be tested prior to backfilling. 2. Plugs: All inlets and outlets shall be plugged with approved stoppers or plugs. 3. Fill Level: The vaults shall be filled with water to a minimum depth of 4 feet and a maximum depth of 22 feet. 4. Test Requirements: The drop in water surface shall be recorded after a period of from 15 minutes to one hour. The time of the test shall be determined by the Construction Manager and may be varied to fit the various field conditions. 5. Visible Leaks: Contractor shall stop any leaks that may be observed, to the satisfaction of the Construction Manager. 3.4 CLEANING AND REPAIRING After installation, precast elements shall be protected from all damage until final acceptance by the Construction Manager. Precast units with cracks, spalls, and other defects shall be subject to rejection. Units reviewed for repair shall be repaired to the satisfaction of the Construction Manager. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03400-7 SECTION 03410 PRECAST STRUCTURAL CONCRETE PART 1 - GENERAL 1.1 REFERENCES The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. Reference ACI 304R ACI305R ACI 309R ACI318/318M ASTM A 27/A 27M ASTM A 36/A 36M ASTM A 47M ASTM A 123/A 123M ASTMA153/A153M ASTM A 307 ASTM A 325M ASTM A 563M Title (2000) Measuring, Mixing, Transporting, and Placing Concrete (1999) Hot Weather Concreting (1996) Consolidation of Concrete (1999) Building Code Requirements for Structural Concrete (1995) Steel Castings, Carbon, for General Application (2003) Carbon Structural Steel (1999) Ferritic Malleable Iron Castings (Metric) (2002) Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products (2003) Zinc Coating (Hot-Dip) on Iron and Steel Hardware (2002) Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength (2002) High-Strength Bolts for Structural Steel Joints (Metric) (2000) Carbon and Alloy Steel Nuts (Metric) 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03410-1 ASTMA615/A615M ASTM A 706/A 706M ASTM A 780 ASTM C 33 ASTM C 94 ASTM C 150 ASTM C 260 ASTM C 494 ASTM C 618 ASTM C 989 ASTM C 1107 ASTM F 436M ASTM F 844 AWSD1.4 PCIMNL-116 PCIMNL-120 1.2 PRECAST MEMBERS (2001) Deformed and Plain Billet-Steel Bars for Concrete Reinforcement (2003) Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement (2001) Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings (2003) Concrete Aggregates (2003) Ready-Mixed Concrete (2002) Portland Cement (1995) Air-Entraining Admixtures for Concrete (1992) Chemical Admixtures for Concrete (2000) Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use as a Mineral Admixture in Concrete (1999) Ground Granulated Blast-Furnace Slag for Use in Concrete and Mortars (2002) Packaged Dry, Hydraulic-Cement Grout (Nonshrink) (1993) Hardened Steel Washers (Metric) (2000) Washers, Steel, Plain (Flat), Unhardened for General Use (1998) Structural Welding Code - Reinforcing Steel (1985) Quality Control for Plants and Production of Precast Prestressed Concrete Products (1992) Design Handbook - Precast and Prestressed Concrete The work includes the provision of precast non-prestressed concrete herein referred to as precast members. Precast members shall be the product of a 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03410-2 manufacturer specializing in the production of precast concrete members. In the ACI publications, the advisory provisions shall be considered to be mandatory, as though the word "shall" has been substituted for "should" wherever it appears; reference to the "Building Official," the "Structural Engineer" and the "Architect/Engineer" shall be interpreted to mean the Engineer. 1.3 SUBMITTALS All subrmttals shall be in accordance with General Provisions, Section 2-5.3. Contractor shall submit the following documents. Shop Drawings - Drawings of precast members Product Data - Anchorage and lifting inserts and devices Design Data - Concrete mix design Test Reports - Contractor-furnished mix design - Submit copies of test reports showing that the mix has been successfully tested to produce concrete with the properties specified and will be suitable for the job conditions. Obtain approval before concrete placement. Certificates - Fabrication - Submit quality control procedures established in accordance with PCI MNL-116 by the precast manufacturer. Closeout Subrmttals - Concrete batch ticket information 1.4 QUALITY CONTROL A. Product Quality Control PCI MNL-116 for PCI enrolled plants. Where conduit banks are manufactured by specialists in plants not currently enrolled in the PCI "Quality Control Program," provide a product quality control system in accordance with PCI MNL-116 and perform concrete and aggregate quality control testing using an approved, independent commercial testing laboratory. Submit test results to the Engineer. 1.5 DELIVERY AND STORAGE Delivery, storage, and handling procedures shall be submitted to the Engineer for approval. Lift and support precast members at the lifting and supporting points indicated on the shop drawings. Store precast members off the ground. Separate stacked precast members by battens across the full width of each bearing point. Protect from weather, marring, damage, and overload. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03410-3 1.6 FACTORY INSPECTION At the option of the Owner's representative, precast units may be inspected prior to being transported to the job site. The Contractor shall give notice 14 days prior to the time the units will be available for plant inspection. Neither the exercise nor waiver of inspection at the plant will affect the Owner's right to enforce contractual provisions after units are transported or erected. 1.7 QUALITY ASSURANCE A. Drawing Information Submit drawings indicating complete information for the fabrication, handling, and erection of the precast member. Drawings shall not be reproductions of contract drawings. The drawings shall indicate, as a minimum, the following information: 1. Marking of members for erection 2. Connections for work of other trades 3. Connections between members, and connections between members and other construction 4. Location and size of openings 5. Reinforcing details 6. Material properties of steel and concrete used 7. Lifting and erection inserts 8. Dimensions and surface finishes of each member 9. Handling requirements 10. All loads used in design (such as live, dead, handling, and erection) B. Design Calculations 1. Precast Unit Designs The design of precast concrete units for fabrication of the conduit banks are shown on the contract drawings. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03410 - 4 C. Concrete Mix Design Thirty days minimum prior to concrete placement, submit a mix design for each strength and type of concrete. Include a complete list of materials including type; brand; source and amount of cement, pozzolan, and admixtures; and applicable reference specifications. D. Certificates: Record Requirement ASTM C 94. Submit mandatory batch ticket information for each load of ready-mixed concrete. PART 2 - PRODUCTS 2.1 CONTRACTOR-FURNISHED MIX DESIGN ACI 318/318M. The minimum compressive strength of concrete at 28 days shall be 5000 psi, unless otherwise indicated. Add air-entraining admixtures at the mixer to produce between 3 and 6 percent air by volume. 2.2 MATERIALS A. Cement ASTM C 150, Type I, II, or III or ASTM C 150, Type II blended cement, except as modified herein. The blended cement shall consist of a mixture of ASTM C 150 cement and one of the following materials: ASTM C 618 pozzolan or fly ash, or ASTM C 989 ground iron blast furnace slag. The pozzolan/fly ash content shall not exceed 25 percent by weight of the total cementitious material. For exposed concrete, use one manufacturer for each type of cement, ground slag, fly ash, and pozzolan. 1. Fly Ash and Pozzolan ASTM C 618, Type N, F, or C, except that the maximum allowable loss on ignition shall be 6 percent for Type N and F. 2. Ground Iron Blast-Furnace Slag ASTM C 989, Grade 100 or 120. B. Water Water shall be fresh, clean, and potable. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03410-5 C. Aggregates 1. Aggregates Selection ASTM C 33, Size 25, except as modified herein. Obtain aggregates for exposed concrete surfaces from one source. Aggregates shall not contain any substance which may be deletenously reactive with the alkalies in the cement. D. Grout 1. Nonshnnk Grout ASTMC 1107. 2. Cementitious Grout Shall be a mixture of portland cement, sand, and water. Proportion one part cement to approximately 2.5 parts sand, with the amount of water based on placement method. Provide air entramment for grout exposed to the weather. E. Admixtures 1. Air-Entraining ASTM C 260. 2. Accelerating ASTM C 494, Type C or E. 3. Water Reducing ASTM C 494, Type A, E, or F. F. Reinforcement 1. Reinforcing Bars ASTM A 615/A 615M, Grade 420 or ASTM A 706/A 706M, Grade 414. G. Metal Accessories Provide ASTM A 123/A 123M or ASTM A 153/A 153M galvanized. 1. Inserts ASTM A 47M, Grade 22010, or ASTM A 27/A 27M Grade 415- 205. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03410 - 6 2. Structural Steel ASTM A 36/A 36M. 3. Bolts ASTM A 307; ASTM A 325M. 4. Nuts ASTM A 563M. 5. Washers ASTM F 844 washers for ASTM A 307 bolts, and ASTM F 436M washers for ASTM A 325Mbolts. 2.3 FABRICATION PCI MNL-116 unless specified otherwise. A. Forms Brace forms to prevent deformation. Forms shall produce a smooth, dense surface. Chamfer exposed edges of beams 200 mm, unless otherwise indicated. Provide threaded or snap-off type form ties. B. Reinforcement Placement ACI 318/318M for placement and splicing. Reinforcement may be preassembled before placement in forms. C. Concrete 1. Concrete Mixing ASTM C 94. Mixing operations shall produce batch-to-batch uniformity of strength, consistency, and appearance. 2. Concrete Placing ACI 304R, ACI 305R for hot weather concreting, and ACI 309R, unless otherwise specified. 3. Concrete Curing Commence curing immediately following the initial set and completion of surface finishing. Provide curing procedures to keep the temperature of the concrete between 10 and 90 degrees C. 17074 CITY OF CARLSBAD LAKE GALA VERA REMEDIAL IMPROVEMENTS - JULY 2006 03410-7 When accelerated curing is used, apply heat at controlled rate and uniformly along the casting beds. Monitor temperatures at various points in a product line in different casts D. Surface Finish Repairs located in a bearing area shall be approved by the Contracting Officer prior to repairs Precast members containing hairline cracks which are visible and are less than 0.5 mm in width, may be accepted, except that cracks larger than 0.1 mm in width for surfaces exposed to the weather shall be repaired. Precast members which contain cracks greater than 0.5 mm in width shall be approved by the Owner's representative, prior to being repaired. Any precast member that is structurally impaired or contains honeycombed section deep enough to expose reinforcing shall be rejected. 1. Unformed Surfaces Provide a floated finish. 2. Formed Surfaces PCI MNL-116 (Appendix A - Commentary), Chapter 3, for grades of surface finishes. a. Provide a standard grade surface finish. PART 3 - EXECUTION 3.1 SURFACE REPAIR Prior to erection, and again after installation, precast members shall be checked for damage, such as cracking, spallmg, and honeycombing. As directed by the Owner's representative, precast members that do not meet the surface finish requirements specified in Part 2 in paragraph entitled "Surface Finish" shall be repaired, or removed and replaced with new precast members. Precast members shall be erected after the concrete has attained the specified compressive strength, unless otherwise approved by the precast manufacturer. Erect in accordance with the approved shop drawings. PCI MNL-116 and PCI MNL-120 (Chapter 8), for tolerances. Brace precast members, unless design calculations submitted with the shop drawings indicate bracing is not required. Follow the manufacturer's recommendations for maximum construction loads. Place precast members level, plumb, square, and true within tolerances. Align member ends. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03410-8 3.2 BEARING SURFACES Shall be flat, free of irregularities, and properly sized. Size bearing surfaces to provide for the indicated clearances between the precast member and adjacent precast members or adjoining field placed surfaces. Correct bearing surface irregularities with nonshnnk grout. Draw-up tight without forcing or distortion, with sides plumb. 3.3 ANCHORAGE Provide anchorage for fastening work in place. 3.4 WELDING AWS D1.4 for welding connections and reinforcing splices. Protect the concrete and other reinforcing from heat during welding. Weld continuously along the entire area of contact. Grind smooth visible welds in the finished installation. Welding of epoxy-coated reinforcing is not allowed. 3.5 OPENINGS Holes or cuts requiring reinforcing to be cut, which are not indicated on the approved shop drawing, shall only be made with the approval of the A-E and the precast manufacturer. Drill holes less than 300 mm in diameter with a diamond tipped core drill. 3.6 GALVANIZING REPAIR Repair damage to galvanized coatings using ASTM A 780 zinc rich paint for galvanized surfaces damaged by handling, transporting, cutting, welding, bolting, or acid washing. Do not heat surfaces to which repair paint has been applied. 3.7 GROUTING Clean and fill keyways between precast members, and other indicated areas, solidly with nonshnnk grout or cementitious grout. Provide reinforcing where indicated. Remove excess grout before hardening. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03410 - 9 SECTION 03600 GROUT PART 1—GENERAL 1.1 DESCRIPTION This section specifies grout for uses other than masonry 1.2 QUALITY ASSURANCE A Quality Control by Contractor To demonstrate conformance with the specified requirements for grout, the Contractor shall provide the services of an independent testing laboratory which complies with the requirements of ASTM E329. The testing laboratory shall sample and test grout materials as required in this section Costs of testing laboratory services shall be borne by the Contractor. B. References This section references the following documents They are a part of this section as specified and modified. In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Reference (Latest Edition) Title ASTM C33 Standard Specification for Concrete Aggregate ASTM C40 Standard Test Method for Organic Impurities in Sand for Concrete ASTMC88 Standard Test Method for Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate ASTM Cl 17 Standard Test Method for Materials Finer than No. 200 Sieve in Mineral Aggregates by Washing ASTM Cl36 Standard Test Method for Sieve or Screen Analysis of Fine and Course Aggregates CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03600 - 1 ASTM Cl 60 Standard Specification for Portland Cement ASTM C289 Standard Test Method for Potential Reactivity of Aggregates (Chemical Method) ASTMC494 Standard Specification for Chemical Admixtures for Concrete ASTME329 Standard Recommended Practice for inspection and Testing Agencies for Concrete, Steel, and Bituminous Materials as Used in Construction Cal Test Method of Test for Sand Equivalent No. 217-1-1969 CRD-G588.78 Corps of Engineers Specification for Nonshrmk Grout 1.3 SUBMITTAL The following information shall be provided in accordance with Section 2-5.3 of the General Provisions. A. Product Data Manufacturer's data shall be provided for the following. 1. Bonding compounds 2 Nonshrmk grout 3. Pressure grout 4. Retardants B. Laboratory Test Reports Before delivery of materials, reports of the tests specified herein shall be provided. Test reports on previously tested materials shall be accompanied by the manufacturer's statement that the previously tested material is the same type, quality, manufacture, and make as that proposed for use in this project. Test reports are required for the following: 1. Cement 2. Aggregates 3. Retardants 4. Bonding compounds CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03600 - 2 C. Evidence of Testing Laboratory Competence The Contractor shall require that the laboratory provide directly to the Construction Manager evidence of the most recent inspection of its facilities by the Cement and Concrete Reference Laboratory of the National Bureau of Standards. The evidences shall show that deficiencies mentioned in the report of that inspection have been corrected. The evidence of inspection shall be provided prior to delivery of materials to the job site. PART 2—PRODUCTS 2.1 MATERIALS A. Cement Portland cement shall be ASTM C150 Type H or Type V, Low Alkali, containing less than 0.60 percent alkalies. B Aggregate 1. GENERAL: Aggregate shall be nonreactive and shall be washed before use. When sources of aggregate are changed, test reports shall be provided for the new material. The tests specified shall be performed prior to commencing grout work. 2. FINE AGGREGATE: Fine aggregate shall be hard, dense, durable particles of either sand or crushed stone regularly graded from coarse to fine and shall conform to ASTM C33 as modified herein. When tested in accordance with ASTM C136, gradation shall be such that 100 percent by weight will pass a standard No. 8 mesh sleeve and no less than 45 percent by weight will pass a standard No. 40 mesh sieve. Variation from the specified gradations in individual tests will be acceptable if the average of three consecutive tests is within the specified limits and the variation is within the permissible variation listed below. U.S. standard Permissible variation in sieve size individual tests, percent 30 or coarser 2 50 or finer 0.5 Other tests shall be in accordance with the following specifications: 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03600-3 Test Test Method Requirements Organic Impurities ASTM C40 Color lighter than standard Amount of Material Passing No. 200 Sieve ASTM Cl 17 3% maximum by weight Soundness ASTMC88 10% maximum loss with sodium sulfate Reactivity ASTM C289 Innocuous aggregate Sand Equivalent Cal Test 217 Minimum 80 C. Admixtures 1. GENERAL: Admixtures shall be compatible with the grout. Calcium chloride or admixtures containing calcium chloride are not acceptable. Admixtures shall be used in accordance with the manufacturer' s recommendations and shall be added separately to the grout mix. 2. WATER REDUCING RETARDER: Water reducing retarder shall be ASTM C494 Type D and shall be Master Builders Pozzohth 300-R; Sika Chemical Corp. Plastiment; or equal. 3. LUBRICANT FOR CEMENT PRESSURE GROUTING: Lubricant additive for cement pressure grouting shall be Intrusion Prepakt Intrusion Aid, Sika Chemical Corporation Intraplast, or equal. D. Water Water for washing aggregate, for mixing and for curing shall be free from oil and deleterious amounts of acids, alkalies, and organic materials; shall not contain more than 1000 mg/1 of chlorides as CI, nor more than 1300 mg/1 of sulfates as 804; and shall not contain an amount of impurities that may cause a change of more than 25 percent in the setting time of the cement nor a reduction of more than 5 percent in the compressive strength of the grout at 14 days when compared with the result obtained with distilled water. Additionally, water used for curing shall not contain an amount of impurities sufficient to discolor the grout. ] 7074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03600 - 4 2.2 GROUT A. Drypack Grout Drypack grout shall be a mixture of approximately one part cement, 1-1/2 to 2 parts sand, water reducing retarder, and sufficient water to make a stiff workable mix. B. Cement Grout Cement grout shall be a mixture of one part cement, two parts sand, proportioned by volume, admixtures for pressure grouting, and sufficient water to form a workable mix. C. Nonshnnk Grout Nonshnnk grout shall be nonrustmg metallic aggregate grout and shall be Master Builders Embeco 636; U.S. Grout Corp. Five Star Grout; or equal. D. Epoxy Grout Epoxy grout shall be Adhesive Engineering Concresive 1380 as applicable; Sika Chemical Corporation Sikastix 350; or equal. 2.3 PRESSURE GROUTING EQUIPMENT Pressure grouting equipment shall include a mixer and holdover agitator tanks and shall be designed to place grout at pressures up to 50 psi. Gages shall be provided to indicate pressure used. The mixer shall be provided with a meter capable of indicating to one-tenth of a cubic foot the volume of grout used. PART 3—EXECUTION 3.1 GENERAL Holes required for grouting shall be blown clean. Horizontal holes for grouting shall be drilled at a slight downward angle to facilitate holding the grout until setting is complete. Bolts or reinforcing steel installed in horizontal grout holes shall be bent slightly accordingly. Bonding compound for use with grout is specified in Section 03300. 3.2 DRYPACK GROUT Drypack grout shall be used for built-up surfaces, setting miscellaneous metal items and minor repairs. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03600 - 5 Surfaces required to be built up with drypack grout shall be roughened by brushing, cleaned, and coated with the bonding compound specified in paragraph 03300-2.01 before the application of the grout. The drypack grout shall be applied immediately following the application of the bonding compound in bands or strips to form a covering of the required thickness. The covering shall be smooth. Construction joints in the grout shall be sloped and shall be cleaned and wetted before application is resumed. Drypack grout shall be cured in accordance with Section 03300. Grout shall not be placed during freezing weather unless adequate protection is provided. 3.3 CEMENT GROUT Cement grout shall be used for filling nonbeanng portions of equipment pads and pressure grouting. Except for the specialized equipment for pressure grouting, mixing and placing apparatus shall be similar to that normally used for cast-m-place concrete. Grout shall be mixed for a period of at least one minute. Diluted grout shall be agitated to keep ingredients mixed. 3.4 NONSHRINK GROUT Nonshnnk grout shall be used for the bearing surfaces of machinery and equipment bases, column baseplates and bearing plates. It also shall be used for setting bolts and reinforcing steel in holes for grouting. Where specified, grout shall meet CRD-G588-78. Grout shall be placed in accordance with manufacturer's instructions. 3.5 EPOXY GROUT Epoxy grout shall be used for repairing cracks by pressure grouting, repairing structural concrete, and setting reinforcing dowels into holes for grouting. Concrete shall be primed in accordance with the grout manufacturer's instructions. 3.6 PRESSURE GROUTING Prior to grouting, systems and holes to be grouted shall be washed clean. Washing is not required for grouting soil voids outside pipe cylinders or casing pipes. Grouting, once commenced, shall be completed without stoppage. In case of breakdown of equipment, the Contractor shall wash out the grouting system sufficiently to ensure 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03600-6 fresh grout and adequate bond and penetration will occur upon restarting the grouting operation. Grout pressure shall be maintained until grout has set. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 03600 - 7 SECTION 04110 CEMENT AND LIME MORTARS PART 1 - GENERAL 1 1 SUMMARY A. Section Includes 1. Cement and lime mortars and masonry grout B. Related Sections include but are not necessarily limited to: 1. Section 03300 - Cast-m-Place Concrete. 2 Section 04220 - Concrete Masonry. 1 2 QUALITY ASSURANCE A. Referenced Standards: 1 American Concrete Institute/American Society of Civil Engineers/The Masonry Society (ACI/ASCE/TMS). a. ACI 530.1/ASCE 6/TMS 602, Specification for Masonry Structures. 2. ASTM International (ASTM). a. C109, Standard Test Method for Compressive Strength of Hydraulic Cement Mortars (Using 2 IN or Cube Specimens). b. C143, Standard Test Method for Slump of Hydraulic Cement Concrete. c. C144, Standard Specification for Aggregate for Masonry Mortar. d. C150, Standard Specification for Portland Cement. e. C207, Standard Specification for Hydrated Lime for Masonry Purposes. f. C270, Standard Specification for Mortar for Unit Masonry. g. C404, Standard Specification for Aggregates for Masonry Grout. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 04110-1 h. C476, Standard Specification for Grout for Masonry i C780, Standard Test Method for Preconstruction and Construction Evaluation of Mortars for Plain and Reinforced Unit Masonry. j. C1019, Standard Test Method for Sampling and Testing Grout. 3 Underwriters Laboratories, Inc. (UL). a Fire Resistance Directory. 4 Building code. a. International Code Conference (ICC): 1) International Building Code and associated standards, 2003 Edition including all City, County and State of California amendments, referred to herein as Building Code. B Qualifications: 1 Testing Laboratory shall have a minimum of 10 years experience in the testing of mortar and grout. 2. Technician conducting tests shall have minimum of 5 years experience in the testing of mortar and grout. G, Mock Upa. -k Provide mortar (and pointing grout] for mock up panels specified in (Section 01210] (Section 01220] (Section 01270]. 1.3 DEFINITIONS A. Coarse grout and fine grout are defined by the aggregate size used in accordance with ASTM C476. B. Coarse aggregate and fine aggregate are defined in ASTM C404, Table 1. 1.4 SUBMITTALS A. Shop Drawings: 1. See Section 2-5.3 of the General Provisions, for requirements for the mechanics and administration of the submittal process. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 04110-2 2. Product technical data including. a. Acknowledgement that products submitted meet requirements of standards referenced. b Proposed mortar mix design, c Proposed masonry grout mix design. 3 Test results a. Strength test results for all mortar and masonry grout (both coarse and fine grout) placed during construction. b. Preconstruction mortar test results. c. Preconstruction masonry grout test results. d. Slump test results of all masonry grout placed during construction. B Samples: 1 Actual colored mortar samples for color selection by Engineer. Color card and plastic simulations are not acceptable. C Miscellaneous Submittals: 1. See Section 2-5.3 of the General Provisions for requirements for the mechanics and administration of the submittal process. 2 Qualifications of testing lab and technician. PART 2- PRODUCTS 2.1 MATERIALS A. Portland Cement. 1. ASTMC150,TypeIorII. 2. No air entramment. 3. Natural color. 4. Maximum percent of alkalis: 0.60 in accordance with ASTM C150, Table 1A. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 04110-3 B. Hydrated Lime. ASTM C207, Type S. 1. Type S A not acceptable. 2. Lime substitutes are not acceptable. C. Mortar Aggregate: ASTM C144, free of gypsum D Masonry Grout: ASTM C476. E. Grout Aggregate' ASTM C404 F. Water: Potable. G Mortar Pigments 1. Commercial colorants suitably compounded for use in mortar mixes Do not exceed manufacturer's recommended pigment-to- cement ratios 2.2 MIXES A Type "S" mortar shall be used- 1. Wherever a fire-resistance classification or rating is shown for unit _^ masonry construction pro vide mortar of type which has been tested f j and listed by UL for construction indicated. 2. Comply with ASTM C270, Table No. 1 3. Do not use masonry cement. 4. Mix materials minimum of 3 minutes and maximum of 5 minutes. 5. Adjust consistency to satisfaction of mason. 6 Use no anti-freeze additives B. Masonry Grout: 1. Comply with ASTM C476. 2. Use no anti-freeze additives. 3. No fly ash additives will be accepted. 4. Mix 5 minutes minimum. 5. Slump: 8 to 11 IN. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 04110-4 6. At Contractor's option, manufactured grout meeting the above minimum requirements may be used. 7. Minimum 28-day compressive strength: 2,000 psi 2.3 SOURCE QUALITY CONTROL A. Perform preconstruction laboratory tests on proposed mortar and masonry grout mix prior to start of masonry work. 1. Perform tests far enough in advance so that any necessary retesting can be accomplished before masonry construction begins. a. Test mortar per ASTMC109. b. Test grout per ASTM C1019. PART 3- EXECUTION 3.1 INSTALLATION A. Install products in accordance with manufacturer's instructions and ACI 530.1/ASCE6/TMS602. B. Use coarse grout in spaces with least dimension over 2 IN. C. Use fine grout for grouting door frames. 1. Grout all door frames unless specifically noted not to be grouted. D. Consolidate all grout while installing. 1. Consolidate grout pours 12 IN or less in height by mechanical vibration or by puddling. 2. Consolidate grout pours exceeding 12 IN in height by mechanical vibration and reconsolidate by mechanical vibration after initial water loss and settlement has occurred. 3.2 FIELD QUALITY CONTROL A. Mortar: 1. Perform one ASTM C780 annex A-l, A-5, A-6 and A-7 test per week on field mortar used during masonry construction. 2. If standard gray mortar begins to stiffen, it may be retempered by adding water and remixing. 17074 crnr OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 04110-5 a. Standard gray mortar shall not be retempered more than one time. 3. Colored mortar shall not be retempered. 4. All mortar {and pointing grout} must be used within 1-1/2 MRS after initial mixing. B. Engineer reserves right to alter mix design based on initial rate of absorption of masonry units. C. Masonry Grout: 1. Use grout within 1-1/2 HRS after initial mixing. 2. Use no grout after it has begun to set. 3. Do not retemper grout after initial mixing. 4. Place grout in lifts not exceeding {4 FT}. D. Masonry Grout Testing: 1. Conduct compressive strength tests and slump tests on all masonry grout used during masonry construction. 2. Perform all compressive strength test sampling, testing and reporting per ASTM C1019. 3. Perform all slump test sampling, testing, and reporting per ASTM C143. 4. Frequency of sampling: One sample (three specimens) collected each grouting operation during masonry construction. 5. Compressive strength testing: a. One strength test shall be the average of three specimens from the same sample, tested at 28 days. **END OF SECTION** 1 /074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 04110-6 SECTION 04220 CONCRETE MASONRY PART 1 - GENERAL 1.1 SUMMARY A. Section Includes 1 Concrete masonry construction (CMU) including all standard concrete masonry, sills, prefaced, ground face and pre-colored units. B Related Sections include but are not necessarily limited to: 1. Section 03200 - Concrete Reinforcement 2. Section 04110 - Cement and Lime Mortars. 3. Section 07900 - Joint Sealants. 1 2 QUALITY ASSURANCE A. Referenced Standards: 1. American Concrete Institute (ACI)/Amencan Society of Civil Engineers (ASCE)/The Masonry Society (TMS)' a. ACI 530.1/ASCE 6/TMS 602, Specification for Masonry Structures. 2. ASTM International (ASTM): a. C33, Specification for Concrete Aggregates. b. C90, Specification for Load-Bearing Concrete Masonry Units. c. C1314, Standard Test Methods for Compressive Strength of Masonry Prisms. 3. National Concrete Masonry Association (NCMA): a. TEK 2-3 A, Architectural Concrete Masonry Units. b. TEK 3-4B, Bracing Concrete Masonry Walls Dunng Construction. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 04220 -1 4. Underwriters Laboratories, Inc (UL). a. Building Materials Directory. 5 Building code a. International Code Conference (ICC). 1) International Building Code and associated standards, 2003 Edition including all City, County and State of California amendments, referred to herein as Building Code. B All masonry units of any one particular type, color or face style shall be from the same production run. 1. Special shapes shall be factory fabricated unless noted otherwise. 1.3 DEFINITIONS A. Definitions to be in accordance with Standard Unit Nomenclature Table 1, NCMA TEK 2-3A. 1.4 SUBMITTALS A. Shop Drawings: 1. See General Provision 2-5.3 for requirements for the mechanics and administration of the submittal process. 2. Product technical data including: a. Manufacturer's information on aggregate and cement type used in manufacture. 3. Certifications: a Certification that concrete masonry units meet or exceed requirements of standards referenced. 4. Qualifications of testing lab and technician. 5. Test results for all masonry testing. B. Samples: 1. Minimum two 2 x 8 x 8 IN samples of prefaced ground face pre- colored units of each color selected or specified. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 04220 - 2 C. Miscellaneous Submittals: 1. See General Provision 2-5 3, for requirements for the mechanics and administration of the submittal process. 1 5 DELIVERY, STORAGE, AND HANDLING A. Deliver units on pallets with tight covers or deliver in cubes and store on dunnage. B Protect units from damage C. Inspect units upon delivery to assure color match with sample wall, dimensional quality, and trueness of unit. 1. Return damaged or otherwise unacceptable units PART 2 - PRODUCTS 2.1 MATERIALS A. Concrete Masonry Units: 1. Modular normal (heavy) weight units, ASTM C90. Provide aggregate in accordance with ASTM C33. a. Total linear drying shrinkage: ASTM C90, 0.065 percent maximum. b. Weight: Minimum of 125 LB/CF. c. Medium weight or light weight units are not acceptable. 2. Face shell and web thickness: ASTM C90, Table 1. 3. Water absorption: ASTM C90 Table 2. 4. Concrete bricks of same material, texture and quality. 5. Compressive strength: ASTM C90, Table 2. 6. Dimensional Tolerance: ASTM C90. B. Reinforcing Bars: Refer to Section 03200, Concrete Reinforcement, and as indicated on Drawings. C. Mortar: Refer to Section 04110, Cement and Lime Mortars. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 04220 - 3 D. Masonry Grout" Refer to Section 04110, Cement and Lime Mortars E Sealants: Refer to Section 07900, Sealants 2.2 FABRICATION A. Concrete Masonry Units: 1 Color a Interior units: Padre with Black Cinders. b. Exposed exterior units- Padre with Black Cinders. 2. Design compressive strength' fm=l,500 psi minimum. a Determine m accordance with unit strength method per ACI 530.1/ASCE 6/TMS 602. 3. Fire resistive units: UL listed. 4 Fabricated in the manufacturing plant. PART 3 - EXECUTION 3.1 PREPARATION A. Verify that anchors and flashings are correct. B. Lay out walls in advance for uniform and accurate spacing of bond patterns and joints. Properly locate openings, movement type joints, returns, offsets, weep joints and weep vents 3.2 INSTALLATION A. Install products in accordance with manufacturer's instructions. B General: 1. Build cavity walls to thickness indicated on Drawings. 2. Build single-wythe walls to actual thickness of masonry units. 3. Build composite walls to thickness indicated on Drawings. 4. Build in flashing, reinforcing, reglets, weeps, weep vents and •related accessory items. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 04220 - 4 5. Perform all cutting with masonry saws using saw blades as recommended by masonry unit manufacturer. 6. Drill holes with power drill using drill bits as recommended by masonry unit manufacturer 7. Holes made by chipping unit will not be accepted 8 Install field units in running bond. a Provide special coursing where indicated on the Drawings 9 Cut as required to maintain bond pattern 10. Use solid units where cutting or laying would expose holes and as noted on Drawings. 11 Avoid use of less than half size units, whenever possible. 12. Do not use chipped, cracked, spalled, stained or imperfect units exposed in finish work. 13. Do not wet concrete masonry units. 14. Build chases and recesses as indicated and required for work of other trades. Provide not less than 8 IN of masonry between chase or recess and jamb of openings, and between adjacent chases and recesses unless detailed otherwise on the Drawings C Concrete Masonry Units: 1. Install grouted hollow units under lintel bearing points. a. Refer to Section 04110, Cement and Lime Mortars, for grouting. D. Laying and Tooling: 1. Lay masonry units with completely filled bed and head joints a. Provide full mortar bed on all block cross webs and completely fill head joints. 1) Do not slush head j omts. 2) Protect cells requiring grout fill from mortar droppings. 3) Omit mortar from head joint at weeps. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 04220 - 5 2. Maintain nominal 3/8 IN joint widths. a. Cut joints flush where concealed and where veneer plaster coating is required. b. Tool exposed joints concave. c. Compress mortar in below ground joints d. Provide wider joints where noted on Drawings. 1) In no case shall any mortar joint be more than 3/4 IN wide. e. Where masonry sets on top of steel support omit the mortar joint on top of the support under the veneer and set masonry directly on top of the thru wall flashing or the steel support member unless a mortar joint is required to maintain coursing 3. During tooling of joints, enlarge any voids or holes {except weeps}, and completely fill with mortar. 4. Point-up all joints at corners, openings, and adjacent work to provide neat, uniform appearance. 5 Remove masonry disturbed after laying, a Clean and relay in fresh mortar. b. Do not pound units to fit. c. If adjustments are required, remove units, clean, and reset in fresh mortar. 6. Where work is stopped and later resumed, rack back 1/2 masonry unit length in each course a. Remove loose units and mortar prior to laying fresh masonry. 7. As work progresses, build in items indicated on Drawings and specified. a. Fill in solidly with mortar around built-in items. b. Where built-in items are to be embedded in cores of hollow masonry units, place grout screen in joint below and fill core solid with mortar. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 04220 - 6 E. Control Joints and Sealants- 1. Provide vertical expansion, control and isolation joints where indicated on Drawings. a Where not indicated on Drawings, provide control joints at maximum 24 FT OC or at natural point of weakness b. Provide at all T intersections c. Rake out mortar in joint. 2 Refer to Section 07900, Sealants, for sealant installation requirements. a. Seal control and expansion joints F. Tolerances: 1. Maximum variation from plumb in vertical lines and surfaces of columns, walls, and arises: a. 1/4 IN in 10 FT. b 3/8 IN m a story height not to exceed 20 FT. c. 1/2 IN in 40 FT or more 2 Maximum variation from plumb for external corners, expansion joints, and other conspicuous lines: a. 1/4 IN in any story or 20 FT maximum. b. 1/2 IN in 40 FT or more. 3. Maximum variation from level of grades for exposed lintels, sills, parapets, horizontal grooves, and other conspicuous lines: a. 1/4 IN in any bay or 20 FT. b. 1/2 IN in 40 FT or more. 4. Maximum variation from plan location of related portions of columns, walls, and partitions: a. 1/2 IN in any bay or 20 FT. b. 3/4 IN in 40 FT or more. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 04220 - 7 5 Maximum variation in cross-sectional dimensions of columns and thicknesses of walls from dimensions shown on Drawings: ( J a Minus 1/4 IN. b. Plus 1/2 IN G. Protect against weather when work is not in progress. During inclement weather conditions, cover top of walls with translucent waterproof membrane, extend at least 4 FT down both sides of walls and anchor in place. 3.3 FIELD QUALITY CONTROL A Bracing Concrete Masonry Walls During Construction: 1 At a minimum, provide bracing in accordance with NCMA TEK 3- 4B. 2. Contractor is responsible for adequately bracing all masonry during construction. B. Remove and replace loose, stained, or damaged units as directed by Engineer 1. Provide new units to match. 2. Install in fresh mortar 3. Point to eliminate evidence of replacement. 3 4 CLEANING A. Clean concrete masonry as the wall is being constructed using fiber brushes, wooden paddles and scrapers. No acid-based cleaning solutions shall be used unless approved in writing by Engineer. **END OF SECTION** CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 04220 - 8 SECTION 05100 STRUCTURAL STEEL PART 1 - GENERAL 1.1 DESCRIPTION This section covers all structural steel and metal fabrication and erection, unless specified otherwise, elsewhere. 1.2 REFERENCES The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. Reference AISC 316 AISC 317 AISC 326 AISC M016 AISC M017 AISCM018L AISC S303 AISC S329 AISC S335 Title (1989) ASD MANUAL CONSTRUCTION OF STEEL (1992; ERRATA 1994) CONNECTIONS (2002) DETAILING FOR STEEL CONSTRUCTION (1989) ASD MANUAL OF STEEL CONSTRUCTION (1992; ERRATA 1994) CONNECTIONS (1994) LRFD MANUAL OF STEEL CONSTRUCTION VOLUME 1 (2000) CODE OF STANDARD PRACTICE FOR STEEL BUILDINGS AND BRIDGES (1985) ALLOWABLE STRESS DESIGN SPECIFICATION FOR STRUCTURAL JOINTS USING ASTM A325 OR A490 BOLTS (1989) STRUCTURAL STEEL BUILDINGS ALLOWABLE STRESS DESIGN AND PLASTIC DESIGN 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 05100-1 AISC S340 ASTM A 6M ASTM A 36 ASTM A 123 ASTM A 153 ASTM A 194 ASTM A 449 ASTM A 500 ASTM A 501 ASTM A 563 ASTM A 572 (1992) METRIC PROPERTIES OF STRUCTURAL SHAPES WITH DIMENSIONS ACCORDING TO ASTM A 6M STANDARD SPECIFICATION FOR GENERAL REQUIREMENTS FOR ROLLED STRUCTURAL STEEL BARS, PLATES, SHAPES, AND SHEET PILING (2003) STANDARD SPECIFICATION FOR CARBON STRUCTURAL STEEL (2002) ZINC (HOT-DIP GALVANIZED) COATINGS ON IRON AND STEEL PRODUCTS (2003) ZINC COATING (HOT-DIP) ON IRON AND STEEL HARDWARE (1994A) SPECIFICATION FOR CARBON AND ALLOY STEEL NUTS FOR BOLTS FOR HIGH- PRESSURE AND HIGH-TEMPERATURE SERVICE (2004) STANDARD SPECIFICATION FOR QUENCHED AND TEMPERED STEEL BOLTS AND STUDS (2003A) STANDARD SPECIFICATION FOR COLD-FORMED WELDED AND SEAMLESS CARBON STEEL STRUCTURAL TUBING IN ROUNDS AND SHAPES (2001) STANDARD SPECIFICATION FOR HOT- FORMED WELDED AND SEAMLESS CARBON STEEL STRUCTURAL TUBING (2004) STANDARD SPECIFICATION FOR CARBON AND ALLOY STEEL NUTS (2003) STANDARD SPECIFICATION FOR HIGH-STRENGTH LOW-ALLOW COLUMBIUM-VANADIUM STRUCTURAL STEEL 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 05100-2 ASTMA653 (2003) STEEL SHEET, ZINC-COATED (GALVANIZED) OR ZINC-IRON ALLOY- COATED (GALVANNEALED) BY THE HOT- DIP PROCESS ASTMA780 (2001) REPAIR OF DAMAGED AND UNCOATED AREAS OF HOT-DIP GALVANIZED COATINGS ASTMB695 (1991; R 1997) COATINGS OF ZINC MECHANICALLY DEPOSITED ON IRON AND STEEL ASTMF436 STANDARD SPECIFICATION FOR HARDENED STEEL WASHERS AWSD1.1 (2000) STRUCTURAL WELDING CODE - STEEL SSPC SP 6 (1994) COMMERCIAL BLAST CLEANING 1.3 SYSTEM DESCRIPTION Provide the structural steel including coating, complete and ready for use. Structural steel systems including design, materials, installation, workmanship, fabrication, assembly, erection, inspection, quality control and testing shall be provided in accordance with AISC MO 16 and AISC MO 17 except as modified in this specification. 1.4 MODIFICATIONS TO REFERENCES In AISC M016, AISC M017, AISC S335, AISC S303, AISC S329, and AISC S340, except as modified in this section, shall be considered a part of AISC M016 and AISC M017 and is referred to in this section as AISC M016 and AISC M017. 1.5 SUBMITTALS A. Shop Drawings for steel cofferdam shell, ring stiffener nbs, and associated hangers shall be submitted for review. Submit fabrication drawings showing layouts, connections to structural system, and anchoring details as specified in AISC S303. B. Test Reports for all products. Supply the certified manufacturer's mill reports which clearly show the applicable ASTM mechanical and chemical requirements together with the actual test results for the supplied products. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 05100-3 C. Certificates for steel, AISC Quality Certification, Bolts, Nuts, and Washers. 1.6 QUALITY ASSURANCE A. Submit shop drawings and fabrication details for approval prior to fabrication. Prepare in accordance with AISC 326, AISC 316 and AISC 317. Drawings shall not be reproductions of contract drawings. Include complete information for the fabrication and erection of the structure's components, including the location, type, and size of bolts, welds, member sizes and lengths, connection details, blocks, copes, and cuts. Use AWS standard welding symbols. 1.7 DELIVERY, STORAGE AND PROTECTION A. Protect from corrosion, deformation, and other types of damage. Store items in an enclosed area free from contact with soil and weather, where practical. Remove and replace damaged items with new items. PART 2 • PRODUCTS 2.1 STRUCTURAL STEEL (INCLUDING STEEL PLATE AND MISC. STEEL SHAPES) A. ASTM A 572 Grade 50, unless noted otherwise. 2.2 STAINLESS STEEL PRODUCTS A. ASTM A240/A240M, Type 316, except 316L where welding is required. Stainless steel fasteners shall be in accordance with ASTM F593 and ASTM F594. 2.3 STRUCTURAL STEEL TUBING A. ASTM A 500 Grade B 2.4 BOLTS, NUTS, AND WASHERS Provide the following unless indicated otherwise: A. Bolts: Bolts shall be ASTM A 325 Type 3. The bolt heads and the nuts of the supplied fasteners must be marked with the manufacturer's identification mark, the strength grade and type specified by ASTM specifications. 17074 crrv OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 05100-4 B. Nuts: Nuts shall be ASTM A563. Nuts for ASTM A325 bolts shall be heavy hex style grade DH3 or C3. C. Washers: Use ASTM F 436 flat washers for ASTM A 325 bolts. Unless otherwise specified, all washers shall be of the same alloy group, and shall have a specified minimum proof stress equal to or greater than the specified minimum full-size tensile strength of the externally threaded fastener. 2.5 STRUCTURAL STEEL ACCESSORIES Welding Electrodes and Rods: Shall be in accordance with AWS Dl.l and E70XX electrodes. 2.6 COATINGS A. H-Piles and cross-beams supporting the 24-inch diameter pipe on the dam embankment shall be epoxy coated, per specification Section 02456, Steel H-Piles. B. Fasteners connecting H-Piles and cross beams shall be coated with a coating material compatible with the approved epoxy coating for the piles. C. The steel cofferdam does not require a protective coating. D. Stainless steel materials do not require additional protective coating. E. All other ferrous metal shall be hot dipped galvanized, unless noted otherwise. 1. Hardware shall be galvanized in accordance with ASTM A 153/A 153M and shall not be less than two ounces per square foot. 2. Galvanizing shall be performed before shipment and shall be by a hot dip process conforming to ASTM A 123 Grade 100. 3. Preparation prior to galvanizing shall be by acid pickling. Galvanizing shall be performed the same day as pickling. After pickling and before galvanizing, all items shall be heated to 300 degrees F to expel hydrogen absorbed during pickling. Care shall be taken to avoid hydrogen embnttlement. 4. Components of bolted assemblies shall be galvanized before assembly. Welded assemblies shall be galvanized after welding. 5. The zinc coating shall adhere tenaciously to the steel surface, shall be free from blisters and excess zinc, and be even, smooth and uniform throughout. All cutting, punching, drilling and other 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 05100-5 machine work shall be performed as far as possible before galvanizing. Should any such work or any welding be necessary after galvanizing, the areas from which galvanizing has been removed shall be touched up in a suitable manner. 2.7 FABRICATION A. Markings: Prior to erection, members shall be identified by a painted erection mark. Connecting parts assembled in the shop for reaming holes in field connections shall be match marked with scratch and notch marks. Do not locate erection markings on areas to be welded. Do not locate match markings in areas that will decrease member strength or cause stress concentrations. Affix embossed tags to hot-dipped galvanized members. B. Cleaning: SSPC SP 6. Maintain steel surfaces free from rust, dirt, oil, grease, and other contaminants through final assembly. PART 3 - EXECUTION 3.1 WORKMANSHIP A. Make all work square, plumb, straight and true, accurately fitted, with tight sharply defined profiles and be free from twists, bends and defects impairing strength and durability. Items not presenting a finished and workmanlike appearance will be rejected. B. Clip off projecting edges and corners. Finish and dress surfaces, edges and welds, smoothly and neatly by grinding, chipping and wire brushing. Reduce sharp edges by grinding to 3mm (1/8 inch) radius. C. Do not flame cut holes or enlarge holes by burning unless approved by the Engineer. 3.2 CONNECTIONS Do not tighten anchor bolts set in concrete with impact torque wrenches. Punch, subpunch and ream, or drill bolt and pin holes. Bolts, nuts, and washers shall be clean of dirt and rust, and lubricated immediately prior to installation. A. Bolts ASTM A307/A307M and ASTM A593 bolts shall be tightened to a "snug tight" fit. "Snug tight" is the tightness that exists when plies in a joint are in firm contract. If firm contact or joint plies cannot be obtained with a 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 05100-6 few impacts of an impact wrench, or the full effort of a man using a spud wrench, contact the Engineer for further instructions. ASTM A 325-SC bolts shall be fully tensioned to the required minimum percent of their minimum tensile strength as per AISC M018L, unless otherwise specified on the contract drawings. Give special attention to ensure that the proper tightening torque is applied. Bolts shall be installed in connection holes and initially brought to a snug tight fit. After initial tightening procedure, bolts shall then be fully tensioned, progressing from the most rigid part of the connection to the free edges. 3.3 SHOP ASSEMBLY Fabricate and assemble structural assemblies in shop to the greatest extent possible. Fabricate items of structural steel in accordance with AISC S303 and as indicated on final shop drawings. 3.4 WELDING All welding shall conform to AWS DLL Provide AWS Dl.l qualified welders, welding operators, and tackers. A. Shop welding shall be performed by the manual shielded metal arc (SMA) or submerged arc (SA) process. B. Welding procedures that conform to Section 3 of AWS Dl.l will be deemed prequalified. C. Procedures other than those prequalified shall be qualified by tests as specified in Section 4 of AWS DLL D. Welding shall be performed only by welders or operators who have been qualified in accordance with Section 4 of AWS Dl.l, and their qualification test records shall be made available to the Owner. E. Welds shall be of uniform width and size throughout their length. Each layer shall be smooth and free from slag, cracks, pinholes and undercut, and completely fused to the adjacent weld beads and base metal. The cover pass shall be free from coarse ripples, high crown deep ridges and valleys between beads, and shall blend smoothly and gradually into the surface of the base metal. F. Fillet and groove welds shall be of specified size with full throat and the legs of uniform length. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 05100-7 G. For all details to be joined by welding, and where other continuous welds are not indicated on the Plans, provide continuous 3/16 - inch seal welds. H. Repair, chipping or grinding of welds shall not gouge, groove or reduce the base metal thickness. I. The manufacturer's recommendations shall be followed for both the oven- storage and reconditioning of electrodes. 3.5 GALVANIZING REPAIR Galvanized items which have been damaged or rusted, shall be repaired in a method and with paint conforming to ASTM A 780. 3.5 FIELD QUALITY CONTROL Owner to perform field tests, and provide labor, equipment, and incidentals required for testing. The Engineer shall be notified in writing of defective welds, bolts, nuts, and washers within 7 working days of the date of weld inspection. A. Welds - Visual Inspection: AWS DLL The Owner will furnish the services of qualified welding inspectors for fabrication and erection inspection and testing and verification inspections. Welding inspectors _.^ shall visually inspect and mark welds, including fillet weld end returns f j with accordance to AWS D1.1/D1.1M Table 6.1 - Visual Inspection Acceptance Criteria. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 05100-8 SECTION 05501 ANCHOR BOLTS PART 1—GENERAL 1.1 DESCRIPTION A. This section specifies anchor bolts complete with washers and nuts. Unless otherwise specified, anchor bolts type 316 stainless steel. 1.2 REFERENCES A. This section contains references to the following documents. They are a part of this section as specified and modified. In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Reference Title ANSI A58.1-82 Minimum Design Loads for Buildings and Other Structures ASTM A36/A36M-96 Structural Steel ASTM A307-94 Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength ASTM A320/A320M-94 Alloy-Steel Bolting Materials for Low Temperature Service UBC-97 Uniform Building Code PART 2—PRODUCTS 2.1 GENERAL A. Anchor bolt holes in equipment support frames shall not exceed the bolt diameters by more than 25 percent, up to a limiting maximum oversizing of 1/4 inch. Unless otherwise specified, minimum anchor bolt diameter shall be 1/2 inch. Anchor bolts for equipment mounting and vibration isolation systems shall be provided as specified in Sections 11002, Equipment Mounting, and 11021, Vibration Isolation Systems, respectively. B. Tapered washers shall be provided where mating surface is not square with the nut. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 05501 - 1 C. Expansion, wedge, or adhesive anchors set m holes drilled in the concrete after the concrete is placed will not be permitted in substitution for anchor bolts except where otherwise specified. Upset threads shall not be acceptable. 2.2 MATERIALS A. Anchor bolt materials shall be as specified in Table A. Table A, Anchor Bolt Materials Matenal Specification Steel bolts ASTM A307, Grade A Fabricated steel bolts ASTM A36 Stainless steel bolts, ASTM A320, Type 304a nuts, washers Expansion anchors HILTI-BOLT, McCulloch Industries, or equal Wedge anchors ITT, Phillips Drill Co., or equal. Adhesive anchors fflLTI-HVA, PARABOND Capsule, or equal aUse Type 316 where specified. 2.3 DESIGN A. Anchor bolts for equipment frames and foundations shall be designed in accordance with UBC 97 for seismic zone 4. 2.4 PRODUCT DATA A. The following information shall be provided for all bolt systems not cast-m- place: 1. Data indicating load capacities. 2. Chemical resistance. 3. Temperature limitations. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 05501 - 2 4. Installation instructions. 5. Evaluation Report for expansion and wedge type anchors. PART 3—EXECUTION 3.1 GENERAL A. Fieldwork, including cutting and threading, shall not be permitted on galvanized items. Dissimilar metals shall be protected from galvanic corrosion by means of pressure tapes, coatings or isolators. 3.2 CAST-IN-PLACE ANCHOR BOLTS A. Anchor bolts to be embedded in concrete shall be placed accurately and held in correct position while the concrete is placed or, if specified, recesses or blockouts shall be formed in the concrete and the metalwork shall be grouted in place. The surfaces of metalwork in contact with concrete shall be thoroughly cleaned. B. After anchor bolts have been embedded, their threads shall be protected by grease and the nuts run on. 3.3 ADHESIVE ANCHOR BOLTS A. Use of adhesive or capsule anchors shall be subject to the following conditions: 1. Use shall be limited to locations where exposure, on an intermittent or continuous basis, to acid concentrations higher than 10 percent, to chlorine gas, or to machine or diesel oils, is extremely unlikely. 2. Use shall be limited to applications where exposure to fire or exposure to concrete or rod temperature above 120 degrees F is extremely unlikely. Overhead applications (such as pipe supports) because of the above concerns, shall be disallowed. 3. Approval from Construction Manager for specific application and from supplier of equipment to be anchored, if applicable. 4. Anchor diameter and grade of steel shall be per contract documents or per equipment supplier specifications. Anchor shall be threaded or deformed full length of embedment and shall be free of rust, scale, grease, and oils. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 05501 - 3 SECTION 05505 MISCELLANEOUS METAL WORK PART 1—GENERAL 1.1 DESCRIPTION This section specifies miscellaneous metalwork, which consists of custom fabricated steel metalwork other than structural metalwork. 1.2 QUALITY ASSURANCE A. General: 1. Shop and field welding shall conform to the requirements of the AISC Manual of Steel Construction. 2. The use of salvaged, reprocessed or scrap materials will not be permitted. B. References: 1. This section contains references to the following documents. They are a part of this section as specified and modified. In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Reference Title AISC Manual of American Institute of Steel Construction, Manual of Steel Construction, Allowable Stress Design-9th Edition ASTM A36/A36M-89 Structural Steel ASTM A48-83 Gray-Iron Castings ASTM A283/ Low and Intermediate Tensile Strength A283M-88 Carbon Steel Plates, Shapes and Bars ASTM A307-90 Carbon Steel Externally Threaded Standard Fasteners P074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 05505 - 1 ASTM A320/ A320M-88 ASTM A500-89 Alloy-Steel Bolting Materials for Low Temperature Service Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes PART 2—PRODUCTS 2.1 MATERIALS A. Materials for miscellaneous metalwork are specified in Table A. Table A, Materials for Miscellaneous Metalwork Material Specification 2.2 Nonstructural steel bars, angles, clips, and similar items Iron castings Structural steel tubing Steel bolts (except flanges and anchor bolts) Stainless steel FABRICATION A. General: 1. ASTM A36 or ASTM A283 ASTM A48 ASTM A500, Grade B ASTM A307, Grade A ASTMA320,type316 2. Holes shall be punched 1/16 inch larger than the nominal size of the bolts, unless otherwise specified. Whenever needed, because of the thickness of the metal, holes shall be subpunched and reamed or shall be drilled. Fabrication including cutting, drilling, punching, threading and tapping required for miscellaneous metal or adjacent work shall be performed pnor to hot-dip galvanizing. B.Seat Angles, Supports and Brackets: 1. Seat angles over slide gate guides shall be welded to the guides. Seat angles for grating, supports for floor plates, clips for precast panels CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 05505 - 2 and brackets for piping shall be 316 stainless steel after fabrication unless otherwise specified. C. Power Dn ven Pins: 1. Power driven pins may be used m interior locations of nonprocess areas. Pins shall be heat treated steel alloy in accordance with AISI 1062 or 4063 and shall be zinc-plated. Pins shall have capped or threaded heads capable of transmitting the loads the shanks are required to support. Pins that are connected to steel shall have longitudinal serrations around the circumference of the shank. Complete information describing pin capacities and connections shall be provided to the Construction Manager. Proposed use and locations shall be approved by the Construction Manager prior to their use. D. Iron Castings: 1. Castings shall be as specified on the drawings. Castings weighing less than 100 pounds shall be hot-dip galvanized after machining. Castings weighing greater than 100 pounds shall be galvanized where specified. E. Other Miscellaneous Steel Metalwork: 1. Other miscellaneous steel metalwork including embedded and nonembedded steel metalwork, hangers and inserts shall be 316 stainless steel. PART 3—EXECUTION 3.1 INSTALLATION A. General: 1. Fieldwork shall not be permitted on galvanized items. Drilling of bolts or enlargement of holes to correct misalignment will not be allowed. 2. Dissimilar metals shall be protected from galvanic corrosion by means of pressure tapes, coatings or isolators. 3. Metalwork to be embedded in concrete shall be placed accurately and held in correct position while the concrete is placed or, if specified, recesses or blockouts shall be formed in the concrete. The surfaces of metalwork in contact with or embedded in concrete shall be thoroughly cleaned. If accepted, recesses may be neatly cored in P074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 05505 - 3 the concrete after it has attained its design strength and the metalwork grouted in place. Embedments shall be as specified in Section 03300, Cast-m-Place Concrete. B. Seat Angles, Supports and Guides: 1. Seat angles for grating and supports for floor plates shall be set so that they are flush with the floor and also maintain the grating and floor plates flush with the floor. C. Power Dn ven Pins: 1.Power driven pins shall be set by a craftsman who is certified by the manufacturer. Pins shall be driven in one initial movement by an instantaneous force that has been selected to attain the required penetration. Driven pins shall conform to the following: Minimum space Penetrated Penetration of from center of Material penetrated by pin Concrete Steel material's minimum thickness 16D 1A inch pin's shank in supporting material 6D minimum Steel thickness plus 2D pin's shank to edge of penetrated matl 14D 4D Minimum pin spacing 20D 7D Where D = pin shank diameter. When required by the Construction Manager, pullout tests shall be carried out by the Contractor to prove the effectiveness of the anchorage and the capacity of the pin. 3.2 CLEANING After installation, damaged surfaces of shop primed metals shall be cleaned and touched up with the same material used for the shop coat. Damaged surfaces of galvanized metals shall be repaired. With acceptable procedure for galvanizing repair in accordance to procedure described in Section 210-3.5.2 metalizing process in SSPWC. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 05505 - 4 SECTION 05530 ALUMINUM ACCESS HATCH PART 1-GENERAL 1.1 DESCRIPTION This section specifies access hatch on concrete vaults 1.2 REFERENCES This section contains references to the following documents. They are a part of this section as specified and modified. In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Reference Title AISC Manual of American Institute of Steel Steel Construction Construction, Manual of Steel Construction, Allowable Stress Design-9th Edition ASCE Journal Suggested Specifications for Vol. 88-ST6-62 Structures of Aluminum Alloys 6061-T6 and 6063-T6 ASTM A36/A36M-89 Structural Steel ASTM A569/A569M-85 Steel, Sheet and Strip, Carbon, Hot Rolled, Commercial Quality ASTM B210-8 8 Aluminum and Aluminum-Alloy Drawn Seamless Tubes ASTM B221-88 Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Shapes and Tubes 1.3 SHOP DRAWINGS AND SAMPLES A. The following shall be submitted in compliance with Section 2-5.3 of the General Provisions' 1. Shop drawings showing dimensions and details of aluminum access hatches. 2. Manufacturer's product data. 3. Manufacturer's installation instructions. 4. Manufacturer's certification of compliance CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 05530 - 1 PART 2-PRODUCTS 2.1 MATERIALS A. ALUMINUM Aluminum grating bearing bars and aluminum floor plates and cover plates shall be of alloy 6061-T6 conforming to ASTM B221. Aluminum grating cross bars shall be of an alloy conforming to either ASTM B221 (extrusions) or B210 (drawn) 2.2 FABRICATION A GENERAL: Rough weld beads and sharp metal edges on plates shall be ground smooth. Welds exposed to view shall be uniform and neat. Holes shall be punched 1/16 inch larger than the nominal size of the bolts, unless otherwise specified. Whenever needed, because of the thickness of the metal, holes shall be sub punched and reamed or shall be drilled. Cutting, drilling, punching, threading and tapping shall be performed prior to hot-dip galvanizing. B. ACCESS HATCH: Hatches (Checkered Plate) shall be Alcoa C-102 aluminum tread plate, Reynolds diamond tread plate, or equal. Hinged cover plates shall be as specified and shall be set flush with surrounding floor. No single piece of floor and cover plate shall weigh more than 80 pounds unless specifically detailed otherwise. PART 3--EXECUTION 3.1 INSTALLATION A. GENERAL: Drilling of bolts or enlargement of holes to correct misalignment will not be allowed. Dissimilar metals shall be protected from galvanic corrosion by means of pressure tapes, coatings or isolators. Aluminum in contact with concrete shall be protected by a heavy coat of bituminous paint. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 05530 - 2 Metalwork to be embedded in concrete shall be placed accurately and held in correct position while the concrete is placed or, if specified, recesses or blockouts shall be formed m the concrete after it has attained its design strength and the metalwork grouted in place as specified in Section 03300. The surfaces of metalwork in contact with or embedded in concrete shall be thoroughly cleaned. If accepted, recesses may be neatly cored in the concrete. B. ACCESS HATCH: Hatches shall be field measured for proper cutouts and proper sizes. Field welding of aluminum grating and cover plates, where specified, shall be in accordance with ASCE Vol. 88-ST6. 3.2 CLEANING After installation, damaged surfaces of shop pnmed metals shall be cleaned and touched up with the same material used for the shop coat. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 05530 - 3 SECTION 06100 ROUGH CARPENTRY PART 1--GENERAL 1.1 DESCRIPTION This section specifies all rough carpentry. 1.2 RELATED SECTIONS Section 04220 Concrete Masonry Section 07311 Asphalt Shingles 1.3 QUALITY ASSURANCE A. REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified. In case of a conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Reference Title ANSIB18.2.1-81 Square and Hex Bolts and Screws, Inch Series Including Hex Cap Screws and Lag Screws ANSI B18.2.2-87 Square and Hex Nuts (Inch Series) ANSI B18.5-78 Round Head Bolts (Inch Series) ANSI B 18.6.1-81 Wood Screws (Inch Series) ASTMA687-89 High-Strength Nonheaded Steel Bolts and Studs AWPAC1-88 All Timber Products-Preservative Treat- ment by Pressure Process AWPA C2-88 , Standard for the Preservative Treatment of Lumber, Timber, Bridge Ties, and Mine Ties by Pressure Treatment 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 06100 -1 AWPA C9-85 AWPA M6-84 AWPB LP-22-88 FEDSPEC FF-B-588C-71 FEDSPEC FF-N-105B-71 FEDSPEC FF-S-325-57 FEDSPEC FF-T-1813-73 FEDSPEC MM-T-371E-75 FEDSPEC UU-B-790A-68 MIL-L-19140E-84 NFP-NDS-86 PS 1-83 PS 20-70 (1986) TPI 78-85 Plywood—Preservative Treatment Pressure Process Brands Used on Forest Products by Standard for Softwood Lumber, Timber, and Plywood Pressure Treated with Waterborne Preservatives for Ground Contact Use Bolt, Toggle, and Expansion Sleeve, Screw Nails, Brads, Staples and Spikes: Wire, Cut and Wrought Shield, Expansion, Nail Expansion, and Nail Drive Screw (Devices, Anchoring, Masonry) Tack Ties, Railroad, Wood (Cross and Switch) Building Paper, Vegetable Fiber: (Kraft, Waterproofed, Water Repellent and Fire Resistant) Lumber and Plywood, Fire-Retardant Treated National Design Specification for Wood Construction and Supplement 1986, Design Values for Wood Construction U.S. Department of Commerce, Product Standard, Construction/Industrial Plywood U.S. Department of Commerce, Product Standard, American Softwood Lumber Standards Design Specification for Metal Plate Connected Wood Trusses 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 06100-2 TPIBWT-76 Bracing Wood Trusses—Commentary and Recommendations TPI HET-80 Handling and Erecting Wood Trusses- Commentary and Recommendations TPI QST-88 Quality Standard for Metal Plate Connected Wood Trusses UBC-88 Uniform Building Code B. GRADING AND MARKING: 1 LUMBER Each piece of framing and board lumber and each bundle of small pieces of lumber shall be marked with the grade mark of a recognized association or independent inspection agency. Such association or agency shall be certified by the Board of Review, American Lumber Standards Committee, to grade the species used. 2. PLYWOOD Each sheet shall be marked with the mark of a recognized association or independent inspection agency that maintains continuing control over the quality of the plywood. The mark shall identify the plywood by species group or span rating, exposure durability classification, grade, and compliance with PS 1. 3. PRESERVATIVE-TREATED LUMBER AND PLYWOOD The Contractor shall be responsible for the quality of treated wood products. Each treated piece shall be permanently marked or branded by the producer in accordance with AWPA M6. The Contractor shall provide the Construction Manager with the inspection report of an independent inspection agency showing that offered products comply with applicable AWPA treatment standards. The AWPB Quality Mark "LP-22" on each piece will be accepted, in lieu of inspection reports, as evidence of compliance with applicable AWPA treatment standards. 4. FIRE-RETARDANT TREATED LUMBER AND PLYWOOD: Each piece shall be marked in accordance with MIL-L-19140, except pieces that are to be natural or transparent finished. In addition, exterior fire-retardant lumber and plywood shall be distinguished by a permanent penetrating blue stain. Labels of a CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 06100-3 nationally recognized independent testing agency will be accepted ^—. as evidence of conformance to the fire-retardant requirements of ( ) MIL-L-19140 " C. SIZES AND SURFACING. Dressed sizes of yard and structural lumber shall comply with PS 20 Unless otherwise specified, lumber shall be surfaced four sides. Size references, unless otherwise specified, are nominal sizes, and actual sizes shall be within manufacturing tolerances allowed by the standard under which the product is produced D MOISTURE CONTENT: Lumber shall be air-dned or kiln-dried Treated lumber shall be kiln-dried after treatment. Maximum moisture content of wood products shall be as follows. 1 Framing lumber and boards— 19 percent maximum. 2 Timbers 5 inches and thicker—25 percent maximum 1 4 SUBMITTALS The following information shall be provided in accordance with Section 2-5.3 of the General Provisions: 1. Detailed list of equipment, joist hangers, and type of fasteners to be used. 2 A copy of this specification section with addenda updates, and all referenced sections with addenda updates, with each paragraph check marked to show specification compliance or marked to show deviations. 1.5 STORAGE Materials shall be stored in an area protected from weather, elevated a minimum of 6 inches above the ground on framework and covered with waterproof covering. Materials shall not be stored in wet or damp areas. 1.6 PRESERVATIVE TREATMENT Lumber and timber, where specified, shall be treated in accordance with AWPA Cl and C2 and plywood in accordance with AWPA Cl and C9. All wood shall be air- or kiln-dried after treatment. Specific treatments shall be verified by the report of an approved independent inspection agency or the AWPB Quality Mark on each piece. Surfaces of lumber that will be exposed shall not be incised. Areas that are cut or drilled after treatment shall be brush coated with either the same preservative used in the treatment or with a 2 percent copper napthenate n--- CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 06100-4 solution. Preservatives used shall be acceptable for specific treatment under local codes and regulations pertaining to toxic and hazardous materials. Unless otherwise specified, the following items shall be preservative treated: 1.7 FIRE-RETARD ANT TREATMENT The following items shall be treated in accordance with MIL-L-19140. Such items which will not be inside a building shall receive exterior fire-retardant treatment. PART 2--PRODUCTS 2.1 LUMBER A. STRUCTURAL LUMBER: Unless otherwise specified, structural lumber shall be any of the species and grades listed in NFPA-NDS that have allowable unit stresses in psi not less than allowable unit stresses specified. Structural lumber shall be used for joists, rafters, headers, trusses, beams, columns, posts, stair stringers, girders, and all other members specified to be stress rated. 2.2 PLYWOOD PANELS A. COMBINATION SUBFLOOR UNDERLAYMENT: Unless otherwise specified, panel subfloonng shall be Exterior Type, C-C Plugged Grade. Minimum thickness shall be as listed below except where specified to have greater thickness: Support spacing Minimum thickness 16 inches 1/2 inch for Group 1 species, 19/32 inch for Group 2 and 3 species, 23/32 inch for Group 4 species 24 inches 23/32 inch for Group 1 species, 7/8 inch for Group 2 and 3 species, 1 inch for Group 4 species B. WALL SHEATHING: Unless otherwise specified, panel wall sheathing shall be C-D Grade, Exposure 1, and a minimum thickness of 3/4 inch. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 06100 - 5 C. ROOF SHEATHING: Unless otherwise specified, panel roof sheathing shall be C-D Grade, Exposure 1, with an identification index of not less than 24/0. 2.3 OTHER MATERIALS A. BUILDING PAPER: Building paper shall conform to FEDSPEC UU-B-790, Type I, Grade D, Style 1. B. TRUSSED RAFTERS: Trussed rafters, where specified, shall be metal plate connected wood trusses designed in accordance with TPI 78 and fabricated in accordance with TPI QST. C. TRUSSED JOISTS: Trussed joists, where specified, shall be metal plate connected parallel chord wood trusses designed in accordance with TPI 78 and fabricated in accordance with TPI QST. D. WOOD BUMPERS: Wood bumpers shall conform to FEDSPEC MM-T-371, Type I, Form A or B, and shall be oak. 2.4 ROUGH HARDWARE Unless otherwise specified, rough hardware shall be of the type and size necessary for the project requirements. Sizes, types, and spacing of fastenings of manufactured building materials shall be as recommended by the product manufacturer unless otherwise specified. Rough hardware exposed to the weather or embedded in or in contact with preservative treated wood, exterior masonry, or concrete walls or slabs shall be hot-dip galvanized. Nails and fastenings for fire- retardant treated lumber and woodwork exposed to the weather shall be copper alloy. Bolts, nuts, studs, and rivets shall conform to ANSI B 18.2.1, ANSI B18.5, ANSI B 18.2.2, and ASTM A687. Expansion shields shall conform to FEDSPEC FF-S-325. Unless otherwise specified, maximum size of devices in Groups IV, V, VI, and VII shall be 3/8 inch. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 06100-6 Lag screws and lag bolts shall conform to ANSI B 18.2.1. Toggle bolts shall conform to FEDSPEC FF-B-588 Wood screws shall conform to ANSI B18.6.1. Wire nails shall conform to FEDSPEC FF-N-105. Joist hangers shall be steel or iron, zinc coated, sized to fit the supported member, of sufficient strength to develop the full strength of the supported member in accordance with the UBC and furnished complete with any special nails required Unless otherwise specified, joist anchors for joists supported by masonry walls shall be 3/16-mch by 1 1/2-inch steel tee or strap, bent and of length to provide 4 inches of embedment into wall and 12 inches along joist Unless otherwise specified, anchors for joists parallel to masonry or concrete walls shall be 1/4-mch by 1 1/4-inch minimum cross-sectional area, steel strap, length as necessary to extend over top of first three joists and into wall 8 inches Door buck anchors, where specified, shall be metal anchors, 1/8-mch by 1-1/4-inch steel, 12 inches long, with ends bent 2 inches. Anchors shall be screwed to the backs of bucks and built into masonry or concrete, and shall be located 8 inches above sills and below heads and not more than 24 inches intermediately between. 2 5 PRODUCT DATA The following information shall be provided in accordance with Section 2-5.3 of the General Provisions- 1. Shop drawings for fabricated wood trusses and other fabricated structural members indicating materials, details of construction, methods of fastening, and erection details. 2 Inspection report specified in paragraph 06100-1.03 B.3. PART 3-EXECUTION 3.1 INSTALLATION A. GENERAL: Framing lumber and other rough carpentry shall be fit and set accurately to the required lines and levels and secured in place in a rigid manner. Framing members between bearing points shall not be spliced. Joists, rafters, and purlins shall be set with their crown edge up. Members shall be framed for the passage of pipes, conduits, and ducts; however, cutting CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 06100 - 7 or bonng of structural members for the passage of ducts or pipes is not permitted. Unless otherwise specified, all members damaged by such cutting or bonng shall be reinforced by means of specially formed and approved sheet metal or bar steel shapes, and spiking and nailing shall be in accordance with the Nailing Schedule contained in UBC. Spikes, nails, and bolts shall be drawn up tight. Timber connections and fastenings shall conform to NFPA-NDS Slate or steel shims shall be used when leveling joists, beams, and girders on masonry or concrete B. SILLS 1. GENERAL- Sills shall be set level and square, wedged with steel or slate shims, and grouted with nonshnnking cement mortar to provide continuous and solid bearing Sills shall be anchored to the foundations as specified Unless otherwise specified, minimum 5/8-inch diameter bolts shall be provided at all corners and splices and spaced at a maximum of 6 feet o.c. between corner bolts. At least two bolts shall be provided for each sill member. Bolts shall be provided with plate washers and nuts. Bolts in exterior walls shall be zinc-coated. 2. ANCHORS IN MASONRY: Unless otherwise specified, anchor bolts shall be embedded not less than 15 inches in masonry unit walls and each provided with a nut and a 2-inch diameter washer at bottom end. Bolts shall be fully grouted with mortar 3 ANCHORS IN CONCRETE: Unless otherwise specified, anchor bolts shall be embedded not less than 8 inches in poured concrete walls and each provided with a nut and a 2-mch diameter washer at bottom end. A bent end may be substituted for the nut and washer; bend shall be not less than 90 degrees. BEAMS AND GIRDERS: Unless otherwise specified, beams and girders shall be set to elevations and alignment specified, and anchored to bearing walls, piers, or supports with U-shaped steel strap anchors. Anchors shall be embedded in concrete or masonry at each bearing and through-bolted to the beams or girders with not less than two bolts. Bolts shall be not less than 1/2 inch in diameter and with plate washers under heads and nuts. Beams and girders, unless otherwise specified, shall be installed with 8-inch minimum end bearing on walls or supports. Joints and splices shall be made over bearings only. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 06100-8 D. JOISTS 1. GENERAL: Joists shall be of the sizes and spacing specified, in alignment, and of uniform width. Joists shall have full bearing on sills, plates, beams, girders, and trusses and shall provide laps over bearing only. Where joists are of insufficient length to produce a 12-inch lap, joists shall be butted together over bearing and provided with sheet metal connectors installed in accordance with the manufacturer's recommendations. Metal hangers shall be provided for joists framing into the side of headers, beams, or girders. The minimum joist end bearing shall be 4 inches, and joists built into concrete or masonry shall have a 1/2-inch minimum clearance at the top, end, and sides. For joists approved to be bored for the passage of pipes or conduits, passage shall be through the neutral axis of the joist. Steel joist hangers of proper size and type shall be provided to receive the ends of all framed joists. Unless otherwise specified, doubled joists shall be provided under bearing walls and partitions running parallel with the floor joists, around stairways, and at other openings where joists are cut and framed. Joists under partitions that are to receive ducts, pipes, and conduits shall be doubled, spaced for clearance, blocked apart 4 feet on center, rigidly framed, and spiked together. 2. JOIST ANCHORS: Anchors shall be provided for each fourth joist supported by a masonry wall. Wall end of anchors shall be built into the wall and nailed to the joist. The first three joists parallel to concrete or masonry walls shall be anchored at bridging points, but not less than 8 feet o.c. from end walls. Anchors shall extend into the wall as specified. E. BRIDGING: Bridging shall be provided for floor and ceiling joists and for roof rafters having slopes of less than 4 inches in 12 inches. Bridging shall be located as specified. Bridging shall be provided for spans greater than 6 feet, but maximum spacing between rows of bridging shall not exceed 8 feet. Rows of bridging shall be installed uniformly. Metal or wood cross- bridging shall be provided except where solid bridging is specified. Unless otherwise specified, wood cross-bridging shall be not less than 2 by 3 inches. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 06100-9 Metal cross-bndging shall be the manufacturer's standard product, not less than 16 gage before forming and coating. Metal bridging shall be the compression type, lodged into or nailed to the wide faces of opposite joists at points diagonally across from each other near the bottoms and tops of joists. WALL FRAMING: 1. STUDS: Studs shall be straight and set plumb, true, and in alignment. In walls and partitions more than 8 feet tall, horizontal bridging shall be provided at not more than 8 feet o.c. using nominal 2-mch material of the same width as the studs. Sizes and spacing of studs shall be as specified. Double studs shall be provided at jambs and heads of openings and triple at comers to form corner posts. Comer posts shall be framed to receive sheathing, lath, and interior finish. Openings exceeding 4 feet in width shall be trussed over or provided with a header of sufficient depth. Studs abutting concrete or masonry walls shall be anchored thereto near the top and bottom and at rmdheight of each story using expansion bolts or powder-actuated drive studs. 2. PLATES: Plates for walls and partitions shall be the same width as the studs to form continuous horizontal ties. Single plates shall be spliced; ends of double plates shall be staggered. Top plates in walls and bearing partitions shall be double, built up of two nominal 2-inch thick members. Top plates for nonbeanng partitions shall be single or double plates of the same size as the studs. Lower members of double top plates and single top plates shall be nailed to each stud and corner post with two 16-penny nails (three nails for 2 x 6 studs). Upper members of double plates shall be nailed to the lower members with 10-penny nails, two near each end, and staggered 16 inches o.c. intermediately between. Sole plates on wood construction shall be nailed through the subfloor to each joist and header. Sole plates on concrete or masonry shall be anchored with expansion bolts, one near each end and at no more than 6 feet o.c., or in accordance with paragraph 06100-3.01 B. Powder-actuated fasteners, one near each end and at not more than 3 feet o.c. may be used only where specified. Plates cut for the passage of pipes or ducts shall be provided with a steel angle as a tie for the plate and bearing for joist. 3. FIRESTOPS: Firestops shall be provided for wood framed walls and partitions and for furred spaces of concrete or masonry walls at each floor level and at the ceiling line in the top story. Where firestops are not automatically provided by the framing system 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 06100-10 used, they shall be formed of closely fitted wood blocks of nominal 2-inch thick material of the same width as the studs and joists. 4. DIAGONAL BRACING: Except where plywood wall sheeting is specified, and unless otherwise specified, diagonal bracing shall be provided at all external corners and internal angles and at maximum 40-foot centers in stud walls. Bracing shall be of 1 by 6 inch material, let into the exterior face of studs. Bracing shall extend from top plates to sill at an angle of approximately 45 degrees. When openings occur near corners, diagonal knee braces shall be provided extending from the corner post above headers to top plates and from below window sills to the mam sill. G. WALL SHEATHING: Plywood panel wall sheathing shall be provided where specified and shall be applied horizontally or vertically. Sheathing shall be extended over and nailed to sill and top plate. Sheathing edges shall abut over centerhnes of supports. A 1/8-inch spacing shall be provided at panel ends and 1/4 inch at panel edges. If sheathing is applied horizontally, vertical end joints shall be staggered. Blocking shall be provided for horizontal edges not otherwise supported. H. BUILDING PAPER: Unless otherwise specified, building paper shall be provided on wood board sheathing behind all types of exterior siding. Paper shall be applied shingle fashion, horizontally, beginning at the bottom of the wall. Edges shall be lapped 4 inches and nailed with 1-inch, zinc-coated roofing nails, spaced 12 inches o.c. and driven through tin discs. I. CEILING JOISTS: Ceiling joists shall be sized as specified and set accurately and in alignment. Joists shall be nailed to all plates with not less than three 10-penny nails. J. RAFTERS: Rafters shall be sized as specified, set accurately, and form a true plane. Unless otherwise specified, members shall be 2 inches thick. Rafters shall have full and solid bearing on plates. Headers and trimmers carrying or supporting two or more rafters shall be doubled unless otherwise specified. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 06100-11 K. METAL FRAMING ANCHORS: v Framing anchors shall be provided at every other rafter to fasten rafter to plates and studs against uplift and movement of any kind. Anchors shall be punched and formed for nailing so that nails will be stressed in shear only. L. TRUSSES: Metal plate connected wood trusses shall be handled and erected in accordance with TPIHET and braced in accordance with TPIBWT. M. PLYWOOD PANEL ROOF SHEATHING: Roof panels shall be installed with the grain of the outer plies or long dimension of full panels at right angles to supports. End joints shall be staggered and located over the centerlmes of supports. A 1/8-mch spacing shall be provided at panel ends and 1/4 inch at panel edges. Unless otherwise specified, panels shall be nailed with common nails or annular rings or screw-type nails spaced 6 inches o.c. at supported edges and 12 inches o.c. at intermediate bearings. Nail size shall be in conformance with APA recommendations for panel type and thickness to be fastened. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 06100- 12 SECTION 06600 SLIP-LINE PIPE REHABILITATION PART 1—GENERAL 1.1 DESCRIPTION. 12 A B. Description of Work This section includes the rehabilitation of the 30- mch outlet pipe line using HDPE insert liner and pressure grouting of the annular space Related sections Section 02200 Section 03600 Section 15065 Earthwork Grout High Density Polyethylene Pipe QUALITY ASSURANCE A. Reference Test Standards and Specifications ASTMD1248 ASTMD1693 ASTMD1928 ASTMD2122 ASTM D2657 ASTMD2837 ASTM D3035 ASTMD3261 Specification for Polyethylene Plastics Molding and Extrusion Materials Test for Environmental Stress - Cracking of Ethylene Plastics Preparation of Compression-Molded Polyethylene Plastics Determining Dimensions of Thermoplastic Pipe and Fittings Practice for Heat - Joining Polyethylene in Pipe and Fittings Obtaining Hydrostatic Design Basis for Thermoplastic Pipe Materials Specification for Polyethylene (PE) Plastic Pipe (SDR-PR) Based on Controlled Outside Diameter - Up to 6" IPS Butt Heat Fusion Polyethylene (PE) Plastic Fittings for Polyethylene (PE) Plastic Pipe and Tubing CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 06600 -1 ASTM D3350 Specification for Polyethylene Plastics and Fittings Materials ASTM F585 Practice for Insertion of Flexible Polyethylene Pipe into Existing pipeline ASTM F714 Specification for Polyethylene (PE) plastic Pipe (SDR-PR) Based on Outside Diameter 3" IPS and Larger 1 3 SUBMITTALS: Submittals shall be in accordance with Section 2-5.3 of the General Provisions. A Manufacturer's Data and Descriptions Submit calculations for the following to prove pipe material and wall thickness proposed will meet all applicable requirements: 1. Dead Load - assume 350 psf/ foot of soil 2. Live load - Use AASHTO H2O full traffic load 3. External Buckling - Use 8ft. water depth 4. Deflection 5. Bending Stress 6 Stiffness B. Pipe and Fittings for liner used the following submittals shall be provided: 1. Detail drawings, which show the type and location of all fittings, joints, and connections to structures. 2. A copy of this specification section, with addendum updates included, and all referenced and applicable sections, with addendum updates included, with each paragraph check-marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. If deviations from the specifications are indicated and, therefore requested by the Contractor, the submittal shall be accompanied by a detailed, written justification for each deviation. Failure to include a copy of the marked-up specification sections, along with justification for any requested deviations to the specification requirements, with the submittal shall be cause for rejection of the entire submittal with no further consideration r<r- CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 06600 - 2 C. Electrofusion Couplings 1. Manufacturer Data and Catalog Cuts D. Grout Properties 1. Proposed grouting mix 2. Density and viscosity of the mix 3. Initial Set Time of the Mix 4. The 24-hour and 28- day minimum compressive strength of the mix 5. Maximum inj ection pressure 6. Proposed grout volumes 7. Bulkhead design 8 Buoyant force calculations 9. Flow control 10. Pressure gauge certifications 11. Vent location E Proposed Grouting Method 1 4 PRODUCT DELIVERY STORAGE AND HANDLING Protect all pipe during unloading, storage and placement against impact and Ultraviolet radiation damage. All damaged or defective materials shall be replaced. Impact damage includes, but is not limited to, gouging, abrasion, flattening, cutting and puncturing. In any case where the suitability of damaged pipe for this job is in question the decision of the Engineer will be final. 1 5 JOB CONDITIONS Maintain the condition and operation of the existing system Reroute the existing flows if required with the appropriate equipment. Costs associated with maintaining the condition and operation of the existing system shall be borne by the Contractor at no additional cost to the Owner. PART 2—MATERIALS 2 1 HIGH-DENSITY POLYETHYLENE (HOPE) SOLID WALL PIPE LINER HPDE solid-wall liner pipe shall comply with ASTM D3350, Cell Classification 345434 C, D and E, and ASTM F714. HDPE pipe liner shall be in compliance with Section 15065, High Density Polyethylene Pipe. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 06600 - 3 2.2 CHEMICAL RESISTANCE AND TESTING The Engineer may, at any time, direct the Contractor to obtain compound samples and to prepare test specimens in accordance with ASTM D1928. These specimens shall comply with the minimum property values shown in Table 06600-1 and also with the applicable ASTM requirements. TABLE 06600-1 Property Tensile Strength (psi) minimum Impact Strength (Ft-Lbs /in.) mm. Weight Change (%) Unconditioned Conditioned ASTM Test Method D638 D256 Method A3.5 (size 1/2"xl/8"x2 !/2") D543 Initial Value 3,200 3.5 Value after 112 Days of Exposure 3,200 3.5 +/- 1 5max. +/- 1.0 max Proof of meeting these requirements shall be provided to the Engineer for approval at least 15 days prior to the commencement of work. 2 4 ANNULAR SPACE GROUTING The annular space between 30-inch outlet pipe and liner shall be grouted after a successful line test. A. Materials The grout material shall consist of Portland cement, fly ash and additives. Biodegradable matenals will not be permitted in the mixture. The grout shall have a minimum penetration resistance of 100 psi on 24 hours when tested in accordance with ASTM C403 and a minimum compressive strength of 300 psi in 28 days when tested in accordance with ASTM C495 or C109. The grouting system shall have sufficient gauges, monitoring devices and tests to determine the effectiveness of the grouting operation. One or more mixes shall be developed to completely fill the annular space. Mixes shall be based on the size of the annular void, void size of the surrounding soil and the absence or presence of groundwater. Mixes shall provide sufficient strength and durability to prevent movement of the liner pipe, adequate retardation and less than one percent shrinkage by volume. The apparent viscosity shall not exceed 20 Ib-s/ft2 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 06600 - 4 in accordance with ASTM C939 unless otherwise directed by the Engineer. B. Equipment: The Contractor shall provide equipment of sufficient size and capacity to provide the desired amount of grout for each stage in a single operation The equipment shall be capable of mixing the grout at the approved density and of changing density as dictated by field conditions. C. Injection Procedure" The gauged pumping pressure shall not exceed the liner pipe manufacturer's recommendations Pumping equipment shall be of sufficient size to inject grout at a velocity and pressure relative to the annular space Gauges to monitor grout pressure shall be attached immediately adjacent to each injection port. The gauge shall conform to an accuracy of one half percent error over the full range of the gauge or better. The range of the gauge shall not be more than 100 percent greater than the design grout pressure. Pressure gauges shall be instrument oil filled and attached to a saddle type diaphragm seal (gauge saver) to prevent clogging. All gauges shall be certified and calibrated in accordance with ANSI B40, Grade 2A. TABLE 06600-2 D SDR 26 21 19 17 15.5 PSGI 8 16 21 28 36 Density and Viscosity Density shall be verified by ASTM C138 or by other methods as determined by the Engineer. Viscosities shall be checked with a flow cone provided by the Contractor and tested per ASTM C939. E. Low Density Grout Contractors may use a low density grout method as an alternative The Engineer must submit the low-density grout mix for approval. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 06600 - 5 2.5 INSERTION PIT CONNECTION HDPE liner pipe connections at the insertion pits shall be rigid electro-fusion couplings, stub-flanged couplings, and concreted encasement or approved equal Banded couplings or flexible rubber couplings are not acceptable PART 3—EXECUTION 3 1 PRELIMINARY INVESTIGATION OF THE WORK The Contractor shall verify that all preliminary work has been performed in accordance with Section 02110, Clearing, Grubbing and Stripping, prior to any pipe line rehabilitation. 3.2 LINER INSTALLATION A Insertion of Liner The liner pipes shall be inserted through the discharge end of the outlet tower into the outlet pipe. The length of the level excavation shall be no shorter than 12 times the Outside Diameter of the liner pipe being inserted. Contractor will be responsible to provide access to the outlet tower by using barge and assembling scaffolding as needed. Contractor to abide by OSHA safety regulations Assemble the full length of liner to be used in the single reach using fusion butt welds in accordance with ASTM D2657. All fusion joining shall be performed with equipment designed for butt fusion of thermoplastic pipe and by trained personnel. Protect the liner pipe to prevent scouring of the outside of the liner as it is being inserted into the host pipe. Once insertion is begun, continue to pull the entire length of liner pipe without stopping. Follow manufacturer's recommendations regarding relaxation of the liner prior to sealing the annular space between the liner with over five years of working experience with HDPE pipe and slip lining with HDPE. The Contractor shall smooth and make flush the butt welds on the exterior of the pipe so that the outside diameter is the same as the pipe at the butt welded joint 3.03 GROUTING A. Qualifications- The Contractor shall provide references of at a minimum of five previous projects demonstrating its capabilities of filing the annular space and performing work in conformance with the Plans and Specifications. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 06600 - 6 B. Equipment- The material shall be mixed in equipment of sufficient size and capacity to provide the desired amount of grout material for each stage in a single operation. The equipment shall be capable of mixing the grout at densities required for the approved procedure and shall also be capable of changing density as dictated by field conditions at any time during the grouting operation. C. Injection Procedure and Pressure - The gauged pumping pressure shall not exceed 15 psi. Pumping equipment shall be of a size sufficient to inject grout at a velocity and pressure relative to the size of the annular space. Gauges to monitor grout pressure shall be attached immediately adjacent to each injection port. The gauge shall have a maximum error of one-half percent over the entire range of the gauge. The range of the gauge shall not be more than 100 percent greater than the design grout pressure. Pressure gauges shall be instrument oil filled and attached to a saddle-type diaphragm seal (gauge saver) to prevent clogging with grout. All gauges shall be certified and calibrated in accordance with ANSI B-40, Grade 2A D. injection Location - The Contractor shall inject grout into the annular space between the host pipe and linear pipe. The grout used on any length of pipe shall be from the same mixture. The injection of the grout on any single length of pipe shall proceed without interruption. 3.4 LINER TERMINATIONS The ends of the HDPE liner shall be fitted with an O-ring water gasket and flange going into the outlet tower and grouted m place. The gasket and grout shall be flush with the surrounding surface. Refer to plan details. The grout shall be finished smooth and be tapered from the flow-line to the edge of the manhole. 3 5 REPAIR AND REJECTION Liner pipe may be repaired for minor pipe damage. Damaged liner pipe that has been penetrated over 10 percent of the wall thickness at either the inner or outer surface shall be repaired by cutting out the damaged section and replacing with new pipe. All repair methods shall be submitted to the Engineer for approval. The remaining liner pipe sections shall be a minimum of 8 feet in length Liner pipes shall be inspected for damage immediately prior to installation If liner pipe is found to be superficially damaged the Engineer may allow the pipe to be repaired or may reject it. Rejected liner pipe shall be replaced with a new section of liner pipe at no additional cost to the Owner. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 06600 - 7 3.6 OUTLET BOX PROTECTION During the rehabilitation process the Contractor shall protect the outlet box from damage by any equipment, water pressure or air pressure. 3 7 VIDEO INSPECTION Upon completion of the entire reach of outlet pipe, the Contractor shall perform a video inspection of the new liner. Provide a written report of all observations m the outlet pipe and deliver inspection tapes to the Owner for review. Tapes shall become property of the owner. 3.8 CLEANUP Following pipe insertion with backfill, compaction, surface replacement and/or landscape repair and clean up Complete all work on the outlet pipe, including surface restoration, within 5 days from completion of the liner work. The engineer shall be the sole determiner as to whether the site has been returned to an acceptable condition. **END OF SECTION** CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 06600 - 8 SECTION 07311 ASPHALT SHINGLES PART 1 - GENERAL 1 1 DESCRIPTION Section includes granular surfaced asphalt shingle roofing, moisture-shedding Underlayment. Provide associated metal flashings and accessories. 1.2 REFERENCES This section references the following documents. They are part of this section as specified and modified In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Reference ASTM A653/A653M ASTM B209/B209M ASTM B370 ASTM D224 ASTM D225 ASTM D226 ASTM D228 ASTM D249 ASTM D2178 Title Steel Sheet, Zinc- Coated (Galvanized) or Zinc- Iron Alloy- Coated by the Hot - Dip Process. Aluminum and Aluminum- Alloy Sheet and Plate Copper Sheet and Strip for Building Construction. Smooth -Surfaced Asphalt Roll Roofing (Organic Felt). Asphalt Shingles (Organic Felt) Surfaced with Mineral Granules. Saturated Organic Felt Used in Roofing and Waterproofing. Testing Asphalt Roll Roofing, Cap Sheets and Shingles. Asphalt Roll Roofing (Organic Felt) Surfaced with Mineral Granules. Asphalt Glass (Felt) Used in Roofing and Waterproofing. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 07311 -1 ASTMD2822 Asphalt Roof Cement. ASTM D3018 Class A Asphalt Shingles Surfaced with Mineral Granules ASTM D3161 Test Method for Wind-Resistance of Asphalt Shingles (Fan-Induced Method) ASTM D3462 Asphalt Shingles Made From Glass Felt and Surfaced With Mineral Granules. ASTM D45 86 Asphalt Roof Cement, Asbestos Free. NRCA (National Roofing Steep Roofing Manual. Contractors Association) UL 55B (Underwaters Class C Asphalt Organic- Felt Sheet Laboratories, Inc ) Roofing and Shingles. UL 580 (Underwriters Tests for Wind Uplift Resistance of Roof Laboratories, Inc.) Assemblies UL 790 (Underwriters Tests for Fire Resistance of Roof Laboratories, Inc.) Covering Materials. UL 997 (Underwriters Wind Resistance of Shingles Laboratories, Inc.) 1 3 PERFORMANCE REQUIREMENTS A. Conform to applicable code for [UL 55B Class C rating] [ASTM D3018 Class A] [UL 790 fire resistance] [UL 580 wind uplift] for shingle types specified. 1.4 SUBMITTALS Submittals shall be in accordance with Section 2-5.3 of the General Provisions. A. Shop Drawings: Indicate metal flashings, jointing methods and locations, fastening methods and locations, and installation details. B. Product Data: Submit data indicating material characteristics, performance criteria, and limitations. C. Samples: Submit two samples of each shingle color indicating color range and finish texture/pattern; for color and texture selection. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 07311 -2 D. Manufacturer's Installation Instructions: Submit installation criteria and procedures. E. Manufacturer's Certificate: Certify products meet or exceed specified requirements. 1.5 QUALITY ASSURANCE A. Perform Work in accordance with NRCA Steep Roofing Manual. B. Maintain one copy of document on site. 1.6 WARRANTY Furnish five year manufacturer warranty for asphalt shingles. 1.7 EXTRA MATERIAL Supply of 10% of total quantity of specified color extra shingles. 1.8 ASPHALT SHINGLES A Manufacturers shall be as listed under or approved equal: 1. Celotex Corporation 2. Certain Teed Corporation 3. Elk Corporation of America 4. GAP Building Materials Corporation 5. Owens Corning Fiberglas Corp. B. Product Description: Asphalt shingles conforming to ASTM D225, Type I uniform thickness; UL Rating of C and Wind Resistance Label, organic felt base, mineral granule surfaced type; standard type; square tab. Roll Roofing: ASTM D249, Type I Asphalt saturated roll roofing; surfaced on weather side with mineral granules. Color shall be "Dove Gray". C. Underlayment: Unperforated asphalt saturated felts as recommended for use in waterproofing and in construction of built-up roofs. 1.9 ACCESSORIES A. Staples: Standard wire shingle hot dipped zinc coated steel type, of sufficient length to penetrate into roof sheathing. B. Plastic Cement: Asphalt type with mineral fiber components, free of toxic solvents, capable of setting within 24 hours at temperatures of 75 °F and 50 percent relative humidity. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 07311-3 C. Lap Cement: Fibrated cutback asphalt type, recommended for use in application of underlayment, free of toxic solvents D. Flashing Materials: Sheet Flashings shall be ASTM A653/A653M, G90 (Z275); 24 mm thick steel with galvanized coating. E. Bituminous Paint: Acid and alkali resistant type; black color. 1.10 FABRICATION A. Form flashings [to profiles indicated on Drawings, and] to protect roofing materials from physical damage and shed water. B. Form flashing sections square and accurate to profile, in maximum possible lengths, free from distortion or defects detrimental to appearance or performance. C. Hem exposed edges of flashings minimum Vi-inch on underside. D. Apply bituminous paint on concealed surfaces of flashings. PART 2 -EXECUTION 2.1 EXAMINATION A. Verify roof penetrations and plumbing stacks are in place and flashed to deck surface. B. Verify roof openings are correctly framed. C. Verify deck surfaces are dry, free of ridges, warps, or voids. 2.2 PREPARATION A. Fill knotholes and surface cracks with latex filler at areas of bonded eave protection. B. Broom clean deck surfaces under eave protection and Underlayment. 2.3 PROTECTION OF INSTALLED CONSTRUCTION A. Do not permit traffic over finished roof surface. **END OF SECTION** o 1 7074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 07311 -4 SECTION 07900 SEALANTS PART 1 -GENERAL 1 1 DESCRIPTION This section specifies sealants for roof flashing, pipe penetrations and joint sealant 1. 2 QUALITY ASSURANCE A. REFERENCES This section contains references to the following documents They are a part of this section as specified and modified. In case of conflict between the requirements of this section and the listed documents, the requirements of this section shall prevail. Reference Title FEDSPECTT-S-00230C-1970 Sealing Compound. Elastomeric Type, Single Component FEDSPECTT-S-00227E-1970 Sealing Compound: Elastomenc Type, Multi-Component 1.3 SHOP DRAWINGS AND SAMPLES A. The following shall be submitted in compliance with Section 01300 1 Shop drawings showing dimensions and details of sealants 2. Manufacturer's product data. 3 Manufacturer's installation instructions 4 Manufacturer's certification of compliance PART 2 - PRODUCTS 2.1 POLYURETHANE SEALANT A. ACCEPTABLE PRODUCTS. Acceptable products shall be Sikaflex by Sika Chemical Corporation, Vulkem by Mameco International, U-Seal Joint Sealant by Burke CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 07900 -1 Company, or Rubber Calk by Products Research and Chemical Corporation. B GENERAL Polyurethane sealants shall conform to FEDSPEC TT-S-0230C for one- component systems and FEDSPEC TT-S-00227E for two-component systems. Polyurethane sealant shall be one of the following two types 1 SELF-LEVELING. Self-leveling polyurethane sealant shall be Type I, Class A as specified by the FEDSPECs referenced above 2 NONSAG Nonsag polyurethane sealant shall be Type II, Class A as specified by the FEDSPECs referenced above C PRIMER- Primer shall be as recommended by the sealant manufacturer. D. BACKER ROD OR BACKER TAPE Backer rod shall be open cell polyethylene or polyurethane foam. Rod shall be cylindrical unless otherwise specified. Backer tape shall be polyethylene or polyurethane with adhesive on one side. 2 2 MASTIC SEALANT A GENERAL: Mastic joint sealant shall consist of a blend of refined asphalts, resins and plasticizmg compounds, reinforced with fiber. Sealant shall be compatible with joint fillers and shall be pressure grade B PRIMER: Primer shall be as recommended by the mastic sealant manufacturer. 2 3 PRODUCT DATA The following information shall be provided in accordance with Section 2-5.3 of the General Provisions: A. Manufacturer's product data showing conformance to the specified products. B. Manufacturer's recommendations for storage, handling and application of sealants and primers I -(i-J. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 07900 - 2 PART 3 - EXECUTION 3.1 GENERAL Sealants and primers shall be applied according to the sealant manufacturer's recommendations. Polyurethane sealants shall be used on all expansion joints and specified construction joints. Joints and spaces to be sealed shall be clean, dry and free of dust, loose mortar, concrete and plaster. Additional preparation of joints and spaces shall be provided in accordance with manufacturer's recommendations. Pnmer shall be applied only to the surfaces that will be covered by the sealant. 3.2 POLYURETHANE SEALANTS A. GENERAL: Nonsag polyurethane sealants shall be used on vertical joints. Self- leveling polyurethane sealants shall be used on horizontal joints. B. JOINT DIMENSIONS: Unless otherwise specified, joints and spaces to be filled shall be constructed to the following criteria. Joints and spaces shall have a minimum width of 1/4 inch and a maximum width of 1 inch. The depth of the sealant shall be one-half the width of the joint, but in no case less than 1/4 inch deep. Sealant depth shall be measured at the point of smallest cross section. When joints exceed the depth requirements, backing rod shall be inserted to provide the joint depth specified. If the joint sealant depth is within the specified tolerances, backer tape shall be placed in the bottom of the joint. 3.3 MASTIC SEALANT A. JOINT DIMENSIONS: Joints to be sealed shall be 2 inches deep, 1 inch wide at the top, and 3/4 inch wide at the base. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 07900-3 SECTION 08120 ALUMINUM DOORS AND FRAMES PART 1 - GENERAL 1.1 DESCRIPTION A. SCOPE: This section specifies aluminum doors and frames B. TYPE- Unless otherwise specified, the doors shall be flush slab type Frames shall be square-cut and mechanically locked at header ends and shall have integral stops C PERFORMANCE REQUIREMENTS: 1. STRUCTURAL- Shapes and thicknesses of framing members shall be sufficient to withstand a design wind load of not less than 30 pounds per square foot of supported area with a deflection of not more than 1/175 times the length of the member and a safety factor of not less than 1.65. 2. AIR INFILTRATION: When tested in accordance with ASTM E 283, air infiltration shall not exceed 0.06 cubic feet per minute per square foot of fixed area at a test pressure of 6 24 pounds per square foot (50 mile per hour wind). 3. WATER PENETRATION: When tested in accordance with ASTME 331, there shall be no water penetration at a pressure of 8 pounds per square foot of fixed area. 1.2 QUALITY ASSURANCE A REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified, hi case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 08120-1 Reference AA DAF45-80 ASTM A36/36M-88 ASTM B209-90 ASTM B221-90 ASTM E283-84 ASTM E331-86 B SSPC-PS 9.01-82 Related Sections Title Designation System for Aluminum Finishes Structural Steel Aluminum and Aluminum-Alloy Sheet and Plate Aluminum and Aluminum-Alloy Extruded Bar, Rod, Wire, Shape, and Tube Rate of Air Leakage Through Exterior Windows, Curtain Walls, and Doors Water Penetration of Exterior Windows, Curtain Walls, and Doors by Uniform Static Air Pressure Difference Cold-Applied Asphalt Mastic Painting System with Extra-Thick Film Section 09900 Coating Systems C. CERTIFICATES OF COMPLIANCE: Manufacturer's certificates shall be submitted to the Project Manager attesting that doors, frames, and accessories meet the specified requirements. 1.3 SUBMITTALS Submittals shall be in accordance with Section 2-5.3 of the General Provisions. Shop drawings containing the following information shall be provided 1. Elevations of each door type 2. Size of doors and frames 3. Metal gauges 4. Details of door and frame construction 5. Methods of anchorage 6. Glazing details 7. Weatherstnpping ! -n-.: CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 08120-2 8. Provisions for and location of hardware 9. Details of installation 10. Schedule showing location of each door, frame, and swing of door 1.4 DELIVERY, STORAGE, AND HANDLING Materials delivered to the site shall be unloaded and stored with minimum handling. Storage space shall be in a dry location with adequate ventilation, free from dust or water, and easily accessible for inspection and handling. Materials shall be stacked on nonabsorptive strips or wood platforms. Doors and frames shall not be covered with tarps, polyethylene film, or similar coverings. Finished surfaces shall be protected during shipping and handling using manufacturer's standard method, except that no coatings or lacquers shall be applied to surfaces to which calking and glazing compounds must adhere. PART 2 - PRODUCTS 2.1 DOORS AND FRAMES Swing-type aluminum doors and frames shall be of size, design, and location indicated. Doors shall be provided complete with frames, framing members trim, and accessories. 2.2 MATERIALS A. ANCHORS: Unless otherwise specified, anchors shall be steel with hot-dipped galvanized finish. B. WEATHERSTRIPPING: Unless otherwise specified, weatherstnppmg shall be continuous wool pile. C. ALUMINUM ALLOY FOR DOORS AND FRAMES: Aluminum alloy for doors and frames shall be ASTM B 221, Alloy 6063-T5 for extrusions and ASTM B 209, alloy and temper best suited for aluminum sheets and strips. D. FASTENERS: Unless otherwise specified, fasteners shall be nonmagnetic stainless steel or aluminum. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 08120-3 E. STRUCTURAL STEEL: Structural steel shall conform to ASTM A 36. F. ALUMINUM PAINT: Unless otherwise specified, aluminum paint shall be as recommended by aluminum door manufacturer. G. BITUMINOUS COATING: Coating shall be cold applied asphalt mastic complying with SSPC-PS 9.01 compounded for 30 mil thickness per coat. 2.3 FABRICATION A. ALUMINUM FRAMES: Frames shall be fabricated from extruded aluminum shapes with contours approximately as indicated. Removable glass stops and glazing beads shall be provided for frames accommodating fixed glass. Countersunk stainless steel Phillips screws spaced not more than 12 inches o.c. shall be used for exposed fastenings. Joints in frame members shall be milled to a hairline fit, reinforced, and secured mechanically. B. ALUMINUM DOORS: Doors shall be of type, size, and design indicated and not less than 1-3/4 inches thick. Minimum wall thickness shall be 0.125 inch, except beads and trim shall be 0.050 inch. Door sizes shown are nominal and shall include standard clearances as follows: 0.093 inch at hinge and lock stiles, 0.125 inch between meeting stiles, 0.125 inch at top rails, 0.187 inch between bottom and threshold, and 0.687 inch between bottom and floor. Single-acting doors shall be beveled 0.125 inch at lock, hinge, and meeting stile edges. Double-acting doors shall have rounded edges at hinge stile, lock stile, and meeting stile edges. Unless otherwise specified, doors shall be flush doors using facing sheets with a plain smooth surface. Construction shall consist of a phenolic resin-impregnated kraft paper honeycomb core, surrounded at edges and around glass and louvered areas with extruded aluminum shapes. The impregnation of core shall have a minimum of 20 percent resin content. Sheet aluminum door facings shall be not less than 0.04-mch thick laminated to a 0.10-inch thick tempered hardboard backing. The backing shall be bonded to the honeycomb core. Facing sheets shall be bonded to core under heat and pressure with a thermosettmg adhesive, and mechanically locked to the extruded edge members. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 08120 - 4 C. WELDING AND FASTENING: Where possible, welds shall be located on unexposed surfaces; on exposed surfaces welds shall be dressed smoothly. Welding rods, filler wire, and flux shall be selected to produce a uniform texture and color in finished work. Flux and spatter shall be removed from surfaces immediately after welding. Exposed screws or bolts will be permitted only in inconspicuous locations, and shall have countersunk heads. Concealed reinforcements for hardware shall be welded in place. D. WEATHERSTRIPPING: Weatherstnpping shall be provided on edges of exterior doors and fit into slots which are integral with doors or frames. Weatherstnpping shall be replaceable without special tools. Installation shall allow doors to swing freely and close positively. E. ANCHORS: Anchors, of the sizes and shapes indicated, shall be provided on the backs of subframes for securing subframes to adjacent construction. Transom bars shall be anchored at ends and mullions at head and sill. Freestanding door frames shall be reinforced and anchored to floor construction in accordance with manufacturer's recommendation. Anchors shall be placed near top and bottom of each jamb and at intermediate points not more than 25 inches apart. F. PROVISIONS FOR HARDWARE: Hardware templates and hardware (except field-applied hardware) shall be delivered to the door manufacturer for use in fabrication of aluminum doors and frames. Doors and frames shall be cut, reinforced, drilled, and tapped at the factory to receive template hardware. Doors to receive surface-applied hardware, except push plates, kick plates, and mop plates, shall be provided with reinforcing only and drilled and tapped in the field. Hardware reinforcements shall be stainless steel or steel with hot-dipped galvanized finish, and secured with stainless steel screws. Reinforcement in core of flush doors shall be provided as required to receive locks, door closers, and other hardware. G. PROVISIONS FOR GLAZING: Extruded aluminum snap-in glazing beads shall be provided on interior side of doors and extruded aluminum, theft-proof, snap-in glazing beads or fixed glazing beads on exterior or security side of doors. Glazing beads shall have 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 08120 - 5 vinyl insert glazing gaskets and be designed to receive glass of thickness specified. H. FINISHES: Finish on doors and frames shall be factory finish of anodic coating. Exposed aluminum surfaces shall be cleaned and provided with an anodized finish conforming to AA DAF45. Finish shall be High Gloss paint per Specification 09900, Coating Systems. Color shall be 'SEDONA' by Sinclair. 2.4 PRODUCT DATA The following information shall be provided in: 1. Detail specifications and instructions for installation, adjustments, cleaning and maintenance. 2. Certificates of compliance specified in paragraph 08120-1.02 C. PART 3-EXECUTION 3.1 INSTALLATION Frames shall be plumb, square, and level and anchored to adjacent construction as specified and in accordance with manufacturer's printed instructions. Bottom of each frame shall be anchored to rough floor construction with 3/32-mch thick stainless steel angle clips secured to back of each jamb and to floor construction; stainless steel bolts and expansion nvets shall be used for fastening clip anchors. Doors shall be hung to produce clearances specified. After erection and glazing, doors and hardware shall be adjusted to operate properly. 3.2 PROTECTION FROM DISSIMILAR MATERIALS A. DISSIMILAR METALS: Where aluminum surfaces come in contact with metals other than stainless steel, zinc, or small areas of white bronze, aluminum shall be protected from direct contact by one or a combination of the following methods: 1. Paint the dissimilar metal with one coat of heavy-bodied bituminous paint. 2. Apply a good quality elastomeric sealant between the aluminum and the dissimilar metal. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 08120-6 3. Paint the dissimilar metal with one coat of primer and one coat of aluminum paint. 4. Use a no absorptive tape or gasket in permanently dry locations. B. DRAINAGE FROM DISSIMILAR METALS: In locations where drainage from dissimilar metals has direct contact with aluminum, provide protective paint, to prevent aluminum discoloration. C. MASONRY AND CONCRETE: Aluminum surfaces in contact with mortar, concrete, or other masonry materials shall be protected with one coat of heavy-bodied bituminous paint. D. WOOD OR OTHER ABSORPTIVE MATERIALS: Aluminum surfaces in contact with absorptive materials subject to frequent moisture, and aluminum surfaces in contact with treated wood, shall be protected with two coats of aluminum paint or one coat of heavy-bodied bituminous paint. In lieu of painting the aluminum, the Contractor shall have the option of painting the wood or other absorptive surface with two coats of aluminum paint and sealing the joints with elastomeric sealant. 3.3 CLEANING Upon completion of installation, door and frame surfaces shall be cleaned in accordance with door manufacturer's recommended procedure, including removal of excess glazing and sealant compounds. Protective coating shall be removed when completion of construction activities no longer requires its retention. Use of abrasive, caustic, or acid cleaning agents is not allowed. 3.4 PROTECTION Doors and frames shall be protected from damage and from contamination by other materials such as cement mortar. Prior to completion and acceptance of the work, damaged doors and frames shall be restored to original condition or replaced with new ones. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 08120-7 SECTION 08520 GLASS BLOCK WINDOWS PART 1 - GENERAL 1 1 SECTION INCLUDES A. Prefabricated exterior glass block window units. B Perimeter treatment 1.2 RELATED SECTIONS A. Section 04110 Cement and Lime Mortars B Section 04220 Concrete Masonry C. Section 07900 Sealants 1.3 REFERENCES A ASTM A123/A123M - Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products B ASTM B221 - Aluminum-Alloy Extruded Bars, Rods, Wire, Shapes, and Tubes. 1.4 SYSTEM DESCRIPTION A. Glass block units: Wood sections, factory fabricated, factory finished, vision glass, related flashings, anchorage and attachment devices 1.5 SUBMITTALS A. Submit under provisions of Section 2-5.3 of the General Provisions. B. Product Data: Provide data for glass units. C. Manufacturer's Installation Instructions: Indicate special procedures, positioning of reinforcement and perimeter conditions requiring special attention. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 08520 - 1 1.7 QUALIFICATIONS A. Manufacturer: Company specializing in manufacturing the Products specified m this section with minimum five years of documented experience. B. Installer: Company specializing in performing the work of this section [with minimum five years of documented experience. 1.8 DELIVERY, STORAGE, AND HANDLING A. Deliver, store, protect, and handle products to site under provisions as per manufacturers recommendations B. Accept glass block units on site on pallets; inspect for damage. 1.9 FIELD MEASUREMENTS A. Verify that field measurements are as indicated on the construction drawings. 1 10 WARRANTY A. Manufacturer's Warranty 10 years for panel assembly, 2 years for wood ^-~~. components, 5 years for glass blocks, against defective materials or ( ) workmanship PART 2 - PRODUCTS 2 1 MANUFACTURERS A. Subject to compliance with the Contract Documents, the following manufacturers are acceptable: 1 Glass unit masonry and accessories' a. Pittsburgh Corning Corp. b. Glass Block Co. 2 Integral waterproofer: a. Sonneborn Building Products. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 08520 - 2 3. Asphalt emulsion: a. Karnak Chemical Corporation. b. Sonneborn Building Products. 4. Other materials: a. As noted. 2.2 MATERIALS A. Glass Masonry Units: 1. Thickness: 3-7/8 IN. 2. Size: 7-3/4 x 7-3/4 IN. 3. Style: Similar to Pittsburgh Corning PC Glass Block "DECORA" pattern. 4. Color: Clear. B. Panel Reinforcing and Panel Anchors: Galvanized steel. C. Sealants: See Section 07900, Sealants. D. Expansion Strip: Glass masonry unit manufacturer's standard. E Asphalt Emulsion: Non-fibrated, non-flammable type as recommended by glass masonry unit manufacturers. F. Packing (Backer Rod): Polyethylene foam or as recommended by glass masonry unit manufacturer. G. Retainer Channel: 1. 4 x 2 x 1/8 IN channel section. 2. Extruded aluminum, ASTM B221, 6063-T52 alloy. 3. Finish: a. Aluminum: Anodized AAM10C22A31 clear. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 08520 - 3 2.3 GLASS UNIT PANELS A. Solid Glass Units: Factory sealed unit cores. Nominal Size: 8x8 inch (204 x 204 mm) 1. Color: Clear. B. Jamb: Wood, 4-9/16 inch (116 mm) wide profile. C. Muntms: Width to match glass block, of same material and finish as jamb. D. Installation Method: Installation Strap, 1-inch (25 mm) setback. E. Jamb cladding: Aluminum, finish to match jamb. PART 3-EXECUTION 3.1 EXAMINATION A. Verify rough openings and confirm sill plate is level. 3.2 INSTALLATION A. Erect glass units and accessories in accordance with manufacturer's instructions. B. Exterior units: Provide thermal isolation where components penetrate or disrupt building insulation. Pack fibrous insulation in shim spaces at perimeter of assembly to maintain continuity of thermal barrier. Do not use foam spray insulation. Coordinate attachment and seal of perimeter air and vapor barrier materials. Install perimeter sealant in accordance with Section 07900, Sealants. C. Attach unit to structure using 2-1/2 inch galvanized casing nails. Drill pilot holes when nailing through frame. D. Shim unit at head and sides at maximum 18-inch (450 mm) centers; do not shim underside of unit. 3.3 CLEANING A. Do not scratch or deface units. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 08520 - 4 3.4 PROTECTION OF FINISHED WORK A. Maintain protective boards at exposed external corners. Provide protection without damaging completed work. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 08520 - 5 SECTION 09900 COATING SYSTEMS PART 1--GENERAL 1.1 DESCRIPTION A SCOPE- This section specifies coating systems, surface preparations, and application requirements. B. DEFINITIONS: Specific coating terminology used in this section is in accordance with definitions contained in ASTM D16, ASTM D3960, and the following definitions: 1. Dry Film Thickness (DFT): The thickness of one fully cured continuous application of coating. 2. Field Coat: The application or the completion of application of the coating system after installation of the surface at the site of the work. 3. Shop Coat: One or more coats applied in a shop or plant prior to shipment to the site of erection or fabrication, where the field or finishing coat is applied. 4. Tie Coat: An intermediate coat used to bond different types of paint coats. Coatings used to improve the adhesion of a succeeding coat. 5. Photochemically Reactive Organic Material: Any organic material that will react with oxygen, excited oxygen, ozone or other free radicals generated by the action of sunlight on components in the atmosphere giving nse to secondary contaminants and reaction intermediates in the atmosphere which can have detrimental effects. 6. Volatile Organic Compound (VOC) Content: The portion of the coating that is a compound of carbon, is photochemically reactive, and evaporates during drying or curing, expressed in grams per liter or pounds per gallon. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-1 7. Touch-Up Painting: The application of a paint on areas of painted surfaces to repair marks, scratches, and areas where the coating has deteriorated to restore the coating film to an unbroken condition. 1.2 QUALITY ASSURANCE A. REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified. In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. B. Reference ASTM D16-93 ASTMD2200-91 (SSPC-Vis 1-89) Title Standard Terminology Relating to Paint, Varnish, Lacquer, and Related Products Pictorial Surface Preparation Standards for Painting Steel Surfaces ASTM D3359 A-92 Methods for Measuring Adhesion by Tape Test ASTM D3960-92 ASTMD4417-84 F 595 B-89 SSPC-89 ANSI/NSF 61-92 STANDARDIZATION: Practice for Determining Volatile Organic Compound (VOC) Content of Paints and Related Coatings Field Measurement of Surface Profile of Blast Cleaned Steel Federal Standard Colors Steel Structures Painting Council Specifications, Vol.2 Drinking Water System Components Health Effects 17074 Materials and supplies provided shall be the standard products of manufacturers. Materials in each coating system shall be the products of a single manufacturer. The standard products of manufacturers other than those specified will be accepted when it is demonstrated to the Construction Manager that they are equal in composition, durability, usefulness, and convenience for the CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-2 purpose intended. Requests for substitutions will be considered, provided the following minimum conditions are met: 1. The proposed coating system shall use an equal or greater number of separate coats to achieve the required dry film thickness. 2. The proposed coating system shall use coatings of the same generic type as that specified. 3. Requests for substitution shall have directions for application and descriptive literature which includes generic type, percent solids by volume, volatile organic content (grams per liter), and information confirming that the substitution is equal to the specified coating system. 4. The Contractor shall provide a list of references where paint of the same generic type has been applied. The reference list shall give the project name, city, state, owner, phone number of owner, coating system reference and number, and year paint was applied. 1.3 DELIVERY AND STORAGE Materials shall be delivered to the job site in their original, unopened containers. Each container shall bear the manufacturer's name, coating type, batch number, date of manufacture, storage life, and special directions. Materials shall be stored in enclosed structures and shall be protected from weather and excessive heat or cold. Flammable materials shall be stored in accordance with state and local codes. Materials exceeding storage life recommended by the manufacturer shall be removed from the site. PART 2--PRODUCTS 2.01 MATERIALS The following list specifies the material requirements for coating systems. Coating systems are by generic name followed by an identifying abbreviation. If an abbreviation has a suffix number, it is for the purpose of identifying subgroups within the coating system. Coating System E-5 and E-6 shall be NSF 61 certified. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900 - 3 Coating system E-2 E-3 E-4 E-5 E-6 Manufacturer Glidden Tnemec Valspar Porter Ameron Devoe Sherwin-Wilhams Carbohne/Kop-Coat Glidden Tnemec Valspar Ameron Devoe Sherwin-Williams Porter Carbohne/Kop-Coat Ghdden Tnemec Valspar Ameron Devoe Sherwin-Williams Porter Carbohne/Kop-Coat Ghdden Tnemec Valspar Ameron Devoe Sherwin-Williams Porter Carbohne/Kop-Coat Tnemec Valspar Ameron Devoe Sherwin-Williams Porter Carbohne/Kop-Coat Tnemec Valspar Ameron Devoe Sherwin-Williams Ghdden Product designation Prime coat(s) 5430 Series Series 69 V89 Series 7300 Series Magna Prime Amerlock 400 Bar-Rust 236 B67H5/B67V5 890 5430 Series Series 69 V89 Series Amerlock 400 Bar-Rust 236 B62/B60V7 MCR-65 890 5430 Series Series 69 V89 Series Amerlock 400 Bar-Rust 236 B62W201/B60V20 MCR-65 890 5430 Series Series 69 V89 Series Amerlock 400 Bar-Rust 236 B67 Senes/B60V3 MCR-65 890 Series 140-1255 32 PWR Series 395 Devran 184 B62, B60V7 7536 Super Hi-Gard 891 Series 140-1255 32 PWR Series 395 FD395 FD Devran 184 B62, B60V7 5230/34 Finish coat(s) 5430 Series Series 69 V89 Series 7600 Series Magna Coat Amerlock 400 Devran 669 B67 Senes/B60V3 890 5430 Series Series 69 V89 Series Amerlock 400 Bar-Rust 236 B62/B60V7 MCR-65 890 5430 Series Series 69 V89 Series Amerlock 400 Bar-Rust 236 B62W201/B60V20 MCR-65 890 5430 Series Series 69 V89 Series Amerlock 400 Bar-Rust 236 B67 Series/B60V3 MCR-65 890 Series 140-AA83 32 PWR Series 395 Devran 184 B62, B60V7 7530 Super Hi-Gard 891 Series 140-AA83 32 PWR Series Devran 184 B62, B60V7 5230/34 P074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-4 E-7 E-8 EP-1 Porter Carbohne/Kop-Coat Ghdden Tnemec Valspar Ameron Devoe Sherwm-Wilhams Porter Carbohne/Kop-Coat Ghdden Devoe Sherwin-Williams Tnemec Valspar Carbohne/Kop-Coat Porter Tnemec Ameron 7536 Super Hi-Gard 891 5430 Series Series 69 V89 Series Amerlock 400 Bar-Rust 236 B67 Senes/B60V3 7510 Series 890 5433 Tru-Glaze WB B58T104/B58V1 Series 201 V89 Series 890 7300 Series Magna Prime Series 69 Amercoat 351 7530 Super Hi-Gard 891 5430 Series Series 69 V89 Series Amerlock 400 Devran 669 B67 Senes/B60V3 7510 Series 890 5433 Tru-Glaze WB B58T104/B58V1 Series 201 V 84 Series 890 7600 Series Magna Coat Series 69 Amercoat 351 EP-2 Porter Tnemec Ameron 7300 Series Magna Prime Series 69 Amercoat 351 7600 Series Magna Coat Series 69 Amercoat 351 EP-3 Porter Tnemec Ameron 7300 Series Magna Prime Series 69 Amercoat 351 7600 Series Magna Coat Series 69 Amercoat 351 Grease G Texaco Chevron Rust Inhibitive Grease EP Roller Grease High Heat HH-1 HH-2 Ghdden Tnemec Valspar Ameron Devoe Sherwm-Williams Porter Ghdden Valspar Ameron Devoe Sherwm-Williams 5536/5537 90E92 V13-F-12 Dimetcote21-5 Catha-Coat 305 B69V3/B69D11 Zinc Lock 371 5542 37-A-l 878 HT-12 Flame 1200-MSF Series Series 5536/5537 90E92 V13-F-12 Dimetcote 21-5 Catha-Coat 305 B69V3/B69D11 Zinc Lock 371 5542 37-A-l 878 HT-12 Flame 1200-MSF 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-5 Latex L-l L-2 L-3 L-4 Miscellaneous M-l M-2 Porter Carbohne/Kop Coat Ghdden Tnemec Valspar Devoe Sherwin-Wilhams Porter Carbohne/Kop-Coat Ghdden Tnemec Valspar Devoe Sherwin-Williams Porter Carbohne/Kop-Coat Ghdden Tnemec Valspar Devoe Sherwin-Williams Porter Carbohne/Kop-Coat Ghdden Tnemec Valspar Devoe Sherwm-Williams Porter Carbohne/Kop-Coat DENSO TRENTON Ghdden Tnemec Valspar Ameron Devoe Sherwin-Williams Porter Carbohne/Kop-Coat 1501 4631 3700 Series Series 7 79-W-81 Wondertone51701 B42W46 3400 3358 6900 Series Series 7 79-W-81 Devflex 604 B42 Series 3400 3358 595 Series 18 13-R-91 Devflex 600 B66W1 215 Rust Screen 3358 300 Series 151 79-W-81 Wonder-Prime 51701 B49WZ2 515 3358 Denso Paste Wax Tape Primer 5475/5476 Series 135 V89 Series Amerlock 400 Bar-Rust 236 B58 Senes/B58Vl 7900 Carbomastic 90 1501 4631 3700 Series Series 7 79 Series Devflex 604 B31W200 3410 Series 3359 6900 Series Series 7 79 Series Devflex 604 B42 Series 3410 Series 3359 3700 Series Series 7 60 Series Devflex 604 B42 Series 3410 Series 3359 3700 Series Series 7 79 Series Devflex 604 B42 Series 3410 Series 3359 Densyl Tape #1 Wax Tape 5475/5476 Series 104 V89 Series Amerlock 400 Bar-Rust 236 B58 Senes/B58Vl 6510 Carbomastic 90 17074 CUY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-6 Urethane U Ghdden 5430 Series 5410/11 Tnemec Senes 69 Senes 75 Color Valspar V89 Senes V40 Series Ameron Amerlock 400 Amershield Devoe Bar-Rust 236 Devthane 359 Sherwm-Williams 920Y137 975 Senes Porter 7300 Senes Hythane Super Magna Prime Carboline/Kop-Coat 893 134 HS 2.2 PRODUCT DATA Before materials are delivered to the job site, the Contractor shall provide the following information in accordance with Section 2-5.3 of the General Provisions: 1. For each primer and finish coating, the Contractor shall furnish a Material Safety Data Sheet (MSDS). 2 For each primer and finish coating, the Contractor shall provide the manufacturer's application instructions which shall include the following: a Surface preparation recommendations. b. Primer type, where required c. Maximum dry and wet mil thickness per coat. d. Minimum and maximum curing time between coats, including atmospheric conditions for each. e Cunng time before submergence in liquid, f Thinner to be used with each paint, g. Ventilation requirements. h. Minimum atmospheric conditions during which the paint shall be applied. i. Allowable application methods. j. Maximum allowable moisture content. k. Maximum storage life. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900 - 7 List of materials proposed to be used under this section and manufacturer's data for each material. PART 3-EXECUTION 3.1 COATINGS A GENERAL: Coating products shall not be used until the Construction Manager has inspected the materials and the coating manufacturer's technical representative has instructed the Contractor and Construction Manager in the surface preparation, mixing and application of each coating. B COATING SYSTEMS: 1. SHOP APPLIED PRIME COAT: Except as otherwise specified, prime coats may be shop- or field-applied. Shop-applied primer shall be compatible with the specified coating system and shall be applied at the minimum dry film thickness recommended by the manufacturer. Product data sheets identifying the shop primer used shall be provided to the on-site finish coat applicator. Adhesion tests shall be performed on the shop primer as specified in paragraph 09900-3.02 A. Damaged, deteriorated and poorly applied shop coatings that do not meet the requirements of this section shall be removed and the surfaces recoated. If the shop primer coat meets the requirements of this section, the field coating may consist of touching up the shop prime coat and then applying the finish coats to achieve the specified film thickness and continuity. 2. FIELD COATS: Field coats shall consist of one or more prime coats and one or more finish coats to build up the coating to the specified dry film thickness. Unless otherwise specified, finish coats shall not be applied until other work in the area is complete and until all previous coats have been inspected. C. COATING REQUIREMENTS: 1. EQUIPMENT, NONIMMERSED: All items of equipment, or parts of equipment which are not immersed in service, shall be shop pnmed and then finish coated in the field after installation with the specified or approved color. The methods, materials, application equipment and all other details of shop painting shall comply with these specifications. If the shop primer requires CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900 - 8 topcoating within a specified period of time, the equipment shall be finish coated in the shop and then touch-up painted after installation. 2. EQUIPMENT, IMMERSED: All items of equipment, or parts and surfaces of equipment which are immersed when in service, with the exception of pumps and valves shall have all surface preparation and coating work performed in the field 3. STEEL WATER TANKS: The interior surfaces of steel water tanks or reservoirs shall have all surface preparation and coating work performed in the field. 4. STEEL PIPING: Steel piping shall be prepared in accordance with SSPC SP-6 (Commercial Blast Cleaning) and primed before installation. 3.2 PREPARATION A. GENERAL: Surfaces to be coated shall be clean and dry. Before applying coating or surface treatments, oil, grease, dirt, rust, loose mill scale, old weathered coatings, and other foreign substances shall be removed except as specified. Oil and grease shall be removed before mechanical cleaning is started. Where mechanical cleaning is accomplished by blast cleaning, the abrasive used shall be washed, graded and free of contaminants which might interfere with the adhesion of the coatings. The air used for blast cleaning shall be sufficiently free of oil and moisture to not cause detrimental contamination of the surfaces to be coated. The Contractor shall examine all surfaces to be coated and shall correct all surface defects before application of any coating. Clean cloths and clean fluids shall be used in solvent cleaning. Cleaning and painting shall be scheduled so that dust and spray from the cleaning process will not fall on wet, newly painted surfaces. Hardware, hardware accessories, nameplates, data tags, machined surfaces, sprinkler heads, electrical fixtures, and similar uncoated items which are in contact with coated surfaces shall be removed or masked prior to surface preparation and painting operations. Following completion of coating, removed items shall be reinstalled. Equipment adjacent to walls shall be disconnected and moved to permit cleaning and painting of equipment and walls and, following painting, shall be replaced and reconnected. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-9 The Contractor shall perform an adhesion test after proper cure in accordance with ASTM D3359 to demonstrate that (1) the shop coat adheres to the substrate, and (2) the specified field coatings adhere to the shop coat. Test results showing an adhesion rating of 5A on immersed surfaces and 4A or better on all other surfaces shall be considered acceptable. Where unacceptable test results are obtained, the Contractor shall be responsible for removing and reapplymg the specified coatings at no expense to the Owner. B. METALLIC SURFACES: Metallic surfaces shall be prepared in accordance with applicable portions of surface preparation specifications of the Steel Structures Painting Council (SSPC) specified in each coating system. The profile depth of the surface to be coated shall be 20 to 25 percent of the coating dry film thickness as measured by Method C of ASTM D4417. Blast particle size shall be selected by the contractor to produce the specified surface profile. The solvent in solvent cleaning operations shall be as recommended by the manufacturer. Preparation of metallic surfaces shall be based upon comparison with SSPC-VIS 1-89 (ASTM D2200), and as described herein. To facilitate inspection, the Contractor shall, on the first day of blasting operations, abrasive blast metal panels to the standards specified. Plates shall measure a minimum of 8-1/2 inches by 11 inches. Panels meeting the requirements of the specifications shall be initialed by the Contractor and the Construction Manager and coated with a clear nonyellowing finish. One of these panels shall be prepared for each type of abrasive blasting and shall be used as the comparison standard throughout the project. C. SOLVENT CLEANING: Any solvent wash, solvent wipe, or cleaner used, including but not limited to those used for surface preparation in accordance with referenced Steel Structures Painting Council (SSPC) specifications, shall be of the emulsifying type which emits no more than 2.8 Ib/gal (340 gms/1) VOCs, contains no phosphates, is biodegradable, removes no zinc, and is compatible with the specified pnmer. D. DETAILED SURFACE PREPARATION: Surface preparations for each type of surface shall be in accordance with the specific requirements of each coating specification sheet (COATSPEC). 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900- 10 3.3 APPLICATION A. WORKMANSHIP- Coated surfaces shall be free from runs, drops, ridges, waves, laps, and brush marks. Coats shall be applied so as to produce an even film of uniform thickness completely coating corners and crevices. Painting shall be done in accordance with the requirements of SSPC Paint Application Specification No. 1. The Contractor's equipment shall be designed for application of the materials specified. Compressors shall have suitable traps and filters to remove water and oils from the air. A paper blotter test shall be performed by the Contractor when requested by the Construction Manager to determine if the air is sufficiently free of oil and moisture to not produce deteriorating effects on the coating system. The amount of oil and moisture in spray air shall be less than the amount recommended by the coating manufacturer. Spray equipment shall be equipped with mechanical agitators, pressure gages, and pressure regulators, and spray nozzles of the proper sizes. Each coat of paint shall be applied evenly and sharply cut to line. Care shall be exercised to avoid overspraying or spattering paint on surfaces not to be coated. Glass, hardware, floors, roofs, and other adjacent areas and installations shall be protected by taping, drop cloths, or other suitable measures. B. PAINT PROPERTIES, MIXING AND THINNING: Paint, when applied, shall provide a satisfactory film and smooth even surface, and glossy undercoats shall be lightly sanded to provide a surface suitable for the proper application and adhesion of subsequent coats. Paints shall be thoroughly stirred, strained, and kept at a uniform consistency during application. Coatings consisting of two or more components shall be mixed in accordance with the manufacturer's instructions. Where necessary to suit the conditions of the surface, temperature, weather and method of application, the paint may be thinned immediately prior to use. The volatile organic content (VOC) of the coating as applied shall comply with prevailing air pollution control regulations. Unless otherwise specified, paint shall not be reduced more than necessary to obtain the proper application characteristics. Thinner shall be as recommended by the coating manufacturer. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-11 C. ATMOSPHERIC CONDITIONS: Paints shall be applied only to surfaces that are dry, and only under conditions of evaporation rather than condensation. Paint shall not be applied during rainy, misty weather, or to surfaces upon which there is frost or moisture condensation. During damp weather, when the temperature of the surface to be coated is within 10 degrees F of the dew point, the surfaces shall be heated to prevent moisture condensation thereon. Bare metal surfaces, except those which may be warped by heat, may be dehydrated by flame-heating devices immediately prior to paint application. During painting, and for a period of at least 8 hours after the paint has been applied, the temperature of the surfaces to be painted, the painted surfaces, and the atmosphere in contact shall be maintained at or above 40 degrees F and 10 degrees F above the dew point. Paint, when applied, shall be approximately the same temperature as that of the surface on which it is applied. Fans or heaters shall be used inside enclosed areas where conditions causing condensation are severe. D. PROTECTION OF COATED SURFACES: Items which have been coated shall not be handled, worked on, or otherwise disturbed, until the paint is completely dry and hard. After delivery at the site of permanent erection or installation, shop-coated metalwork shall be repainted or retouched with specified paint when it is necessary to maintain the integrity of the film. E. METHOD OF PAINT APPLICATION: Where two or more coats are required, alternate coats shall contain sufficient compatible color additive to act as indicator of coverage, or the alternate coats shall be of contrasting colors. Color additives shall not contain lead, or any lead compound which may be destroyed or affected by hydrogen sulfide or any other corrosive gas. Mechanical equipment, on which the manufacturer's coating is acceptable, shall be touch-up primed and painted with two coats of the specified coating system to match the color scheduled. Electrical and instrumentation equipment specified in Divisions 16 and 17 shall be painted as specified in paragraph 09900-3.03 H. Paint shall not be applied to a surface until it has been prepared as specified. The primer or first coat shall be applied by brush to ferrous surfaces which are not blast-cleaned. All coats for blast-cleaned ferrous surfaces and subsequent coats for nonblast-cleaned ferrous surfaces may be either brush or spray applied. "After the prime coat is dry, pinholes and holidays shall be marked, repaired in accordance with coating 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-12 manufacturer's recommendations and retested before succeeding coats are applied. Unless otherwise specified, coats for concrete and masonry shall be brushed or rolled. F. FILM THICKNESS AND CONTINUITY: Coating system thickness is the total thickness of pnmer and finish coats. The surface area covered per gallon of paint for various types of surfaces shall not exceed those recommended by the manufacturer. The first coat, herein referred to as the prime coat, on metal surfaces refers to the first full paint coat and not to any solvent wash, grease emulsifiers or other pretreatment applications. Coatings shall be applied to the thickness specified, and in accordance with these specifications. Unless otherwise specified, the average total thickness (dry) of any completed protective coating system on exposed metal surfaces shall be not less than 1.25 mils per coat. The minimum thickness at any point shall not deviate more than 25 percent from the required average. Unless otherwise specified, no less than two coats shall be applied. In testing for continuity of coating about welds, projections (such as bolts and nuts), and crevices, the Construction Manager will determine the minimum conductivity for smooth areas of like coating where the dry mil thickness has been accepted. This conductivity shall then be taken as the minimum required for these rough or irregular areas. Pinholes and holidays shall be repainted to the required coverage. G. SPECIAL REQUIREMENTS: Before erection, Contractor shall apply all but the final finish coat to interior surfaces of roof plates, roof rafters and supports, pipe hangers, piping in contact with hangers, and all contact surfaces which are inaccessible after assembly. The final coat shall be applied after erection. Structural friction connections and high tensile bolts and nuts shall be painted after erection. Areas damaged during erection shall be hand- cleaned or power-tool cleaned and recoated with pnmer coat prior to the application of subsequent coats. Touch-up of all surfaces shall be performed after installation. All surfaces to be coated shall be clean and dry at the time of application. Except for those to be filled with grout, the underside of ungalvanized equipment bases and supports shall be coated with at least two coats of primer specified for system E-2 prior to setting the equipment in place. Where specified, ferrous metal shall receive an inorganic zinc-rich coating containing 84 percent metallic zinc by weight in the applied dry film. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900- 13 H. ELECTRICAL AND INSTRUMENTATION EQUIPMENT AND MATERIALS: Electncal and instrumentation equipment and materials shall be coated by the manufacturer as specified below. 1. FINISH: Electncal equipment shall be treated with zinc phosphate, bondenzed or otherwise given a rust-preventive treatment. Equipment shall be primed, painted with enamel, and baked. Minimum dry film thickness shall be 3 mils. Unless otherwise specified, instrumentation panels shall be coated with system E-l for indoor mounting and system U for outdoor mounting. Before final acceptance, the Contractor shall touch up any scratches on equipment with identical color paint. Finish shall be smooth, free of runs, and match existing finish. Prior to touching up scratches, Contractor shall fill them with an appropriate filler. 2. COLOR: Exterior color of electrical equipment shall be FS 26463 (ANSI 61) light grey. Interior shall be painted FS 27880 white. Nonmetallic electrical enclosures and equipment shall be the manufacturer's standard grey color. Exterior color of instrumentation panels and cabinets mounted indoors shall be FS 26463 light grey; unless otherwise specified, exterior color for cabinets mounted outdoors shall be FS 27722, white. Cabinet interiors shall be FS 27880, white. I. SAFETY AND VENTILATION REQUIREMENTS : Requirements for safety and ventilation shall be in accordance with SSPC Paint Application Guide No. 3. 3.4 CLEANUP Upon completion of coating, the Contractor shall remove surplus materials, protective coverings, and accumulated rubbish, and thoroughly clean all surfaces and repair any overspray or other paint-related damage. 3.5 COATING SYSTEM SPECIFICATION SHEETS (COATSPEC) Coating systems for different types of surfaces and general service conditions for which these systems are normally applied are specified on the following COATSPEC sheets. Surfaces shall be coated in accordance with the COATSPEC 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900 - 14 to the system thickness specified. Coating systems shall be as specified in paragraph 09900-3.06, Coating System Schedule. In case of conflict between the schedule and the COATSPECS, the requirements of the schedule shall prevail. Coating System Identification: Coating Material: Surface: Service Condition: Surface Preparation: General: Ferrous Metal: Nonferrous and Galvanized Metal: Application: E-l Epoxy Metal Interior; exterior, covered, not exposed to direct sunlight. Shop pnmed surfaces which are to be incorporated in the work shall be prepared in the field by cleaning all surfaces in accordance with SSPC SP-2 (Hand Tool Cleaning). Damaged shop coated areas shall be cleaned in accordance with SSPC SP-5 (White Metal Blast Cleaning) and spot pnmed with the primer specified. Shop epoxy pnmed surfaces shall require light abrasive blasting pnor to receiving finish coats. Bare ferrous metal surfaces shall be prepared in accordance with SSPC SP-6 (Commercial Blast Cleaning). Ferrous metal with rust bleeding shall be cleaned in accordance with SSPC SP-1 (Solvent Cleaning). Areas of rust penetration shall be spot blasted to SSPC SP-10 (Near White Blast) and spot primed with the specified primer. Nonferrous and galvanized metal shall be prepared in accordance with SSPC SP-7 (Brush-off Blast Cleaning). Field 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-15 General: Ferrous Metal: Nonferrous and Galvanized Metal: System Thickness: Coatings: Pnmer: Finish: Coating System Identification: Coating Material: Surface: Service Condition: Surface Preparation: Ferrous Metal: Prime coat may be thinned and applied as recommended by the manufacturer, provided the coating as applied complies with prevailing air pollution control regulations. Prime coats shall be an epoxy pnrner compatible with the specified finish coats and applied in accordance with the written instructions of the coating system manufacturer. Nonferrous and galvanized metal shall be cleaned prior to the application of the prime coat in accordance with SSPC SP-1 (Solvent Cleaning). 10 mils dry film. One coat at manufacturer's recommended dry film thickness. One or more coats at manufacturer's recommended dry film thickness per coat to the specified system thickness. E-2 Epoxy Metal Immersed, nonpotable; nonimmersed, corrosive environment, color required. Ferrous metal surfaces shall be prepared m accordance with SSPC SP-5 (White Metal Blast Cleaning). 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900 - 16 Nonferrous and Galvanized Metal: Application: General: Ferrous Metal: Nonferrous and Galvanized Metal: System Thickness: Coatings: Pnmer: Finish: Shop primed surfaces which are to be incorporated in the work shall be prepared in the field by cleaning all surfaces in accordance with SSPC SP-2 (Hand Tool Cleaning). Damaged shop coating shall be cleaned in accordance with SSPC SP-5 (White Metal Blast Cleaning) and spot pnmed with the primer specified. Shop epoxy pnmed surfaces shall require light abrasive blasting prior to receiving finish coats. Nonferrous and galvanized metal shall be prepared in accordance with SSPC SP-7 (Brush-off Blast Cleaning). Field Prime coat may be thinned and applied as recommended by the manufacturer, provided the coating as applied complies with prevailing air pollution control regulations. Prime coat shall be an epoxy pnmer compatible with the specified finish coats. Nonferrous and galvanized metal, nonimmersed, shall be coated prior to the application of the prime coat with a grease emulsifying agent in accordance with the manufacturer's written instructions. Nonferrous and galvanized metal, immersed, shall not be painted. 15 mils dry film. One coat at manufacturer's recommended dry film thickness. Two or more coats at manufacturer's recommended dry film thickness per coat to the specified system thickness. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900 - 17 Coating System Identification: Coating Material: Surface: Service Condition: Surface Preparation: Concrete: Masonry: Application: E-3 Epoxy Concrete or masonry Immersed, nonpotable; nommmersed, corrosive environment, color required. Concrete surfaces shall be allowed to age for at least 28 days and allowed to dry to the moisture content recommended by the coating manufacturer. Moisture content may be tested by the Construction Manager with a Delmhorst Instrument Company moisture detector, or equal. Except as otherwise specified, loose concrete, form oils, surface hardeners, curing compounds, and laitance shall be removed from surfaces by abrasive blasting and chipping, and voids and cracks shall be repaired as specified in Section 03300, Cast-m-Place Concrete. Masonry surfaces shall be allowed to age for at least 28 days. Holes or other joint defects shall be filled with mortar and repointed. Loose or splattered mortar shall be removed by scraping and chipping. Masonry surfaces shall be cleaned with clear water by washing and scrubbing to remove foreign and deleterious substances. Muriatic acid shall not be used. After cleaning, masonry surfaces shall be sealed or filled with a sealer or block filler compatible with the specified primer. Field Sealer or filler shall dry a minimum of 48 hours prior to application of prime coat. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-18 System Thickness: Coatings: Primer: Finish: Coating System Identification: Coating Material: Surfaces: Service Condition: Surface Preparation: Concrete: Prime coat shall be thinned and applied as recommended by the manufacturer, provided the coating as applied complies with prevailing air pollution control regulations. Drying time between coats shall be as recommended by coating manufacturer. 15 mils dry film. One coat at manufacturer's recommended dry film thickness. Two or more coats at manufacturer's recommended dry film thickness per coat to the specified system thickness. E-4 Epoxy Concrete, masonry, plaster, gypsum board. Interior Concrete surfaces shall be allowed to age for at least 28 days and allowed to dry to the moisture content recommended by the coating manufacturer. Moisture content may be tested by the Construction Manager with a Delmhorst Instrument Company moisture detector, or equal. Loose concrete, form oils, surface hardeners, curing compounds and laitance shall be removed from surfaces, and voids and cracks shall be repaired as specified in Section 03300, Cast- in-Place Concrete. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900 - 19 Masonry- Plaster: Application: System Thickness: Masonry surfaces shall be allowed to age for at least 28 days. Holes or other joint defects shall be filled with mortar and repomted. Loose or splattered mortar shall be removed by scrapping and chipping. Masonry surfaces shall be cleaned with clear water by washing and scrubbing to remove foreign and deleterious substances. Muriatic acid shall not be used. After cleaning, exterior masonry surfaces shall be sealed or filled with a sealer or block filler compatible with the specified pnmer. Plaster surfaces shall be dry and clean and free from gnt, loose plaster, and surface irregularities. Cracks and holes shall be repaired with acceptable patching materials, keyed to existing surfaces, and sandpapered smooth. Surfaces shall be cleaned with clear water by washing and scrubbing to remove foreign and deleterious substances. Field Block Filler shall be a multiple component epoxy block filler and shall dry a minimum of 48 hours prior to pnmer application. Prime coat shall be thinned and applied as recommended by coating manufacturer, provided the coating as applied complies with prevailing air pollution control regulations. Drying time between coats shall be recommended by coating manufacturer. as 10 mils dry film, excluding block filler and sealer. Coatings: Primer:One coat at manufacturer's recommended dry film thickness. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900 - 20 Finish: Coating System Identification: Coating Material: Surface: Service Condition: Surface Preparation: Ferrous Metal: Nonferrous and Galvanized Metal: Application: General: Ferrous Metal: One or more coats at manufacturer's recommended dry film thickness per coat to the specified system thickness. E-5(NSF 61 certified) Epoxy Metal Interior potable water tanks and reservoirs and any other metal components in contact with water being treated and stored. Ferrous metal surfaces shall be prepared in accordance with SSPC SP-5 (White Metal Blast Cleaning). Shop primed surfaces which are to be incorporated in the work shall be prepared in the field by cleaning all surfaces in accordance with SSPC SP-2 (Hand Tool Cleaning). Damaged shop coating shall be cleaned in accordance with SSPC SP-5 (White Metal Blast Cleaning) and spot pnmed with the primer specified. Shop epoxy pnmed surfaces shall require light abrasive blasting prior to receiving finish coats. Nonferrous and galvanized metal shall be prepared in accordance with SSPC SP-7 (Brush-off Blast Cleaning). Field Prime coat shall be thinned and applied as recommended by the manufacturer, provided the coating as applied complies with prevailing air pollution control regulations. Prime coat shall be an epoxy primer compatible with the specified finish coats. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900 - 21 Nonferrous and Galvanized Metal: System Thickness: Coatings: Pnmer: Finish: Coating System Identification: Coating Material: Surface: Service Condition: Surface Preparation: Concrete: Nonferrous and galvanized metal above the high water elevation shall be cleaned prior to the application of the prime coat in accordance with SSPC SP-1 (Solvent Cleaning). 10 mils dry film. One coat at the manufacturer's recommended dry film thickness. One or more coats at manufacturer's recommended dry film thickness per coat to the specified system thickness. E-6 (NSF 61 certified) Epoxy Concrete Interior potable water tanks and reservoirs. Concrete surfaces shall be allowed to age for at least 28 days and allowed to dry to the moisture content recommended by the coating manufacturer. Moisture content may be tested by the Construction Manager with a Delmhorst Instrument Company moisture detector, or equal. Except as otherwise specified, loose concrete, form oils, surface hardeners, curing compounds, and laitance shall be removed from surfaces by abrasive blasting and chipping, and voids and cracks shall be repaired as specified in Section 03300, Cast-m-Place Concrete. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900 - 22 Masonry: Application: System Thickness: Coatings: Primer: Finish: Coating System Identification: Coating Material: Surface: Masonry surfaces shall be allowed to age for at least 28 days. Holes or other joint defects shall be filled with mortar and repomted. Loose or splattered mortar shall be removed by scraping and chipping. Masonry surfaces shall be cleaned with clear water by washing and scrubbing to remove foreign and deleterious substances. Muratic acid shall not be used. After cleaning, masonry surfaces shall be sealed or filled with a sealer or block filler compatible with the specified primer. Field Sealer or filler shall dry a minimum of 48 hours prior to application of prime coat.Pnme coat shall be thinned and applied as recommended by the manufacturer, provided the coating as applied complies with prevailing air pollution control regulations. Drying time between prime coat and finish coat shall be as recommended by coating manufacturer. 15 mils dry film. One coat at manufacturer's recommended dry film thickness. Two or more coats at manufacturer's recommended dry film thickness per coat to the specified system thickness. E-7 Epoxy Plastic 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-23 Service Condition: Surface Preparation: Application: System Thickness: Coatings: Coating System Identification: Coating Material: Surface: Service Condition: Surface Preparation: Interior; exterior covered, not exposed to direct sunlight. Plastic shall be prepared in accordance with SSPC SP-1 (Solvent Cleaning) and light sanding. Field 5 mils dry film. One or more coats at manufacturer's recommended dry film thickness per coat to the specified system thickness. E-8 Clear epoxy Wood Interior Wood surfaces shall be cleaned of dirt, oil or other foreign substances with mineral spirits, scrapers, sandpaper or wire brush. Finished surfaces exposed to view shall be smoothed by planing or sandpapering. Millwork shall be sandpapered and given a coat of the specified exterior primer on all sides before installation. Built-m surfaces of window sills shall be double pnmed. Glazing rabbets and beads in exterior sash and doors shall be double primed. Small, dry, seasoned knots shall be surfaced scraped, sandpapered, and thoroughly cleaned and shall be given a thin coat of a clear knot sealer before application of the priming coat. Large, open, unseasoned knots, and beads or streaks of pitch shall be scraped off; however, if the pitch is still soft, it shall be removed with mineral spirits or turpentine, and the resinous area shall be coated with knot sealer. After priming, holes and imperfections shall be filled with putty or plastic wood, colored to match the finish 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-24 Application: System Thickness: Coatings: Primer: Finish: Coating System Identification: Coating Material: Surface: Service Condition: Surface Preparation: Ferrous Metal: coat, allowed to dry and sandpapered smooth. Field Prime coat shall be thinned and applied as recommended by the manufacturer, provided the coating as applied complies with prevailing air pollution control regulations. 4 mils One coat at manufacturer's recommended dry film thickness. One or more coats at manufacturer's recommended dry film thickness per coat to the specified system thickness. EP-1 Polyamidoamine epoxy Metal Immersed, nonpotable; nommmersed, corrosive environment, color not required. Ferrous metal surfaces shall be prepared in accordance with SSPC SP-5 (White Metal Blast Cleaning). Shop primed surfaces which are to be incorporated in the work shall be prepared in the field by cleaning all surfaces in accordance with SSPC SP-2 (Hand Tool Cleaning). Damaged shop coated areas shall be cleaned in accordance with SSPC SP-5 (White Metal Blast Cleaning) and spot primed with the primer specified. Shop epoxy pnmed surfaces shall require light 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-25 Nonferrous and Galvanized Metal: Application: General: Ferrous Metal: System Thickness: Coatings: Primer: Finish: Coating System Identification: Coating Material: Surface: abrasive blasting prior to receiving finish coats. Nonferrous and galvanized metal shall be prepared in accordance with SSPC SP-7 (Brush-off Blast Cleaning). Field Prime coat may be thinned and applied as recommended by the manufacturer, provided the coating as applied complies with prevailing air pollution control regulations. Drying time between coats shall be as specified by the manufacturer for the site conditions. If the maximum recoat time is exceeded, surface preparation shall require solvent washing, light abrasive blasting, or other procedures per manufacturer's instructions. Prime coat shall be an epoxy pnmer compatible with the specified epoxy. Shop prime coat on nonimmersed surfaces shall be epoxy pnmer (applied in accordance with the written instructions of the coating system manufacturer). 16 mils dry film. One coat at manufacturer's recommended dry film thickness, black. One or more coats at manufacturer's recommended dry film thickness per coat to the specified system thickness, black. EP-2 Polyamidoamine epoxy Concrete or masonry 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900 - 26 Service Condition: Surface Preparation: Concrete: Masonry: Application: (1) Immersed, nonpotable; non- immersed, corrosive environment, color not required. Concrete surfaces shall be allowed to age for at least 28 days and allowed to dry to the moisture content recommended by the coating manufacturer. Moisture content may be tested by the Construction Manager with a Delmhorst Instrument Company moisture detector, or equal. Except as otherwise specified, loose concrete, form oils, surface hardeners, curing compounds, and laitance shall be removed from surfaces by abrasive blasting and chipping, and voids and cracks shall be repaired as specified in Section 03300, Cast-in-Place Concrete. Masonry surfaces shall be allowed to age for at least 28 days. Holes or other joint defects shall be filled with mortar and repomted. Loose or splattered mortar shall be removed by scrapping and chipping. Masonry surfaces shall be cleaned with clear water by washing and scrubbing to remove foreign and deleterious substances. Muriatic acid shall not be used. After cleaning, masonry surfaces shall be sealed or filled with sealer or block filler compatible with the specified primer. Field Sealer or filler shall dry a minimum of 48 hours prior to application of prime coat. Prime coat shall be thinned and applied as recommended by the coating manufacturer, provided the coating as applied complies with prevailing air pollution control regulations. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-27 System Thickness: Coatings: Primer: Finish: Drying time between coats shall be as specified by the manufacturer for the site conditions. If the maximum recoat time is exceeded, surface preparation shall require solvent washing, light abrasive blasting, or other procedures per manufacturer's instructions. 16 mils dry film. One coat at manufacturer's recommended dry film thickness, black. One or more coats at manufacturer's recommended dry film thickness per coat to the specified system thickness, black. Coating System Identification: Coating Material: Surface: Service Condition: Surface Preparation: Ferrous Metal: Nonferrous Metal: Water proofing and caulking for concrete will be per manufacturer's recommendation EP-3 Polyamidoamine epoxy Metal or concrete Below grade (buried) Ferrous metal surfaces shall be prepared in accordance with SSPC SP-5 (White Metal Blast Cleaning). Nonferrous and galvanized metal shall be prepared in accordance with SSPC SP-7 (Brush-off Blast Cleaning). 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900 - 28 Concrete: Application: System Thickness: Coating: Coating System Identification: Coating Material: Surface: Surface Preparation: Ferrous Metal: Application: System Thickness: Coating: Coating System Identification: Coating Material: Concrete surfaces shall be allowed to age for at least 28 days and allowed to dry to the moisture content recommended by the coating manufacturer. Moisture content may be tested by the Construction Manager with a Delmhorst Instrument Company moisture detector, or equal. Except as otherwise specified, loose concrete and laitance shall be removed from surfaces by abrasive blasting and chipping, and voids and cracks shall be repaired as specified in Section 03300, Cast-m-Place Concrete. Field 16 mils Two or more coats at manufacturer's recommended dry film thickness per coat to the specified system thickness. G Grease Metal Ferrous metal surfaces shall be prepared in accordance with SSPC SP-1 (Solvent Cleaning). Field Coating shall be applied with stiff brush, hand swab, or airless spray gun. 50 square feet per gallon One coat of grease coating HH-1 Inorganic zinc 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-29 Surface: Service Condition: Surface Preparation: Application: System Thickness: Coating: Coating System Identification: Coating Material: Surface: Service Condition: Surface Preparation: Application: System Thickness: Coating: Coating System Identification: Coating Material: Surfaces: Service Condition: Metal Temperature to 750 degrees F. Metal surfaces shall be prepared in accordance with SSPC SP-10 (Near White Metal Blast Cleaning). Field Curing as required by coating manufacturer. 3-1/2 mils dry film Two or more coats at manufacturer's recommended dry film thickness per coat to the specified system thickness. HH-2 Aluminum silicone, or equal Metal Temperature to 1000 degrees F. Metal surfaces shall be prepared in accordance with SSPC SP-10 (Near White Metal Blast Cleaning). Field Curing as required by coating manufacturer. 3-1/2 mils dry film Two or more coats at manufacturer's recommended dry film thickness per coat to the specified system thickness. L-l Latex Concrete, masonry, plaster, gypsum board. Interior 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-30 Surface Preparation: Concrete: Masonry: Plaster: Gypsum Wallboard: Application: Concrete surfaces shall be allowed to age for at least 28 days and allowed to dry to the moisture content recommended by the coating manufacturer. Moisture content may be tested by the Construction Manager with a Delmhorst Instrument Company moisture detector, or equal. Loose concrete and laitance shall be removed from surfaces, and voids and cracks shall be repaired as specified in Section 03300. Masonry surfaces shall be allowed to age for at least 28 days. Holes or other joint defects shall be filled with mortar and repomted. Loose or splattered mortar shall be removed by scraping and chipping. Masonry surfaces shall be cleaned with clear water by washing and scrubbing to remove foreign and deleterious substances. Muriatic acid shall not be used. After cleaning, masonry surfaces shall be filled with block filler compatible with the specified primer. Plaster surfaces shall be dry and clean and free from grit, loose plaster, and surface irregularities. Cracks and holes shall be repaired with acceptable patching materials, keyed to existing surfaces, and sandpapered smooth. Surfaces shall be cleaned with clear water by washing and scrubbing to remove foreign and deleterious substances. After cleaning, surfaces shall be sealed with a compatible sealer. Tape joints and spackled nail heads shall be sanded smooth and dusted. Seal with PVA sealer. Field Sealer or filler shall dry a minimum of 48 hours prior to primer application. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-31 System Thickness: Coatings: Pnmer: Finish: Coating System Identification: Coating Material: Surface: Service Condition: Surface Preparation: Application: System Thickness: Coatings: Pnmer: Finish: Coating System Identification: Coating Material: Surface: Service Condition: Drying time between coats shall be as recommended by coating manufacturer. 4 mils dry film. One coat at manufacturer's recommended dry film thickness. Two or more coats at manufacturer's recommended dry film thickness per coat to the specified system thickness. L-2 Latex PVC and CPVC pipe. Exterior, direct sunlight exposure. Plastic pipe shall be cleaned with solvent compatible with the specified primer and sanded to roughen surfaces. Field 3 mils dry film. One coat at manufacturer's recommended dry film thickness. One or more coats at manufacturer's recommended dry film thickness per coat to the specified system thickness. L-3 Latex Metal Interior 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-32 Surface Preparation: Ferrous Metals: Nonferrous and Galvanized Metal: Application: System Thickness: Coatings: Primer: Finish: Coating System Identification: Coating Material: Latex Surface: Service Condition: Bare ferrous metal surfaces shall be prepared in accordance with SSPC SP-2 (Hand Tool Cleaning) unless specified otherwise. Ferrous metal with rust bleeding shall be cleaned in accordance with SSPC SP-1 (Solvent Cleaning). Areas of rust penetration shall be spot blasted to SSPC SP-10 (Near White Blast) and spot primed with the specified primer. Shop primed surfaces which are to be incorporated in the work shall be prepared in the field by cleaning all surfaces in accordance with SSPC SP-2 (Hand Tool Cleaning). Galvanized or nonferrous surfaces shall be prepared in accordance with SSPC SP-1 (Solvent Cleaning). Field 4 mils dry film excluding sealer One coat at manufacturer's recommended dry film thickness. Two or more coats at manufacturer's recommended dry film thickness per coat to the specified system thickness. L-4 Wood Interior 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900 - 33 Surface Preparation- Application: System Thickness: Coatings: Pnmer: Finish: Coating System Identification: Coating Material: Surfaces: Wood surfaces shall be cleaned of dirt, oil or other foreign substances with mineral spirits, scrapers, sandpaper or wire brush. Finished surfaces exposed to view shall be smoothed by planing or sandpapering. Millwork shall be sandpapered and given a coat of the specified primer on all sides before installation. Built-in surfaces of window sills shall be double primed. Glazing rabbets and beads in exterior sash and doors shall be double primed. Small, dry, seasoned knots shall be surfaced scraped, sandpapered, and thoroughly cleaned and shall be given a thin coat of an acceptable knot sealer before application of the priming coat. Large, open, unseasoned knots, and beads or streaks of pitch shall be scraped off; however, if the pitch is still soft, it shall be removed with mineral spirits or turpentine, and the resinous area shall be coated with knot sealer. After priming, holes and imperfections shall be filled with putty or plastic wood, colored to match the finish coat, allowed to dry and sandpapered smooth. Field 4.0 mils dry film. One coat at manufacturer's recommended dry film thickness. Two or more coats at manufacturer's recommended dry film thickness per coat to the specified system thickness. M-l Petrolatum based mastic and wrapping tapes. Metal 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900 - 34 Service Condition: Surface Preparation: Application: Below grade (buried). Remove loose scale, rust, dirt, excessive moisture, or frost from the surface in accordance with SSPC SP-2 (Hand Tool Cleaning). All surfaces shall be hand rubbed or brushed with a priming paste recommended by the manufacturer. Sharp projections such as threads, irregular contours, or badly pitted areas shall receive a liberal amount of priming paste to ensure maximum protection of metal throughout. On irregular shaped surfaces, i.e., nuts, bolts, flanges, valves, etc., Contractor shall use either of the following systems recommended by the manufacturer. A. Apply recommended mastic by hand in sufficient quantity to build an even contour over entire surface. Contractor shall pay particular attention to ensure that all folds and air pockets within the mastic layer are thoroughly pressed out prior to subsequent application of tape. OR: B. An extra layer of tape shall be cut and carefully molded around all sharp projections, nuts, bolts, etc., before final application of tape, in order to meet specified system thickness. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS -JULY 2006 09900 - 35 System Thickness: Coating: Coating System Identification: Coating Material: Surface: Service Condition: Surface Preparation: Ferrous Metal: Nonferrous and Galvanized Metal: Application: Tape shall be spirally wrapped with a 55 percent overlap and sufficient tension and pressure to provide continuous adhesion without stretching the tape. Edges of tape must be continuously smoothed and sealed by hand during wrapping. On vertical application, contractor shall begin at bottom and proceed upward creating a weather board overlap. Smooth (contours shall have a minimum thickness'-of 50 mils while nuts, bolts, and sharp projections shall be 100 mils. Number and types of coating shall be in accordance with the manufacturer's written instructions. M-2 Epoxy mastic or equal Metal Interior, corrosive environment, confined enclosures, minimal surface preparation. All uncoated ferrous metal surfaces shall be prepared in accordance with SSPC SP-3 (Power Tool Cleaning), prior to assembly. Shop primed ferrous metal surfaces and fabricated assemblies shall be clean and dry prior to the application of field coats. Following assembly, Contractor shall smooth all welds and prominemes using power tools prior to the application of the field applied coatings. Nonferrous and galvanized metal shall be prepared in accordance with SSPC SP-1 (Solvent Cleaning). Field 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-36 General: Nonferrous and Galvanized Metal: System Thickness: Coatings: Prime: Finish: Coating System Identification: Coating Material: Surface: Service Condition: Surface Preparation: General: Ferrous Metal: Prior to the application of any field applied coatings, all welds, back-to-back angles, sharp or rough edges and weld splatter shall be brushed with the specified prime coat and allowed to cure overnight. Nonferrous and galvanized metal shall be cleaned prior to the application of the prime coat in accordance with SSPC SP-1 (Solvent Cleaning). 15 mils dry film. One coat of the manufacturer's recommended dry film thickness. One or more coats of manufacturer's recommended dry film thickness per coat to the specified system thickness. U Urethane Metal Exterior, exposed to direct sunlight. Shop primed surfaces which are to be incorporated in the work shall be prepared in the field by cleaning all surfaces in accordance with SSPC SP-2 (Hand Tool Cleaning). Damaged shop coated areas shall be cleaned in accordance with SSPC SP-3 (Power Tool Cleaning) and recoated with the primer specified. Bare ferrous metal surfaces shall be prepared in accordance with SSPC SP-6 (Commercial Blast Cleaning). 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900 - 37 Nonferrous and Galvanized Metal: Application: General: Ferrous Metal: Nonferrous and Galvanized Metal: System Thickness: Coatings: Primer: Finish: Ferrous metal with rust bleeding shall be cleaned in accordance with SSPC SP-1 (Solvent Cleaning). Areas of rust penetration shall be spot blasted to SSPC SP-10 (Near White Blast) and spot primed with the specified primer. Nonferrous and galvanized metal shall be prepared in accordance with SSPC SP-1 (Solvent Cleaning). Field Prime coat may be thinned and applied as recommended by the manufacturer, provided the coating as applied complies with prevailing air pollution control regulations. Prime coats shall be an epoxy primer compatible for use with urethane finish coats and applied in accordance with written instructions of the coating system manufacturer. Nonferrous and galvanized metal shall be cleaned prior to the application of the prime coat in accordance with SSPC SP-1 (Solvent Cleaning). 5 mils dry film of epoxy and 2 mils dry film of urethane. One coat at manufacturer's recommended dry film thickness. One or more coats at manufacturer's recommended dry film thickness per coat to the specified system thickness. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-38 3.6 COATING SYSTEMS SCHEDULE (FINISH SCHEDULE) Specific coating systems, colors, and finishes for rooms, galleries, piping, equipment, and other items which are painted or have other architectural finishes are specified in the following coating system schedule. Unless otherwise specified in the coating system schedule, the word "interior" shall mean the inside of a building or structure, and the word "exterior" shall mean outside exposure to weather elements. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 09900-39 SECTION 10520 FIRE EXTINGUISHERS PARTI- GENERAL 1.1 WORK OF THIS SECTION A. The WORK of this Section includes providing fire protection equipment, cabinets, and appurtenant work, complete. 12 CODES A The WORK of this Section shall comply with the current editions of the following codes as adopted by the City of San Diego Municipal Code: B. Uniform Building Code C. Uniform Fire Code 1.3 SPECIFICATIONS AND STANDARDS A Except as otherwise indicated, the current editions of the following apply to the WORK of this Section. 1 Trade Standards. National Fire Protection Association, Standard No. 10, "Portable Fire Extinguishers" Underwriter's Laboratory, Fire Protection Equipment List 1 4 SHOP DRAWINGS AND SAMPLES A. The following shall be submitted in compliance with Section 2.5.3 of the General Provisions.. 1. Manufacturer's catalogue containing technical data, installation instructions, and details. 1.5 PRODUCT DELIVERY, STORAGE, AND HANDLING A. Delivery of Materials: Fire extinguishers and appurtenant matenals shall be delivered in onginal unbroken packages or containers, bearing the manufacturer's label with manufacturer's name, product description, and rating B. Storage: All materials shall be carefully stored in an area which is protected from deleterious elements as recommended by the material CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 10520 -1 manufacturer Storage shall be in a manner that will prevent damage to the material and its finish. PART 2- PRODUCTS 2.1 GENERAL A. All fire protection equipment shall be from the same manufacturer (unless otherwise indicated) and shall meet the requirements of NFPA Standard No. 10, "Portable Fire Extinguishers" 2 2 FIRE EXTINGUISHERS A Type A extinguisher shall be 201b minimum capacity, dry chemical type with minimum UL rating of 10-A'60B:C, in enameled steel container, for Class A, Class B, and Class C fires B. Five extinguishers shall be installed as shown on the plans 2.3 CABINETS A Fire extinguisher cabinet shall be semi-recessed steel cabinet with clear anodized aluminum door and door frame, and projecting, convex, butyrate plastic, canopy type viewing door panel. The size shall be as necessary to hold fire extinguisher at cabinet location. 2.4 BRACKETS AND OTHER MATERIALS A. Mounting brackets shall be specially designed for extinguishers or cabinets. B. All other matenals, not specifically described, but required for a complete and proper installation of fire fighting devices shall be as selected by the CONTRACTOR. 2 5 MANUFACTURERS A. Fire protection equipment shall be manufactured by one of the following (or equal): 1. General Fire Extinguisher Corp. 2 J.L. Industries 3 Potter-Roemer 4. Standard Fire Equipment (Division of Zurn Co.) 5. Walter Kidde and Co. 2.6 MISCELLANEOUS EQUIPMENT A. CONTRACTOR shall install a facility noteboard and operations and maintenance shelf in the MCC Room as shown on the plans. I -< r - CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 10520-2 PARTS- EXECUTION 3.1 INSTALLATION A. Brackets: All fire extinguishers shall be provided with and installed on brackets or brackets within cabinets. The CONTRACTOR shall block and reinforce the wall area as necessary to support the fire extinguishers. B. Locations: Fire protection equipment locations shall be verified with the RESIDENT ENGINEER and Fire Marshall before installation and shall be installed, where directed, per NFPA Standard No. 10, "Portable Fire Extinguishers." **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 10520 - 3 SECTION 11000 GENERAL REQUIREMENTS FOR EQUIPMENT PART 1—GENERAL 1.1 DESCRIPTION A. Scope: This section specifies general requirements, which are applicable to all mechanical equipment. The Contractor is responsible for ensuring that all mechanical equipment meets the requirements of this section in addition to the specific requirements of the individual equipment specification section. B. Equipment Lists: Equipment lists, presented in these specifications and as specified on the drawings, are included for the convenience of the Construction Manager and Contractor and are not complete listings of all equipment, devices and material to be provided under this contract. The Contractor agrees to prepare his own material and equipment takeoff lists as necessary to meet the requirements of this project manual. 1.2 QUALITY ASSURANCE A Arrangement: The arrangement of equipment shown on the drawings is based upon information available to the Owner at the time of design and is not intended to show exact dimensions particular to a specific manufacturer. The drawings are, in part, diagrammatic, and some features of the illustrated equipment installation may require revision to meet actual equipment installation requirements. Structural supports, foundations, connected piping, valves, and electrical conduit specified may have to be altered to accommodate the equipment provided. No additional payment will be made for such revisions and alterations. B. References: This section contains references to the following documents. They are n part of this section as specified and modified. In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11000 - 1 Reference (Latest Edition) Title AFBMA Std 9 AFBMAStdll ANSIB1.1 ANSI B 1.20.1 ANSI B 16.1 ANSI B 18.2.1 Load Ratings and Fatigue Life for Ball Bearings Load Ratings and Fatigue Life for Roller Bearings Unified Screw Threads Pipe Threads, General Purpose (Inch) Cast Iron Pipe Flanges and Flanged Fittings, Class 125 Square and Hex Bolts and Screws, Including Askew Head Bolts, Hex Cap Screws, and Log Screws ANSI B18.2.2 Square and Hex Nuts C. UNIT RESPONSIBILITY: Equipment systems made up of two or more components shall be provided as a unit by the responsible manufacturer. Unless otherwise specified, the Contractor shall assign unit responsibility to, and obtain each system from, the supplier of the driven equipment. The supplier shall provide all components of the system to enhance compatibility, ease of construction and efficient maintenance. The responsible manufacturer shall coordinate selection and design of all system components such that all equipment is compatible and operates properly to achieve the performance requirements specified. Assignment of unit responsibility shall in no way relieve the Contractor of his responsibility to the Owner for performance of all systems. Where the detailed specification requires the Contractor to furnish a certificate from the Unit Responsibility Manufacturer, such certificates shall be signed by an officer of the manufacturer's corporation and shall be notarized. No other submittal material will be processed until a Certificate of Unit Responsibility has been received and has been found to be satisfactory. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11000-2 PART 2—PRODUCTS 2.1 FLANGES AND PIPE THREADS Flanges on equipment and appurtenances provided under this section shall conform in dimensions and drilling to ANSI B16.1, Class 125. Pipe threads shall conform in dimension and limits of size to ANSI Bl.l, coarse thread series, Class 2 fit. Threaded flanges shall have a standard taper pipe thread conforming to ANSI B 1.20.1. Unless otherwise specified, flanges shall be flat faced. Flange assembly bolts shall be heavy pattern, hexagonal head, carbon steel machine bolts with heavy pattern, hot pressed, hexagonal nuts conforming to ANSI B 18.2.1 and B 18.2.2. Threads shall be Unified Screw Threads, Standard Coarse Thread Series, Class 2A and 2B, ANSI Bl.l. 2.2 BEARINGS Unless otherwise specified, equipment bearings shall be oil or grease lubricated, ball or roller type, designed to withstand the stresses of the service specified. Each bearing shall be rated m accordance with the latest revisions of AFBMA Methods of Evaluating Load Ratings of Ball and Roller Bearings. Unless otherwise specified, equipment bearings shall have a minimum L-10 rating life of 50,000 hours. The rating life shall be determined using the maximum equipment operating speed. Grease lubricated bearings, except those specified to be factory sealed and lubricated, shall be fitted with easily accessible grease supply, flush, drain and relief fittings. Extension tubes shall be used when necessary. Grease supply fittings shall be standard hydraulic alemite type. Oil lubricated bearings shall be equipped with either a pressure lubricating system or a separate oil reservoir type system. Each oil lubrication system shall be of sufficient size to safely absorb the heat energy normally generated in the bearing under a maximum ambient temperature of 60 degrees C and shall be equipped with a filler pipe and an external level indicator gage. All bearings accessible to touch and located within 7 feet measured vertically from floor or working level or within 15 inches measured horizontally from stairways, ramps, fixed ladders or other access structures shall either incorporate bearing housings with sufficient cooling to maintain surface temperature at 65 degrees C or less for continuous operation at bearing rated load and a 50 degrees C ambient temperature or appropriate shielding shall be provided that will prevent inadvertent human contact. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11000-3 2.3 COUPLINGS Unless otherwise specified in the particular equipment sections, equipment with a driver greater than 1/2 HP, and where the input shaft of a driven unit is directly connected to the output shaft of the driver, shall have its two shafts connected by a flexible coupling which can accommodate angular misalignment, parallel misalignment and end float, and which cushions shock loads and dampens torsional vibrations. The flexible member shall consist of a tire with synthetic tension members bonded together in rubber. The flexible member shall be attached to flanges by means of clamping rings and cap screws, and the flanges shall be attached to the stub shaft by means of taperlock bushings which shall give the equivalent of a shrunk-on fit. There shall be no metal-to-metal contact between the driver and the driven unit. Each coupling shall be sized and provided as recommended by the coupling manufacturer for the specific application, considering horsepower, speed of rotation, and type of service. Where torque or horsepower capacities of couplings of the foregoing type is exceeded, Thomas-Rex, Falk Steel Flex, or equal, couplings will be acceptable provided they are sized in accordance with the equipment manufacturer's recommendations and sizing data are submitted. They shall be installed in conformance to the coupling manufacturer's instructions. 2.4 GUARDS Exposed moving parts shall be provided with guards which meet the requirements of OSHA. Guards shall be fabricated of 14-gage steel, 1/2-13-15 expanded metal screen to provide visual inspection of moving parts without removal of the guard. Guards shall be galvanized after fabrication and shall be designed to be readily removable to facilitate maintenance of moving parts. Reinforced holes shall be provided. Lube fittings shall be extended through guards. 2.5 GAGE TAPS, TEST PLUGS AND GAGES Gage taps shall be provided on the suction and discharge sides of pumps, blowers and compressors. Pressure and vacuum gages shall be provided where specified. Gage taps, test plugs, and gages shall be as specified in Divisions 15 and 16. 2.6 NAMEPLATES Nameplates shall be provided on each item of equipment and shall contain the specified equipment name or abbreviation and equipment number. Equipment nameplates shall be engraved or stamped stainless steel and fastened to the equipment in an accessible location with stainless steel screws or drive pins. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11000-4 2.7 LUBRICANTS The Contractor shall provide for each item of mechanical equipment a supply of the lubricant required for the commissioning period. Lubricants shall be of the type recommended by the equipment manufacturer and shall be products of the Owner's current lubricant supplier. The Contractor shall limit the various types of lubricants by consolidating them, with the equipment manufacturer's approval, into the least number of different types. Not less than 90 days before the date shown in his construction schedule for starting, testing and adjusting equipment, the Contractor shall provide the Owner with three copies of a list showing the required lubricants, after consolidation, for each item of mechanical equipment. The list shall show estimated quantity of lubricant needed for a full year's operation, assuming the equipment will be operating continuously. 2.8 ANCHOR BOLTS Anchor bolts shall be designed for lateral forces for both pullout and shear in accordance with the provisions of Section 05501. Unless otherwise stated m the detailed specification, anchor bolt materials shall conform to the provisions of Section 05501, Anchor Bolts. 2.9 SPARE PARTS Spare parts, wherever required by detailed specification sections, shall be stored in accordance with the provisions of this paragraph. Spare parts shall be tagged by project equipment number and identified as to part number, equipment manufacturer, and subassembly component (if appropriate). Spare parts subject to deterioration such as ferrous metal items and electrical components shall be properly protected by lubricants or desiccants and encapsulated in hermetically sealed plastic wrapping. Spare parts with individual weights less than 50 pounds and dimensions less than 2 feet wide, or 18 inches high, or 3 feet in length shall be stored in a wooden box with a hinged wooden cover and locking hasp. Hinges shall be strap type. The box shall be painted and identified with stenciled lettering stating the name of the equipment, equipment numbers, and the words "spare parts." A neatly typed inventory of spare parts shall be taped to the underside of the cover. PART 3—EXECUTION Installation of equipment accessories included in this section shall be as recommended by the equipment manufacturer unless otherwise specified m the individual equipment specification section. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11000-5 SECTION 11002 EQUIPMENT MOUNTING PART 1—GENERAL 1.1 DESCRIPTION This section specifies equipment mounting, consisting of equipment base, supports, anchorage and accessories. 1.2 QUALITY ASSURANCE A. Requirements of Regulatory Agencies: All tanks, piping, equipment, supports and anchorages shall be designed by the contractor in accordance with requirements of the Uniform Building Code (UBC) and Structural Engineering Association of California (SEAOC), latest edition, unless specified otherwise herein. All elements required to resist the calculated forces described herein shall be provided by the Contractor. B. Calculations and Shop Drawings: Calculations and shop drawings shall be submitted for all of the work required above. All calculations must be made and signed by a civil or structural engineer currently registered in the State of California. Inasmuch as all anchorage of equipment is to be made of poured-in-place concrete elements, it is imperative that types of anchorage be coordinated with the concrete subcontractor so that anchorage may be installed at time of pouring. If calculations and anchorage details are not submitted prior to pouring of concrete, the Contractor will become responsible for any strengthening of concrete elements because of superimposed seismic loading 1 3 SUBMITTALS Submittals shall be in accordance with Section 2-5.3 3 of the General Provisions. The following information shall be provided: 1. Shop drawings for all equipment base and anchorage details. 2. Certification of anchor bolt calculations specified in paragraph 11002- 1.02. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11002-1 PART 2—PRODUCTS 2.1 GENERAL Equipment mountings shall be as shown. All equipment located on floor slabs shall be mounted on concrete pads. Where a steel or cast base is shown or specified between the equipment and the concrete pedestal, it shall be hot-dip galvanized after fabrication 2.2 CAST IRON BASES Cast iron bases located within a building do not require galvanizing but must be sealed in accordance with the requirements specified in Section 09900 All fasteners requiring connections to the base shall be terminated by nuts welded to the bottom side of the base and plugged with cork, plastic plugs or grease, or acorn nuts In no case shall the fastener terminate only into the metal base. 2.3 CONCRETE PEDESTALS Concrete pedestals shall be 3 inches larger than the steel or cast base All conduits, piping connections, drains, etc., shall be enclosed by the concrete base. No conduits, piping connections, drains, etc., will be accepted which rise directly from the floor. PART 3—EXECUTION 3.1 INSTALLATION A. Equipment: Except where a higher lateral force is required by code, each piece of equipment installed shall be anchored to resist a minimum lateral seismic force of 60 percent of the operating weight of the equipment. This force shall be considered acting at the center of gravity of the piece under consideration No equipment shall be anchored to vertical structural elements without written approval of the Construction Manager. Non-vibrating isolation equipment shall be anchored directly to the supporting floor system. In addition to the anchorage, all equipment shall be internally designed so that all static and moving parts are anchored to the supporting framework to resist the imposed seismic force. All forces must be transmitted to the base in order to be anchored as required. Equipment, piping supports and anchorage located outside the buildings shall be designed to comply with the UBC, latest edition. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11002-2 B. Piping: All piping, raceways, accessories, and appurtenances, furnished with equipment shall be anchored to resist a lateral seismic force of 60 percent of its operating weight without excessive deflection. This force shall be considered acting at the center of gravity of the piece under consideration. C. Ductwork: All ductwork for ventilating equipment shall be anchored to the wall system(s) to resist a lateral seismic force of 60 percent of the operating weight. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11002-3 SECTION 11004 EQUIPMENT CONTROL DEVICES PART 1—GENERAL 1 1 DESCRIPTION This section specifies electrical and instrumentation devices specified as part of equipment systems 1.2 QUALITY ASSURANCE A. GENERAL- Control devices shall be listed by Underwriters Laboratories Inc. (UL) or Factory Mutual (FM) for their intended purpose where such listing has been applied to similar products B. REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail Reference (Latest Edition) Title JIC EMP-1 Electrical Standards for Mass Production Equipment NEMA ICS 2 Industrial Control Devices, Controllers and Assemblies NEC National Electrical Code 1.3 SUBMITTALS Submittals shall be in accordance with Section 2-5.3.3 of the General Provisions. 1. Sufficient data for materials and components to demonstrate compliance with the specifications. 2. Location of ancillary devices, conduit, junction boxes, safety and control devices, and conduit entries for feeding or controlling the equipment. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11004-1 3. Electrical elementary diagrams, internal connection diagrams, and external interconnection diagrams, drawn in accordance with JIC and/or ICS standards. Connection diagrams shall be the conventional type with lines showing point-to-point wiring and must show terminals and devices as viewed by the electrician; wireless or wire schedule types are not acceptable. 4. Process flow diagrams and process and instrumentation diagrams (P&IDs) using ISA symbols for equipment which interfaces with the instrumentation system or has internal control loops. 5. Range and setting of indicators, instruments, timers, and devices PART 2—PRODUCTS 2.1 POWER RATINGS Devices shall be suitable for the control circuit voltage. Where more than one piece of equipment (each having its own power source) have a common control power system, provision shall be made for transferring the control power system to an active source should the main source of control power fail. 2.2 PILOT DEVICES Electrical pilot devices including switches, relays, and contacts shall be heavy- duty industrial quality devices. Contacts which provide alarm, malfunction or control to external systems shall be rated NEMA A600 (10 amps continuous at 600 volts AC), except that pressure switches and temperature switches shall be rated NEMA B600 (5 amps continuous at 600 volts AC). Range of switches shall be that recommended by the mechanical equipment manufacturer. 2 3 ALARM AND MALFUNCTION DETECTION Devices which are used to directly signal alarm or malfunction conditions shall be externally manually reset. The devices shall have a minimum of one contact which shall open on malfunction or alarm condition, as scheduled. Other output relays and devices shall have a minimum of one normally open and one normally closed contact which may be a NEMA Form C contact. If the contact of the device is required for internal equipment control as well as to signal alarm or malfunction conditions, then the manufacturer may make the reset function a part of his equipment's master shutdown system. However, each source of shutdown shall be shown by local trouble lights or flags which are manually reset at the equipment control panel. Trouble output contacts shall open and remain open until manually reset when equipment is shut down due to a malfunction. Trouble I -i i -.1 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11004-2 contacts shall not indicate abnormal conditions when the equipment has been manually shut down. Alarm and malfunction signals shall be initiated by a contact opening. 2.4 CABLE Rubber covered multi-conductor cable shall not be used on stationary equipment for any voltage exceeding 250 volts AC, nor shall it be used for connections to any motor rated 1/4 horsepower or larger. For these purposes, JIC EMP-1-1967 E12.4.4 through E12.4.8 and E13.3 shall apply. 2.5 LIQUIDTIGHT CONDUIT Flexible conduit shall be liquidtight flexible metal conduit, formed from spirally wound galvanized steel strip with successive convolutions securely interlocked, jacketed with liquidtight plastic cover. Minimum size shall be 1/2 inch. Fittings for liquidtight conduit shall have cadmium-plated malleable iron body and gland nut, brass grounding ferrule threaded to engage conduit spiral and O-nng seals around the conduit and box connection and isolated throat. Forty-five and 90- degree fittings shall be used where applicable. Maximum length of flexible conduit shall be 36 inches. 2.6 INDICATING LIGHTS Indicating lights shall be oiltight transformer type with low voltage lamps and push-to-test features and shall be equipped with colored lenses in accordance with the following schedule: Color Red Amber (yellow) Green White or clear Typical function Danger, abnormal condition, fault condition Attention Safe condition (security Normal condition lubrication Example Voltage applied, cycle in automatic, faults in air, water, lubricating or filtering systems, ground detector circuits. Motors running, machine in cycle, unit or head in forward position. End of cycle, unit or head returned, motors stopped, motion stopped, contactors open Normal pressure of air, water. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11004-3 2.7 GROUNDING A separate ground conductor shall be run in each power conduit. The conductor shall be sized in accordance with NEC Table 250-95. The conductor shall be bonded to the inside of the device junction box. Freestanding control panels shall be equipped with a 1/4-inch by 1-mch copper ground bus running the length of the panel, with the steel structure connected to the bus so as to effectively ground the entire structure. A compression fitting shall be provided at each end of the ground bus for accepting plant ground connections. 2.8 DEVICES WITH MOTOR STARTERS AND CONTACTORS Equipment which is provided with control devices having motor starters or contactors shall also comply with the following. A. DISCONNECT SWITCHES: Equipment shall be provided with a disconnect switch. If the disconnect switch is not located within sight of the drive, it shall be provided with a padlock hasp. The disconnect shall be a horsepower rated disconnect switch or molded case circuit breaker, except that a manual motor starter may be used for drives less than 2 kVA. Horsepower rated disconnect switches for equipment 2kVA or greater shall be provided with UL Class RK1 fuses. Circuit breaker interrupting ratings shall be 10,000 symmetrical amperes for service at 240 volts or below and shall be 22,000 symmetrical amperes for service above 240 volts unless otherwise noted. When the disconnecting device is not a circuit breaker or fused disconnect, the circuit feeding the disconnecting device shall have adequate overcurrent and short circuit protection. B. OVERLOAD PROTECTION: Protection shall be provided for full motor running overload in ungrounded conductors for motors. C. OVERLOAD RELAY CONTACTS: Overload relay contacts shall not be connected in the line having provision for grounding. Grounding connections shall be provided in the unfused side of control circuits and shall be connected. 1 "074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11004-4 D. POWER: Power will be supplied at one voltage as shown or specified. Additional voltage requirements, such as 120 volt control power, shall be derived from transformers provided internal to the control device as required. Each control power transformer shall be rated at least 150 percent of the calculated maximum load it serves. PART 3—EXECUTION 3.1 INSTALLATION Control devices, when installed, shall comply with the requirements of the NEC. 3.2 FIELD WIRING Conduit, wiring, or mounting of devices not shown on the electrical or instrumentation drawings but required for a complete and operable system shall be provided under this section. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11004-5 SECTION 11021 VIBRATION ISOLATION SYSTEMS PARTI- GENERAL 1.1 DESCRIPTION This section includes vibration isolation system requirements for mechanical equipment. Additional vibration isolation system requirements are provided in individual mechanical equipment specification sections. 1.2 QUALITY ASSURANCE A. TESTING: Unless the equipment incorporates unit construction using an integral rigid frame or is specified otherwise, each item of mechanical equipment, along with its drive unit, shall be mounted on a rigid steel or steel and concrete base. Cast iron bases will be permitted only when the equipment is not furnished with a vibration isolation system. Where specified or noted on the drawings, the equipment, including the base, shall be mounted on or suspended from vibration isolators to prevent the transmission of vibration and mechanically transmitted sound to the supporting structure. Vibration isolation available internally in the equipment will not be considered equivalent and shall not be provided when vibration isolation as specified herein is required. Normally provided internal vibration isolators shall be replaced with rigid supports in such cases. Vibration isolators shall be selected in accordance with unit weight distribution to produce reasonably uniform deflections at each support. Bases, isolators and deflections shall be as specified in the Equipment Vibration Isolation Selection Guide. B. SEISMIC RESTRAINTS: Where seismic restraint is required by the detailed specification, equipment and appurtenances resiliency mounted on spring or pad type vibration isolators, except for curb mounted equipment, shall be provided with seismic restraints or snubbers as specified herein. Seismic restraints for equipment mounted on vibration isolation curbs shall consist of slack stainless steel cables designed to provide 4 g restraint in the four primary horizontal directions. For all spring mounted equipment with an operating weight (dead plus live loads, including any integral supports) of 250 pounds or more, the selection of the particular seismic snubber shall be based upon complete dynamic analysis calculations using seismic response data derived for the system. Seismic response data are available in the soils report. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11021-1 The dynamic analysis report shall include a listing and explanation of all assumptions made which affect the calculations and the following information along the three principal orthogonal axes: 1. The six natural frequencies of the system both with and without snubbing. 2. The most probable movements (RMS values) at all mounting or combination mounting and snubber locations as well as at duct, pipe, and electrical connection points and the equipment extremities. 3. Maximum accelerations at the center of each significant system element such as the motor, fan, compressor, heat exchanger, or engine as well as at the mounting or combination mounting and snubber locations, all expressed in g units. 4. The most probable force (RMS value) at each mounting or mounting and snubber location expressed in pounds. It is the intent of this specification that the acceleration shall not exceed 4 g nor shall the excursion from center exceed 5/8 inch at the snubbers based on the RMS values. The capacity of each seismic snubber at 3/8-inch deflection shall be 3 to 4 times the load assigned to the mount grouping in its immediate area. When the analysis shows that levels higher than 4 g occur at the snubbers because of the maximum allowable amplitude, the Contractor shall suggest an alternate mount system based upon an additional dynamic analysis that will maintain the 4 g level. The Engineer will express a preference for either the higher g level or the alternate method at his option. The analysis shall have the equipment modeled as a single 3-dimensional rigid body composed of several rigidly attached lumped masses. The system must be conservative and have six natural modes and frequencies. The final solution shall be obtained as a combination of model responses in the form of a most probable value equal to the RMS values of the six modes. The report must be signed by a professional engineer registered in the State of California with demonstrated competence in the field. C. DESIGN REQUIREMENTS: The Contractor shall cause all vibration isolation systems, including the isolators, seismic restraints and flexible connectors between the isolated 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11021-2 equipment and associated piping, ducting and/or electrical work, to be designed by an engineer qualified in this type of work This provision, however, shall not be construed as relieving the Contractor of his overall responsibility for the work. The Contractor shall submit the engineer's qualifications to the Construction Manager for the Engineer's review prior to starting the vibration isolation design. Vibration isolation mountings and seismic restraints shall be as manufactured by mason kinetics Corporation, or equal Flexible connectors shall be provided by the manufacturer of the mechanical equipment item in accordance with the recommendations of the vibration isolation system engineer. D. TESTING Seismic restraint tests shall be conducted in an independent laboratory or under the supervision of an independent professional engineer registered in the State of California. The snubber assemblies shall be bolted to the test machine as the snubber is normally installed. Test reports shall certify that nether the elastomer elements nor the snubber body sustained any obvious deformation after release of load. 1.3 SUBMITTALS Submittals shall be in accordance with Section 2-5.3.3 of the General Provisions. The Contractor shall submit to the Construction Manager for the Engineer's review the following: 1. Vibration isolation system design engineer's qualifications 2. Complete calculations showing static and dynamic deflections, weights, isolator locations and flexible connector designs 3. Spring deflections and diameters, compressed spring heights and solid spring heights. 4. Curb mounted base seal and wind resistance details. 5. Scale drawing of Type D mounting hanger showing the 30-degree arc capability. 6. Seismic restraint load deflection curves up to 1/2-inch deflection along the three principal orthogonal axes. 7. Seismic restraint dynamic analysis report. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11021 -3 14 INFORMATION Information to be furnished to the Construction Manager shall include certified copies of all seismic restraint test reports PART 2—PRODUCTS 2.1 BASES A CURB-MOUNTED BASES Curb mounted equipment where vibration isolation is required, principally roof top heating, ventilating and air conditioning equipment, shall be mounted on vibration isolation bases that fit over the curb and under the isolated equipment The extruded aluminum top and bottom members shall contain cadmium-plated springs having a 1-inch minimum deflection with 50 percent additional travel to solid. Spring diameters shall be no less than 0.8 times the spring height at rated load. Wind resistance shall be provided by means of resilient snubbers in the corners with a minimum clearance of 1/4 inch so as not to interfere with spring action except in high winds. The weather seal shall consist of continuous closed cell sponge materials both above and below the base and a waterproof flexible neoprene connection duct joining the outside perimeter of the aluminum members. Foam or other contact seals are unacceptable at the spring cavity closure. Calking shall be kept to a minimum. B TYPE I BASES: Type I bases shall be structural steel bases. The bases shall be rectangular in shape for all equipment other than centrifugal refrigeration machines and pump bases, which may be "T" or "L" shaped. Pump bases for split case pumps shall include supports for suction and discharge base ells. All perimeter members shall be beams with a minimum depth equal to 1/1 Oth of the longest dimension of the base. Beam depth need not exceed 14 inches provided that the deflection and misalignment is kept within acceptable limits as determined by the manufacturer. Grout holes shall be provided for the bases of all equipment where vibration isolation is not specified. Where vibration isolation is required, height saving brackets shall be employed in all mounting locations to provide a base clearance of 1 inch. C. TYPE II BASES • Type II bases shall be steel members used to cradle machines having legs or bases that do not require a complete supplementary base. All members shall be sufficiently rigid to prevent strains in the equipment. Where CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11021 -4 vibration isolation is required, height saving brackets shall be employed in all mounting locations to provide a clearance of 1 inch below the base. D. TYPE III BASES: Type III bases shall be rectangular foundations consisting of concrete filled structural steel beam or channel forms. Bases for split case pumps shall be of sufficient size to provide support for suction and discharge base ells. The base depth need not exceed 12 inches unless specifically recommended by the base manufacturer or required for mass or rigidity. In general, base depth shall be a minimum of 1/12th of the longest dimension of the base but not less than 6 inches. Forms shall include, as a minimum, concrete reinforcement consisting of 1/2-inch bars or angles welded in place on 6-inch centers each way in a layer 1-1/2 inches above the bottom or additional steel as required by structural conditions. Forms shall be furnished with drilled steel members with sleeves welded below the holes to receive equipment anchor bolts where the anchor bolts fall in concrete locations. Where vibration isolation is required, height saving brackets shall be employed in all mounting locations to maintain a 1-inch clearance below the base. 2.2 VIBRATION ISOLATION MOUNTINGS A. TYPE A MOUNTINGS: Type A mountings shall be double deflection neoprene mountings having a minimum static deflection of 0.35 inch. All metal surfaces shall be neoprene covered to avoid corrosion and shall have fhction pads both top and bottom so that they need not be bolted to the floor. Bolt holes and anchor bolts shall be provided where required to resist lateral migration. Resilient washers and bushings shall be provided to prevent contact between the bolts and the equipment support bases. On equipment such as small vent sets, steel rails shall be used above the mountings to compensate for the overhang. B. TYPE B MOUNTINGS: Type B mountings shall be free-standing, spring-type isolators laterally stable without any housing and complete with 1/4-inch neoprene acoustical friction pads between the base and the support. Mountings shall have leveling bolts that must be rigidly bolted to the equipment. Spring diameters shall be no less than 0.8 times the compressed height of the spring at rated load. Springs shall have a minimum additional travel to solid equal to 50 percent of the rated deflection. Mountings shall be hot-dip galvanized steel. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11021 -5 C. TYPE C MOUNTINGS: Type C mountings shall be Type B mountings with a housing having vertical limit stops to prevent spring extension when weight is removed. Type C mountings shall be provided for equipment with operating weight different from the installed weight, such as chillers, boilers, etc., and equipment exposed to the wind, such as cooling towers. The housing shall serve as blocking during erection and shall be located between the supporting steel and roof or the grillage and dunnage as shown on the drawings. The installed and operating heights shall be the same. A minimum clearance of 1/2 inch shall be maintained around restraining bolts and between the housing and the spring to prevent interference with the spring action. Limit Stops shall be out of contact during normal operations. Mountings shall be hot-dip galvanized steel. D. TYPE D MOUNTINGS: Type D mountings shall be steel hangers which contain a steel spring and a 0.3-inch deflection neoprene element in series. The neoprene element shall be molded with a rod isolation bushing which passes through the hanger box. Spring diameters and hangerbox lower hole sizes shall be of sufficient size to permit the hanger rod to swing through a 30-degree arc before contacting the hole. Springs shall have a minimum additional travel to solid equal to 50 percent of the rated deflection. E. TYPE E MOUNTINGS: Type E mountings shall be double-deflection, cork and rubber sandwich pads consisting of a high-density cork layer permanently bonded to top and bottom layers of corrugated oil-resistant synthetic rubber. The corrugated design shall allow deflection to increase with load and shall form a non-skid surface to resist lateral migration of the equipment. Bolt holes and anchor bolts shall be provided where required to resist migration. Resilient washers and bushings shall be provided to prevent contact between the bolts and the equipment support bases. 2.3 SEISMIC RESTRAINTS Each resihently mounted base shall have a minimum of four all-directional double acting seismic snubbers located as close to the vibration isolators as possible to facilitate attachment both to the base and to the structure. The snubbers shall consist of interlocking steel members restrained by replaceable shock absorbent elastomenc materials compounded to the specifications set forth in the Elastomenc Snubber Materials Table. 17074 - CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11021 -6 The thickness of the elastomenc material shall be not less than 3/4 inch. Snubbers shall be designed and manufactured with an air gap between rigid and resilient surfaces of not less than 1/8 inch nor more than 1/4 inch. Snubbers shall be installed with factory set clearances. EQUIPMENT VIBRATION ISOLATION SELECTION GUIDE Equipment Typer Refrigeration equipment* Centrifugal chillers or heat pumps Cooler condenser mounted hermetic compressors Cooler Condenser alongside hermetic compressor Open Type Compressors Refrigeration reciprocating compressors 500 rpm to 750 rpm Over 750 rpm Reciprocating chillers or heat pumps 500 rpm to 750 rpm Over 750 rpm Factory assembled air handling equipment(see blowers for fan heads) Suspended units Through 5 hp Over 5 hp - 275 rpm to 400 rpm Over 5 hp - over 400 rpm Floor mounted units Through 5 hp Over 5 hp - 275 rpm to 400 rpm Over 5 hp - over 400 rpm Compressors' Tank Type8 V-W Type8 Slow Speed (to 500 rpm) honz, vert, 1 or 2 cylinder11 Rotary Positive11 Centrifugal' Vacuum Pumps' ' Deflection and Mounting Criteria for Solid Concrete Floors1'11 Slab on Grade Mount A A A B B C C D D D A A A B C E E Base' I III III I III Defld 035 035 035 075 075 075 075 10 15 10 035 035 15 15 - - 20' Floor Span Mount C C C B B C C D D D B B B B B B C B B Base' I II III III III III I iim Defl" 075 075 075 15 075 15 075 10 15 1 0 075 1 5 075 075 075 15 15 075 075 30' Floor Span Mount C C C B B C C D D D B B B B B B C B B Base' 1 II II II III III III III 1 III Defld 15 15 15 15 15 15 15 10 15 10 075 15 075 5 5 5 5 5 5 40' Floor Span Mount C C C B B C C D D D B B B B B B C B B Base' I II II II II II II III III III III 1 III Defl" 15 15 15 25 25 25 25 10 1 5 15 075 15 15 25 25 25 25 15 15 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11021-7 EQUIPMENT VIBRATION ISOLATION SELECTION GUIDE Equipment Typer Blowers' Utility Sets Floor Mounted10 Roof Mounted1" Suspendedk Centrifugal fans" Fan Heads0 Floor Mounted Suspended Tubular Centrifugal and axial fans Suspended units'" Floor Mounted - AMCA arrangement 91 q Floor mounted 0 AMCA arrangement 1 * Cooling Towers (Steel) and Condensing Units Engine Driven Equipment and engine drivers'1' 500 rpm to 750 rpm Over 750 rpm Blower Minimum Deflection Deflection Guide Deflection and Mounting Criteria for Solid Concrete Floors1'1" Slab on Grade Mount A A A A A A Base* I or III III II Defld 035 035 035 035 035 035 20' Floor Span Mount B B D B B D D B B C Base' - HI I or III III II Defld - - - - - - - - . - 15 30' Floor Span Mount B B D B B D D B B C Base' III I or III _ III II Defld - - - - - - - - _ - 20 40' Floor Span Mount B B D B B D D B B C Base' - HI I or III _ III II Defl" _ , - - - - - -_ - 25 When floors or roofs are lighter than 4-mch solid concrete, it is desirable to introduce a localized mass under the vibration mountings in the form of a sub-base The sub-base should be 12 inches thick and 12 inches longer and wider than the mechanical equipment above it When the sub-base is provided the 30 foot minimum static deflection requirements will suffice even for longer spans When the sub-base cannot be provided, select deflection requirements for the next larger span For equipment mounted on elevated reinforced concrete slabs at least 8 inches thick, use selection criteria for 20 foot floor span regardless of span length Where bases are not specified, the Contractor shall provide a base appropriate for the equipment type and mounting specified Deflections are not "nominal" but certifiable minimums in inches The 0 75-mch, 1 5-inch, 2 5-inch, 3 5-mch and 4 5-inch mmimums shall be selected from manufacturers nominal 1-inch, 2-mch, 3-inch, 4-mch and 5-mch series, respectively Flexible hoses shall be used to connect the unit to fixed piping Lengths shall be six times the diameter up to a maximum of 36 inches Use Type I base under drive side Use Type C mountings under the cooler and condenser Attach directly without vibration isolation where located on slabs on grade Type III bases shall be sized to reduce the maximum dynamic movement of the system to ± I/16-inch single amplitude (or 1/8-inch double amplitude Minimum static deflection or loading for Type F mounts shall be as recommended by equipment manufacturer Where deflections are not shown for blowers, select deflections from Blower Minimum Deflection Guide located at the bottom of the table When blowers are 60 HP or larger, select deflection requirements for next larger span A minimum of 2 5 inches shall be used unless larger deflections are called for on the Guide of these large fans are located on a slab on grade Maximum deflection shall not exceed 2 5 inches Type II base is required where equipment is located on elevated floors and minimum static deflection exceeds 0 75-inch hi lieu of Type B mount and Type III base, Type C mount may be substituted with Type II base required if minimum static deflection exceeds 0 75-inch Type III base preferred for fans operating at static pressures exceeding 4 inches and on roof tops Horizontal thrust restraints consisting of a spring element in series with a neoprene pad as described for Type 3 mountings and with the same deflection as specified for the mounting, shall be provided between the equipment and ductwork or structure on the centerhne of thrust symmetrically on each side of the unit The assembly shall include rods and angle brackets for attachment The spring element shall be contained within a steel frame so it can be preset for thrust at the factory and adjusted in the field to allow for a maximum of /4-mch movement Where fans operate at static pressures exceeding 4 inches, horizontal thrust restraints are required (see Note O) 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11021 -8 Where equipment is located on elevated floors and fans operate at static pressures exceeding 4 inches, use Type III base or had horizontal thrust restraints (see Note O) For eccentric cam-type vacuum pumps, centrifuges, and engine driven centrifuges or chillers, refer to detailed specifications for vibration isolation requirements Elastomer Snubber Materials Table Durometer" 40 ±5 50 ±5 60 ±5 Tensile strength, (min)b 2,000 psi 2,500 psi 2,500 psi Elongation at break, (min)b 450% 400% 350% Tests for Aging Oven Aging (70 h/212°F)c Hardness, (max) +15% +15% +15% Tensile strength (max) ± 15% ±15% ±15% Elongation at break (min)b -40% -40% -40% Ozone" 1 ppm in air by volume 20% strain 100°F No cracks No cracks No cracks Compression Sete 22 hours 158°F Method B 30% (max) 25% (max) 25% (max) a ASTM D676 bASTMD412 c ASTM D573 d ASTM Dl 149 e ASTM D395 ** END OF SECTION ** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11021 -9 SECTION 11060 ELECTRIC MOTORS PART 1—GENERAL 1.1 DESCRIPTION A. SCOPE: This section provides specifications for all electric motors furnished under this contract. B. TYPE: Motors specified herein are 3 phase, squirrel cage, 1/2 HP and above; or single phase types smaller than 1/2 HP. 1.2 QUALITY CONTROL A. PERFORMANCE AND DESIGN REQUIREMENTS: 1. GENERAL: The motors specified are, in general, premium quality motors and shall be suitable for continuous duty operation. 2. RATING: Each motor shall develop ample torque for its required service throughout its acceleration range at impressed voltages in the range between 10 percent above and below nameplate rating. In addition, all motors shall be selected to be non-overloading at all points along the driven machines' full speed characteristic curve. Motors with 1.15 service factor shall not be required to deliver more than its rated nameplate horsepower under the specified loading condition. 3. APPLICATION a. GENERAL: Motors supplied under this specification shall be suitable for continuous duty where ambient temperatures may range between 30 degrees F and 125 degrees F. Ambient relative humidities will range between 30 and 100 percent. Details regarding environmental conditions for specific applications will be found in the detailed specifications for the driven equipment. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11060- 1 b. ENCLOSURE TYPES: Enclosures shall be as defined by NEMA, and for the purpose of this specification shall be identified in the following manner Type Enclosure A Open dnp proof (ODP) B Totally enclosed fan cooled (TEFC) C Totally enclosed nonventilated (TENV) D Weather protected NEMA type H (WP-H) E Explosion-proof c. APPLICATION TYPES: Type I. Process motors n. Non-process motors Unless noted otherwise, all motors in these specifications shall be Type I (process motors). Type I motors shall be employed for the operation of all process-related equipment, equipment mounted below grade and all ventilation equipment serving process equipment areas. Unless otherwise specified, Type n (non-process) motors are those driving equipment with "built-in" or integral construction motors; and fractional horsepower motors below 1/2 HP. B. STANDARDS Motors shall be designed and built in accordance with the latest revisions of the following reference standards: 1. NEC; Environmental Operating Requirements. 2. ANSI Requirements for Numbering and Schematic Representation. 3. IEEE Standards for Electric Motors. 4. NEMA MG1 - latest revision. 5. NEMA 4; Requirements for Watertight Equipment. 6. NEMA 4X; Requirements for Outdoor Installations. 7. NEMA 7D; Requirements for Explosive Environments. 17074 CUY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11060-2 8 NEC Requirements for Hazardous Locations. 9. UL Requirements for Motors and Their Appurtenances. 10 UL Requirements for Explosive Environments. C. PERFORMANCE TESTS 1. GENERAL' Should any motor exhibit indication of questionable performance, the Construction Manager, at his discretion, may request information or load test at any time after delivery of a motor to the job site. If any motor proves to be defective, all costs of testing and repair or replacement of defective motor shall be borne by the Contractor If any motor proves to be in accordance with recommendations or manufacturer's tolerances, the cost of testing will be borne by the Owner. 2. INSULATION: Insulation resistance tests shall be performed by the Contractor. Tests for acceptability shall be made using a 1000 volt megohm meter (megger). Interpretations of test results for minimum acceptable values of insulation resistance will be made in accordance with IEEE publication 43. 3. LOAD TESTING: Load tests shall be performed to determine the motor's ability to meet service factor loading conditions within the temperature limits of the manufacturer's submittal data. Tests shall be conducted in accordance with IEEE publication 112A. In the event that a motor does not meet the load test requirements, the Contractor shall replace the motor at no cost to the Owner 13 SUBMITTAL DATA Submittals shall be in accordance with Section 2-5.3.3 of the General Provisions. The following material shall be submitted for each size and type of electric motor furnished under this contract: A. Descriptive bulletins, including full description of insulation system. B. Manufacturer's connection diagrams for motors furnished with over- temperature protectors, heaters, or other auxiliary devices. C. Sufficient data on over-temperature devices verify required protection D. Service factor. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11060-3 E Efficiency at 1/2, 3/4 and 4/4 nameplate horsepower. F. Power factor at 1/2, 3/4 and 4/4 nameplate horsepower. G. Temperature rise at service factor horsepower. PART 2—PRODUCTS 2 1 GENERAL Open drip proof motors shall have openings constructed so that falling liquids or solid particles staking or entenng the enclosure at any angle from 0 to 15 degrees from vertical will not interfere with the performance. Totally enclosed fan cooled and totally enclosed non-ventilated motors shall be provided with drilled and tapped holes to drain all cavities within the motor. Motors with frames 286T or smaller and with frame 324T or larger shall be provided with automatic breather-drain devices. Weather protected NEMA Type II (WP-H) motors shall be provided with screens to prevent objects larger than 1/2 inch from entenng the enclosure. If weather- protected NEMA Type II enclosures cannot be supplied for the required frame sizes, subtypes B or C motor enclosures may be substituted. Explosion-proof motors shall be UL listed for Class I, Division 1 Group D hazardous location and be provided with UL approved combination breather drains suitable for hazardous locations. Heaters shall be provided to prevent moisture condensation after shutdown on all motors 50 HP and above and for all other motors where specified. Heaters shall be cartridge type or flexible wrap-around type installed adjacent to core iron. Heaters shall be rated 120 volts, single phase, and rating in watts and volts shall be noted on motor nameplate or on a second nameplate. The space heater terminals shall be brought to a separate terminal in the box. The motor manufacturer's nameplates shall be engraved or stamped on stainless steel and fastened to the motor frame with No. 4 or larger oval head stainless steel screws or drive pins. Nameplates shall indicate clearly all the items of information enumerated in NEMA Standards MG1-10.37, MG1-10.38, or MG1-20.60, as applicable The nameplate shall be positioned to be readily visible for inspection in the complete machine. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11060-4 2.2 THREE PHASE MOTORS -1/2 THROUGH 250 HORSEPOWER A. GENERAL All motors 1/2 HP through 250 HP shall be 3 phase, squirrel cage, induction motors on NEMA frame 143T or larger. Type A motors shall be open dnp proof motors with modification to obtain premium quality motors. Types B, C, and D motors shall be of the type generally designated by Westmghouse as "Mill and Chemical;" by Reliance as "Model XT;" or equal. Conductors shall be copper. B. RATING: Motors shall be designed and connected for 460 volt, 3 phase, 60 Hz operation. Dual voltage (230/460) rated motors are acceptable if all leads are brought out to the motor terminal box. All motors shall have a 1.15 continuous duty service factor at 50 degrees C ambient temperature, unless noted otherwise. Starting kVA/HP shall not exceed the values given in NEMA Standard MG1-12.34. The motors shall be suitable for operation in either direction (clockwise or counterclockwise) of rotation. C. INSULATION: Insulation systems shall be NEMA Class F, non-hygroscopic, and shall be suitable for use in moisture laden atmospheres and atmospheres containing acid or alkali vapor. Insulation systems shall be manufacturer's premium grade, capable of withstanding contaminated atmospheres. D. CURRENT BALANCE: Motor current unbalance on polyphase motors shall not exceed the values tabulated below when motor is operating at any load within its service factor rating and is supplied by a balanced voltage system: Under 5 horsepower 25 percent 5 horsepower and above 10 percent If, however, the unbalanced currents cause mechanical vibrations, the Contractor shall correct the problem even if the measured unbalanced is less than listed above. E. OVERTEMPERATURE PROTECTION: Winding over-temperature devices shall be provided for all motors rated 50 horsepower and larger, for all Type E (explosion-proof) motors, and for all other motors where specified. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11060-5 Over-temperature devices shall provide a normally closed contact suitable for wiring into the motor control circuit. Any relays or solid state contacts which are required shall be provided in an enclosure on or near the motor. These enclosures shall be NEMA 12 for Type A motors, NEMA 4 for Type B, C, or D motors, NEMA 7D for Type E, and NEMA 4X for Type F motors. F. ENCLOSURES: All motors shall have cast iron housing, bearing brackets, fan guard and conduit box. Open drip proof and totally-enclosed motors shall be furnished with silicon rubber gaskets at the base of the conduit box and between the halves of the motor terminal box. All motors shall be provided with a pad with a drilled and tapped hole, not less than 1/4 inch diameter, inside the conduit box for a motor frame grounding stud. Motors weighing more than 50 pounds shall be equipped with two lifting eyes. All hardware shall be corrosion-resistant. Motors shall be delivered with the manufacturer's standard epoxy enamel finish. G. BEARINGS: Three-phase motor bearings shall be conservatively designed to withstand all stresses of the service specified. Antifriction motor 11003-6 bearings shall be designed to be regreasible and initially shall be filled with grease suitable for ambient temperatures to 50 degrees C. If a higher ambient temperature is specified for motor insulation rating purposes, bearings shall be sized and designed for the same ambient. Bearing identification by AFBMA number shall be indicated on the motor nameplate. 2.3 SINGLE-PHASE MOTORS A. GENERAL: Unless otherwise specified, single-phase motors shall be capacitor-start induction motors. Small single-phase fan motors may be split-phase or shaded-pole type, if such is standard for the equipment. Universal (AC-DC) type single-phase motors are not acceptable unless their specific characteristics are necessary for the application. Conductors shall be copper. Single-phase motors shall be designed and connected for operation on a 115 volt, 60 Hz alternating current electrical system, or 208 volt where indicated. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11060-6 B. RATING: Unless otherwise specified, single-phase motors shall not be required to deliver more than its rated nameplate horsepower under any condition of required loading. Type IB and HE single-phase motors shall be continuous- time rated in conformity with NEMA Standard MG1-10.35. Single-phase motor locked rotor current shall not be greater than that specified in NEMA Standard MG1-12.32, Design "N." C. ENCLOSURES: Unless otherwise specified, single-phase motors shall be Type IB or HE. Small single-phase fan motors may have open-type enclosures if they are suitably protected from moisture, dripping water and lint buildup. D. INSULATION: Unless otherwise specified, single-phase motor insulation systems shall be as recommended by the motor manufacturer. E. CONSTRUCTION: Unless otherwise specified, single-phase motor construction shall be as recommended by the motor manufacturer. F. BEARINGS: Unless otherwise specified, single-phase motors shall be provided with sealed ball bearings lubricated for 10 years normal use. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11060-7 SECTION 11295 HYDRAULIC-PNEUMATIC POWER AND ACTUATOR CONTROL SYSTEM PART 1 - GENERAL 1.1 WORK OF THIS SECTION A. The WORK of this Section includes providing packaged hydraulic power system complete with reservoir, hydraulic pump, motor, accumulator, hydraulic solenoid positioning and fail-safe valves, flow control and isolation valves, piping, fittings, filters, pressure gages, wiring, and control panel for a complete installation to operate the hydraulic actuators. B. The control system shall include pneumatic solenoid positioning and flow control valves to operate three back up pneumatic valve actuators. The system shall include lockout valve, air pressure regulator, filter and gauge and all necessary piping and fittings. Pneumatic control system shall be supplied integrated in the same hydraulic control system panel. System control shall allow for local and remote switch over from hydraulic to pneumatic valve control. C. The WORK requires that one manufacturer accepts responsibility for furnishing the WORK as indicated but without altering or modifying the Contractor's responsibilities under the Contract Documents. D. The WORK also includes coordination of design, assembly, testing and installation. 1.2 RELATED SECTIONS A. The WORK of the following Sections applies to the WORK of this Section. Other Sections of the Specifications, not referenced below, shall also apply to the extent required for proper performance of this WORK. 1. Section 11000 General Requirements for Equipment 2. Section 11004 Equipment Control Devices 3. Section 15100 Valves and Actuators 1.3 SPECIFICATIONS AND STANDARDS A. Except as otherwise indicated, the current editions of the following apply to the WORK of this Section: CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11295-1 ASME Boiler and Pressure Section VIII, Pressure Vessels Vessel Code 2.ASME B31.1 3. JICH-1 4.ASTMA105 Power Piping Hydraulic Standards for Industrial Equipment and General Purpose Machine Tools Specification for Forgings, Carbon Steel, for Piping Components 1.4 SUBMITTALS Submittals shall be in accordance with Section 2-5.3 of the General Provisions. A The following shall be submitted in: 1. Piping, wiring and control schematics and diagrams. 2. Calculations demonstrating that the equipment will satisfy the indicated requirements. 3. Control panel arrangement drawing. 4. Information on installations by MANUFACTURER Include contact name, address and telephone number. 1 5 SERVICES OF MANUFACTURER A. Inspection, Startup, and Field Adjustment: An authorized representative of the manufacturer shall visit the site and witness the following- 1. Installation of the equipment for not less than 2 days. 2. Inspection, checking, and adjusting the equipment for not less than 1 day. 3. Startup and field-testing for proper operation for not less than 1 day. A. Instruction of OWNER'S Personnel: The authorized service representative shall visit the site for not less than 2 days to instruct the OWNER'S personnel in the operation and maintenance of the equipment including step-by-step troubleshooting procedures with necessary test equipment. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11295-2 1.6 QUALIFICATIONS A. Manufacturer: Company specializing in packaged hydraulic power systems with minimum five installations of comparable size and complexity constructed during the last 5 years. B. Installer: Authorized installer of manufacturer with minimum 5 years' experience. PART 2 -- EXECUTION 2.1 GENERAL This system will control three underwater eighteen-inch quarter turn butterfly valves. As shown on the contract drawings and as described in the valve and actuator specification. To ensure proper coordination of all interfacing details, the hydraulic and pneumatic operating system shall be manufactured at a single location. Virginia Valve, Rodney Hunt Company or equal shall manufacture the hydraulic-pneumatic power unit system. The valves will have both hydraulic and pneumatic actuators with controls designed so that any of the three valves can be operated in either mode. Pneumatic operation will require a pressurized air supply and electrical power. An air receiver tank integral to the system will supply air to the control unit. The hydraulic power unit will include a motor, pump, and reservoir system that will store energy for fail-safe and additional valve operations in a nitrogen-pressurized accumulator. Hydraulic operation will be fail-safe resulting in valve closure if electrical power is lost. A. GENERAL PARAMETERS 1. Three 18-inch quarter turn butterfly valves and actuators. 2. Valves are 20 feet underwater 3. Distance from control unit to valves is approximately 450 feet 4. Control enclosure to be NEMA 12 padlock and located indoors 5. Operating time (open or close) to be 1 to l'/2 minutes, no valve throttling required. Operation to be closed or fully open. 6. Underwater limit switches (by others) on each valve to provide contact closures to indicate valve fully open and valve fully closed. 7. Valves may be operated from the control enclosure or from remote contact inputs from an automated SCADA system. 8. Control unit is not installed in a hazardous area 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11295-3 9. Design ambient temperatures at the hydraulic system shall be 45 to ( J 100 degrees Fahrenheit. ^ ^ 10. The CONTRACTOR shall provide hydraulic fluid, accumulator prechargmg nitrogen gas, interconnecting wiring and piping between the hydraulic and pneumatic control system and the hydraulic and pneumatic actuator mounted on the valves. 2.2 HYDRAULIC PARAMETERS Actuators (by others) to be double acting with a volume of 50 cubic inches. The system shall be a nominal 1,500-psi self-contained, pressurized hydraulic fluid system capable of operating the valves at the specified speeds against the specified operating head requirements. In addition, the hydraulic fluid system shall be designed to automatically, and immediately close the valves upon a loss of main electrical power or other specified emergency condition. Actuators operating pressure to be 1500 psi Hydraulic system operating pressure to be a maximum of 200 psi limited by a pump bypass relief valve Pressure reducing valve will reduce pressure from system pressure to 1500 psi Accumulators to operate all valves for three full cycles (six strokes) with system pressure between 2400 and 1500 psi Hydraulic pump to start at 2400 psi and stop at 2900 psi, controlled by pressure switches Reservoir float switch to stop pump when the oil level is too low Pressure switch to provide alarm if pressure drops below 1500 psi The system shall be designed to use a premium grade, FDA approved, hydraulic fluid. Permanently installed lifting eyes shall be provided to facilitate the handling of the unit. Additionally, it shall be constructed so as to allow lifting by fork truck. All openings in hydraulic equipment shall be sealed prior to shipment. All field connections points shall be clearly labeled. Hydraulic control for each valve will include a solenoid valve for normal open- stop-close operation Hydraulic control for each valve will include a solenoid valve for fail-safe closure 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11295-4 Hydraulic control for each valve will include solenoid valves and a mini-reservoir to allow pneumatic control Hydraulic control for each valve will have speed controls to independently adjust open and closing rates Unit to be tested and operated with food-grade, vegetable-based, high- performance hydraulic oil 2.3 PNEUMATIC PARAMETERS Actuators (by others) to be double-acting with a volume of 507 cubic inches (332 cubic inches on the rod end) Actuator operating pressure to be 90 to 100 psi Electrical power will be required for pneumatic operation of the valves The system shall be provided with pneumatic accumulator to operate the pneumatic actuators. The accumulator shall be sized based on 45-psi differential pressure and 9,000 cubic-inch of displaced volume. The accumulator shall be base mounted, epoxy coated, vertical and maximum 4-feet tall. Accumulator shall be rated for 250 psi, with %-inch drain and %-mch supply pipe. An adjustable pressure relief valve shall be provided. Air to the 400-gallon receiver tank will be supplied by dual reciprocating compressors alternating on starts. Pneumatic control for each valve will include a solenoid valve for normal open- close operation Pneumatic control will not allow valves to stop in intermediate position Pneumatic control for each valve will include a solenoid valve to allow hydraulic control Pneumatic control for each valve will have speed controls to independently adjust open and closing rates 2.4 ELECTRICAL CONTROL PARAMETERS Power input to the control unit will be 230V, 3 phase, 60 hertz Control power will be 115V, single phase, 60 hertz Unit will include a 230/115 step-down control transformer 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11295-5 Unit will include a transfer relay to switch the controls to a back-up power supply when normal control power is lost No controls will be on the exterior of the main enclosure Unit will have a small NEMA 12 enclosure within the mam enclosure with all local controls. Each valve will have a Remote-Local selector switch The Local position on the Local-Remote selector switches for all valves will not be operative unless a secure interlock (by others) is closed Unit will have LED indicating lights and remote alarms as contact closures for Pump E-Stop, Low Oil Pressure, Motor Overload Trip, and Low Oil Level Unit will have LED indicating lights and contact closures for remote signals to indicate valve position Unit will have Manual-Off-Auto selector switch for pump control E-Stop pushbutton will stop pump motor, but will not stop valve operation Pump motor will be started and stopped by pressure switches when in the pump Manual-Off-Auto selector switch is in the Auto position Pump will be started and stopped by a manual control Off-On selector switch when the pump Manual-Off-Auto selector switch is in the Manual position When valve Remote-Local selector switch is in Remote, valve control mode and position will be determined by an automatic system via contact closure. 2.5 HYDRAULIC POWER SYSTEM TUBING AND FITTINGS: A. Seamless or welded hydraulic steel tubing shall be used for all tubing and fittings located on the hydraulic power unit. B. Line Sizes: 1. The pipe size and wall thickness shall be selected to have a minimum safety factor of 6:1 based on the maximum working pressure of the line. 2. Suction piping shall be selected such that the fluid velocity does not exceed 4 feet per second. 3. Return line piping shall be selected such that the fluid velocity does not exceed 15 feet per second. j 7074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11295-6 4. Pressure line piping shall be selected such that the fluid velocity does not exceed 20 feet per second. C. All fittings shall be of the type most appropriate for the tubing and the application. 1. All hydraulic tube fittings shall be JIC 37 degree flare type. 2. All pressure hose ends shall be female 37 degree and permanently cnmped to the hose. 3. All rigid black iron piping shall utilize threaded NPTF (Dry seal) connections. Black iron pipe shall only be used on suction and return lines. D. Fittings shall be Parker, or equal. 2.6 INTERCONNECTING PIPING A. Rigid Seamless stainless steel hydraulic piping shall be installed between the hydraulic power unit, the hydraulic valves and accumulator. This shall be provided by the valve control system supplier. Interconnecting hydraulic lines between the control valves and actuators shall be flexible metal hose, provided and installed by the Contractor. Rigid and flexible lines shall be of a minimum size as recommended by the valve manufacturer. All Hydraulic lines shall be rated with a minimum burst pressure of 6 times the maximum working pressure of the line. B. All hydraulic shall have abrasion resistant external cover. Internal reinforcement for hydraulic hoses shall be of high-tensile stainless steel. External abrasion resistant cover shall be non-metal material, synthetic rubber, woven nylon or approved equal. Temperature range shall be between -40 °F to 185 °F. The hoses shall be rated for constant working pressure of 3000 PSI and minimum burst pressure of 12,000 PSI. Hydraulic hose shall be provided in minimum of 100 feet lengths. Hose ends and fittings shall be male 37 degree and stainless steel cnmped. C. Pneumatic hose shall have polymeric core tube, fiber reinforcement and abrasion resistant urethane external cover. Hose shall be resistant to oil mist. Temperature range shall be between —40 °F to 212 °F. The hoses shall be rated for constant working pressure of 1250 PSI and minimum burst pressure of 5000 PSI. Hydraulic hose shall be provided in minimum of 100 feet lengths. Hose ends and fittings shall be male 37 degree and stainless steel crimped. D. Hydraulic and pneumatic hoses shall be Parker or approved equal. ] 7074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11295-7 2.7 HYDRAULIC RESERVOIRS A The reservoir shall be designed and constructed to minimize entry of foreign matter including water. B. Reservoir Size: 1. Minimum reservoir size shall be 1.25 times the total return oil volume. 2. The reservoir shall be designed for adequate heat dissipation. 3. The reservoir shall be large enough to provide an adequate mounting surface for the hydraulic system components. 4. Ample and accessible provisions shall be made for complete cleaning of the reservoir. C. Reservoir Features: 1. The fluid level shall be visible in the sight gage throughout the normal operating cycle. 2. The reservoir shall be fabricated of steel. 3. A combination breather and filler assembly shall be supplied. 4. There shall be a baffle provided between the intake and return lines to facilitate the separation of air and foreign matter from the hydraulic fluid. 5. The reservoir shall be provided with a tank drain. 6. If required, an immersion heater shall be installed in the reservoir sized to maintain the oil at a temperature, which will ensure protection of the pumps from starvation, and to allow for proper operation of the system under the Performance Specifications. 2.8 PUMPS AND MOTORS A. The pump and motor shall be sized to provide capacity of not less than 1.5 times combined flow rate of all connected cylinders as specified at the design speed and pressure. Pumps shall be capable of recharging all system accumulators within 15 minutes after power restoration. The pumps shall be positive displacement, variable axial piston type. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11295 - 8 B. The motor(s) shall be totally enclosed fan cooled. C. Flexible couplings shall be used between the pump and motor. D. Pump and motor shall be provided with the following features: 1. Each pump shall be provided with a Hand/Off/Auto selector switch, a red Fail indicating light, and a green Running indicating light mounted on the control panel. 2. If pump fails to establish pressurized flow within an adjustable time period, a pump failure will be assumed and indicated at the appropriate light. The pump will be automatically shut down and prevented from operating until the condition is cleared by pressing a "Pumping Reset" pushbutton mounted on the control panel. E. The direction of rotation of each pump shall be clearly indicated on the pump. F. Pump shall be Parker or approved equal. G. Motor shall be Baldor or approved equal. 2.9 ACCUMULATOR A. Accumulator shall be sized to provide sufficient volume and pressure to operate three times each of three butterfly valves at the specified design conditions through a complete opening and closing cycle without the operation of the pumps. B. All accumulator oil bottles shall be of the piston type construction. Bladder accumulators shall not be used. C. All accumulators shall be built in accordance with the requirements for pressure vessels in ASME Section VIII. Accumulators shall be rated for 1,500-psi working pressure. D. Means shall be provided for safely relieving accumulator gas and liquid pressure. E. Each accumulator shall be provided with individual shut-off valves at both gas and liquid ends. F. The precharge fluid shall be nitrogen gas. The CONTRACTOR shall provide all necessary dry nitrogen. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11295-9 G. There shall be a means of measuring precharge gas pressure. H. There shall be a means of automatically determining when there is a loss of precharge pressure. This condition shall be reported as an alarm. I. Accumulators shall be mounted in a package skid for floor mounting with suitable means for handling. J. Where accumulators are isolated from the main system, they should be provided with a separate pressure switch to maintain proper operating pressure. K. A charging assembly with gauge and valvmg shall be provided for connecting the gas side of the accumulators to standard brass gas bottle fittings during start-up. L. Accumulators shall be Hanna, Parker or approved equal. 2.10 ELECTRICAL CONTROLS A. All power unit electrically activated devices shall be factory wired to a NEMA 4 rated panel. 1. Electrical controls shall include all necessary disconnect switches, motor starters and circuit breakers plus control power transformer to provide a complete system requiring only a single input power connection. 2. The 120 VAC grounded single phase control voltage shall be transformed from the primary input power source. The transformer primary shall have both leads fused. The secondary of the transformer shall be wired to a single pole circuit breaker rated at 10 amps on the ungrounded leg. 3. A panel mounted disconnect switch shall be provided. 4. Each motor circuit shall be protected with a properly sized adjustable magnetically tripped three pole motor circuit protector. 5. Each motor shall be controlled by a 3-phase motor starter with overload relay NEMA rated for the nameplate HP and voltage of the motor being operated. B. All necessary electrical controls, operating devices, and monitoring devices required on the HPS shall be wired to the electrical control enclosure mounted on the HPS. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11295-10 C. Lights and Switches: 1. All indicating lights, pushbuttons and other devices shall be of the heavy-duty, full-size, oil tight type. 2 Each indicating light and pushbutton shall have its own lamicoid plastic legend plate. 3. All switches and lights shall be GE or approved equal. D. Internal Wiring: 1. Terminal blocks shall be track mounted, tubular screw type with pressure plate. Terminal blocks shall be marked with the same identification as the wire terminated there. 2. All wiring shall be identified with wiring markers with alphanumeric characters. The identification of each wire shall be the same as that shown on the electrical schematic. Each wire shall be so identified at each end. 3. All field connections shall be wired to a terminal strip in the electrical enclosure. These connections shall be labeled and shall correspond to the electrical schematic diagram. 4. Tp provide a ready source of power for test equipment, a ground fault protected 120 VAC duplex outlet powered by the control circuit shall be provided within the control panel mounted on the hydraulic power unit (HPS). 2.11 TESTING, PAINTING, SPARE PARTS A. Testing: 1. A detailed shop test procedure shall be submitted for approval during the initial submittal process. 2. The hydraulic power unit and electrical controls shall be assembled and fully tested at the valve manufacturer's facility to verify proper mechanical, electrical and control design and coordination. 3. A completed, dated and signed copy of the detailed test procedure shall be shipped with each piece of equipment for verification of start-up settings. 17074 Cmr OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11295-11 B. Painting: 1. The power unit shall be thoroughly cleaned to remove all traces of oil and grease prior to painting. 2. The paint shall be Amerlock 400 medium grey, or equal. Apply two coats of 5 mils minimum dry film thick (mdft) each, according to the manufacturer's recommendations. C. Spare Parts: 1. The following parts are the parts that shall be provided with the hydraulic power unit. These spare parts shall be provided at the same time as the hydraulic power unit. a. All spare parts shall be clearly tagged and labelled. Two spare filter elements/canisters for each type of filter. Two spare lamps shall be provided for each type and size of indicating light. One spare, complete directional valve of each type and size shall be provided. 2.12 MANUFACTURERS A. Hydraulic power system shall be manufactured by the following or approved equal: 1. Virginia Valves 2. Rodney Hunt Company PART 3 - EXECUTION 3.1 INSTALLATION A. Hydraulic power systems and equipment shall be installed in accordance with the manufacturer's written instructions. 3.2 CLEANING A. Before installation, all piping components must be shipped to a pickling plant to undergo the following cleaning process. Remove all extraneous materials, remove all oils or grease in an alkaline bath, rinse with water, coat all vulnerable surfaces of valves, flanges, etc., acid-pickle, dry, and inspect piping before closing cleaned pipes. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11295-12 B. After installation, the piping shall be thoroughly inspected and cleaned, to remove all foreign material, including mill scale, dirt, rust, oil, grease, weld spatter, and cutting chips. Cleaning may be accomplished by hot oil flush or other approved method. All cleaning shall be done in strict accordance with the manufacturer's written instructions. 3.3 FIELD TESTING A. After installation, the hydraulic power system and piping shall be hydrauhcally tested to 150 percent of the maximum working pressure. The reservoir shall be tested for leakage by hot oil or other approved method, prior to painting. Operational tests shall be performed on all equipment and devices to demonstrate their proper function. Adjustable devices shall be checked for range of adjustment and given final adjustment. ** END OF SECTION ** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11295-13 SECTION 11435 INTAKE SCREENS AND AIR BACKWASH ASSEMBLY PART 1--GENERAL 1.1 DESCRIPTION A. SCOPE: This section specifies intake screens and automatic screen back wash assembly. The general requirements applicable to all mechanical equipment, as specified in Section 11000-1.01 A., are applicable to the equipment specified in this section. B. TYPE: The intake screen shall be of all-welded continuous slot construction to provide a maximum open area as specified here in. The intake assembly shall include an internal flow modifier to provide a low head loss uniform flow field over the entire screen surface. The backwash assembly shall include but not limited to, air compressor, receiver unit, air dryer, pneumatically actuated ball valve and associated hoses and piping. Compressor shall be of the two-stage, air-cooled, belt- dnven reciprocating, alternating type, assembled in a self-contained unit consisting of the compressors, motors, V-belt drives, and regulators, all skid mounted. Suitable piping between compressor, control, and receiver shall be provided. The air dryer shall cool, dry and remove oil aerosols from the compressed air. C. EQUIPMENT LIST: Item Equipment No. Intake Screens CP 001 Air Compressor CP 001 Air dryer AD 001 Ball Valve BV 001-003 17074 crnr OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11435-1 D. DESIGN REQUIREMENTS: The air-cooled compressor and accessories shall be designed and selected for continuous duty operation and shall deliver air which at all times meets operating requirements listed in paragraph 1.01 E. of this section. E. OPERATING REQUIREMENTS AND CHARACTERISTICS. The package unit shall meet the following requirements: CP001 Capacity, gpm 14.3 Through slot velocity, fps 0.4 Differential Hydrostatic Collapse Pressure, psi 6.94 CP001 Inlet pressure, psig 14.3 Maximum working pressure, psig 250 Discharge pressure, psig 175 Maximum rated motor, horsepower 5 AD 001 Rated capacity, scfm 50 Operating pressure, psig 175 Inlet air temperature, degrees F 50 1.2 QUALITY ASSURANCE A. REFERENCES: This paragraph references the following documents. They are a part of this section as specified and modified. In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Reference Title ASME Heat Exchanger Code B. UNIT RESPONSIBILITY: The Screen Manufacturer shall provide the entire package unit complete x-~x with air backwash system and control panel. \ J CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11435-2 C. VIBRATION AND CRITICAL SPEED LIMITATIONS: The equipments shall conform to the requirements specified in Section 11021 1 3 ENVIRONMENTAL CONDITIONS The air backwash assembly including the compressor, air dryer, receiver tanks, pneumatically controlled ball valves will be installed indoors in the operations building as indicated on the drawings. Temperatures are expected to range between 60 and 100 degrees F. 14 SUBMITTALS Submittals shall be m accordance with Section 2-5 3 of the General Provisions. The following submittals shall be provided : PART 1 - DRAWINGS SHOWING EQUIPMENT LAYOUT, SCREEN DIAMETER, LENGTH, OUTLET AND AIR BACKWASH CONNECTIONS, MATERIAL OF CONSTRUCTION. PART 2- CERTIFICATE OF UNIT RESPONSIBILITY ASSIGNMENT ATTESTING THAT THE CONTRACTOR HAS ASSIGNED UNIT RESPONSIBILITY IN ACCORDANCE WITH THE REQUIREMENTS OF THIS SECTION AND PARAGRAPH 11000- 1.02C. NO OTHER SUBMITTAL MATERIAL WILL BE REVIEWED UNTIL THE CERTFICATE HAS BEEN RECEIVED AND FOUND TO BE IN CONFORMANCE WITH THESE REQUIREMENTS. PART 3- MANUFACTURER AND MANUFACTURER'S TYPE DESIGNATION. PART 4- MANUFACTURER'S CATALOG DATA INCLUDING WEIGHT OF EACH COMPONENT. PART 5 - PREDICTED PERFORMANCE CURVES DEVELOPED FOR THE SPECIFIC APPLICATION, INCLUDING SPEED, CAPACITY, PRESSURE, POWER AND EFFICIENCY AS APPLICABLE. PART 6 - MOTOR DATA FORM 11060-A PER SECTION 11060. PART 7- CONTROL PANEL LAYOUT, FRONT ELEVATION AND SCHEMATIC WIRING DIAGRAM. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11435-3 PART 2--PRODUCTS 2 1 ACCEPTABLE PRODUCTS Intake screens shall be Johnson Screens type T-24 and S-36 or approved equal Air compressor shall be Quincy, Ingersoll Rand or equal, modified as necessary to provide the specified features and to meet specified operating requirements. Air dryer shall be Hankison HIT50 or approved equal. 2.2 MATERIALS Materials of components shall be as follows: Component Material Intake Screens Air Back wash pipe Piston rings Cylinders and counterweights Low pressure piston High pressure piston and heads Crankshaft Connecting rods Frame, mtercooler, and manifolds Baseplates Gaskets Valves Intercooler piping 2 3 EQUIPMENT FEATURES A. INTAKE SCREENS: Type 316 stainless steel Chlorobutyl tubing Steel Cast iron, ASTM, Class 30B Aluminum alloy, AISI S-132 Cast iron or cast aluminum Forged Steel Forged Steel Cast iron, ASTM A48, Class 20A Fabncated steel Asbestos Type 316 stainless steel Copper Intake screens shall be two 24-inch Tee screens and one 36-inch Drum screens as shown on construction drawings. The intake screen shall be manufactured of 316 SST material The mam outlet flange shall mate with an 18-inch flange with a flange pattern equal to AWWA C-207, Table 1, Class D. The intake assembly screen surface wire shall be Johnson Vee-Wire #63 or approved equal The surface wire, support beam and stiffener structure shall be an all welded matrix designed to provide the specified strength with minimal interference with the through screen flow pattern. End plates and tee body shall be a minimum 0.15-inch thick. All structural butt welds shall be full penetration; structural fillet weld size shall be the thickness of the thinner component. The average through slot velocity shall be 90% or more of the maximum velocity. At this flow rate the CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11435-4 o pressure drip through the clean screen surface shall not exceed 0.1 psi. Pressure drop through the entire intake assembly shall be in the range of 0.75 to 1.0 foot of water at the rated flow. B. BACKWASH ASSEMBLY: The backwash assembly shall clean the screen at a regular automatic interval using water displaced by compressed air. The components that make up a complete system are receiver tank, compressor, air dryer and automatic valves. Each component is specified as under: 1. COMPRESSOR: a. GENERAL: The compressor shall be either V-configuration or vertical two-stage type, with deep-ribbed construction for efficient heat dissipation. Valves shall be readily accessible. Connecting rods shall be of forged steel with babbit-lined crankpin bearings. The crankshaft shall be a balanced, single steel forging. Crankshaft bearings shall be Class M3, (50,000 hr) designed for the radial and thrust loads imposed by the operating conditions specified. Lubrication shall be splash or pressure type. The interstage cooler shall be finned and of copper multitube construction. The interstage cooler shall have a pressure relief valve and an automatic condensate drain valve. Compressors shall automatically unload during shutdown. An ASME relief valve, set at 110 percent of the compressor's rated discharge pressure and sized for not less than the unit's maximum capacity, shall be provided on the compressor discharge. The crankcase shall be provided with a low oil level switch. The discharge of the compressor shall be provided with an adjustable high temperature discharge switch. The oil level and discharge temperature switches shall be SPDT rated 5 amps at 120 volts for use with the circuit shown on the electrical drawings. Vibration isolation shall be provided as specified in Section 11002, Equipment Mounting. Inlet air shall be filtered with medium efficiency filter. b. DRIVE UNIT: The compressor shall be driven by a 1,750-rpm, 3-phase, 480-volt, Type 2 energy-efficient motor in accordance with Section 11060, Electric Motors. c. BASE: The compressor and dnve unit shall be mounted on a common base rigidly mounted on the receiver. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11435-5 2. RECEIVER: The vertical receiver shall have a rated pressure of 200 psig and shall have a capacity of 240 gallons. Tank shall meet the requirements for Section VIII, Division 1 or Division 2 of the ASME Boiler Code. The tank shall bear an ASME inspector's stamp, complete with design working pressure and date and place of manufacture. Pressure relief valves delivered under this specification shall bear the ASME stamp. The receiver shall be delivered with threaded or flanged bosses for inlet, outlet, relief valve and connection of control pressure sensors, pressure gage, and receiver drain. 3. SEPARATOR: The moisture separator shall be of the centrifugal impingement type selected for airflows specified herein. Moisture separator shall be Wnght-Austin, Adams, Basco, or equal. The trap size shall be as recommended by the separator manufacturer and shall be the automatic, float-actuated type. 4. INTAKE FILTER-SILENCER: Each compressor shall be equipped with an oil bath type inlet air filter and inlet silencer. The filter element shall be of the cleanable type. Each filter-silencer shall be provided with threaded or flanged connections and mounting brackets suitable for proper installation. Interior surfaces shall receive a rust-inhibitive coating and exterior surface shall be prime coated. Each filter-silencer shall be sized so that the back pressure produced will not adversely affect performance of the compressor to which it is connected. Minimum noise reduction by octave frequency band shall be as follows: Octave band, Hz Attenuation, decibels 63 14 125 19 250 25 500 22 1,000 21 2,000 18 4,000 17 8,000 17 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11435 - 6 5. AIR DRYER: Air dryers shall be Hankinson HIT 50 , Wilkerson or equal. The compressor for each air dryer shall be driven by a 115-volt, single- phase, 60-hertz motor. Air dryer shall be supplied with flexible plug and cord connection. Motors shall be 1-1/4 horsepower, maximum, and shall comply with the requirements of specification Section 11060. Air dryers shall be equipped with the following accessories: 1. Refrigerant flow control valves. 2. Refrigerant compressor overload switch. 3. Refrigerant filter dryer. 4. High evaporator temperature light. 5. Air-cooled condenser. 6. Automatic drain solenoid valve. 6. BALL CHECK VALVE: Non-clog ball check valves shall be Flygt HDL Type 2016, Golden Anderson Figure 240, or approved equal, modified to meet specified requirements. Valve body and cover shall be ductile iron. Flange drilling shall be according to ANSI B16.1, Class 125. The valve ball shall be hollow steel with an exterior of nitnle rubber. Valve shall be "fusion bonded" epoxy lined and Coated Minimum 12-mil dry film thickness except where limited by valve operating tolerances. The valves will be pneumatically operated. The pneumatic actuator shall be mounted directly on the ball check valve and shall be included within the packaged unit. 7. AIR BLOW LINE: Air blow line for backwash shall be 3-inch diameter. The length of the air line form the screen to the compressor is 450-feet. Pipe material for the exposed air blow line from the air compressor within the operations building shall be 316 SST tubing. The buried air blow line shall be high-pressure brewery discharge hose. Hose material shall be white chlorobutyl with multiple plies of polyester yarn reinforcement. The hose shall have protective abrasion resistance outer covering. The temperature rating for the hose shall be -40° F to 225° F and working pressure rating shall be 350 psi. Hose material shall confirm FDA requirements. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11435 - 7 C. CONTROLS: The system shall be provided with a local control panel. Provide a main disconnect switch with the handle accessible from outside the control panel door. The control panel shall have a NEMA4X nonmetalhc enclosure. The control panel shall include the motor starter for the compressor The control panel shall have a light for each alarm switch on the front of the panel door. The compressor shall be provided with a run time meter. Provide a HAND-OFF-AUTO switch with a spring return to "OFF" from the "HAND" position on the panel door. Each compressor shall be supplied with low oil level switch, discharge air high temperature switch. Control devices shall conform to Section 11004 of these specifications and shall be housed in NEMA 4 enclosures. Low oil level switch and discharge air high temperature switch shall be manual reset type. Three pressure switches shall be supplied with the receiver. Provide a dry contact for a low pressure alarm for remote alarm indication. Pressure gage shall be provided. The compressor shall monitor the high and low pressure switches. When the selector switch is in the "AUTO" position, the compressor shall run when the low-pressure switch is actuated. The compressor shall shut off when the high pressure switch is actuated. In the hand position, the compressor shall run until the high pressure switch is actuated. The compressor shall shut off when the high discharge temperature or the low oil switches are actuated The control system shall automatically start and stop the compressor to maintain pressure in the receiver between 150 and 175 psig. The control shall not load the compressor until it has reached full speed. In addition , the control panel should indicate backwash cycle initiation, system pressure, automatic valve ON-OFF, valve open, fail, close. 2.4 PRODUCT DATA The following information shall be provided: 1. Operation and maintenance information 2. Catalog cut sheets for control devices (pressure switch, temperature switch, level switch, pressure gage). 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11435-8 2.5 SPARE PARTS The following standby components shall be furnished for the compressor: 1 - complete set of crankshaft oil seals 1 - complete set of compressor bearings 1 - complete set of gaskets 1 - set of piston rings 1 - set of valve fingers, plates, and springs 2 - filter pads PART 3--EXECUTION 3.1 INSTALLATION Equipment shall be provided and tested as recommended by the equipment manufacturer. In addition, equipment shall be installed and tested under the direction of installers who have been trained by the equipment manufacturer. These requirements, however, shall not be construed as relieving the Contractor of his overall responsibility for this portion of the work. 3.2 FIELD INSPECTION AND TESTING Inspection, testing and certification shall be provided, and testing procedures and forms shall be submitted. 3.3 TRAINING A minimum of 4 hours of training, scheduled at least 3 days in advance with the Owner, shall be provided by a qualified manufacturer's representative. 3.4 PAINTING Equipment shall be shop pnmed prior to shipment from the factory with a primer compatible with the field finish coating as specified in Section 09900, Coating Systems. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 11435 - 9 SECTION 15042 HYDROSTATIC TESTING OF PRESSURE PIPELINES PART 1—GENERAL 1.1 DESCRIPTION These specifications designate the requirements for field pressure and leakage testing of all pressure piping. The Contractor shall furnish all labor, materials (including water), tools, and equipment necessary to provide and complete field testing as specified. All pipelines shall be tested for water tightness by subjecting each section to Hydrostatic Pressure and Leakage Tests m accordance with the applicable requirements of AWWA C 600 except as modified herein. PART 2—MATERIALS 2.1 TEST BULKHEADS Design and fabricate test bulkheads per Section VIII of the ASME Boiler and Pressure Vessel Code. Materials shall comply with Part UCS of said code. Design pressure shall be at least 2.0 times the specified test pressure for the section of pipe containing the bulkhead. Limit stresses to 70% of yield strength of the bulkhead material at the bulkhead design pressure. Include air-release and water drainage connections. 2.2 MANUAL AIR-RELEASE VALVES Provide temporary manual air-release valves for pipeline test. Construct the pipe outlet in the same manner as for a permanent air valve and after use, seal with a blind flange, pipe cap, or plug and coat equal to the adjacent pipe. PART 3—EXECUTION 3.1 TESTING AND DISINFECTION SEQUENCE A. Perform required chlonnation subsequent to hydrostatic testing, except when pipeline being tested is connected to a potable waterlme. B. The test shall be conducted with valves open, and the open ends of pipes, valves, and fittings suitably closed. Valves shall be operated and checked during to the test period. No leakage shall be allowed when testing across any valves. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15042 - 1 3.2 LENGTH OF TEST SECTION The maximum length of pipe to be included in any one test shall be no more than 2500 feet or the distance between valves, whichever is greater. The Contractor shall provide suitable test bulkheads, blocking, and fittings to permit such sectionahzmg. 3.3 INITIAL PIPELINE FILLING Maximum rate of filling shall not cause water velocity in pipeline to exceed 1 fps. Filling may be facilitated by removing automatic air valves and releasing air manually. 3.4 PRESSURE AND DURATION OF TEST A. Pressure piping shall be tested at 200 psi. B. When the system is pumped to the required test pressure, the pump shall be disconnected and maintain the test pressure for a four hour duration. C. Temporary or permanent thrust blocks shall be cast-m-place as required prior to tests, and the Contractor shall provide all necessary braces, plugs, thrust blocks, caps, flanges, and other materials to permit proper conduct of the pressure testing. Concrete blocks shall be cast not less than 5 days before the test. All concrete anchor blocks shall be allowed to cure a sufficient time to develop a minimum strength of 2,000 psi before testing. 3.5 ALLOWABLE LEAKAGE No leakage allowed. 3.6 REPETITION OF TEST If the actual leakage exceeds the allowable, locate and correct the faulty work and repeat the test. Restore the work and all damage resulting from the leak and its repair. All visible leakage shall be eliminated. 3.7 BULKHEAD AND TEST FACILITY REMOVAL After a satisfactory test, drain the water, remove test bulkheads and other test facilities, and restore the pipe coatings. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15042 - 2 SECTION 15065 HIGH DENSITY POLYETHYLENE PIPE PART1-GENERAL 1.1 DESCRIPTION A. SCOPE This section specifies high-density polyethylene (HDPE) pipe, fittings, and appurtenances for piping 4-mches to 63-mches in nominal diameter. B. CHARACTERISTICS' The piping system shall conform with the following: Dimension ratio (DR) 11 1.2 QUALITY ASSURANCE A. REFERENCES: This section references the following documents. They are a part of this section as specified and modified. In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail References Title ANSI/AWWA C906-90 Polyethylene (PE) Pressure Pipe and Fittings, 4-inch through 63-inch, for Water Distribution ASTMD2321-89 Underground Installation of Thermoplastic Pipe for Sewers and Other Gravity-Flow Applications ASTM D2657-90 Heat Joining Polyolefin Pipe and Fittings ASTM D3350-84 Polyethylene Plastics Pipe and Fittings Material PPITR 31 -88 Underground Installation of Polyolefin Piping CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15065-1 B INSPECTION AND TESTING: All HDPE materials, pipe and fittings shall be inspected and tested in accordance with the requirements of AWWA C906. C AFFIDAVIT OF COMPLIANCE- The manufacturer shall furnish an affidavit of compliance conforming to the requirements of AWWA C906, Section 1 5, affirming that the piping components comply with the requirements of AWWA C906 and this section. The affidavit shall be signed under penalty of perjury by an officer of the pipe manufacturer's company 1 3 SUBMITTALS Submittals shall be in accordance with Section 2-5 3.3 of the General Provisions. The following submittals shall be provided: 1. Detail drawings, which show the type and location of all fittings, joints, and connections to structures. 2 A copy of this specification section, with addendum updates included, and all referenced and applicable sections, with addendum updates included, with each paragraph check-marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. If deviations from the specifications are indicated and, therefore requested by the Contractor, the submittal shall be accompanied by a detailed, written justification for each deviation. Failure to include a copy of the marked-up specification sections, along with justification for any requested deviations to the specification requirements, with the submittal shall be cause for rejection of the entire submittal with no further consideration. PART 2-PRODUCTS 2.1 GENERAL HDPE materials, pipe and fittings shall be manufactured, inspected, sampled and tested in accordance with the requirements of AWWA C906 and this section In case of conflict between the requirements of this section and AWWA C906, the requirements of this section shall prevail. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15065-2 2.2 MATERIALS HDPE piping components shall be manufactured from materials that meet or exceed the requirements of the Plastic Piping Institute designation PE3408 and that conform to the requirements of ASTM D3350 for a cell classification of PE 345434C. Bolts and nuts for buried mechanical joining components such as flanges shall be made of non corrosive, high-strength, low-alloy steel having the characteristics specified in ANSI/AWWA Cl 11/A21, regardless of any protective coating. 2.3 PIPE Pipe shall have the nominal dimensions shown with an IPS outside diameter basis and the dimensions and tolerances specified in AWWA C906. DR rating and shall be as specified in paragraph 15065-1.01 B. Pipe shall be rated for operating pressure of 150 psi. 2.4 FITTINGS Fittings shall conform to the applicable requirements of AWWA C906 for the joining methods specified in paragraph 15065-3.02 B. 2.5 PIPE MARKINGS Pipe marking shall conform to the requirements of AWWA C906. 2.6 PRODUCT DATA The following product data shall be provided: 1. Affidavit of Compliance specified in paragraph 15065-1.02 C. 2. A report containing a copy of all manufacturer's test results for all tests conducted in accordance with paragraph 15065-1.02 B. PART 3--EXECUTION 3.1 PIPE HANDLING AND STORAGE The Contractor shall use care in handling and storage of the pipe. Pipe shall be stored on clean, level ground to prevent undue scratching or gouging of the pipe. If the pipe must be stacked for storage, such stacking shall be done in accordance with the pipe manufacturer's recommendations. The handling of the pipe shall be done in such a manner that it is not damaged by dragging over sharp objects or cut by chokers or lifting equipment. 17074 CITY OF CARLSBAD LAKE CALA VERA REMEDIAL IMPROVEMENTS - JULY 2006 15065-3 Sections of pipe with cuts, gouges, or scratches on the outside diameter (OD) surface that exceed 10-percent of the wall thickness of the pipe shall be removed completely and the ends of the pipeline rejoined. The inside diameter (ID) surface shall be free of cuts, gouges, and/or scratches. 3.2 INSTALLATION A. GENERAL: Unless otherwise specified, the piping system shall be installed in accordance with ASTM D2321, AWWA C906 and the manufacturer's recommendations. B. JOINING: Pipe and fittings shall be joined into continuous lengths on the job site above ground. Unless otherwise specified, joining shall by the butt-fusion method performed in accordance with the pipe manufacturer's recommendations and ASTM D2657. Socket fusion, extrusion welding and hot gas welding shall not be used. The pipe supplier shall be consulted to obtain machinery and expertise for the joining by butt-fusion of HDPE pipe and fittings. No pipe or fittings shall be joined by fusion by any of the Contractor's personnel unless they are adequately trained and qualified in the techniques involved. Butt fusion joining shall yield a joint strength equal to or greater than the tensile strength of the pipe. Flanged joining, or other mechanical joining methods specified, may be used to make connections to differing piping materials, to equipment, valves and other appurtenances, and where specified. C. TRENCH EXCAVATION: Trenches shall be excavated to ensure that sides will be stable under all working conditions. Trench walls or supports shall comply with all local and national standards for safety. 3.3 TESTING A. GENERAL: Testing of piping shall be as specified in Section 15050 and this section. In case of conflict, the requirements of this section shall prevail. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15065-4 B. HYDROSTATIC PRESSURE TESTING: HDPE piping systems shall be fully pressure tested prior to covering the piping and placing the line into service. Water shall be the test medium for hydrostatically testing the pipe. Test procedures shall be as specified in Section 15042, Hydrostatic Testing of Pressure Pipelines, and the following procedure. In case of conflict, the following procedures shall apply. Cover the pipe at intervals and/or at curves if necessary to hold the pipe in place during testing. Connections shall be left exposed for visual leak inspection. After all free air is removed from the test section, the pressure in the pipe shall be raised at a steady rate to the required pressure. The pressure in the section shall be measured at the lowest point of the test section. Test pressure shall be as specified in Section 15042, Hydrostatic Testing of Pressure Pipelines. The initial pressure shall be applied and allowed to stand without makeup pressure for 2-3 hours to allow for diametric expansion or pipe stretching to stabilize. After the equilibrium period, the test section shall be returned to the required test pressure and held for 3 hours. Amounts of makeup water allowable for expansion during the pressure test shall be as listed in the Plastic Pipe Institute Technical Report TR 31-88. No visual leaks or pressure drops shall be observed during the final test period. C. DEFLECTION TESTING: 1. GENERAL: Deflection testing shall be performed on the entire length of installed pipe no sooner than 30 days after completion of work adjacent to and over the pipeline, including leakage tests, backfilling, placement of fill, grading, paving, concreting, and any other superimposed loads. Deflection of pipe and fittings in the installed pipeline under external loads shall not exceed the maximum deflection of 15%. Either of the following devices and procedures may be used to measure deflection. 2. PULL-THROUGH DEFLECTION TESTING: The Contractor shall determine whether the allowable deflection has been exceeded by use of a pull-through device. a. PULL-THROUGH DEVICE: This device shall be a spherical, spheroidal, or elliptical ball, a cylinder, or circular sections fused to a common shaft. Circular sections shall be so spaced on the shaft that distance from external faces of front and back sections will equal or 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15065-5 exceed diameter of the circular section. Pull-through device may also be of a design promulgated by the Uni- Bell Plastic Pipe Association, provided that the device meets the applicable requirements specified in this paragraph, including those for diameter of the device. Ball, cylinder, or circular sections shall conform to the following: (1) A diameter, or minor diameter as applicable, equal to the average inside diameter of the pipe minus the dimension equivalent of the maximum installed deflection specified in paragraph 15065-1.01 B. A tolerance of plus 0.5 percent in the diameter of the test device will be permitted. (2) A homogeneous material throughout, with a density greater than 1.0 as related to water at 39.2 degrees F, and a surface Bnnell hardness of not less than 150. (3) Center bored and through bolted with a 1/4-inch minimum diameter steel shaft having a yield strength of not less than 70,000 pounds per square inch, with eyes or loops at each end for attaching pulling cables. (4) Each eye or loop shall be suitably backed with a flange or heavy washer such that a pull exerted on opposite end of shaft will produce compression throughout remote end. b. PULL-THROUGH DEVICE PROCEDURE: Pass the pull-through device through each run of pipe, either by pulling it through or flushing it through with water. If the device fails to pass freely through a pipe run, replace pipe which has the excessive deflection and completely retest in same manner and under same conditions as specified. 3. DEFLECTION DEVICE: The Contractor shall determine whether the allowable deflection has been exceeded by use of a deflection measuring device. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15065-6 a. DEFLECTION MEASURING DEVICE: This device shall be sensitive to 1.0 percent of the diameter of the pipe being tested and accurate to 1.0 percent of the indicated dimension. The deflection measuring device shall be approved by the Construction Manager prior to use. b. DEFLECTION MEASURING DEVICE PROCEDURE: Measure deflections through each run of installed pipe. If deflection readings in excess of the maximum allowable specified in paragraph 15065-1.02 B are obtained, retest pipe by a run from the opposite direction. If retest continues to show a deflection in excess of the allowable, remove pipe which has excessive deflection, replace with new pipe, and completely retest in the same manner and under the same conditions. **END OF SECTION** i 1014 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15065 - 7 SECTION 15067 STAINLESS STEEL PIPES AND FITTINGS PART 1--GENERAL 1.1 DESCRIPTION A. SCOPE- This section specifies stainless steel pipe and fittings. B. TYPES OF SERVICE: Stainless steel piping specified in this section shall be used for inlet/outlet pipe applications as shown on construction drawings. 1.2 QUALITY ASSURANCE A. REFERENCES: This section contains references to the following documents. They are a part of this section as specified and modified. In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Reference Title ANSI B16.1-89 Cast Iron Pipe Flanges and Flanged Fittings Classes 25, 125, 250, and 800 ANSI B16.11.80 Forged Steel Fittings, Socket Welding and Threaded. ANSI B31.1 -89 Power Piping ANSI B36.19M-85 Stainless Steel Pipe ASME Section IX (1989) Boiler and Pressure Vessel Code; Welding and Brazing Qualifications ASTM A182/A182M-90 Forged or Rolled Alloy-Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15067 - 1 ASTM A193/A193M-90 ASTMA194/A194M-88 Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service Carbon and Alloy Steel Nuts for Bolts for High Pressure and High-Temperature Service ASTM A240-90 Heat-Resisting Chromium and Chromium Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels ASTM A276-90 ASTMA312/A312M-89 ASTM A320/A320M-88 ASTM A403/A403M-90 ASTM A409/A409M-89 Stainless and Heat-Resistmg Steel Bars and Shapes Seamless and Welded Austenitic Stainless Steel Pipes Alloy Steel Bolting Materials for Low- Temperature Service Wrought Austenitic Stainless Steel Piping Fittings Welded Large Diameter Austenitic Steel Pipe for Corrosive or High Temperature Service ASTM A480/A480M-90 ASTM A774/A774M-90 ASTM A778-90 General Requirements for Flat-Rolled Stainless and Heat-Resistmg Steel Plate, Sheet and Strip As-Welded Wrought Austenitic Stainless Steel Fittings for General Corrosive Service at Low and Moderate Temperatures Welded, Unannealed Austenitic Stainless Steel Tubular Products B. QUALIFICATIONS: All shop fabricated stainless steel pipe and fittings shall be furnished by a single manufacturer who is experienced and qualified in the manufacture and fabrication of the items to be furnished. The pipe and fittings shall be shop-fabricated and field-installed m accordance with common industry wide practices and methods and shall comply with these specifications. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15067 - 2 Only weld procedures which have been qualified under ASME Section IX and only welders who have successfully completed performance qualification tests per ASME Section DC on these qualified procedures shall be utilized. C. TESTING: Factory testing shall conform to the requirements of ASTM A312, ASTM A409 HT-0, or ASTM A778, depending on the size and type of stainless steel pipe provided in accordance with conditions and directions in Section 01300, Submittals, of this document. 1.3 SUBMITTALS The following information shall be provided: A. Shop fabrication drawings showing details of materials, piping, fittings, couplings, dielectric connections, joint locations and details, types and locations of supports. B. Other data necessary to show conformance of the complete piping system to these specifications. C. A copy of this specification section with addenda updates, and all referenced sections with addenda updates, with each paragraph check marked to show specification compliance or marked to show deviations. PART 2--PRODUCTS 2.1 PIPE A. Unless otherwise specified, stainless steel piping 3 inches and larger shall be manufactured from ASTM A240 annealed and pickled sheets and plates, Type 316, in accordance with ASTM A778 or ASTM A409 HT-0. Only extra-low carbon (ELC) materials with .03 percent maximum carbon shall be used. Pipe shall be manufactured to nominal pipe sizes as listed in ANSI B36.19, Table 2: Nominal pipe Schedule size, inches gage/plate 8 10 24 10 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15067 - 3 2.2 FITTINGS Unless otherwise specified, stainless steel fittings, 3-inch and larger, shall be butt- welded type manufactured m accordance with ASTM A774 of the same material and in the same thickness as the pipe. Long radius elbows up to 24 inches in diameter shall be smooth flow. All short radius, special radius, and reducing elbows and long radius elbows greater than 24 inches in diameter shall be of mitered construction. Reducers shall be straight tapered, cone type. Tees, crosses, laterals, and wyes shall be shop-fabricated from pipe. 2.3 JOINTS Stainless steel pipe fabricated into spool pieces shall have shop-welded circumferential butt-weld joints or flanges. Unless otherwise specified, flanged joints shall be Van Stone joints made up of stainless steel slip-on type rolled- angle face rings and ductile iron back-up flanges drilled to ANSI 16.1, Class 125 standard. The angle face ring thickness shall be at a minimum of 2 gages thicker than the wall of the pipe or fitting to which it is welded, and it shall be continuously welded on both sides to the pipe or fitting. The angle leg shall not interfere with the flange boltholes. For submerged joints, back-up flanges shall be stainless steel plate flanges. 2.4 COUPLINGS A. GENERAL: Fabricated stainless steel piping shall be shop-prepared for pipe couplings where specified. Unless otherwise specified, couplings shall be arched- band or grooved type. B. SLEEVE TYPE: Unless otherwise specified, sleeve-type mechanical pipe couplings shall be Rockwell Type 411, Dresser Style 38, or equal, with the stop removed from the middle ring. Reducing couplings shall be Rockwell Type 415, Dresser Style 62, or equal. Sleeve-type flanged coupling adapters shall be Rockwell Type 913, Dresser Style 128, or equal. Insulating couplings shall be Rockwell Type 416, Dresser Style 39, or equal. Bolts and nuts for submerged service shall be made of Type 316 stainless steel in conformance with ASTM F593F and ASTM F594F. Bolts and nuts for buned service shall be made of non-corrosive high-strength, low- alloy steel having the characteristics specified in ANSI/AWWA Cl 11/A21, regardless of any other protective coating. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15067 - 4 Pipe shall be plain-end with external weld beads ground smooth to ensure proper gasket seating. For pressure pipelines, sleeve coupling joints shall be restrained by the use of harness rods connecting across the joint to flange lugs on adjacent flange joints. Where no adjacent flange joints exist, stainless steel harness lugs shall be welded to the pipe to receive the harness rods. C. ARCHED-BAND TYPE: Arched-band type couplings shall be stainless steel of the same material and wall thickness as the pipe and shall be Depend-O-Lok type as manufactured by Brico or equal. Couplings shall be Fixed—F x F, Expansion—E x E, or Fixed by Expansion—F x E as specified or as required. The pipe shall be plain-end with external weld beads ground smooth and with S.S. restraining rings shop-welded to the piping for fixed type couplings. D. GROOVED-END TYPE: Grooved end flexible-type couplings shall be Gustm-Bacon 100, Victaulic Style 77, or equal. Grooved end rigid-type couplings shall be Gustin- Bacon 120 Rigi-Gnp, Victaulic Style 07 Zero-Flex, or equal. Flexible- type couplings shall be used for all piping greater than 12 inches in diameter; for pipe 12 inches in diameter and less in rack-mounted tunnel piping applications, and for grooved joints adjacent to pump or blower suction and discharge where grooved couplings are used for noise and vibration control. All other applications for piping 12 inches in diameter and less shall utilize rigid-type couplings. Grooved end flanged coupling adapters shall be either Gustm-Bacon 154, Victaulic Style 741, or equal. Snap-joint grooved end couplings shall be Gustin-Bacon 115, Victaulic Style 78, or equal. Cut grooves are not permitted on fabricated or hghtwall pipe. Unless otherwise specified, bolts and nuts shall comply with AWWA C606. Bolts and nuts for submerged service shall be Type 316 stainless steel in conformance with ASTM F593F and ASTM F594F. Bolts and nuts for buried service shall be made of noncorrosive high-strength, low- alloy steel having the characteristics specified in ANSI/AWWA Cl 11/A21, regardless of any other protective coating. Submerged couplings shall be the same material as the pipe. The pipe ends shall be roll-grooved to the coupling manufacturer's specifications. Where roll grooving is impractical, the pipe shall have heavy-wall machine-grooved pipe nipples or machined ring collars fully welded to the pipe or fitting. Nipples shall be taper-bored to the I.D. of the adjoining pipe to allow full-weld penetration. Collars shall be welded on both sides to the piping. Nipples and collars shall be of the same alloy as the piping. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15067 - 5 E. EXPANSION TYPE: Spool type expansion joints shall be of the resilient arch type and shall be standard or tapered as specified. Spool type expansion joints shall be constructed of multiple plies of woven fabric impregnated with elastomer and reinforced with steel rings or wire embedded in the body. Standard arch type expansion joints suitable for the specified temperature and pressure shall be provided with retaining rings or backup nngs. Retaining rings shall be 3/8-inch thick steel, split, either galvanized or zinc shield coated. Expansion joints shall be Mason Style EJBN, Garlock Style 204, Mercer Style 500, Goodall Style E-1462, General Style 1025, or equal. High pressure couplings suitable for 240 degree F operating temperatures shall be Mason Style EJBN-HD, Mercer Style 510, Garlock Style 204-HP, Goodall Style E- 1489, General Style 1015, or equal. Pipe flanges shall be provided for these couplings. 2.5 THREADED CONNECTIONS Threaded pipe, gage, or instrument connections shall be made using stainless steel, 150-pound, threaded half-couplings conforming to ASTM A182 or ASTM A276, shop welded to the pipe at the locations specified. 2.6 GASKETS Gaskets shall be as follows: 1. EPDM: ethylene-propylene-diene-terpolymer. 2. Neoprene: neoprene. 3. Nitrile: nitrile (Buna N). 4. Compressed gasketing consisting of organic fibers (Kevlar) and neoprene binder; ASTM F104 (F712400), 2500 psi (ASTM F152), 0.2 ML/HR LEAKAGE FUEL A (ASTM F37). 5. Compressed gasketing consisting of organic fibers (Kevlar) and SBR binder; ASTM F104 (F712400), 2500 PSI (ASTM F152), 0.1 ml/hr leakage Fuel A (ASTM F37). 6. Gylon gasketing, Garlock Style 3500, 2000 psi (ASTM F152), 0.22 ml/hr Fuel A (ASTM F37). 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15067 - 6 7. Gylon gasketmg, Oarlock Style 3510, 2000 psi (ASTM F152), 0.04 ml/hr Fuel A (ASTM F37). 8. Gylon gasketmg, Garlock Style 3504, 2000 psi (ASTM F152), 0.12 ml/hr Fuel A (ASTM F37). 9. TFE: noncreepmg tetrafluoroethylene (TFE) with insert filler. 10. TFE bonded EPDM: TFE bonded to EPDM in full-face gasket having concentric-convex molded rings. For air lines, gaskets shall be neoprene or EPDM suitable for use at temperatures to 240 degrees F. 2.7 BOLTS Bolts, nuts, and washers for stainless steel flange assemblies and stainless steel couplings shall be the same material, conforming to ASTM A320 for low- temperature service and ASTM A193 and ASTM A194 for high-temperature service. Bolts, nuts and washers for other couplings shall be as specified in referenced paragraphs for the couplings. 2.8 PIPE SUPPORT SYSTEMS Unless otherwise specified, all hangers, rods, structural attachments, and other components of support systems for stainless steel pipe shall be of the same materials as the pipe and conform to Section 15096, Pipe Hangers and Supports. 2.9 FINISH After all shop operations have been completed, pipe and fittings shall be pickled and passivated in manufacturer's plant, and scrubbed and washed until discoloration and possible iron picked up from manufacturing process are removed. The standard finish for 16-gage through 8-gage material shall be No. 1 or 2B per ASTM A480; 3/16-mch and heavier plate material shall be No. 1 mill finish or better per ASTM A480. 2.10 PRODUCT DATA The following information and data shall be provided. 1. Certifications specified in the following documents: ASTM A403, paragraph 14.1 ASTM A774, paragraph 14.1 ASTM A778, paragraph 14.1 ASTM A409, paragraph 17.1 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15067 - 7 2. Test results specified in paragraph 15067-1.02 C. 3. Names and qualification records of proposed welders. PART 3--EXECUTION 3.1 PIPE CUTTING, THREADING, AND JOINTING Pipe cutting, threading, and jointing shall conform to the requirements of ANSI B31.1. All pipe threads shall be lubricated with Teflon tape. 3.2 WELDING A. GENERAL: Piping with wall thickness up to 11-gage (0.120-inch) shall be welded with the TIG (GTAW) process. Unless otherwise specified, heavier walls shall be properly beveled and have a root pass with the TIG (GTAW) process followed by subsequent passes with the TIG (GTAW), MIG (GMAW), or Metallic Arc (SMAW) process. Filler wire of ELC grades only shall be added to all welds to provide a cross section at the weld equal to or greater than the parent metal. Weld deposit shall be smooth and evenly distributed and have a crown of no more than 1/16-inch on the ^^ I.D. and 3/32-inch on the O.D. of the piping. Concavity, undercut, cracks, ( J or crevices shall not be allowed. Butt welds shall have full penetration to the interior surface, and inert gas shielding shall be provided to the interior and exterior of the joint. Excessive weld deposits, slag, spatter, and projections shall be removed by grinding. Welds on gasket surfaces shall be ground smooth. B. FIELD WELDING: Field welding shall be minimized to the greatest extent possible by use of couplings and prefabrication of pipe systems at the factory. Pipe butt welds may be performed at the job site, providing the but welds are performed only with an inert gas shielded process and that other applicable specified welding requirements are rigidly adhered to. All residue, oxide, and heat stain is to be removed from any type of field weld and the affected areas adjacent by the use of stainless steel wire brushes, followed by cleaning with an agent such as Eutectic Company's "Eucleen" or equal, followed by complete removal of the agent. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15067 - 8 C. PREPARATION OF SURFACES TO BE WELDED: Surfaces of joints to be welded shall be free from mill scale, slag, grease, oil, paint, rust, and other foreign material. Joints to be welded shall be wire-brushed with stainless steel wire brushes and precisely fitted before welding. D. WEATHER CONDITIONS: Welding shall be done only when the surfaces are completely free of any moisture. Welding of the pipe shall not be done during periods of high winds or rain unless the areas being welded are properly shielded. E. TACK WELDS, CLIPS, AND OTHER ATTACHMENTS: Nicks, gouges, notches, and depressions in the base metal in the area of the joint shall be repaired before the joint weld is made. Tack welds, clips, and other attachments shall be removed and defects repaired, except where the tack welds occur within the weld area and these tack welds do not exceed the size of the completed weld. Cracked tack welds shall be removed. Areas to be repaired shall be ground to clean metal and then repaired by building up with weld metal. The repaired areas shall be ground smooth to form a plane surface with the base metal. F. DEFECTS AND REPAIRS: Welds with cracks, slag inclusions, porosity, undercutting, incomplete penetration, or which are otherwise deficient in quality or made contrary to any provisions of these specifications shall be removed by chipping or grinding throughout their depth to clean base metal. Calking or peemng of welds to correct defects shall not be done. Welds found deficient in dimension but not in quality shall be enlarged by additional welding after thoroughly cleaning the surface of previously deposited metal and the adjoining plate. Weld deposits, slag, weld spatter, and projections into the interior of the pipe shall be removed by grinding. 3.3 MARKING, SHIPPING, AND STORAGE All pipe, fittings, and fabrications shall be properly marked with type, gage, and heat number. All fabricated piping shall have openings plugged and flanges secured for storage and/or transport after fabrication. All fabricated piping shall be piece-marked with identifying numbers or codes which correspond to the contractor's layout and installation drawings. The marks will be located on the spools at opposite ends and 180 degrees apart. Pipe spools shall be loaded and blocked and lagged as necessary to ensure protection from damage during shipping. Stainless steel pipe and fittings shall be stored per manufacturer's 17074 CITY OF CARLSBAD LAKE GALA VERA REMEDIAL IMPROVEMENTS - JULY 2006 15067-9 recommendation. Dents, gouges, and scratches in stainless steel pipe and fittings are not acceptable and are reason for rejecting pipe and fittings. 3.4 FABRICATION/INSTALLATION REQUIREMENTS The piping supplier during manufacturing, fabricating and handling stages, and the contractor during handling and installation stages, shall use extreme care to avoid the contact of any ferrous materials with the stainless steel piping. All saws, drills, files, wire brushes, etc. shall be used for stainless steel piping only. Pipe storage and fabrication racks shall be nonferrous or stainless steel or rubber- lined. Nylon slings or straps shall be used for handling stainless steel piping. Contact with ferrous items may cause rusting of iron particles embedded in the piping walls. After installation, the contractor shall wash and rinse all foreign matter from the piping surface. All welded joints shall be treated with a pickling solution, brushed with stainless steel wire brushes and rinsed clean. If rusting of embedded iron occurs, the contractor shall pickle the affected surface with Oakite Deoxidizer SS or equal, scrub with stainless steel brushes, and rinse clean. 3.5 COATINGS After installation, the contractor shall paint all steel or iron flanges, couplings, and appurtenances in accordance with Section 09900, Coating Systems. Painting of the stainless steel pipe is not required. However, the contractor shall be ^-^ responsible for supplying and installing the stainless steel piping with a con- ( ) sistently clean surface. Identifying spool piece marks shall be removed with paint thinner or solvents and the entire stainless steel surface shall be washed with detergent and hot water and nnsed clean. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15067 - 10 SECTION 15096 PIPE HANGERS AND SUPPORTS PART 1--GENERAL 1.1 DESCRIPTION A. SCOPE- This section specifies hangers and supports for all piping systems. This section does not include pipe supports for fire sprinkler systems, pipe anchors, guides or seismic restraints. B. OPERATING CONDITIONS: The hangers and supports specified in this section are provided to resist pipe loads occurring primarily in the downward (gravity) direction. For the purpose of pipe hanger and support selection, this section establishes pipe support classifications based on the operating temperatures of the piping contents. Pipe support classifications are as follows: 1. Hot Systems A - 1. 120 degrees F to 450 degrees F A - 2. 451 degrees F to 750 degrees F A - 3. Over 750 degrees F 2. Ambient Systems B. 60 degrees F to 119 degrees F 3. Cold Systems C - 1. 33 degrees F to 59 degrees F C - 2. -20 degrees F to 32 degrees F C. HANGER AND SUPPORT SELECTION: The Contractor shall select pipe hangers and supports as specified in the project manual. Selections shall be based upon the pipe support classifications specified in this section, and any special requirements, which may be specified in the project manual. P074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15096 - 1 The Contractor shall review the piping layout in relation to the surrounding structure and adjacent piping and equipment before selecting the type of support to be used at each hanger point. Hangers and supports shall withstand all static and specified dynamic conditions of loading to which the piping and associated equipment may be subjected. As a minimum, consideration shall be given to the following conditions: 1. Weights of pipe, valves, fittings, insulating materials, suspended hanger components, and normal fluid contents. 2. Weight of hydrostatic test fluid or cleaning fluid if normal operating fluid contents are lighter. 3. Reaction forces due to the operation of safety or relief valves. 4. Wind, snow or ice loadings on outdoor piping. Hangers and supports shall be sized to fit the outside diameter of pipe, tubing, or, where specified, the outside diameter of insulation. Where negligible movement occurs at hanger locations, rod hangers shall be used for suspended lines, wherever practical. For piping supported from below, bases, brackets or structural cross members shall be used. Hangers for the suspension of size 2 1/2 inches and larger pipe and tubing shall be capable of vertical hanger component adjustment under load. The supporting systems shall provide for and control the free or intended movement of the piping including its movement in relation to that of connected equipment. Where there is horizontal movement at a suspended type hanger location, hanger components shall be selected to allow for swing. The vertical angle of the hanger rod shall not, at any time, exceed 4 degrees. There shall be no contact between a pipe and hanger or support component of dissimilar metals. Prevent contact between dissimilar metals when supporting copper tubing by use of copper-plated, rubber, plastic or vinyl coated, or stainless steel hanger and support components. Unless otherwise specified, existing pipes and supports shall not be used to support new piping. Unless otherwise specified, pipe support components shall not be attached to pressure vessels. Stock hanger and support components shall be used wherever practical. 17(174 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15096 - 2 1 2 REFERENCES This section contains references to the following documents. They are a part of this section as specified and modified, In case of a conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail. Reference Title AISC Manual of Steel American Institute of Steel Construction, Manual of Steel Construction, Allowable Stress Design - 9th Edition MSS SP-58-88 Pipe Hangers and Supports - Materials, Design and Manufacture MSS SP-69-83 Pipe Hangers and Supports - Selection and Application FEDSPEC Hangers and Supports, Pipe WW-H-171e-78 MFMA-1-84 Metal Framing Standards Publication 1.3 SHOP DRAWINGS AND SAMPLES A The following shall be submitted in compliance with Section 2-5.3 of the General Provisions: 1. Shop drawings showing dimensions and details of pipe hangers and supports 2. Manufacturer's product data. 3 Manufacturer's installation instructions. 4. Manufacturer's certification of compliance. PART 2-PRODUCTS 2.1 ACCEPTABLE PRODUCTS Standard pipe supports and components shall be manufactured by B-Line, Carpenter & Patterson, Kin-Line, Gnnnell, Michigan, Pipe Shields Incorporated, Superstrut, Unistrut, or equal. Pipe support components shall conform to the requirements of MSS SP-69 and FEDSPEC WW-H-171e. Pipe support materials shall conform to the requirements of MSS SP-58. Metal framing system CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15096-3 components shall conform to the metal framing manufacturers' Association Standard MFMA-1. 2.2 MATERIALS A. GENERAL: Unless otherwise specified, pipe hangers and supports, structural attachments, fittings and accessories shall be hot-dip or mechanically galvanized after fabrication Nuts, bolts and washers may be zinc-plated except for those subject to moisture or corrosive atmosphere shall be type 304 stainless steel. B. PIPE HANGERS AND SUPPORTS. 1. TYPE 1 - DOUBLE BOLT PIPE CLAMP: Pipe clamp shall be carbon steel, with configuration and components equivalent to MSS and FEDSPEC Type 3. a. Steel pipe (insulated) - shall be B-Lme B3144, Grmnell Fig. 295, or equal, with insulation shield. Insulation shield is optional for hot and ambient systems. b. Steel pipe (uninsulated) - shall be B-Lme B3144, Gnnnell Fig. 295, or equal. c. Copper pipe (insulated only) - shall be B-Lme B3144, Gnnnell Fig. 295, or equal, with insulation shield 2. TYPE 2 - FRAMING CHANNEL PIPE CLAMP: Pipe clamps shall be steel with galvanized finish and material thickness as listed below: a. Steel pipe (uninsulated) - Pipe size 3/8 inch and 1/2 inch shall be 16 gage; 3/4 inch through 11/4 inches shall be 14 gage; 11/2 inches through 3 inches shall be 12 gage; 3 1/2 inches through 5 inches shall be 11 gage; 6 and 8 inches shall be 10 gage; Michigan model 431, Powerstrut PS 1100, Umstrut P 1109 series, or equal. b. Steel pipe (insulated) - Pipe clamp shall be as described in paragraph 15096-2.02 B.6.a with insulation shield 3. TYPE 3 - U-BOLT: U-bolts shall be carbon steel with configuration equivalent to MSS and FEDSPEC Type 24. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15096-4 a. Steel pipe (uninsulated) - shall be Gnnnell Fig. 137, B-Line B3188, or equal. b. Steel pipe (insulated) - shall be Gnnnell Fig. 137, B-Lme B3188, or equal, with insulation shield. c. Plastic pipe - shall be Grinnell Fig. 137C, Michigan model 151, B-Lme B3188 C, or equal. 4. TYPE 4- PIPE STANCHION SADDLE: Saddles and yokes shall be carbon steel and comply with MSS Type 37 and FEDSPEC Type 38. a. Steel pipe (insulated) - shall be Carpenter & Patterson Fig. 125, B-Lme B3090, or equal, with insulation shield. b. Steel pipe (uninsulated) - shall be Carpenter & Patterson Fig. 125, B-Lme B3090, or equal. c. Plastic pipe - shall be Carpenter & Patterson Fig. 125, B- Lme B3090, or equal. 5. TYPE 5 - OFFSET PIPE CLAMP: Pipe clamp shall be carbon steel with configuration and components as specified and shall be of standard design manufactured by a pipe hanger component manufacturer. a. Steel pipe (insulated) - shall be B-Line B3148, Gnnnell Fig. 103, or equal, with insulation shield. b. Steel pipe (uninsulated) - shall be B-Line B3148, Gnnnell Fig. 103, or equal. c. Plastic pipe - shall be B-Line B3148, Gnnnell Fig. 103, or equal. Vertical pipe support applications shall be as specified above except that insulation shields shall not be used for insulated pipe. 6. TYPE 6- RISER CLAMP: Riser clamp shall be carbon steel with configuration and components equivalent to MSS and FEDSPEC TypeS. a. Steel pipe (insulated) - shall be B-Line B3373, Grinnell Fig. 261, or equal. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15096-5 b. Steel pipe (uninsulated) - shall be B-Lme B3373, Gnnnell Fig. 261, or equal. c. Plastic pipe - shall be B-Lme B3373, Gnnnell Fig. 261c, or equal. 7. TYPE 7 - FRAMING CHANNEL PIPE STRAP: Pipe strap shall be carbon steel, with configuration equivalent to MSS Type 26. a. Steel pipe (uninsulated) - shall be Superstrut No. C-708-U, Powerstrut PS 3126, Kin-Line No. 477, or equal. b. Steel pipe (insulated) - shall be Superstrut No. C-708-U, Powerstrut PS 3126, Kin-Line No. 477, or equal, with insulation shield. c. Plastic pipe - shall be Superstrut No. C-708-U, Powerstrut PS 3126, Kin-Line No. 477, or equal. C. RACK AND TRAPEZE SUPPORTS: 1. GENERAL: Unless otherwise specified, trapeze and pipe rack components shall have a minimum steel thickness of 12 gage, with a maximum deflection 1/240 of the span. 2. TYPE 20 - TRAPEZE PIPE SUPPORT: Trapeze pipe support cross members shall be framing channel as specified in paragraph 15096-2.02 E.5. Flat plate fittings shall be 1 5/8-inch square carbon steel of standard design manufactured by framing channel manufacturer, Unistrut P2471, B-Lme B202-2, or equal. 3. TYPE 21 - PIPE RACK SUPPORT: Post and cross members shall be framing channel as specified in paragraph 15096-2.02 E.5. Pipe rack fittings shall be carbon steel, of standard design manufactured by framing channel manufacturer. 90-degree fittings shall be gusseted Unistrut P2484, B-Lme B844, or equal. Post base fittings shall be as specified in paragraph 15096-2.02 D.5. D. STRUCTURAL ATTACHMENTS: 1. TYPE A - FRAMING CHANNEL POST BASE: Post bases shall be carbon steel, of standard design manufactured by framing channel manufacturer. Single channel: Unistrut P2072A, B-Line B280, or equal. Double channel: Unistrut P2073A, B-Line B281, or equal. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15096 - 6 2. TYPE B - WELDED STEEL BRACKET: Bracket shall be carbon steel and comply with MSS Type 32 and FEDSPEC Type 33 for medium welded bracket. Heavy welded bracket shall comply with MSS Type 33 and FEDSPEC Type 34. 3. TYPE C - DOUBLE CHANNEL BRACKET: Wall channel shall be single channel framing channel as specified in paragraph 15096-2.02 E.5. Cantilever bracket shall be a carbon steel double framing channel assembly, Unistrut P2542 through P2546, B-Line B297-12 through B297-36, or equal. 4. TYPE D - SINGLE CHANNEL BRACKET: Wall channel shall be single channel framing channel as specified in paragraph 15096-2.02 E.5. Cantilever bracket shall be a carbon steel single framing channel assembly, Unistrut P2231 through P2234, B-Line B198-6, B198-12, B196-18 andB196-24, or equal. 5. TYPE E - WALL MOUNTED CHANNEL: Wall channel shall be single channel framing channel as specified in paragraph 15096- 2.02 E.5. 6. TYPE F - PIPE STANCHION FLOOR ATTACHMENT: Baseplate shall be carbon steel with 1/2 inch minimum thickness. Anchor bolt holes shall be 1/16 inch larger than the anchor bolt diameter. The space between the baseplate and the floor shall be filled with nonshnnk grout. E. ACCESSORIES: 1. FRAMING CHANNEL: Framing channel shall be 1 5/8 inches square, roll formed, 12-gage carbon steel. Channel shall have a continuous slot along one side with in-turned clamping ridges. Single channel: Unistrut P1000, B-Line B22, or equal. Double channel: Unistrut P1001, B-Line B22A, or equal. Triple channel: Unistrut P1004A, B-Line B22X, or equal. PART 3--EXECUTION 3.1 HANGER AND SUPPORT LOCATIONS The Contractor shall locate hangers and supports as near as possible to concentrated loads such as valves, flanges, etc. Locate hangers, supports and accessories within the maximum span lengths specified in the project manual to support continuous pipeline runs unaffected by concentrated loads. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15096-7 At least one hanger or support shall be located within 2 feet from a pipe change in direction. The Contractor shall locate hangers and supports to ensure that connections to equipment, tanks, etc., are substantially free from loads transmitted by the piping. Where piping is connected to equipment, a valve, piping assembly, etc., that will require removal for maintenance, the piping shall be supported in such a manner that temporary supports shall not be necessary for this procedure. Pipe shall not have pockets formed in the span due to sagging of the pipe between supports caused by the weight of the pipe, medium in the pipe, insulation, valves and fittings. 3.2 INSTALLATION Hanger components shall not be used for purposes other than for which they were designed. They shall not be used for rigging and erection purposes. The Contractor shall install items to be embedded before concrete is poured. Fasten embedded items securely to prevent movement when concrete is poured. Embedded anchor bolts shall be used instead of concrete inserts for support installations in areas below water surface or normally subject to submerging. Hanger and support components in contact with plastic pipe shall be free of burrs and sharp edges. Finished floor beneath Type N structural attachments and framing channel post bases shall be roughed prior to grouting. Grout between base plate and floor shall be free of voids and foreign material. Base plates shall be cut and drilled to specified dimensions prior to welding stanchions or other attachments and prior to setting anchor bolts. Plastic or rubber end caps shall be provided at the exposed ends of all framing channels that are located up to 7 feet above the floor. 3.3 ADJUSTMENTS The Contractor shall adjust hangers and supports to obtain required pipe slope and elevation. Shims made of material that is compatible with the piping material may be used. Stanchions shall be adjusted prior to grouting their base plates. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15096 - 8 SECTION 15100 VALVES AND ACTUATORS PART 1—GENERAL 1.1 DESCRIPTION This section specifies valves and actuators required under this contract document. 1 2 RELATED SECTIONS Section 11295 Hydraulic-Pneumatic Power and Actuator Control System Section 15104 Butterfly Valves 1.3 REFERENCES This section contains reference to the following documents They are part of this section as specified and modified. In case of conflict between the requirements of this section and those on the listed documents, the requirements of this section shall prevail. Reference (Latest Edition) Title ANSI B16.1 Cast Iron Pipe Flanges and Flanged Fittings. ASTMA276 Standard Specification for Stainless and Heat- Resistmg Steel Bars and Shapes. ASTMB61 Standard Specification for Steam or Valve Bronze Castings ASTMB62 Standard Specification for Composition Bronze or Ounce Metal Castings. ASTMB98 Standard Specification for Copper-Silicon Alloy Rod, Bar, and Shapes. ASTMB127 Standard Specification for Nickel-Copper Alloy (UNS N04400) Plate, Sheet, and Strip. ASTMB164 Standard Specification for Nickel-Copper Alloy Rod, Bar, and Wire CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15100-1 Reference (Latest Edition) Title ASTMB194 ASTM B584 ASTM D429 ASTM D1784 AWWA C504 AWWAC511 AWWA C540 AWWA C550 Standard Specification for Copper-Beryllium Alloy Plate, Sheet, Strip, and Rolled Bar Standard Specification for Copper Alloy Sand Castings for General Applications. Test Methods for Rubber Property-Adhesion to Rigid Substrates Standard Specification for Rigid Poly(Vmyl Chloride) (PVC) Compounds and Chlorinated Poly (Vinyl Chloride) (CPVC) Compounds. Standard for Rubber-Seated Butterfly Valves. Required Pressure Backflow-Prevention Assembly Power-Actuating Devices for Valves and Sluice Gates. Protective Epoxy Interior Coatings for Valves and Hydrants. Grooved and Shouldered Joints. Underground Service Line Valves and Fittings. AWWA C606 AWWA C800 14 SUBMITTALS Submittals shall be m accordance with Section 2-5.3 3 of the General Provisions. A. Shop Drawings 1. Product data sheets for make and model. 2. Complete catalog information, descriptive literature, specifications, and identification of materials of construction. 3. Operation and maintenance manual. 4. Provide 5-year product warranty for continuous submerged operation. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15100-2 PART 2—PRODUCTS 2.1 GENERAL A. Valve to be suitable for intended service. Renewable parts not to be of a lower quality than specified. B. Size actuator to operate valve for the full range of pressures and velocities. C. Valve to open by turning counterclockwise. D. Factory mount operator and accessories. 2.2 MATERIALS A. Brass and bronze valve components and accessories that have surfaces in contact with water to be alloys containing less than 16 percent zinc and 2 percent aluminum. B. Approved alloys are of the following ASTM designations 1. B6 1, B62, B98 (Alloy UNS No. C65 I 00, C65500, or C66 I 00), B 139 (Alloy UNS No. C51000), B584 (Alloy UNS No. C90300 or C94700), B 164, B 194, and B 127. 2. Stainless steel Alloy 18-8 may be substituted for bronze. 2.3 FACTORY FINISHING A. Epoxy Lining and Coating 1. In accordance with AWWA C550 unless otherwise specified. 2. Either two-part liquid material or heat-activated (fusion) material except only heat-activated material if specified as "fusion" or "fusion bonded" epoxy. 3. Minimum 12-mil dry film thickness except where limited by valve operating tolerances. 2.4 VALVES A. Gate Valves 1. Type V405 Eccentric Valve 3 Inches through 12 Inches 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15100-3 a) Non-lubricated type rated 175 psig CWP, dnp-tight shutoff with pressure from either direction, cast iron body with flanged ends or grooved ends in accordance with AWWA C606 for rigid joints, mechanical joint ends for buried valve. Plug cast iron with round or rectangular port of no less than 80 percent of connecting pipe area and coated with Buna-N or Hycar, grit seal, seats Type 316 stainless steel or nickel, stem bearing self-lubncating stainless steel or reinforced Teflon, stem seal multiple V-nngs, U-cups, or O-nngs of mtnle rubber, grit seals on stem. b) Valve 3 through 4 inches with wrench lever manual operator. Valve 6 through 12 inches with totally enclosed, geared, manual operator with handwheel, or 2-mch nut. c) Manufacturers and Products 1) Keystone; Ballcentric 2) DeZunk; Series 100 3) Or equal 2.6 OPERATORS Hydraulic and pneumatic actuators shall be supplied by single manufacturer to ensure mounting plate and drive shaft compatibility. A. Hydraulic Actuator The hydraulic actuator shall be the primary actuator to control the butterfly valve operation. Actuator shall be double acting for underwater operation. The actuator shall be rated for an operating pressure of 1,500 pound-square-mch gage pressures (PSIG). Torque developed shall be more than or equal to 12,000 inch-pound at 1,500 PSIG. Hydraulic piston displacement shall be 50 cubic-inch in both directions. Hydraulic actuator shall be provided with "go" switches indicating end of rotation. The switch shall be rated for continuous submerged conditions. Hydraulic actuators shall be Dantorque, Parker, Automax or approved equal. The hydraulic actuator shall be mounted on the pneumatic actuator. Manufacturer shall coordinate with butterfly valve manufacturer for mounting plate details prior to shipping product at the project site. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15100-4 B. Pneumatic Actuator Pneumatic actuators shall be double acting rack and pinion type suitable for continuously submerged condition and corrosive environments. The actuator shall provide 500 cubic-inch of clockwise displacement and 350 cubic-inch of counter clockwise displacement. The actuator shall be capable of providing 12,000 inch-pound of torque. The actuator shall be rated for 150 PSIG. The pneumatic actuator is a back-up control system and shall be mounted directly on the butterfly valve. Pneumatic actuator manufacturer shall be Dantorque, Parker, Automax or approved equal. Actuator manufacturer to coordinate with valve and hydraulic actuator manufacturer for mounting plate details and drive shaft compatibility prior to shipping product to project site. PART 3—EXECUTION 3.1 INSTALLATION A. Flange Ends 1. Flanged valve bolt holes shall straddle vertical centerhne of pipe. 2. Clean flanged faces, insert gasket and bolts, and tighten nuts progressively and uniformly. B. Valve Orientation 1. Install operating stem vertical when valve is installed in horizontal runs of pipe having centerline elevations 4 feet 6 inches or less above finished floor, unless otherwise shown. 3.2 TESTS AND INSPECTION A. Valve may be either tested while testing pipelines, or as a separate step B. Test that valves open and close smoothly with operating pressure on one side and atmospheric pressure on the other, in both directions for two-way valve and applications. C. Count and record number of turns to open and close valve; account for any discrepancies with manufacturer's data. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15100-5 SECTION 15104 BUTTERFLY VALVES PART 1 -- GENERAL 1.1 WORK OF THIS SECTION A. The WORK of this Section includes providing butterfly valves and accessories. 1.2 RELATED SECTIONS A. The WORK of the following Section applies to the WORK of this Section. Other Sections of the Specifications, not referenced below, shall also apply to the extent required for proper performance of this WORK. 1 Section 11295 Hydraulic-Pneumatic Power and Actuator Control System 2. Section 15100 Valves and Actuators 1.3 SHOP DRAWINGS A. Shop drawings shall comply with the requirements of Sections 15100. 1.4 FACTORY TESTING A. Valves shall be tested in compliance with AWWA C 504 and Section 15100, Valves and Actuators. B. Proof-of-design tests reports shall be submitted in compliance with Section 15100, Valves and Actuators, and AWWA C504. 1.5 OWNER'S MANUAL A. The OWNER'S Manual shall be submitted in compliance with Section 15100, Valves and Actuators. PART 2 -- PRODUCTS 2.1 BUTTERFLY VALVES (AWWA) A. General: Butterfly valves shall conform to ANSI/AWWA C504 and shall be lug type, flanged, of the size and class indicated on contract drawings. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15104-1 Flanged valves shall have 150-lb flanges complying with ANSI B 16.5, or 250-lb where so indicated, and may be either short-bodied or long-bodied except as otherwise indicated. Valve seat shall be both self and pressure energized with an elastomenc core. The self-energizing member shall be isolated form the line media. Valves shall be retained top and bottom low friction bearings. Shaft shall be single or dual piece. Retainer rings must be recessed in the body so that the line gasket prevents any potential external leakage. Valves shall have internal stop to prevent disc over travel. Seating and unseating torque for the valves at 150 PSIG pipe pressure shall not exceed 7000 inch-pound. Valve body shall be rated for non- shock working pressure of 275 PSI with in the temperature range of 20 °F -100°F B. Material: Butterfly vales shall be 316 stainless steel. Valve Body shall be ASTM A182 Gr. F316 or A351 Gr. CF8M. Disc shall be ASTM A182 Gr. F316 or A351 Gr. CF8M. Shafts shall be ASTM A564 type 630 H 1150 or316SS. C. Actuator Mounting. Valve manufacturer shall supply actuator-mounting plate through taps, compatible with actuator body mounting threaded taps. Valve shaft size and geometry shall match actuator drive or adaptor shall be supplied. Contractor to ensure valve manufacturer coordinates mounting details with actuator manufacturer. D. Pneumatic and Hydraulic Operators: Operators shall comply with Section 15100, Valves and Actuators. 2.2 MANUFACTURERS A. Butterfly valves shall be manufactured by one of the following (or equal): Crane Company De Zunk Corporation Henry Pratt Company Gnnnell PART 3 -- EXECUTION 3.1 INSTALLATION A. Exposed butterfly valves shall be installed to permit removal of valve assembly without dismantling the valve or operator. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15104-2 B. Installation shall be in accordance with Section 15100, Valves and Actuators. ** END OF SECTION ** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15104-3 SECTION 15400 PLUMBING PART1-GENERAL 1 1 DESCRIPTION This section specifies drams, piping, appurtenances and general requirements for plumbing systems. 1 2 QUALITY ASSURANCE A. REFERENCES. This section contains references to the following document. It is a part of this section as specified and modified. In case of conflict between the requirements of this section and those of the listed document, the requirements of the listed document shall prevail. Reference Title UPC (1988) Uniform Plumbing Code 1.3 SHOP DRAWINGS AND SAMPLES A The following shall be submitted in compliance with Section 2-5.3 of the General Provisions- 1. Shop drawings showing dimensions and details of floor drains and type II cleanouts 2 Manufacturer's product data. 3. Manufacturer's installation instructions. 4. Manufacturer's certification of compliance. PART 2--PRODUCTS 2.1 CLEANOUTS A. GENERAL: Unless otherwise specified, cleanouts shall be the same size as the pipe connected. Cleanouts shall be provided with clamping collars where CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15400-1 waterproofing membranes are located in the floor. Cleanouts located inside buildings shall be provided with bronze covers. Bronze plug with (/ tapered thread shall be provided for cleanouts on pressurized systems ^ ^ Cleanouts on chemical waste or dram lines shall be of the same material and type of joint as the pipe B TYPE II CLEANOUT. Unless otherwise specified, Type II cleanouts shall be Josam series 56010(12), J. R Smith series 4140, or equal. 2.2 DRAINS A. FLOOR DRAINS: 1. GENERAL: Floor drains shall be provided with clamping collars where waterproofing membranes are located m the floor. 2 TYPE II, III, AND IV FLOOR DRAINS: Unless otherwise specified, Type II, III, and IV floor drains shall be Josam series 32120, J. R. Smith series 2220, or equal. B. CONDENSATE DRAINS: Unless otherwise specified, condensate drains shall be as specified for piping system 24 in Section 15050 2.3 COUPLINGS, NIPPLES AND UNIONS Couplings and nipples shall be of the same material as the pipe on which they are used. Unions 2 inches and smaller shall be ground joint screwed pattern unions. Unions larger than 2 inches shall be flanged. Unions shall be packed with 1/16-inch thick rubber packing. Dielectric unions shall be as specified in paragraph 15085-2 04. 2.4 HOSE BIBBS Hose bibbs shall be Acorn No 8126, Chicago 387-LF, Josam Series 71700 , Zurn Series 138S01390or equal. 2.5 SLEEVES Sleeves shall be 22-gage sheet metal. CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15400-2 2.6 WALL MOUNTED HOSE RACKS Wall mounted hose racks shall be installed at locations indicated. Racks shall be of all-welded steel construction, minimum 1A" sheet steel, hot -dip galvanized after fabrication and shall have a capacity to hold 100 feet of 3/4 -inch or 1-1/2 inch hose. Where racks are located in open locations, racks shall be supported from two 2"x2"xl/4" galvanized steel angle posts, and shall be set in a concrete base. 2.7 HOSES AND NOZZLES A. The work includes the following quantities of the lengths indicated: 2-50- foot sections of 1" diameter hose with nozzles. B. Hose shall include male and female connectors and nozzle and shall be seamless, extruded rubber with Dacron cotton exterior and shall be designed for a working pressure of at least 200 psi. C. Nozzles shall be capable of complete shut-off and shall produce a solid straight stream and up to a 90 degree conical fog. Nozzle material shall be brass with polished finish, and nozzles shall include rubber bumper. 2.6 PRODUCT DATA Brochures of plumbing equipment, including catalog data and installation information, shall be provided. PART 3--EXECUTION 3.1 INSTALLATION A. GENERAL: Work shall be in accordance with the Uniform Plumbing Code. Plumbing shall be provided to avoid obstructions, allow 7.5 feet minimum headroom, and keep openings and passageways clear. No holes shall be made in structural members. Torn and pierced waterproofing shall be repaired. Fixtures, fittings, valves, and copper and brass items shall be wrapped with burlap or building paper. Wrapping shall be removed at completion of the work. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15400-3 B. VALVES AND ACCESSORIES: Valves shall be provided upstream of branches, apparatus and fixtures. Valves on branch lines and at distribution points shall be provided with a 2-mch heavy brass disc, stamped and stenciled with 1/4-inch high letters, stating portion of system controlled by valve. Valve locations shall be shown on record drawings. The Contractor shall provide a chart of location and use of main valves. Adjustable shaft valve boxes shall be provided for underground valves. C. DIELECTRIC UNIONS: Dielectric unions shall be provided at connections between pipe or fittings of different material. D. PIPING: Piping shall be earned in chases or recesses where provided in walls, through floors and partitions, and over ceilings. Unless otherwise specified, piping shall not be run in floor slabs. Pipes shall not be supported by plumbing fixtures or equipment. Changes in pipe size shall be made with reducing fittings. The use of bushings is not acceptable. Where galvanized steel pipe is calked into a cast iron hub, a soil pipe adapter shall be provided on the calked end of the steel pipe. Unless otherwise specified, underground piping outside buildings shall have a minimum cover of 24 inches. Piping under buildings shall have a minimum clearance from structure of 12 inches. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 15400-4 SECTION 16000 ELECTRICAL, INSTRUMENTATION AND CONTROLS TABLE OF CONTENTS PART 1 - GENERAL 1 1.1 PROJECT DESCRIPTION 1 1.2 SCOPE OF WORK 1 1.3 GENERAL DESIGN REQUIREMENTS 1 1.4 ENVIRONMENTAL CONDITIONS 3 1.5 EXAMINATION OF SITE 4 1.6 CODES AND STANDARDS 4 1.7 PERMITS AND INSPECTIONS 6 1.8 COORDINATION OF WORK 6 1.9 COORDINATION OF ELECTRICAL SYSTEM 7 1.10 EQUIPMENT, MATERIALS AND WORKMANSHIP 7 1.11 SUBMTTTALS 8 1.12 QUALITY ASSURANCE 11 1.13 GROUNDING 12 1.14 CLEANUP 12 1.15 GUARANTY 13 1.16 DEFINITIONS 13 PART 2 - PRODUCTS 14 2.1 GENERAL 14 2.2 CONDUIT 15 2.3 CONDUIT FITTINGS, OUTLET AND PULLBOXES 15 2.4 UNDERGROUND PULLBOXES AND MANHOLES 16 2.5 WIRE AND CABLE 17 2.6 MOTORS 17 2.7 MOTOR CONTROL CENTER 19 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-1 2.8 POWER DISTRIBUTION 22 2.9 CABINETS AND PANEL EQUIPMENT 23 2.10 UNINTERRUPTIBLE POWER SUPPLIES 28 2.11 REMOTE TELEMETRY UNIT 30 2.12 LEVEL TRANSMITTER 30 2.13 PROCESS TUBING 31 2.14 IDENTIFICATION TAGS 31 2.15 SPARE PARTS 31 PART 3 - EXECUTION 32 3.1 GENERAL 32 3.2 RACEWAYS 33 3.3 BOXES AND FITTINGS 34 3.4 CONDUCTORS AND CABLES 35 3.5 MOTORS AND CONTROLS 36 3.6 OVERCURRENT PROTECTION 36 3.7 SUPPORTS 37 3.8 SEISMIC ANCHORING RESTRAINTS 37 3.9 HANDHOLES AND PULLBOXES 37 3.10 CHECKING, ADJUSTING AND TESTING 37 3.11 CLEANUP 40 PART 4 - SYSTEM CONTROL DESCRIPTIONS 40 4.1 DESCRIPTION 40 4.2 COMMON CONTROL AND MONITORING LOOPS 41 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-n SECTION 16000 ELECTRICAL, INSTRUMENTATION AND CONTROL PART 1 - GENERAL 1.1 PROJECT DESCRIPTION A. The electrical work generally consists of procurement, fabrication, installation, implementation and start-up of an Electrical, Instrumentation and Control system for an Input/Output facility. The work shall include all site electrical and instrumentation as shown on the drawings and specified herein. 1.2 SCOPE OF WORK A. Major electrical work consists of: 1. Furnishing and installing a utility transformer pad or slab box, pull-boxes, conduit and conductors from a location approximately as shown on the plans. 2. Furnishing and installing utility metering, mam disconnect, and distribution switchgear as shown on the drawings. 3. Furnishing and installing all conduit, wire, pull boxes and appurtenances to connect the Control Building electrical and instrumentation equipment to the Input/Output structure as shown on the drawings and specified herein. 4. Furnish and install new instrumentation, communications and controls necessary to provide a complete and operable facility. 5. Furnish all Remote Telemetry Unit equipment as specified and deliver to the OWNER for configuration by the OWNER'S SCADA Consultant. Upon receipt of configured equipment, install as shown on the drawings and as coordinated with the OWNER'S SCADA Consultant. 6. Provide qualified personnel for the coordination of installation and provide testing, start-up and training services for complete system commissioning of the pump station electrical, instrumentation and control system. 1.3 GENERAL DESIGN REQUIREMENTS A. The Contractor shall furnish and install all equipment shown on the drawings to provide electrical service to the site. The WORK shall 17074 CrrV OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-1 include a new SDG&E approved transformer slab box at the site shown on the drawings, all conduit from the utility service connection to the transformer and conduit from the transformer to the Control Building. It shall be the responsibility of the Contractor to coordinate with SDG&E to assure compliance with utility company requirements. The Contractor shall furnish and install telephone company approved pull boxes and conduit from the telephone company termination location to the Control Building. The Contractor shall coordinate with the telephone company to assure compliance with the utility's requirements. B. The Contractor shall furnish the Switchboard and Process Control Panel (PCP) complete and factory tested as integral components, and all field instrumentation as shown on the drawings. The Contractor shall install all equipment provided by process equipment suppliers in the approximate locations shown on the drawings. C. The Contractor shall be responsible for coordination with the process equipment suppliers to assure final equipment positions and adequate conduit capacity and conductor counts to meet the supplier's requirements. D. The Contractor shall furnish all Remote Telemetry Unit components as specified herein and shall deliver such components to the Owner for integration into the Owner's SCADA system. Once configured by the Owner's SCADA consultant, the Contractor shall mount equipment in the control room as shown on the drawings and shall coordinate with the Owner's SCADA consultant for proper wire terminations. E. The Contractor shall furnish, install, and place into service the operating process instrumentation, control systems, and all appurtenant work, all in accordance with the requirements of the Contract Documents. F. The Contractor shall have full responsibility for the complete operation of all instrumentation and control systems. The Contractor shall perform all engineering and coordination necessary in order to select, furnish, install and connect, calibrate, and place into operation all sensors, instruments, alarm equipment, control boards and panels, accessories and all other equipment as specified herein. Furthermore, the Contractor shall calibrate and demonstrate the operabihty of said system in accordance with the Contract Documents. G. The Contractor shall provide all engineering work and installation drawings to produce a complete instrumentation system. If it is necessary for the Contractor to produce additional drawings in order to complete its work, the cost of the drawings shall be included in the Contract bid price and is considered a part of the scope of work. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-2 H. The Contractor shall examine all drawings, specifications, and details to become fully acquainted with the method of construction and to evaluate the quantity of Work to be performed. In case of conflicting or incomplete technical information, the Contractor shall include costs in its lump sum bid to coordinate resolution of these conflicts and deficiencies with the Owner's Representative at no additional cost to the Owner. Resolution of these discrepancies shall be obtained from the Owner's Representative by the Contractor prior to purchasing of the instrument item. I. The Contractor shall coordinate and direct all testing and start-up efforts for the complete system. 60 days prior to start-up and commissioning, a commissioning plan shall be submitted for review. 1.4 ENVIRONMENTAL CONDITIONS A. General All field equipment shall be rated for continuous operation under ambient environmental conditions of 0°C to 60°C dry bulb and 5 to 95 percent relative humidity, noncondensmg. Instrumentation and control elements shall be rated for continuous operation under the ambient environmental temperature, pressure, humidity, and vibration conditions specified or normally encountered for the installed location. Where installed out of doors, sensors shall be capable of operating between -30°F and 122°F and of being saturated by ambient weather conditions without suffering damage or affecting their calibration. B. Overvoltage and Surge Protection All components shall be protected from the effects of overvoltage and surge as follows: 1. Power Line Surge Protection a. All equipment connected to AC circuits shall be protected from power line surges. Equipment protection shall meet the requirements of IEEE C62.41. Fuses shall not be used for surge protection. 2. Sensor and Control Wiring Surge Protection a. All digital and analog inputs and outputs shall be protected against surges induced on control and sensor wiring installed outdoors and as shown. The inputs and outputs shall be tested in both normal mode and common mode using the following two waveforms: 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-3 1) A 10-microsecond by 1,000-microsecond waveform with a peak voltage of 1,500 volts and a peak current of 60 amperes. 2) An 8-rrucrosecond by 20-microsecond waveform with a peak voltage of 1,000 volts and a peak current of 500 amperes. b. Fuses shall not be used for surge protection. 3. Communications Circuits Surge Protection a. All communication equipment shall be protected against surges induced on its communications circuits. Where not protected by the telephone Utility, all cables and conductors which serve as communications circuits from SCS to PLCs, and between PLCs or other field hardware shall have surge protection installed at each end. Protection shall be furnished at equipment and additional triple electrode gas surge protectors rated for the application on each communications circuit shall be installed within 3 feet of the building cable entrance. The inputs and outputs shall be tested in both normal mode and common mode using the following two waveforms: 1. A 10-microsecond by 1,000-microsecond waveform with a peak voltage of 1,500 volts and a peak current of 60 amperes. 2. An 8-microsecond by 20-microsecond waveform with a peak voltage of 1,000 volts and a peak current of 500 amperes. b. Fuses shall not be used for surge protection. 1.5 EXAMINATION OF SITE A. Bidders shall visit the sites at the time scheduled by the Owner. Bidders shall make allowance in the bid proposal for existing site conditions as related to the work that is to be performed. 1.6 CODES AND STANDARDS A. All the equipment and materials shall conform to the latest revision of the following standards. The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-4 1. American National Standards Institute (ANSI) a) ANSIX3.64 (1979) Additional Controls for Use with American National Standard Code for Information Interchange 2. Electronic Industries Association (EIA) a) EIA 232-D (Jan. 1987) Interface Between Data Terminal Equipment and Data Circuit-Terminating Equipment Employing Serial Binary Data Interchange b) EIARS-485 (1983) Standard for Electrical Characteristics of Generators and Receivers for Use in Balanced Multipoint System 3. Federal Communications Commission (FCC) a) FCC Part 68 (Jul 1986) Connection of Terminal Equipment to the Telephone Network 4. The Institute of Electrical and Electronics Engineers, Inc. (IEEE) a) IEEE No. 100 (1988) IEEE Standard Dictionary of Electrical and Electronic Terms ,b) IEEEC57.13 (1978) Instrument Transformers c) IEEEC62.41 (1980) Surge Voltages in Low-Voltage AC Power Circuits d) IEEE 802.3 Carrier Sense Multiple Access/Collision Detection (CSMA/CD) 5. National Electrical Manufacturers Association (NEMA) a) NEMA 250 (1985; Incl. Rev. 1 and 2; ICS-6) Enclosures for Electrical Equipment b) NEMA ICS 1 (1988) General Standards for Industrial Controls and Systems 6. Underwriters' Laboratories (UL) 7. Insulated Power Cable District's Representatives Association (IPCEA) 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-5 8. American Society for Testing and Materials (ASTM) 9. National Electrical Code (NEC) B. All electrical equipment and materials, and the design, construction, and installation thereof, shall comply with all applicable provisions of the Federal Occupational Safety and Health Act (OSHA), State Building Standards, and applicable local codes and regulations. C. Where the Plans or these Specifications call for equipment and workmanship to be of better quality or higher standard than required by the above codes, standards, rules, and regulation, then said Plans and Specifications shall prevail. Nothing on the Plans or in these Specifications shall be construed to permit work in violation of the above codes, standards, rules, and regulations and the Contractor shall be held responsible for any work which is not acceptable. D. In case of differences between the building codes, specifications, state law, local ordinances, industry standards, utility company regulations, fire insurance earner's requirements, and the contract documents, the most stringent shall govern. The Contractor shall promptly notify the Owner's Representative in writing of such differences. 1.7 PERMITS AND INSPECTIONS A. The drawings show the installation as it shall be installed with the minimum requirements of the codes above as a base, and all cost incident thereto shall be included in the Electrical Contractor's Bid. The Electrical Contractor shall obtain all permits, licenses required by the local ordinances and shall include the cost of all such permits required for this installation in his bid. Upon completion of the work, the Electrical Contractor shall furnish the Owner's Representative a certificate of final inspection and approval from the local Electrical Inspection Department. 1.8 COORDINATION OF WORK A. Electrical apparatus on all equipment shall be handled, set in place, connected, checked out, serviced, and placed in readiness for proper operation to the satisfactions of the Owner and Owner's Representative all within the scope of work intended under this section. B. Before any work is started, the Contractor shall verify, with the equipment manufacturers, that equipment dimensions and arrangements will allow for equipment installation in the spaces provided for on the Plans for motor control line-up, and that the installation indicated will provide for all required ventilation, clearances, access, and work space. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-6 1.9 COORDINATION OF ELECTRICAL SYSTEM A. The Contractor shall verify all actual equipment and motor full-load and locked-rotor current ratings. The necessary minimum equipment, wire, and conduit sizes are shown on the Plans. If the Contractor furnishes equipment of different ratings, the Contractor shall coordinate the actual current rating of equipment furnished with the branch circuit conductor size, the controller size, the motor starter, and the branch circuit overcurrent protection. The branch circuit conductors shall have a carrying capacity of not less than 125 percent of the actual full-load current rating. The size of the branch circuit conductors shall be such that the voltage drop from the overcurrent protection devices up to the equipment shall not be greater than 2 percent when the equipment is running at full load and rated voltage. B. The motor running overcurrent protection devices shall be rated or selected to trip at no more than 125 percent of the motor full-load current rating for motors marked to have a temperature nse not over 40 degrees C or motors marked with a service factor not less than 1.15, and at no more than 115 percent for all other types of motors. The motor controller frame size shall be coordinated to the current rating and horsepower size of the installed motor but in no case shall the controller frame size be less than Size 1. C. The motor branch circuit overcurrent protection device shall trip open in 30 seconds or less on locked-rotor current of the motor. This device shall also protect the motor branch circuit conductors and the motor control apparatus against overcurrent due to short-circuits or grounds. The motor control circuits shall have overcurrent protection of the type indicated on the Plans. 1.10 EQUIPMENT, MATERIALS AND WORKMANSHIP A. It is the intent of these Specifications and of the Plans, to secure high quality in all equipment and materials, and to require first-class workmanship, in order to facilitate trouble free operation and minimum maintenance of the electrical system. B. All equipment and materials shall be new, listed by UL, and bear the UL label, unless exception to this requirement is inherent to an individual item specified herein, or exception is otherwise granted by the Owner's Representative. C. Equipment and materials shall be products of reputable, experienced manufacturers. Similar items in the project shall be the products of the same manufacturer. All equipment shall be of industrial grade and standard of construction, shall be of sturdy design and manufacture, and shall be capable of long, reliable, trouble-free service. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-7 D. All work, including installation, connection, calibration, testing and /^~^ adjustment, shall be done by qualified, experienced personnel who are V J technically skilled in their trades, are thoroughly instructed, and are competently supervised. The resulting complete installation shall reflect professional quality work, employing industrial standards and methods. Any and all defective material or inferior workmanship shall be corrected immediately to the Satisfaction of the Owner's Representative at no additional cost to the Owner. 1.11 SUBMITTALS A. Subrmttals are described herein. See product equipment specifications for additional submittal requirements specific to that product. B. Shop Drawings, General 1. Shop drawings shall include, as appropriate: a) Product specific catalog cuts. b) A drawing index. c) A list of symbols. d) A series of drawings for each cabinet or console using abbreviations, symbols, nomenclature, and identifiers as shown on the contract drawings. e) A complete materials list. 2. Drawings submitted for review shall include front views, sections, and anchoring details to meet seismic requirements. Separate drawings shall be submitted for elementary control and wiring diagrams. Wiring diagrams shall be complete for all electrical equipment furnished except lighting. Should an error be found in a shop drawing during installation of equipment, the proposed correction, field changes found necessary, shall be noted on the drawing and submitted for review again. All shop drawings shall be checked by the Contractor before submittal for review by the District's Representative and the Contractor shall certify that the subrmttals are in accordance with the Plans and Specifications. Primary shop drawings to be submitted: a) Motor Control Center. b) Pump Control Panel layout, interface and communication diagrams. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-8 C. Record Drawings Prior to the completion of the Contract, the Contractor shall furnish the Owner's Representative with two (2) sets of Electrical Plans marked with any changes, deviations or additions to any part of the electrical work. D. Delivery of Project Subrmttals and Manuals All items of technical data which is specifically identified in this specification will be delivered strictly in accordance with the following requirements. All data delivered shall be identified by reference to the particular specification paragraph against which it is furnished. Data to be submitted shall be organized as described herein. Two copies of specified number of submittals shall be returned to the Contractor for record, unless otherwise noted herein. E. Group I Technical Data Package The Group I Technical Data Package shall include complete system descriptions and calculations used in sizing equipment required by these specifications. Descriptions and calculations shall show how the equipment will operate as a system to meet the performance requirements of this specification. A complete data package shall be delivered for all equipment and materials, including instrumentation hardware/software, support hardware, and field equipment. The data package shall include the following as a minimum: 1. Submittal Data and System Drawings (eight copies). Submit system data and drawing sections as a complete package at one time within 30 days after the Notice to Proceed. a) Detailed Bill of Materials including complete manu- facturers name and model number, and quantities. Manufacturers cut sheets and manuals for all hardware and software to be provided. Each item shall be prefaced with an ISA style data sheet showing manufacturer name, model number, location of equipment, input/output characteristics, power requirements, range (if applicable), device tag (if applicable), and equipment supplier information (name, address, and telephone number). Provide data sheets for each individual equipment item with one cut sheet or manual covering all identical uses of that item. Single Line diagram and pump controls. Details of connections to power sources. Miscellaneous details. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-9 Loop interconnection wiring diagrams for the PCP showing all control equipment, instrumentation, electrical equipment, component wiring, termination numbering, wire color, and routing for all control equipment provided under this contract, other concurrent contracts, or existing. Loop and interconnection drawings shall be prepared in accordance with ISA Standards (S5.3 and S5.4). Discrete wiring diagrams prepared in accordance JlC-style ladder diagrams and field device installation diagrams. 2. Updated System Subnuttal (eight copies): a) The Group I technical data package shall be updated upon completion of the in-house verification and testing and pnor to installation by the Contractor. The submittal shall consist of completely updated hardware and software information and drawings for use during field installation, start-up and testing. One set of the updated submittal shall remain in the Owners facility at all times and shall be continuously updated to reflect as-built conditions. F. Group II Technical Data Package The Technical Data Package shall consist of the operation and maintenance manuals. Final copies of the manuals, bound in hardback, loose-leaf binders, shall be delivered to the Owner's Representative within 30 days after successfully completing the final field testing. The draft copy used during site testing shall be updated with any changes required prior to final delivery of the manuals. Each manual's contents shall be identified on the cover. The manuals shall include the names, addresses, and telephone numbers of each supplier of equipment and systems, and of the nearest service representatives for each item of equipment and each system. The manuals shall have a table of contents and tab sheets. Tab sheets shall be placed at the beginning of each chapter or section and at the beginning of each appendix. The final copies delivered after completion of the test shall include all modifications made during installation, checkout, and acceptance. The manuals and quantities to be delivered shall include: 1. Hardware Manual (eight copies) a) The hardware manual shall provide detailed data describing all equipment furnished, including: b) General description and specifications. c) Complete materials list. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-10 d) Installation and checkout procedures. e) Equipment electrical schematics and layout drawings. f) System schematics and I/O wiring lists. g) Alignment and calibration procedures. h) Manufacturer's repair parts list indicating sources of supply. i) Interface definition. 1.12 QUALITY ASSURANCE A. All materials and equipment shall be installed in accordance with printed recommendations of the manufacturer which have been approved by the Owner's Representative. The installation shall be accomplished by workmen skilled in this type of work and installation shall be coordinated in the field with other trades so that interference's are avoided. B. The Contractor shall provide adequate means for and shall fully protect all finished parts of the materials and equipment against damage from any cause during the progress of the work and until accepted by the Owner's Representative. C. All materials and equipment, both in storage and during construction, shall be covered in such a manner that no finished surfaces will be damaged, marred, or splattered with water, foam, plaster, or paint, and all moving parts shall be kept clean and dry. D. The Contractor shall replace or have refimshed by the manufacturer, all damaged materials or equipment, including face plates of panels and switchboard sections, at no expense to the Owner. E. The Contractor shall perform the tests described hereinafter and any other tests that may be required by the Owner's Representative or other authorities having jurisdictions. The entire electrical installation shall be tested, adjustments made, and defects corrected as an obligation under the work of this section. The Contractor shall furnish all necessary replacement parts and labor necessary due to damage resulting from damaged equipment or from test and correction of faulty installation. The following testing, as a minimum, shall be accomplished: 1. Insulation resistance tests 2. Continuity test of all wiring 3. Test for proper grounding 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000- 11 4. Test for short circuits in system ^—^ 5. Complete operational test on all equipment '•- J 6. Participate in site start-up F. After each electrical installation is complete, it shall be tested thoroughly to demonstrate that the entire system is in proper working order and in accordance with the Plans and Specifications. In no case shall the tests be less than those outlined hereinafter. G. All tests shall be conducted in the presence of the Owner's Representative and shall be subject to his approval. The Owner's Representative shall be notified three (3) calendar days prior to the date upon which the test is to take place, and no testing shall be started without the approval of the Owner's Representative. H. The project will be subject to continued inspection during construction. The Contractor shall cooperate with the Owner's Representative and shall provide assistance at all times for the inspection of the electrical work. He shall remove covers, operate machinery, or perform any reasonable work that, in the opinion of the Owner's Representative, will be necessary to determine the quality and adequacy of the work. The "Record Drawings" shall be subject to inspection at any time and shall be updated as the work progresses. 1.13 GROUNDING A. A grounding system shall be installed in accordance with the National Electrical Code and all state and local codes and regulations. The grounding system shall bond together and effectively ground all exposed non-energized metal surfaces containing energized parts, devices or conductors. 1.14 CLEANUP A. Exposed parts shall be clean of all materials, and all oil and grease spots shall be removed with a non-flammable cleaning solvent. Such surfaces shall be carefully wiped and all cracks and comers scraped out. B. During the progress of the work, the Contractor shall clean up after his men and shall leave the premises and all portions of the site in which he is working free from debris and surplus materials. P074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000- 12 1.15 GUARANTY A. In addition to the requirements of the General Conditions, the Contractor shall guaranty his work against any defects in materials ad workmanship for a period of one year from the date of final inspection. This guaranty shall be in written form and acceptable to the Owner's Representative to whom it shall be delivered before final acceptance and payment is made. Any latent defects in Contractor-furnished material or workmanship which are discovered during the time of this guaranty shall be repaired or replaced at no cost to the District. The Contractor shall respond in a professional manner to a notification of defect or failure. Services shall be performed within five (5) calendar days after notification by the District or within a time period as mutually agreed to by both parties. 1.16 DEFINITIONS A. The following are definitions of terms that may be used in this Section: 1. "AS DIRECTED": As directed by the Owner's Representative 2. "AS REQUIRED": As needed to obtain successful operation and conform to governing codes, regulations, safety requirements and the intent of the Contract Plans and these Specifications. 3. "CONCEALED": Embedded in masonry or other construction, installed behind wall fumng, within double partitions or hung ceilings, in trenches, underground or in drawl spaces. 4. "CONTRACTOR": The general Contractor and his Sub- Contractors. 5. "EXPOSED": Not installed underground or "CONCEALED" as defined above. 6. "FURNISH" or "PROVIDE": To supply, install and connect complete and ready for safe and regular operation particular work referred to unless specifically indicated or specified otherwise. 7. "INDICATED" or "SHOWN": As indicated or shown on Plans and/or in the Specifications. 8. "INSTALL": To erect, mount and connect complete with all related accessories, wiring, conduit, etc., necessary and required. 9. "MOUNT": To erect and connect complete with all related accessories. 10. "NOTED": As indicated on Plans and/or specified. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000 -13 11. "SIMILAR" or "EQUAL". Equal in kind, materials, weight, design and efficiency of performance as approved by the Owner's Representative. 12. "SUPPLY": To purchase, procure, acquire and deliver complete with all related accessories necessary or required. 13. "WIRING": Conduit, fittings, wire, junction and outlet boxes, switches, cutouts and receptacles and all necessary or required in connection with or related thereto. 14. "WORK": All labor, materials, wiring, equipment, apparatus controls, accessories, and other items customarily furnished and/or required for proper and complete installation. B. All symbols, definitions, and engineering unit abbreviations utilized in information displays and program printouts shall conform to the designations shown in the drawings and with ISA standards PART 2 - PRODUCTS 2.1 GENERAL A. Except as may be specifically indicated otherwise, materials furnished under this Section shall be new and in accordance with industry standards and as herein specified. Equipment used for the same purpose shall be of the same make. Outdoor equipment, fixtures and wiring devices shall be of approved weatherproof construction or shall be in weatherproof enclosure or as noted in the plans. B. Standard Products Materials and equipment submitted for approval shall be the cataloged products of companies regularly engaged in the manufacture of such items, shall be the latest standard design that conforms to the Specification requirements and shall essentially duplicate material and equipment that has been in satisfactory use for at least 2 years. Replacement parts shall be stocked locally within a radius of two hundred (200) miles fromjobsite. C. Approved Manufacturers Wherever on the plans or in the Specifications, materials or equipment are identified by the names of one or more manufacturers, it is intended only to indicate an acceptable standard for quality. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-14 2.2 CONDUIT A. Rigid metal conduit shall be in accordance with ANSI C80.01 and shall be hot dipped galvanized. B. Electric metallic tubing shall not be used. C. Flexible metal conduit shall be constructed of interlocking steel stops with continuous zinc coating. D. Liquid tight flexible metal conduits shall be constructed of galvanized interlocking steel strips with a smooth moisture and oil-proof, abrasive- resistant neoprene jacket. E. Nonmetallic conduit shall be Type II, Schedule 40 polyvmyl chloride rated for 90 degrees C. F. Jacketed steel conduits shall conform to Federal specification WW-C581- d, ANI rigid steel conduit specification C80.1 and to UL specification UL-6. The zinc surface inside and outside shall remain intact. A 40 mil thickness PVC coating shall be bonded to the outside of the conduit. A PVC coated coupling shall be furnished with each length of conduit. A PVC sleeve equal to the outside diameter of the conduit shall extend l'/2-inches from each end of the coupling. G. Minimum conduit size shall be W unless otherwise noted on Plan Drawings. 2.3 CONDUIT FITTINGS, OUTLET AND PULLBOXES A. Conduit fittings shall be cast or malleable of a non-ferrous metal. B. Jacketed fitting shall have a 40 mil thickness PVC coating bonded to the outside body of the fitting. A PVC sleeve equal to the trade diameter of the conduit opening shall extend ll'/i-inches beyond each threaded opening. C. Expansion joints shall be OZ type "AX" Crouse-Hinds type "XJ" or equal and shall be complete with bonding jumper. D. Flashing for conduits through roof shall be Stonemen Strometile No. S10-4, Semco or equal. E. Outlet boxes shall be galvanized or sheadized, one piece pressed steel, knockout type. F. Weatherproof outlet boxes shall be cast of non-ferrous metal with threaded conduit entry and gasketed covers FS or FD type. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000- 15 G. Insulated bushings shall be malleable iron with insulating bushing and ground lug. H. Conduit hubs shall be Appleton type HUB, Myers "Scru-tite"or equal I. Explosion-proof fitting shall be approved for the area classification and shall be as manufactured by Crouse-Hmds, Appleton or equal. J. Explosion-proof seals shall be Crouse-Hmds type "Eys" or equal. K. Sealing bushings shall be provided on the ends of Exterior underground conduits that terminate at indoor equipment. The bushing shall consist of a neoprene sealing nng secured between two compressing metal plates. When the conduit sealing bushing is in place it shall effectively form a watertight seal at the conduit ends. L. Wall and floor seals shall be provided to completely seal the areas around conduits that pass through concrete walls and floors. Seals shall be furnished with an outer sleeve body enclosing a neoprene grommet compressed between two pressure rings tightening the rings. Provide a watertight seal on the outer surface of the entering conduits. M. Pullboxes shall be code gauge steel with removable covers secured with machine screws. The pullbox shall be painted with two (2) coats of pnmer .—^ and one (1) finished coat of light gray enamel, ANSI No. 61. Pullboxes ( j shall meet all code requirements as to size for number and size of conduits terminating. N. Weatherproof pull boxes shall be hot dip galvanized with two (2) coats of pnmer paint and one (1) coat of enamel, ANSI No. 61 Grey. Covers shall be gasketed and made boxes completely watertight. 2.4 UNDERGROUND PULLBOXES AND MANHOLES A. Pullboxes and manholes shall be precast type designed and manufactured for heavy traffic loading with heavy duty, cast iron, traffic type covers. Pullboxes for utility conduits shall be as required by the serving utility. B. All pullboxes shall have bolt-down covers complete with fiber gaskets for a weathertight fit. C. All joints between precast sections shall be sealed. D. Box and manhole covers shall be permanently identified as follows: 1. Telephone service-"T" 2. Electrical Systems 600 volts and less - "E" 3. Electrical Systems above 600 volts -"High Voltage" 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-16 2.5 WIRE AND CABLE A. 600 Volt Conductors 1. All conductors shall be soft-drawn copper, 97% conductivity minimum. 2. All conductors No. 6 and smaller shall be type "THHW" 600 volt insulation unless otherwise noted on drawings. 3. All conductors No. 4 and larger shall be stranded. 4. 120 volt power wiring shall be No. 12 AWG and control wiring shall be No. 14 AWG stranded with type "THWN" 600 volt insulation or as noted on the Plans. B. Instrumentation Cable - Shielded 1. Instrumentation cable shall be single shielded pairs. Conductors shall be No. 18 AWG copper, unless otherwise noted on Plan Drawings. 2. Insulation shall be PVC 60°C rated, 300 volts. Each conductor shall be color coded, and each pair shall be number or color coded. 3. The assembled pairs shall have an aluminum/polyester shield with a tinned copper dram wire over it. 4. The assembly shall be covered with PVC jacket. 5. The instrumentation cable shall be #8760 as manufactured by Belden or equal. C. Control Cable 1. Shall be similar to instrumentation cable, except without shield. 2.6 MOTORS A. Motors shall be suitable for the application and shall conform to ASTM C 50 AND ALL APPLICABLE NEMA standards. The motor shall be supplied by the manufacturer of the driven equipment. B. Motors 1/2 horsepower and larger shall be 3 phase, unless otherwise specified, squirrel-cage, NEMA B induction type. Motors shall be suitable for across-the-hne, full voltage starting except where noted part winding or reduced voltage starting. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000- 17 C. All 3-phase motors shall be suitable for operation on 460-volt, 3-phase, 60-hertz power as indicated. Motors smaller than 1/2 horsepower shall be single-phase, capacitor start, and shall be suitable for operation on 115- volt, single phase, 60 hertz power. Single-phase motors shall be equipped with 3-wire grounded cable provided with plug when located indoors and with cable connection to weatherproof junction box utilizing a rubber cord gnp seal at box when located outdoors. D. Except where otherwise specified in these Standard Specifications, motors installed outdoors shall have NEMA weather-protected, Type 1 enclosures with bird, insect, and rodent screens. Motors installed indoors shall have open splash-proof enclosures. All motors 25 horsepower and larger and all other motors shown on the plans with space heaters shall be provided with 120-volt strip heaters to prevent condensation. Space heaters shall be wired to an off-auto selector switch through a normally closed starter contact so that space heater is energized when motor is not operating. E. Unless otherwise specified in these Specifications, the horsepower rating of said motor shall be such that it will continuously drive the load developed at the motor rated speed without exceeding the nameplate ratings and without benefit of the service factor ratings. F. It is the responsibility of the equipment manufacturer and of the Contractor to furnish motors, electrical circuits, and equipment of ample horsepower capacity and efficiencies to operate the equipment without overloading, exceeding the rated full-load current with service factor, or overheating at full-load capacity under the specified operating conditions of this equipment. G. Motors rated at 10 horsepower or over shall be constructed to limit inrush currents to not more than those permitted by NEMA MG1, Code G. Motor rated at 3 horsepower or over shall be designed for continuous duty under rated full-load conditions with a service factor of 1.15 and for ambient temperature at 40 degrees C. Motors shall be constructed with NEMA MG1, Class F insulation and shall limit the maximum temperature nse over the above-stated design ambient temperature to the values listed in NEMA MG1 for Class B insulation system. H. Motors 150 HP and larger shall be provided with a 5 KV class power conduit termination box. I. Vertical motors shall be hollow or solid shaft as required to accommodate driven equipment and shall be equipped with cast-iron mounting base of adequate height to permit access to the coupling between the motor and pump shaft. The diameter of the mounting base shall be at least as large as the diameter of the motor. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-18 J. The vertical motors shall be equipped with thrust bearings designed to carry the weight of the rotating parts of motor and pump including the unbalanced hydraulic thrust of the pump impeller under any operating condition. The bearings shall be oil or grease lubricating without disturbing the bearing housing. The bearings shall be self-cooled and shall be sealed against entrance of dirt and loss of lubricant. K. Motors 100 HP and larger shall be provided with upper and lower or front and rear bearing temperature sensors and winding temperature sensor for each phase shall be provided to monitor the temperature. Motors smaller than 100 HP shall be supplied with noted sensors as shown on the contract drawings. Platinum RTD sensors shall be installed. Coordinate the interfacing requirements with the VFD supplier. L. Horizontal motors shall be equipped with either anti-fnction or sleeve- type bearings on each end of the motor. If the motor is equipped with anti- friction bearings, the bearings shall be designed for the maximum thrust of the driven equipment. M. The Contractor shall refer to the specification on the driven equipment for additional specific requirements and operating conditions. N Submittal for motors 50 horsepower and larger shall contain: 1. Efficiency -1/2 load Power Factor -1/2 load 2. Efficiency - 3/4 load Power Factor - 3/4 load 3. Efficiency - 4/4 load Power Factor - 4/4 load O. Motors to be installed indoors, inside buildings, or covered pipe galleries out of the weather shall receive standard manufacturer' finish. All other motors shall be shop primed and field painted in accordance with the Section on painting, lining, and coating in these Specifications. P. Motors driven by Variable Frequency Drives shall be high efficiency type and constructed for use with a PWM variable frequency drive with an adjustable earner frequency of up to 15,000 Hz, and shall be indicated on the motor nameplate. Motor shall meet NEMA Premium efficiency standard. 2.7 MOTOR CONTROL CENTER A. The Contractor shall furnish and install the motor control centers as specified herein and as shown on the contract drawings. The Motor Control Centers and all components shall be designed, manufactured and tested in accordance with the latest applicable standards of NEMA, ANSI and UL 845. The MCC and Service Entrance shall be 600-volt class suitable for operation on a three-phase, 60-hertz system. The system 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-19 operating voltage and number of wires shall be as indicated on the drawings. The MCC shall be rated NEMA 12 approximately dimensioned as show in the Contract drawings. B. Motor Control Center(s) shall be supplied in accordance with the contract single line and elevation drawings. MCC line up including Service Entrance Equipment and Control Section shall be housed in a NEMA 12 structure. MCC and Distribution Busses shall be braced for 65,000 amperes RMS symmetrical. Each interior shall be equipped with a fluorescent lamp, 120-volt switch and one 20-ampere duplex outlet minimum. C. Structures shall be totally enclosed deadfront, free-standing assemblies. They shall be 90 inches high and 21 inches deep for front-mounted units. Structures shall contain a horizontal wireway at the top, isolated from the horizontal bus and shall be readily accessible through a hinged cover. Adequate space for conduit and wiring to enter the top or bottom shall be provided without structural interference. D. Compartments for mounting control units shall be incrementally arranged such that not more than six (6) size 1 starters for front mounted only can be mounted within each vertical structure. Guide rails shall be provided. Motor control compartments shall be constructed of proper width to house later retrofit of 60 horsepower, size 4, VFDs or SSMCs. E. A vertical wireway with minimum of 35 square inches of cross sectional area shall be adjacent to each vertical unit and shall be covered by a hinged door. Wireways shall contain steel rod cable supports. F. All full voltage starter units through NEMA Size 5 shall be of the drawout type. Draw-out provisions shall include a positive guide rail system and stab shrouds to absolutely ensure alignment of stabs with the vertical bus. Draw-out units shall have a tin-plated stab assembly for connection to the vertical bus. No wiring to these stabs shall extend into the bus compartment. Interior of all units shall be painted white for increased visibility. Units shall be equipped with side-mounted, positive latch pull- apart type control terminal blocks rated 600-volts. Knockouts shall be provided for the addition of future terminal blocks. In addition, a master terminal block, when Type C wiring is specified, shall be drawout and shall be located in the bottom wireway, readily accessible through a hinged cover. All control wire to be 14 gauge minimum. G. All drawout units shall be secured by a spring-loaded quarter turn indicating type fastening device located at the top front of the unit. Each unit compartment shall be provided with an individual front door. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000 - 20 H. An operating mechanism shall be mounted on the primary disconnect of each starter unit. It shall be mechanically interlocked with the unit door to prevent access unless the disconnect is in the OFF position. A defeater shall be provided to bypass this interlock. With the door open, an interlock shall be provided to prevent inadvertent closing of the disconnect. A second interlock shall be provided to prevent removal or re-insertion of the unit while in the ON position. Padlocking facilities shall be provided to positively lock the disconnect in the OFF position with from one (1) to three (3) padlocks with the door open or closed. In addition, means shall be provided to padlock the unit in a partially withdrawn position with the stabs free of the vertical bus. I. Each structure shall contain a mam horizontal copper tin-plated bus, with minimum ampacity of 600 amperes. The horizontal bus shall be rated at 50 degrees C temperature rise over a 40 degree C ambient in compliance with UL standards. Vertical busses feeding unit compartments shall be copper and shall be securely bolted to the horizontal main bus. All joints shall be front accessible for ease of maintenance. The vertical bus shall have a minimum rating of 300 amperes for front mounted units. J. Isolation of the vertical bus compartment from the unit compartment shall be by means of a full height insulating barrier. This barrier shall be a single sheet of glass reinforced polyester with cutouts to allow the unit stabs to engage the vertical bus. Provide snap-in covers for all unused openings. K. Combination starter units shall be full-voltage non-reversing, unless otherwise shown, and shall utilize type MCP Motor Circuit Protectors. 1. Each combination unit shall be rated 65,000 AIC symmetrical at 480V. The MCP shall provide adjustable magnetic protection and be provided with pin insert to stop magnetic adjustment at 1300% motor nameplate full load current to comply with NEC requirements. All HMCP combination starter units shall have a "tripped" position on the unit disconnect and a push-to-test button on the MCP. Type MCP motor circuit protectors shall include transient override feature for motor inrush current. 2. Each starter compartment shall be equipped with a fused control power transformer, two indicating lights, HOA selector switch, and two NO contacts, unless otherwise scheduled on the drawings. Device panel to have space to accommodate six oil-tight pilot- control devices or indicating ammeters, voltmeters, or elapsed time meters. 3. Motor starters shall be electrically operated, electrically held, three-pole assemblies with arc extinguishing characteristics and 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000 - 21 shall have silver-to-silver renewable contacts. They shall have provisions for a total of eight (8) NO or eight (8) NC auxiliary contacts. The overload relay assembly shall be of the thermal bimetallic ambient compensated type. Overload relays shall be reset from outside the enclosure by means of an insulated button. The overload relay shall have a built-in push-to-test button, electrically isolated NO-NC contacts and single phase sensitivity delay. 2.8 POWER DISTRIBUTION A. Main feeder and shall be supplied and sized as indicated within the contract plans. B. The Feeder Breaker shall be a molded case, 400 ampere, 480 volt, 3 pole GFI type with a minimum short circuit rating of 65,000 RMS symmetrical amperes. Assembly shall be complete with ground fault sensor connected to tnp the main breaker. C. Circuit Breakers shall be provided with independently adjustable Long Time Setting, Long Time Delay, Short Time Setting, Short Time Delay and Instantaneous settings for coordination with both upstream and downstream protective devices. D. All wiring in this and any other section shall be neatly arranged and securely clamped, to prevent movement, breaking, and protected against contact with any sharp edges. Wiring clamps, supports, or other means, at hinge transition points, shall be furnished to prevent chafing due to doors being opened or closed. Metal clamps, if used, shall be equipped with insulating inserts between wiring cables and clamps. E. The following equipment shall be mounted in separate compartments and isolated from each other: 1. The power distribution transformer shall be equivalent to Sorgel Electric Division, Square D company "Quiet Quality", General Electric Company "QHT," or approved equal. Transformer shall be mounted as recommended by the manufacturer. The primary winding of the transformer shall be rated as shown on the Contract drawings, 480 volts, 1-phase as indicated. The secondary winding of the transformer shall be 120/240 volts, 1-phase. A primary circuit breaker and secondary circuit breaker of the sizes indicated shall be furnished and installed. Transformer insulation shall conform to NEMA TR1, Class B or Class H insulation systems. The transformer shall be UL listed and labeled. F. A three-phase power monitor shall be provided to monitor phase failure, C j phase loss, phase imbalance overvoltage and undervoltage conditions. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000 - 22 Trip parameters shall be user adjustable and provide positive indication of a fault. The power monitor shall be supplied with two NO/NC DPDT contacts for interfacing with the PLC and motor control circuits. The monitor shall be mounted behind the front panel. The power monitor compartment shall contain the disconnect with a front panel handle lockable in the off position. The power monitor shall be Diversified, Timemark or Equal. G. A lighting and power panel board shall be provided in the MCC and configured as within the contract plans. The panelboard shall be flush mounted within in motor control center. Panelboard shall be a NEMA PB1, Type 1 enclosure, front cover with a door. The panelboard finish shall match the finish of motor control center. The ground and neutral buses of panelboard shall be copper, with minimum interruptible short circuit rating of 10,000 amperes RMS symmetrical for 120/240 Volts AC. H. Molded Case Circuit Breakers: NEMA AB 1 FS W-C-375; bolt-on type thermal magnetic tnp circuit breakers, with common trip handle for all poles. Provide circuit breakers UL listed as Type SWD for lighting circuits. Provide UL Class A ground fault interrupter circuit breakers where scheduled. I. Surge protection devices are to be used for the protection of all AC electrical circuits from the effects of lightning induced currents, substation switching transients and internally generated transients resulting from inductive and/or capacitive load switching. The surge protectors shall be tested in accordance with the requirements of ANSI/IEEE C62.41 standards for Categories A, B, and C environments and shall be a UL 1449 listed component. J. The surge protection device shall be sized for voltage and phase requirements listed on the contract plans and shall provide independent phase-phase, phase-neutral, and neutral-ground surge protection. Surge protection shall be installed at the locations shown on the contract plans. Surge protection components shall be as manufactured by Leviton, Hubbell or Liebert. 2.9 CABINETS AND PANEL EQUIPMENT A. Process Control Panel 1. The pump control panel (PCP) shall be floor mounted, stand-alone structure, pre-wired and tested at the factory. 2. The interior shall be provided with a formed 12-gauge steel subpanel for attaching surface-mounted components. All components shall be attached with screws and the subpanel threaded. Rivets or back of panel nuts shall not be allowed. The 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-23 interior shall be painted with two coats of white paint. The pump control panel indicators and hand switches shall be arranged in accordance with the details provided in the drawings. 3. The panel interior shall be equipped with a fluorescent lamp, 120- volt, one 20-ampere duplex outlet minimum, and three single pole 120-volt, 20-ampere circuit breakers minimum, as indicated on the Contract drawings. B. Panel Control Circuit Devices and Components 1. General a) All components, except those mounted on the cabinet door, shall be mounted behind on fixed or swing-out panels; terminal blocks for field connections shall be mounted fixed channels located near the bottom of the cabinet but clear of the conduit entry area. Fixed panels shall be located so as not to prevent access within the cabinets to other components, wiring, and terminals. 2. Control Relays and Timers a) Control relays and timers shall have either 24-volt d-c or 120-volt a-c coils and have form C contacts (a normally open and normally closed contact). Control relays and timers shall be 10-ampere, 300-volt, pin or blade style, plug-in type with dust cover, LED "on" and applicable "timeout" indication, and sockets. All relays shall be provided with a minimum of one spare contact. Timers shall be adjustable with indication of the full time range and of the time setting. 1) Relays and Timers shall be as manufactured by Idee, timers type RTE or equal. 3. Wire Marking a) Each signal and circuit conductor connected to a given electrical point shall be designated by a single unique number which shall be shown on all shop drawings. The numbers shall be marked on all conductors at every terminal using Raychem Shrinkmark heat shrinkable printer identification sleeve or equal. Self-laminated markers shall not be used. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-24 4. Terminal Blocks a) Terminal blocks shall be high-density type molded plastic with barriers and box lug terminals and shall be rated 25 amperes at 300 volts. Provide a minimum of 10% spare terminals. b) White marking strips, fastened securely to the molded sections shall be provided with printed wire numbers or circuit identifications. Terminal block manufacturer shall be Phoenix Contact with mounting rack or equal. 5. D-C Power Supplies a) Provide d-c power supplies as required for analog loops and d-c circuits. Each power supply shall be enclosed and include internal short-circuit protection. Current requirements shall not exceed 75% of manufacturer maximum rating. 6. Receptacles a) Duplex receptacles shall be molded composition, ivory (utility power) or orange (UPS power) with matching colored covers, specification grade. Duplex receptacles for 120-volt, single-phase, 3-wire service to be rated 20 amperes, 125 volts, back or side wired, NEMA Type 5- 20R. Arrow-Hart No. 6739-1, Bryant No. 5362-1, Hubbell No. 5362-1, or equal. 7. Nameplates a) Nameplates for panel mounted devices shall be laminated plastic, black on white, with engraving through the black surface to form 3/16-inch high white letters. Relays and other devices mounted inside the control panels shall be identified with permanent nonferrous metal tags. All tags shall match device numbers shown on all shop and as-built drawings. C. Panel Control Circuit Wmng 1. Wire Type and Size a) Instrumentation signal cables shall be of the type used for process control with shielded pairs or triads with polyvinyl jacket and overall shield over the multiple pairs or triads. The instrumentation cable shall be rated 300 volts at 90 C 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-25 or better. The size of the instrumentation cable shall be AWG No. 18 minimum, unless otherwise specified elsewhere. All instrumentation cables shall meet all the requirements of IPCEA S-61-402 and shall be UL listed. 1) Control wiring shall be AWG No. 14 THHN. Inner panel control wiring may be AWG No. 14 MTW. Main power (120-volt a-c) to the panels and inner panel utility shall be wired using color coded AWG No. 12 THHN. A-C power to all system power supplies, CRTs, printer, and disk drives, shall be accomplished using molded 3-wire plug cords. Wires shall be color coded in accordance with the following table: Black LI (hot) White L2 (neutral) Red a-c control circuits Blue d-c circuits Yellow Interlock control circuits, Foreign Voltage Green Equipment ground 2) All interfacing between the cabinets and the field shall be accomplished at a terminal strip (TB). No internal panel wiring shall be connected to terminals on the "field side" of TB. Likewise, no field wiring shall be connected to terminals on the "panel side" ofTB. 3) Precision (1%) 250-ohm resistors shall be installed at the field wiring terminal strip; each incoming analog signal shall be converted to a voltage signal (1 to 5 volt d-c) where required. 4) Wiring run from components on a swing-out panel to other components on a fixed panel shall be made up in tied bundles. These shall be tied with nylon wire ties and shall be secured to panels at both sides of the "hinge loop" so that conductors are not strained at terminals. 5) Wiring run to control devices on the front panels shall be tied together at short intervals and secured to the inside face of the panel using Panduit adhesive mounts with Eastman No. 910 adhesive. Wiring to rear terminals on panel-mount instruments shall be run in plastic wireways secured to horizontal brackets run above or below the 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000 - 26 instruments in about the same plane as the rear of the instruments. 6) Conformance to the above wiring installation requirements shall be reflected by details shown on the shop drawings for the Owner's Representative review. 7) Signal conditioners and control interface relays shall be provided wherever proper instrument interfacing dictates use of these components. Each auxiliary device shall be assigned a tag number and shall appear on the panel shop loop drawings. 8) All electrical devices within the panel shall be identified by tag number, machine printed on a label visible from the panel interior. Labels shall be laminated plastic with an adhesive backing. The labels shall be consistent in size throughout the panel. 9) When input connections are made to existing circuits, the Contractor shall verify the control voltage. Provide power for the existing circuits compatible with the existing controls for dry contact inputs, powered outputs, and analog circuits as required. D. Panel Indicators and Hand switches 1. General a) All electrical materials and equipment shall be new and shall bear the label of the Underwriters' Laboratory (UL), Inc., Factory Mutual (FM) or equivalent where standards have been established and label service regularly applies. 2. Indicators a) Panel mounted indicators shall be 4 inch vertical 101 segment LED bargraph with a four-digit digital display suitable for flush mounting. The indicator shall display a 4 to 20 ma signal in the designated District's Representative units. The unit shall be 120 volt a-c powered with a +7-0.1% accuracy. 17074 crry OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-27 3. Hand Switches a) New back panel mounted, non miniature, hand switches shall be the indicating rotary hand switch type. The unit shall be industrial quality, oiltight grade with 10-ampere contacts. Switch function shall be as indicated on the instrument drawings. Replacement hand switches shall match existing manufacturer type and size, and meet the functions noted on the Plan Drawings. 2.10 UNINTERRUPTIBLE POWER SUPPLIES A. General 1. The Contractor shall furnish and install uninterruptible power supplies as shown on the drawings and specified herein. There are two UPSs required to be furnished for this project, UPS-1 shall be installed in the PCP, UPS-2 shall be a stand-alone device that shall supply three phase, 240 VAC to the HPU. B. UPS-1 1. Provide a line interactive UPS to protect equipment from line disturbances, subcycle power losses, and power outages. In normal operation, the a-c power shall be rectified to d-c power. The d-c power from the charger shall maintain the batteries at full charge. When line power fails, the inverter shall change the battery d-c power back to a-c while it regulates and provides a sine wave power to the load. The load shall automatically transfer to the inverter a-c line in less than 10 milliseconds. The UPS shall be complete with power indication, inverter circuit breaker protection, power fail, and low battery alarm relay contacts. These alarm contacts shall be wired to the PLC. Batteries shall be sealed leakproof and maintenance free mounted internal to the UPS. UPS shall come complete with connecting cables. The UPS shall be sized to power the PLC and DC power supplies 2 hours minimum. 2. System Requirements a) The UPS system shall have the following requirements: 1) Input/Output Voltage: 120-volt a-c, single phase, 60 Hz. 2) Minimum Output Rating: 650 va. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-28 3) Output Harmonic Distortion: 5% maximum at full load. 4) Frequency Stability: +/- 0.5%. 5) Overload Capacity: 125% for 10 minutes. 6) Maximum Charge Rate With Load: 20 amperes. 7) Minimum Run Time: 35 minutes at half load. 8) Minimum Recharge Time: 8 hours. 9) The UPS system shall be American Power Conversion or equal. C. UPS-2 (3-Phase, 240 VAC) 1. Provide a 3-phase UPS to protect equipment from line disturbances, subcycle power losses, and power outages. In normal operation, the a-c power shall be rectified to d-c power. The d-c power from the charger shall maintain the batteries at full charge. When line power fails, the inverter shall change the battery d-c power back to a-c while it regulates and provides a sine wave power to the load. The load shall automatically transfer to the inverter a-c line in less than 10 milliseconds. The UPS shall be complete with power indication, inverter circuit breaker protection, power fail alarm relay contacts, and low battery alarm relay contacts. These alarm contacts shall be wired to the PLC. Batteries shall be sealed leakproof and maintenance free mounted internal to the UPS. UPS shall come complete with connecting cables. The UPS shall be sized to power the HPU panel 1 hour minimum upon failure of commercial power. 2. System Requirements 1) The UPS system shall have the following requirements: 2) Input/Output Voltage: 480 VAC 3-phase/240 VAC 3- phase, 60 Hz. 3) Minimum Output Rating: 7 KVA. 4) Output Harmonic Distortion: 5% maximum at full load. 5) Frequency Stability: +/- 1%. 6) Overload Capacity: 110% for 10 minutes. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-29 7) Maximum Charge Rate With Load: 20 amperes. 8) Minimum Run Time: 30 minutes at half load. 9) Minimum Recharge Time: 8 hours. 2.11 REMOTE TELEMETRY UNIT A. General 1. The Contractor shall furnish the Remote Telemetry Unit (RTU) components specified herein. Such components shall be delivered to the Owner for configuration by the Owner's SCAD A Consultant. The Contractor shall provide specified RTU, as standardized by the Owner, to match existing equipment. The Contractor shall mount the configured equipment into the PCP upon receipt of the configured components and shall make all field termination in cooperation with the SCADA Consultant. B. RTU components shall be manufactured and supplied by Opto 22 and shall include: 1. Qty 1 - SNAP PS24 Power Supply (25 VDC to 5 VDC) 2. Qty 1- SNAP B8MC (8 channel Rack) 3. Qty 1- SNAP B3000 (Brain Board) 4. Qty 5 -SNAP ODC5 (DC Input Module) 5. Qty 2 -SNAP ODC5-I (4 channel isolated DC Output Module) 6. Qty 1 -SNAP AIMA-I (2 channel isolated Input Module) 2.12 LEVEL TRANSMITTER A. Submersible Transducer Level Measuring Systems: The level measurement system shall consist of a submersible transducer, electronic transmitter, support cable, and interconnecting cable. The submersible transducer shall be the strain gage type suitable for sensing pressure equivalent to the liquid level range indicated. The transducer shall have titanium process wetted parts and shall be furnished with a waterproof interconnecting cable. A corrosion resistant cable as supplied by the manufacturer shall suspend the transducer from the pull box at the top of the Input/Output structure. The cable shall be continuous, without splices from the above referenced pull box to the transducer. The installation shall allow easy removal of the transducer and cable assembly for maintenance purposes. The electronic level transmitter shall be remote mounted and 170^4 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-30 shall produce a 4-20 mA DC signal linearly proportional to the level range indicated. The unit shall be suitable for operation over a temperature range of 32 to 122 degrees Fahrenheit with an accuracy of ± 0.5 percent of span. The transmitter shall be supplied with the manufactures supplied termination enclosure with vent tube exposed The Vent tube shall be fitted with a maintenance free aneroid bellows to prevent moisture buildup within the vent tube. The submersible level transmitter shall be Druck PTX Series, KPSI series 710 or equal. 2.13 PROCESS TUBING A. Process tubing and associated connections shall be 316 SS. Tubing shall be a minimum of 3/8 inch O.D. All fittings and connections shall be threaded. 2.14 IDENTIFICATION TAGS A. All primary sensors and field instruments shall have an identification tag meeting the following requirements: 1. Tag numbers for primary sensors and field instruments shall be as indicated on the Contract Drawings. 2. The identifying tag number shall be permanently etched or embossed onto a stainless steel tag which shall be fastened to the device housing with stainless-steel rivets or self-tapping screws of appropriate size. 3. Where neither of the above fastenings can be accomplished, tags shall be permanently attached to the device by a circlet of 1/16- mch diameter stainless-steel wire rope. 4. All primary sensors and field instruments mounted on or within panels shall have the stainless-steel identification tag installed so that the numbers are easily visible to service personnel. 2.15 SPARE PARTS A. The Contractor shall furnish to the Owner all necessary spare parts of components required to maintain the system. Prior to final acceptance of work, the Contractor shall provide a spare parts listing of all necessary spare parts and quantities for review by the Owner's Representative. The spare parts shall include the following minimum requirements: 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-31 MINIMUM SPARE PARTS LIST PART DESCRIPTION A B CONTROL RELAYS FUSES QUANTITY 4 EACH 2 EACH OF EACH SIZE AND TYPE PART 3 - EXECUTION 3.1 GENERAL A. Provide the wiring installations and equipment installations, including connections and interconnections as indicated, specified and required. Assure proper fits for all equipment and materials in the spaces shown on the plans. 1. Excavations and Backfills a) Except where specifically provided to the contrary, the Contractor shall perform all excavation necessary for the completion of the Contract. This shall include without classification, the removal of all materials of whatever nature encountered, including all obstruction of any nature that would interfere with the proper execution and completion of the work. Any and all excess or over- excavation performed by the Contractor for any reason, except as ordered in writing by the Owner or Owner's representative, whether or not due to fault of the Contractor, shall be at the expense of the Contractor. Fill and compacting of fill for such excess or over-excavation shall be placed and compacted at the expense of the Contractor under the requirements of these specifications. Unless otherwise shown or prohibited by Federal or State safety regulations, excavations for conduit shall be open- cut trenches. The bottom of the trench shall have a minimum width equal to the outside diameter of the conduit plus 6 inches. All conduit shall be placed at a minimum depth of eighteen (18) inches. The Contractor shall provide all labor, equipment and material required to cut, trench, backfill, and replace any concrete or asphalt surfaces. Refer to Specification Section 02511 and drawing C-3 for pavement replacement requirements. Trenches shall be backfilled with select soil, free of solid materials in excess of one half inch in diameter. Trenches shall be compacted to 90 percent. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-32 2. Concrete: Concrete shall be provided for electrical equipment foundations, support foundations and conduit encasements as indicated, as specified in the Section on Concrete. 3. Painting: Painting shall be provided for installations having unfinished surfaces as specified in the Section on Painting. Field damaged factory finishes on equipment shall be touched-up with paint that is equal in quality and color to the original factor finish. 4. Existing Wiring a) The Contractor shall remove existing abandoned electrical wiring installations as necessary or required for existing conduit re-use for new power wiring. Provide necessary conduit systems, wire, and connections for a complete and operable system. B. Contractor shall furnish the services of qualified factory-trained servicemen to assist in the installation of the instrumentation and control system equipment when required. C. Install each item in accordance with manufacturer's recommendations and in accordance with the Contract Documents. Locate devices, including accessories, where they shall be accessible from grade, except as shown otherwise. D. Mount equipment so that each device is rigidly supported, level and plumb, and in such a manner as to provide accessibility; protection from damage; isolation from heat, shock, and vibration; and freedom from interference with other equipment, piping, and electrical work. E. Install equipment after heavy construction work adjacent to the equipment location has been completed to the extent that there shall be no damage to the equipment, primary sensor, or field instrument. F. All items shall be mounted and anchored using stainless-steel hardware unless otherwise noted. All mounting support hardware, straps, anchor bolts, etc., shall be sized for equipment installations to meet seismic requirements. G. Conform to all applicable provisions of the NEMA standards, NEC and local, state, and federal codes when installing the equipment and interconnecting wiring. 3.2 RACEWAYS A. Provide all the cable tray and conduit installations, including outlet bodies, boxes, gaskets, covers, fittings and supports to complete the raceway 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS -JULY 2006 16000-33 systems as shown on plans and as required. Install ground conductors in all nonmetallic conduits. 1. Underground Installations: Conduits shall be schedule 40 PVC. All conduit stub-ups and vault/wet installations shall be PVC jacketed steel. 2. Exposed Installations: Outdoor installations shall be completed with PVC coated rigid steel conduits with wrench tight connections. Indoor installations shall be completed with rigid steel conduits with wrench tight connections. 3. Flexible Conduits: Flexible conduits shall be liquid tight with fittings for short tight connections (30-inches maximum) in equipment. A separate ground conductor shall be installed in flexible conduit that does not have the internal copper bonding conductor included by the manufacturer. 4. Threads: All steel conduit threads shall be coated with a corrosion resisting lubricant, and the connections shall be made watertight. The lubricant shall maintain the grounding continuity. 5. Locknuts and Bushings: Locknuts and bushings shall be installed on the threads of steel conduits that enter through close-fit openings in enclosures. 6. Sealing Bushings: The bushings shall be installed on the ends of exterior conduit that terminate at indoor equipment. The bushing shall provide a watertight seal inside the conduit. 7. Penetrations: Penetrations through concrete for sleeves and conduits shall be approved by the Owner. Submit the sizes, location and method for all penetrations. 8. Tool Marks: Conduits and fittings that have tool marks shall be smoothed and finished with paint that matches the original finish. 9. Furnished Equipment: Provide conduit installations as shown on the plans and specified in other sections of the specification for furnished equipment. 3.3 BOXES AND FITTINGS A. Outlet bodies, boxes, gaskets, covers, fittings and supports shall be installed as indicated, specified and required. 1. Cast Metal: Cast metal outlet bodies, boxes, gasket covers and fittings shall be connected to exposed galvanized steel conduits. ^~~^\ 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000 - 34 2. PVC Coated: Outlet bodies, boxes, gasketed covers and fittings shall be PVC coated and connected to rigid plastic and PVC coated steel conduits. 3. Sheet Steel: Sheet steel boxes shall be provided with close-fit holes for steel conduit connections. Weatherproof boxes shall be provided with interchangeable conduit hubs for steel conduit connections as indicated. 4. Interchangeable Hubs: The hubs shall be installed in NEMA 3R enclosures for rigid steel conduit connections. Cut close fitting holes in the sheet steel enclosure and place the interchangeable hub in the opening. Connect the hub on the conduit and make a tight connection to the enclosure. 3.4 CONDUCTORS AND CABLES A. General Conductors shall be completely installed and connected. Apply wire lubricant to ease the pulling of conduits in conduits. Recommended pulling tensions shall not be exceeded. Cable and wire pulls shall be continuous from end-to-end. Splicing shall only be performed where required. Spliced and terminal connections shall be made tight with spring and compression connectors. The connectors shall be cnmped with a tool that provided uniform and tight connections. Include all the required wiring interconnections. B. Splice Insulation All splice connections shall be insulated as required with tight wraps of plastic tape to prevent moisture intrusion and corrosion. Apply insulation putty to fill irregularities and voids in splices. High and medium voltage cable splices shall be completed as instructed by the cable manufacturer. C. Furnished Equipment Provide wiring installations a shown on the plans and specified in other sections of the specifications for furnished equipment. D. Fiber Optic Cable The fiber optic cable shall be installed without field splices. Cable shall be run continuously between connection centers. All new conduit runs shall be installed as to not exceed the maximum bending radius of the fiber optic cable, as defined by the cable manufacturer. The manufacturers maximum bending radius and tension strength shall be strictly observed through existing conduits/pull boxes. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-35 3.5 MOTORS AND CONTROLS A. Install all the wiring and control equipment as indicated, specified and required. B. Motors 1. Motors shall be provided with the driven mechanical equipment. C. Wiring 1. The wiring installations shall be complete. Include all the required wiring interconnections between the motor magnetic starters, and between the starters and the instrument control panels. Provide motor frame conduit connection boxes as required. Be certain that all wiring connections provide the proper motor rotation. 2. Provide power, control, alarm and grounding installations for all motors as indicated and required. 3. Record the full load current to each motor, and the overload relay rating in each motor starter for the certified data submittal. 4. Provide the wiring for heaters in the motor frames and the required control to de-energize the heater when the motor operates. 5. Provide the required wiring for all control equipment that shall be furnished and installed by other sections of the specifications. D. Relays 1. Provide control relays as required to prevent simultaneous start-up of motors after power failure. 3.6 OVERCURRENT PROTECTION A. Install all the overcurrent protective equipment as indicated, specified and required. B. Metal Enclosures The enclosures for individual equipment shall be constructed to satisfy the condition in the location where they shall be installed. C. Thermal and Magnetic Tnp Settings, for circuit breakers shall assure the required circuit protection with thermal magnetic tnp settings. o 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000 - 36 D. Fuses Provide fuses that have the current and voltage ratings to protect the circuits shown on the drawings. 3.7 SUPPORTS A. Install the required structural channels, brackets, stanchions, U-bolts, clamps, anchors, hangers, fittings and other hardware to securely attach and support all the equipment and conduits. 3.8 SEISMIC ANCHORING RESTRAINTS A. All electrical equipment shall be securely anchored. Anchoring shall have the capability of withstanding seismic forces per the 1989 California Code of Regulations, Title 24, Part 2, Section 2312, Seismic Zone 4, with Z=0.4, Cp=1.0, and Ip=1.5. Cp may be two-thirds of the value specified for components mounted on foundations at grade or on floor slabs on earth grade. B. Install equipment anchors in accordance with the final shop drawing and manufacturer's recommendations. Properly torque all bolts to the required values. 3.9 HANDHOLES AND PULLBOXES A. Precast concrete handholes and pull boxes shall be installed in excavations as shown on the drawings and as required. C. Accessories shall be installed, which include pull eyes and required hardware. D. Covers shall be installed on all handholes and pull boxes. 3.10* CHECKING, ADJUSTING AND TESTING A. Provide the required labor and equipment, and all checking, adjusting, and testing operation on the electrical installation in accordance to Section 12, Startup and Field Testing. B. Manufacturer' Supervision and Field Installation Check 1. Where specified or required, electrical equipment manufacturer shall furnish the services of an authorized representative especially trained and experienced in the installation of his equipment to (1) supervise the equipment installation in accordance with the approved submittals and manufacturer's instruction, (2) be present when the equipment is first put into operation, (3) inspect, check, adjust as necessary, and approve the installation, (4) repeat the 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-37 inspection, checking, and adjusting until all trouble or defects are corrected and the equipment installation and operation are acceptable, and (5) prepare and submit the specified Manufacturer' Certified Report. Include all costs for representatives services in the Contract Price. C. Wiring Check 1. All wire terminations shall be checked to assure tight connections. D. Adjust 1. Adjust all time delay relays and other devices so the controls shall operate in the indicated or specified sequence. 2. VFD ramping speed adjustments shall be coordinated with hydraulic and PLC control requirements. E. Wiring Tests 1. Wiring tests shall be performed to detect wrong connections, short circuits, continuity and ground. Insulation tests shall be made with a hand crank test instrument on all cables and conductors. Power feeders and branch conductors shall be tested phase to phase and phase to ground. Phase to ground tests on shielded cable shall mean "conductor to shield". Voltage shall be applied and removed in a low, even manner, and the conductors shall be grounded for at least one minute after the voltage is removed to insure that no charge remains. Test voltage and application time for the various cables and conductors shall be submitted to the owner. Correct any defects in the wiring systems. F. Motor Test 1. Perform tests as indicated, specified and required. 2. Factory test all motors 100 HP and larger complete, including but not limited to the following tests and submit certified data. a) No load running current. b) Locked rotor current. c) Full load heat run. d) High potential test. e) Winding resistance. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-38 f) Bearing inspection. g) Locked and idle saturation curves, h) Service factor heat run. i) Percent slip. j) Breakdown torque. k) Locked rotor torque. 1) Efficiency at full, 3/4 and 1/2 load. m) Power factor at full, 3/4 and 1/2 load. n) Balanced to 0.001 inches total amplitude. o) Noise test. p) Tests (except locked rotor current) shall be made at full voltage and rated frequency. G. Equipment Tests 1. Equipment tests shall be performed on all equipment as indicated and directed by the manufacturer. H. Supply Voltage Tests 1. Test the supply voltage while the normal plant loads are operating, if the voltage is not within normal limits (plus or minus one percent, notify the power company and requires a voltage correction. I. Operational Demonstrations 1. Operational demonstrations shall be in accordance with Section 12. J. Final Operation Tests 1. Final operational tests shall be in accordance with Section 12. 2. Testing Materials a) Furnish instruments, recorders, gauge, materials, and power for tests. 17074 CFTY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000 - 39 Testing Methods a) Operate systems continuously 24 hours a day under constant inspection of trained operators. Induce simulated alarm and distressed operating conditions, and test controls and protective devices for correct operation in adjusting system functions or causing system shutdown. Perform other final operation tests as may be required under other sections of the specifications. 4. Defects a) Immediately correct all defects and malfunctions disclosed by tests. Use new ports and materials as required and approved. Add the interruption time for corrective work to the specified total test period. 5. Test Records a) Furnish approved instruments, gages, chart recorders, and other devices as required. Continuously record all function and operation parameters during entire test period. 3.11 CLEANUP A. Remove all rubbish from site that has resulted from the electrical work. Work areas shall be kept clear of rubbish as work progresses. B. Exterior and interior surfaces of fixtures and equipment shall be vacuumed and wiped clean. Use special cleaning solvent if necessary to restore finishes to original condition. PART 4 - SYSTEM CONTROL DESCRIPTIONS 4.1 DESCRIPTION A. The control descriptions and drawings comprise the functional design criteria of the control system. The Contractor shall coordinate all installation and testing with the Owner, Owner's Representative, and Process Equipment Suppliers to completely verify all manual and automatic modes of operation. B. The following control descriptions narratively describe the control logic and monitoring capabilities to be configured. The RTU and RTU communications shall be configured by the Owner's SCAD A Consultant. The individual control descriptions are grouped by like controls established in the drawings. 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-40 4.2 COMMON CONTROL AND MONITORING LOOPS A. General 1. The following loops are commonly used throughout the System. The Contractor shall verify the Contract Drawings to verify applicable loops. B. Level Monitoring 1. The new level transmitter shall provide an analog signal to be scaled and displayed on the front of the PCP. The level signal shall be also transmitted to the RTU as a 4-20 current loop. C. Power Monitoring 1. A station power fail signal received from UPS-1 shall be transmitted to the RTU. 2. A low battery / UPS fault status signal generated by either UPS shall be transmitted to the RTU. D. Valve Position Monitoring 1. Each valve shall be equipped with prove opened and prove closed limit switches which shall be transmitted to the RTU via the HPU. E. HPU and HydroBurst Control Monitoring 1. Failure alarms shall be generated by the HPU and HydroBurst control panels and shall be transmitted to the RTU for SCADA monitoring. F. Compressor Monitoring 1. Compressor status shall be monitored (running, off or failed) and shall be transmitted to the RTU for SCADA monitoring. **END OF SECTION** 17074 CITY OF CARLSBAD LAKE CALAVERA REMEDIAL IMPROVEMENTS - JULY 2006 16000-41