completed. These shall be submitted in hard copy and electronic format. The reports are described below. One each of these tests is required even though not specifically listed in the detailed specification section.
B. Pre -commissioning Report: The Pre -commissioning Report is a collection of all test reports, test data, certificates and commissioning forms that are produced during the Pre -commissioning Stage. The first section of this document will be a summary of the contents certifying that all prescribed tests and procedures have been successfully completed. The Commissioning Coordinator is responsible for producing this document.
C. Commissioning — Phase 1 Report
1. The Phase 1 Report is a collection of all test reports, test data, certificates and commissioning forms that are produced during the Phase 1 Stage. The first section of this document will be a summary of the contents certifying that all prescribed tests and procedures have been successfully completed. The Commissioning Coordinator is responsible for producing this document.
D. Commissioning — Phase 2 Report
1. The Phase 2 Report is a collection of all test reports, test data, certificates and commissioning forms that are produced during the Phase 2 Stage. The first section of this document will be a summary of the contents certifying that all prescribed tests and procedures have been successfully completed. The Commissioning Coordinator is responsible for producing this document.
a. Manufacturer's equipment data.
b. Field recorded dimensional measurements and clearances. c. Pressure, pressure differential, level, flow and other field settings. d. All electrical devices field settings.
e. Operational pressure tests, control system timing tests and settings and other test data specified.
f. Field wiring changes made, including marked up drawings.
2.6 SUBMITTALS
A. Contractor shall submit the following information in addition to specific equipment where specified in individual sections and paragraphs:
1. Manufacturer's Certification of Proper Installation of all equipment.
2. Completed ORT, FAT and RAT forms.
B. Submit design and details of temporary test equipment and facilities.
C. Formal Reports
1. Submit two (2) bound copies and one (1) digital file of all start-up and test reports within thirty days after completion of last test.
CITY OF BEAUMONT COMMISSIONING
MESA LIFT STATION UPGRADE 017500-10
PART 3 - EXECUTION
3.1 PRE -COMMISSIONING AND COMMISSIONING ACTIVITIES
A. The following is a partial list of activities that shall be complete during each stage of Commissioning.
B. Pre -commissioning
1. Electrical Service Tie-ins.
2. Electrical Testing.
3. Electrical Equipment is Clean and Energized.
4. Mechanical Equipment is Clean and Energized.
5. Verify Rotation of Motors.
6. Verify Alignment of Equipment.
7. Perform Local Manual Mode Tests.
8. Piping Equipment is Complete and Pressure Tested.
9. Pipe Supports Complete.
10. Pipe is Clean of Debris (inside and out).
11. Verify Valve Operation and Positions for Commissioning.
12. SCADA System is Complete and Energized.
13. Perform Wiring and Loop Tests.
14. PLC Programming Complete.
15. Perform Electrical Power System Energization Test (EPSET).
16. Perform Operational Readiness Test.
17. Pre -commissioning Requirements.
C. Commissioning
1. Operator Training.
2. Prepare As -Built Drawings.
3. Functional Acceptance Test (FAT).
4. Reliability Acceptance Test (RAT).
5. Prepare Final Maintenance Manuals.
6. Complete Final Punch List.
CITY OF BEAUMONT COMMISSIONING
MESA LIFT STATION UPGRADE 017500-11
TABLE 1
PRE -COMMISSIONING AND COMMISSIONING
PRE -COMMISSIONING
COMMISSIONING
PHASE 1
PHASE 2
Equipment Submittal Process Complete
Redline As -Built Drawings
Received Prior to Operator
Training
Reliability Acceptance
Test (RAT)
RFI's and Responses up to Date
All Electrical Equipment Tests Complete
Operational Readiness Tests
Reports Approved
All Manufactures
Certificates of Proper
Installation and Training
All Process and Instrumentation Tests
Complete
All Mechanical Equipment Tests
Complete
Operator Training Completed
Prior to Phase 2
Commissioning - Phase
2 Report
Loop Drawings
Substantial Completion
of System
P&ID Drawings
Functional Acceptance
tance Test
(FAT)
Contractor Safety Procedures in place
Commissioning - Phase 1
Report
Final O&M Manuals
Equipment, Valve and Pipe Labeling
Complete
Obtain operational acceptance
from the Owner to Proceed to
Phase 2
Final Punch List
Complete
All Manufactures Certificates of Proper
Installation
Final As -Built Drawings
All Pressure Test Reports
Final Completion
All Loop Test Reports
All Conductivity and Megger Test
Reports
All Instrument Calibration Reports
All Breaker Setting Reports
All Mechanical Alignment Reports
Operator and Maintenance Training Plan
Commissioning Plan Accepted
Draft O&M Manuals Submitted and
Approved
Electrical Power System Energization
Test
Operational Readiness Tests (ORT's)
Complete
Pre -commissioning Report Submitted
Obtain Owner Approval to Proceed
to Commissioning Phase 1
CITY OF BEAUMONT
MESA LIFT STATION UPGRADE
COMMISSIONING
017500-12
TABLE 2
RELIABILITY ACCEPTANCE TEST PARAMETERS
SYSTEM
TEST DURATION
Group #1
7 Continuous Days without a problem
Lift Station Pumps #1 and #2
Grinder System
Group #2
7 Continuous Days without a problem
Lift Station Pumps #3 and #4
CITY OF BEAUMONT COMMISSIONING
MESA LIFT STATION UPGRADE 017500-13
EXHIBIT 1
COMMISSIONING DOCUMENT SAMPLES
OPERATIONAL READINESS TEST (ORT)
FUNCTIONAL ACCEPTANCE TEST PROCEEDURE (FAT)
SAMPLE RELIABILITY ACCEPTANCE TEST PROCEEDURE (RAT)
CITY OF BEAUMONT COMMISSIONING
MESA LIFT STATION UPGRADE 017500-14
OPERATIONAL READINESS TEST
CITY OF BEAUMONT
MESA LIFT STATION UPGRADE
Date:
Equipment Name: Equipment #:
Test Type: System:
Signature or comments for non-
ok ok acceotance(Owners Re
Step Contractor Sub
Comment / Sign Off
Verify ready for startup by manufacture if
applicable
Verify correct installation
Verify correct electrical and control
wiring (voltage, breaker settings, etc.)
Verify all lubrication is complete and
correct
Check rotation (uncouple motor from
equipment if required)
Verify all alarms and signals are
functioning (simulate signal if needed)
Verify all H/O/A switches function
Verify all emergency stops function
Check clearances and verify all guards are
in place
Verify loop checks are complete and test
operation through the PLC
Equipment is ready for system Functional
Acceptance Test (FAT)
CITY OF BEAUMONT
MESA LIFT STATION UPGRADE
COMMISSIONING
017500-15
FUNCTIONAL ACCEPTANCE TEST PROCEDURE (FAT)
1.1 OVERVIEW
A. The purpose of the Functional Acceptance Test (FAT) is to demonstrate to the Owner that both the software and hardware installed under this Contract is performing as specified. The test is performed with the equipment in service using plant water. The FAT is a combined effort between Contractor and Owner. The tests will require coordination with Operations to ensure normal processing is not disrupted. A Plant Operator must be present when any system operated may disrupt normal plant operation. Each individual piece of equipment shall have a completed ORT prior to the system FAT. This schedule will be based on work sequencing as discussed in the Contract Documents.
1.2 TEST PROTOCOL
A. The combined software/hardware system is tested from this point forward. The test is performed with equipment in service under normal operating conditions, and extreme design conditions (max and min), to the extent that test conditions allow. The purpose of the test is to ensure that the PLC and Operator Graphics software configuration is working in conjunction with the hardware and plant as intended.
B. Equipment will operate with plant water. Application software problems encountered during the test will be investigated and corrected by the Contractor. Problems with PLC and/or SCADA software programming done by the Owner will be corrected by the Owner. The Contractor shall provide a qualified person familiar with the installation and trouble -shooting of PLC panels, working full time, under the direction of the Commissioning Coordinator, for the duration of the test. Prior to the test, the Contractor shall submit a written FAT procedure, prepared by the Commissioning Coordinator, to the Owner for approval. The Owner's approval of the procedure prior to the start of the FAT is required.
C. Alarms and interlocks are simulated in the field by activating the final element (sensor) or where this is not possible, by simulating the test condition at field terminals as close as possible to the final element. Calibration checks completed for the Operational Readiness Test will not be repeated.
D. The Owner must be notified 48 hours prior to the start of the FAT and must be present during the test.
E. Any sections of the test are found to be unsatisfactory; the Contractor will be required to repeat the test at his expense.
1.3 COMPONENTS
A. Each component of a system shall be brought on line as required to simulate a fully functioning system.
CITY OF BEAUMONT COMMISSIONING
MESA LIFT STATION UPGRADE 017500-16
B. Each component shall be tested at normal plant flows. If it is not possible to produce the flow, it can be simulated for this testing purpose.
C. Each component shall be fully functional and compatible with the system at the conclusion of the FAT.
D. Any repair or replacement of system components shall be completed and tested prior to final approval and beginning the RAT (Reliability acceptance Test).
1.4 TEST PROCEDURE
A. The Commissioning Coordinator shall prepare a written procedure and sign off sheet for each system. The sheet shall include all necessary components and requirements for the system. The procedure must be submitted to the Owner twenty-one (21) working days prior to the test for approval and comments. The Owner must approve the procedure prior to proceeding with the test.
B. Following is a general procedure for conducting the FAT:
1. Schedule test time with the Owner.
2. Set all valves and gates to the required position.
3. Fill channels and basins with Plant Water to prepare for the startup.
4. Energize electrical equipment.
5. Check and calibrate all transmitters, sensors, alarms and meters.
6. Simulate high, normal and low flow conditions.
7. Verify operation and reporting of the system through the SCADA System as well by manual operation.
8. Obtain approval from the Owner prior to terminating the test.
CITY OF BEAUMONT COMMISSIONING
MESA LIFT STATION UPGRADE 017500-17
SAMPLE FUNCTIONAL ACCEPTANCE TEST PROCEDURE
EXAMPLE PUMP STATION #1
#
Test and Setup
Required Results
Sign -off / Comments
1 Verify all ORT's are complete and accepted by
Owner
All ORT' s complete
(Provide copies of all ORT's)
2 Notify Owner
All required people notified
to observe test
3 Verify all local and remote switches are in the
off position
No unwanted starting of
equipment
4 Energize equipment at the MCC and power
panel
Example Pumps #1 through #2
1 Open isolation valves
Pumps should not operate
unless the isolation valves are
open.
2 Verify proper operation of level instruments
Verify the level instruments
operate as intended.
4 Verify downstream processes are ready to
receive flow.
Pumps should not be
operated unless downstream
processes are available to
receive flow.
5 Provide utility water to wet well and fill wet
well as needed.
Pumps should not operate
without water in the wet well.
6 Turn HOA switch to Hand
Verify the pump operates and
run at appropriate flow/head
conditions.
7 Turn HOA switch to Auto
Pump should not operate
until water level is at high
level setpoint.
8 Verify pump alarms along with pump on and
pump off sequence with HOA in Auto.
Pump should operate as
intended in Auto.
9 De -energize equipment until Reliability
Acceptance Test (RAT)
Contractor lock out tag out
procedure
Rep)
Test Completion Endorsements
Signature/Date (Contractor) Signature/Date(Owners
1 All components are complete and
functioning.
2 Acceptance to move on to Reliability
Acceptance Test (RAT)
CITY OF BEAUMONT
MESA LIFT STATION UPGRADE
COMMISSIONING
017500-18
SAMPLE RELIABILITY ACCEPTANCE TEST PROCEDURE (RAT)
EXAMPLE PUMP STATION #1
1.1 OVERVIEW
A. The RAT for the Example Pump Station #1 will involve other areas or systems that must start simultaneously; they are listed in Sequence of Construction in Section 011000, "Summary of Work" and/or in Section 011002 "Sequence of Operations." Each related area will have its own RAT. The Commissioning Coordinator will be responsible to prepare each RAT and schedule the startup of the systems with the Owner. The RAT cannot begin until the Functional Acceptance Tests (FAT) is complete and passed off by the Owner for all of the related areas.
1.2 CONSTRAINTS
A. The RAT will run for 7 continuous days without interruption or problem (unless a different duration is noted in Table 2 above). During the test, the responsibility for operation of the system and direction for testing falls on the Contractors Commissioning Coordinator with assistance from Equipment Manufacturers, Sub -Contractors, Engineer, Owner and Plant Operators. The test, to the greatest extent possible, will take place at 80% of design flow for each process or piece of equipment. The test may need to be terminated due to above average rainfall, unforeseen conditions at the plant or any malfunction with the equipment causing the plant not to meet its discharge requirements. A contingency plan in case the RAT is suspended must be submitted.
B. If the system test is suspended for a period over 4 hours, due to equipment malfunction or break down, the entire test will be void and will need to start at the beginning of the test period.
C. The RAT must be repeated and run for an additional 7 continuous days without interruption and or problem following the construction and FAT for the Equalization Basin.
1.3 PROCEDURE
A. Prior to beginning the Influent Pump Station RAT, all of the related systems must be ready for their own RAT. These are identified in the Sequence of Construction in Section 011000, "Summary of Work" and/or in Section 011002 "Sequence of Operations." The contractor, with the approval of the Owner, may modify this list of related areas.
B. All ORT's and the FAT must be complete and approved prior to beginning the RAT.
Documentation requirements will be discussed with the Commissioning Coordinator and Owner.
The Commissioning Coordinator will create the logs, and record the information. The logs will be submitted to the Owner for acceptance at the conclusion of the test and have the logs available for review during the test.
C. A written procedure will be submitted to the Owner 60 days prior to the test for approval and comment. A sample startup activity list for the Influent Pump Station is provided below.
CITY OF BEAUMONT COMMISSIONING
MESA LIFT STATION UPGRADE 017500-19
EXAMPLE WET WELL #1 STARTUP ACTIVITY
1. Verify completion of ORT's and FAT.
2. Verify the Owner has approved the RAT procedure.
3. Verify all downstream systems are ready to accept flow. (See Section 011000 for a list of related systems.)
4. Startup meeting with Owner, Plant Operators, Commissioning Coordinator and Engineer reviewing the startup plan.
Influent Pump Station
Downstream Process Equipment should be operating
1. Open the appropriate pump isolation valves.
2. Energize Pumps #1, #2 and #3
4. Set the HOA switch for Pumps #1, #2 and #3 to Auto.
5. Open the appropriate isolation valves and/or gates to introduce flow to the wet well.
6. Verify the operation of the pump station.
8. Start the clock for the RAT.
DOCUMENTATION
A test and issue log will be the only required documentation for the Influent Pump Station RAT.
A sample log sheet is provided below.
CITY OF BEAUMONT COMMISSIONING
MESA LIFT STATION UPGRADE 017500-20
EXAMPLE PUMP STATION #1
TEST AND ISSUE LOG
Activity/Equipment
Start
Time/Date
Verify Proper Operation
Initial Y=Yes N=No
Stop
Time/Date
Comments/Issues
(Use additional sheet if
needed.)
SMTWTFS
Pump #1
Pump #2
Pump #3
Level Sensor #1
Level Alarm Low
Level Alarm High
Level Alarm
High/High
Note:
Contractor Approval:
Engineer Approval:
Owner Approval:
CITY OF BEAUMONT COMMISSIONING
MESA LIFT STATION UPGRADE 017500-21
THIS PAGE INTENTIONALLY LEFT BLANK
CITY OF BEAUMONT COMMISSIONING
MESA LIFT STATION UPGRADE 017500-22
SECTION 017700 - CLOSEOUT PROCEDURES
PART 1 - GENERAL
1.1 SUMMARY
A. Section includes administrative and procedural requirements for contract closeout, including, but not limited to, the following:
1. Substantial Completion procedures.
2. Final completion procedures.
3. Warranties.
4. Final cleaning.
5. Repair of the Work.
B. Related Requirements:
1. Section 017500 "Commissioning" for commissioning requirements.
2. Section 017823 "Operation and Maintenance Data" for operation and maintenance manual requirements.
3. Section 017839 "Project Record Documents" for submitting record Drawings, record Specifications, and record Product Data.
1.2 ACTION SUBMITTALS
A. Product Data: For cleaning agents (submitted by the Contractor) B. Contractor's List of Incomplete Items: Initial submittal by the Contractor at Substantial Completion.
C. Certified List of Incomplete Items: Final submittal by the Contractor at Final Completion.
1.3 CLOSEOUT SUBMITTALS
A. Certificates of Release: From authorities having jurisdiction.
B. Certificate of Insurance: For continuing coverage.
1.4 SUBSTANTIAL COMPLETION PROCEDURES
A. Contractor's List of Incomplete Items: Include name and identification of each space and area affected by construction operations for incomplete items and items needing correction including, if necessary, areas disturbed by Contractor that are outside the limits of construction.
1. Organize list of spaces in sequential order.
CITY OF BEAUMONT CLOSEOUT PROCEDURES
MESA LIFT STATION UPGRADE 017700-1
2. Organize items applying to each space by major element, including categories for ceiling, individual walls, floors, equipment, and building systems.
3. Include comments from the Construction Manager, Owner and Engineer.
4. Submit list of incomplete items in the following format:
a. MS Excel electronic file. Engineer will return annotated copy.
B. Submittals Prior to Substantial Completion: Complete the following a minimum of 14 days prior to requesting inspection for determining date of Substantial Completion. List items below that are incomplete at time of request.
1. Certificates of Release: Obtain and submit releases from authorities having jurisdiction permitting Owner unrestricted use of the Work and access to services and utilities.
Include occupancy permits, operating certificates, and similar releases.
2. Submit closeout submittals specified in other Division 01 Sections, including project record documents, operation and maintenance manuals, final completion construction photographic documentation, damage or settlement surveys, property surveys, and similar final record information.
3. Submit closeout submittals specified in individual Sections, including specific warranties, workmanship bonds, maintenance service agreements, final certifications, and similar documents.
4. Submit maintenance material submittals specified in individual Sections, including tools, spare parts, extra materials, and similar items, and deliver to location designated by Engineer. Label with manufacturer's name and model number where applicable. a. Schedule of Maintenance Material Items: Prepare and submit schedule of maintenance material submittal items, including name and quantity of each item and name and number of related Specification Section. Obtain Engineer's signature for receipt of submittals.
5. Submit test/adjust/balance records.
6. Submit changeover information related to Owner's occupancy, use, operation, and maintenance.
C. Procedures Prior to Substantial Completion: Complete the following a minimum of 14 days prior to requesting inspection for determining date of Substantial Completion. List items below that are incomplete at time of request.
1. Advise Owner of pending insurance changeover requirements.
2. Make final changeover of permanent locks and deliver keys to Owner. Advise Owner's personnel of changeover in security provisions.
3. Complete startup and testing of systems and equipment.
4. Perform preventive maintenance on equipment used prior to Substantial Completion.
5. Instruct Owner's personnel in operation, adjustment, and maintenance of products, equipment, and systems. Submit demonstration and training video as required.
6. Advise Owner of changeover in heat and other utilities.
7. Participate with Owner in conducting inspection and walkthrough with local emergency responders.
8. Terminate and remove temporary facilities from Project site, along with mockups, construction tools, and similar elements.
9. Complete final cleaning requirements, including touchup painting.
CITY OF BEAUMONT CLOSEOUT PROCEDURES
MESA LIFT STATION UPGRADE 017700-2
10. Touch up and otherwise repair and restore marred exposed finishes to eliminate visual defects.
D. Inspection: Submit a written request for inspection to determine Substantial Completion a minimum of 14 days prior to date the work will be completed and ready for final inspection and tests. On receipt of request, Engineer and Construction Manager will either proceed with inspection or notify Contractor of unfulfilled requirements. Engineer will prepare the Certificate of Substantial Completion after inspection or will notify Contractor of items, either on Contractor's list or additional items identified by Engineer, that must be completed or corrected before certificate will be issued.
1. Re -inspection: Request re -inspection when the Work identified in previous inspections as incomplete is completed or corrected.
2. Results of completed inspection will form the basis of requirements for final completion.
1.5 FINAL COMPLETION PROCEDURES
A. Preliminary Procedures: Before requesting final inspection for determining final completion, complete the following:
1. Certified List of Incomplete Items: Submit certified copy of Engineer's Substantial Completion inspection list of items to be completed or corrected (punch list), endorsed and dated by Engineer. Certified copy of the list shall state that each item has been completed or otherwise resolved for acceptance.
2. Instruct Owner's personnel in operation, adjustment, and maintenance of products, equipment, and systems.
B. Inspection: Submit a written request for final inspection to determine acceptance. On receipt of request, Engineer will either proceed with inspection or notify Contractor of unfulfilled requirements. Engineer will prepare a final Certificate for Payment after inspection or will notify Contractor of construction that must be completed or corrected before certificate will be issued.
1. Re -inspection: Request re -inspection when the Work identified in previous inspections as incomplete is completed or corrected.
1.6 SUBMITTAL OF PROJECT WARRANTIES
A. Time of Submittal: Submit written warranties on request of Engineer for designated portions of the Work where commencement of warranties other than date of Substantial Completion is indicated, or when delay in submittal of warranties might limit Owner's rights under warranty.
B. Organize warranty documents into an orderly sequence based on the table of contents of the Project Manual.
1. Bind warranties and bonds in heavy-duty, three-ring, vinyl -covered, loose-leaf binders, thickness as necessary to accommodate contents, and sized to receive 8 -1/2 -by -11 -inch paper.
2. Provide heavy paper dividers with plastic -covered tabs for each separate warranty. Mark tab to identify the product or installation. Provide a typed description of the product or
CITY OF BEAUMONT CLOSEOUT PROCEDURES
MESA LIFT STATION UPGRADE 017700-3
installation, including the name of the product and the name, address, and telephone number of Installer.
3. Identify each binder on the front and spine with the typed or printed title "WARRANTIES," Project name, and name of Contractor.
4. Warranty Electronic File: Scan warranties and bonds and assemble complete warranty and bond submittal package into a single indexed electronic PDF file with links enabling navigation to each item. Provide bookmarked table of contents at beginning of document.
C. Provide additional copies of each warranty to include in operation and maintenance manuals.
D. Operating manuals, technical manuals and instructions. The Contractor's attention is directed to the condition that one percent (1%) of the contract price will be deducted from any monies due the Contractor as progress payments if at the seventy-five percent (75%) construction completion point the approved technical manuals have not been submitted in accordance with Section 013300 entitled, "Contractor Submittals". The aforementioned amount will be retained by the Owner as the agreed estimated value of the approved technical manuals. Any such retention of money for failure to submit the approved technical manuals on or before the seventy-five percent (75%) construction completion point shall be in addition to the retention of any payments due to the Contractor as specified in Article 4 of the Contract.
E. Releases from all parties who are entitled to claims against the subject project, property or improvement pursuant to the provisions of law.
PART 2 - PRODUCTS
2.1 MATERIALS
A. Cleaning Agents: Use cleaning materials and agents recommended by manufacturer or fabricator of the surface to be cleaned. Do not use cleaning agents that are potentially hazardous to health or property or that might damage finished surfaces.
1. Use cleaning products that comply with Green Seal's GS -37, or if GS -37 is not applicable, use products that comply with the California Code of Regulations maximum allowable VOC levels.
PART 3 - EXECUTION
3.1 FINAL CLEANING
A. General: Perform final cleaning. Conduct cleaning and waste -removal operations to comply with local laws and ordinances and Federal and local environmental and antipollution regulations.
B. Cleaning: Employ experienced workers or professional cleaners for final cleaning. Clean each surface or unit to condition expected in an average commercial building cleaning and maintenance program. Comply with manufacturer's written instructions.
CITY OF BEAUMONT CLOSEOUT PROCEDURES
MESA LIFT STATION UPGRADE 017700-4
1. Complete the following cleaning operations before requesting inspection for certification of Substantial Completion for entire Project or for a designated portion of Project:
a. Clean Project site, yard, and grounds, in areas disturbed by construction activities, including landscape development areas, of rubbish, waste material, litter, and other foreign substances.
b. Sweep paved areas broom clean. Remove petrochemical spills, stains, and other foreign deposits.
c. Rake grounds that are neither planted nor paved to a smooth, even -textured surface.
d. Remove tools, construction equipment, machinery, and surplus material from Project site.
e. Remove snow and ice to provide safe access to building. f. Clean exposed exterior and interior hard -surfaced finishes to a dirt -free condition, free of stains, films, and similar foreign substances. Avoid disturbing natural weathering of exterior surfaces. Restore reflective surfaces to their original condition.
g. Remove debris and surface dust from limited access spaces, including roofs, plenums, shafts, trenches, equipment vaults, manholes, attics, and similar spaces. h. Sweep concrete floors broom clean in unoccupied spaces. i. Vacuum carpet and similar soft surfaces, removing debris and excess nap; clean according to manufacturer's recommendations if visible soil or stains remain. j. Clean transparent materials, including mirrors and glass in doors and windows.
Remove glazing compounds and other noticeable, vision -obscuring materials.
Replace chipped or broken glass and other damaged transparent materials. Polish mirrors and glass, taking care not to scratch surfaces. k. Remove labels that are not permanent.
1. Wipe surfaces of mechanical and electrical equipment and similar equipment.
Remove excess lubrication, paint and mortar droppings, and other foreign substances.
m. Clean plumbing fixtures to a sanitary condition, free of stains, including stains resulting from water exposure.
n. Replace disposable air filters and clean permanent air filters. Clean exposed surfaces of diffusers, registers, and grills.
o. Clean light fixtures, lamps, globes, and reflectors to function with full efficiency. p. Leave Project clean and ready for occupancy.
C. Pest Control: Comply with pest control requirements in Section 015000 "Temporary Facilities and Controls." Prepare written report.
3.2 REPAIR OF THE WORK
A. Complete repair and restoration operations before requesting inspection for determination of Substantial Completion.
B. Repair or remove and replace defective construction. Repairing includes replacing defective parts, refinishing damaged surfaces, touching up with matching materials, and properly adjusting operating equipment. Where damaged or worn items cannot be repaired or restored, provide replacements. Remove and replace operating components that cannot be repaired.
CITY OF BEAUMONT CLOSEOUT PROCEDURES
MESA LIFT STATION UPGRADE 017700-5
Restore damaged construction and permanent facilities used during construction to specified condition.
1. Remove and replace chipped, scratched, and broken glass, reflective surfaces, and other damaged transparent materials.
2. Touch up and otherwise repair and restore marred or exposed finishes and surfaces.
Replace finishes and surfaces that that already show evidence of repair or restoration. a. Do not paint over "UL" and other required labels and identification, including mechanical and electrical nameplates. Remove paint applied to required labels and identification.
3. Replace parts subject to operating conditions during construction that may impede operation or reduce longevity.
4. Replace burned -out bulbs, bulbs noticeably dimmed by hours of use, and defective and noisy starters in fluorescent and mercury vapor fixtures to comply with requirements for new fixtures.
END OF SECTION 017700
CITY OF BEAUMONT CLOSEOUT PROCEDURES
MESA LIFT STATION UPGRADE 017700-6
SECTION 017823 - OPERATION AND MAINTENANCE DATA
PART 1 - GENERAL
1.1 SUMMARY
A. Section includes administrative and procedural requirements for preparing operation and maintenance manuals, including the following:
1. Operation and maintenance documentation directory.
2. Emergency manuals.
3. Operation manuals for systems, subsystems, and equipment.
4. Product maintenance manuals.
5. Systems and equipment maintenance manuals.
1.2 CLOSEOUT SUBMITTALS
A. Manual Content: Operations and maintenance manual content is specified in individual Specification Sections to be reviewed at the time of Section submittals. Submit reviewed manual content formatted and organized as required by this Section.
1. Engineer will comment on whether content of operations and maintenance submittals are acceptable.
2. Where applicable, clarify and update reviewed manual content to correspond to revisions and field conditions.
B. Format: Submit operations and maintenance manuals in the following format:
1. PDF electronic file. Assemble each manual into a composite electronically indexed file.
Submit on digital media acceptable to Engineer.
a. Name each indexed document file in composite electronic index with applicable item name. Include a complete electronically linked operation and maintenance directory.
b. Enable inserted reviewer comments on draft submittals.
2. Four (4) paper copies. Include a complete operation and maintenance directory. Enclose title pages and directories in clear plastic sleeves. One set will be provided to the Engineer and three sets to the Owner.
C. Manual Submittal: Submit each manual in final form prior to requesting inspection for Substantial Completion and at least 15 days before commencing demonstration and training.
Engineer will return copy with comments.
1. Correct or revise each manual to comply with Engineer's comments. Submit copies of each corrected manual within 15 days of receipt of Engineer's comments and prior to commencing demonstration and training.
CITY OF BEAUMONT OPERATION & MAINTENANCE DATA
MESA LIFT STATION UPGRADE 017823 - 1
PART 2 - PRODUCTS
2.1 REQUIREMENTS FOR EMERGENCY, OPERATION, AND MAINTENANCE MANUALS A. Directory: Prepare a single, comprehensive directory of emergency, operation, and maintenance data and materials, listing items and their location to facilitate ready access to desired information.
B. Organization: Unless otherwise indicated, organize each manual into a separate section for each system and subsystem, and a separate section for each piece of equipment not part of a system.
Each manual shall contain the following materials, in the order listed:
1. Title page.
2. Table of contents.
3. Manual contents.
C. Title Page: Include the following information:
1. Subject matter included in manual.
2. Name and address of Project.
3. Name and address of Owner.
4. Date of submittal.
5. Name and contact information for Contractor.
6. Name and contact information for Construction Manager.
7. Name and contact information for Engineer.
8. Name and contact information for Commissioning Authority.
9. Names and contact information for major consultants to the Engineer that designed the systems contained in the manuals.
10. Cross-reference to related systems in other operation and maintenance manuals.
D. Table of Contents: List each product included in manual, identified by product name, indexed to the content of the volume, and cross-referenced to Specification Section number in Project Manual.
E. Manual Contents: Organize into sets of manageable size. Arrange contents alphabetically by system, subsystem, and equipment. If possible, assemble instructions for subsystems, equipment, and components of one system into a single binder.
F. Manuals, Electronic Files: Submit manuals in the form of a multiple file composite electronic PDF file for each manual type required.
1. Electronic Files: Use electronic files prepared by manufacturer where available. Where scanning of paper documents is required, configure scanned file for minimum readable file size.
2. File Names and Bookmarks: Enable bookmarking of individual documents based on file names. Name document files to correspond to system, subsystem, and equipment names used in manual directory and table of contents. Group documents for each system and subsystem into individual composite bookmarked files, then create composite manual, so that resulting bookmarks reflect the system, subsystem, and equipment names in a readily
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navigated file tree. Configure electronic manual to display bookmark panel on opening file.
G. Manuals, Paper Copy: Submit manuals in the form of hard copy, bound and labeled volumes.
1. Binders: Heavy-duty, three-ring, vinyl -covered, loose-leaf binders, in thickness necessary to accommodate contents, sized to hold 8 -1/2 -by -11 -inch paper; with clear plastic sleeve on spine to hold label describing contents and with pockets inside covers to hold folded oversize sheets.
a. Identify each binder on front and spine, with printed title "OPERATION AND MAINTENANCE MANUAL," Project title or name, subject matter of contents.
Indicate volume number for multiple -volume sets.
2. Dividers: Heavy -paper dividers with plastic -covered tabs for each section of the manual.
Mark each tab to indicate contents. Include typed list of products and major components of equipment included in the section on each divider, cross-referenced to Specification Section number and title of Project Manual.
3. Protective Plastic Sleeves: Transparent plastic sleeves designed to enclose diagnostic software storage media for computerized electronic equipment.
4. Drawings: Attach reinforced, punched binder tabs on drawings and bind with text. a. If oversize drawings are necessary, fold drawings to same size as text pages and use as foldouts.
b. If drawings are too large to be used as foldouts, fold and place drawings in labeled envelopes and bind envelopes in rear of manual. At appropriate locations in manual, insert typewritten pages indicating drawing titles, descriptions of contents, and drawing locations.
2.2 OPERATION MANUALS
A. Content: In addition to requirements in this Section, include operation data required in individual Specification Sections and the following information:
1. System, subsystem, and equipment descriptions. Use designations for systems and equipment indicated on Contract Documents.
2. Performance and design criteria if Contractor is delegated design responsibility.
3. Operating standards.
4. Operating procedures.
5. Operating logs.
6. Wiring diagrams.
7. Control diagrams.
8. Piped system diagrams.
9. Precautions against improper use.
10. License requirements including inspection and renewal dates.
B. Descriptions: Include the following:
1. Product name and model number. Use designations for products indicated on Contract Documents.
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2. Manufacturer's name.
3. Equipment identification with serial number of each component.
4. Equipment function.
5. Operating characteristics.
6. Limiting conditions.
7. Performance curves.
8. Engineering data and tests.
9. Complete nomenclature and number of replacement parts.
C. Operating Procedures: Include the following, as applicable:
1. Startup procedures.
2. Equipment or system break-in procedures.
3. Routine and normal operating instructions.
4. Regulation and control procedures.
5. Instructions on stopping.
6. Normal shutdown instructions.
7. Seasonal and weekend operating instructions.
8. Required sequences for electric or electronic systems.
9. Special operating instructions and procedures.
D. Systems and Equipment Controls: Describe the sequence of operation, and diagram controls as installed.
E. Piped Systems: Diagram piping as installed and identify color -coding where required for identification.
2.3 PRODUCT MAINTENANCE MANUALS
A. Content: Organize manual into a separate section for each product, material, and finish.
Include source information, product information, maintenance procedures, repair materials and sources, and warranties and bonds, as described below.
B. Source Information: List each product included in manual, identified by product name and arranged to match manual's table of contents. For each product, list name, address, and telephone number of Installer or supplier and maintenance service agent, and cross-reference Specification Section number and title in Project Manual.
C. Product Information: Include the following, as applicable:
1. Product name and model number.
2. Manufacturer's name.
3. Color, pattern, and texture.
4. Material and chemical composition.
5. Reordering information for specially manufactured products.
D. Maintenance Procedures: Include manufacturer's written recommendations and the following:
1. Inspection procedures.
2. Types of cleaning agents to be used and methods of cleaning.
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3. List of cleaning agents and methods of cleaning detrimental to product.
4. Schedule for routine cleaning and maintenance.
5. Repair instructions.
E. Repair Materials and Sources: Include lists of materials and local sources of materials and related services.
F. Warranties and Bonds: Include copies of warranties and bonds and lists of circumstances and conditions that would affect validity of warranties or bonds.
2.4 SYSTEMS AND EQUIPMENT MAINTENANCE MANUALS
A. Content: For each system, subsystem, and piece of equipment not part of a system, include source information, manufacturers' maintenance documentation, maintenance procedures, maintenance and service schedules, spare parts list and source information, maintenance service contracts, and warranty and bond information, as described below.
B. Source Information: List each system, subsystem, and piece of equipment included in manual, identified by product name and arranged to match manual's table of contents. For each product, list name, address, and telephone number of Installer or supplier and maintenance service agent, and cross-reference Specification Section number and title in Project Manual.
C. Manufacturers' Maintenance Documentation: Manufacturers' maintenance documentation including the following information for each component part or piece of equipment:
1. Standard maintenance instructions and bulletins.
2. Drawings, diagrams, and instructions required for maintenance, including disassembly and component removal, replacement, and assembly.
3. Identification and nomenclature of parts and components.
4. List of items recommended to be stocked as spare parts.
D. Maintenance Procedures: Include the following information and items that detail essential maintenance procedures:
1. Test and inspection instructions.
2. Troubleshooting guide.
3. Precautions against improper maintenance.
4. Disassembly; component removal, repair, and replacement; and reassembly instructions.
5. Aligning, adjusting, and checking instructions.
6. Demonstration and training video recording, if available.
E. Maintenance and Service Schedules: Include service and lubrication requirements, list of required lubricants for equipment, and separate schedules for preventive and routine maintenance and service with standard time allotment.
F. Spare Parts List and Source Information: Include lists of replacement and repair parts, with parts identified and cross-referenced to manufacturers' maintenance documentation and local sources of maintenance materials and related services.
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G. Maintenance Service Contracts: Include copies of maintenance agreements with name and telephone number of service agent.
H. Warranties and Bonds: Include copies of warranties and bonds and lists of circumstances and conditions that would affect validity of warranties or bonds.
PART 3 - EXECUTION
3.1 MANUAL PREPARATION
A. Emergency Manual: Assemble a complete set of emergency information indicating procedures for use by emergency personnel and by Owner's operating personnel for types of emergencies indicated.
B. Product Maintenance Manual: Assemble a complete set of maintenance data indicating care and maintenance of each product, material, and finish incorporated into the Work.
C. Operation and Maintenance Manuals: Assemble a complete set of operation and maintenance data indicating operation and maintenance of each system, subsystem, and piece of equipment not part of a system.
D. Manufacturers' Data: Where manuals contain manufacturers' standard printed data, include only sheets pertinent to product or component installed. Mark each sheet to identify each product or component incorporated into the Work. If data include more than one item in a tabular format, identify each item using appropriate references from the Contract Documents.
Identify data applicable to the Work and delete references to information not applicable.
E. Drawings: Prepare drawings supplementing manufacturers' printed data to illustrate the relationship of component parts of equipment and systems and to illustrate control sequence and flow diagrams. Coordinate these drawings with information contained in record Drawings to ensure correct illustration of completed installation.
1. Do not use original project record documents as part of operation and maintenance manuals.
F. Comply with Section 017700 "Closeout Procedures" for schedule for submitting operation and maintenance documentation.
END OF SECTION 017823
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SECTION 017839 - PROJECT RECORD DOCUMENTS
PART 1 - GENERAL
1.1 SUMMARY
A. Section includes administrative and procedural requirements for project record documents, including the following:
1. Record Drawings.
2. Record Specifications.
3. Record Product Data.
B. Related Requirements:
1. Section 017823 "Operation and Maintenance Data" for operation and maintenance manual requirements.
1.2 CLOSEOUT SUBMITTALS
A. Record Drawings: Comply with the following:
1. Number of Copies: The Contractor shall submit one (1) set of marked -up record prints to the Engineer.
B. Record Specifications: The Contractor shall submit one paper copy of Project's Specifications, including addenda and contract modifications.
C. Record Product Data: Submit one paper copy of each submittal to the Engineer.
PART 2 - PRODUCTS
2.1 RECORD DRAWINGS
A. Record Prints: Maintain one set of marked -up paper copies of the Contract Drawings and Shop Drawings, incorporating new and revised Drawings as modifications are issued.
1. Preparation: Mark record prints to show the actual installation where installation varies from that shown originally. Require individual or entity who obtained record data, whether individual or entity is Installer, subcontractor, or similar entity, to provide information for preparation of corresponding marked -up record prints. a. Give particular attention to information on concealed elements that would be difficult to identify or measure and record later.
b. Record data as soon as possible after obtaining it.
c. Record and check the markup before enclosing concealed installations.
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2. Mark the Contract Drawings and Shop Drawings completely and accurately. Use personnel proficient at recording graphic information in production of marked -up record prints.
3. Mark record sets with erasable, red -colored pencil. Use other colors to distinguish between changes for different categories of the Work at same location.
4. Note Construction Change Directive numbers, alternate numbers, Change Order numbers, and similar identification, where applicable.
B. Record Digital Data Files: Immediately before inspection for Certificate of Substantial Completion, review marked -up record prints with Engineer and Construction Manager. When authorized, prepare a full set of corrected digital data files of the Contract Drawings, as follows:
1. Format: Same digital data software program, version, and operating system as the original Contract Drawings.
2. Incorporate changes and additional information previously marked on record prints.
Delete, redraw, and add details and notations where applicable.
3. Refer instances of uncertainty to Engineer through Construction Manager for resolution.
4. Engineer will furnish Contractor one set of digital data files of the Contract Drawings for use in recording information.
C. Format: Identify and date each record Drawing; include the designation "PROJECT RECORD DRAWING" in a prominent location.
1. Record Prints: Organize record prints and newly prepared record Drawings into manageable sets. Bind each set with durable paper cover sheets. Include identification on cover sheets.
2. Identification: As follows:
a. Project name.
b. Date.
c. Designation "PROJECT RECORD DRAWINGS."
d. Name of Engineer and Construction Manager.
e. Name of Contractor.
2.2 RECORD SPECIFICATIONS
A. Preparation: Mark Specifications to indicate the actual product installation where installation varies from that indicated in Specifications, addenda, and contract modifications.
1. Give particular attention to information on concealed products and installations that cannot be readily identified and recorded later.
2. Mark copy with the proprietary name and model number of products, materials, and equipment furnished, including substitutions and product options selected.
3. Record the name of manufacturer, supplier, Installer, and other information necessary to provide a record of selections made.
4. Note related Change Orders, record Product Data, and record Drawings where applicable.
B. Format: Submit record Specifications as paper copy.
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2.3 RECORD PRODUCT DATA
A. Preparation: Mark Product Data to indicate the actual product installation where installation varies substantially from that indicated in Product Data submittal.
1. Give particular attention to information on concealed products and installations that cannot be readily identified and recorded later.
2. Include significant changes in the product delivered to Project site and changes in manufacturer's written instructions for installation.
3. Note related Change Orders, record Specifications, and record Drawings where applicable.
B. Format: Submit record Product Data as paper copy.
2.4 MISCELLANEOUS RECORD SUBMITTALS
A. Assemble miscellaneous records required by other Specification Sections for miscellaneous record keeping and submittal in connection with actual performance of the Work. Bind or file miscellaneous records and identify each, ready for continued use and reference.
B. Format: Submit miscellaneous record submittals as paper copy.
PART 3 - EXECUTION
3.1 RECORDING AND MAINTENANCE
A. Recording: Maintain one copy of each submittal during the construction period for project record document purposes. Post changes and revisions to project record documents as they occur; do not wait until end of Project.
B. Maintenance of Record Documents and Samples: Store record documents and Samples in the field office apart from the Contract Documents used for construction. Do not use project record documents for construction purposes. Maintain record documents in good order and in a clean, dry, legible condition, protected from deterioration and loss. Provide access to project record documents for Engineer's and Construction Manager's reference during normal working hours.
END OF SECTION 017839
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SECTION 020960 — TEMPORARY BYPASS PUMPING SYSTEMS
PART 1 - GENERAL
1.1 DESCRIPTION
A. Section includes requirements for implementing a temporary pumping system for the purpose of diverting sewage and process flows around work areas as needed to accomplish the work.
B. The Contractor shall maintain the sewage and process flows through the existing system at all times during construction. Sewage and process flows shall not be allowed to back up and surcharge within the system. To accomplish this, bypass pumping of sewage and process flows may be required by the Contractor. Section 2.3 identifies potential areas of work where temporary bypass pumping may be required. Contractor shall determine where additional bypass pumping associated with the project work is required and shall provide additional bypass pumping at no additional cost to the Owner.
C. The Contractor shall coordinate all bypass pumping work with the Owner or Owner's Representative.
D. If bypass pumping is required or desired, the requirements of this section shall apply.
1.2 QUALITY ASSURANCE
A. Follow national standards and as specified herein.
B. Perform leakage and pressure tests on discharge piping using clean water, before operation.
Notify Engineer 24 hours prior to testing.
C. Maintain and inspect temporary pumping system every two hours. The Contractor shall have a responsible operator on site when pumps are operating.
D. Keep and maintain spare parts for pumps and piping on site, as required.
E. Maintain adequate hoisting equipment and accessories on site for each pump.
1.3 SUBMITTALS
A. Submit the following in accordance with Section 013300.
1. Detailed plan and description of proposed pumping system. Indicate number, size, material, location and method of installation of suction and discharge piping, size of pipeline or conveyance system to be bypassed, staging area for pumps, site access point, and expected flow.
a. Size and location of manhole or access points for suction and discharge hose or piping.
b. Sections showing suction and discharge pipe depth, embedment, select fill and special backfill, if buried.
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c. Temporary pipe supports and anchoring required.
d. Thrust and restraint block sizes and locations.
e. Sewer plugging method and type of plugs.
f. Bypass pump sizes, capacity, number of each size to be on site and power requirements.
g. Backup pump, power and piping equipment.
h. Calculations of static lift, friction losses, and flow velocity. Pump curves showing pump operating range.
i. Design plans and computation for access to bypass pumping locations indicated on drawings.
j. Calculations for selection of bypass pumping pipe size. k. Method of noise control for each pump and/or generator.
1. Method of protecting discharge manholes or structures from erosion and damage. m. Schedule for installation and maintenance of bypass pumping lines. n. Procedures to monitor upstream mains for backup impacts. o. Procedures for setup and breakdown of pumping operations. p. Emergency plan detailing procedures to be followed in event of pump failures, sewer overflows, service backups, and sewage spillage.
q. List of equipment for spill containment and cleanup.
2. Maintain copy of emergency plan on site for duration of project.
B. Certify bypass system will meet requirements of codes, and regulatory agencies having jurisdiction.
1.4 CONTRACTORS RESPONSIBILITY FOR OVERFLOWS AND SPILLS A. Schedule and perform work in manner that does not cause or contribute to incidence of overflows, releases or spills of sewage from sanitary sewer system or bypass operation.
1.5 DELIVERY AND STORAGE
A. Transport, deliver, handle, and store pipe, fittings, pumps, ancillary equipment and materials to prevent damage and following manufacturer's recommendations.
1. Inspect all material and equipment for proper operation before initiating work.
B. For material found to be defective or damaged due to manufacturer or shipment;
1. When repairable: Repair as recommended by manufacturer.
2. When not repairable: Replace before initiating work.
3. Repair or replacement of defective or damaged material and equipment will be at no cost to the Owner.
PART 2 - PRODUCTS
2.1 MATERIALS
A. Discharge and Suction Pipes: Approved by Engineer.
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1. Discharge piping: Determined according to flow calculations and system operating calculations.
2. Suction piping: Determined according to pump size, flow calculations, and manhole/structure depth following manufacturer's specifications and recommendations.
B. Polyethylene Plastic Pipe:
1. High density solid wall and following ASTM F714 Polyethylene (PE) Plastic Pipe (SDR-DR) based on Outside Diameter, ASTM D1248 and ASTM D3550.
2. Homogenous throughout, free of visible cracks, discoloration, pitting, varying wall thickness, holes, foreign material, blisters, or other deleterious faults.
C. High -Density Polyethylene (HDPE).
1. Homogenous throughout, free of visible cracks, discoloration, pitting, varying wall thickness, holes, foreign material, blisters, or other deleterious faults. a. Defective areas of pipe: Cut out and joint fused as stated herein.
2. Assembled and joined at site using couplings, flanges or butt -fusion method to provide leak proof joint. Follow manufacturer's instructions and ASTM D 2657. a. Threaded or solvent joints and connections are not permitted.
3. Fusing: By personnel certified as fusion technicians by manufacturer of HDPE pipe and/or fusing equipment.
4. Butt -fused joint: True alignment and uniform roll -back beads resulting from use of proper temperature and pressure.
a. Allow adequate cooling time before removal of pressure. b. Watertight and have tensile strength equal to that of pipe. c. Acceptance by Engineer before insertion.
D. Flexible Hoses and Associated Couplings and Connectors.
1. Abrasion resistant.
2. Suitable for intended service.
3. Rated for external and internal loads anticipated, including test pressure. a. External loading design: Incorporate anticipated traffic loadings, including traffic impact loading.
4. When subject to traffic loading, compose system, such as traffic ramps or covers. a. Install system and maintain H-20 loading requirements while in use or as directed by the Engineer.
E. Valves and Fittings: Determined according to flow calculations, pump sizes previously determined, and system operating pressures.
F. Plugs: Selected and installed according to size of line to be plugged, pipe and manhole configurations, and based on specific site.
1. Additional plugs: Available in the event a plug fails. Plugs will be inspected before use for defects which may lead to failure.
G. Aluminum "irrigation type" piping or glued PVC piping will not be permitted.
H. Discharge hose will only be allowed in short sections when approved by Engineer.
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2.2 EQUIPMENT
A. Pumps.
1. Fully automatic self -priming units that do not require the use of foot -valves or vacuum pumps in priming system.
2. Electric or diesel powered.
a. Diesel powered equipment shall be supplied with hospital grade mufflers for noise suppression. Equipment shall meet air quality exhaust criteria of the local Air Pollution Control District as applicable.
3. Constructed to allow dry running for long periods of time to accommodate cyclical nature of influent flows.
B. Provide.
1. Necessary stop/start controls for each pump.
2. One standby pump of each size maintained on site.
a. On-line, isolated from primary system by a valve.
3. Quiet flow pumps.
2.3 DESIGN REQUIREMENTS
A. The anticipated flow in areas that may require bypass pumping is given based on historical plant influent and/or process flows. Please note that the plant flows are not constant and vary during any given day and/or season. Bypass pumping will be required to accommodate hourly flow variations based on influent flow received at the treatment facility. Flow areas are given for the following areas where bypass pumping may occur:
1. Bypass Line from Existing MH # 4 to Lift Station Wet Well a. Peak Flow = 2,000 gpm (Verify with Engineer prior to completing the bypass pumping system design).
b. This line will be required during the construction of the new grinder manhole.
B. Provide pipeline plugs and pumps of adequate size to handle peak flow, and temporary discharge piping to ensure total flow associated with structures can be safely diverted around structures to be constructed or modified.
PART 3 - EXECUTION
3.1 PREPARATION
A. Determining location of bypass pipelines.
1. Minimal disturbance to existing utilities and facilities. a. Field locate existing utilities in proposed bypass area including convenient points.
2. Obtain Engineer's approval of location.
3.2 INSTALLATION AND REMOVAL
A. Provisions and requirements must be reviewed by Engineer before starting construction.
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B. Construct temporary bypass pumping structures and make connections to existing and/or newly constructed structures requiring bypass pumping and as required to provide adequate suction conduit.
C. Plugging or blocking of sewage flows shall incorporate a primary and secondary plugging device.
When plugging or blocking is no longer needed for performance and acceptance of work, remove in a manner that permits the sewage flow to slowly return to normal without surge, to prevent surcharging or causing other major disturbances downstream.
D. When working inside structure and manholes, exercise caution. Follow OSHA, Local, State and Federal requirements. Take required measures to protect workforce against sewer gases and/or combustible or oxygen -deficient atmosphere.
E. Installation of Bypass Pipelines:
1. Pipeline may be placed along shoulder of roads and access ways.
2. If a pipeline must be placed across a roadway and/or access way provide adequate roadway maps suitable for expected traffic loads associated with normal plant operations and construction traffic.
3. Following Engineer's approval, the contractor may place bypass piping in trenches and cover with temporary pavement.
F. During bypass pumping operation, protect existing utilities and infrastructure from damage inflicted by equipment.
G. Upon completion of bypass pumping operations, and after the receipt of written permission from Engineer, remove piping, restore property to pre -construction condition and restore pavement.
3.3 MEASUREMENT AND PAYMENT
A. Except as otherwise specified herein, providing for and complying with requirements in this Section will not be measured for payment, but cost will be considered incidental to Contract.
END SECTION 020960
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SECTION 024100 - DEMOLITION, SALVAGE, AND RECONSTRUCTION PART 1 - GENERAL
1.1 SUMMARY
A. The Contractor shall demolish, salvage and reconstruct existing civil, landscaping, structural, architectural, mechanical, HVAC, electrical, and instrumentation facilities as indicated, in accordance with the Contract Documents.
1.2 MATERIALS OWNERSHIP
A. Unless otherwise indicated, demolition waste becomes property of Contractor.
B. Historic items, relics, antiques, and similar objects including, but not limited to, cornerstones and their contents, commemorative plaques and tablets, and other items of interest or value to Owner that may be uncovered during demolition remain the property of Owner.
1. Carefully salvage in a manner to prevent damage and promptly return to Owner.
1.3 COORDINATION AND PROJECT CONDITIONS
A. The Contractor shall carefully coordinate the Work in areas where existing facilities are interconnected with new facilities and where existing facilities remain operational. The Work as indicated is not all inclusive, and the Contractor shall be responsible to perform the reconstruction indicated plus that which can be reasonably inferred from the Contract Documents as necessary to complete the Project. The Specifications and Drawings identify the major facilities that shall be demolished and reconstructed, but auxiliary utilities such as water, air, chemicals, drainage, lubrication, fluid power, electrical wiring, controls, and instrumentation are not necessarily shown.
The Contractor shall comply with sequencing requirements in Section 011000 — Summary of Work B. The Contractor shall note that the Drawings used to indicate demolition and reconstruction are based on record drawings of the existing facilities. Prior to bidding, the Contractor shall conduct a comprehensive survey at the Site to verify the scope of Work, and the extent of auxiliary utilities.
A partial set of record drawings is available for review from the Owner.
C. Buildings and/or structures to be demolished will be vacated and their use discontinued before start of the demolition.
D. Owner assumes no responsibility for buildings and structures to be demolished.
1. Conditions existing at time of inspection for bidding purpose will be maintained by Owner as far as practical.
E. Hazardous Materials:
1. If materials suspected of containing hazardous materials are encountered, do not disturb; immediately notify Engineer and Owner. Hazardous materials will be removed by Owner under a separate contract or negotiated with the Contractor via a change order.
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F. On -site storage or sale of removed items or materials is not permitted.
G. Arrange demolition schedule so as not to interfere with Owner's operations.
H. While demolition and reconstruction are being performed, the Contractor shall provide adequate access for the continued operation and maintenance of equipment and treatment processes at the existing facility. The Contractor shall erect and maintain fences, warning signs, barricades, and other devices around the reconstruction as required for the protection of the Contractor's employees and the Owner's personnel. The Contractor shall remove such protection when reconstruction activities are complete, or as work progresses, or when directed by the Engineer.
1.4 QUALITY ASSURANCE
A. Regulatory Requirements: Comply with governing EPA notification regulations before beginning demolition. Comply with hauling and disposal regulations of authorities having jurisdiction.
B. Standards: Comply with ANSIIASSE A10.6 and NFPA 241.
C. Pre -demolition Conference: Conduct conference at Project site.
1.5 CONTRACTOR SUBMITTALS
A. Demolition and reconstruction activities and procedures, including operational sequence, shall be submitted to the Engineer for approval. The procedures shall provide for safe conduct of the Work, careful removal and disposition of materials and equipment, protection of existing facilities which are to remain undisturbed, coordination with existing facilities to remain in service, and timely disconnection and reconnection of utility services. The procedures shall include a detailed description and time schedule of the methods and equipment to be used for each operation and the sequence of operation. A storage plan for salvaged items shall be included.
1.6 DEMOLITION AND ABANDONMENT
A. Existing pavement, concrete, retaining walls, curb and gutter, sidewalks, buildings, yard structures, equipment, piping, valves, ductwork, duct banks, electrical gear, instrumentation, utilities, and related appurtenances such as anchors, supports, and hardware indicated or required to be demolished as part of the Work shall be removed and disposed of unless otherwise indicated.
Removal of buried structures, utilities, and appurtenances includes the related excavation and backfill as required. Removed items shall be disposed of offsite by the Contractor.
1.7 SALVAGE
A. Items of existing equipment, piping, valves, electrical gear, instrumentation, utilities, and appurtenances indicated in the drawings to be salvaged shall be removed without any degradation in condition from that prior to removal. Salvaged items shall be stockpiled and protected on the Site at a location directed by the Engineer. The Contractor shall be responsible to properly safeguard the salvaged items against damage and loss during removal and handling.
1.8 RELOCATION
A. Items of existing equipment, piping, valves, electrical gear, instrumentation, utilities, and appurtenances required to be relocated shall be removed without any degradation in condition from
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that prior to removal. The Contractor shall be responsible to properly safeguard the relocated items against damage and loss during removal, handling, storage, and installation in the new location.
1.9 REHABILITATION
A. Existing lift station site shall be restored and landscaped as noted in the drawings.
1.10 DISPOSAL
A. The Contractor shall be responsible for the legal, offsite disposal of debris resulting from reconstruction in compliance with local, state, and federal codes and requirements.
PART 2 - PRODUCTS (NOT USED)
PART 3 - EXECUTION
3.1 EXAMINATION
A. Verify that utilities have been disconnected and capped before starting demolition operations.
B. Inventory and record the condition of items to be removed and salvaged.
3.2 GENERAL
A. The Contractor shall coordinate demolition and reconstruction Work with the Owner and Engineer.
Unless otherwise indicated, the Contractor shall be responsible for the sequence of activities. Work shall be performed in accordance with applicable safety rules and regulations.
B. The Contractor shall verify that any utilities connected to structures, equipment, and facilities to be removed, relocated, salvaged, replaced, or abandoned are rendered inoperable, replaced with new utilities, or adequately bypassed with temporary utilities before proceeding with demolition and reconstruction. The Owner shall arrange the shutoff of indicated utilities when requested by the Contractor.
C. The Contractor shall take precautions to avoid damage to adjacent facilities and to limit the Work activities to the extent indicated. If reconstruction beyond the scope indicated is required, the Contractor shall obtain approval from the Engineer prior to commencing.
3.3 PROTECTION OF EXISTING FACILITIES
A. Before beginning any reconstruction, the Contractor shall carefully survey the existing facilities and examine the Specifications and Drawings to determine the extent of reconstruction and coordination with the Work. Existing facilities not subject to demolition shall be protected and maintained in accordance with Section 015300 — Protection of Existing Facilities. Damaged existing facilities shall be repaired to the previous condition or replaced.
B. Persons shall be afforded safe passages around areas of demolition.
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C. Erect a plainly visible fence around drip line of individual trees or around the perimeter drip line of groups of trees to remain.
D. Provide temporary barricades and other protection required to prevent injury to people and adjacent buildings and facilities to remain.
E. Provide protection to ensure safe passage of people around demolition areas.
F. Structural elements shall not be overloaded. The Contractor shall be responsible for shoring, bracing, or adding new supports as may be required for adequate structural support as a result of Work performed under this Section. The Contractor shall remove temporary protection when the Work is complete or when so authorized by the Engineer.
G. The Contractor shall carefully consider bearing loads and capacities before placement of equipment and material on Site. In the event of any questions as to whether an area to be loaded has adequate bearing capacity, the Contractor shall consult with the Engineer prior to the placement of such equipment or material.
H. The Contractor shall not destroy any permanent survey points without the consent and review of the Owner. Any permanent monuments or points destroyed shall be replaced by a licensed land surveyor who is licensed in the State of California. Replacement shall be at the Contractor's expense.
I. All valve boxes, catch basins, manholes, and vaults that are to remain in service shall be adjusted to new grade to coordinate with final grade or pavement.
3.4 DEMOLITION, SALVAGE, AND RELOCATION
A. The Contract Documents indicate existing facilities to be demolished, salvaged, and/or relocated.
Auxiliary utilities including such services as water, air, chemicals, drainage, lubrication, fluid power, electrical wiring, controls, and instrumentation are not necessarily indicated. The Contractor shall verify the scope of the Work to remove the equipment indicated; coordinate its shutdown, removal, replacement, or relocation; and submit an outage plan in accordance with Section 011000 — Summary of Work. The removal of existing facilities for demolition, salvage, and relocation shall include the following requirements:
1. Demolish indicated buildings/structures and site improvements completely. Use methods required to complete the Work within limitations of governing regulations.
2. Equipment supports, including concrete pads, baseplates, mounting bolts, and support hangers, shall be removed. Damage to the existing structure shall be repaired as indicated.
3. Exposed piping including vents, drains, and valves shall be removed. Where exposed piping penetrates existing floors and walls, the piping, including wall thimbles, shall be removed to a minimum depth of 2 -inches. Resultant openings in the structure shall be repaired as indicated.
4. Electrical control panels, junction boxes, motor control centers, and local switches and pushbuttons shall be removed.
5. Exposed electrical conduits and associated wiring shall be removed. Resultant openings in structures shall be repaired as indicated.
6. Connections to embedded electrical conduits shall be removed a minimum of 2 -inches inside the finished surface of the existing structure. Wiring shall be removed and the resulting openings shall be repaired as indicated.
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7. Associated instrumentation devices shall be removed.
8. Auxiliary utility support systems shall be removed.
9. The area shall be thoroughly cleaned such that little or no evidence of the previous equipment installation will remain.
10. Asphalt and concrete pavement, curbs, and gutters shall be removed as necessary to perform reconstruction. The limits of removal shall be sawcut. When the required improvements have been constructed, new asphalt and concrete pavement, curbs, and gutters shall be placed to match the original unless otherwise indicated.
11. Footings, foundation walls, below -grade construction and concrete slabs on grade shall be demolished and removed completely.
12. Below -grade areas and voids resulting from demolition of structures shall be completely filled. Fill and compaction shall be in accordance with Section 312000 — Earth Moving.
After fill and compaction, surfaces shall be graded to meet adjacent contours and to provide flow to surface drainage structures, or as indicated.
13. When existing pipe is removed, the Contractor shall plug the resulting open ends whether or not so indicated. Where removed piping is exposed, the remaining piping shall be blind - flanged or fitted with a removable cap or plug.
14. When existing piping is removed from existing structures, the Contractor shall fill resulting openings in the structures and repair any damage such that the finished rehabilitated structure shall appear as a new homogeneous unit with little or no indication of where the new and old materials join. The openings in water -bearing structures shall be filled with non -shrink grout to be watertight and reinforced as required or indicated. In locations where the surface of the grout will be exposed to view, the grout shall be recessed approximately 1/2 -inch and the recessed area filled with cement mortar grout.
15. Electrical reconstruction shall be conducted by the Contractor in a safe and proper manner to avoid injury from electrical shock to the Owner's and Contractor's personnel. Electrical equipment to be shut off for a period of time shall be tagged, locked out, and sealed with a crimped wire and lead seal and made inoperable. At no time shall electrical wiring or connections, which are energized or could become energized be accessible to Contractor, Owner, or other personnel without suitable protection or warning signs.
B. The Contractor shall perform, in the presence of Owner, an initial and final inspection of existing equipment that will be relocated to ensure the equipment condition is maintained as documented during the initial inspection. The Contractor shall make repairs and modifications necessary to restore the equipment to its original condition at no additional cost to the Owner.
3.5 ABANDONMENT
A. Existing facilities to be abandoned shall be prepared as indicated. Where existing buried piping is to be abandoned, the Contractor shall completely remove the abandoned pipe to the points indicated on the plans. For abandoned segments that connect into active segments to remain, piping shall be removed to the connection pint, and stubbed and capped at the connection point.
B. Where removal is deemed unfeasible, the contractor may abandon in place after receiving permission from Owner. In this case, abandoned pipe shall be removed for a distance of 5 -feet from any connecting structures. Openings at the existing structures shall be repaired. The remaining pipe shall be capped at both ends prior to backfill. Buried piping, 12 -inches diameter or greater shall be completely sand -filled prior to closure of the piping ends.
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C. Where abandoned underground structures are encountered, the contractor shall remove the abandoned structures to sufficient depth to allow for new underground lines to cross or for new structures/foundations. Extent of removal shall be coordinated with Owner.
3.6 REHABILITATION
A. Certain areas of existing structures, piping, conduits, and the like will be affected by Work necessary to complete modifications under this Contract. The Contractor shall be responsible to rehabilitate those areas affected by its construction activities.
B. Where new piping is installed in existing structures, the Contractor shall accurately position core - drilled openings in the concrete as indicated or otherwise required. Openings shall be of sufficient size to permit a final alignment of pipelines and fittings without deflection of any part and to allow adequate space for satisfactory packing where pipe passes through the wall to provide watertightness around openings so formed. The boxes or cores shall be provided with continuous keyways to hold the filling material in place, and they shall have a slight flare to facilitate grouting and the escape of entrained air during grouting. Before placing the non -shrink grout, concrete surfaces shall be sandblasted, thoroughly cleaned of sand and any other foreign matter, and coated with epoxy bonding compound.
C. Pipes, castings, or conduits shall be grouted in place by pouring in grout under a head of at least 4 - inches. The grout shall be poured or rammed or vibrated into place to fill completely the space between the pipes, castings, or conduits, and the sides of the openings so as to obtain the same watertightness as through the wall itself. The grouted casings shall then be water cured.
D. When new piping is to be connected to existing piping, the existing piping shall be cut square and ends properly prepared for the connection. Any damage to the lining and coating of the existing piping shall be repaired. Dielectric insulating joints shall be installed at interconnections between new and existing piping.
E. Abandoned connections to piping and conduits shall be terminated with blind flanges, caps, and plugs suited for the material, type, and service of the pipe or conduit.
F. Where existing handrailing is removed, post embedments and anchors shall be removed and post holes shall be filled with non -shrink grout flush to the floor surface. At the point of continuation of existing handrailing, a new post with rail connections matching the existing handrailing system shall be installed. New posts in existing concrete floors shall be installed in core -drilled socket holes and the annular space between the post and hole filled with non -shrink grout.
G. Where reconstruction activities damage the painting and coating of adjacent or nearby facilities, the damaged areas shall be surface prepared and coated in accordance with Section 09 90 00 — Painting and Coating to match the original painting and coating with a compatible system.
3.7 DISPOSAL
A. Demolition and removal of debris shall minimize interference with roads, streets, walks, and other adjacent occupied or used facilities, which shall not be closed or obstructed without permission from the Owner. Alternate routes shall be provided around closed or obstructed traffic ways.
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B. Site debris, rubbish, and other materials resulting from reconstruction operations shall be legally removed and disposed of. Structures and equipment to be demolished shall be cleaned prior to demolition and the wash water properly disposed of. No trace of these structures shall remain prior to placing of backfill in the areas from which structures were removed.
C. Refuse, debris, and waste materials resulting from demolition and clearing operations shall not be burned.
3.8 OCCUPANCY AND POLLUTION CONTROL
A. Water sprinkling, temporary enclosures, chutes, and other suitable methods shall be used to limit dust and dirt rising and scattering in the area. The Contractor shall comply with government regulations pertaining to environmental protection.
B. Water shall not be used if it creates hazardous or objectionable conditions such as ice, flooding, or pollution.
3.9 CLEANING
A. During and upon completion of Work, the Contractor shall promptly remove tools and equipment, surplus materials, rubbish, debris, and dust and shall leave areas affected by Work in a clean, approved condition.
B. Adjacent structures shall be cleaned of dust, dirt, and debris caused by reconstruction, as directed by the Engineer or governing authorities, and adjacent areas shall be returned to condition existing prior to start of Work.
END OF SECTION 024100
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SECTION 032900 — JOINTS IN CONCRETE
PART 1 - GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall construct all construction joints, expansion joints and control joints in concrete at the locations shown (where not shown the Contractor shall submit joint layout for Engineer's approval) and formed in accordance with the details shown in the drawings.
B. Waterstops shall be provided in all construction and expansion joints of hydraulic or below grade structures unless specifically noted otherwise on the drawings.
1.2 RELATED WORK SPECIFIED ELSEWHERE
A. Cast -In -Place Concrete. 033000
B. Joint Sealants. 079200
1.3 REFERENCE SPECIFICATIONS, CODES AND STANDARDS
A. Federal Specifications:
TT -S -00227E
B. Commercial Standards:
ASTM C920
ASTM D624
ASTM D1752
Sealing Compound, elastomeric type, multi -component (for Caulking, Sealing, Glazing Buildings and Other Structures).
Specification for Elastomeric Joint Sealants.
Standard Test Method for Tear Strength of Conventional
Vulcanized Rubber and Thermoplastic Elastomers.
Specification for Preformed Sponge Rubber and Cork Expansion Joint Fillers for Concrete Paving and Structural Construction.
C. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.
1.4 CONTRACTOR SUBMITTALS
A. Waterstop: Prior to production of the waterstop material required under this Contract, the Contractor shall submit for review complete product data, including qualification samples of extruded sections of each size and shape to be used, catalogue cut, technical data, storage requirements, and splicing methods. The submittal shall also include the manufacturer's certification that the water stop material meets the physical requirements as outlined under paragraph 2.1, herein.
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1.5 QUALITY ASSURANCE
A. Waterstop Inspection: Waterstop installation shall be subject to rigid inspection, and no such work shall be scheduled or started without the Contractor having made prior arrangements with the Construction Manager to provide for the required inspections. Not less than twenty-four (24) hours notice shall be provided to the Construction Manager for scheduling such inspections.
B. Waterstop Field Samples: Prior to use of the waterstop material in the field, a sample of a fabricated mitered cross and a tee constructed of each size or shape of material to be used shall be submitted to the Engineer for review. These samples shall be fabricated so that the material and workmanship represent in all respects the fittings to be furnished under this Contract. Field samples of fabricated fittings (crosses, tees, etc.) may be selected at random by the Engineer for testing by a laboratory at the Owner's expense. When tested, they shall have a tensile strength across the joints equal to at least 600 psi.
C. All field joints in waterstops shall be subject to rigid inspection for misalignment, bubbles, inadequate bond, porosity, cracks, offsets and other defects which would reduce the potential resistance of the material to water pressure at any point. All defective joints shall be replaced and all weathered, damaged or otherwise faulty material shall be removed from the site and disposed of by the Contractor at its own expense.
D. Waterstops shall be stored on site where it will not be subjected to freezing temperatures or exposed to the direct rays of the sun.
E. Construction Joint Sealant: The Contractor shall prepare adhesion and cohesion test specimens as specified herein from each shipment of material received at the jobsite. Sealant shall be stored at room temperature and shall not be stored longer than seventy-five percent (75%) of the manufacturer's stated shelf life.
F. The sealant material shall show no signs of adhesive or cohesive failure when tested in accordance with the following procedure:
1. Sealant specimen shall be prepared between two concrete blocks (1 -inch by 2 -inch by 3 - inch). Spacing between the blocks shall be 1/2 -inch. Coated spacers (2 -inch by 1-1/2 inch by 1/2 -inch) shall be used to ensure sealant cross -sections of 1/2 -inch by 2 -inches with a width of 1/2 -inch.
2. Sealant shall be cast and cured according to manufacturer's recommendations except that curing period shall not exceed twenty-four (24) hours.
3. Following curing period, the gap between blocks shall be widened to 1 -inch. Spacers shall be used to maintain this gap for twenty-four (24) hours prior to inspection for failure.
1.6 GUARANTEE
A. The Contractor shall provide a three (3) year written guarantee of the entire joint sealant and waterstop installations against faulty and/or incompatible materials and workmanship, together with a statement that it agrees to repair or replace, to the satisfaction of the Owner, at no additional
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cost to the Owner, any such defective areas which become evident within said three (3) year guarantee period.
PART 2 - PRODUCTS
2.1 PVC WATERSTOPS
A. General: Waterstops shall be extruded from an elastomeric plastic compound consisting of virgin polyvinylcloride and additional plasticizers and stabilizers necessary to meet or exceed the requirements and performance criteria of these Specifications and the Corps of Engineers Specifications CRD-0572. No reclaimed scrap or reprocessed material shall be used.
B. Flatstrip, Center -Bulb and Multi -Rib Waterstops: Flatstrip, center -bulb and multi -rib waterstops shall be detailed and as manufactured by: Sika Greenstreak, Vinylex Corp or approved equal; provided, that at no place shall the thickness of flat strip waterstops, including the center -bulb type, be less than 3/8 -inch. Prefabricated joint fittings shall be used at all intersections of the ribbed -type waterstops.
C. Other Types of Waterstops: When other types of waterstops not listed above are required and indicated, they shall be subjected to the same requirements as those listed herein.
D. Physical Properties: When tested in accordance with the specified test standards, the waterstop material shall meet or exceed the following requirements:
ASTM Test
Physical Property, Sheet Material Value Method
Tensile Strength -Min (psi) 1750 D 638
Ultimate Elongation -Min (percent) 350 D 638
Low Temp. Brittleness -Max (degrees F) -35 D 746
Stiffness in Flexure -Min (psi) 400 D 747
Accelerated Aging (CRD-0572)
Tensile Strength -Min (psi)
Ultimate Elongation -Min (percent)
2.2 HYDROPHILIC WATERSTOPS
1500 D 638
300 D 638
A. Hydrophilic waterstops where shown on the Drawings, shall be Adeka Ultra Seal MC -2010 MN, Greenstreak "Hydrotite" Hydrophilic rubber waterstops or equal. Hydrophilic waterstops shall be installed according to the manufacturer's recommendations.
B. Physical Properties: When tested in accordance with the specified test standards, the waterstop material shall meet or exceed the following requirements:
ASTM TEST
Physical Property Value Method
Hardness 30 2240
Tensile Strength 100 D412
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Elongation % 500 D412
Specific Gravity 1.18 D792
C. Hydrophilic Paste: Where required, use a paste to adhere the waterstop to the surface. Paste shall be Adeka P-201 or equal. Paste shall be applied according to the manufacturer's recommendations.
2.3 JOINT SEALANTS
A. Joint sealant shall be Sikaflex 2c NS or equal. Where sealant is applied in areas to be submerged in liquid, Sikaflex Primer -429 or equal shall be applied first. Contractor shall follow the manufacturer' s recommended application methods.
PART 3 - EXECUTION
3.1 GENERAL
A. Unless otherwise shown, waterstops of the type specified herein, shall be fully continuous for the extent of the joint. The Contractor shall take suitable precautions and means to support and protect the waterstops during the progress of the work and shall repair or replace at its own expense any waterstops damaged during the progress of the work.
B. Suitable precautions shall be taken to shade and protect the exposed waterstop from direct rays of the sun during the entire exposure and until the exposed portion of the waterstop is embedded in concrete.
C. Splices in waterstops shall be performed by heat sealing the adjacent waterstop sections in accordance with the manufacturer's printed recommendations. It is essential that the splices have a tensile strength of not less than sixty percent (60%) of the unspliced materials tensile strength and the continuity of the waterstop ribs and of its tubular center axis be maintained.
3.2 INSTALLATION OF WATERSTOP
A. All joints with waterstops involving more than two (2) ends to be jointed together and all joints which involve an angle cut, alignment change or the joining of two (2) dissimilar waterstop sections shall be prefabricated by the Contractor prior to placement in the forms, allowing not less than 24 -inch long strips of waterstop material beyond the joint. Upon being inspected and approved, such prefabricated waterstop joint assemblies shall be installed in the forms and the ends of the 24 -inch strips shall be butt welded to the straight run portions of waterstop in place in the forms.
B. Adequate provisions must be made to support the waterstops during the progress of the work and to ensure the proper embedment in the concrete. The symmetrical halves of the waterstops shall be equally divided between the concrete pours at the joints. The center axis of the waterstops shall be coincident with the joint openings. Maximum density and imperviousness of the concrete shall be ensured by thoroughly working it in the vicinity of all joints.
C. Adequate means shall be provided to prevent waterstops from being folded over by the concrete as it is placed. Unless otherwise shown, all waterstops shall be held in place with light wire ties on
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12 -inch centers which shall be passed through the edge of the waterstop and tied to the curtain of reinforcing steel. In placing concrete around horizontal waterstops, with their flat face in a horizontal plane, concrete shall be carefully worked under the waterstops so as to avoid the formation of air and rock pockets.
3.3 JOINT CONSTRUCTION
A. Joint Location: Construction joints and control joints shall be provided where shown on Drawings or as approved by the Engineer. Do not eliminate or relocate control joints. Any additional or relocation of construction joints proposed by the Contractor must be submitted to the Engineer for written approval. The location of all joints shall be submitted for acceptance by the Engineer.
B. Construction Joints
1. Locate additional or relocated joints where they least impair strength of the member. In general, locate joints within the middle third of spans of slabs, beams and girders. However, if a beam intersects a girder at the joint, offset the joint a distance equal to twice the width of the member being connected. Locate joints in walls and columns at the underside of floors, slabs, beams or girders and at tops of footings or floor slabs. Do not locate joints between beams, girders, column capitals, or drop panels and the slabs above them. Do not locate joints between brackets or haunches and walls or columns supporting them
2. At all construction joints and at concrete joints indicated on the Drawings to be "roughened", uniformly roughen the surface of the concrete to a full amplitude (distance between high and low points and side to side) of 1/4 -in with chipping tools to expose a fresh face. Thoroughly clean joint surfaces of loose or weakened materials by waterblasting or sandblasting and prepare for bonding. At least two hours before and again shortly before the new concrete is deposited, saturate the joints with water. After glistening water disappears, coat joints with neat cement slurry mixed to the consistency of very heavy paste. The surfaces shall receive a coating at least 1/8 -in thick, scrubbed -in by means of stiff bristle brushes. Deposit new concrete before the neat cement dries.
3. Unless indicated otherwise, provide joints perpendicular to main reinforcement. Continue reinforcing steel through the joint as indicated on the Drawings.
4. Provide waterstops in wall and slab construction joints in liquid retaining structures and at other locations shown on the Drawings.
5. Do not use keyways in construction joints unless specifically shown on the Drawings or approved by the Engineer.
C. Control Joints
1. Make control joints at locations shown on the Drawings. Do not eliminate or relocate control joints.
2. Provide waterstops, sealant grooves, and sealants in wall and slab control joints in liquid retaining structures and at other locations shown on the Drawings.
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3. Extend every other bar of reinforcing steel through control joints or as indicated on the Drawings. Coat the concrete surface with a bond breaker prior to placing new concrete against it as shown on the Drawings. Do not coat reinforcement or waterstops with bond breaker.
D. Sealant
1. Install sealants in clean dry recesses free of frost, oil, grease, form release agent, loose material, laitance, dirt, dust and other materials which will impair bond at the locations shown on the Drawings. Apply sealant conforming to the manufacturer's recommendations including concrete cure, temperature, moisture, mixing, primer, primer cure time, joint and recess preparation, tooling, and curing. Apply masking tape to each side of the joint prior to the installation of the sealant and remove afterwards along with any spillage to leave a sealant installation with neat straight edges.
2. Sealant grooves shall be formed as shown on the drawings and shall be protected from damage until final application of the sealant. Care shall be taken to prevent chipping of the sealant grove during removal of forms.
E. Special care shall be used in preparing concrete surfaces at joints where bonding between two (2) sections of concrete is required. Unless otherwise shown, such bonding will be required at all horizontal joints in walls and wall to slab joints. Surfaces shall be prepared by sandblasting and washing for removal of laitance or any objectional material. Joints shall be kept clean until the concrete is placed. Vertical joints shall be clean and free of concrete fins, rock pockets or any objectional material.
END OF SECTION 032900
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SECTION 033000 - CAST -IN -PLACE CONCRETE
PART 1 - GENERAL
1.1 SUMMARY
A. Section includes cast -in -place concrete, including formwork, reinforcement, concrete materials, mixture design, placement procedures, and finishes.
B. Related Sections:
1. Section 312000 "Earth Moving" for drainage fill under slabs -on -grade.
1.2 ACTION SUBMITTALS
A. Product Data: For each type of product indicated.
B. Design Mixtures: Before placing any concrete, the Contractor shall submit to the Engineer, for review, the complete details of all concrete mix designs which he proposes to use including proportions and gradations of all materials for each class and type of concrete specified herein.
The mix designs shall be designed by a certified testing laboratory acceptable to the Engineer.
The mix design submittal shall also include test results from at least one (1) trial batch of each class and type concrete. From each trial batch six (6) 6 -inch X 12 -inch test cylinders shall be cast in accordance with ASTM C 31. Three (3) of these cylinders shall be compression tested in accordance with ASTM C 39 at 7 -days and the other three (3) at 28 -days. Test results shall include full information on each cylinder as to mix and slump in accordance with ASTM C 143.
Three (3) drying shrinkage specimens shall also be cast and tested in accordance with ASTM C 157 on each type of structural concrete mix design. All costs for such mix design including mix design tests shall be borne by the Contractor.
C. If fly ash concrete is proposed by the concrete supplier, the Contractor shall submit to the Engineer for review the design mix for fly ash concrete together with the design mix for Portland Cement (non -fly ash) concrete as specified in this Section. The Contractor shall furnish a Certificate of Compliance signed by the supplier identifying the type of fly ash and stating that the fly ash complies with ASTM C 618 and these specifications, together with all supporting test data including a certified chemical and physical analysis report prior to the use of the fly ash the sample represents. The supporting data shall also contain test results confirming that the fly ash in combination with the cement and water to be used meets all strength requirements and is compatible with air -entraining agents and other admixtures.
D. Delivery Tickets: Where ready -mix concrete is used, the Contractor shall provide certified weighmaster delivery tickets at the time of delivery of each load of concrete. Each certificate shall show the total quantities, weight of cement, sand, each class of aggregate, admixtures and the amounts of water in the aggregate and added at the batching plant as well as the amount of water allowed to be added at the site for the specific design mix. Each certificate shall also state the mix number, total yield in cubic yards, the time the batch was dispatched, when it left the plant, when it arrived at the site, when unloading began, and when unloading was finished.
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E. Steel Reinforcement Shop Drawings: Placing drawings that detail fabrication, bending, and placement.
F. Formwork Shop Drawings: Prepared by or under the supervision of a qualified professional engineer detailing fabrication, assembly, and support of formwork.
G. Welding certificates.
H. Material certificates.
1. Certify that admixtures used in the same concrete mix are compatible with each other and the aggregates.
2. Certify that the Contractor is not associated with the independent testing laboratory proposed for use by the Contractor nor does the Contractor or officers of the Contractor's organization have a beneficial interest in the laboratory.
3. Certify that cement is produced by a manufacturer that does not use hazardous waste derived fuel as an energy source for its kilns.
4. Certificate of conformance for concrete production facilities from the NRMCA.
I. Material test reports.
1. Aggregates: Conformance to ASTM standards, including sieve analysis, mechanical properties, deleterious substance content, and mortar bar expansion test results.
2. Cement and fly ash: Conformance to ASTM standards, including chemical analysis and physical tests.
3. Concrete mixes: For each formulation of concrete proposed for use, submit constituent quantities per cubic yard, water cementitious ratio, air content, concrete slump, type and manufacturer of cement and type and manufacturer of fly ash. Provide for each mix proposed.
a. Standard deviation data for each proposed concrete mix based on statistical records.
Provide the following for each strength data point used in the calculation of the standard deviation for determination of the minimum required average strength:
1) Date of sampling and name of testing laboratory.
2) Name of concrete batch plant.
3) Water cementitious ratio.
4) Slump of batch.
5) Air content of batch.
6) 28 day compression test results.
7) If available, temperature and unit weight of batch.
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Provide data from projects not more strictly controlled than outlined in these specifications. Provide summary sheet showing all pertinent data and the computation of the standard deviation.
4. Concrete Mixes: Shrinkage test results for concrete used in hydraulic structures.
J. Floor surface flatness and levelness/slope measurements and wall plumbness measurements.
1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS
A. American Society for Testing and Materials (ASTM)
1. ASTM A615/A615M — Standard Specification for Deformed and Plain Carbon -Steel Bars for Concrete Reinforcement.
2. ASTM A884/A884M — Standard Specification for Epoxy -Coated Steel Wire and Welded Wire Reinforcement.
3. ASTM A1064/A1064M — Standard Specification for Carbon -Steel Wire and Welded Wire Reinforcement, Plain and Deformed, for Concrete.
4. ASTM C31 - Standard Practice for Making and Curing Concrete Test Specimens in the Field.
5. ASTM C33 - Standard Specification for Concrete Aggregates.
6. ASTM C39 - Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens.
7. ASTM C40 - Standard Test Method for Organic Impurities in Fine Aggregates for Concrete.
8. ASTM C42 - Standard Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete.
9. ASTM C94 - Standard Specification for Ready -Mixed Concrete.
10. ASTM C 109 - Standard Test Method for Compressive Strength of Hydraulic Cement Mor- tars (Using 2 -inch or 50 -mm Cube Specimens).
11. ASTM C138 — Standard Test Method for Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete.
12. ASTM C143 - Standard Test Method for Slump of Hydraulic -Cement Concrete.
13. ASTM C150 - Standard Specification for Portland Cement.
14. ASTM C156 - Standard Test Method for Water Loss (from a Mortar Specimen) Through Liquid Membrane -Forming Curing Compounds for Concrete.
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15. ASTM C157 - Standard Test Method for Length Change of Hardened Hydraulic -Cement Mortar and Concrete.
16. ASTM C171 - Standard Specification for Sheet Materials for Curing Concrete.
17. ASTM C173 - Standard Test Method for Air Content of Freshly Mixed Concrete by the Volumetric Method.
18. ASTM C192 — Standard Practice for Making and Curing Concrete Test Specimens in the Laboratory.
19. ASTM C231 - Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method.
20. ASTM C260 - Standard Specification for Air -Entraining Admixtures for Concrete.
21. ASTM C309 - Standard Specification for Liquid Membrane -Forming Compounds for Curing Concrete.
22. ASTM C311 - Standard Test Methods for Sampling and Testing Fly Ash or Natural Pozzolans for use in Portland Cement Concrete.
23. ASTM C494 - Standard Specification for Chemical Admixtures for Concrete.
24. ASTM C596 - Standard Test Method for Drying Shrinkage of Mortar Containing Hydraulic Cement.
25. ASTM C618 - Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete.
26. ASTM C827 - Standard Test Method for Change in Height at Early Ages of Cylindrical Specimens of Cementitious Mixtures.
27. ASTM C 1077 - Standard Practice for Agencies Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Testing Agency Evaluation.
28. ASTM C1218 - Standard Test Method for Water -Soluble Chloride in Mortar and Concrete.
29. ASTM C 1260 - Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar - Bar Method).
30. ASTM E329 - Standard Specification for Agencies Engaged in Construction Inspection, Testing, or Special Inspection.
B. American Concrete Institute (ACI).
1. ACI 117 — Specification for Tolerances for Concrete Construction and Materials.
2. ACI 211.1 - Standard Practice for Selecting Proportions for Normal, Heavyweight and Mass Concrete.
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3. ACI 232.2R - Use of Fly Ash in Concrete.
4. ACI 301 — Specifications for Structural Concrete for Buildings.
5. ACI 304R - Guide for Measuring, Mixing, Transporting and Placing Concrete.
6. ACI 304.2R - Placing Concrete by Pumping Methods.
7. ACI 305R - Hot Weather Concreting.
8. ACI 306R - Cold Weather Concreting.
9. ACI 318 - Building Code Requirements for Structural Concrete and Commentary.
10. ACI 347R — Guide to Formwork for Concrete.
11. ACI 350 - Code Requirements for Environmental Engineering Concrete Structures and Commentary.
C. National Ready Mixed Concrete Association (NRMCA)
1. Quality Control Manual, Section 3 - Certification of Ready Mixed Concrete Production Facilities.
D. Truck Mixer Manufacturers Bureau (TMMB)
1. TMMB 100 - Truck Mixer, Agitator and Front Discharge Concrete Carrier Standards.
E. Corps of Engineers Specification
1. CRD-C 621-85 Corps of Engineers Specification for Non -Shrink Grout F. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.
1.4 QUALITY ASSURANCE
A. Manufacturer Qualifications: A firm experienced in manufacturing ready -mixed concrete products and that complies with ASTM C 94/C 94M requirements for production facilities and equipment.
1. Manufacturer certified according to NRMCA's "Certification of Ready Mixed Concrete Production Facilities."
B. Testing Agency Qualifications: An independent agency, acceptable to authorities having jurisdiction, qualified according to ASTM C 1077 and ASTM E 329 for testing indicated.
1. Name and address.
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2. Names and positions of principal officers and the name, position, and qualifications of the responsible registered professional engineer in charge.
3. Listing of technical services to be provided. Indicate external technical services to be provided by other organizations.
4. Names and qualifications of the supervising laboratory technicians.
5. Statement of conformance provided by evaluation authority defined in ASTM C1077.
Provide report prepared by evaluation authority when requested by the Engineer.
6. Submit as required above for other organizations that will provide external technical services.
C. Welding Qualifications: Qualify procedures and personnel according to AWS D1.4/D 1.4M, "Structural Welding Code - Reinforcing Steel."
D. ACI Publications: Comply with the following unless modified by requirements in the Contract Documents:
1. ACI 301, "Specifications for Structural Concrete."
E. Concrete Testing Service: Engage a qualified independent testing agency to perform material evaluation tests and to design concrete mixtures.
F. Preinstallation Conference: Conduct conference at Project site.
G. Mix design tests on component materials and for compressive strength and shrinkage of concrete shall be performed as specified herein. The mix shall not at any time be changed without approval of the Engineer, except that at all times the batching of fine aggregate shall be adjusted to compensate for the moisture content. Satisfactory means shall be provided at the batching plant for checking the moisture content of the fine aggregate. The details of concrete mixes submitted for approval shall include information on the correction of the batching for varying moisture contents of the fine aggregate.
To avoid unnecessary or haphazard changes in consistency, the aggregate shall be obtained from a source which will ensure a uniform quality.
H. During the progress of construction, the Owner will have tests made to determine whether the concrete, as being produced, complies with the standards of quality specified herein. These tests will be made in accordance with ASTM C 31, ASTM C 39, and ASTM C 157. The testing expense during construction, except for the trial batch or mix design testing, will be borne by the Owner. The number of sets of concrete test cylinders taken of each class of concrete placed each day shall comply with the requirements of the California Building Code (CBC), Section 1903, but shall not be less than one set per day, nor less than one set for each 150 cubic yards of concrete nor less than one set for each 5,000 square feet of surface area for slabs and walls. The costs of additional tests, including non-destructive tests and core drilling, needed to verify or investigate the quality of concrete that is questionable as to meeting the specification, shall be borne by the Contractor.
I. Specimens shall be formed in 6 -in by 12 -in long non-absorbent cylindrical molds.
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1. A "set of test cylinders shall consist of five cylinders; one to be tested at seven days, one to be tested at 14 days, and two to be tested and their strengths averaged at 28 days. The remaining cylinder will be held to verify test results, if needed.
J. Concrete for testing shall be supplied by the Contractor at no cost to the Owner, and the Contractor shall provide assistance to the Owner in obtaining samples and disposal and cleanup of excess material.
K. Evaluation and Acceptance of Concrete:
1. Concrete is expected to reach a higher compressive strength than that which is indicated in Paragraph 2.9, as compressive strength. The strength level of the concrete will be considered satisfactory if the average strength of the two (2) 28 -day specimens equals or exceeds the required strength and no individual specimen strength falls below the required strength by more than 500 psi. Where an individual strength test falls below the required strength by more than 500 psi, the Engineer shall have the right to ask for cores taken in accordance with ASTM C 42 and ACI 318, all at the Contractors expense.
2. If any concrete fails to meet these requirements, immediate corrective action shall be taken to increase the compressive strength for all subsequent batches of the type of concrete affected.
3. All concrete which fails to meet the ACI requirements and these specifications, is subject to removal and replacement at the cost of the Contractor.
L. Test slump immediately prior to placing the concrete. Test shall be made in accordance with ASTM C143. When concrete is pumped, slump will be determined at point of truck discharge.
If the slump is outside the specified range, the concrete will be rejected.
M. Test for air content shall be conducted on a fresh concrete sample. Air content for concrete made of ordinary aggregates having low absorption shall be made in compliance with either the pressure method complying with ASTM C231 or by the volumetric method complying with ASTM C173.
If aggregates with high absorptions are used, the latter test method shall be used. When concrete is pumped, air content will be determined at point of placement.
N. Shrinkage Tests: Shrinkage tests will be made during construction to ensure continued compliance with these specifications.
O. Ready -mix concrete shall conform to the requirements of ASTM C 94.
P. The Engineer shall have access to and have the right to inspect all batch plants, cement mills and supply facilities providing products under these specifications. Batch plants shall have current certificates that all scales have been tested and are certified within the tolerances as set forth in the National Bureau of Standards Handbook No. 44.
Q.
Construction Tolerances: The Contractor shall set and maintain concrete forms and perform finishing operations so as to ensure that the completed work is within the tolerances specified herein. Surface defects and irregularities are defined as finishes and are to be distinguished from tolerances. Tolerance is the specified permissible variation from lines, grades or dimensions shown. Where tolerances are not stated in these specifications, permissible deviations will be in
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accordance with ACI 347. Where tolerances are not met, the concrete shall be repaired or replaced at the Contractor's expense until the tolerances are met.
The following construction tolerances are hereby established and apply to finished walls and slab unless otherwise shown:
Structural Component
Variation of the constructed
linear outline from the
established position in plan.
Variation from the level or
from the grades shown.
Variation from the plumb.
Variation in the thickness of
slabs and walls.
Variation in the locations and
sizes of slab and wall openings.
PART 2 - PRODUCTS
Tolerance
In 10 -feet: 1/4 -inch;
In 20 -feet or more: 1/2 -inch.
In 10 -feet: 1/4 -inch;
In 20 -feet or more: 1/2 -inch.
In 10 -feet: 1/4 -inch;
In 20 -feet or more: 1/2 -inch.
Minus 1/4 -inch; Plus 1/2 -inch.
Plus or minus 1/4 -inch.
2.1 FORM -FACING MATERIALS
A. Smooth -Formed Finished Concrete: Form -facing panels that will provide continuous, true, and smooth concrete surfaces. Furnish in largest practicable sizes to minimize number of joints.
B. Rough -Formed Finished Concrete: Plywood, lumber, metal, or another approved material.
Provide lumber dressed on at least two edges and one side for tight fit.
2.2 STEEL REINFORCEMENT
A. Reinforcing Bars: ASTM A 615/A 615M, Grade 60, deformed.
B. Plain -Steel Welded Wire Reinforcement: ASTM A 1064/A 1064M, plain, fabricated from as -drawn steel wire into flat sheets.
C. Deformed -Steel Welded Wire Reinforcement: ASTM A 1064/A 1064M, flat sheet.
D. Galvanized -Steel Welded Wire Reinforcement: ASTM A 1064/A 1064M, plain, fabricated from galvanized -steel wire into flat sheets.
E. Epoxy -Coated Welded Wire Reinforcement: ASTM A 884/A 884M, Class A coated, Type 1 steel.
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F. Bar Supports: Bolsters, chairs, spacers, and other devices for spacing, supporting, and fastening reinforcing bars and welded wire reinforcement in place. Manufacture bar supports from steel wire, plastic, or precast concrete according to CRSI's "Manual of Standard Practice.
2.3 CONCRETE MATERIALS
A. Cementitious Material: Use the following cementitious materials, of the same type, brand, and source, throughout Project:
1. Portland Cement: ASTM C 150, Type II/V, Low Alkali. Supplement with the following:
a. Fly Ash: ASTM C 618, Class F, including the requirements of Section 2.9 but with the Loss of Ignition (LOI) limited to 3 percent maximum and the optional physical requirements of Table 3. Test in compliance with ASTM C311 with a minimum of one sample weighing four pounds taken from each 200 tons of fly ash supplied for the project.
b. Portland Cement shall contain not more than 0.60 percent total alkalies. The term "alkalies" is defined as the sum sodium oxide (Na2O), potassium oxide (I(20), calculated as sodium oxide (.658 1(20). Only one (1) brand of cement shall be used for exposed concrete in any individual structure. The cement shall be suitably protected from exposure to moisture until used. Certified mill test reports for each shipment of cement to be used shall be submitted to the Engineer. Mill test reports shall include the alkali content. Do not use cement produced by a manufacturer that uses hazardous waste derived fuel as an energy source for its kilns. c. Do not use air entraining cements.
B. Normal -Weight Aggregates: ASTM C 33, graded.
1. Maximum size aggregate in foundations and mass concrete shall be 1 inch. The maximum size aggregate in slabs on grade, walls, and all other concrete shall be 1 inch.
C. Water: ASTM C 94/C 94M and potable. Water shall be clean and free from objectionable quantities of silty organic matter, oils, chlorides, alkali, salts and other impurities. The water shall be considered potable, for the purpose of this Section only, if it meets the requirements of the local governmental agencies. Agricultural water with high total dissolved solids (over 1000 mg/1 TDS) shall not be used.
2.4 AGGREGATES
A. All concrete aggregates shall be obtained from pits acceptable to the Engineer, shall be non -reactive, sound, uniformly graded and free of deleterious material in excess of allowable limits specified.
B. Combined aggregates shall be well graded from coarse to fine sizes, and be uniformly graded between screen sizes to produce a concrete that has optimum workability and consolidation characteristics. Lightweight sand for fine aggregate will not be permitted. Aggregates shall conform to ASTM C 33.
1. Coarse Aggregate: Coarse aggregate shall consist of gravel, crushed gravel or crushed stone made up of clean, hard, durable particles free from calcareous coatings, organic
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matter or other foreign substances. Thin or elongated pieces having a length greater than four (4) times the average thickness shall not exceed fifteen percent (15%) by weight.
Deleterious substances shall not be present in excess of the following percentages by weight, and in no case shall the total of all deleterious substances exceed one and one-half percent (1.5%):
2. Fine Aggregate: Fine aggregate for concrete or mortar shall consist of clean, natural sand or a combination of natural and manufactured sands that are hard and durable. Deleterious substances shall not be present in excess of the following percentages by weight of contaminating substances. In no case shall the total exceed three percent (3%):
Fine aggregate shall not contain strong alkali nor organic matter which gives a color darker than a standard color when tested in accordance with ASTM C 40. Fine aggregate shall have a fineness modulus not less than 2.50 nor greater than 3.00. Except as otherwise specified, fine aggregate shall be graded from coarse to fine in accordance with the requirements of ASTM C 33.
3. The fine and coarse aggregates used shall not cause expansion of mortar bars greater than
0.1 percent in 16 days when tested in accordance with ASTM C1260 and using the cement proposed for the project. If aggregates proposed for use do not meet this requirement, then satisfy either a. or b. below.
a. Total equivalent alkali content of the cement used shall not exceed 0.6 percent as provided in the Optional Chemical Requirements of ASTM C150. b. The fine and coarse aggregates used shall not cause expansion of mortar bars greater than 0.1 percent in 16 days when tested in accordance with ASTM C 1260 and using the cement and fly ash proposed for the project. The proportions of the cement -fly ash mix shall be the same as those proposed for the project.
2.5 ADMIXTURES
A. Air -Entraining Admixture: ASTM C 260. Proportion and mix in accordance with manufacturer's recommendations.
B. Chemical Admixtures: Provide admixtures certified by manufacturer to be compatible with other admixtures and that will not contribute water-soluble chloride ions exceeding those permitted in hardened concrete. Do not use calcium chloride or admixtures containing calcium chloride.
1. All concrete shall contain five percent (5%), plus or minus one percent (1%) entrained air of evenly dispersed air bubbles at the time of placement. Air entrainment requirement may be modified or waived following an approval from the Engineer for concrete construction not exposed to freeze/thaw cycles. The air -entraining agent shall contain no chloride and conform to ASTM C 260, or U.S. Army Corps of Engineers Specifications CRD-C 13. The air -entraining agent shall be added to the batch in a portion of the mixing water. The solution shall be batched by means of a mechanical batcher capable of accurate measurement. The Engineer, or Owner and his duly authorized representatives reserve the right, at any time, to sample and test the air -entraining agent or the air content of concrete received on the job by the Contractor. Air entrainment in the concrete shall be tested by
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ASTM C 138, ASTM C 231 or ASTM C 173. If any sample tested does not have the specified air content, a second test shall be performed. If the second test does not meet the specified air content, the concrete represented by the test shall be removed from the job.
2. Retain one or more chemical admixtures from three subparagraphs below. a. Water -Reducing Admixture: ASTM C 494/C 494M, Type A. Proportion and mix in accordance with manufacturer's recommendations.
b. High -Range, Water -Reducing Admixture (Plasticizer): ASTM C 494/C 494M, Type F resulting in non -segregating plasticized concrete with little bleeding and with the physical properties of low water/cementitious ratio concrete. The treated concrete shall be capable of maintaining its plastic state in excess of 2 hours.
Proportion and mix in accordance with manufacturer's recommendations. c. Do not use admixtures causing retarded or accelerated setting of concrete without written approval from the Engineer. Use retarding or accelerating water reducing admixture when so approved.
2.6 SHEET VAPOR RETARDER
A. Provide under building slabs. ASTM E 1745, Class A. Include manufacturer's recommended adhesive or pressure sensitive tape.
1. Sheet Vapor Retarder: Polyethylene sheet, ASTM D 4397, not less than 10 mils thick.
2. Vaporblock VB10, by Raven Industries,
3. Or Equal.
2.7 CURING MATERIALS
A. Evaporation Retarder: Waterborne, monomolecular film forming, manufactured for application to fresh concrete.
B. Absorptive Cover: AASHTO M 182, Class 2, burlap cloth made from jute or kenaf, weighing approximately 9 oz./sq. yd. when dry.
C. Moisture -Retaining Cover: ASTM C 171, polyethylene film or white burlap -polyethylene sheet.
The loss of moisture, when determined in accordance with the requirements of ASTM C 156, shall not exceed 0.055 grams per square centimeter of surface.
D. Polyethylene sheet for use as concrete curing blanket shall be white and shall have a normal thickness of 6 mils.
E. Water: Potable.
F. Clear, Waterborne, Membrane -Forming Curing Compound: ASTM C 309, Type 1, Class B, dissipating. The curing compound shall contain a fugitive dye so that areas of application will be readily distinguishable. Compound shall contain no wax, paraffin, or oil. Curing compound shall be non -yellowing and have a unit moisture loss no greater than 0.039 gm/cm2 at 72 hours as
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measured by ASTM C156. Curing compound shall comply with Federal, State, and local VOC limits.
2.8 RELATED MATERIALS
A. Expansion- and Isolation -Joint -Filler Strips: ASTM D 1751, asphalt -saturated cellulosic fiber or ASTM D 1752, cork or self -expanding cork.
2.9 CONCRETE MIXTURES
A. Prepare design mixtures for each type and strength of concrete, proportioned on the basis of laboratory trial mixture or field test data, or both, according to ACI 301.
B. Cementitious Materials: Use fly ash as needed to reduce the total amount of portland cement.
Fly ash, as a percent by weight of total cementitious materials, shall not exceed 15 percent.
1. Class F Fly Ash
a. Loss on ignition, maximum 1%
b. SO3 content, maximum 3%
c. Moisture content, maximum 1%
d. R = (CaO - 5%)/(Fe2O3), maximum 1.5
C. Admixtures: Use admixtures according to manufacturer's written instructions.
1. Use water -reducing high -range water -reducing or plasticizing admixture in concrete, as required, for placement and workability.
2. Use water -reducing admixture when required by high temperatures, low humidity, or other adverse placement conditions.
3. Use water -reducing admixture in pumped concrete, concrete for heavy -use industrial slabs, concrete required to be watertight, and concrete with a water-cementitious materials ratio below 0.50.
D. Proportion normal -weight concrete mixture as follows:
1. Minimum Compressive Strength: 4000 psi at 28 days.
2. Maximum Water-Cementitious Materials Ratio: 0.45
3. Minimum Cement W/C per cubic yard (941b sacks): 6.0
4. Slump Limit: 3 inches, plus or minus 1 inch or 8 inches for concrete with verified slump of 2 to 4 inches before adding high -range water -reducing admixture or plasticizing admixture, plus or minus 1 inch.
5. Air Content: 4 percent, plus or minus 1 percent at point of delivery.
6. Air Content: Do not allow air content of trowel -finished floors to exceed 3 percent.
7. Type of Work: Structural Concrete.
E. Proportion Lean concrete mixture as follows:
1. Minimum Compressive Strength: 2500 psi at 28 days.
2. Maximum Water-Cementitious Materials Ratio: 0.60
3. Minimum Cement W/C per cubic yard (94 lb sacks): 4.5
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4. Slump Limit: 3 inches, plus '/z inch or minus 1 inch or 8 inches for concrete with verified slump of 2 to 4 inches before adding high -range water -reducing admixture or plasticizing admixture, plus or minus 1 inch.
5. Air Content: 4 percent, plus or minus 1 percent at point of delivery.
6. Air Content: Do not allow air content of trowel -finished floors to exceed 3 percent.
7. Type of Work: Lean Concrete.
2.10 FABRICATING REINFORCEMENT
A. Fabricate steel reinforcement according to CRSI's "Manual of Standard Practice."
2.11 CONCRETE MIXING
A. Ready -Mixed Concrete: Measure, batch, mix, and deliver concrete according to ASTM C 94/C 94M, and furnish batch ticket information.
1. When air temperature is between 85 and 90 deg F, reduce mixing and delivery time from 60 minutes to 45 minutes.
2.12 TRIAL BATCH AND LABORATORY TESTS
A. The Contractor shall take sets of field control cylinder specimens during the progress of the work in compliance with ASTM C31. The number of sets of concrete test cylinders taken of each class of concrete place each day shall comply with the requirements of the California Building Code (CBC), Section 1903, but shall not be less than one set per day, nor less than one set for each 150 cubic yards of concrete nor less than one set for each 5,000 square feet of surface area for slabs or walls.
B. Before placing any concrete, the Contractor shall submit the certified trial batch results of each class of concrete having a 28 -day strength of 4,000 psi or higher, based on the preliminary concrete mixes submitted by the Contractor. All concrete shall conform to the requirements of this Section, whether the aggregate proportions are from the Contractors preliminary mix design, or whether the proportions have been adjusted during the trial batch process. The trial batch shall be prepared using the aggregates, cement and admixture proposed for the project. The costs for the trial batch tests shall be borne by the Contractor.
C. Specimens shall be formed in 6 -in by 12 -in long non-absorbent cylindrical molds.
1. A "set" of test cylinders shall consist of five cylinders; one to be tested at seven days, one to the tested at 14 days, and two to be tested and their strengths averaged at 28 days. The remaining cylinder will be held to verify test results, if needed.
2. When the average 28 day compressive strength of the cylinders in any set falls below the required compressive strength or below proportional maximum seven-day or 14 -day strengths (where proper relation between seven, 14, and 28 day strengths have been established by tests), change proportions, cementitious content, or temperature conditions to achieve the required strengths at no additional cost to the Owner.
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D. Provide four firmly braced, insulated, heated, closed wooden curing boxes, each sized to hold ten specimens, complete with cold weather temperature and hot weather temperature control thermostat for initial curing and storage from time of fabrication until shipment to the Contractor's testing lab. Protect the specimens against injury or loss through construction operations.
E. Test slump immediately prior to placing the concrete. Test shall be made in accordance with ASTM C143. When concrete is pumped, slump will be determined at point of truck discharge. If the slump is outside the specified range, the concrete will be rejected.
F. Test for air content shall be conducted on a fresh concrete sample. Air content for concrete made of ordinary aggregates having low absorption shall be made in compliance with either the pressure method complying with ASTM C231 or by the volumetric method complying with ASTM C173.
If aggregates with high absorptions are used, the latter test method shall be used. When concrete is pumped, air content will be determined at point of placement.
G. A standard sieve analysis of the combined aggregate for each trial batch shall be performed according to the requirements for ASTM C 136. Values shall be given for percent passing each sieve.
2.13 SHRINKAGE LIMITATION
A. Drying shrinkage specimens shall be 4 -inch by 4 -inch by 11 -inch prisms with an effective gage length of 10 -inches, fabricated, cured, dried and measured in accordance with ASTM C 157 modified as follows: Specimens shall be removed from molds at an age of 23+ hours after trial batching, shall be placed immediately in water at 70 degrees F. +3 degrees F. for at least thirty (30) minutes, and shall be measured within thirty (30) minutes thereafter to determine original length and then submerged in saturated lime water at 73 degrees F. +3 degrees F. Measurement to determine expansion expressed as a percentage of original length shall be made at age 7 -days.
This length at age 7 -days shall be the base length for drying shrinkage calculations ("0" days drying age). Specimens then shall be stored immediately in a humidity control room maintained at 73 degrees F. +3 degrees F. and fifty percent (50%) ±4 percent relative humidity for the remainder of the test. Measurements to determine shrinkage expressed as percentage of base length shall be made and reported separately for 7, 14, 21 and 28 -days of drying after 7 -days of moist curing.
The drying shrinkage deformation of each specimen shall be computed as the difference between the base length (at "0" days drying age) and the length after drying at each test age. the average drying shrinkage deformation of the specimens shall be computed to the nearest 0.0001 -inch at each test age. If the drying shrinkage of any specimen departs from the average of that test age by more than 0.0004 -inch, the results obtained from that specimen shall be disregarded. Results of the shrinkage test shall be reported to the nearest 0.001 percent of shrinkage. Compression test specimens shall be taken in each case from the same concrete used for preparing during shrinkage specimens. These tests shall be considered a part of the normal compression tests for the project.
Allowable shrinkage limitations shall be specified herein.
B. The maximum concrete shrinkage for specimens cast in the laboratory from the trial batch, as measured at 21 -day drying age and at 28 -day drying age, shall be 0.036 percent and 0.042 percent, respectively. The Contractor shall only use a mix design for construction that has first met the trial batch shrinkage requirements.
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C. The maximum concrete shrinkage for specimens cast in the field shall not exceed the trial batch maximum shrinkage requirement by more than twenty percent (20%).
D. If the required shrinkage limitation is not met during construction, the Contractor shall take all necessary action, at no additional cost to the Owner, for securing the specified shrinkage requirements. These actions may include changing the source of aggregates, cement and/or admixtures; reducing water content ratio; washing or aggregate to reduce fines; increasing the number of construction joints; modifying the curing requirements; or other actions designed to minimize shrinkage or the effects of shrinkage.
2.14 GROUT
A. Grout shall be a mixture of one part Portland cement to 4-1/2 parts sand. Water content shall be such that the grout can be readily spread, yet not wet enough to cause trouble with surface water or laitance, or failure to stay in place after screeding. All grout mixes and mixing procedures shall be submitted in accordance with section 013300 -Contractor Submittals, and shall be subject to review and approval by the Engineer prior to commencing the grouting operations.
B. Procedures for grout placement shall be approved by the equipment supplier, to ensure that no equipment is overstressed, as well as proper placement tolerances. Equipment supplier shall have final say on grouting procedures and final tolerances.
PART 3 - EXECUTION
3.1 MIXING CONCRETE
A. Mixing equipment shall be subject to the Engineer's approval. Mixers shall be of the stationary plant or truck mixer type. Adequate equipment and facilities shall be provided for accurate measurement and control of all materials and for readily changing the proportions of the material.
The mixing equipment shall be maintained in good working order and shall be capable of combining the aggregates, cement and water within the specified time into a thoroughly mixed and uniform mass and of discharging the mixture without segregation. Cement and aggregate shall be proportioned by weight.
B. The batch plant shall be capable of controlling and delivering of all material to within one percent (1%) by weight of the individual material. If bulk cement is used, it shall be weighed on a separate visible scale which will accurately register the scale load at any stage of the weighing operation from zero to full capacity.
C. Cement shall not come in contact with aggregate or with water until the materials are in the mixer ready for complete mixing with all mixing water. The procedure of mixing cement with sand or with sand and coarse aggregate for delivery to the jobsite for final mixing and an addition of mixing water will not be permitted. Re -tempering of concrete will not be permitted. The entire batch shall be discharged before recharging. The volume of the mixed material per batch shall not exceed the manufacturers rated capacity of the mixer.
D. Each mixer shall be equipped with a device for accurately measuring and indicating the quantity of water entering the concrete, and the operating mechanism shall be such that leakage will not
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occur when the valves are closed. Each mixer shall be equipped with a device for automatically measuring, indicating and controlling the time required for mixing. This device shall be interlocked to prevent the discharge of concrete from the mixer before the expiration of the mixing period.
E. Transit -mixed concrete shall be mixed and delivered in accordance with ASTM C 94. After the drum is once started, it shall be revolved continuously until it has completely discharged its batch.
Water shall not be admitted to the mix until the drum has started revolving. The right is reserved to increase the required minimum number of revolutions allowed, if necessary, to obtain satisfactory mixing, and the Contractor will not be entitled to additional compensation because of such an increase or decrease.
F. Mixed concrete shall be delivered to the site of the work and discharge shall be completed within one (1) hour after the addition of the cement to the aggregates. In hot weather or under conditions contributing to quick stiffening of the concrete, or when the temperature of the concrete is 85 degrees F. or above, the time between the introduction of the cement to the aggregates and discharge shall not exceed forty-five (45) minutes. The use of non -agitating equipment for transporting concrete will not be permitted.
G. Truck mixers shall be equipped with counters so that the number of revolutions of the drum may be readily verified. The counter shall be of the resettable type and shall be actuated at the time of starting mixers at mixing speeds. Concrete shall be mixed in a truck mixer for not less than seventy (70) revolutions of the drum or blades at the rate of rotation designated by the manufacturer of equipment. Additional mixing, if any, shall be at the speed designated by the manufacturer of the equipment as agitating speed. All materials including mixing water shall be in the mixer drum before actuating the revolution counter for determining the number of revolutions of mixing.
H. Truck mixers and their operation shall be such that the concrete throughout the mixed batch as discharged is within acceptable limits of uniformity with respect to consistency, mix, and grading.
If slump tests taken at approximately the 1/4 and 3/4 points of the load during discharge give slumps differing by more than one inch when the specified slump is more than 3 inches, the mixer shall not be used on the work unless the causing condition is corrected and satisfactory performance is verified by additional slump test. All mechanical details of the mixer, such as water measuring and discharge apparatus, condition of the blades, speed of rotation, general mechanical condition of the unit, and clearance of the drum, shall be checked before a further attempt to use the unit will be permitted.
I. Comply with ACI 318 and ASTM C94.
J. Select equipment of size and design to provide continuous flow of concrete at the delivery end.
Use metal or metal -lined non -aluminum discharge chutes with slopes not exceeding one vertical to two horizontal and not less than one vertical to three horizontal. Chutes more than 20 -foot long and chutes not meeting slope requirements may be used if concrete is discharged into a hopper before distribution.
K. Furnish a delivery ticket for ready mixed concrete to the Engineer as each truck arrives. Provide a printed record of the weight of cement and each aggregate as batched individually on each ticket. Use the type of indicator that returns for zero punch or returns to zero after a batch is discharged. Indicate for each batch the weight of fine and coarse aggregate, cement, fly ash, and water, moisture content of fine and coarse aggregate at time of batching, and types, brand and
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quantity of each admixture, the quantity of concrete delivered, the time any water is added and the amount, and the numerical sequence of the delivery. Show the time of day batched and time of discharge from the truck. Indicate the number of revolutions of transit mix truck.
3.2 PREPARATION OR SURFACES FOR CONCRETING
A. Earth surfaces shall be undisturbed and/or graded and compacted prior to placing reinforcing as required by the Contract Documents. Earth surfaces shall be thoroughly and uniformly wetted by sprinkling prior to the placing of any concrete. These surfaces shall be kept moist by frequent sprinkling up to the time concrete is placed thereon. The surface shall be free from standing water, mud and debris at the time of placing concrete.
B. The surfaces of all horizontal construction joints shall be cleaned of all laitance, loose or defective concrete and foreign material. Such cleaning shall be accomplished by sandblasting followed by thorough washing. All pools of water shall be removed from the surface of construction joints before the new concrete is placed.
C. No concrete shall be placed until all formwork, installation of parts to be embedded, reinforcement steel and preparation of surfaces involved in the placing have been completed and accepted by the Construction Manager at least four (4) hours before placement of concrete. All reinforcement, anchor bolts, sleeves, inserts and similar items shall be set and secured in the forms where shown or by shop drawings and shall be acceptable to the Construction Manager before any concrete is placed. Accuracy of placement is the responsibility of the Contractor. All surfaces of embedded items that have become encrusted with dried grout from concrete previously placed shall be cleaned of all such grout before the surrounding or adjacent concrete is placed.
D. All form surfaces in contact with the concrete shall be thoroughly cleaned of all previous concrete, dirt and other surface contaminants prior to use. Damaged form surfaces shall not be used.
Wood form surfaces in contact with the concrete shall be coated with an approved release agent prior to form installation. The release agent shall be non -staining and non-toxic after thirty (30) days. Mill scale and other ferrous deposits shall be sandblasted or otherwise removed from the contact surface of steel forms. All steel forms shall have the contact surfaces coated with an approved release agent. The release agent shall be effective in preventing discoloration of the concrete from rust and shall be non-toxic after thirty (30) days.
E. Where concrete is to be cast against old existing concrete, the old concrete shall be thoroughly roughened to exposed, hard aggregate by sandblasting or chipping. Any additional surface preparation shall be as called for in the drawings.
F. No concrete shall be placed in any structure until all water entering the space to be filled with concrete has been properly cut off or diverted out of the forms and clear of the work. No concrete shall be deposited under water or allowed to rise on any concrete until the concrete has attained its initial set. Pumping or other necessary dewatering operations for removing ground water, if required, shall be the responsibility of the Contractor and will be subject to review by the Construction Manager.
G. Pipe, conduit, dowels, sleeves and other ferrous items required to be embedded in concrete construction shall be adequately positioned and supported prior to placement of concrete. There shall be a minimum of 2 -inches clearance between embedded items and any of the concrete
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reinforcement. Securing embedments in position by wiring or welding them to the reinforcement will not be permitted.
3.3 FORMWORK
A. Design, erect, shore, brace, and maintain formwork, according to ACI 301, to support vertical, lateral, static, and dynamic loads, and construction loads that might be applied, until structure can support such loads.
B. Construct formwork so concrete members and structures are of size, shape, alignment, elevation, and position indicated, within tolerance limits of ACI 117.
C. Chamfer exterior corners and edges of permanently exposed concrete except where grating will be installed.
3.4 EMBEDDED ITEMS
A. Place and secure anchorage devices and other embedded items required for adjoining work that is attached to or supported by cast -in -place concrete. Use setting drawings, templates, diagrams, instructions, and directions furnished with items to be embedded.
B. Do not embed piping or electrical conduits in concrete unless shown on the Drawings.
C. Pipes and conduits embedded within a slab or wall (other than those merely passing through) shall satisfy the following, unless otherwise shown on the Drawings or approved:
1. Maximum outside dimension of pipe or conduit shall not be greater than one third the overall thickness of the slab or wall.
2. Spacing of pipes or conduits shall be greater than or equal to three diameters or widths on center.
D. Close open ends of piping, conduits, and sleeves embedded in concrete with caps or plugs prior to placing concrete.
E. Fabricate piping and conduit such that the cutting, bending, or relocation of reinforcing steel is not required.
F. Pipe, conduit, dowels, sleeves and other ferrous items required to be embedded in concrete construction shall be adequately positioned and supported prior to placement of concrete. There shall be a minimum of 2 -inches clearance between embedded items and any of the concrete reinforcement. Securing embedments in position by wiring or welding them to the reinforcement will not be permitted. Embedded items shall be clean and free of rust, mud, dirt, grease, oil, ice, or other contaminants which would reduce or prevent bonding with concrete.
G. Coat or isolate all aluminum embedments to prevent aluminum -concrete reaction or electrolytic action between aluminum and steel.
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H. Ensure all specified tests and inspections on embedded piping are completed and satisfactory before starting concrete placement. Ensure all mechanical or electrical tests and inspections are completed and satisfactory prior to starting concrete placement. Do not place concrete until unsatisfactory items and conditions have been corrected.
3.5 VAPOR RETARDERS
A. Sheet Vapor Retarders: Place, protect, and repair sheet vapor retarder according to ASTM E 1643 and manufacturer's written instructions.
1. Lap joints 6 inches and seal with manufacturer's recommended tape.
3.6 STEEL REINFORCEMENT
A. General: Comply with CRSI's "Manual of Standard Practice" for placing reinforcement.
1. Do not cut or puncture vapor retarder. Repair damage and reseal vapor retarder before placing concrete.
3.7 JOINTS
A. General: Construct joints true to line with faces perpendicular to surface plane of concrete.
B. Construction Joints: Install so strength and appearance of concrete are not impaired, at locations indicated or as approved by Engineer.
C. Contraction Joints in Slabs -on -Grade: Form weakened -plane contraction joints, sectioning concrete into areas as indicated. Construct contraction joints for a depth equal to at least one- fourth of concrete thickness as follows:
1. Grooved Joints: Form contraction joints after initial floating by grooving and finishing each edge of joint to a radius of 1/8 inch. Repeat grooving of contraction joints after applying surface finishes. Eliminate groover tool marks on concrete surfaces.
2. Sawed Joints: Form contraction joints with power saws equipped with shatterproof abrasive or diamond -rimmed blades. Cut 1/8 -inch- wide joints into concrete when cutting action will not tear, abrade, or otherwise damage surface and before concrete develops random contraction cracks.
D. Isolation Joints in Slabs -on -Grade: After removing formwork, install joint -filler strips at slab junctions with vertical surfaces, such as column pedestals, foundation walls, grade beams, and other locations, as indicated.
E. Waterstops: Install in construction joints and at other joints indicated according to manufacturer's written instructions.
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3.8 CONCRETE PLACEMENT
A. Placement of concrete shall conform to the requirements and recommendations of ACI 301, 304 and 318, except as modified herein.
B. Before placing concrete, verify that installation of formwork, reinforcement, and embedded items is complete and that required inspections have been performed.
C. Deposit concrete continuously in one layer or in horizontal layers of such thickness that no new concrete will be placed on concrete that has hardened enough to cause seams or planes of weakness. If a section cannot be placed continuously, provide construction joints as indicated.
Deposit concrete to avoid segregation.
1. Consolidate placed concrete with mechanical vibrating equipment according to ACI 301.
D. Cold -Weather Placement:
1. For this Specification, "cold weather" is defined as a period when for more than three successive days, the average daily outdoor temperature drops below 40 degrees F.
Calculate average daily temperature as the average of the highest and the lowest temperature during the period from midnight to midnight.
2. Batch, deliver, place, cure and protect concrete during cold weather in compliance with the recommendations of ACI 306R and the additional requirements of this Section.
3. Review the cold weather concreting plan at the preconstruction meeting. Include the methods and procedures for use during cold weather including the production, transportation, placement, protection, curing and temperature monitoring of the concrete and the procedures to be implemented upon abrupt changes in weather conditions or equipment failures.
4. The minimum temperature of concrete immediately after placement and during the protection period shall be as indicated in Table 3. The temperature of the concrete in place and during the protection period shall not exceed these values by more than 20 degrees F.
Prevent overheating and non -uniform heating of the concrete.
TABLE 3
Concrete Temperatures
Minimum Dimension of Section
Min. conc temp:
< 12 -in
55 Degree F
12 to 36 -in
50 Degree F
5. Protect concrete during periods of cold weather to provide continuous warm, moist curing (with supplementary heat when required by weather conditions) for a total of at least 350 degree-days of curing.
a. Degree-days are defined as the total number of 24 hour periods multiplied by the weighted average daily air temperature at the surface of the concrete (e.g., 7 days at an average 50 degrees F = 350 degree-days).
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b. To calculate the weighted average daily air temperature, sum hourly measurements of the air temperature in the shade at the surface of the concrete taking any measurement less than 50 degrees F as 0 degrees F. Divide the sum thus calculated by 24 to obtain the weighted average temperature for that day.
6. Do not use salt, manure, or other chemicals for protection.
7. At the end of the protection period, allow the concrete to cool gradually to the ambient temperature. If water curing has been used, do not expose concrete to temperatures below those shown in Table 3 until at least 24 hours after water curing has been terminated and air dry concrete for at least 3 days prior to first exposure to freezing temperatures.
8. During periods not defined as cold weather, but when freezing temperatures are expected or occur, protect concrete surfaces from freezing for the first 24 hours after placing.
E. Hot -Weather Placement:
1. For this Specification, "hot weather" is defined as any combination of high air temperatures, low relative humidity and wind velocity which produces a rate of evaporation as estimated in ACI 305R, approaching or exceeding 0.2 pounds per square foot per hour (lb/sq ft/hr).
2. Batch, deliver, place, cure and protect concrete during hot weather in compliance with the recommendations of ACI 305R and the additional requirements of this Section. a. Temperature of concrete being placed shall not exceed 90 degrees F. Maintain a uniform concrete mix temperature below this level. The temperature of the concrete shall not cause loss of slump, flash set or cold joints.
b. Promptly deliver concrete to the site and promptly place the concrete upon its arrival at the site, not exceeding the maximum time interval specified in Paragraph 3.1F. Provide vibration immediately after placement.
c. The Engineer may direct the Contractor to immediately cover concrete with sheet curing material.
3. Review the hot weather concreting plan at the preconstruction meeting. Include the methods and procedures for use during hot weather including production, placement, and curing.
F. No concrete shall be placed without prior inspection of the forms, reinforcing and embedded items and approval from the Construction Manager. Verify that all formwork completely encloses concrete to be placed and is securely braced prior to concrete placement. The Contractor shall notify the Construction Manager at least twenty-four (24) hours in advance of any scheduled concrete placement and shall call for final inspections no later than four (4) hours in advance of the scheduled placement. The Contractor shall notify the Construction Manager at least two (2) hours in advance of setting the opposite side of wall forms so that the construction joint preparation, water stop installation and reinforcing steel inspections can be conducted. It is the Contractor's responsibility to see that the forms are properly cleaned and oiled before being set, the construction joints properly prepared, reinforcing steel is securely and properly supported in the correct position and that all embedment items including electrical conduit is correctly installed before calling for inspections. The Engineer may at his option require the use of placement cords if deemed necessary.
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G. Concrete which upon or before placing is found not to conform to the requirements specified herein shall be rejected and immediately removed from the work. Concrete which is not placed in accordance with these specifications, or which is of inferior quality, shall be removed and replaced at the expense of the Contractor.
H. No concrete shall be placed during rain or snow storms, unless completely covered to prevent storm water from coming in contact with it. Sufficient protective covering material shall be kept on hand at all times should rain or snow storms arise during concrete placement operations.
I. Concrete shall be deposited at or near its final position to avoid segregation caused by rehandling or flowing. Concrete shall not be deposited in large quantities in one place and worked along the forms with vibrator or other means. Concrete shall be uniformly distributed during the placing process and in no case after depositing shall any portion be displaced in the forms more than 2 - feet in horizontal direction. Concrete shall be deposited in forms in horizontal layers not to exceed 24 -inches in depth and shall be brought up evenly in all parts of the form. The rate of placement of concrete in forms shall not exceed 5 -feet of vertical rise per hour. As the concrete is placed it shall be consolidated thoroughly and uniformly by mechanical vibration to secure a dense mass, close bond with reinforcement and other embedded items and smooth surface. The mechanical vibrator shall penetrate not only the freshly placed concrete, but also the previously placed lift to ensure the lifts become monolith. New concrete shall be placed against previously placed concrete, not away from it. When concrete is placed on a slope, placement shall begin at the lower end of the slope and progress to the upper end for the full width of the placement.
Consolidation by mechanical vibration shall follow directly behind placement and the rate of placement shall never get ahead of the consolidation crew. Concrete placement shall continue without avoidable interruption, in a continuous operation until the end of the placement is reached.
J. The drop of concrete into slab or wall forms shall be vertical. Concrete shall not be dropped through reinforced steel, but deposited in forms using a hopper with a drop chute to avoid segregation and to keep mortar from coating the reinforcement steel and forms above the in -place concrete. In no case shall the free fall of concrete exceed 4 -feet below the end of the hopper or chute.
K. If it takes more than 20 -minutes to get back to place concrete over concrete previously placed, the depth of the layers being placed at one time shall be reduced, and/or placing equipment increased, until it is possible to return with the placing operation to previously placed concrete within 20 -minutes. If concrete is to be placed over previously poured concrete and more than 20 -minutes have elapsed, then a layer of grout not less than 1/2 -inch thick shall be spread over the surface before placing the additional concrete.
L. The placement of concrete for slabs, beams or walkways cast monolithically with walls or columns shall not commence until the concrete in the walls or columns has been allowed to set and shrink. The time allowed for shrinkage shall be not less than one (1) hour.
M. Concrete shall be placed with the aid of approved mechanical vibrators. Vibration shall be supplemented by manual forking or spading adjacent to the forms on exposed faced in order to secure smooth dense surfaces. The concrete shall be thoroughly consolidated around reinforcement, pipes or other shapes built into the work. The vibration shall be sufficiently intense to cause the concrete to flow and settle readily into place and to visibly affect the concrete over a radius of at least 18 -inches.
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Sufficient vibrators shall be on hand at all times to vibrate the concrete as placed. In addition to the vibrators in actual use while concrete is being placed, the Contractor shall have on hand one (1) spare vibrator in serviceable condition. No concrete shall be placed until it has been ascertained that all vibrating equipment, including spares, is in serviceable condition.
Special care shall be taken to place the concrete solidly against the forms so as to leave no voids.
Every precaution shall be taken to make all concrete solid, compact and smooth, and if for any reason the surfaces or interiors have voids or are in any way defective, such concrete shall be repaired as directed by the Engineer. No defective work shall be patched or repaired without the prior inspection and approval of the Engineer.
N. The temperature of concrete when it is being placed shall be not more than 90 degrees F. nor less than 40 degrees F. in moderate weather, and not less than 50 degrees F. in weather during which the mean daily temperature drops below 40 degrees F. Concrete ingredients shall not be heated to a temperature higher than that necessary to keep the temperature of the mixed concrete, as placed, from falling below the specified minimum temperature. If concrete is placed when the weather is such that the temperature of the concrete would exceed 90 degrees F., the Contractor shall employ effective means, such as precooling of aggregates and mixing water using ice or placing at night, as necessary to maintain the temperature of the concrete, as it is placed, below 90 degrees F. The Contractor shall be entitled to no additional compensation on account of the foregoing requirements.
O. Concrete shall not be placed on a frozen subgrade or subgrade that contains frozen materials. All ice and snow shall be removed from inside forms and from reinforcing steel and embedded items.
The temperature of all surfaces that the concrete will contact shall be raised above the freezing point for at least 12 -hours prior to placing new concrete.
The minimum temperature of fresh concrete as mixed shall be 60 degrees F. for ambient temperature above 30 degrees F.; 65 degrees F. for ambient temperature 0 degrees F. to 30 degrees F.; and 70 degrees F. for ambient temperature below 0 degrees F. The minimum temperature of fresh concrete after placing shall be 55 degrees F. for the first 72 -hours.
The use of calcium chloride shall not be permitted.
In general, the Contractor shall adhere to the recommendations as outlined in ACI Standard 306 for cold weather concreting, except as required herein.
3.9 REMOVAL OF FORMS
A. Do not remove forms before the concrete has attained a strength of at least 75 percent of the 28 -day specified design strength for beams and slabs and at least 50 percent of its specified design strength for walls and vertical surfaces, nor before reaching the following number of day -degrees of curing (whichever is the longer):
TABLE 4
Forms for
Elevated beams and elevated slabs
Walls and vertical surfaces
Degree Days
500
150
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Foundation footings and slabs -on -grade 150
(See definition of degree-days in Paragraph 3.8D)
B. Do not remove shores until the concrete has attained at least 75 percent of its specified design strength and also sufficient strength to support safely its own weight and the construction live loads upon it.
C. In cold weather, when temperature of concrete exceeds ambient air temperature by 20 degrees F at the end of the protection period, loosen forms and leave in place for at least 24 hours to allow concrete to cool gradually to ambient air temperature.
3.10 FINISHING FORMED SURFACES
A. Rough -Formed Finish: As -cast concrete texture imparted by form -facing material with tie holes and defects repaired and patched. Remove fins and other projections that exceed specified limits on formed -surface irregularities. Fill tie holes and depressions and bug -holes 1/4 inch or larger in width or depth with mortar.
1. Apply to concrete surfaces to be covered by backfill or coated with below grade waterproofing systems.
B. Smooth -Formed Finish: As -cast concrete texture imparted by form -facing material, arranged in an orderly and symmetrical manner with a minimum of seams. Repair and patch tie holes and defects. Remove fins and other projections that exceed specified limits on formed -surface irregularities.
1. Apply to concrete surfaces in water channels, below water surface of basins, inside meter and valve vaults, inside cells of hydraulic splitter boxes and weirs.
C. Rubbed Finish: Apply the following to smooth -formed finished as -cast concrete for formed concrete surfaces inside buildings and machine rooms, and for all exposed exterior concrete surfaces of foundations, basins, vaults, hydraulic structures and curbs.
1. Smooth -Rubbed Finish: Not later than one day after form removal, moisten concrete surfaces and rub with carborundum brick or another abrasive until producing a uniform color and texture. Do not apply cement grout other than that created by the rubbing process.
2. Grout -Cleaned Finish: Wet concrete surfaces and apply grout of a consistency of thick paint to coat surfaces and fill small holes. Mix one part portland cement to one and one- half parts fine sand with a 1:1 mixture of bonding admixture and water. Add white portland cement in amounts determined by trial patches so color of dry grout will match adjacent surfaces. Scrub grout into voids and remove excess grout. When grout whitens, rub surface with clean burlap and keep surface damp by fog spray for at least 36 hours.
3. Cork -Floated Finish: Wet concrete surfaces and apply a stiff grout. Mix one part portland cement and one part fine sand with a 1:1 mixture of bonding agent and water. Add white portland cement in amounts determined by trial patches so color of dry grout will match adjacent surfaces. Compress grout into voids by grinding surface. In a swirling motion, finish surface with a cork float.
4. Formed concrete surfaces inside buildings and machine rooms and all exposed exterior surfaces of foundations, basins, vaults, hydraulic structures and curbs.
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D. Related Unformed Surfaces: At tops of walls, horizontal offsets, and similar unformed surfaces adjacent to formed surfaces, strike off smooth and finish with a texture matching adjacent formed surfaces. Continue final surface treatment of formed surfaces uniformly across adjacent unformed surfaces unless otherwise indicated.
3.11 FINISHING FLOORS AND SLABS
A. General: Comply with ACI302.1R recommendations for screeding, restraightening, and finishing operations for concrete surfaces. Do not wet concrete surfaces.
B. Scratch Finish: While still plastic, texture concrete surface that has been screeded and bull -floated or darbied. Use stiff brushes, brooms, or rakes to produce a profile amplitude of 1/4 inch in one direction.
1. Apply scratch finish to surfaces indicated and to receive concrete floor toppings.
C. Float Finish: Consolidate surface with power -driven floats or by hand floating if area is small or inaccessible to power driven floats. Restraighten, cut down high spots, and fill low spots. Repeat float passes and restraightening until surface is left with a uniform, smooth, granular texture.
Surface irregularities shall not exceed 1/4 inch.
1. Apply float finish to surfaces indicated and to be covered with fluid -applied or sheet waterproofing, built-up or membrane roofing, or floor slabs to be covered with grouted tile or topping grout and slabs to be covered with built-up roofing.
D. Trowel Finish: After applying float finish, apply first troweling and consolidate concrete by hand or power -driven trowel. Continue troweling passes and restraighten until surface is free of trowel marks and uniform in texture and appearance. Grind smooth any surface defects that would telegraph through applied coatings or floor coverings.
1. Apply a trowel finish to surfaces all building and machine room floors, basin floors not receiving a grout topping, channel floors, top of interior walls, top of interior curbs, steps and walkways.
2. Finish and measure surface so gap at any point between concrete surface and an unleveled, freestanding, 10 -ft.- long straightedge resting on two high spots and placed anywhere on the surface does not exceed 1/4 inch.
E. Trowel and Fine -Broom Finish: Apply a first trowel finish to exterior walkways, curb, gutter, sidewalk and steps, top of valve or meter vaults, electrical pull boxes and catch basins. While concrete is still plastic, slightly scarify surface with a fine broom.
1. Comply with flatness and levelness tolerances for trowel -finished floor surfaces.
F. The schedule for finished unformed surfaces shall be as follows:
Unformed Concrete Surface Schedule
Area Finish
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Grade slabs and foundations to be covered with
concrete or fill material. Scratch Finish
Floor slabs to be covered with grouted tile or
topping grout and slabs to be covered with built-up
roofing.
All building and machine room floors, basin floors
not receiving a grout topping, channel floors, top
of interior walls, top of interior curbs, steps and
walkways.
Float Finish
Trowel Finish
Exterior walkways, curb, gutter, sidewalk and steps,
top of valve or meter vaults, electrical pull boxes and catch basins. Fine -Broom Finish
3.12 CONCRETE PROTECTING AND CURING
A. General: Protect freshly placed concrete from premature drying and excessive cold or hot temperatures. Comply with ACI 306.1 for cold -weather protection and ACI 301 for hot -weather protection during curing.
B. Evaporation Retarder: Apply evaporation retarder to unformed concrete surfaces if hot, dry, or windy conditions cause moisture loss approaching 0.2 lb/sq. ft. x h before and during finishing operations. Apply according to manufacturer's written instructions after placing, screeding, and bull floating or darbying concrete, but before float finishing.
C. Cure concrete according to ACI 308.1, by one or a combination of the following methods:
1. Moisture Curing: Keep surfaces continuously moist for not less than seven days.
2. Moisture -Retaining -Cover Curing: Cover concrete surfaces with moisture -retaining cover for curing concrete, placed in widest practicable width, with sides and ends lapped at least 12 inches, and sealed by waterproof tape or adhesive. Cure for not less than seven days.
Immediately repair any holes or tears during curing period using cover material and waterproof tape.
3. Curing Compound: Apply uniformly in continuous operation by power spray or roller according to manufacturer's written instructions. Recoat areas subjected to heavy rainfall within three hours after initial application. Maintain continuity of coating and repair damage during curing period.
a. Removal: After curing period has elapsed, remove curing compound without damaging concrete surfaces by method recommended by curing compound manufacturer unless manufacturer certifies curing compound will not interfere with bonding of floor covering used on Project.
4. Curing and Sealing Compound: Apply uniformly to floors and slabs indicated in a continuous operation by power spray or roller according to manufacturer's written instructions. Recoat areas subjected to heavy rainfall within three hours after initial application. Repeat process 24 hours later and apply a second coat. Maintain continuity of coating and repair damage during curing period.
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D. Immediately following the first frost in the fall, the Contractor shall be prepared to protect all concrete against freezing.
3.13 CONCRETE SURFACE REPAIRS
A. It is the intent of these Specifications to require quality work including forming, mixture and placement of concrete and curing so completed concrete surfaces will require no patching or repairs.
B. Defective Concrete: Repair and patch defective areas when approved by Engineer. Remove and replace concrete that cannot be repaired and patched to Engineer's approval.
C. As soon as the forms have been stripped and the concrete surfaces exposed: Remove fins and other projections; fill recesses left by the removal of form ties; and repair surface defects which do not impair structural strength. Clean all exposed concrete surfaces and adjoining work stained by leakage of concrete.
D. Immediately after removal of forms remove tie cones and metal portions of ties. Fill holes promptly upon stripping as follows: Moisten the hole with water, roughen first if necessary for adhesion, followed by a 1/16 -in brush coat of neat cement slurry mixed to the consistency of a heavy paste. Immediately plug the hole with a 1 to 1.5 mixture of cement and concrete sand mixed slightly damp to the touch (just short of "balling"). Hammer the grout into the hole until dense, and an excess of paste appears on the surface in the form of a spider web. Trowel smooth with heavy pressure. Avoid burnishing.
E. When filling tie cone holes and patching or repairing exposed surfaces use the same source of cement and sand as used in the parent concrete. Adjust color to match by addition of white cement.
Rub lightly with a fine carborundum stone at an age of one to five days if necessary to bring the surface down with the parent concrete. Do not damage or stain the virgin skin of the surrounding parent concrete. Wash thoroughly to remove all rubbed matter.
F. Defective concrete and honeycombed areas: Chip down square and at least 1 -in deep to sound concrete with hand chisels or pneumatic chipping hammers. Irregular voids or surface stones need not be removed if they are sound, free of laitance, and firmly embedded in the parent concrete. If honeycomb exists around reinforcement, chip to provide a clear space at least 3/8 -in wide all around the steel. For areas less than 1 -1/2 -in deep, the patch may be made in the same manner as described above for filling form tie holes, care being exercised to use adequately dry (non- trowelable) mixtures and to avoid sagging. Thicker repairs will require build-up in successive 1- 1/2 -in layers on successive days, each layer being applied (with slurry, etc.) as described above.
G. For very heavy (generally formed) patches, the Engineer may order the addition of pea gravel to the mixture and the proportions modified as follows:
Material Volumes Weights
Cement 1.0 1.0
Sand 1.0 1.0
Pea Gravel 1.5 1.5
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H. The Contractor may use a pre-packaged patching compound, such as: Poly -Patch by Euclid Chemical Company; Emaco R310 by BASF Chemical Company; Sikatop 122 Plus by Sika Chemical Corporation or equal only if approved by the Engineer for use and for color match.
3.14 FIELD QUALITY CONTROL
A. Testing and Inspecting: Owner will engage a qualified testing and inspecting agency to perform field tests and inspections and prepare test reports.
B. Air entrainment in the concrete shall be tested by ASTM C 138, ASTM C 231 or ASTM C 173.
If any sample tested does not have the specified air content, a second test shall be performed. If the second test does not meet the specified air content, the concrete represented by the test shall be removed from the job.
C. The Engineer may have cores taken from any questionable area in the concrete work such as construction joints and other locations as required for determination of concrete quality. The results of tests on such cores shall be the basis for acceptance, rejection or determining the continuation of concrete work. The right of the Engineer to take such cores shall not be construed as creating any obligation to take such cores, and not exercising this right to do so shall not relieve the Contractor from meeting the requirements of these Specifications.
D. Cooperate in obtaining cores by allowing free access to the work and permitting the use of ladders, scaffolding and such incidental equipment as may be required. Repair all core holes with non - shrink grout as specified in Section 036000. The work of cutting, testing and repairing the cores will be at the expense of the Contractor if defective work is uncovered. If no defective work is found, such cost will be at the expense of the Owner.
3.11 FAILURE TO MEET REQUIREMENTS
A. Should the strengths shown by the test specimens made and tested in compliance with the previous provisions fall below the values given in Section 2.9, the Engineer may require changes in proportions or materials, or both, to apply to the remainder of the work. Furthermore, the Engineer may require additional curing on those portions of the structure represented by the test specimens which fall below the values given in Section 2.9. The cost of such additional curing shall be at no additional cost to the Owner. In the event that such additional curing does not give the strength required, as evidenced by core and/or load tests, the Engineer may require strengthening or replacement of those portions of the structure which fail to develop the required strength. Coring and testing and/or load tests and any strengthening or concrete replacement required because strengths of test specimens are below that specified, shall be at no additional cost to the Owner. In such cases of failure to meet strength requirements the Contractor and Owner shall confer to determine what adjustment, if any, can be made in compliance with Sections titled "Strength" and "Failure to Meet Strength Requirements" of ASTM C94. The "purchaser" referred to in C94 is the Contractor.
B. When the tests on control specimens of concrete fall below the required strength, the Engineer will permit check tests for strengths to be made by means of typical cores drilled from the structure in compliance with ASTM C42 and C39. In cases where tests of cores fall below the values given in Section 2.9, the Engineer, in addition to other recourses, may require load tests on any one of the slabs, walls, beams, and columns in which such concrete was used. Test need not be made until concrete has aged 60 days. The Engineer may require strengthening or replacement of those portions of the structure which fail to develop the required strength. All
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coring and testing and/or load tests and any strengthening or concrete replacement required because strengths of test specimens are below that specified, shall be at no additional cost to the Owner.
C. Should the strength of test cylinders fall below 60 percent of the required minimum 28 day strength, the concrete shall be rejected and shall be removed and replaced at no additional cost to the Owner.
END OF SECTION 033000
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SECTION 036000 — GROUTING MORTAR
PART 1 - GENERAL
1.1 THE REQUIREMENT
A. The Contractor shall furnish, place, finish and cure the following types of grouting mortars as called for herein and as shown in the Contract Documents B. Perform all sampling and furnish all testing of materials and products by an independent testing laboratory acceptable to the Engineer but engaged by and at the expense of the Contractor
1. Non -Shrink Grout: This type of grout shall be used wherever grout is shown or called for in the Contract Documents, unless another type is specifically referenced.
2. Topping Grout: This type of grout shall be used for concrete fill for built-up surfaces of tank, channel, and basin bottoms.
3. Epoxy Grout: This type of grout shall be used for anchor bolt or reinforcing steel embedment, repairs and resurfacing.
1.2 RELATED WORK SPECIFIED ELSEWHERE
A. Cast -In -Place Concrete. 033000
1.3 REFERENCE SPECIFICATIONS, CODES AND STANDARDS
A. Specifications, codes and standards is listed under Section 033000 entitled, "Cast -In -Place Concrete", and those additional commercial standards as follows:
CRD-C 621 Corps of Engineers Specification for Non -Shrink Grout.
ASTM C109 Standard Test Method for Compressive Strength of Hydraulic Cement Mortars (Using 2 -inch or 50 -mm Cube
Specimens).
ASTM C150 Standard Specification for Portland Cement.
ASTM C531 Standard Test Method for Linear Shrinkage and Coefficient of Thermal Expansion of Chemical -Resistant Mortars, Grouts, and Monolithic Surfacings and Polymer
Concrete.
ASTM C579
Standard Test Methods for Compressive Strength of
Chemical -Resistant Mortars, Grouts, and Monolithic
Surfacings and Polymer Concrete.
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ASTM C827
ASTM C1077
ASTM C1107
ASTM D695
ASTM E329
Standard Test Method for Change in Height at Early Ages of Cylindrical Specimens of Cementitious Mixtures.
Standard Practice for Agencies Testing Concrete and
Concrete Aggregates for use in Construction and Criteria for Testing Agency Evaluation.
Standard Specification for Packaged Dry, Hydraulic -
Cement Grout (Non -shrink).
Standard Test Method for Compressive Properties of Rigid Plastics.
Standard Specification for Agencies Engaged in
Construction Inspection, Testing, or Special Inspection.
B. Where reference is made to one of the above standards, the revision in effect at the time of bid opening shall apply.
1.4 CONTRACTOR SUBMITTALS
A. Non -Shrink Grout: Submit manufacturer's catalogue cuts, technical data including compressive strength and expansion data at plastic, flowable and fluid consistencies, storage requirements, product life, working time after mixing, temperature consideration, conformity to the specified ASTM standards, and Material Safety Data Sheets. Also submit manufacturer's applications manual containing instructions and recommendations for mixing, handling, placement and appropriate uses for each type of non -shrink grout used in the work.
B. Topping Grout: Provide certified mix design including type and brand of cement, proportions and gradations of all materials, product data on any proposed admixtures, and compressive strength test results from at least one (1) trial batch. Tests shall be performed by a certified testing laboratory.
All costs for such mix design and trial batch tests shall be borne by the Contractor.
C. Non -shrink Epoxy Grout: Submit manufacturer's catalog cuts, technical data including strengths and application manual of instructions for mixing, handling and placing, storage requirements, product life, working time after mixing, temperature consideration, conformity to the specified ASTM standards, and Material Safety Data Sheets.
1.5 QUALITY ASSURANCE
A. Qualifications
1. Grout manufacturers shall have a minimum of 10 years experience in the production and use of the type of grout proposed.
2. Independent testing laboratory shall meet the requirements of ASTM E329 and ASTM C 1077 and be acceptable to the Engineer. Laboratories affiliated with the Contractor or in which the Contractor or officers of the Contractor's organization have beneficial interest are not acceptable.
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B. Pre -installation Meeting
1. At least ten working days before grouting, hold a pre -installation meeting to review the requirements for surface preparation, mixing, placing and curing procedures for each product proposed for use. Notify all parties involved with grouting, including the Engineer, of the meeting at least ten working days prior to its scheduled date.
C. Services of Manufacturer's Representative
1. Provide services of a field technician of the non -shrink grout manufacturer who has performed at least five projects of similar size and complexity during the last five years, to attend the pre -installation meeting, to be present for the initial installation of each type of non -shrink grout, and to correct installation problems.
D. Field Testing
1. All field testing and inspection services will be provided by the Owner. Assist in the sampling of materials, and cooperate by allowing free access to the work and permitting the use of ladders, scaffolding, and such incidental equipment as may be required.
Methods of testing will comply with the applicable ASTM Standards.
2. Field testing of concrete grout will be as specified for concrete in Section 033000.
3. Mix design tests for topping grout shall be performed per the standards referenced herein.
B. During the progress of construction the Engineer may have tests made of each type of grout used in the work to ensure compliance with the Contract Documents. These tests will be made in accordance with the standards referenced herein. The test expense during construction, except for the mix design and trial batch tests, will be borne by the Owner. The costs of additional tests including non-destructive tests and core drilling needed to verify or investigate the quality of questionable work or material shall be borne by the Contractor.
C. Grout for testing shall be supplied by the Contractor at no cost to the Owner.
D. If any grout fails to meet the requirements of these specifications, immediate corrective action shall be taken for all subsequent batches. Grout already in place which fails to meet these requirements is subject to removal and replacement with all costs borne by the Contractor.
E. Construction tolerances shall be as specified in Section 033000 entitled, "Cast -In -Place Concrete", except as modified herein and elsewhere in the Contract Documents.
PART 2 - PRODUCTS
2.1 NON -SHRINK GROUT
A. Non -shrink grout shall be a prepackaged, inorganic, non-gasliberating, non-metallic, cement -based grout requiring only the addition of water. Manufacturer's instructions shall be printed on each bag or other container in which the materials are packaged.
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B. Non -shrink grouts for use as herein specified shall conform to the Corps of Engineers specifications for Non -Shrink Grout, CRD-C621 and to these specifications. The grout shall have a 28 -day compressive strength of 6,000 psi or greater.
C. Non -shrink grouts shall be as manufactured by: Tremcrete Systems Incorporated, Woodland, California; Gifford -Hill & Company, Inc., Dallas, Texas; or approved equal.
2.2 TOPPING GROUT
A. Cement topping grout for channels shall be composed of one part cement, three parts sand, and the minimum amount of water necessary to obtain the desired consistency. The minimum compressive strength at 28 -days shall be 4,000 psi.
B. Cement grout materials shall be as specified in Section 033000 entitled, "Cast -In -Place Concrete".
2.3 EPDXY GROUT
A. Epoxy grout shall be a pourable, non -shrink, one -hundred percent (100%) solids system. The epoxy grout system shall have three components; resin, hardener, and specially blended aggregate, all premeasured and prepackaged. The resin component shall not contain any non -reactive diluents. Resins containing butyl glycidyl ether (BGE) or other highly volatile and hazardous reactive diluents are not acceptable. Variation of component ratios is not permitted unless specifically recommended by the manufacturer. The chemical formulation of the epoxy grout shall be that recommended by the manufacturer for the particular application. Manufacturer's instructions shall be printed on each container in which the materials are packaged.
B. The mixed epoxy grout system shall have a minimum working life of 45 minutes at 75 degrees F.
The epoxy grout shall develop a minimum compressive strength of 5,000 psi in 24 -hours and 10,000 psi in 7 -days.
2.4 CURING MATERIALS
A. Curing materials shall be as specified in Section 033000 entitled, "Cast -In -Place Concrete", for cement topping grout and as recommended by the manufacturer of non -shrink grouts.
PART 3 - EXECUTION
3.1 PLACING NON -SHRINK AND EPDXY GROUT
A. All forming, mixing, surface preparation, handling, placing and consolidated of non -shrink and epoxy grouts shall be done according to the instructions and recommendations of the manufacturer.
B. Curing shall be as specified herein.
END OF SECTION 036000
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SECTION 055000 - METAL FABRICATIONS
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Miscellaneous steel framing and supports.
2. Shelf angles.
3. Metal ladders.
4. Ladder safety cages.
5. Metal floor plate and supports.
6. Miscellaneous steel trim.
7. Metal bollards.
8. Pipe guards.
9. Abrasive metal nosings, treads, and thresholds.
10. Loose bearing and leveling plates.
B. Products furnished, but not installed, under this Section include the following:
1. Anchor bolts, steel pipe sleeves, slotted -channel inserts, and wedge -type inserts indicated to be cast into concrete or built into unit masonry.
2. Steel weld plates and angles for casting into concrete for applications where they are not specified in other Sections.
1.2 ACTION SUBMITTALS
A. Product Data: For the following:
1. Metal nosings and treads.
2. Paint products.
3. Grout.
B. Shop Drawings: Show fabrication and installation details. Include plans, elevations, sections, and details of metal fabrications and their connections. Show anchorage and accessory items.
C. Samples for Verification: For each type and finish of extruded nosing and tread.
D. Delegated -Design Submittal: For ladders, including analysis data signed and sealed by the qualified professional engineer responsible for their preparation.
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PART 2 - PRODUCTS
2.1 PERFORMANCE REQUIREMENTS
A. Delegated Design: Engage a qualified professional engineer, as defined in Section 014000 "Quality Requirements," to design ladders.
B. Structural Performance of Aluminum Ladders: Aluminum ladders, including landings, shall withstand the effects of loads and stresses within limits and under conditions specified in ANSI A14.3.
C. Thermal Movements: Allow for thermal movements from ambient and surface temperature changes acting on exterior metal fabrications by preventing buckling, opening of joints, overstressing of components, failure of connections, and other detrimental effects.
1. Temperature Change: 120 deg F, ambient; 180 deg F, material surfaces.
2.2 METALS
A. Metal Surfaces, General: Provide materials with smooth, flat surfaces unless otherwise indicated. For metal fabrications exposed to view in the completed Work, provide materials without seam marks, roller marks, rolled trade names, or blemishes.
B. Steel Plates, Shapes, and Bars: ASTM A 36/A 36M.
C. Stainless -Steel Bars and Shapes: ASTM A 276, Type 304 and Type 316.
D. Rolled -Steel Floor Plate: ASTM A 786/A 786M, rolled from plate complying with ASTM A 36/A 36M or ASTM A 283/A 283M, Grade C or D.
E. Rolled -Stainless -Steel Floor Plate: ASTM A 793.
F. Abrasive -Surface Floor Plate: Steel plate with abrasive granules rolled into surface or with abrasive material metallically bonded to steel.
G. Steel Tubing: ASTM A 500/A 500M, cold -formed steel tubing.
H. Steel Pipe: ASTM A 53/A 53M, Standard Weight (Schedule 40) unless otherwise indicated.
I. Slotted Channel Framing: Cold -formed metal box channels (struts) complying with MFMA-4.
1. Size of Channels: As indicated.
2. Material: Galvanized steel, ASTM A 653/A 653M, commercial steel, Type B, with G90 coating; 0.108 -inch nominal thickness.
3. Material: Cold -rolled steel, ASTM A 1008/A 1008M, commercial steel, Type B; 0.0966 - inch minimum thickness; hot -dip galvanized after fabrication.
J. Cast Iron: Either gray iron, ASTM A 48/A 48M, or malleable iron, ASTM A 47/A 47M, unless otherwise indicated.
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K. Aluminum Extrusions: ASTM B 221, Alloy 6063-T6.
L. Aluminum -Alloy Rolled Tread Plate: ASTM B 632/B 632M, Alloy 6061-T6.
M. Aluminum Castings: ASTM B 26/B 26M, Alloy 443.0-F.
N. Bronze Extrusions: ASTM B 455, Alloy UNS No. C38500 (extruded architectural bronze).
O. Bronze Castings: ASTM B 584, Alloy UNS No. C83600 (leaded red brass) or No. C84400 (leaded semired brass).
P. Nickel Silver Castings: ASTM B 584, Alloy UNS No. C97600 (20 percent leaded nickel bronze).
Q. Corrosion Protection: Unless otherwise shown, miscellaneous metalwork of fabricated steel, which will be used in a corrosive environment and/or will be submerged in water/wastewater shall be coated in accordance with Section 098000 "Protective Coatings" and shall not be galvanized prior to coating. All other miscellaneous steel metalwork shall be hot -dip galvanized after fabrication as specified herein.
R. Stainless Steel: Stainless steel metal work shall be of Type 316 stainless steel.
2.3 FASTENERS
A. General: Unless otherwise indicated, provide Type 304 stainless -steel fasteners for exterior use.
Select fasteners for type, grade, and class required.
1. Provide stainless -steel fasteners for fastening aluminum.
2. Provide stainless -steel fasteners for fastening stainless steel.
3. Provide stainless -steel fasteners for fastening nickel silver.
4. Provide bronze fasteners for fastening bronze.
B. Steel Bolts and Nuts: Except as otherwise specified herein, steel for bolts, anchor bolts and cap screws shall be in accordance with the requirements of ASTM A 307 Grade B, or threaded parts of ASTM A 36 and shall meet the following additional requirements
1. The nut material shall be free -cutting steel.
2. The nuts shall be capable of developing the full strength of the bolts. Threads shall be Coarse Thread Series conforming to the requirements of the American Standard for Screw Threads. All bolts and cap screws shall have hexagon heads and nuts shall be Heavy Hexagon Series.
3. The length of all bolts shall be such that after joints are made up, each bolt shall extend through the entire nut, but in no case more than 1/2 -inch beyond the nut.
C. Stainless Steel Bolts and Nuts: Regular hexagon -head annealed stainless steel bolts, ASTM F 593; with hex nuts, ASTM F 594: and, where indicated, flat washers; Alloy Group 1. Unless otherwise shown or approved, all bolts, anchor bolts, washers and nuts which are buried, submerged or below the top of the wall inside any hydraulic structure shall be of Type 316 stainless steel.
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D. Cast -in -Place Anchors in Concrete: Either threaded type or wedge type unless otherwise indicated; galvanized ferrous castings, either ASTM A 47/A 47M malleable iron or ASTM A 27/A 27M cast steel. Provide bolts, washers, and shims as needed, all hot -dip galvanized per ASTM F 2329.
E. Post -Installed Anchors: Torque -controlled expansion anchors or chemical anchors.
1. Material for Interior Locations: Carbon -steel components zinc plated to comply with ASTM B 633 or ASTM F 1941, Class Fe/Zn 5, unless otherwise indicated.
2. Material for Exterior Locations and Where Stainless Steel Is Indicated: Alloy Group 1 stainless -steel bolts, ASTM F 593, and nuts, ASTM F 594.
F. Slotted -Channel Inserts: Cold -formed, hot -dip galvanized -steel box channels (struts) complying with MFMA-4, 1-5/8 by 7/8 inches by length indicated with anchor straps or studs not less than 3 inches long at not more than 8 inches o.c. Provide with temporary filler and tee -head bolts, complete with washers and nuts, all zinc -plated to comply with ASTM B 633, Class Fe/Zn 5, as needed for fastening to inserts.
2.4 MISCELLANEOUS MATERIALS
A. Universal Shop Primer: Fast -curing, lead- and chromate -free, universal modified -alkyd primer complying with MPI#79 and compatible with topcoat.
1. Use primer containing pigments that make it easily distinguishable from zinc -rich primer.
B. Galvanizing Repair Paint: High -zinc -dust -content paint complying with SSPC-Paint 20 and compatible with paints specified to be used over it.
C. Bituminous Paint: Cold -applied asphalt emulsion complying with ASTM D 1187/D 1187M.
D. Nonshrink, Nonmetallic Grout: Factory -packaged, nonstaining, noncorrosive, nongaseous grout complying with ASTM C 1107/C 1107M. Provide grout specifically recommended by manufacturer for interior and exterior applications.
E. Concrete: Comply with requirements in Section 033000 "Cast -in -Place Concrete" .
2.5 FABRICATION, GENERAL
A. Shop Assembly: Preassemble items in the shop to greatest extent possible. Use connections that maintain structural value of joined pieces.
B. Cut, drill, and punch metals cleanly and accurately. Remove burrs and ease edges. Remove sharp or rough areas on exposed surfaces.
C. Weld comers and seams continuously to comply with the following:
1. Use materials and methods that minimize distortion and develop strength and corrosion resistance of base metals.
2. Obtain fusion without undercut or overlap.
3. Remove welding flux immediately.
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4. At exposed connections, finish exposed welds and surfaces smooth and blended.
D. Form exposed connections with hairline joints, flush and smooth, using concealed fasteners or welds where possible. Locate joints where least conspicuous.
E. Fabricate seams and other connections that are exposed to weather in a manner to exclude water. Provide weep holes where water may accumulate.
F. Where units are indicated to be cast into concrete or built into masonry, equip with integrally welded steel strap anchors not less than 8 inches from ends and corners of units and 24 inches o.c.
2.6 MISCELLANEOUS FRAMING AND SUPPORTS
A. General: Provide steel framing and supports not specified in other Sections as needed to complete the Work.
B. Fabricate units from steel shapes, plates, and bars of welded construction unless otherwise indicated. Fabricate to sizes, shapes, and profiles indicated and as necessary to receive adjacent construction.
C. Fabricate steel pipe columns for supporting wood frame construction from steel pipe with steel baseplates and top plates as indicated. Drill or punch baseplates and top plates for anchor and connection bolts and weld to pipe with fillet welds all around. Make welds the same size as pipe wall thickness unless otherwise indicated.
2.7 SHELF ANGLES
A. Fabricate shelf angles from steel angles of sizes indicated and for attachment to concrete framing. Provide horizontally slotted holes to receive 3/4 -inch bolts, spaced not more than 6 inches from ends and 24 inches o.c., unless otherwise indicated.
B. For cavity walls, provide vertical channel brackets to support angles from backup masonry and concrete.
C. Galvanize shelf angles located in exterior walls.
D. Prime shelf angles located in exterior walls with primer specified in Section 098000 "Protective Coatings."
E. Furnish wedge -type concrete inserts, complete with fasteners, to attach shelf angles to cast -in - place concrete.
2.8 METAL LADDERS
A. General:
1. Comply with ANSI A14.3.
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B. Steel Ladders:
1. Ladders which may be partially or wholly submerged or which are located inside a hydraulic structure shall be entirely of Type 316 stainless steel. All other ladders shall be of carbon steel, hot -dip galvanized after fabrication unless noted otherwise on the drawings.
2. Space siderails 18 inches apart unless otherwise indicated.
3. Siderails: As indicated.
4. Rungs: 1/2 -inch- diameter steel bars.
5. Fit rungs in centerline of siderails; plug -weld and grind smooth on outer rail faces.
6. Provide nonslip surfaces on top of each rung.
2.9 LADDER SAFETY CAGES
A. Fabricate ladder safety cages to comply with ANSI A14.3. Assemble by welding or with stainless -steel fasteners.
B. Provide primary hoops at tops and bottoms of cages and spaced not more than 20 feet o.c.
Provide secondary intermediate hoops spaced not more than 48 inches o.c. between primary hoops.
C. Hot -dip galvanize steel ladder safety cages, including brackets and fasteners.
2.10 METAL FLOOR PLATE
A. Fabricate from rolled -stainless -steel floor plate of thickness indicated below:
1. Thickness: As indicated.
B. Provide stainless -steel angle supports as indicated.
C. Provide flush stainless -steel bar drop handles for lifting removable sections, one at each end of each section.
2.11 MISCELLANEOUS STEEL TRIM
A. Unless otherwise indicated, fabricate units from steel shapes, plates, and bars of profiles shown with continuously welded joints and smooth exposed edges. Miter corners and use concealed field splices where possible.
B. Provide cutouts, fittings, and anchorages as needed to coordinate assembly and installation with other work.
C. Galvanize exterior miscellaneous steel trim.
D. Prime exterior miscellaneous steel trim with primer specified in Section 098000 "Protective Coatings."
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2.12 METAL BOLLARDS
A. Fabricate metal bollards from 1/4 -inch wall -thickness, steel shapes, as indicated.
B. Prime and coat bollards with coatings specified in Section 098000 "Protective Coatings." C. For removable bollard requirements, see Drawings.
2.13 PIPE GUARDS
A. Fabricate pipe guards from 3/8 -inch- thick by 12 -inch- wide steel plate, bent to fit flat against the wall or column at both ends and to fit around pipe with 2 -inch clearance between pipe and pipe guard. Drill each end for two 3/4 -inch anchor bolts.
B. Galvanize pipe guards.
C. Prime pipe guards with primer specified in Section 098000 "Protective Coatings."
2.14 ABRASIVE METAL NOSINGS, TREADS, AND THRESHOLDS
A. Cast -Metal Units: Cast aluminum, with an integral -abrasive, as -cast finish consisting of aluminum oxide, silicon carbide, or a combination of both.
B. Provide anchors for embedding units in concrete, either integral or applied to units, as standard with manufacturer.
C. Drill for mechanical anchors and countersink. Locate holes not more than 4 inches from ends and not more than 12 inches o.c.
D. Apply bituminous paint to concealed surfaces of cast -metal units.
E. Apply clear lacquer to concealed surfaces of extruded units.
2.15 LOOSE BEARING AND LEVELING PLATES
A. Provide loose bearing and leveling plates for steel items bearing on masonry or concrete construction. Drill plates to receive anchor bolts and for grouting.
2.16 STEEL WELD PLATES AND ANGLES
A. Provide steel weld plates and angles not specified in other Sections, for items supported from concrete construction as needed to complete the Work. Provide each unit with no fewer than two integrally welded steel strap anchors for embedding in concrete.
2.17 FINISHES, GENERAL
A. Finish metal fabrications after assembly.
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2.18 STEEL AND IRON FINISHES
A. Galvanizing: Hot -dip galvanize items as indicated to comply with ASTM A 153/A 153M for steel and iron hardware and with ASTM A 123/A 123M for other steel and iron products.
B. Shop prime iron and steel items not indicated to be galvanized unless they are to be embedded in concrete, sprayed -on fireproofing, or masonry, or unless otherwise indicated.
1. Shop prime with primers specified in Section 098000 "Protective Coatings" are indicated.
C. Preparation for Shop Priming: Prepare surfaces to comply with requirements indicated below:
1. Exterior Items: SSPC-SP 6/NACE No. 3, "Commercial Blast Cleaning."
2. Items Indicated to Receive Zinc -Rich Primer: SSPC-SP 6/NACE No. 3, "Commercial Blast Cleaning."
3. Items Indicated to Receive Primers Specified in Section 098000 "Protective Coatings":
SSPC-SP 6/NACE No. 3, "Commercial Blast Cleaning."
4. Other Items: SSPC-SP 3, "Power Tool Cleaning."
D. Shop Priming: Apply shop primer to comply with SSPC-PA 1, "Paint Application Specification No. 1: Shop, Field, and Maintenance Painting of Steel," for shop painting.
PART 3 - EXECUTION
3.1 INSTALLATION, GENERAL
A. Cutting, Fitting, and Placement: Perform cutting, drilling, and fitting required for installing metal fabrications. Set metal fabrications accurately in location, alignment, and elevation; with edges and surfaces level, plumb, true, and free of rack; and measured from established lines and levels.
B. Fit exposed connections accurately together to form hairline joints. Weld connections that are not to be left as exposed joints but cannot be shop welded because of shipping size limitations.
Do not weld, cut, or abrade surfaces of exterior units that have been hot -dip galvanized after fabrication and are for bolted or screwed field connections.
C. Field Welding: Comply with the following requirements:
1. Use materials and methods that minimize distortion and develop strength and corrosion resistance of base metals.
2. Obtain fusion without undercut or overlap.
3. Remove welding flux immediately.
4. At exposed connections, finish exposed welds and surfaces smooth and blended so no roughness shows after finishing and contour of welded surface matches that of adjacent surface.
D. Fastening to In -Place Construction: Provide anchorage devices and fasteners where metal fabrications are required to be fastened to in -place construction.
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E. Provide temporary bracing or anchors in formwork for items that are to be built into concrete, masonry, or similar construction.
3.2 INSTALLING METAL BOLLARDS
A. Fill metal -capped bollards solidly with concrete and allow concrete to cure seven days before installing.
B. Anchor bollards in concrete. Fill annular space around bollard solidly with concrete.
C. Anchor bollards in place with concrete footings. Place concrete and vibrate or tamp for consolidation. Support and brace bollards in position until concrete has cured.
D. Fill bollards solidly with concrete, mounding top surface to shed water.
E. For removable bollard installation requirements see Drawings.
3.3 INSTALLING BEARING AND LEVELING PLATES
A. Clean concrete and masonry bearing surfaces of bond -reducing materials and roughen to improve bond to surfaces. Clean bottom surface of plates.
B. Set bearing and leveling plates on wedges, shims, or leveling nuts. After bearing members have been positioned and plumbed, tighten anchor bolts. Do not remove wedges or shims but, if protruding, cut off flush with edge of bearing plate before packing with nonshrink grout. Pack grout solidly between bearing surfaces and plates to ensure that no voids remain.
3.4 ADJUSTING AND CLEANING
A. Touchup Painting: Immediately after erection, clean field welds, bolted connections, and abraded areas. Paint uncoated and abraded areas with the same material as used for shop painting to comply with SSPC-PA 1 for touching up shop -painted surfaces.
B. Galvanized Surfaces: Clean field welds, bolted connections, and abraded areas and repair galvanizing to comply with ASTM A 780/A 780M.
END OF SECTION 055000
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SECTION 055300 - METAL GRATINGS
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Metal bar gratings.
2. Formed -metal plank gratings.
3. Metal frames and supports for gratings.
1.2 PERFORMANCE REQUIREMENTS
A. Delegated Design: Design gratings and grating supports, including comprehensive engineering analysis by a qualified professional engineer, using performance requirements and design criteria indicated.
B. Structural Performance: Gratings shall withstand the effects of gravity loads and the following loads and stresses within limits and under conditions indicated.
1. Floors: Uniform load of 125 lbf/sq. ft. or concentrated load of 2000 lbf whichever produces the greater stress.
2. Walkways and Elevated Platforms Other Than Exits: Uniform load of 60 lbf/sq. ft.
3. Walkways and Elevated Platforms Used as Exits: Uniform load of 100 lbf/sq. ft.
4. Sidewalks and Vehicular Driveways, Subject to Trucking: Uniform load of 250 lbf/sq. ft. or concentrated load of 8000 lbf, whichever produces the greater stress.
5. Unless noted otherwise, deflection of grating shall not exceed '/4" under the loading described above.
C. Seismic Performance: Provide gratings capable of withstanding the effects of earthquake motions determined according to ASCE/SEI 7.
1.3 ACTION SUBMITTALS
A. Product Data: For the following:
1. Formed -metal plank gratings.
2. Clips and anchorage devices for gratings.
3. Paint products.
B. Shop Drawings: Include plans, sections, details, and attachments to other work.
C. Delegated -Design Submittal: Provide design data and analysis signed and sealed by a registered professional engineer in the State of California, responsible for their preparation.
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1.4 QUALITY ASSURANCE
A. Metal Bar Grating Standards: Comply with NAAMM MBG 531, "Metal Bar Grating Manual " and NAAMM MBG 532, "Heavy -Duty Metal Bar Grating Manual." PART 2 - PRODUCTS
2.1 FERROUS METALS
A. Steel Plates, Shapes, and Bars: ASTM A 36/A 36M.
B. Steel Bars for Bar Gratings: ASTM A 36/A 36M or steel strip, ASTM A 1011/A 1011M or ASTM A 1018/A 1018M.
C. Wire Rod for Bar Grating Crossbars: ASTM A 510 (ASTM A 510M).
D. Uncoated Steel Sheet: ASTM A 1011/A 1011M, structural steel, Grade 30 (Grade 205).
E. Galvanized -Steel Sheet: ASTM A 653/A 653M, structural quality, Grade 33 (Grade 230), with G90 (Z275) coating.
F. Stainless -Steel Sheet, Strip, Plate, and Flat Bars: ASTM A 666, Type 304.
G. Stainless -Steel Bars and Shapes: ASTM A 276, Type 304.
2.2 ALUMINUM
A. Extruded Bars and Shapes: ASTM B 221 (ASTM B 221M), alloys as follows:
1. 6061-T6 or 6063-T6, for bearing bars of gratings and shapes.
2. 6061-T1, for grating crossbars.
2.3 FASTENERS
A. General: Unless otherwise indicated, provide Type 316 stainless -steel fasteners. Select fasteners for type, grade, and class required.
1. Provide stainless -steel fasteners for fastening aluminum.
2. Provide stainless steel fasteners for fastening stainless steel.
B. Post -Installed Anchors: Torque -controlled expansion anchors or chemical anchors capable of sustaining, without failure, a load equal to six times the load imposed when installed in unit masonry and four times the load imposed when installed in concrete, as determined by testing according to ASTM E 488, conducted by a qualified independent testing agency.
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2.4 MISCELLANEOUS MATERIALS
A. Low -Emitting Materials: Paints and coatings shall comply with the testing and product requirements of the California Department of Health Services' "Standard Practice for the Testing of Volatile Organic Emissions from Various Sources Using Small -Scale Environmental Chambers."
B. Universal Shop Primer: Fast -curing, lead- and chromate -free, universal modified -alkyd primer complying with MPI#79 and compatible with topcoat.
C. Galvanizing Repair Paint: High -zinc -dust -content paint complying with SSPC-Paint 20 and compatible with paints specified to be used over it.
2.5 FABRICATION
A. Cut, drill, and punch material cleanly and accurately. Remove burrs and ease edges to a radius of approximately 1/32 inch unless otherwise indicated. Remove sharp or rough areas on exposed surfaces.
B. Form from materials of size, thickness, and shapes indicated, but not less than that needed to support indicated loads.
C. Fit exposed connections accurately together to form hairline joints.
D. Fabricate toeplates for attaching in the field.
2.6 METAL BAR GRATINGS
A. Pressure -Locked, Aluminum I -Bar Grating, unless noted otherwise on drawings:
1. Bearing Bar Spacing: 1-3/16 inches
2. Bearing Bar Depth: 2 inch.
3. Bearing Bar Flange Width: 1/4 inch.
4. Crossbar Spacing: 4 inches o.c.
5. Traffic Surface: Grooved.
6. Aluminum Finish: Class I, clear, anodized finish.
B. Removable Grating Sections: Fabricate with banding bars attached by welding to entire perimeter of each section. Include anchors and fasteners of type indicated or, if not indicated, as recommended by manufacturer for attaching to supports.
C. Fabricate cutouts in grating sections for penetrations indicated. Arrange cutouts to permit grating removal without disturbing items penetrating gratings.
1. Edge -band openings in grating that interrupt four or more bearing bars with bars of same size and material as bearing bars.
D. Do not notch bearing bars at supports to maintain elevation.
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2.7 GRATING FRAMES AND SUPPORTS
A. Frames and Supports for Metal Gratings: Fabricate from metal shapes, plates, and bars of welded construction to sizes, shapes, and profiles necessary to receive gratings. Miter and weld connections for perimeter angle frames. Cut, drill, and tap units to receive hardware and similar items.
1. Unless otherwise indicated, fabricate from same basic metal as gratings.
2.8 STEEL FINISHES
A. Finish gratings, frames, and supports after assembly.
B. Galvanizing: Hot -dip galvanize items as indicated to comply with ASTM A 153/A 153M for steel and iron hardware and with ASTM A 123/A 123M for other steel and iron products.
C. Shop prime gratings, frames and supports unless otherwise indicated.
D. Preparation for Shop Priming: Prepare surfaces to comply with SSPC-SP 7/NACE No. 4, "Brush-off Blast Cleaning."
E. Shop Priming: Apply shop primer to comply with SSPC-PA 1, "Paint Application Specification No. 1: Shop, Field, and Maintenance Painting of Steel," for shop painting.
PART 3 - EXECUTION
3.1 INSTALLATION, GENERAL
A. Cutting, Fitting, and Placement: Perform cutting, drilling, and fitting required for installing gratings. Set units accurately in location, alignment, and elevation; measured from established lines and levels and free of rack.
B. Fit exposed connections accurately together to form hairline joints.
1. Weld connections that are not to be left as exposed joints but cannot be shop welded because of shipping size limitations. Do not weld, cut, or abrade the surfaces of exterior units that have been hot -dip galvanized after fabrication and are for bolted or screwed field connections.
C. Attach toeplates to gratings by welding at locations indicated.
D. Corrosion Protection: Coat concealed surfaces of aluminum that will come into contact with grout, concrete, masonry, wood, or dissimilar metals, with a heavy coat of bituminous paint.
3.2 INSTALLING METAL BAR GRATINGS
A. General: Install gratings to comply with recommendations of referenced metal bar grating standards that apply to grating types and bar sizes indicated, including installation clearances and standard anchoring details.
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B. Attach removable units to supporting members with type and size of clips and fasteners indicated or, if not indicated, as recommended by grating manufacturer for type of installation conditions shown.
C. Attach nonremovable units to supporting members by welding where both materials are same; otherwise, fasten by bolting as indicated above.
3.3 ADJUSTING AND CLEANING
A. Touchup Painting: Immediately after erection, clean field welds, bolted connections, and abraded areas of shop paint, and paint exposed areas with same material as used for shop painting to comply with SSPC-PA 1 requirements for touching up shop -painted surfaces.
B. Galvanized Surfaces: Clean field welds, bolted connections, and abraded areas and repair galvanizing to comply with ASTM A 780.
END OF SECTION 055300
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SECTION 079200 - JOINT SEALANTS
PART 1 — GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes joint sealants for the following applications, including those specified by reference to this Section:
1. Exterior joints in the following vertical surfaces and horizontal nontraffic surfaces:
a. Construction joints in cast -in -place concrete.
b. Control and expansion joints in unit masonry and cast stone units. c. Joints between metal panels.
d. Joints between different materials listed above.
e. Perimeter joints between materials listed above and frames of doors and windows.
f. Control and expansion joints in ceilings and other overhead surfaces. g. Other joints as indicated.
2. Exterior joints in the following horizontal traffic surfaces:
a. Isolation and contraction joints in cast -in -place concrete slabs. b. Tile control and expansion joints.
c. Joints between different materials listed above.
d. Other joints as indicated.
3. Interior joints in the following vertical surfaces and horizontal nontraffic surfaces:
a. Control and expansion joints on exposed interior surfaces of exterior walls. b. Perimeter joints of exterior openings where indicated. c. Tile control and expansion joints.
d. Vertical joints on exposed surfaces of walls and partitions. e. Perimeter joints between interior wall surfaces and frames of interior doors, windows and elevator entrances.
f. Joints between plumbing fixtures and adjoining walls, floors, and counters. g. Other joints as indicated.
4. Interior joints in the following horizontal traffic surfaces:
a. Isolation joints in cast -in -place concrete slabs.
b. Control and expansion joints in tile flooring.
c. Other joints as indicated.
B. Related Sections include the following:
1. Division 8 Section "Glazing" for glazing sealants.
2. Division 9 Section "Gypsum Board Assemblies" for sealing perimeter joints of gypsum board partitions to reduce sound transmission.
3. Division 9 Section "Tiling" for sealing tile joints.
1.3 PERFORMANCE REQUIREMENTS
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A. Provide elastomeric joint sealants that establish and maintain watertight and airtight continuous joint seals without staining or deteriorating joint substrates.
B. Provide joint sealants for interior applications that establish and maintain airtight and water-resistant continuous joint seals without staining or deteriorating joint substrates.
1.4 SUBMITTALS
A. Product Data: For each joint -sealant product indicated.
B. Samples for Selection: Manufacturer's color charts consisting of strips of cured sealants showing the full range of colors available for each product exposed to view.
C. Product Certificates: For each type of joint sealant and accessory, signed by product manufacturer.
D. Qualification Data: For Installer.
E. Preconstruction Field Test Reports: Indicate which sealants and joint preparation methods resulted in optimum adhesion to joint substrates based on preconstruction testing specified in "Quality Assurance" Article.
F. Compatibility and Adhesion Test Reports: From sealant manufacturer, indicating the following:
1. Materials forming joint substrates and joint -sealant backings have been tested for compatibility and adhesion with joint sealants.
2. Interpretation of test results and written recommendations for primers and substrate preparation needed for adhesion.
G. Product Test Reports: Based on comprehensive testing of product formulations performed by a qualified testing agency, indicating that sealants comply with requirements.
H. Warranties: Special warranties specified in this Section.
1.5 QUALITY ASSURANCE
A. Installer Qualifications: Manufacturer's authorized Installer who is approved or licensed for installation of elastomeric sealants required for this Project.
B. Source Limitations: Obtain each type of joint sealant through one source from a single manufacturer.
C. Preconstruction Compatibility and Adhesion Testing: Submit to joint -sealant manufacturers, for testing indicated below, samples of materials that will contact or affect joint sealants.
1. Use ASTM C 1087 to determine whether priming and other specific joint preparation techniques are required to obtain rapid, optimum adhesion of joint sealants to joint substrates.
2. Submit not fewer than eight pieces of each type of material, including joint substrates, shims, joint -sealant backings, secondary seals, and miscellaneous materials.
3. Schedule sufficient time for testing and analyzing results to prevent delaying the Work.
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4. For materials failing tests, obtain joint -sealant manufacturer's written instructions for corrective measures including use of specially formulated primers.
5. Testing will not be required if joint -sealant manufacturers submit joint preparation data that are based on previous testing of current sealant products for adhesion to, and compatibility with, joint substrates and other materials matching those submitted.
D. Preconstruction Field -Adhesion Testing: Before installing elastomeric sealants, field test their adhesion to Project joint substrates as follows:
1. Locate test joints where indicated on Project or, if not indicated, as directed by Architect.
2. Conduct field tests for each application indicated below:
a. Each type of elastomeric sealant and joint substrate indicated. b. Each type of nonelastomeric sealant and joint substrate indicated.
3. Notify Architect seven days in advance of dates and times when test joints will be erected.
4. Test Method: Test joint sealants according to Method A, Field -Applied Sealant Joint Hand Pull Tab, in Appendix X1 in ASTM C 1193.
a. For joints with dissimilar substrates, verify adhesion to each substrate separately; extend cut along one side, verifying adhesion to opposite side.
Repeat procedure for opposite side.
5. Report whether sealant in joint connected to pulled -out portion failed to adhere to joint substrates or tore cohesively. Include data on pull distance used to test each type of product and joint substrate. For sealants that fail adhesively, retest until satisfactory adhesion is obtained.
6. Evaluation of Preconstruction Field -Adhesion -Test Results: Sealants not evidencing adhesive failure from testing, in absence of other indications ofnoncompliance with requirements, will be considered satisfactory. Do not use sealants that fail to adhere to joint substrates during testing.
E. Mockups: Build mockups incorporating sealant joints, as follows, to verify selections made under sample submittals and to demonstrate aesthetic effects and set quality standards for materials and execution:
1. Joints in mockups of assemblies specified in other Sections that are indicated to receive elastomeric joint sealants, which are specified by reference to this Section.
1.6 PROJECT CONDITIONS
A. Do not proceed with installation of joint sealants under the following conditions:
1. When ambient and substrate temperature conditions are outside limits permitted by joint -sealant manufacturer or are below 40 deg F (5 deg C).
2. When joint substrates are wet.
3. Where joint widths are less than those allowed by joint -sealant manufacturer for applications indicated.
4. Contaminants capable of interfering with adhesion have not yet been removed from joint substrates.
1.7 WARRANTY
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A. Special Installer's Warranty: Installer's standard form in which Installer agrees to repair or replace elastomeric joint sealants that do not comply with performance and other requirements specified in this Section within specified warranty period.
1. Warranty Period: Three years from date of Substantial Completion.
B. Special warranties specified in this Article exclude deterioration or failure of elastomeric joint sealants from the following:
1. Movement of the structure resulting in stresses on the sealant exceeding sealant manufacturer's written specifications for sealant elongation and compression caused by structural settlement or errors attributable to design or construction.
2. Disintegration of joint substrates from natural causes exceeding design specifications.
3. Mechanical damage caused by individuals, tools, or other outside agents.
4. Changes in sealant appearance caused by accumulation of dirt or other atmospheric contaminants.
PART 2 — PRODUCTS
2.1 MANUFACTURERS
A. Available Products: Subject to compliance with requirements, products that may be incorporated into the Work include, but are not limited to, products listed in other Part 2 articles.
2.2 MATERIALS, GENERAL
A. Compatibility: Provide joint sealants, backings, and other related materials that are compatible with one another and with joint substrates under conditions of service and application, as demonstrated by sealant manufacturer, based on testing and field experience.
B. Colors of Exposed Joint Sealants: As selected by Architect from manufacturer's full range.
2.3 ELASTOMERIC JOINT SEALANTS
A. Elastomeric Sealants: Comply with ASTM C 920 and other requirements indicated for each liquid -applied chemically curing sealant specified, including those referencing ASTM C 920 classifications for type, grade, class, and uses related to exposure and joint substrates.
B. Stain -Test -Response Characteristics: Where elastomeric sealants are specified to be nonstaining to porous substrates, provide products that have undergone testing according to ASTM C 1248 and have not stained porous joint substrates indicated for Project.
C. Suitability for Immersion in Liquids. Where elastomeric sealants are indicated for Use I for joints that will be continuously immersed in liquids, provide products that have undergone testing according to ASTM C 1247 and qualify for the length of exposure indicated by reference to ASTM C 920 for Class 1 or 2. Liquid used for testing sealants is deionized water, unless otherwise indicated.
D. Suitability for Contact with Food: Where elastomeric sealants are indicated for joints that will come in repeated contact with food, provide products that comply with 21 CFR 177.2600.
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E. Single -Component Neutral -Curing Silicone Sealant:
1. Available Products:
a. Pecora Corporation; 895.
2. Type and Grade: S (single component) and NS (nonsag).
3. Class: 50.
4. Use Related to Exposure: NT (nontraffic).
5. Uses Related to Joint Substrates: M, G, A, and, as applicable to joint substrates indicated, O.
a. Use 0 Joint Substrates: Aluminum coated with a high-performance coating.
6. Stain -Test -Response Characteristics: Nonstaining to porous substrates per ASTM C 1248.
F. Single -Component Acid -Curing Silicone Sealant:
1. Available Products:
a. Dow Corning Corporation; 999-A.
b. GE Silicones; Construction
c. Pecora Corporation; 860.
d. Tremco; Proglaze.
2. Type and Grade: S (single component) and NS (nonsag).
3. Class: 25.
4. Use Related to Exposure: NT (nontraffic).
5. Uses Related to Joint Substrates: G, A, and, as applicable to joint substrates indicated, O.
a. Use 0 Joint Substrates: Aluminum coated with a high-performance coating.
G. Single -Component Mildew -Resistant Neutral -Curing Silicone Sealant:
1. Available Products:
a. Pecora Corporation; 898.
b. Tremco; Tremsil 600 White.
2. Type and Grade: S (single component) and NS (nonsag).
3. Class: 25.
4. Use Related to Exposure: NT (nontraffic).
5. Uses Related to Joint Substrates: G, A, and, as applicable to joint substrates indicated, O.
a. Use 0 Joint Substrates: Ceramic tile.
H. Multicomponent Nonsag Urethane Sealant:
1. Available Products:
a. Pecora Corporation; Dynatrol II.
b. Tremco; Dymeric 511.
2. Type and Grade: M (multicomponent) and NS (nonsag).
3. Class: 50.
4. Use Related to Exposure: NT (nontraffic).
5. Uses Related to Joint Substrates: M, A, and, as applicable to joint substrates indicated, O.
a. Use 0 Joint Substrates: Aluminum coated with a high-performance coating.
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I. Multicomponent Pourable Urethane Sealant:
1. Available Products:
a. Pecora Corporation; Dynatrol II -SG.
b. Sika Corporation, Inc.; Sikaflex - 2c SL.
c. Sonneborn, Division of ChemRex Inc.; SL 2.
2. Type and Grade: M (multicomponent) and P (pourable).
3. Class: 25.
4. Uses Related to Exposure: T (traffic) and NT (nontraffic).
5. Uses Related to Joint Substrates: M, G, A, and, as applicable to joint substrates indicated, O.
J. Single -Component Nonsag Urethane Sealant:
1. Available Products:
a. Pecora Corporation; Dynatrol I -XL.
b. Sika Corporation, Inc.; Sikaflex - 15LM.
c. Tremco; DyMonic.
2. Type and Grade: S (single component) and NS (nonsag).
3. Class: 25.
4. Use Related to Exposure: NT (nontraffic).
5. Uses Related to Joint Substrates: M, A, and, as applicable to joint substrates indicated, O.
2.4 SOLVENT -RELEASE JOINT SEALANTS
A. Acrylic -Based Solvent -Release Joint Sealant: Comply with ASTM C 1311 or FS TT -S-00230.
1. Available Products:
a. Tremco; Mono 555.
B. Butyl -Rubber -Based Solvent -Release Joint Sealant: Comply with ASTM C 1085.
1. Available Products:
a. Sonneborn, Division of ChemRex Inc.; Sonneborn Multi -Purpose Sealant. b. Tremco; Tremco Butyl Sealant.
2.5 LATEX JOINT SEALANTS
A. Latex Sealant: Comply with ASTM C 834, Type P, Grade NF.
B. Available Products:
1. Pecora Corporation; AC -20+.
2. Sonneborn, Division of ChemRex Inc.; Sonolac.
3. Tremco; Tremflex 834.
2.6 ACOUSTICAL JOINT SEALANTS
A. Acoustical Sealant for Exposed and Concealed Joints: Manufacturer's standard nonsag, paintable, nonstaining latex sealant complying with ASTM C 834 and the following:
1. Product effectively reduces airborne sound transmission through perimeter joints and openings in building construction as demonstrated by testing representative assemblies according to ASTM E 90.
2. Available Products:
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a. Pecora Corporation; AC -20 FTR Acoustical and Insulation Sealant. b. United States Gypsum Co.; SHEETROCK Acoustical Sealant.
2.7 JOINT -SEALANT BACKING
A. General: Provide sealant backings of material and type that are nonstaining; are compatible with joint substrates, sealants, primers, and other joint fillers; and are approved for applications indicated by sealant manufacturer based on field experience and laboratory testing.
B. Cylindrical Sealant Backings: ASTM C 1330, Type C (closed -cell material with a surface skin), and of size and density to control sealant depth and otherwise contribute to producing optimum sealant performance:
C. Elastomeric Tubing Sealant Backings: Neoprene, butyl, EPDM, or silicone tubing complying with ASTM D 1056, nonabsorbent to water and gas, and capable of remaining resilient at temperatures down to minus 26 deg F (minus 32 deg C). Provide products with low compression set and of size and shape to provide a secondary seal, to control sealant depth, and to otherwise contribute to optimum sealant performance.
D. Bond -Breaker Tape: Polyethylene tape or other plastic tape recommended by sealant manufacturer for preventing sealant from adhering to rigid, inflexible joint -filler materials or joint surfaces at back of joint where such adhesion would result in sealant failure. Provide self-adhesive tape where applicable.
2.8 MISCELLANEOUS MATERIALS
A. Primer: Material recommended by joint -sealant manufacturer where required for adhesion of sealant to joint substrates indicated, as determined from preconstruction joint -sealant -substrate tests and field tests.
B. Cleaners for Nonporous Surfaces: Chemical cleaners acceptable to manufacturers of sealants and sealant backing materials, free of oily residues or other substances capable of staining or harming joint substrates and adjacent nonporous surfaces in any way, and formulated to promote optimum adhesion of sealants to joint substrates.
C. Masking Tape: Nonstaining, nonabsorbent material compatible with joint sealants and surfaces adjacent to joints.
PART 3 — EXECUTION
3.1 EXAMINATION
A. Examine joints indicated to receive joint sealants, with Installer present, for compliance with requirements for joint configuration, installation tolerances, and other conditions affecting joint -sealant performance.
B. Proceed with installation only after unsatisfactory conditions have been corrected.
3.2 PREPARATION
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A. Surface Cleaning of Joints: Clean out joints immediately before installing joint sealants to comply with joint -sealant manufacturer's written instructions and the following requirements:
1. Remove all foreign material from joint substrates that could interfere with adhesion of joint sealant, including dust, paints (except for permanent, protective coatings tested and approved for sealant adhesion and compatibility by sealant manufacturer), old joint sealants, oil, grease, waterproofing, water repellents, water, surface dirt, and frost.
2. Clean porous joint substrate surfaces by brushing, grinding, blast cleaning, mechanical abrading, or a combination of these methods to produce a clean, sound substrate capable of developing optimum bond with joint sealants. Remove loose particles remaining after cleaning operations above by vacuuming or blowing out joints with oil -free compressed air. Porous joint substrates include the following:
a. Concrete.
b. Masonry.
c. Unglazed surfaces of ceramic tile.
3. Remove laitance and form -release agents from concrete.
4. Clean nonporous surfaces with chemical cleaners or other means that do not stain, harm substrates, or leave residues capable of interfering with adhesion of joint sealants. Nonporous joint substrates include the following:
a. Metal.
b. Glass.
c. Glazed surfaces of ceramic tile.
B. Joint Priming: Prime joint substrates, where recommended in writing by joint -sealant manufacturer, based on preconstruction joint -sealant -substrate tests or prior experience.
Apply primer to comply with joint -sealant manufacturer's written instructions. Confine primers to areas of joint -sealant bond; do not allow spillage or migration onto adjoining surfaces.
C. Masking Tape: Use masking tape where required to prevent contact of sealant with adjoining surfaces that otherwise would be permanently stained or damaged by such contact or by cleaning methods required to remove sealant smears. Remove tape immediately after tooling without disturbing joint seal.
3.3 INSTALLATION OF JOINT SEALANTS
A. General: Comply with joint -sealant manufacturer's written installation instructions for products and applications indicated, unless more stringent requirements apply.
B. Sealant Installation Standard: Comply with recommendations in ASTM C 1193 for use of joint sealants as applicable to materials, applications, and conditions indicated.
C. Acoustical Sealant Application Standard: Comply with recommendations in ASTM C 919 for use of joint sealants in acoustical applications as applicable to materials, applications, and conditions indicated.
D. Install sealant backings of type indicated to support sealants during application and at position required to produce cross-sectional shapes and depths of installed sealants relative to joint widths that allow optimum sealant movement capability.
1. Do not leave gaps between ends of sealant backings.
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2. Do not stretch, twist, puncture, or tear sealant backings.
3. Remove absorbent sealant backings that have become wet before sealant application and replace them with dry materials.
E. Install bond -breaker tape behind sealants where sealant backings are not used between sealants and backs of joints.
F. Install sealants using proven techniques that comply with the following and at the same time backings are installed:
1. Place sealants so they directly contact and fully wet joint substrates.
2. Completely fill recesses in each joint configuration.
3. Produce uniform, cross-sectional shapes and depths relative to joint widths that allow optimum sealant movement capability.
G. Tooling of Nonsag Sealants: Immediately after sealant application and before skinning or curing begins, tool sealants according to requirements specified below to form smooth, uniform beads of configuration indicated; to eliminate air pockets; and to ensure contact and adhesion of sealant with sides of joint.
1. Remove excess sealant from surfaces adjacent to joints.
2. Use tooling agents that are approved in writing by sealant manufacturer and that do not discolor sealants or adjacent surfaces.
3. Provide concave joint configuration per Figure 5A in ASTM C 1193, unless otherwise indicated.
3.4 CLEANING
A. Clean off excess sealant or sealant smears adjacent to joints as the Work progresses by methods and with cleaning materials approved in writing by manufacturers of joint sealants and of products in which joints occur.
3.5 PROTECTION
A. Protect joint sealants during and after curing period from contact with contaminating substances and from damage resulting from construction operations or other causes so sealants are without deterioration or damage at time of Substantial Completion. If, despite such protection, damage or deterioration occurs, cut out and remove damaged or deteriorated joint sealants immediately so installations with repaired areas are indistinguishable from original work.
3.6 JOINT -SEALANT SCHEDULE
A. Joint -Sealant Application: Exterior vertical construction joints in cast -in -place concrete.
1. Joint Sealant: Multicomponent nonsag urethane sealant.
2. Joint -Sealant Color: As selected by Architect/Engineer from manufacturer's full range.
B. Joint -Sealant Application: Exterior horizontal nontraffic and traffic isolation and contraction joints in cast -in -place concrete slabs.
1. Joint Sealant: Multicomponent pourable urethane sealant.
2. Joint -Sealant Color: As selected by Architect/Engineer from manufacturer's full range.
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C. Joint -Sealant Application: Exterior vertical control and expansion joints in unit masonry.
1. Joint Sealant: Multicomponent nonsag urethane sealant or Single -component nonsag urethane sealant.
2. Joint -Sealant Color: As selected by Architect/Engineer from manufacturer's full range.
D. Joint -Sealant Application: Exterior butt joints between metal panels.
1. Joint Sealant: Single -component nonsag urethane sealant.
2. Joint -Sealant Color: As selected by Architect/Engineer from manufacturer's full range.
E. Joint -Sealant Application: Exterior vertical joints between different materials listed above.
1. Joint Sealant: Multicomponent nonsag urethane sealant or Single -component nonsag urethane sealant.
2. Joint -Sealant Color: As selected by Architect/Engineer from manufacturer's full range.
F. Joint -Sealant Application: Exterior perimeter joints between unit masonry and frames of doors and windows.
1. Joint Sealant: Multicomponent nonsag urethane sealant or Single -component nonsag urethane sealant.
2. Joint -Sealant Color: As selected by Architect/Engineer from manufacturer's full range.
G. Joint -Sealant Application: Exterior control and expansion joints in ceilings and other overhead surfaces.
1. Joint Sealant: Multicomponent nonsag urethane sealant or Single -component nonsag urethane sealant.
2. Joint -Sealant Color: As selected by Architect/Engineer from manufacturer's full range.
H. Joint -Sealant Application: Vertical control and expansion joints on exposed interior surfaces of exterior walls.
1. Joint Sealant: Multicomponent nonsag urethane sealant or Single -component nonsag urethane sealant.
2. Joint -Sealant Color: As selected by Architect/Engineer from manufacturer's full range.
I. Joint -Sealant Application: Interior perimeter joints of exterior openings.
1. Joint Sealant: Multicomponent nonsag urethane sealant or Single -component nonsag urethane sealant.
2. Joint -Sealant Color: As selected by Architect/Engineer from manufacturer's full range.
J. Joint -Sealant Application: Interior ceramic tile expansion, control, contraction, and isolation joints in horizontal traffic surfaces.
1. Joint Sealant: Multicomponent nonsag urethane sealant.
2. Joint -Sealant Color: As selected by Architect/Engineer from manufacturer's full range.
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K. Joint -Sealant Application: Interior joints between plumbing fixtures and adjoining walls, floors, and counters.
1. Joint Sealant: Single -component mildew -resistant neutral -curing silicone sealant.
2. Joint -Sealant Color: As selected by Architect/Engineer from manufacturer's full range.
L. Joint -Sealant Application: Vertical joints on exposed surfaces of interior unit masonry walls and partitions.
1. Joint Sealant: Single -component nonsag urethane sealant.
2. Joint -Sealant Color: As selected by Architect/Engineer from manufacturer's full range.
M. Joint -Sealant Application: Perimeter joints between interior wall surfaces and frames of interior doors, windows and elevator entrances.
1. Joint Sealant: Latex sealant.
2. Joint -Sealant Color: As selected by Architect/Engineer from manufacturer's full range.
END OF SECTION 079200
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SECTION 098000 - PROTECTIVE COATINGS
PART 1 - GENERAL
1.1 DESCRIPTION
A. Section includes the surface preparation and application requirements of paint systems as specified herein.
B. The coating system schedule included in the drawings, and the specifications herein identify the surfaces to be coated with the designated coating system number including the required surface preparation, and the products to be applied. If used, coating notes on the Drawings are to show or extend the limits of coating schedules, to show exceptions to the schedules, or to clarify or show details for application of the coating systems.
C. Scope of Work
1. The Contractor shall furnish all materials, labor, equipment, and incidentals required to provide a protective coating system for the surfaces listed herein and not otherwise excluded.
2. The work includes surface preparation and cleaning, painting and finishing of interior and exterior exposed items and surfaces such as ceilings, walls, floors, miscellaneous metal, doors, frames, construction signs, guardrails, posts, pipes, fittings, valves, equipment, and all other work obviously required to be painted unless otherwise specified herein or on the Drawings. The omission of minor items in the schedule of work shall not relieve the Contractor of his obligation to include such items where they come within the general intent of the Specifications as stated herein.
1.2 REFERENCES
A. American National Standards Institute:
1. ANSI/NSF Standard 61 Listing of Certified Drinking Water System Components - Health Effects.
2. ANSI Z53.1, Safety Color Code for Marking Physical Hazards.
B. ASTM International (ASTM):
1. ASTM D4263 — Standard Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method.
2. ASTM D4414 — Standard Practice for Measurement of Wet Film Thickness by Notch Gages
3. ASTM D4417 — Standard Test Method for Field Measurement of Surface Profile of Blast Cleaned Steel.
4. ASTM D6386 — Standard Practice for Preparation of Zinc (Hot -Dip Galvanized) Coated Iron and Steel Product and Hardware Surfaces for Painting.
5. ASTM F1869 — Standard Test Method for Measuring Moisture Vapor Emission Rate of Concrete Subfloor Using Anhydrous Calcium Chloride.
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6. ASTM F2170 — Standard Test Method for Determining Relative Humidity in Concrete Floor Slabs Using in situ Probes.
C. International Concrete Repair Institute (ICRI):
1. Guideline No. 310.1 — Guide for Surface Preparation for the Repair of Deteriorated Concrete Resulting from Reinforcing Steel Corrosion
2. Guideline No. 310.2 — Selecting and Specifying Concrete Surface Preparation for Sealer, Linings, and Polymer Overlays
D. NACE International, (NACE)
1. NACE RP0287 — Field Measurement of Surface Profile of Abrasive Blast -Cleaned Steel Surfaces Using a Replica Tape
2. NACE SP0188 — Standard Practice for Discontinuity (Holiday) Testing of Protective Linings
3. NACE No. 1/SSPC-SP 5 - White Metal Blast Cleaning.
4. NACE No. 2/SSPC-SP 10 - Near -White Metal Blast Cleaning.
5. NACE No. 3/SSPC-SP 6 Commercial Blast Cleaning
6. NACE No. 6/SSPC-SP13 — Surface Preparation of Concrete E. National Association of Pipe Fabricators (NAPF)
1. NAPF 500-03 — Surface Preparation Standard for Ductile Iron Pipe and Fittings in Exposed Locations Receiving Special External Coatings and/or Special Internal Linings F. Occupational Safety and Health Act (OSHA):
1. OSHA 1910.144, Safety Color Code for Marking Physical Hazards.
2. OSHA 1910.145, Specifications for accident prevention signs and tags.
G. SSPC: The Society for Protective Coatings, (SSPC)
1. SSPC PA1 - Shop, Field, and Maintenance Painting of Steel
2. SSPC-PA2 — Paint Application Specification No. 2: Measurement of Dry Coating Thickness with Magnetic Gages.
3. SSPC-PA11 - Protecting Edges, Crevices, and Irregular Steel Surfaces by Stripe Coating
4. SSPC-SP1 Solvent Cleaning
5. SSPC-SP2 Hand Tool Cleaning
6. SSPC-SP3 Power Tool Cleaning
7. SSPC-SP5/NACE No. 1 — White Metal Blast Cleaning
8. SSPC-SP 6/NACE No. 3 - Commercial Blast Cleaning.
9. SSPC-SP 10/NACE No. 2 - Near -White Metal Blast Cleaning.
10. SSPC-SP 13/NACE No. 6 — Surface Preparation of Concrete
11. SSPC-SP16 Brush -Off Blast Cleaning of Coated and Uncoated Galvanized Steel, Stainless Steels, and Non -Ferrous Metals
12. SSPC-VIS 1 - Guide to Reference Photographs for Steel Surfaces Prepared by Dry Abrasive Blast Cleaning
H. Unless otherwise specified, references to documents shall mean the documents in effect at the time of receipt of Bids. If referenced documents have been discontinued by the issuing organization references
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to those documents shall mean the replacement documents or the last version of the document before it was discontinued.
1.3 DEFINITIONS
A. "Paint" as used herein means all coating systems, materials, including primers, emulsions, enamels, sealers and fillers, and other applied materials whether used as prime, intermediate or finish coats.
B. Dry Film Thickness (DFT): Thickness of fully cured coating, measured in mils.
C. Volatile Organic Compound (VOC): Content of air polluting hydrocarbons in uncured coating product measured in units of grams per liter per pounds per gallon, as determined by EPA Method 24.
D. The term "exposed" as used in this Section shall mean all items not covered with concrete, masonry, or similar material.
1.4 ACTION SUBMITTALS
A. Product Data: For each type of product indicated. Include preparation requirements and application instructions.
1. Submit to the Engineer as provided in the General Conditions and Section 013300: Contractor Submittals, Working Drawings, and Samples; shop drawings, manufacturer's specifications and data on the proposed paint systems and detailed surface preparation, application procedures and dry film thickness (DFT).
2. Submit material manufacturer's technical information, including paint label analysis and application instructions for each material proposed
a. List each material and cross-reference to specific paint and finish system and application.
Identify by manufacturer's catalog number and general classification. b. Submit copies of manufacturer's complete color charts for each coating system. c. Provide certifications from manufacturers verifying that factory applied prime coats are compatible with specified finish coatings.
d. Pipe Markers and Safety Signs: Submit copies of manufacturer's technical brochure, including color chart and list of standard signs. Owner will set titles on pipe markers and safety signs.
B. Safety Data Sheets: Copies of current Safety Data Sheets (SDS) for materials.
C. Qualification Data: Submit proof of acceptability of Applicator by manufacturer to Engineer.
D. Jobsite Reports: Submit at the completion of Work
1. Daily Reports: Include surface preparation, ambient conditions, application methods, material applied, material quantities, material batch number, and description of items completed.
2. Applicator shall maintain a copy of records until the expiration of the specified warranty period.
E. Schedule:
1. The Contractor shall submit for approval to the Construction Manager, a complete typewritten Schedule of Painting Operations within 90 days after the Notice to Proceed. This Schedule is
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imperative so that the various fabricators or suppliers may be notified of the proper shop prime coat to apply. It shall be the Contractor's responsibility to properly notify and coordinate the fabricator's or suppliers' surface preparation and painting operations with these specifications.
Record of notification shall be transmitted to the Construction Manager or be available for review. This Schedule shall include for each surface to be painted, the brand name, generic type, solids by volume, application method, the coverage and the number of coats in order to achieve the specified dry film thickness, and color charts. When the Schedule has been approved, the Contractor shall apply all material in strict accordance with the approved Schedule and the manufacturer's instructions. Wet and dry paint film gauges may be utilized by the Owner to verify the proper application while work is in progress.
2. It is the intent of this section that as much as possible all equipment and piping utilize coating systems specified herein supplied by a single manufacturer. All exceptions must be noted on the Schedule. For each coating system, only one (1) manufacturer's product shall be used.
3. Contractor is responsible for the compatibility of all shop primed and field painted items in this Contract. Furnish information on the characteristics of the finish materials proposed to use, to ensure that compatible prime coats are used. As directed by the Engineer, provide barrier coats over incompatible primers or remove and re -prime. Notify the Engineer in writing of anticipated problems using the coating systems as specified with substrates primed by others.
F. Color Samples: Manufacturer's standard color charts for color selection by Owner.
G. Samples — Painting:
1. Paint colors will be selected by Owner unless other standards are noted. Compliance with all other requirements is the exclusive responsibility of the Contractor.
H. Applicator Qualifications: Submit qualifications as specified under Quality Assurance article.
I. Closeout Submittals:
1. Submit certificate stating Work was properly prepared and painted in accordance with Specifications.
2. Submit manufacturer's certificate stating quantity of paint furnished was sufficient to properly coat all surfaces.
3. Maintenance Manual: Upon completion of work, furnish copies of a detailed maintenance manual including following information:
a. Product name and number.
b. Name, address and telephone number of manufacturer and local distributor. c. Detailed procedures for routine maintenance and cleaning. d. Detailed procedures for light repairs such as dents, scratches and staining.
1.5 MAINTENANCE MATERIAL SUBMITTALS
A. Furnish extra materials, from the same product run, that match products installed and that are packaged with protective covering for storage and identified with labels describing contents.
1. Coatings: 5 percent, but not less than 1 gal. of each material and color applied.
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1.6 QUALITY ASSURANCE
A. Provide the best quality grade of the various types of coatings suitable for use in corrosive water and wastewater treatment and pumping environments as regularly manufactured by approved paint materials manufacturers. Materials not displaying the manufacturer's identification as a standard, best grade product will not be acceptable.
B. Provide undercoat paint produced by the same manufacturer as the finish coats. Undercoat and finish coat paints shall be compatible. Use only thinners approved by the paint manufacturer and list the manufacturer, and use only within recommended limits as listed on the manufacturer's product data sheets.
C. Painting shall be accomplished by experienced painters specializing in industrial painting familiar with all aspects of surface preparations and applications required for this project. Work shall be done in a safe and workmanlike manner.
D. Applicator Qualifications:
1. Successfully painted water and wastewater utility installations for at least five (5) years. Submit name and experience record of painting applicator to Engineer. Submit a list of at least five (5) similar installations painted within the last five (5) years, along with responsible officials, architects or engineers involved with the project, and the approximate contract price.
2. Painting applicators whose submissions indicate a lack of experience required to perform the work, or have performed work in an unsatisfactory manner, will not be approved.
E. Pre -Installation Conference:
1. Before start of Work — General Contractor, Applicator, and Manufacturer's Technical Representative shall meet on -site with Engineer to discuss approved products and workmanship to ensure proper surface preparation and application of the coatings.
2. Review foreseeable methods and procedures related to the coating Work including but not necessarily limited to the following:
a. Review Project requirements and the Contract Documents. b. Review required submittals.
c. Review requirements of on -site quality control inspection and testing. d. Review the requirements for preparing the quality control report as specified herein. e. Review availability of materials, tradesmen, equipment and facilities needed to make progress and avoid delays.
f. Review material storage and staging.
g. Review equipment storage and staging.
h. Review waste management and disposal.
i. Review environmental conditions, other Project conditions, and procedures for coping with unfavorable conditions.
j. Review regulations concerning code compliance, environmental protection, health, safety, fire and similar considerations.
k. Review procedures required for the protection of the completed work during the remainder of the construction period.
F. Single -Source Responsibility:
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1. Materials shall be products of a single manufacturer or items standard with manufacturer of specified coating materials.
2. Provide secondary materials which are produced or are specifically recommended by coating system manufacturer to ensure compatibility of system.
G. Regulatory Requirements: Conform to applicable codes and ordinances for flame, fuel, smoke and volatile organic compounds (VOC) ratings requirements for finishes at time of application.
1. The products specified meet the South Coast Air Quality Management District (SCAQMD) Rule 1113.
a. This area includes all of Orange County, and all the urban areas of Los Angeles, Riverside, and San Bernardino counties.
H. Acceptable Manufacturers:
1. Tnemec Co. (Where noted otherwise in the coating specification use specified product or equal).
2. Sherwin Williams, subject to meeting the requirements of individual coating systems requirements and the requirements of an "or equal" product as described below.
3. Or Equal. No substitutions will be considered that decrease film thickness, number of coats, surface preparation or generic type of coating specified. Furnish same color selection of substituted manufacturers as manufacturer specified, including accent colors in coating systems.
Substitutions must meet the performance requirements of the materials selected.
1.7 DELIVERY, HANDLING AND STORAGE
A. Deliver, store and handle paint in accordance with manufacturer's recommendations, and as supplemented below.
B. Delivery of Materials:
1. Deliver materials to job site in original, new, and unopened packages and containers bearing manufacturer's name and label with following information:
a. Name or title of material.
b. Manufacturer's stock number, batch number and date of manufacture (shelf life). c. Manufacturer's name.
d. Contents by volume, for major pigment and vehicle constituents. e. Thinning instructions where recommended.
f. Application instructions.
g. Color name and number.
C. Storage of Materials:
1. Store only acceptable project materials on project site.
2. Store in a suitable location approved by Owner. Keep area clean and accessible.
3. Restrict storage to paint materials and related equipment.
4. Comply with health and fire regulations including the Occupational Safety and Health Act of 1970. Flammable materials shall be separated and stored in a suitable area as required.
5. Keep temperature of storage area above 50° F or manufacturer's recommended storage temperature, whichever is higher. Consult the manufacturer's written literature for storage condition requirements.
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6. Containers shall be clearly marked to indicate any hazards connected with the use of the paint and steps which should be taken to prevent injury to those handling the product.
1.8 JOB CONDITIONS
A. Environmental Requirements:
1. Proceed with coating Work only when temperature of substrate, air temperature, relative humidity, dew point and other conditions comply with the manufacturer's written recommendations and when no damaging environmental conditions are forecasted for the time when the material will be vulnerable to such environmental damage. Record such conditions and include in Daily Report.
2. Maintain substrate temperature and ambient temperature before, during and after installation in accordance with manufacturer's instructions.
3. Provide adequate ventilation during installation and full curing periods of the coating.
4. Coatings shall not be applied when ambient air temperature is within 5°F of the dew point and falling.
B. Dust and Contaminants: Protect work and adjacent areas from excessive dust and airborne contaminates during coating application and curing. Schedule Work to avoid excessive dust and airborne contaminants.
1.9 WARRANTY AND GUARANTEES
A. Unless otherwise noted herein, warranty period shall be 12 months from the date of project substantial completion.
B. All paint and coatings work performed under these specifications shall be guaranteed by the coatings applicator for 100 percent of the total coated area for both materials and labor against failures during the warranty period.
C. Failure under this warranty shall include flaking, peeling, or delaminating of the coating due to aging, chemical attack, or poor workmanship; but it shall not include areas which have been damaged by unusual chemical, thermal, or mechanical abuse.
1.10 SURFACES TO BE COATED
A. Design Requirements:
1. Ensure surfaces are properly prepared, proper primer applied to correct mil thickness, and finish coat is compatible with primer coat and applied to correct mil thickness. This requirement applies to all equipment and material, whether the total process is done in the shop, in the field, or partially in shop and partially in field.
2. Provide paint products supplied by one manufacturer unless otherwise approved by the Engineer.
B. Paint all exposed surfaces, except where natural finish of material is specifically noted as a surface not to be painted.
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C. Where items or surfaces are not specifically mentioned, paint these the same as adjacent similar materials or areas.
D. The following items will not be painted unless otherwise noted.
1. Any code -requiring labels, such as Underwriters' Laboratories and Factory Mutual, or any equipment identification, performance rating, name or nomenclature plates.
2. Any moving parts of operating units, mechanical and electrical parts, such as valve and damper operators, linkages, sensing devices, motor and fan shafts, unless otherwise indicated.
3. Aluminum except where in contact with dissimilar metals.
4. Fiberglass items including but not limited to handrails, walkways, toeboards, windows, louvers, fans, grating, and tanks.
5. Stainless steel, chromium plate/polished chrome, anodized aluminum, nickel and similar finished products.
6. Brass and bronze other than exposed utility tubing.
7. Flexible couplings, lubricated bearing surfaces, insulation and plastic pipe or duct interiors.
8. Plastic switch plates and receptacle plates.
9. Signs and nameplates.
10. Finish hardware.
11. Packing glands and other adjustable parts, unless otherwise indicated.
12. Portions of metal, other than aluminum, embedded in concrete. This does not apply to the back face of items mounted to concrete or masonry surfaces which shall be painted before erection.
This also does not apply to concrete encased piping which shall be coated as specified in the Coating Schedule included in the drawings. Aluminum to be embedded in, or in contact with, concrete shall be coated to prevent electrolysis.
13. Galvanized metals unless specifically noted otherwise.
14. Prefinished Items.
a. Unless otherwise shown or specified, factory finishing such as baked -on factory porcelain, polyvinyl fluoride or other similar finish is specified for such items as, but not limited to, mechanical and electrical equipment such as instruments, light fixtures and distribution cabinets. Touch up factory finished items with paint supplied by the item manufacturer. As directed by Engineer, field paint damaged prefinished items or return them to the factory for repair and repainting.
b. Any prefinished item not having generic type of paint or proper mil thickness to withstand corrosive atmosphere of water treatment plants, wastewater treatment plants and/or pumping stations shall be returned to the factory for painting or shall have additional coats applied in the field.
PART 2 - PRODUCTS
2.1 MATERIALS
A. The following coating systems list a product by name to establish a standard of quality; other products of the same generic types may be submitted to the Engineer for approval as described in Paragraph 1.6 H., herein. When other than the specified coating system is proposed, the Contractor shall submit on a typewritten list giving the proposed coatings, brand, trade name, generic type and catalog number of the proposed system and the requested test results for the Engineer's approval.
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B. Paint used in successive field coats shall be produced by the same manufacturer. Paint used in the first field coat over shop painted or previously painted surfaces shall cause no wrinkling, lifting, or other damage to underlying paint. Shop paint shall be of the same type and manufacturer as used for field painting by the Contractor.
C. Provide paints, pipe marker and safety signs of durable and washable quality. Use materials which will withstand normal washing as required to remove grease, oil, chemicals, etc., without showing discoloration, loss of gloss, staining, or other damage.
2.2 COLORS AND FINISHES
A. Provide surface treatments and finishes as specified in paragraph 2.4 of this Section.
B. Color Schedule: Colors for painted surfaces will be selected by Owner or as shown on Drawings.
C. Piping Color Code: Colors for piping will be in accordance with Section 220553 "Identification for Plumbing Piping and Equipment".
D. Use representative colors when preparing samples for Engineer's review. Final acceptance of colors will be from samples applied on the job.
E. Color Pigments: Pure, nonfading, applicable types to suit substrates and service indicated.
F. Paints specified for application on submerged metal in contact with potable water shall meet NSF 61 and be approved by the governing health and safety codes.
2.3 MANUFACTURERS
A. Products of Tnemec Company, Inc., Kansas City, Missouri are listed to establish a standard of performance and quality.
B. Materials specified are those that have been evaluated for the specific service. Request for material substitutions shall be in accordance with requirements of the project specifications. Equivalent materials of other manufacturers may be submitted on written approval of the Engineer. No request for substitution shall be considered that would decrease film thickness or offer a change in the generic type of coating specified. In no case, will the request be considered unless information is received, in writing, ten (10) days prior to the bid opening date.
C. Requests for substitution shall include:
1. Manufacturer's literature for each product giving name, product number, generic type, descriptive information, laboratory testing showing results equal to the performance criteria of the products specified herein.
2. Side by side comparison of the performance attributes of the proposed materials as compared to the specified coating system.
3. List of ten (10) projects in which each product has been used and rendered satisfactory service.
4. The sum which will be added to or deducted from the base bid should alternate materials be accepted.
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2.4 MATERIALS
A. STEEL - STRUCTURAL, TANKS, PIPE AND EQUIPMENT
1. SYSTEM 101 - EXTERIOR EXPOSED - STRUCTURAL, TANKS, AND EQUIPMENT a. Surface Preparation: SSPC-SP6 Commercial Blast Cleaning with a minimum angular anchor profile of 1.5 mils
b. Primer: Hydro -Zinc Series 94-H20 2.5 - 3.5 mils dft c. Intermediate: Hi -Build Epoxoline II Series L69 at 3.0 - 5.0 mils dft d. Finish: Finish: Endura-Shield Series 1095 2.0 to 3.0 mils dft
2. SYSTEM 102 - EXTERIOR EXPOSED - PIPE
a. Surface Preparation: SSPC-SP6 Commercial Blast Cleaning with a minimum angular anchor profile of 1.5 mils
b. Primer: Hi -Build Epoxoline II Series L69 at 3.0 - 5.0 mils dft c. Intermediate: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft d. Finish: Finish: Endura-Shield Series 1095 2.0 to 3.0 mils dft
3. SYSTEM 103- INTERIOR EXPOSED
a. Surface Preparation: SSPC-SP6 Commercial Blast Cleaning with a minimum angular anchor profile of 1.5 mils
b. Primer: Hi -Build Epoxoline II Series L69 at 3.0 - 5.0 mils dft c. Finish: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft
4. SYSTEM 104 - IMMERSION - TYPICAL MUNICIPAL WASTEWATER a. Surface Preparation: SSPC-SP10 Near White Blast Cleaning with a minimum angular anchor profile of 1.5 mils
b. Primer: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft c. Intermediate: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft d. Finish: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft
5. SYSTEM 105 - IMMERSION - POTABLE WATER REQUIRING NSF 61 CERTIFICATION a. N/A
6. SYSTEM 106 - IMMERSION - MODERATE TO SEVERE CHEMICAL EXPOSURE INCLUDING H2S
VAPOR EXPOSURE - SMALL STRUCTURES - MECHANISMS
a. Surface Preparation: SSPC-SP10 Near -White Blast Cleaning with a minimum angular anchor profile of 2.0 mils
b. Primer: Tneme-Liner Series 61 at 10.0 - 12.0 mils dft c. Finish: Tneme-Liner Series 61 at 10.0 - 12.0 mils dft
7. SEVERE WASTEWATER H2S VAPOR EXPOSURE - LARGE STRUCTURES a. N/A
8. SYSTEM 107 - BELOW GRADE
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a. Steel Surface Preparation: SSPC-SP10 Near White Blast Cleaning b. Primer: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft c. Intermediate: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft d. Finish: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft
9. SYSTEM 108 - MARGINALLY PREPARED SURFACES (MAINTENANCE) (NON -IMMERSION)
INTERIOR/EXTERIOR
a. Surface Preparation: SSPC-SP2/SP3 Hand and Power Tool Cleaning, feather all rough edges, remove loose rust, dirt, and other surface contaminants with sandpaper, scotch brite, etc.
b. Primer: Chem -Build Series 135 3.0 to 5.0 mils dft
c. Interior Finish: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft d. Exterior Finish: Endura-Shield Series 1095 2.0 to 3.0 mils dft B. FACTORY PRIMED STEEL - DOORS, FRAMES & EQUIPMENT
1. SYSTEM 121 - CHEMICAL EXPOSURE
a. Surface Preparation: SSPC-SP2/SP3 Hand and Power Tool Cleaning, feather all rough edges, remove loose rust, dirt, and other surface contaminants with sandpaper, scotch brite, etc.
b. Primer: Chem -Build Series 135 3.0 to 5.0 mils dft
c. Finish: Endura-Shield Series 1095 2.0 to 3.0 mils dft
2. SYSTEM 122 - NON -CHEMICAL EXPOSURE
a. Surface Preparation: Clean & Dry
b. Primer: Enduratone Series 1028 at 2.0 - 3.0 mils dft c. Finish: Enduratone Series 1028 at 2.0 - 3.0 mils dft C. GALVANIZED STEEL, STAINLESS STEELS, & NON- FERROUS METALS
1. SYSTEM 201 - INTERIOR/EXTERIOR EXPOSED PIPE & MISC. FABRICATIONS a. Surface Preparation: SSPC-SP16 Brush -Off Blast Cleaning of Coated and Uncoated Galvanized Steel, Stainless Steels, and Non -Ferrous Metals to achieve a uniform anchor profile of 1.0 - 2.0 mils
b. Primer: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft c. Interior Finish: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft d. Exterior Finish: Endura-Shield Series 1095 2.0 to 3.0 mils dft
2. SYSTEM 202 -IMMERSION PIPE & MISC. FABRICATIONS
a. Surface Preparation: SSPC-SP16 Brush -Off Blast Cleaning of Coated and Uncoated Galvanized Steel, Stainless Steels, and Non -Ferrous Metals to achieve a uniform anchor profile of 1.0 - 2.0 mils
b. Primer: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft c. Finish: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft
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3. SYSTEM 203 -DISSIMILAR METAL INSULATION - ALUMINUM IN CONTACT WITH CONCRETE, STAINLESS IN CONTACT WITH CARBON STEEL.
a. Surface Preparation: SSPC-SP16 Brush -Off Blast Cleaning of Coated and Uncoated Galvanized Steel, Stainless Steels, and Non -Ferrous Metals to achieve a uniform anchor profile of 2.0 - 3.0 mils
b. Primer: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft c. Intermediate: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft d. Finish: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft
4. SYSTEM 204 - INTERIOR DRY EXPOSED - OVERHEAD DECKING AND DUCT WORK a. Surface Preparation: Clean and Dry
b. Prime: Uni-Bond DF Series V115 at 2.0 - 4.0 dft mils c. Finish: Uni-Bond DF Series V115 at 2.0 - 4.0 dft mils D. DUCTILE OR CAST IRON - PIPE, PUMPS & VALVES
1. SYSTEM 211 - BELOW GRADE
a. Ductile Iron Surface Preparation: Prepare all surfaces as per NAPF 500-03 - Uniformly abrasive blast the entire exterior surface using abrasive to an NAPF 500-03-04 with a minimum angular anchor profile of 1.5 mils.
b. Primer: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft c. Intermediate: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft d. Finish: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft
2. SYSTEM 212 -EXTERIOR EXPOSED OUTSIDE DIAMETER)
a. Surface Preparation of Ductile Iron: Prepare all surfaces as per NAPF 500-03 - Uniformly abrasive blast the entire exterior surface using abrasive to an NAPF 500-03-04 with a minimum angular anchor profile of 1.5 mils.
b. Primer: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft c. Intermediate: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft d. Finish: Endura-Shield Series 1095 2.0 to 3.0 mils dft
3. SYSTEM 213 - INTERIOR EXPOSED AND/OR IMMERSION OUTSIDE DIAMETER) a. Surface Preparation of Ductile Iron: Prepare all surfaces as per NAPF 500-03 - Uniformly abrasive blast the entire exterior surface using abrasive to an NAPF 500-03-04 with a minimum angular anchor profile of 1.5 mils.
b. Primer: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft c. Finish: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft
4. INTERIOR EXPOSED AND/OR IMMERSION, H2S VAPOR EXPOSURE INSIDE DIAMETER) a. N/A
E. PVC
1. SYSTEM 221 - EXTERIOR EXPOSED
CITY OF BEAUMONT PROTECTIVE COATINGS
MESA LIFT STATION UPGRADE 098000-12
a. Surface Preparation: Scarify, Clean and Dry
b. Primer: Hi -Build Epoxoline II Series L69 at 2.0 - 4.0 mils dft c. Finish: Endura-Shield Series 1095 2.0 to 3.0 mils dft
2. SYSTEM 222- INTERIOR EXPOSED
a. Surface Preparation: Scarify, Clean and Dry
b. Primer: Hi -Build Epoxoline II Series L69 at 2.0 - 4.0 mils dft c. Finish: Hi -Build Epoxoline II Series L69 at 2.0 - 4.0 mils dft F. CONCRETE & MASONRY -PRECAST, POURED -IN -PLACE, CAST -IN -PLACE AND CMU
1. SYSTEM 301 - INTERIOR WALLS NON -CHEMICAL EXPOSED
a. Surface Preparation: SSPC-SP13/NACE 6 - Clean & Dry
b. Filler for Porous Surfaces: Epoxoblock WB Series 1254 at 75 - 150 sq. ft./gal c. Primer: Enduratone Series 1028 at 2.0 - 3.0 mils dft d. Finish Enduratone Series 1028 at 2.0 - 3.0 mils dft
2. SYSTEM 302 - INTERIOR WALLS CHEMICAL EXPOSED
a. Surface Preparation: SSPC-SP13/NACE 6 - Clean & Dry
b. Filler (if needed): Epoxoblock WB Series 1254 at 75 - 150 sq. ft./gal c. Primer: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft d. Finish: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft
3. ULTRAFILTRATION TANKS - MEMBRANE BASINS - NSF61 POTABLE WATER a. N/A
4. SYSTEM 306 - BELOW GRADE OR IMMERSION
a. Surface Preparation: SSPC-SP13/NACE 6, ICRI CSP 3
b. Primer: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft c. Intermediate: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft d. Finish: Hi -Build Epoxoline II Series L69 at 4.0 - 6.0 mils dft
5. SYSTEM 307 - IMMERSION - MODERATE CHEMICAL AND H2S EXPOSURE a. Surface Preparation: SSPC-SP13/NACE 6, ICRI CSP 2-3
b. Surfacer/Filler: Surfacing Epoxy Series 215 as needed for surfacing, patching, filling voids and bugholes as per product data sheet.
c. Primer: Tneme-Liner Series 61 at 10.0 - 12.0 mils dft d. Finish: Tneme-Liner Series 61 at 10.0 - 12.0 mils dft
6. SYSTEM 308 - WASTEWATER H2S VAPOR EXPOSURE
a. Surface Preparation: Abrasive Blast to remove laitance, form release agents, curing compounds, sealers, and other contaminants and to provide surface profile in accordance with SSPC-SP13/NACE6, ICRI CSP5.
CITY OF BEAUMONT PROTECTIVE COATINGS
MESA LIFT STATION UPGRADE 098000-13
b. Filler: MortarClad Series 218 - parge coat of entire surface at a minimum thickness of 1/16" inch.
c. Finish: Perma-Glaze Series 435 at 30 - 40 mils DFT applied in multiple coats G. CONCRETE FLOORS
1. SYSTEM 311— LIGHT TRAFFIC, MILD CHEMICAL EXPOSURE
a. Surface Preparation: SSPC-SP13/NACE 6, Minimum ICRI CSP-2 b. Primer: Hi -Build Epoxoline II Series L69 at 4.0 — 6.0 mils dft c. Finish: Hi -Build Epoxoline II Series L69 at 4.0 — 6.0 mils dft
2. SYSTEM 312— MODERATE TO SEVERE ABUSE, CHEMICAL EXPOSURE a. Surface Preparation: SSPC-SP13/NACE 6, Minimum ICRI CSP-3 b. Primer: Epoxoprime Series 201 at 6.0 — 8.0 mils dft
c. Intermediate: Tneme-Glaze Series 282 at 6.0 — 8.0 mil dft d. Finish: Tneme-Glaze Series 282 at 6.0 — 8.0 mil dft
3. SYSTEM 313— DRY AREAS — WAREHOUSE STORAGE
a. Surface Preparation: Clean and Dry — as per product data sheet b. Finish: CT Densifyer Series 629 at 300 — 350 square feet per gallon
4. RESINOUS FLOORING
a. N/A
H. CONCRETE — SECONDARY CONTAINMENT
1. N/A
I. WALLS
1. SYSTEM 401 - GYPSUM WALL BOARD - INTERIOR
a. Prime: Uni-Bond DF Series V115 at 2.0 — 4.0 mils dft b. Intermediate: Enduratone Series 1028 at 2.0 — 3.0 mils dft c. Finish: Enduratone Series 1028 at 2.0 — 3.0 mils dft
2. SYSTEM 402 - WALL BOARD — WATER RESISTANT — INTERIOR WALLS CHEMICAL EXPOSURE a. Surface Preparation: Clean & Dry
b. Surfacer/Filler for joints and screw holes: Surfacing Epoxy Series 215 and Series 273 Part D fiberglass tape
c. Primer: Hi -Build Epoxoline II Series L69 at 4.0 — 6.0 mils dft d. Finish: Hi -Build Epoxoline II Series L69 at 4.0 — 6.0 mils dft J. WOOD
1. SYSTEM 411 - INTERIOR
CITY OF BEAUMONT PROTECTIVE COATINGS
MESA LIFT STATION UPGRADE 098000-14
a. Surface Preparation: Sand rough areas. Clean and dry. b. Prime: Uni-Bond DF Series V115 at 2.0 — 4.0 mils dft c. Intermediate: Enduratone Series 1028 at 2.0 — 3.0 mils dft d. Finish: Enduratone Series 1028 at 2.0 — 3.0 mils dft K. MISCELLAENOUS
1. SYSTEM — 601- EXPOSED SAWCUT CONCRETE FACE AND EXPOSED REINFORCEMENT a. Surface Preparation: According to manufacturer's recommendations. b. Coating: Sika Armatec 110 EpoCem, or equal (Coverage per manufacturer's recommendations. Minimum 20 mil. thickness).
PART 3 - EXECUTION
3.1 EXAMINATION
A. Examine areas and conditions under which coating systems are to be applied. Notify Engineer of areas or conditions not acceptable. Do not begin surface preparation or application until unacceptable areas or conditions have been corrected.
B. Do not paint over dirt, rust, scale, grease, moisture, scuffed surfaces, or conditions otherwise detrimental to formation of a durable paint film.
C. Remove by blast cleaning to SSPC-SP 10 Near White Blast Cleaning any bitumastic coating or improper primer on any material or equipment which is to be painted and arrives at the construction site with a bitumastic coating or a priming system not specified in paragraph 2.4 Coating Systems.
3.2 PROTECTION OF SURFACES NOT SCHEDULED TO BE COATED
A. Protect surrounding areas and surfaces not scheduled to be coated from damage during surface preparation and application of coatings.
B. Immediately remove coatings that fall on surrounding areas and surfaces not scheduled to be coated.
C. Remove mask, or otherwise protect hardware, lighting fixtures, switchplates, machines, surfaces, couplings, shafts, bearings, nameplates on machinery, and other surfaces not intended to be painted.
Provide drop cloths to prevent paint materials from falling on or marring adjacent surfaces. Protect working parts of mechanical and electrical equipment from damage during surface preparation and painting. Mask openings in motors and equipment to prevent abrasives, paint and other materials from entering.
D. Exercise care not to damage adjacent work during sandblasting operations. Conduct spray painting under controlled conditions. Promptly repair any damage to adjacent work or adjoining property occurring from sandblasting or spray -painting operations.
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MESA LIFT STATION UPGRADE 098000-15
3.3 SURFACE PREPARATION
A. Surfaces shall be prepared in accordance with manufacturer's written instructions as outlined in the product data sheet and application guides.
1. Surface preparation shall be as specified in the designated coating system.
B. Clean substrates of substances that could impair bond of paints, including dust, dirt, oil, grease, and incompatible paints.
1. Remove incompatible primers and reprime substrate with compatible primers or apply tie coat as required to produce coating systems indicated.
C. Steel — Structural, Tanks, Pipe and Equipment:
1. Grind smooth to a rounded contour sharp edges and welds, and remove weld splatter.
2. Prior to the specified surface preparation SSPC-SP1 Solvent Cleaning shall be performed to all surfaces.
3. SSPC-SP2 Hand Tool Cleaning: Removal of loose rust, loose mill scale, loose paint, and other loose detrimental foreign matter, by hand chipping, scraping, sanding, and wire brushing.
4. SSPC-SP3 Power Tool Cleaning: Removal of loose rust, loose mill scale, loose paint, and other loose detrimental foreign matter, by power tool chipping, descaling, sanding, wire brushing, and grinding.
5. SSPC-SP5/NACE 1 White Metal Blast Cleaning: Removal of all visible rust, oil, grease, soil, dust, mill scale, paint, oxides, corrosion products and foreign matter by blast cleaning.
6. SSPC-SP6/NACE 3 Commercial Blast Cleaning: Removal of all visible oil, grease, soil, dust, mill scale, rust, paint, oxides, corrosion products, and other foreign matter, except that staining shall be limited to no more than 33 percent of each 9 -square inch of surface area.
7. SSPC-SP10/NACE 2 Near -White Blast Cleaning: Removal of all visible oil, grease, soil, dust, mill scale, rust, paint, oxides, corrosion products, and other foreign matter, except that staining shall be limited to no more than 5 percent of each 9 -square inch of surface area.
8. Apply prime coat before rust bloom forms or within 24 -hours, whichever is earlier.
9. Do not allow blast cleaned or bare surfaces to stand overnight before coating.
D. Ductile or Cast Iron — Pipe, Pumps, Valves and Fittings
1. Ductile iron pipe and fittings shall be delivered without asphalt, cement lining, or any other lining.
2. All oils, small deposits of asphalt paint, grease, and soluble deposits shall be removed in accordance with NAPF 500-03-01 Solvent Cleaning prior to abrasive blasting.
3. Exterior Preparation: Uniformly abrasive blast the entire exterior surface using angular abrasive to an NAPF 500-03-04: "External Pipe Surface Condition". When viewed without magnification, the exterior surfaces shall be free of all visible dirt, dust, loose annealing oxide, loose mold coating, rust and other foreign matter. Tightly adherent annealing oxide, mold coating and rust staining may remain on the surface provided they cannot be removed by lifting with a dull putty knife. Any area where rust reappears before application shall be re -blasted. The surface shall contain a minimum angular anchor profile of 1.5 mils in accordance with ASTM D 4417, Method C.
E. Galvanized Steel, Aluminum, Stainless Steel, and Non -Ferrous Metal Substrates:
CITY OF BEAUMONT PROTECTIVE COATINGS
MESA LIFT STATION UPGRADE 098000-16