D. All stockpiled materials not actively being used shall be bermed and covered from wind and rain. All chemicals shall be stored in watertight containers (with appropriate secondary containment to prevent any spillage or leakage) or in a storage shed. All waste containers shall be covered at the end of each day and before rain events.
E. Concrete transit mixers shall only be washed out in designated wash-out areas where the water will flow into a temporary pit in dirt area or onto stockpiles of aggregate base or sand. Concrete washouts must be water tight.
F. All construction entrances and exits shall be stabilized to sufficiently control sediment tracking from the site. Construction activity traffic to and from the project shall be limited to the stabilized entrances and exits.
G. All storm drain inlet and perimeter controls, as well as construction entrances and exits shall be maintained and replaced as necessary or as determined by the City inspector.
BMP maintenance and repair shall begin within 72 hours of failure or shortcoming identification.
3.07 EQUIPMENT AND VEHICLE REFUELING
A. Contractor shall prepare and implement a spill prevention and response plan for refueling equipment, machinery, and vehicles at the project site. Appropriate spill response personnel must be assigned and trained.
1. Submit to Engineer for review prior to beginning any refueling activity.
B. Machinery, vehicles, and construction equipment shall not be refueled within 60 feet of the creek.
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3.08 DISPOSAL OF MATERIAL
A. The Contractor shall make arrangements for disposing of materials outside the Site and the Contractor shall pay all costs involved. The Contractor shall first obtain permission from the property owner on whose property the disposal is to be made and absolve the City from any and all responsibility in connection with the disposal of material on said property. When material is disposed of as provided above, the Contractor shall conform to all required codes pertaining to grading, hauling, and filling of earth.
B. This provision also applies to any material stockpile and equipment storage areas.
C. During the course of construction activities, all trash and debris shall be collected in trash receptacles with a tightly secured lid to prevent attracting predators to the site. All trash cans shall be removed and emptied at an appropriate facility once per week at minimum. If no garbage receptacles are available, all debris including food wrappers and drink containers shall be collected and removed from the area on a daily basis for disposal at an appropriate facility.
3.09 SITE CONTROL DURING INCLEMENT WEATHER
A. The Contractor is solely responsible for site protection during periods of inclement weather.
B. All construction activity with the potential to cause erosion, sedimentation, or water pollution shall be suspended during periods of inclement weather.
1. Inclement weather is defined as a rain event with a forecasted probability of 50% or greater of measurable (0.01 inch or more) rainfall.
2. The Contractor is responsible for keeping track of upcoming inclement weather and must obtain the precipitation forecast information from the National Weather Service Forecast Office (http://www.srh.noaa.gov/).
3. Contractor shall notify the City 48 hours prior to forecast inclement weather.
4. Contractor shall develop a Rain Event Action Plan (REAP) 48 hours prior to any likely precipitation event forecast of 50% or greater probability. The REAP shall be a written document, specific for each rain event and shall be designed to protect all exposed portions of the site. REAP shall contain all information outlined in the State Water Resources Control Board NPDES General Permit Requirements (Order No. 2009-0009-DWQ) for Risk Level 2 sites. Permit requirements are available for download on the State Water Resource Control Board’s website (http://www.waterboards.ca.gov).
5. Contractor shall begin implementation and make the REAP available onsite no later than 24 hours prior to the likely precipitation event. a. If a defined rain event is forecast for a weekend or holiday, all site protection shall be deployed and in place before the Contractor stops work prior to that weekend or holiday.
b. The Contractor has discretion as to how he runs his operations while maintaining an adequately protected site at the onset of rainfall. 258
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3.10 WATER POLLUTION MONITORING
A. The City will monitor the Contractor’s operations and site maintenance to ensure compliance with the NPDES General Construction Permit and other regulatory requirements.
B. During discharge events the City will sample site runoff for the following constituents and compare to Regional Water Quality Control Board numeric effluent limits (NELs):
1. Turbidity: Maximum turbidity measured in runoff leaving the construction sites will not be allowed to exceed 250 NTU (roughly equivalent to 750 mg/l).
2. pH: Measured pH runoff leaving the construction sites must be between 6.5 and
8.5 pH units.
C. If effluent limits are exceeded during a discharge event, all work shall cease and the Engineer will direct the Contractor to employ other housekeeping and pollution control measures until compliance is reached.
D. The contractor is responsible for maintaining the identified effluent limits for all runoff leaving the construction site. No exceptions will be made for poor quality run-on water.
Run-on from off site shall be directed away from the disturbed area or shall collectively be in compliance with the effluent limits.
3.11 FINES FOR PERMIT VIOLATION
A. Contractor is responsible for all permit violation fines and necessary corrective actions due to his negligence.
B. NPDES permit violation fines will be identified within the permit language. Typical fines per violation are:
1. Maximum of $25,000/day and $10/gallon over 1,000 gallons discharged
2. Minimum mandatory penalties of $3,000 per violation
3.12 DOCUMENTATION
A. Contractor shall retain storm water monitoring and control and BMP records for a period of at least three years. Records shall be retained on-site while construction is ongoing.
Documentation shall be well organized and shall contain the following items at a minimum:
1. Document all housekeeping BMPs in the WPCP and REAP(s) in accordance with the nature and phase of the construction project.
2. Printed copies of all likely precipitation event forecast of 50% or greater probability during all phases of construction.
3. Copies of all storm water related inspection, sampling, observation, and annual reports.
4. Records of any corrective actions and follow-up activities that resulted from analytical results, visual observations, or inspections.
3.13 ACCIDENTAL DISCOVERIES
A. Significant cultural resources are not known to exist at the project sites. 259
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1. In the event than an archaeological resource is found during construction, all construction work within a 50-foot radius of the find shall be halted, and the Engineer notified.
2. A qualified archaeologist will be retained by the City to examine the find and a mitigation plan may be implemented.
3. Any resulting changes in the scope of work or time delays caused by the discovery of cultural resources shall be dealt with in conformance with these Contract Documents.
B. In the event that human remains are encountered during excavation or backfilling activities, there shall be no further disturbance until the County Coroner has made the necessary findings as to origin and disposition.
1. Notify the Engineer immediately upon the discovery of possible human remains.
2. Do not resume work until so directed in writing.
***END OF SECTION***
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SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 01610
SEISMIC ANCHORAGE AND BRACING
PART 1 GENERAL
1.01 SECTION INCLUDES
A. Requirements for seismic anchorage and bracing for equipment, tanks, pipe, ducts, conduit and other nonstructural components.
1.02 REFERENCED SECTIONS
A. The following Sections are referenced in this Section
1. Section 01300 – Contractor Submittals
2. Section 01611 – Seismic Design Requirements
3. Section 05501 – Anchor Bolts
1.03 AREAS OF DESIGN RESPONSIBILITY
A. The Contractor shall be responsible for:
1. Designing seismic attachments, braces, and anchors to the structure for tanks, mechanical equipment and electrical equipment included in the Work that weigh more than 20 pounds.
2. Design of seismic anchorage and bracing for piping systems and ventilation ducting
B. Equipment manufacturers shall provide design calculations and details for their specific pieces of equipment as part of the submittal for that equipment.
1.04 REFERENCES
A. The following is a list of standards which may be referenced in this section.
1. International Code Council (ICC)
2. California Building Code (CBC)
3. Evaluation Service (ICC-ES) Reports and Legacy Reports
4. American Society of Civil Engineers (ASCE): ASCE 7, Minimum Design Loads for Building and Other Structures.
1.05 SUBMITTALS
A. Comply with Section 01300.
B. Seismic Anchorage and Bracing Calculations
1. Submit manufacturer’s engineered seismic hardware data and installation requirements.
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2. Provide calculations for seismic attachments, braces and anchorages clearly showing the criteria used for the design. Calculations for anchorage of components shall be sealed by a California registered Civil Engineer.
C. Shop Drawings: Show details of seismic attachment assemblies including connection hardware, bracing, and anchor bolts.
1.06 DESIGN AND PERFORMANCE REQUIREMENTS
A. In accordance with CBC, tanks, mechanical and electrical components, and other elements of the Work that are permanently attached to structures shall be designed and constructed to transfer the component seismic forces specified in ASCE 7, Chapter 13 to the structure.
1. Seismic attachments, braces, and anchorages shall be designed in accordance with the provisions of the California Building Code and the site-specific criteria in Section 01611.
PART 2 PRODUCTS
2.01 MATERIALS
A. Attachments and supports transferring seismic loads to the structure shall be constructed of materials and products suitable for the application and designed and constructed in accordance with the design criteria shown on the Drawings and nationally recognized standards.
B. Powder driven fasteners and sleeve anchors shall not be used for seismic attachments and anchorage where resistance to tension loads is required.
C. Anchor Bolts: In accordance with Section 05501.
PART 3 EXECUTION
3.01 GENERAL
A. Design seismic anchorage systems to provide restraint in all directions, for each component or system so anchored.
B. Tall and narrow equipment such as motor control centers and electrical control panels shall be anchored at the base and within 12 inches from the top of the equipment.
C. Mechanical and electrical components shall not be attached to more than one element of a building structure at a single restraint location where such elements may respond differently during a seismic event. Such attachments shall also not be made across building expansion and contraction joints.
D. Seismic attachments and braces shall be provided and installed by the Contractor in accordance with the size and number of braces determined by the design calculations prepared by the Contractor.
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SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) E. Anchor bolts and concrete and masonry anchors for the anchorage of equipment shall be provided and installed by the Contractor in accordance with the bolt sizing, minimum embedment, and spacing requirements determined by the calculations prepared by the Contractor.
***END OF SECTION***
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SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 01611
SEISMIC DESIGN REQUIREMENTS
PART 1 GENERAL
1.01 SECTION INCLUDES
A. The following primary and secondary structural system elements, non-structural components, and/or equipment supported by structures.
1. Pre-Engineered Metal Buildings and Canopies.
2. Mechanical, electrical, and plumbing equipment and appurtenances.
3. Conduit, piping, cable trays, raceways, ducts and similar systems.
4. Tanks and vessels (include contents), including support systems.
5. Storage racks, suspended ceilings, light fixtures, raised floors, partitions, storefronts, windows, louvers, architectural features and other non-structural components.
1.02 REFERENCED SECTIONS
A. The following Sections are referenced in this Section
1. Section 01300 – Contractor Submittals
2. Section 05501 – Anchor Bolts
1.03 REFERENCES
A. 2025 California Building Code (CBC)
1.04 DEFINITIONS
A. Engineer of Record: The Engineer responsible for the preparation of Contract Documents.
B. Specialty Engineer: Structural or Civil Engineer provided by the Contractor licensed in the State where the project is being built responsible for specific elements of the primary structural system, the secondary structural system, non-structural elements and/or equipment supported by structures.
1.05 GENERAL DESIGN REQUIREMENTS
A. The Contractor is responsible for producing designs that resist the total seismic forces in accordance with the seismic design criteria.
B. The Contractor is responsible for coordinating between the Engineer of Record and the Specialty Engineer.
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SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) C. The seismic design for non-structural components and equipment shall be in accordance with the CBC Chapter 16, and the required coefficients and factors for determining the total design seismic forces are provided in the Seismic Design Criteria in Paragraph E below.
D. Coordinate the layout so that adequate space is provided between items for relative motion. Provide additional supports and restraints between items of different systems when necessary to prevent seismic impacts or interaction.
E. Seismic forces shall be determined in accordance with the following seismic design criteria:
1. Site-Specific Spectral Response Coefficients
a. Short Period Mapped Maximum Considered Earthquake, 5 Percent Damped:
Ss = 2.480g
b. 1 Second Period Mapped Maximum Considered Earthquake, 5 Percent Damped: S1 = 0.970g
c. Short Period Design Spectral Response Acceleration, 5 percent Damped: SDS = 1.770g
d. 1 Second Period Design Spectral Response Acceleration, 5 percent Damped:
SD1 = 1.290g
2. Site Class: CD
3. Seismic Design Category: F, unless noted otherwise
4. Risk Category: IV, unless noted otherwise
5. Component Importance Factor, Ip:
a. Mechanical and Electrical Equipment: Use 1.5.
b. Tanks and Tank Anchorage: Use 1.5.
c. Components that contain hazardous materials: Use 1.5. d. Components that are required for life safety: Use 1.5. e. Components that must remain functional after an earthquake, such as fire protection sprinkler systems: Use 1.5.
6. Do not use more than 60 percent of the weight of tanks and mechanical and electrical equipment for designing anchors for resisting overturning due to seismic forces.
7. Do not use friction to resist sliding due to seismic forces.
1.06 DESIGN REQUIREMENTS FOR PIPING, CONDUIT, AND DUCTS A. The Contractor is responsible for producing designs for support of piping, conduit, duct or other systems to resist total seismic forces based on the seismic design criteria coefficients specified above, unless shown on the Contract Documents. Except where the technical specifications give specific exemption from resistance of seismic forces, all supports shall be designed to meet seismic criteria.
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SEISMIC DESIGN REQUIREMENTS 01611- 3
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) B. Where possible, pipes, conduit, and their connections shall be constructed of ductile materials (e.g., copper, ductile iron, steel or aluminum and brazed, welded or screwed connections). Pipes, conduits and their connections, constructed of nonductile materials (e.g., cast iron, no-hub pipe and plastic), shall have the brace spacing reduced to onehalf of the spacing allowed for ductile material.
C. Seismic restraints may be omitted for the following conditions, where flexible connections are provided between components and the associated ductwork, piping and conduit:
1. Fuel piping less than 1-inch inside diameter.
2. All other piping less than 2.5-inches inside diameter or all piping suspended by individual hangers 12 inches or less in length from the top of the pipe to the bottom of the structural support for the hanger or electrical conduit less than 2.5- inches trade size.
3. All rectangular air-handling ducts less than 6 square feet in cross-sectional area or all round air-handling ducts less than 28-inches diameter or all ducts suspended by individual hangers 12 inches or less in length from the top of the duct to the bottom of the structural support for the hanger, where the hangers are detailed to avoid bending of the hangers and their connections.
D. All trapeze assemblies supporting pipes, ducts and conduit shall be braced to resist the total seismic forces considering the weight of the elements on the trapeze. Pipes, ducts and conduit supported by a trapeze where none of those elements would individually be braced need not be braced if connections to the pipe/conduit/ductwork or directional changes do not restrict the movement of the trapeze. If this flexibility is not provided, bracing will be required when the aggregate weight of the pipes and conduit exceed 10 pounds/foot. The weight shall be determined assuming all pipes and conduit are filled with water.
E. As an alternative to designing the supports and anchorage, where an approved national standard provides a basis for the earthquake-resistant design, submit standard, data, and details for piping, conduit, duct or other systems:
1. For ductwork, mechanical piping, process piping and electrical conduits, follow Guidelines for Seismic Restraints of Mechanical Systems by SMACNA modified as follows:
a. Seismically brace piping regardless of size or location. Provide transverse braces at all changes in direction and at the end of all pipe runs. Space transverse braces not more than 20 feet apart. Provide longitudinal braces at 40-foot centers.
b. Seismically brace all ductwork regardless of size or location. Provide transverse braces at all changes in direction and at each end of run. Space braces not over 20 feet apart. Provide longitudinal braces at 40-foot centers.
2. For fire protection systems, follow NFPA 13 modified as in Paragraph 1.b above.
Ensure that no seismic interaction occurs with items of other systems. 266
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1.07 DESIGN REQUIREMENTS FOR UNDERWATER ITEMS
A. To allow for water sloshing, design rigid items such as piping or equipment supports for twice the lateral force, computed as if the item were above water.
B. Design flexible items to accommodate sloshing motions without damage to rigid machinery.
C. Provide retainers to hold items from falling and damaging rotating equipment below, if bolted connections will fail because of ground motion displacing the supports.
1.08 SUBMITTALS
A. Comply with Section 01300.
B. Shop Drawings
1. Submit signed and sealed structural calculations and detailed drawings for the following listed elements and where required in Divisions 2 through 16 of the primary structural system and their attachments, the secondary structural system and their attachments, permanent non-structural components and their attachments, and the attachments and anchorage for all permanent equipment supported by the structures.
C. Structural calculations and detailed drawings shall be prepared by a Specialty Engineer licensed in the State where the project is being built.
D. Structural calculations and detailed drawings shall clearly show the total design seismic forces which will be transferred from the elements of the structural system, nonstructural components, and/or equipment and their attachments to the primary structure.
E. The Engineer's review of items within a Specification Section cannot be completed until all related items have been coordinated and submitted for review.
F. Quality Assurance Submittals
1. Test Reports: Submit test reports for tension testing of anchors.
2. Where required in the equipment specifications in Divisions 2 through 16 submit certification that the equipment itself is designed to resist all internal seismic forces based on the seismic design criteria for the project.
3. Where required in the equipment specifications in Divisions 2 through 16, submit signed and sealed structural calculations and detailed drawings from a specialty Structural or Civil Engineer licensed in the State where the project is being built for the attachments and anchorage to the primary structure.
4. Where required in the equipment specifications in Divisions 2 through 16, submit certification that the attachments and anchorage are designed to resist all seismic forces based on the seismic design criteria for the project. 267
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1.09 QUALITY ASSURANCE
A. Qualifications: The Contractor is responsible for submitting signed and sealed structural calculations and detailed drawings from a Specialty Structural or Civil Engineer licensed in the State where the project is being built.
1. Regulatory Requirements: Comply with the State of California adopted and amended versions of CBC Chapter 16 - Earthquake Design plus clarifications and additions specified in this Section.
PART 2 PRODUCTS
Not Used.
PART 3 EXECUTION
3.01 FIELD QUALITY CONTROL
A. Site Tests: Tension testing of expansion or adhesive anchors utilized for anchorage shall be done in the presence of the special inspector and a report of the test results shall be submitted. See Specification Section 05501 for additional requirements.
B. Inspection: Special inspection shall be provided for high strength bolting or bolts installed in concrete. See Specification Section 05501 for additional requirements. ***END OF SECTION***
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 02100
CLEARING AND DEMOLITION
PART 1 GENERAL
1.01 SUMMARY
A. Section includes all work necessary to move or remove and legally dispose of all interfering or objectionable material from the project site, including but not necessarily limited to trees, tree branches, tree stumps, brush, shrubs, weeds, debris, roots, rocks, concrete rubble, concrete masonry units, pipe, concrete curbs and gutters, asphalt pavement, concrete structures and concrete slabs, but only as required.
B. Related Sections:
1. Section 02200 – Excavation and Backfill.
2. Section 02532 – Manhole and Pipe Abandonment and Demolition
1.02 REFERENCES
A. State of California Department of Transportation (Caltrans).
1.03 DEFINITIONS
A. Clearing: Clearing shall consist of cutting, removing, and disposing of trees, shrubs, brush, limbs, and other vegetative growth. Clearing shall also include the removal and disposal of trash piles, rubbish, and fencing, and the preservation of trees, shrubs, and vegetative growth which are not designated for removal.
B. Grubbing: Grubbing is the removal and disposal of wood or root matter below the ground surface remaining after clearing.
C. Stripping: Stripping refers to the removal and disposal of all organic sod, topsoil, grass, and grass roots; all evidence of surface improvements and other objectionable material remaining after clearing and grubbing.
D. Demolition: The removal of existing structures, portions of existing structures, equipment, utilities, concrete curbs, sidewalks, driveways, pipelines and other appurtenances.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) PART 2 PRODUCTS
Not Used.
PART 3 EXECUTION
3.01 EQUIPMENT
A. Equipment shall be suitable for the work to be done and shall be in good operating condition. Equipment operators and workmen are to be skilled in such operations and shall be competently supervised.
3.02 CLEARING, GRUBBING AND STRIPPING
A. Clearing and grubbing shall be in accordance with the provisions of Section 16 of the Caltrans Standard Specifications.
B. Clear, grub and strip areas to be excavated or surfaced.
3.03 DEMOLITION
A. Remove existing structures, portions of existing structures, and equipment called for on the plans and as directed by the Engineer.
B. Contractor shall not demolish existing facilities beyond the limits designated on the drawings unless specifically directed to do so by the Engineer.
3.04 PRESERVATION OF PROPERTY
A. The project area shall be cleared and grubbed only to the extent necessary to accommodate the work in conformance with the notes and details shown on the plans.
Trees or growth shall not be trimmed back unnecessarily.
B. Contractor shall take extreme care not to damage shrubs, trees, fences, irrigation systems, and other improvements of adjacent property owners.
C. All existing improvements not specifically designated on the plans to be removed or relocated shall remain in their original condition and location undisturbed. However, upon written permission by the Owner, existing improvements may, for the convenience of the Contractor, and at his expense, be removed and temporarily relocated during construction and shall be replaced in their original location in as good or better condition as when the Contractor entered upon the work site.
3.05 DEMOLITION OF SURFACE IMPROVEMENTS
A. Removal of sidewalks, curbs and gutters, driveways, concrete slabs, pavement, pavement markings, and traffic striping if necessary shall be in accordance with the provisions of Section 15-1.03B of the Caltrans Standard Specifications. Curbs, gutters, sidewalks, driveways, slabs and pavement shall be removed by full depth saw cut to the nearest joint from the lines shown on the plans or as directed by the Engineer. 270
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) B. Where the plans indicate replacement of existing asphaltic pavement, the existing pavement shall be removed and disposed of off-site.
3.06 DEMOLITION OF UNDERGROUND PIPE
A. Demolition of underground pipe shall be only as shown on the Drawings or necessary as determined in the field by the Engineer.
3.07 DEMOLITION OF EXISTING PUMP STATION
A. Demolition, removal, and disposal of existing sanitary sewer pump station equipment shall be performed by the Contractor as shown on the Drawings and as necessary to remove all pump station equipment indicated for removal.
B. The following pump station equipment shall be salvaged by the Contractor and delivered to 3the City’s maintenance yard at 110 Sem Lane, Belmont, CA.
1. Pumps
2. Mission Communication Box
3. Electrical Cabinet with all components in one piece
4. Transducer level sensor
5. Automatic Transfer Switch (ATS)
6. Stainless steel chains and hardware
3.08 REMOVAL OF DEBRIS
A. All demolished and cleared material shall become the property of the Contractor and shall be legally disposed of by the Contractor.
B. Removed concrete and asphalt concrete shall be legally disposed of off the right-of-way at a location provided by the Contractor. Demolished concrete shall not be buried in structure backfill areas.
***END OF SECTION***
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 02200
EXCAVATION AND BACKFILL
PART 1 GENERAL
1.01 SUMMARY
A. Furnish all labor, materials, equipment, facilities, transportation and services to complete all excavation, backfill, fill, grading and related work as shown on the plans and/or specified herein.
B. Section Includes:
1. Removal of excess and unsuitable material from the site.
2. Excavation of material to allow for the placement of underground structures, including any necessary shoring and bracing.
3. Backfilling of underground conduit, pipe, and structures.
4. Preparation of subgrade for concrete slab work and pavement.
5. Furnish and compact artificial fill.
6. Finish grading.
7. Shoring of excavations
8. Control of water (groundwater)
9. Hazardous materials
C. Related Sections:
1. Section 02100 - Clearing and Demolition
2. Section 02318 - Trenching
3. Section 02742 - Asphaltic Concrete Paving
4. Section 02722 - Aggregate Base
5. Section 02772 - Concrete Curbs, Gutters, and Sidewalks
1.02 REFERENCES
A. Associated General Contractors (AGC):
1. Manual of Accident Prevention in Construction (Section 9).
B. American Society for Testing and Materials (ASTM):
1. C 131 - Test Method for Resistance to Degradation of Small-Size Course Aggregate by Abrasion and Impact in the Los Angeles Machine.
2. C 136 - Test Method for Sieve Analysis of Fine and Course Aggregates.
3. D 422 - Standard Test Method for Particle - Size Analysis of Soils.
4. D 1556 - Test Method for Density and Unit Weight of Soil in Place by the Sand Cone Method.
5. D 1557 - Test Method for Laboratory Compaction Characteristics of Soil Using Modified Effort (56,000 ft-lbf/ft3 (2,700 kN-m/m).
6. D 2419 - Test Method for Sand Equivalent Value of Soils and Fine Aggregate.
7. D 2922 - Test Methods for Density of Soil and Soil-Aggregate in Place by Nuclear Methods (Shallow Depth).
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8. D 6938 - Test Method for Water Content of Soil and Rock in Place by Nuclear Methods (Shallow Depth).
9. D 4253 - Standard Test Methods for Maximum Index Density and Unit Weight of Soils Using a Vibratory Table
10. D 4318 - Test Method for Liquid Limit, Plastic Limit, and Plasticity Index of Soils.
11. D 6938 Standard Test Methods for In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods (Shallow Depth)
C. Division of Industrial Safety (DIS).
D. Occupational Safety and Health Act (OSHA).
E. State of California Department of Transportation (Caltrans).
F. Project geotechnical report: Geotechnical Investigation, San Juan Pump Station Wet Well and Valve Vault, March 2025, which is included as Appendix A to these specifications.
1.03 DEFINITIONS
A. Excavation: Work shall consist of excavation, storage and any necessary removal of native soil material for structures, foundations, and pavement. Excavation may include the removal and disposal of existing on-site soil and bedrock (including cobbles and boulders), pavement, or concrete slab materials.
B. Fill: Material placed to backfill excavations.
C. On-Site Material: Material obtained from the project site.
D. In-Place Density of Compacted Backfill: Is the in-place density determined in accordance with ASTM D 1556, or with ASTM D 2922 and ASTM D 6938.
E. Maximum Dry Density: Is maximum dry density obtained in the laboratory when tested in accordance with ASTM D 1557 and ASTM D4253.
F. Optimum Moisture Content: Is the water content at the maximum dry density when tested in accordance with ASTM D 1557.
1.04 SUBMITTALS
A. Product Data: Submit material source, gradation, Plasticity Index, and other test data as required for all materials, including imported and on-site materials to be used as backfill.
B. Dewatering Plan: Submit dewatering plan including arrangement, location and depths of system components, size, type, and required permits.
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2.01 MATERIALS
A. General:
1. All fill material shall be free from sod, large lumps, boulders, rocks, roots, brush, or other objectionable material (as determined by the Engineer), and free of hazardous materials as defined by Section 25117 of the State Health and Safety Code.
B. Class 2 AB shall conform to Section 02722 of these specifications.
C. CDF shall conform to specification Section 03301.
D. Bedding Material:
1. Where shown on the plans bedding material shall be Class 1, Type a Permeable Material meeting the requirements identified herein.
2. The percentage composition by weight of Class 1, Type A permeable material in place must comply with the gradation requirements shown in the following table:
Sieve Size % Passing Sieve
¾” 100
½” 95-100
3/8” 70-100
No. 4 0-55
No. 8 0-10
No. 200 0-3
3. Bedding Material shall be CDF where shown on the plans, as specified in Section 03301.
E. Native Backfill Material:
1. Use of native material for backfill is not acceptable except for in landscaped areas where topsoil material is being reused.
F. Drain Rock:
1. Drain rock shall match the requirements of the Crushed Rock Material as specified herein.
G. Crushed Rock:
1. Crushed rock shall be clean and durable meeting the requirements of ASTM No. 57 stone with the following gradation:
Sieve Size % Passing Sieve
1-1/2” 100
1” 95-100
½” 25-60
No. 4 0-10
No. 8 0-5
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) H. Geotextiles, Filter Fabrics, and Geogrid:
1. Stabilization Fabric:
a. Mirafi 140N
b. Approved Equal
PART 3 EXECUTION
3.01 EXAMINATION
A. Verification of Conditions:
1. The Contractor shall, prior to submitting his bid, visit all sites and become familiar with actual site and soil conditions. No allowance will be made by the City for any unfavorable conditions or events which should have been foreseen from a thorough examination of the contract documents, the geotechnical reports, the site, and working conditions.
B. Verification of Prepared Subgrade prior to Constructing Improvements:
1. The Contractor shall request the City to visually inspect and provide written confirmation of the suitability of prepared subgrade soils prior to the continuation of work.
a. Work completed without such confirmation is at the Contractor’s risk and subject to removal at the direction of the City.
2. Contractor shall protect excavation prior to and during the inspection.
C. Retaining walls and structures shall not be backfilled for at least 10 days after the last concrete and until concrete has attained 3000 psi minimum per Section 03100 - Concrete Forming and Accessories section 3.08E.
3.02 HAZARDOUS MATERIALS
A. See Section 01354.
3.03 OFF-HAUL TESTING
A. The Contractor shall remove and dispose of all excess excavated material to a suitable site. The proper and legal disposal shall be the responsibility of the Contractor.
B. Contractor shall include export and disposal of material in the cost of work to be performed. The Contractor shall include environmental analytical testing in the cost of the work to be performed.
C. Contractor shall maintain proper documentation, in accordance with applicable laws, to provide evidence of proper disposal of off-hauled materials.
3.04 PROTECTION
A. If existing live utilities are encountered, they are to be protected from damage and the proper authorities and affected utility companies notified.
B. Service shall not be interrupted except as directed or accepted; allow sufficient time for 275
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) utility companies to arrange for continuation of services.
C. Record unmarked utility locations on record drawings and notify the Engineer.
D. Open excavations, trenches, and the like are to be protected with fences, barricades, covers, and railings as required.
E. Every precaution shall be taken to prevent spillage when hauling on or adjacent to any public street or highway. Any spillage shall be promptly removed.
F. Except where trees are shown to be removed, trees shall be protected from injury during construction operations. No tree roots over 2 inches in diameter shall be cut without written permission of the Engineer. Trees shall be supported during excavation by means previously reviewed by the Engineer and no construction work shall occur within the tree dripline unless authorized by the Engineer. See the tree preservation notes on the Plans.
3.05 SAFETY
A. The Contractor is solely responsible for excavation safety, including support to all adjacent improvements at all times.
B. Excavation shall be in accordance with the State of California Construction Safety Orders. The Contractor shall, in accordance with Section 6705 of the California Labor Code, submit a detailed drawing to the Engineer before excavation begins, showing the design of shoring, bracing, sloping or other provisions to be made for worker protection from the hazard of caving ground during any excavation of five or more feet in depth C. If the Contractor presents a drawing which varies from shoring system standards established by the Construction Safety Orders, the drawing shall be prepared and signed by a registered civil or structural engineer licensed by the State of California. Any Engineer's review of said drawings will in no way relieve the Contractor from responsibility and liability for the adequacy of shoring systems and excavations.
3.06 EXCAVATION SUPPORT AND PORTECTION
A. Shoring and support of the excavation shall be in conformance with specification section 02260.
3.07 CONTROL OF WATER
A. Water may be encountered within the Work at any time, and the presence of such water is likely to be continuous. Contractor shall control site water so that work may be done in the dry in a safe working environment according to relevant provisions of the Safety Orders.
B. Prior to the preparation of bedding or subgrade, the excavation shall be thoroughly dewatered by the use of sump pumps and dewatering equipment as necessary to safely convey water away from structural excavations to positive draining outlets.
C. All site water discharge shall be into a City’s sewer system or at an approved facility. 276
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) D. The Contractor shall apply for and obtain a discharge permit from the Silicon Valley Clean Water Treatment Plant prior to discharging any water into the sanitary sewer system. Contractor shall adhere to all permit conditions including testing, filtering, discharge rates, fees, etc.
E. The Contractor shall notify the City two working days prior to discharging into the sewer system. The notice shall include the proposed discharge location, flow rate, and duration.
F. Contractor shall make adequate provisions for the removal of sediment from groundwater prior to discharge.
G. The Contractor shall prevent surface water (e.g. rainwater) and subsurface or groundwater from flowing into excavations and from flooding the project site and surrounding areas.
H. The Contractor shall remove all water which accumulates in all excavations during the progress of work so that all work can be done in the dry. Excavated areas shall be kept free from water while structures are constructed, while concrete is setting and until backfill has been placed to a sufficient height to anchor the work against possible floatation.
I. Contractor shall implement sufficient measures to limit the inflow of groundwater so that the maximum allowed dewatering pumping rate of 50 gpm is sufficient to keep excavated areas free from water.
J. Provide sufficient pumping capacity to maintain the groundwater level at least two feet below the lowest level of excavation or backfill at all times.
K. Sufficient pumping equipment for immediate use shall be on the project site at all times, including standby pumps for use in case other pumps become inoperable. Water shall be disposed of so as to cause no injury to public or private property, or to be a menace to the public health.
L. Dewatering devices shall be adequately filtered to prevent the removal of fines from the soil.
M. The Contractor shall be responsible for any damage to foundations or other parts of existing structures or of the new work, caused by the failure of any part of the Contractor’s protective works.
N. Depending upon groundwater conditions and the degree of project completion, underground structures are susceptible to floatation prior to backfill and anchorage.
Contractor shall prevent the floatation or movement of structures during construction.
O. As recommended by the Engineer or City, the Contractor shall be prepared to backfill the trench with drain rock (3/4” crushed rock) encapsulated with filter fabric to control groundwater. All drain rock shall be compacted as specified herein.
P. Groundwater cutoff plugs shall be placed as indicated on the plans or as directed by the Engineer/City.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) Q. After dewatering is no longer necessary, all dewatering pumps and appurtenances shall be removed by the Contractor.
3.08 PREPARATION OF SUBGRADE
A. Strip surface vegetation, weeds, and at least the top six inches from areas underlying surface structures and areas to be paved. Excavate soft, wet, or otherwise unsuitable base grade to firm, unyielding soil.
B. Where mud or other soft or unstable material is encountered as determined by the Engineer in the field, remove such material to a minimum of 12 inches. The bottom of the over-excavation should then be completely covered with geotextile and backfilled with drain rock. The stabilization fabric should be wrapped around the backfill to completely encapsulate the drain rock.
3.09 EXCAVATION
A. Contractor shall notify the Engineer of any site condition not reflected on the plans or in these specifications, such as conflict in grade, bad soil, or unexpected utility lines. The Engineer will observe the excavation bottom prior to placing permeable material, and may recommend further excavation if soils are not suitable.
B. Strip surface vegetation, weeds, and at least the top six inches from areas underlying surface structures and areas to be paved. Excavate soft, wet, or otherwise unsuitable base grade to firm, unyielding soil.
C. Excavation to the lines, grades, and dimensions shown on the plans. Excavations shall be made to such width outside the lines of the structure to be constructed as may be required for proper working methods, the erection of forms, and the protection of work.
Any resulting over-excavation extending beyond the lines, grades, and dimensions shown on the plans shall be backfilled with material complying with these specifications at no additional cost to the District.
D. Care shall be taken to preserve foundation surfaces in an undisturbed condition, and excavation at or near property lines shall be performed in a manner that minimizes disturbances to adjacent property. Any foundation surfaces disturbed without the Engineer’s authorization shall be replaced at the Contractor’s expense with material approved by the Engineer so that by test, the bearing capacity of the replacement material is equal to or better than the undisturbed foundation material.
E. Existing structures and completed work shall be adequately braced and cared for so that no damage will result.
F. Excavated material unsuitable for backfill or in excess of the amount required for backfill shall be disposed of by the Contractor off the site at his expense, and in accordance with “Greenbook”, Subsection 300- 2.6.
3.10 BACKFILLING
A. All debris, form work, etc. shall be removed from the excavation prior to backfilling. 278
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) B. Pipe and conduits shall be supported during the placement and compaction of bedding and backfill.
C. Backfill with crushed rock encapsulated in geotextile fabric in areas where groundwater is encountered as recommended by the Engineer or City.
D. Contractor shall construct backwater cutoff plugs as indicated on the plans and as directed by the Engineer or City.
E. Fill materials shall be spread in level layers of appropriate thickness for the compaction equipment to be used and moisture content of the material, and compacted as specified.
Layers shall not exceed 8 inches in thickness after compaction.
F. Granular backfill shall be tamped mechanically or manually along the sides of pipes and structures to minimize voids in the material between the pipe or structure and excavation walls. No flooding or jetting shall be used to compact bedding or backfill materials.
G. Where the backfill material moisture content is too low to permit the specified degree of compaction, water shall be added before or during spreading until the proper moisture content is achieved. Jetting will not be permitted for compaction.
H. Where the backfill material moisture content is too high to permit the specified degree of compaction, the material shall be dried until the moisture content is satisfactory.
I. No fill shall be placed during conditions that will alter the moisture content of the fill material sufficiently to make adequate compaction impossible. After placing operations have been stopped due to adverse conditions, no additional fill material shall be placed until the last layer compacted has been checked and found to be compacted to the specified densities.
J. All ground surfaces shall be finished to uniform grades and slopes as indicated on the plans so that the ground drains properly and is free from depressions which may cause areas of standing water. Drainage shall be away from foundations and slabs. Clods are to be broken up and the surface of the ground shall be uniformly pulverized and graded K. Crushed rock should be consolidated in place with light vibratory equipment. Rubbertire equipment should not be allowed to operate on the exposed subgrade; the crushed rock should be stockpiled and pushed out over the stabilization fabric.
L. Excavations should be backfilled simultaneously with shoring removal to ensure that all voids are filled.
M. Placement of CDF as Structural Backfill: Where indicated on the Drawings, CDF shall be placed around structures as backfill evenly so that uneven loading of the structure does not occur as a result of the CDF placement. A minimum of two lifts shall be used in placing the CDF around structures. Where structures have pipes entering/exiting the structure, CDF shall be placed in accordance with placement of CDF for pipe installation locations.
N. Placement of CDF as Pipe Backfill: Where CDF is used as trench backfill within the pipe zone, it shall be placed into the trench around the pipe so that the CDF is placed 279
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) evenly on both sides of the pipe to prevent uneven loading of the pipe. CDF shall not be placed directly onto the pipe. The maximum depth of the first lift of CDF shall not allow the pipe to move or float. Subsequent lifts of CDF shall be placed so that the pipe does not shift or float. CDF placed in trenches with steep slopes shall be placed in lifts to prevent flotation of the pipe, and the Contractor shall install approved anchor blocks as needed to secure the pipe in place during placement of the CDF. Use of anchor blocks or deadman concrete collars may be used by Contractor with written approval by the City.
O. Tests: Tests are to be made on each layer of fill to assure adequate compaction throughout the entire area. If the field densities are not satisfactory, the Contractor will be required to recompact each layer and/or work area as necessary to achieve the specified densities. Compaction testing will be performed in accordance with ASTM D1556, D1557, D2922, and D6938. Compaction testing will be performed and paid for by the City. See Section 02318-3.03 for additional compaction testing requirements.
3.11 COMPACTION
A. Unless otherwise indicated on the drawings, fill materials shall be compacted to relative compactions based on the ASTM D1557 maximum dry density as follows:
Pipe or Conduit Bedding 90%
Trench Backfill under Paved Areas 95%
Backfill under structures 95%
Trench Backfill under Non-Paved Areas 90%
All Other Backfill 90%
3.12 GRADING
A. Contractor shall grade the site as required to match improvements to existing contours.
B. All ground surfaces shall be finished to uniform grades and slopes as indicated on the plans so that the ground drains properly and is free from depressions which may cause areas of standing water. Drainage shall be away from foundations and slabs. Clods are to be broken up and the surface of the ground shall be uniformly pulverized and graded.
C. Temporary benches cut into hillsides shall be restored to pre-construction contours.
Benches shall be backfilled and compacted as specified herein.
D. At the completion of grading work, the site shall be left in a clean and finished condition.
***END OF SECTION***
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 02260
EXCAVATION SUPPORT AND PROTECTION
PART 1 GENERAL
1.01 SUMMARY
A. Section Includes: Requirements for designing, furnishing and installing, maintaining, and removing excavation support and protection.
B. Related Sections:
1. Section 02200 – Excavation and Backfill
2. Section 02318 – Trenching.
1.02 REFERENCES
A. American Institute of Steel Construction, Inc. (AISC):
1. Manual of Steel Construction Allowable Stress Design.
B. American Society of Civil Engineers:
1. Guidelines of Engineering Practice for Braced and Tied-Back Excavations.
C. California Code of Regulations (CCR):
1. Title 8 - Construction Safety Orders.
D. California Labor Code Sections 6705 to 6707 (CLC).
E. Department of the Navy Naval Facilities Engineering Command (NAVFAC):
1. NAVFAC Design Manual 7.2 - Foundations and Earth Structures.
2. NAVFAC Design Manual 7.3 - Soil Dynamics Deep Stabilization and Special Geotechnical Construction.
F. California Building Code (CBC).
G. State of California Department of Transportation (Caltrans):
1. Caltrans California Trenching and Shoring Manual.
H. United States Steel Corporation (USS):
1. USS Steel Sheet Piling Design Manual.
1.03 DEFINITIONS
A. General Engineering Design Practice: General engineering design practice in area of the Project, performed in accordance with recent engineering literature on subject of shoring and stability of excavations.
B. Shoring: A temporary structural system designed to support vertical faces, or nearly vertical faces, of soil or rock for purposes of excavation. Shoring includes internally braced sheet piling, slurry walls, soldier piles and lagging, and other similar shoring systems. Sloping of the soil is not shoring.
281
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2025-???)
1.04 CONTRACTOR’S RESPONSIBILITIES
A. Contractor assumes full and complete responsibility for excavation support and protection, including shoring design and installation.
B. The review of Contractor’s shoring system design, submittals, and/or installations by the Engineer does not relieve Contractor of his responsibility for excavation safety. This requirement shall apply continuously and is not limited to normal working hours.
C. Contractor’s reliance upon documents furnished by City does not provide relief from these requirements.
1.05 SYSTEM DESCRIPTION
A. Where General Engineering Design Practice is specified, provide drawings and signed calculations and have design performed by civil or structural engineer registered in California.
1. Provide design calculations that clearly disclose assumptions made, criteria followed, and stress values used for the materials being used.
2. Furnish references acceptable to Engineer substantiating appropriateness of design assumptions, criteria, and stress values.
B. Design Requirements:
1. General:
a. Design means for safe and stable excavations in accordance with general engineering design practice.
1) The preceding requirement shall not apply to trench excavation support conforming to standards set forth in CCR Title 8 - Construction Safety Orders.
b. Design steel members in accordance with the Uniform Building Code and the AISC Manual of Steel Design.
c. Design shoring involving materials other than steel in accordance with Uniform Building Code.
d. When electing to design with material stresses for temporary construction higher than allowable stresses prescribed in the Manual of Steel Construction and the Uniform Building Code, increase in such stresses shall not exceed 10 percent of value of prescribed stresses.
e. Minimum safety factor used for design shall not be less than 1.5. f. The calculated minimum depth of penetration of shoring below the bottom of the excavation shall be increased not less than 30 percent if the full value of passive pressure is used in the design.
g. The maximum height of cantilever shoring above the bottom of excavation shall not exceed 15 feet. Use braced shoring when the height of shoring above the bottom of excavation exceeds 15 feet.
h. The location of the point of fixity for shoring shall not be less than half the calculated minimum embedment depth below the bottom of the excavation. i. Generally acceptable references for the design of shoring and excavations are as follows:
1) Caltrans California Trenching and Shoring Manual.
2) NAVFAC Design Manual 7.2 - Foundations and Earth Design. 3) NAVFAC Design Manual 7.3 - Soil Dynamics Deep Stabilization and Special Geotechnical Construction.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) 4) USS Steel Sheet Piling Design Manual.
5) Guidelines of Engineering Practice for Braced and Tied-Back Excavations published by American Society of Civil Engineers.
Shoring design shall be performed by a Civil or Structural Engineer licensed to practice in California. Include costs for this shoring design in the bid.
2. Soldier Piles and Lagging:
a. Soldier pile and lagging systems shall not be used in areas where bay mud soils are encountered.
b. Provide lagging over the full face of the excavation. Joints between pieces of lagging shall be tight to prevent loss of soil.
c. Provide full face lagging all around penetrations through the lagging. d. If the soldier piles are installed in predrilled holes, the predrilled holes shall be filled with control density backfill after the soldiers piles are installed. e. The effective width of driven soldier piles for passive soil resistance shall not exceed 2 times the width of the pile. The effective width of concrete encased soldier piles for passive soil resistance shall not exceed 2 times the width of the concrete encasement.
f. Fill voids behind lagging with gravel or other material acceptable to the Engineer.
g. Apply loads from tie back soil, rock, or deadman anchors concentrically to soldier piles or wales spanning between soldier piles. Wales shall be back-toback double channels or other members acceptable to the Engineer.
Eccentrically loaded with section soldier piles or wales are not acceptable. h. Tie backs shall not be used in bay mud soils.
3. Soil Anchors, Rock Anchors, and Deadmen Anchors:
a. Design tie back anchors for a safety factor of not less than 2 times the calculated load from the shoring.
b. Proof load all production anchors to not less than 125 percent of the calculated load from the shoring. Lock off anchors at the calculated anchor load.
c. The length of soil anchors used to calculate resistance to load from the shoring, shall not include any length within the potential active pressure soil failure zone behind the face of shoring.
d. Apply load from anchors concentrically to wales and other shoring members. e. Design tie rods for anchors for 130 percent of the calculated load from the shoring.
f. Design tie rods for anchors for 150 percent of the calculated load from the shoring when tie rod couplers are used and for other conditions where stress concentrations can develop.
C. Performance Requirements:
1. General:
a. Support faces of excavations and protect structures and improvements in vicinity of excavations from damage and loss of function due to settlement or movement of soils, alterations in ground water level caused by such excavations, vibration associated with installation and removal of excavation support structures, and related operations.
b. Herein Specified Provisions:
1) Complement, but do not substitute or diminish, obligations of Contractor for the furnishing of a safe place of work pursuant to provisions of the Occupational Safety and Health Act of 1970 and its subsequent 283
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2025-???) amendments and regulations and for protection of the Work, structures, and other improvements.
2) Represent minimum requirement for:
a) Number and types of means needed to maintain soil stability. b) Strength of such required means.
c) Methods and frequency of maintenance and observation of means used for maintaining soil stability.
2. Provide safe and stable excavations by means of sheeting, shoring, bracing, sloping, and other means and procedures, such as draining and recharging groundwater and routing and disposing of surface runoff, required to maintain the stability of soils and rock.
3. Provide support for trench excavations for protection of workers from hazard of caving ground.
4. Provide Shoring:
a. Where, as result of excavation work and analysis performed pursuant to general engineering design practice, as defined in this Section:
1) Excavated face or surrounding soil mass may be subject to slides, caving, or other types of failures.
2) Stability and integrity of structures and other improvements may be compromised by settlement or movement of soils, or changes in soil load on structures and other improvements.
b. For trenches 5 feet and deeper.
c. For trenches less than 5 feet in depth, when there is a potential for cave-in. d. Where indicated on the Drawings.
5. For safe and stable excavations, use appropriate design and procedures for construction and maintenance to minimize settlement of supported ground and to prevent damage to structures and other improvements, including:
a. Using stiff support systems.
b. Following appropriate construction sequence.
c. Preventing soil loss through or under support system. 1) Provide support system that is tight enough to prevent loss of soil and extend deep enough to prevent heave or flow of soils from supported soil mass into the excavation.
d. Providing surface runoff routing and discharge away from excavations. e. Where dewatering is necessary, recharge groundwater as necessary to prevent settlement in area surrounding excavation.
f. Where sheet piling is used, use interlocking type sheets including interlocking corners. The sheet piles shall be continuous and driven in interlock. If the bottom of the excavation is located below the water table, use "thumb and finger" type interlock.
g. Not applying shoring loads to existing structures and other improvements. h. Not changing existing soil loading on existing structures and other improvements.
i. Provide welded steel packing between soil retaining members such as sheet piles and wales and similar members when the gap exceeds 1/2 inch before the wales are loaded.
6. Do not use cantilever sheet pile shoring. When sheet piling is used, provide a braced system with a minimum of 2 levels of wales and braces. Locate top level of wales and bracing within 5 feet of the top of the sheets.
7. Use template for driving sheet piles to minimize need for pulling and redriving sheet piles in the attempt to drive them plumb in areas where bay mud is present. 284
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
1.06 SUBMITTALS
A. Shop Drawings and Calculations:
1. In accordance with requirements in California Labor Code for trench excavations 5 feet or more in depth and for trenches less than 5 feet in depth when there is potential for cave-in. Submit in advance of excavation work, detailed drawings showing means for safe and stable excavations.
a. Where such drawings vary from excavation support standards set forth in California Code of Regulations Title 8 - Construction Safety Orders, submit design calculations pursuant to general engineering design practice. b. Provide means for safe and stable excavations that are not less effective than required in CCR Title 8 - Construction Safety Orders.
2. For excavations other than trenches, submit, in advance of excavation work, design calculations as performed pursuant to general engineering design practice, as specified in this Section, and detail drawing showing means for safe and stable excavations. In design calculations and detail drawing, cover, as a minimum:
a. Excavations adjacent to structures and other improvements, and b. Excavations 5 feet or more in depth, or less than 5 feet in depth when there is potential for cave-in, at other locations.
3. Submit Following:
a. Provide calculations for the different load, support, and other conditions that occur during the sequence of installation of shoring, construction of facilities protected by the shoring, and sequence of removal of shoring. b. Provide sketches showing the condition at various stages of installation and removal of shoring.
c. Show structures, pipelines, and other improvements located near the shoring, and the shoring on a plan.
d. When utilities penetrate the shoring, submit an elevation of all sides of the shoring showing the locations of the penetrations. Submit details on ground support and sealing around utility penetrations.
B. Detailed Sequence of Installation and Removal of Shoring:
1. Consider effects of ground settlement in the sequence of installation and removal of shoring.
2. Provide sketches showing the conditions at various stages in the sequence of installation and removal of shoring.
3. Clay and silt may stick to sheet piles when sheet piles are removed.
4. Backfilling of excavations shall occur simultaneously with shoring removal.
Backfilling of the excavation with shoring measures in-place will not be acceptable.
C. Submit submittals for stability of excavations as a complete package and include all items required in this section. Incomplete submittals will not be reviewed and will be returned for resubmittal as a complete package. Complete submittal shall include all necessary information regarding the dewatering system as specified in Section 02300.
1.07 SEQUENCING AND SCHEDULING
A. Do not begin work on excavations, trenches, and means for providing stability of excavation and trenches until submittals have been accepted by Engineer and until materials necessary for installation are on site.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2025-???) B. Submit submittals a minimum of 30 days prior to the scheduled date to begin excavation work.
C. Do not begin construction of any shoring or excavation operations until:
1. Control points as specified in this Section and as indicated on the Drawings on existing structures and other improvements have been established and surveyed to document initial elevations and locations.
PART 2 PRODUCTS
Not Used.
PART 3 EXECUTION
3.01 INSTALLATION AND REMOVAL
A. Install means for providing safe and stable excavations as indicated in the submittals section above.
B. Except for concrete encased soldier piles, slurry walls, and similar shoring systems, remove shoring by completion of the Work. Select shoring system and method of removal, which will minimize soil that sticks to shoring from creating large voids and causing settlement. To prevent settlement caused by pulling shoring, fill voids with sand, pea gravel, or pressure injected grout. The methods used shall prevent settlement.
Pressure preservative treated wood lagging may be left in place when acceptable to the Engineer.
C. Backfilling of excavations shall occur simultaneously with shoring removal. Backfilling of the excavation with shoring measures in-place will not be acceptable.
3.02 MAINTENANCE
A. Where loss of soil occurs, plug gap in shoring and replace lost soil with fill material acceptable to Engineer.
B. Where measurements and observations indicate possibility of failure or excessive movement of excavation support, determined in accordance with general engineering design practice, take appropriate action immediately.
**END OF SECTION**
286
TRENCHING 02318 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 02318
TRENCHING
PART 1 GENERAL
1.01 SUMMARY
A. Section Includes: Trench excavation, fine grading, pipe bedding, backfilling, compaction, tracer wire, and warning tape for the construction of new pipe.
B. Related Sections:
1. Section 02200 – Excavation and Backfill
2. Section 02700 – PVC Pipe and Fittings
3. Section 02710 – HDPE Pipe
4. Section 02720 – Ductile Iron Pipe and Fittings
1.02 REFERENCES
A. American Society for Testing and Materials (ASTM):
1. C 131 - Test Method for Resistance to Degradation of Small-Size Course Aggregate by Abrasion and Impact in the Los Angeles Machine.
2. C 136 - Test Method for Sieve Analysis of Fine and Course Aggregates.
3. D 1556 - Test Method for Density and Unit Weight of Soil in Place by the Sand Cone Method.
4. D 1557 - Test Method for Laboratory Compaction Characteristics of Soil Using Modified Effort (56,000 ft.lbf/ft^3 (2,700 kN.m/m^3)).
5. D 2922 - Test Methods for Density of Soil and Soil-Aggregate in Place by Nuclear Methods (Shallow Depth).
6. D 4318 - Test Method for Liquid Limit, Plastic Limit, and Plasticity Index of Soils.
1.03 SUBMITTALS
A. Products Data: For all proposed bedding and backfill materials.
1. Material source.
2. Gradation.
3. Testing data and testing laboratory qualifications including lab certification.
PART 2 PRODUCTS
2.01 MATERIALS
A. General:
1. Materials derived from processing demolished or removed asphalt concrete are not acceptable.
B. Geotextile Filter Fabric: As specified in Section 02200. 287
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) C. Bedding: As specified in Section 02200 and as shown on the plans.
D. Backfill: Backfill as specified in Section 02200 and as shown on the plans.
E. Tracer Wire: Shall be No. 8 AWG, standard copper THW or THHN, 600 volt with solid green insulation.
F. Warning Tape: Shall be metallic foil bonded to plastic film 2-inches or greater wide.
The warning tape shall identify the appropriate utility with letter such as “Caution Force Main Buried Below” with 3/4-inch-tall minimum lettering and colored per the appropriate AWWA utility color designation.
PART 3 EXECUTION
3.01 PREPARATION
A. General:
1. Trench Condition:
a. Install pipe and materials as specified herein and detailed on the Plans.
2. Embankment Condition:
a. Exists where width of pipe trench exceeds limits specified herein. b. Before laying pipes in fill, place fill and compact it to not less than 2 feet above top of pipe or conduit.
c. After placing and compacting fill, excavate through fill and fine grade as required in this Section.
3.02 INSTALLATION
A. Trench Excavation:
1. General Requirements:
a. Trench Widths: As shown on the plans
b. For Manholes, inlets, or Other Accessories:
1) Provide excavations sufficient to leave at least 12 inches clear between their outer surfaces and embankment or shoring which may be used to hold banks and protect them.
2) Do not backfill with earth under manholes, vaults, tanks, or valves. 3) Fill any unauthorized excess excavation below elevation indicated on the Plans for foundation of any structure with foundation material at no additional cost. Backfill material may be substituted for foundation material in areas where foundation material is not required and when approved by the Engineer.
4) Backfilling of Manhole Excavation: Conform to backfilling requirements as specified for trenches in this Section.
B. Pipe Bedding:
1. Bedding material shall be as scheduled herein unless otherwise specified.
2. General:
a. Over excavate bottom of trench as shown on the plans. b. Place bedding material at uniform density.
3. Bell or Coupling Holes:
a. Dig holes after trench fine grading has been placed. 288
TRENCHING 02318 - 3
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) b. Provide holes of sufficient width to provide ample room for grouting, banding, or welding.
c. Excavate holes only as necessary in making joints and to ensure that pipe rests upon prepared trench bottom and not supported by any portion of the joint.
4. Depressions for Joints, Other than Bell-and-spigot:
a. Make in accordance with recommendations of joint manufacturer for particular joint used.
5. After Pipe Laid:
a. Place bedding material under, around, and above pipe in maximum 6-inch lifts and compact to the maximum density identified on the plans and in Section 02200.
6. Pipe Displacement:
a. Take necessary precautions in placement and compaction of bedding material to prevent displacement of piping.
b. In event there is movement or floating, re-excavate, re-lay, and backfill the pipe.
7. Consolidation:
a. Bedding shall be mechanically compacted at optimum moisture content or above according to ASTM D1557 with non-vibratory compaction equipment.
Water settling methods such as flooding and jetting are prohibited.
C. Trench Backfill:
1. Backfill material shall be as scheduled herein unless otherwise specified.
2. See Section 02200 for CLSM backfill placement requirements.
3. Place and compact backfill in accordance with following requirements:
a. From top of pipe zone backfill to natural surface level. Match finish grade as indicated on the plans.
b. Backfill trench from top of pipe zone backfill to finish grade with backfill material compacted to maximum density specified in Section 02200 and as shown on the plans.
c. Existing Conditions: Where existing underground pipes or conduits larger than 3 inches in diameter cross trenches above new work:
1) Refer to drawings where there is less than 12 inches of clearance. 2) Where there is more than 12 inches of clearance:
a) Backfill from bottom of intersecting trench to spring line of intersecting pipe or conduit with backfill material compacted to 95 percent of maximum density when tested in accordance with ASTM D 1556 or ASTM D 2922.
b) Provide Controlled Low Strength Material (CLSM) as specified herein, below existing pipe or conduit where backfill cannot be placed and compacted as specified. CLSM shall have a minimum thickness of 12 inches beneath the existing pipe or conduit and shall extend up to the springline of the pipe or conduit. CLSM shall extend a minimum of 12 inches beyond the outside of the pipe or conduit in either direction and as a minimum shall extend to the edge of the trench crossing the pipe or conduit. c) Extend backfill material 2 feet on either side of intersecting pipe or conduit to ensure that material remains in place while other backfill is placed.
289
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) d. Backfill shall be mechanically compacted at optimum moisture content or above according to ASTM D1557 with non-vibratory equipment weighing no more than 12 tons static weight. All backfill shall be placed in maximum 8- inch lifts. Water settling methods such as flooding and pooling or jetting are prohibited.
D. Warning Tape and Tracer Wire
1. Place warning tape and tracer wire above the pipe as indicated on the Drawings.
Tracer wire shall be terminated at tracer wire connection boxes.
E. Excess Material:
1. Remove excess excavated material from the project site and dispose of legally offsite.
3.03 FIELD QUALITY CONTROL
A. Tests: Compaction testing will be performed by the City or the City’s consultant.
1. Initial Compaction Demonstration:
a. Adequacy of Compaction Equipment and Procedures: Demonstrate adequacy of compaction equipment and procedures before exceeding any of following amounts of earthwork quantities:
1) 50 linear feet of trench backfill.
2) 50 cubic yards of structural backfill.
3) 100 cubic yards of embankment work.
4) 50 cubic yards of base material.
b. Compaction Sequence Requirements: Until specified degree of compaction on previously specified amounts of earthwork is achieved, do not perform additional earthwork of the same kind.
c. After satisfactory conclusion of initial compaction demonstration and at any time during construction, provide confirmation tests as directed by the Engineer.
2. Confirmation Tests:
a. The Contractor shall accomplish specified compaction of trench backfill. b. Confirmation Test submittals are not required.
c. Coordination with Engineer during Testing: Remove overburden above level at which the Engineer wishes to test and backfill and recompact excavation after testing is completed.
3. If compaction fails to meet specified requirements, perform remedial work by one of the following methods:
a. Remove and replace backfill at proper density.
b. Bring density to specified level by means acceptable to the Engineer. c. Retesting:
1) Costs of Retesting: Costs of any retesting required to confirm and verify that remedial work has brought compaction within specified requirements shall be borne by the CONTRACTOR.
2) CONTRACTOR is responsible for compliance testing of remedial work.
3) Confirmation Tests during performance of remedial work will be performed as follows:
a) Tests will be performed in a manner acceptable to the Engineer. b) Frequency: Double amount specified for initial compaction tests. 290
TRENCHING 02318 - 5
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) ***END OF SECTION***
291
MANHOLE AND PIPE ABANDONMENT AND DEMOLITION 02532 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 02532
MANHOLE AND PIPE ABANDONMENT AND DEMOLITION
PART 1 GENERAL
1.01 SUMMARY
A. Section includes the abandonment of existing sewer mains and manholes as indicated on the contract drawings.
B. Related Sections:
1. Section 02100 – Clearing and Demolition
2. Section 02200 – Excavation and Backfill
3. Section 03301 – Cast in Place Concrete
1.02 REFERENCES
1. Not Used.
1.03 SUBMITTALS
A. Products Data: For all proposed fill materials.
1. Material source.
2. Gradation.
3. Testing data and testing laboratory qualifications including lab certification.
B. Plans:
1. For abandonment, describing proposed sequence and methods of plugging and filling mains and manholes to be abandoned
PART 2 PRODUCTS
2.01 MATERIALS
A. CDF: As specified in Section 03301.
B. Concrete: As specified in Section 03301.
C. Crushed Rock: As specified in Section 02200.
D. Sand:
1. Free from clay and organics
2. Sand Equivalent: 35 minimum
3. Percent composition by weight determined by laboratory sieves:
Sieve Size Percent Passing
No. 4 100
No. 10 95 - 100
No. 40 20 - 65
No. 100 5 - 30
No. 200 0
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MANHOLE AND PIPE ABANDONMENT AND DEMOLITION 02532 - 2
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) PART 3 EXECUTION
3.01 PREPARATION
A. General:
1. Contractor shall submit abandonment plan detailing approximate volume of fill required to abandon each pipe segment and each manhole.
3.02 INSTALLATION
A. Gravity Sewer Pipe Abandonment: Fill pipe with CDF, sand, or concrete as indicated on Drawings. When filling with Sand, contactor shall plug pipe at each end with 6” minimum thick concrete plug. Material placed within pipe shall be placed by the use of a horizontal tremie to fill the entire pipe volume. Contractor shall calculate the volume of material required to fill the pipe and document the volume of material placed to ensure all voids are filled.
B. Force Main Pipe Abandonment: Plug all exposed ends of pipe with a concrete plug as shown on the plans.
C. Manhole Abandonment:
1. Contractor shall puncture the structure base with a minimum of 2-inch holes at 18” maximum on center.
2. Fill structure with CDF or crushed rock as indicated on Drawings.
3. Remove upper portion of wet well as indicated on Drawings.
4. Restore site as indicated on the Drawings.
D. See Section 02100 for additional demolition and abandonment requirements. ***END OF SECTION***
293
PVC PIPE AND FITTINGS 02700 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 02700
POLYVINYL CHLORIDE (PVC) PIPE AND FITTINGS
PART 1 GENERAL
1.01 SUMMARY
A. Section Includes:
1. PVC Pipe and Fittings.
B. Related Sections:
1. Section 02200 – Excavation and Backfill.
2. Section 02318 – Trenching.
3. Section 02760 – Closed Circuit Television (CCTV) Inspection.
4. Section 02770 – Sanitary Sewer Testing
5. Section 03301 – Cast in Place Concrete.
6. Section 03400 – Pre-Cast Concrete.
7. Section 03600 – Grouts.
1.02 REFERENCES
A. American Society for Testing and Materials (ASTM):
1. D 3034 – Specifications for Type PSM Poly (Vinyl Chloride) (PVC) Sewer Pipe and Fittings.
2. D 3212 – Specification for Joint for Drain and Sewer Plastic Pipes Using Flexible Elastomeric Seals.
3. D 3965 – Classification System and Basis for Specifications for Rigid Acrylonitrile-Butadiene-Styrene (ABS) Materials for Pipe and Fittings.
4. F 477 - Specifications for Elastomeric Seals (Gaskets) for Joining Plastic Pipe.
B. American Water Works Association (AWWA):
1. C110 - Ductile Iron and Gray Iron Fittings, 3-inch through 48-inch
2. C116 - Protective Fusion-bonded Epoxy Coatings for the Interior and Exterior Surfaces of Ductile Iron and Gray Iron Fittings
1.03 SUBMITTALS
A. Product Data:
1. PVC Pipe.
2. Fittings.
B. Summary of deflection test results.
C. Post installation CCTV inspection report and video.
PART 2 PRODUCTS
2.01 MANUFACTURERS
A. Pipe Manufacturers:
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
1. Diamond Plastic Corporation.
2. JM Eagle.
3. North American Specialty Products.
4. Or Approved Equal.
B. Manhole Connection:
1. New manholes: Refer to water stops Section 03301 and 03400.
2. Existing manholes:
a. Concrete manhole adapter water stop manufactured by Fernco. b. Or approved equal.
2.02 MATERIALS
A. Gravity PVC Pipe and Fittings:
1. Minimum wall and strength requirements of SDR-26 in conformance with ASTM D-3034.
2. Pipe shall be made of PVC plastic having a cell classification of 12454 or 12364 as defined in ASTM D 1784.
3. Bell and spigot type joints conforming to ASTM D 3212.
4. Sealing gaskets shall meet the requirements of ASTM F477.
5. Pipe shall be marked with “SANITARY SEWER” in 1-5/8” high block lettering with permanent ink. The marking shall be repeated at 2-foot spacing along the pipe length.
B. Bedding and Backfill
1. Per specification Sections 02200 and 02318 and as detailed on the Plans.
PART 3 EXECUTION
3.01 PIPE STORAGE
A. Pipe may be stored on the project site at the Contractor’s own risk. Precautions shall be taken to prevent damage to the stored pipe.
B. PVC shall be protected from damage due to sunlight exposure.
3.02 HANDLING
A. Care shall be taken in handling, transporting and placing pipe to prevent damage. No interior hooks or slings shall be used in lifting pipe. All handling operations shall be done with an exterior sling or with a suitable fork lift.
B. No damaged pipe will be accepted and will be replaced with new pipe to the next joint.
3.03 EXCAVATION AND BACKFILL
A. Trenching, Excavating and Backfilling shall be done in accordance with Sections 02200 and 02318.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
3.04 CONNECTIONS
A. Thoroughly clean pipe and fittings of dirt, dust, and moisture before installation.
Installation and joining methods shall be as recommended by the pipe and fitting manufacturers.
B. Cut pipe square for good joint integrity. After cutting pipe, ream inside and chamfer outside to remove burrs, shoulders, and ragged edges.
3.05 MANHOLE CONNECTION
A. Core drill through existing manhole as necessary to accommodate the new sewer pipe.
B. Manhole sewer connection shall be installed with a water stop and non-shrink epoxy grout applied 360 degrees around new sewer pipe in conformance with manufacturer’s instructions.
3.06 INSPECTION
A. All installed sewers and connections shall be visually inspected by the City prior to backfill. The City may require the Contractor to excavate any sewer pipe or connection that is not visually inspected by the City prior to backfill.
B. All new sewer pipes shall be video inspected by the contractor per Section 02760.
C. Post installation videos shall be prepared and submitted to the City in accordance with Section 02760.
3.07 TESTING
A. Testing shall be done in accordance with Section 02770. ***END OF SECTION***
296
HDPE PIPE AND FITTINGS 02720 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 02710
HIGH DENSITY POLYETHYLENE (HDPE) PIPE AND FITTINGS
PART 1 GENERAL
1.01 SUMMARY
A. Section Includes:
1. High Density Polyethylene (HDPE) Pipe.
B. Related Sections:
1. Section 02200 – Excavation and Backfill.
2. Section 02318 – Trenching.
3. Section 02760 – Closed Circuit Television (CCTV) Inspection.
4. Section 03301 – Cast in Place Concrete.
5. Section 03400 – Pre-Cast Concrete.
6. Section 03600 – Grouts.
1.02 REFERENCES
A. American Society for Testing and Materials (ASTM):
1. D 2122 – Determining Dimensions of Thermal Plastic Pipe and Fittings
2. D 2321 – Underground Installation of Thermoplastic Pipe for Sewers and Other Gravity Flow Applications
3. D 2837 – Hydrostatic Design Basis for Thermal Plastic Pipe Materials
4. D 3350 – Polyethylene Plastics Pipe and Fittings Material
5. F 714 – Polyethylene Plastic Pipe Based on Outside Diameter
6. F 1667 – Guide for Construction Procedures for Buried Plastic Pipe
1.03 SUBMITTALS
A. Product Data:
1. HDPE Pipe.
2. Fittings, flange adapters, etc.
3. Electrofusion Couplings.
B. Submit debeading process and equipment for use in removing the internal bead for the newly joined HDPE pipe sections.
C. The Contractor shall submit a copy of the technician’s certification(s) for the operation of the fusion equipment.
D. The Contractor shall perform trial fusion welds and submit samples to the City for review prior to installation of the pipe. The fusion machine used for the trial welds shall be the same machine to be utilized for the installation work.
E. Pipe Fusion Logs.
297
HDPE PIPE AND FITTINGS 02720 - 2
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) PART 2 PRODUCTS
2.01 MATERIALS
A. Materials used for the manufacture of HDPE pipe and fittings shall be extra high molecular weight, high density ethylene/hexene copolymer PE 3408 polyethylene resin meeting a minimum cell classification of 445474C or 445574C per ASTM D3350.
B. The HDPE pipe manufacturer shall provide certification that stress regression testing has been performed on the specified material. Said certification shall be done in conformance with ASTM D2837, and the manufacturer shall provide a product supplying a minimum hydrostatic design basis (HDB) of 1,600 psi.
C. HDPE materials shall be listed by the Plastics Pipe Institute in PPI TR-4 with a 73°F hydrostatic design stress rating of 800 psi, and a 140°F hydrostatic design stress rating of 400 psi. The PPI listing shall be in the name of the pipe manufacturer, based on ASTM D2837 and PPI TR-3 testing and validation of samples of the pipe manufacturer's production pipe.
D. The physical properties of the pipe and fittings material shall be as indicated in the table below:
PROPERTY
TEST
METHOD VALUE
Density ASTM D 1505 >0.947 g/cm^3
Melt Index ASTM D 1238 <0.15 g/10 min
Tensile Strength, Yield ASTM D 638 >3,000 psi
Flexural Modulus ASTM D 790 >80,000 psi
2.02 HDPE PIPE
A. Pipe supplied under this specification shall have a nominal IPS (iron pipe size) outside diameter. Pipe shall be produced to the specifications of ASTM F714.
B. The DR (dimension ratio) shall be 11 for the sanitary sewer force main.
C. Pipe shall have green stripes along the exterior of the pipe.
D. Pipe shall be marked with nominal size, dimension ration (DR), trade name, material classification (PE4710), certification base (ASTM F714), and date produced.
2.03 HDPE FITTINGS
A. Material for HDPE fittings shall comply with ASTM A 3261 for butt heat fusion fittings. Material for standard HDPE fittings shall comply with ASTM D3350.
B. Standard HDPE fittings shall be commercial products manufactured by injection molding or by extrusion and machining, or shall be fabricated from HDPE pipe conforming to this specification.
C. Fittings shall be fully pressure rated by the manufacturer to provide a working pressure equal to that of the pipe.
D. Fittings shall be manufactured from the same resin type, grade and cell classification as the pipe itself.
298
HDPE PIPE AND FITTINGS 02720 - 3
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) E. HDPE Flange Adapters:
1. HDPE Flange Adapters shall be provided as shown on the Drawings.
2. New HDPE Flange Adapter and back up ring shall be ANSI Class 150/AWWA C207.
3. All collar-type adapters shall be installed with butt fusion methods per manufacturer instructions. Couplings shall be factory coated to prevent corrosion.
F. Electrofusion Couplings:
1. The use of electrofusion couplings shall be minimized to the extent feasible. The Contractor shall submit proposed electrofusion coupling locations for review and approval prior to use.
2. HDPE electrofusion couplings shall be installed by a qualified installer with equipment certified for use with the supplied coupling.
3. Electrofusion coupling shall be specifically designed for use with the SDR rating of the host pipes.
4. Shall be manufactured in accordance with ASTM F-1055 for use with pipe conforming to ASTM D2513/3035.
5. Shall be supplied with a 24 Digit ISO Compliant Universal Barcode Label.
6. Shall be tested and supplied in accordance with AWWA C906 specification and supplied with a 24-digit ISO compliant barcode label which facilitates the fusion of electrofusion fitting with other manufacturer’s processors.
7. This resin shall have a NSF Standard 61 listing for use with potable water.
PART 3 EXECUTION
3.01 PIPE STORAGE AND HANDLING
A. Pipe shall be stored and handled in conformance with the pipe supplier’s guidelines.
B. Pipe may be stored on the project site at the Contractor’s own risk. Precautions shall be taken to prevent damage to the stored pipe.
C. Care shall be taken in handling, transporting and placing pipe to prevent damage. No interior hooks or slings shall be used in lifting pipe. All handling operations shall be done with an exterior sling or with a suitable fork lift.
D. No damaged pipe will be accepted.
3.02 FUSION PROCESS
A. Fusing pipe shall only be done by qualified fusion technicians holding current qualification credentials for the pipe being fused.
B. Pipe supplier’s procedures shall be followed at all times during fusion operation.
C. Each fusion join shall be recorded and logged by an approved electronic monitoring device (data logger) connected to the fusion machine, which utilizes a current version of the pipe supplier’s recommended and compatible software. A copy of all fusion logs shall be submitted to the City.
D. Use only appropriately sized and outfitted fusion machines. 299
HDPE PIPE AND FITTINGS 02720 - 4
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) E. Pipe shall be joined using the butt fusion method providing a joint weld strength equal or greater than the tensile strength of the pipe.
F. All internal beads for newly joined HDPE force main pipe sections shall be removed.
3.03 INSTALLATION
A. Refer to the plans and Sections:
1. Section 02200 – Excavation and Backfill.
2. Section 02318 – Trenching.
3.04 TESTING
A. Testing shall be done in accordance with Section 02770. ***END OF SECTION***
300
DUCTILE IRON PIPE AND FITTINGS 02720 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 02720
DUCTILE IRON PIPE AND FITTINGS
PART 1 GENERAL
1.01 SUMMARY
A. Section Includes: Ductile Iron Pipe (DIP) and fittings.
B. Related Sections:
1. Section 02200 – Excavation and Backfill.
2. Section 02318 – Trenching.
3. Section 09800 – Coating System
1.02 REFERENCES
A. American Society for Testing and Materials (ASTM):
1. D 1248 - Specification for Polyethylene Plastic Extrusion Materials for Wire and Cable
2. F 593 - Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs
3. F 594 - Specification for Stainless Steel Nuts
B. American Water Works Association (AWWA):
1. C 105 - Polyethylene Encasement for Ductile-Iron Pipe Systems
2. C 110 - Ductile-Iron and Gray-Iron Fittings
3. C 111 - Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings
4. C 151 - Ductile-Iron Pipe, Centrifugally Cast
5. C 153 - Ductile-Iron Compact Fittings
6. C219 – Bolted, Sleeve-Type Couplings for Plan-End Pipe
7. C 600 - Installation of Ductile Iron Water Mains and Their Appurtenances C. Society for Protective Coatings (SSPC)
1. 10 – Near-White Blast Cleaning
1.03 SUBMITTALS
A. Product Data:
1. Ductile Iron Pipe
2. Fittings
PART 2 PRODUCTS
2.01 MANUFACTURERS
A. Mechanical Joints and Coupling Adapters:
1. EBAA
2. Or Approved Equal
B. Pipe:
1. American Pipe
301
DUCTILE IRON PIPE AND FITTINGS 02720 - 2
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
2. Griffin Pipe Products Company
3. McWane
4. United States Pipe and Foundry Company (U.S. Pipe)
5. Or Approved Equal
2.02 MATERIALS
A. Ductile Iron Pipe and Fittings:
1. Manufactured in accordance with AWWA C151.
2. Pressure class 350.
3. Material for ductile iron fittings shall comply with ASTM A536, Grade 65-45-12.
Fittings shall meet specifications included in ASME/ANSI B16.1.
4. Pipes shall be joined by flanged or mechanical joints as shown on the Drawings.
Flanges shall be factory assembled
5. All fittings shall be flanged to ANSI B16.1 Class 125 standard pattern.
B. Pipe and Fittings Coating Systems:
1. Fittings and Valves: All fittings and valves shall be fusion bonded epoxy lined and coated as specified herein unless otherwise specified. Additional ferrous metals for immersed service shall also be fusion bonded epoxy lined and coated.
2. Ductile Iron Pipe: Ductile iron pipe shall be lined and coated as specified herein:
a. Interior lined with Protecto 401 Ceramic Epoxy or Tnemec 431 PermaShield. The lining material shall be amine cured novalac epoxy containing at least 20 percent by volume of ceramic quartz pigment. The dry film thickness shall be no less than 40 mils. Exterior coating shall be:
1) Buried Pipe: Buried pipe shall be coated with asphaltic material as specified in AWWA C151. A minimum thickness of 1-mil asphaltic coating shall be applied.
2) Exposed Pipe: Exposed pipe within the wetwell and valve vault shall be prepared per the National Association of Pipe Fabricators Standard NAPF 500-03 and coated with an exterior protective pipe coating incorporating high solids amine cured epoxy for maximum protection of the exterior of ductile iron pipe. Coating shall be Tnemec Series 141 at a minimum of 16 mils dry film thickness, or US Pipe Ceramawrap at a minimum dry film thickness of 20 mils.
3. Buried Pipe and Fittings: Ferric discharge piping and associated fittings for buried service shall be coated in conformance with these specifications and in addition, shall be wrapped with a plastic film wrap as specified herein.
C. Gaskets:
1. Gaskets shall be rated for wastewater service, made of synthetic rubber such as Buna-N not less than one-eighth (1/8) inch thick. All gaskets shall be the full width of the flange to which applied.
D. Plastic Film Wrap
1. All ductile-iron pipe, fittings, and valves buried underground shall be protected with plastic film wrap in accordance with AWWA C105, unless noted otherwise below. Wrap shall be a loose 8-mil-thick polyethylene tube. All joints between plastic tubes shall be wrapped with 2-inch-wide polyethylene adhesive tape, Polyken 900, Scotch wrap 50, or approved equal.
E. Thrust Restraint Glands: All fittings, joints, and connections shall be restrained against trust. Thrust restraint glands shall be EBAA Iron MEGALUG Series 1100 or approved 302
DUCTILE IRON PIPE AND FITTINGS 02720 - 3
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) equal. Cast gland bodies shall be coated with MEGA-BOND. The wedge assemblies and all nuts and bolts shall be coated with Xylan Fluoropolymer coating.
F. Coupling Adapters: All fittings, joints, and connections shall be restrained against thrust. Coupling adapters shall be EBAA Iron MEGA-COUPLING Series 3800 or approved equal. Cast gland bodies shall be coated with MEGA-BOND. The wedge assemblies and all nuts and bolts shall be coated with Xylan Fluoropolymer coating.
G. Restrained Flanged Coupling Adapters (RFCA):
1. Flange coupling adapters shall be provided as shown on the Drawings or as deemed necessary by the Contractor for pipe assembly.
2. Couplings shall be EBAA Megaflange Series 2100 or Romac restrained flange coupling adapter, or approved equal. Adapter material shall be ductile iron coated with fusion bond epoxy in conformance with AWWA C116.
3. Coupling shall be specifically designed for the pipe material and size.
H. Restrained Couplings: Restrained couplings shall be constructed with a solid ductile iron mechanical joint sleeve with thrust restrain glands on both sides. Ductile iron sleeve shall be fusion bond epoxy lined and coated at the factory in conformance with AWWA C116.
I. Bolts and Nuts
1. All bolts and nuts shall be Type 316 stainless steel conforming to ASTM F593 G or H for bolts. All nuts and bolts shall be coated with Xylan Fluoropolymer coating.
2. The length of each bolt or stud shall be such that between 1/4 inch and 3/8 inch will project through the nut when drawn tight.
J. Flanged Fittings:
1. Fittings for flanged connection shall be Fusion Bonded Epoxy coated and lined in conformance with AWWA C110.
2. Flanges shall match the connecting flanges on adjacent fitting, valve, or piece of equipment.
3. Provide full face gaskets per AWWA C111.
K. Flexible Ring Adapter Couplings:
1. Collar-type Ring Adapters and Couplings shall be provided as shown on the Drawings. See Section 02710.
L. Cam-lock Fitting:
1. Fittings shall be 316 stainless steel.
2. Metal coupling shall be able to withstand 100 psi of working pressure
3. The body of the fitting shall meet material requirements included in ASTM A356 and ASTM A380.
PART 3 EXECUTION
3.01 GENERAL
A. Pipe shall be installed in accordance with good trade practice and AWWA C600. The methods employed in the handling and placing of pipe, fittings, and equipment shall be such as to insure that after installation and testing they are in good condition. Should damage occur to the pipe, fittings, or equipment, repairs satisfactory to the City shall be made prior to final acceptance at no additional cost to the City. 303
DUCTILE IRON PIPE AND FITTINGS 02720 - 4
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
3.02 EXCAVATION AND BACKFILL
A. Excavate and Backfill in accordance with Sections 02200 and 02318.
3.03 PLACING PIPE
A. During loading, transportation, and unloading, every precaution shall be taken to prevent pipeline damage. Any damaged pipe shall be replaced or repaired to the satisfaction of the City. Where pipe is placed in stockpiles, it shall be neatly piled and blocked with strips between tiers.
B. All damaged coatings shall be coated after assembly with a mastic, 3M, Minnesota Mining and Manufacturing EC 244, or an approved equal.
3.04 TESTING FOR PRESSURE PIPE
A. See Section 02770.
END OF SECTION
304
AGGREGATE BASE 02722 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 02722
AGGREGATE BASE
PART 1 GENERAL
1.01 SUMMARY
A. Section Includes: Aggregate base.
B. Related Sections:
1. Section 02200 - Excavation and Backfill.
2. Section 02742 - Asphaltic Concrete Paving.
3. Section 03301 - Cast in Place Concrete.
4. Section 03400 – Precast Concrete
1.02 REFERENCES
A. American Concrete Institute (ACI):
1. C 117 - Test Method for Material Finer than 75-µm (No. 200) Sieve in Mineral Aggregate by Washing.
2. C 136 - Method for Sieve Analysis of Fine and Coarse Aggregates.
3. D 4318 - Test Method for Liquid Limit, Plastic Limit, and Plasticity Index of Soils.
B. State of California Department of Transportation.
1. CALTRANS - Standard Specifications.
1.03 SUBMITTALS
A. Product Data:
1. Source, gradation, and testing data for aggregate base course.
B. Quality Control:
1. Test Reports: Reports for tests required by Sections of CALTRANS Standard Specifications.
C. Certificates of Compliance: Certificates as required by Sections of CALTRANS Standard Specifications.
1.04 DELIVERY, STORAGE, AND HANDLING
A. Storage and Protection: Protect from segregation and excessive moisture during delivery, storage, and handling.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) PART 2 PRODUCTS
2.01 MATERIALS
A. Aggregate Base Course:
1. Class 2, 3/4-inch maximum aggregate size free from vegetable matter and other deleterious substances, and of such nature that aggregate can be compacted readily under watering and rolling to form a firm, stable base.
2. Materials derived from processing demolished or removed asphalt concrete are not acceptable.
3. Coarse aggregate material retained in Number 4 sieve shall consist of material of which at least 25 percent by weight shall be crushed particles when tested in accordance with California Test 205.
4. Aggregate shall not be treated with lime, cement, or other chemical material before the Durability Index test is performed.
5. Aggregate grading and sand equivalent tests shall be performed to represent not more than 500 cubic yards or one day's production of material, whichever is smaller.
6. Grade within the limits and conform to quality requirements as follows when tested in accordance with California Test 202:
Sieve Sizes
(Square Openings)
Percent by Weight
Passing Sieve
1 inch 100
3/4 inch 90-100
Number 4 35-55
Number 30 10-30
Number 200 2-9
Quality Requirements
Description California Test Minimum Test Result
Resistance (R Value) 301 78
Sand Equivalent 217 22
Durability Index 229 35
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) PART 3 EXECUTION
3.01 EXAMINATION
A. Verification of Conditions: Examine conditions upon which the work specified in this Section depends for defects that may influence installation and performance.
B. Do not proceed with installation until unsatisfactory conditions have been corrected.
3.02 PREPARATION
A. Subgrade Preparation: Prepare as specified in Section 02200, "Excavation and Backfill"
3.03 INSTALLATION
A. Furnish, spread, and compact aggregate base course material to the lines, grades, and dimensions indicated on the Drawings.
1. Spreading: Spread in accordance with sections of CALTRANS Standard Specifications.
2. Compacting: per Sections 02200 and 02318.
3.04 FIELD QUALITY CONTROL
A. Tests: Perform field tests per Sections 02200 and 02318. ***END OF SECTION***
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ASPHALTIC CONCRETE PAVING 02742 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 02742
ASPHALTIC CONCRETE PAVING
PART 1 GENERAL
1.01 SUMMARY
A. All asphaltic concrete paving shall adhere to the requirements within this specification section.
B. Section Includes: Asphaltic concrete pavement on prepared subgrade or aggregate base course or on existing pavement to lines, grades and compacted thickness as indicated on the Plans and as necessary to restore all existing asphaltic concrete pavement disturbed during the course of the Work.
1.02 REFERENCES
A. State of California Department of Transportation Standard Specifications, 2018 (CALTRANS Standard Specifications).
1. Section 37 - Bituminous Seals.
2. Section 39 - Hot Mix Asphalt.
3. Section 92 - Asphalts.
4. Section 93 - Liquid Asphalts.
5. Section 94 - Asphaltic Emulsions.
B. CALTRANS Standard Test Methods:
1. Calif Test 202 - Sieve Analysis of Fine and Coarse Aggregates.
2. Calif Test 304 - Preparation of Bituminous Mixtures for Testing.
3. Calif Test 362 - Determining Asphalt Content in Bituminous Mixtures by Vacuum Extraction.
4. Calif Test 375 - Determining the In-Place Density and Relative Compaction of AC Pavement.
5. Calif Test 379 - Determining Asphalt Content in Bituminous Mixtures (Troxler Nuclear Gage Model 3241).
C. American Society for Testing and Materials (ASTM) Standards:
1. ASTM D1557 - Test Method for Laboratory Compaction Characteristics of Soil Using Modified Effort.
2. ASTM D1561 - Practice for Preparation of Bituminous Mixture Test Specimens by Means of California Kneading Compactor.
1.03 SYSTEM DESCRIPTION
A. This WORK shall consist of furnishing and mixing aggregate and asphalt binder at a central mixing plant, spreading and compaction of the mixtures as specified and as indicated on the Plans.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) B. In general, asphalt concrete and asphalt concrete base shall conform to Section 39 “Hot Mix Asphalt” and all applicable referenced sections of the CALTRANS Standard Specifications.
1. Where conflicts exist, this specification shall govern.
1.04 DEFINITIONS
A. “Asphalt Concrete” as used by CALTRANS shall be considered the “Surface Course,” or the final lift of the pavement section.
B. “Asphalt Concrete Base” as used by CALTRANS shall be the remaining portion of the asphalt pavement section excluding the final lift.
C. “Asphalt Pavement” shall be the total pavement section of asphalt including Asphalt Concrete and Asphalt Concrete Base.
1.05 SUBMITTALS
A. Proposed Mix Design and Gradation of Materials.
B. Product data:
1. Asphalt.
2. Asphalt aggregate
3. Pavement reinforcing fabric.
C. Quality Control Submittals:
1. Test Results.
2. Certificate of Compliance.
3. Certificate of Competence.
D. Equipment List.
1.06 DELIVERY, STORAGE, AND HANDLING
A. Asphalt Pavement Delivery:
1. Transport the mixture from the mixing plant to the point of use in vehicles having tight bodies previously cleaned of all foreign materials.
2. Treat bodies as necessary to prevent material from sticking to the bodies.
3. Cover each load with canvas or other suitable material of sufficient size and thickness to protect the asphalt mixture from the weather.
1.07 PROJECT CONDITIONS
A. Environmental Requirements:
1. Asphalt Concrete:
a. Place asphalt concrete only when surface is dry, when atmospheric temperature in the shade is 40 degrees F and rising, or above 50 degrees F if falling.
b. Do not place asphalt concrete when weather is foggy or rainy nor when base on which material is to be placed is in wet or frozen conditions or when, in 309
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) the opinion of the Engineer, weather conditions will prevent proper handling, finishing, compaction of the mixtures.
2. Prime Coat:
a. Do not apply prime coat when atmospheric temperature is below 60 degrees F.
b. Apply prime coat only when base course is dry or contains moisture not in excess of that which will permit uniform distribution and desired penetration.
PART 2 PRODUCTS
2.01 ASPHALT PAVEMENT MATERIALS
A. Asphalts:
1. Asphalt Binder: Grade PG64-10 conforming to Section 92-1.02 “Grades” of the CALTRANS Standard Specifications.
2. Prime Coat and Tack Coat: Grade SC-70, conforming to Section 93-1.01 of the CALTRANS Standard Specifications.
3. Fog Seal: Asphaltic Emulsion, Grade SS-1h, conforming to Section 94-1.01 of the CALTRANS Standard Specifications.
4. Slurry Seal: Asphaltic Emulsion, Grade CQS1h Cationic., conforming to Section 94-1.02E, and aggregate Type II conforming to Section 37-3 of the CALTRANS Standard Specifications.
B. Asphalt Aggregate:
1. Aggregate for asphalt concrete shall conform to Section 39-1.02 of the CALTRANS Standard Specifications for Type A or B grading, 1/2-inch maximum.
C. Asphalt pavement shall be produced in a batch mixing plant, a continuous pugmill mixing plant, or drier-drum mixing plant.
1. Mixing shall conform to Section 39-1.08 of the CALTRANS Standard Specifications.
2.02 AGGREGATE BASE COURSE
A. Aggregate base shall conform to Section 02722.
B. Aggregate Base Course shall be placed at the following locations:
1. Under all asphalt pavement.
C. Compacted thickness of Aggregate Base Course shall be as indicated on the Plans.
2.03 EQUIPMENT
A. Spreading and Compacting Equipment:
1. Spreading and compacting equipment shall conform to Section 39-3.03 and all applicable referenced sections, of the CALTRANS Standard Specifications. 310
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2.04 SOURCE QUALITY CONTROL
A. The ENGINEER will perform sampling and tests of materials in accordance with California Test Method Number 304 and California Test Method Number 362 or 379, as applicable. Samples will be taken from materials as delivered to the site.
PART 3 EXECUTION
3.01 ASPHALT DEMOLITION
A. Asphalt shall be cut away, grinded, and/or milled to the depth and width as indicated on the Drawings in a manner that does not damage existing utilities and nearby pavement and concrete that is to remain. Removed asphalt and aggregate shall be disposed of by the contractor.
B. Streets that have been ground shall be overlaid within three (3) days of grinding operation. In the event that the CONTRACTOR cannot pave the streets that are ground within three calendar days, the CONTRACTOR shall be prohibited to grind any more streets and must complete all paving work.
3.02 PREPARATION
A. Preparation:
1. Immediately prior to applying prime coat or tack coat, or immediately prior to placing the asphalt pavement when prime coat or tack coat is not required, the subgrade to receive asphalt pavement shall conform to the compaction requirement and elevation tolerances specified for the material involved and shall be cleaned to remove any loose or extraneous material.
2. If the asphalt pavement is to be placed on an existing base or pavement which was not constructed as part of the contract, the CONTRACTOR shall clean the surface by sweeping, flushing or other means to remove all loose particles of paving, all dirt and all other extraneous material immediately before applying the prime coat or tack coat. If the asphalt pavement is to be placed against a vertical gutter face or other vertical surface, the CONTRACTOR shall roughen and clean vertical surface as required for proper bonding of asphalt immediately before applying prime coat or tack coat.
3.03 ADJUSTMENT OF UTILITY FRAMES AND COVERS TO GRADE
A. Utility frames and covers within an area to be paved or graded will be set by the CONTRACTOR with coordination with owners thereof to finished grade. Repaving required as a result of reconstructing or adjusting all manhole and vault frames and covers to grade shall be the responsibility of the CONTRACTOR and the cost thereof shall be included in the bid item for pavement. The CONTRACTOR shall remove all debris from the interior of utility riser and shall clean all foreign material from the top of the frames and covers.
B. The CONTRACTOR shall adjust utility riser/rings/covers within three (3) days after paving is done.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) C. In the event that the CONTRACTOR fails to complete adjusting all manholes and other utility frames and covers within ten (10) days after the street is resurfaced, the CONTRACTOR shall cease all grinding and paving operations until all utility frames and covers are adjusted to finished grade or as directed by the ENGINEER.
D. Utility covers located outside of the paving areas shall not be adjusted to grade as part of this contract unless directed by the ENGINEER.
E. Utility structures extending 2 inches or more above the new subgrade shall be removed by the CONTRACTOR to the new subgrade before paving. Structures projecting less than 2 inches above the subgrade may be paved over and later adjusted to grade. All structures from which frames and covers have been removed to facilitate paving shall be temporarily covered with a steel plate by the CONTRACTOR. When this procedure is impractical, such as for large vaults, special structures, pressure manhole frames and covers, or where portland cement concrete pavement is to be constructed, all remodeling or reconstruction shall be completed to finish permanent surface prior to paving operations. The CONTRACTOR shall notify utility owners, at least 2 working days in advance, of the need to commence work required prior to paving operations and again for work required after paving operations. After the pavement has been completed, the necessary portions of the subgrade, base, and pavement shall be neatly removed, the structure built up, and the manhole frame set to be backfilled to within 1-1/2 inches of the surface with portland cement concrete. The CONTRACTOR shall fill the remaining 1-1/2 inches with an asphalt concrete wearing surface mixture to match the project surface course. This material shall be placed and compacted in a workmanlike manner to conform to the appearance of the surrounding pavement.
3.04 PRIME COAT AND TACK COAT
A. Prime Coat:
1. A prime coat of liquid asphalt shall be applied on all surfaces of base course material to be paved.
2. Prime coat shall be applied at a rate of 0.25 gallons per square yard, and shall conform to Section 93 of the CALTRANS Standard. Specifications for the distributor application of the grade of liquid asphalt being used.
B. Tack Coat:
1. A tack coat of asphaltic emulsion shall be applied to all vertical surfaces of existing pavement, curbs, gutters, and construction joints in the surfacing against which additional material is to be placed, or as otherwise specified herein.
2. Tack coat shall be applied in one application at a rate of 0.1 gallons per square yard of surface covered.
3.05 ASPHALT PAVEMENT
A. Asphalt Pavement thickness section shall be 4-inches minimum or match existing pavement thickness (whichever is greater).
B. Placing materials in a windrow, then picking it up and placing it in the asphalt paver with loading equipment will not be permitted.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) C. Unless lower temperatures are directed by the ENGINEER, asphalt concrete shall be spread, and the first coverage of initial or breakdown compaction shall be performed when the temperature of the mixture is not less than 250 degrees F, and all breakdown compaction shall be completed before the temperature of the mixture drops below 205 degrees F.
D. Asphalt pavement shall be spread and compacted in the number of layers and of the thicknesses indicated in the following table:
1. A thickness tolerance of ±0.1 inches is allowed for asphalt concrete.
2. A total thickness tolerance of ±0.2 inches is allowed for asphalt concrete base.
3. Permeable pavement shall be 2.5 inches thick.
Total
Thickness
Indicated on
Plans(1)
Number
of Lifts
Top Layer Thickness
Next Lower Layer
Thickness
All Other Lower Layer
Thicknesses
Min Max Min Max Min Max
< 2¾” 1 ----- ----- ----- ----- ----- -----
3” 2 1¼” 1½” 1¼” 1½” ----- -----
3¼” - 4¾” 2 1¾” 2¼” 1¾” 3” ----- -----
> 5” (2) 1¾” 2¼” 1¾” 3” 1¾” 4¾”
(1) When pavement reinforcing fabric is shown to be placed between layers of asphalt pavement, the thickness of asphalt pavement above the pavement reinforcing fabric shall be considered to be the “Total Thickness Indicated on the Plans” for the purpose of spreading and compacting the asphalt pavement above the pavement reinforcing fabric.
(2) At least two layers shall be placed if the total thickness is less than 5”. At least three layers shall be placed if the total thickness is more than 5”, and less than 10½”. At least four layers shall be placed if the total thickness is greater than 10½”.
E. A layer shall not be placed over another layer which exceeds 3 inches in compacted thickness until the temperature of the layer which exceeds 3 inches in compacted thickness is less than 160 degrees F at mid depth.
1. If the temperature of any layer drops below 140 degrees F, or if directed by the ENGINEER, apply tack coat before placing next layer.
F. Unless otherwise indicated on the Plans, asphalt mixtures shall not be handled, spread or windrowed in a manner that will stain the finished surface of any pavement or other improvements.
G. The completed mixture shall be deposited on the prepared subgrade at a uniform quantity per linear foot, as necessary to provide the required compacted thickness without resorting to spotting, picking-up or otherwise shifting the mixture.
H. Spreading:
1. All layers of asphalt pavement shall be spread with an asphalt paver and shall conform to Section 39-3.03 and all applicable referenced sections of the CALTRANS Standard Specifications.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
2. At locations where the asphalt pavement is to placed over areas inaccessible to spreading and rolling equipment, all layers of asphalt pavement shall be distributed directly out of the back of the dump truck and spread by hand. a. Asphalt pavement spread by hand shall be compacted thoroughly to the required lines, grades and cross-sections by means of pneumatic tampers, or by other methods that will produce the same degree of compaction as pneumatic tampers.
I. Compaction:
1. Compaction of asphalt pavement shall conform to Section 39-3.03 and all applicable referenced sections of the CALTRANS Standard Specifications.
2. Minimum required density for each layer of asphalt pavement shall be 95 percent of that obtained in the laboratory according to ASTM Test Method D-1561.
3. Vibratory compaction equipment shall not be used irrespective of the Standard Specifications.
J. Segregation shall be avoided and the surfacing shall be free of pockets of coarse or fine material. Asphalt pavement containing hardened lumps shall not be used.
1. In areas inaccessible to paving and compacting equipment where spreading is done by hand, minimize the amount of segregation.
K. Location of longitudinal joints in the top layer will be determined by the Engineer and shall not adversely affect the quality of the finished product.
L. At all locations, or as directed by the ENGINEER, the asphalt concrete shall be square and at least 1 inch thick when conforming to existing surfacing. Tapering or feathering is not allowed.
3.06 SLURRY SEAL
A. Slurry Seal shall be mixed and spread in conformance with Section 37-3 of the CALTRANS Standard Specifications.
3.07 FIELD QUALITY CONTROL
A. The CONTRACTOR shall control the quality of WORK and shall provide adequate testing to assure compliance with these Specifications.
1. The CITY will arrange and pay for samples to be taken to determine conformance with stability, density, thickness and other specified requirements. The CONTRACTOR shall replace the pavement where samples are removed.
B. All asphalt pavement shall match the grades indicated on the Plans and shall be completely free from unintended hollows and high spots.
1. After completion of paving work, all paving shall be flooded with water. Any ponding that results in standing water greater than 3/4 inches in depth shall be ringed with chalk. Such hollows shall be corrected by removing and replacing the asphalt concrete. The asphalt concrete patch shall be square and at least 1 inch thick when conforming to existing surfacing. Tapering or feathering is not allowed.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) C. The City will arrange and pay for in-place density and compaction tests of the completed pavement in accordance with California Test Method Number 375, to determine compliance with the specified requirements.
1. If compaction fails to meet specified requirements, the CONTRACTOR shall perform remedial work to meet the specified requirements.
2. Retesting:
a. Costs of Retesting: Costs of any retesting required to confirm and verify that remedial work has brought compaction within specified requirements shall be borne by the CONTRACTOR.
b. CONTRACTOR is responsible for compliance testing of remedial work. c. Confirmation Tests during performance of remedial work will be performed in a manner acceptable to the Engineer.
D. Cracks, settling of surface, improper drainage, improper compaction, and sloppy connection to previously laid surfaces will be construed as improper workmanship and will not be accepted.
3.08 MAINTENANCE OF PAVEMENT
A. Upon completion of final rolling, traffic shall not be permitted on the finished pavement for at least 6 hours, or until the asphalt pavement has cooled sufficiently to withstand traffic without being deformed.
3.09 WORKMANSHIP AND WARRANTY
A. Contractor shall provide written warranty against defects in materials or workmanship for a period of not less than 1 year upon completion of Work. ***END OF SECTION***
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PAVEMENT MARKINGS 02750 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 02750
PAVEMENT MARKINGS
PART 1 GENERAL
1.01 SUMMARY
A. Section Includes: All Pavement and Concrete paint, markings, and reflectors.
B. Related Sections:
1. Section 02742 – Asphaltic Concrete Paving
2. Section 02772 – Concrete Curbs, Gutters, and Sidewalks
1.02 REFERENCES
A. State of California Department of Transportation Standard Specifications, latest edition (CALTRANS Standard Specifications).
1. Section 84 –Markings
1.03 WORK RESTRICTIONS
A. Prior to the removal of any of the existing traffic control delineation and markings, the CONTRACTOR shall document existing striping configuration including lane width, type of details, arrows, markings and legends and any other existing delineation for reinstallation.
The CONTRACTOR shall take whatever action is necessary to ensure that said delineation can be accurately replaced at its previous location upon completion of paving operations.
B. If on those streets not designated to be resurfaced, the existing traffic control system is impacted construction activities, the CONTRACTOR shall install traffic tape or paint until the permanent traffic control system can be replaced by the CONTRACTOR.
C. The CONTRACTOR shall provide temporary stop legend and cross-walk replacement as necessary until the permanent installation has been done per direction of the ENGINEER.
1.04 SUBMITTALS
A. The CONTRACTOR is required to provide shop drawings and/or submittals for the following items listed:
1. Thermoplastic Striping Paint
1.05 QUALITY ASSURANCE
A. The CONTRACTOR warrants and guarantees that all material and equipment used or furnished and all workmanship are of the type and quality specified herein. The CONTRACTOR further guarantees that any latent fault in construction or defective material discovered within one year after acceptance of the work shall be remedied by him without cost to the CITY, upon written notice given to him. Other subsequent latent defects shall be covered by responsibilities set forth in the law.
B. In the event of failure to comply with the above-mentioned conditions within a reasonable time after notice, the CITY will have the defects repaired and made good at the expense of 316
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) the CONTRACTOR, who agrees to pay the costs and charges therefore immediately upon demand.
PART 2 MATERIALS
2.01 PAINT AND PROTECTIVE COATINGS FOR TRAFFIC STRIPING, PAVEMENT
MARKING, CURB MARKING, AND RELFLECTIVE MARKERS
A. Paint shall conform to the provisions of Section 84 of Caltrans Specifications.
Thermoplastic paints are required on this project.
B. Paint Colors:
1. Text: White
2. Parking Dividers: White
3. No Parking Curb: Red
4. Directional Arrows: White
5. Driving Lane Dividers: White
6. Intersection Stop Lines: White
7. Crosswalk Lines: White
8. Road Centerlines: Yellow
C. Pavement Markers shall conform to the provisions of Section 85 of Caltrans Specifications.
D. Reflective Markers shall conform to ASTM D7888 Grade 8. Location and type of markers shall conform to Caltrans standard drawings.
PART 3 EXECUTION
3.01 PAINT AND PROTECTIVE COATINGS FOR TRAFFIC STRIPING, PAVEMENT
MARKING, AND CURB MARKING
A. Application of striping, marking, and setting pavement markers shall conform to Sections 84 of Caltrans Specifications, in addition to the requirements in this Section.
B. Remove dirt, oil, grease, and other materials which may affect paint adhesion.
C. Apply paint with specifically designed and manufactured equipment for pavement marking.
Provide:
1. Uniform straight edges without overspray.
2. Six inch wide lines, unless indicated otherwise.
D. Apply paint to obtain thickness recommended by paint manufacturer.
E. Replace removed or damaged control markings, including striping, directional arrows, cross walks, lettering, symbols, and reflective markers in accordance with Caltrans standards. Use stencils for arrows, lettering, and symbols.
***END OF SECTION***
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CCTV INSPECTION 02760 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 02760
CLOSED CIRCUIT TELEVISION (CCTV) INSPECTION
PART 1 - GENERAL
1.01 SUMMARY
A. Section Includes: Closed circuit television (CCTV) inspection of sanitary sewer pipes.
B. Related Sections:
1. Section 02700 – PVC Pipe and Fittings
2. Section 02710 – HDPE Pipe and Fittings
3. Section 02720 – Ductile Iron Pipe and Fittings
1.02 DEFINITIONS
A. NASSCO: National Association of Sewer Service Companies.
B. PACP: Pipeline Assessment Certification Program.
C. MACP: Manhole Assessment and Certification Program
1.03 SUBMITTALS
A. Inspections on hard drive at the completion of inspection:
1. Inspection videos saved in MPEG format or Windows Media video format.
2. Electronic version (.pdf) of the pipe inspection reports.
3. PACP export pipe inspection database (.mdb).
4. Inspection digital photographs in JPEG format.
1.04 DELIVERY, STORAGE, AND HANDLING
A. Storage and Protection: Protect from segregation and excessive moisture during delivery, storage, and handling.
PART 2 - PRODUCTS
2.01 EQUIPMENT
A. Closed Circuit Television Camera:
1. The television camera used for the inspection shall be one specifically designed and constructed for sanitary sewer inspection with an accurate footage counter. Lighting for the camera shall be suitable to allow a clear picture of the entire periphery of the pipe. The rotating camera and lighthead configuration shall provide 240 degrees of pan and tilt angle measuring centerline to centerline and 70 degree lens viewing angle.
2. The camera shall be color and shall provide a minimum of 1280H x 720W pixels for a total of 921,600 pixels at 30 frames per second resolution. Geometrical distortion of the image shall not exceed one percent (1%).
3. The color camera shall be equipped with the necessary circuitry to allow for the remote adjustment of the optical focus and iris from the power control unit at the viewing station. 318
CCTV INSPECTION 02760 - 2
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) B. Video Capture System:
1. The video and audio recordings of the sewer inspections shall be made using digital video equipment. A video enhancer may be used in conjunction with, but not in lieu of, the required equipment. The digital recording equipment shall capture sewer inspection on hard drive, with each sewer reach inspection recorded as an individual movie file (.MPEG, .MPG, or .WMV) or approved equal.
2. The video file name shall contain both the upstream and downstream manhole number and date of inspection.
3. The video file names will be referenced in the inspection database and in an inspection report generated in PDF format. The pipeline collection and real time video capture and data acquisition systems shall be provided.
4. The system shall use the most current PACP compliant application software and shall be fully object oriented or approved equal. It shall be capable of printing pipeline inspection reports with captured images of defects or other related significant visual information on a standard color printer.
5. The imaging capture system shall store digitized color picture images and be saved in digital format on a hard drive or approved equal storage device. Also, this system shall have the capability to supply the City with inspection data reports for each line segment.
6. The contractor's equipment shall have the ability to "Link". “Linking” is defined as storing the video time frame code with each observation or defect with the ability to navigate from/to any previously recorded observation or defect instantaneously.
7. The system shall be able to produce data reports to include, at a minimum, all observation points, and pertinent data. All data reports shall match the defect severity codes in accordance with PACP naming conventions.
8. Camera footage, date, & manhole numbers shall be maintained in real time and shall be displayed on the video monitor as well as the video character generators illuminated footage display at the control console.
9. The audio portion shall be sufficiently free of background and electrical noise so as to produce an oral report that is clear and discernible.
10. Acceptable Inspection software includes Pipeline Observation System Management (POSM) or approved equal.
11. The CCTV equipment/software shall be capable of producing digitized images of all sewer line defects, manhole defects, and sewer line service connections in .jpeg format.
CONTRACTOR shall plan to take digital still images of each defect, construction features and service connection to clearly depict it. More images may be necessary depending upon the condition of the pipe.
2.02 REPORTING CAPABILITIES
A. The following information is mandatory for all inspections:
1. Inspection Information – Refers to the area of pipe to be inspected between two manholes or the address of the lateral to be inspected.
a. Project Name;
b. Surveyed by (Operator/Surveyor’s name);
c. Operator/Surveyor Certificate number;
d. Date;
e. Time;
f. Street Name and Number;
g. Additional Location Information (e.g. backyard, parking lot, etc.); h. Upstream Manhole Number (City standard Asset Number); i. Upstream MH rim to invert (depth);
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) j. Downstream Manhole Number (City standard Asset Number); k. Downstream MH rim to invert (depth);
l. Direction of inspection (Upstream or Downstream);
m. Flow control (e.g. plugged, lift station, bypassed, not controlled); n. Type of Pipe;
o. Pipe Size;
p. Pipe Material;
q. Lining Material (for lined sewers);
r. Purpose of Inspection (pre-construction, post construction, etc.) s. Pre Cleaning (jetter, heavy cleaning, no pre-cleaning); t. Weather;
u. Additional information/Comments
2. Observation Data – Refers to the portion of pipe where an observation is discovered.
Observations shall be noted by text descriptions and defect code number using PACP defects codes, still frame pictures and video clips captured and recorded. Each observation shall include the following:
a. Actual observation footage;
b. Location and clock position of any defects;
c. Location and clock position of any connection;
d. Code (Group/Descriptor/Modifier/Severity)
e. Whether it is a continuous defect
f. Whether the defect occurs at a joint
g. Severity level;
h. Counter;
i. Final footage;
j. Video clip ID for each observation
k. Image reference (file name of photos)
l. Remarks (as appropriate or needed)
3. Formats - Standard and/or custom designed reports shall have the following formats available and shall be able to be produced in hard copy or viewed on the monitor. a. Site Observation: Displays detailed site observation reports in landscape or portrait views.
b. Directory Report: Displays a list of all the projects sorted by pump station number and manhole number
c. Picture Reports: Displays site data and include full size single photos or half size double photos of discrepancies
d. Pipe Run: Displays a graphical display of the site indicating footage, observations, and comments.
e. Project Data: Displays the project, client, and contractor information. f. Custom Sort: Creates user-defined reports of selected site, project, and observation data.
PART 3- EXECUTION
3.01 GENERAL
A. Sewers shall be cleaned by contractor within 24 hours prior to performing inspection.
B. Inspection of newly installed sewers (not yet in service) shall not begin prior to completion of the following:
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1. Deflection pipe testing
2. All manhole work, including installation of inverts
3. Installation of all lateral services
C. After the sewer main and/or lateral cleaning operation is completed, the line sections shall be visually inspected internally by means of color closed-circuit television. The television inspection shall be performed one line section at time.
D. The camera shall pan the periphery of the start and finish manhole from casting to invert. To achieve this, the CCTV camera operator shall pan and zoom the manhole to obtain the best possible image of the manhole, including the wall, cone and chimney section(s).
E. The depth of each manhole shall be measured to the nearest 1/10th of a foot and documented on the inspection forms. Estimates of manhole depths will not be accepted.
F. The CCTV camera shall be positioned as close to the spring line as possible while maintaining the required equipment stability.
G. Wherever possible the inspections shall be performed in the upstream to downstream direction.
All sewer segments shall be recorded in a logical order in the same direction they are cleaned and televised.
H. When sewer conditions prevent forward movement of the camera, the camera shall be withdrawn, and CONTRACTOR shall televise the line from the opposite direction.
I. The camera shall be directed through the sewer in a downstream direction, with the flow, at a uniform, slow rate. In no case will the video camera record while moving at a speed greater than 30 feet per minute. If, during the course of the project, the inspection is rejected due to camera speeds exceeding 30 feet per minute, the inspection recordings shall be redone, at no additional cost to the City.
J. Flow levels within existing sewers to be inspected shall not exceed 5% of the pipe diameter. If water levels prevent adequate televising of the sewer, then conducting the work during low flow periods or other methods like plugging and bypass pumping shall be implemented.
K. For inspection of new sewers (not yet in service), the CONTRACTOR shall introduce clean water into the upstream manhole and keep water flowing until flow is observed at the downstream manhole location.
L. The survey unit shall be slowed, stopped, or backed-up to perform detailed inspections of significant features. The camera shall be stopped at all defects, changes in material, water level, size, side connections, manholes, junctions, or other unusual areas. When stopped at the defect or feature, the operator shall pan the camera to the area and along the circumference of the pipe.
When stopped at a connection the camera shall pan to look into the connected pipe.
M. The camera unit shall be paused long enough at areas suspected of leaking to determine if a leak exists currently or if deposits have occurred.
N. The operator shall also record audio of the type of defect or feature, clock position, footage, extent or other pertinent data.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) O. Audio shall be recorded during each inspection by the operating technician, and shall include the sewer location (address), identification of beginning and terminating manholes, inspection direction, length of inspection, side sewer identification, flow information, complete descriptions of the sewer line conditions as they are encountered, reason for termination, and other relevant commentary to the inspections. Voice descriptions should be made:
1. At points of pipe failure or weakness,
2. At points of infiltration,
3. At service connections,
4. Where unusual conditions are noted, and
5. Where digital still photos are taken
P. Audio reports shall include the distance traveled on the specific run, a description of abnormal conditions in the sewer and side sewer connections as they are encountered, explanations for pausing, backing up, or stopping the survey, and the final measured center to center distances between consecutive manholes. The audio portion of the composite video shall be sufficiently free from electrical interference and background noise to provide complete intelligibility of the oral report. Audio dubbing after the inspection is prohibited.
Q. If the video and/or audio recording is of poor quality, the City has the right to require a resubmittal of the sewer and no payment will be made until an acceptable video and audio recording is made and accepted by the City.
R. The contractor shall be responsible for all traffic control measures required to perform the work.
3.02 PRE-CONSTRUCTION INSPECTION
A. Procedure:
1. Prior to construction the entire existing gravity sewer line (from manhole to manhole) shall be televised. The pre-construction inspection shall be used to determine lateral locations and depths.
2. The camera shall be moved through the line in either direction at a moderate rate, stopping when necessary to permit documentation. In no case will the television camera be pulled at a speed greater than 30 feet per minute. Manual winches, power winches, TV cable, and power rewinds or other devices that do not obstruct the camera view or interfere with proper documentation of the sewer conditions shall be used to move the camera through the sewer line. If, during the inspection operation, the television camera will not pass through the entire manhole section, the contractor shall set up his equipment so that the inspection can be performed from the opposite manhole (reverse set-up).
3. When manually operated winches are used to pull the television camera through the line, telephones, radios or other suitable means of communication shall be set up between the two manholes of the section being inspected to insure good communication between members of the crew.
4. The importance of accurate distance measurements is emphasized. The location of laterals shall be within one (1) foot.
5. During the internal inspection the television camera shall be temporarily stopped at each lateral along the line. The contractor shall record the location. Flows from service connections that are determined to be infiltration/inflow shall also be recorded.
B. Documentation:
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1. Television Inspection Logs - Printed location records shall be kept by the contractor and will clearly show the location in relation to an adjacent manhole of each lateral. In addition, other points of significance such as locations of unusual conditions, roots, storm sewer connections, broken pipe, presence of scale and corrosion, and other discernible features will be recorded and a copy of such records shall be supplied to the City. The contractor shall record all visuals observations on a “Television Inspection Report” form.
2. Once recorded, the digital data shall be labeled and become the property of the City.
The contractor shall have all readings and necessary playback equipment readily accessible for review by the City during the project.
3. The Contractor shall deliver pre-construction inspections to the City for review prior to proceeding with the proposed work.
3.03 POST CONSTRUCTION INSPECTION
A. Procedure:
1. After the sewer line installation has been completed, the entire sewer line from manhole to manhole shall be televised. The post construction inspection shall be used to determine whether or not all of the approved sewer line defects and infiltration sources previously located have been fully repaired to the satisfaction of the City.
2. All new gravity sewer and force mains shall be CCTV inspected.
3. The camera shall be moved through the line in either direction at a moderate rate, stopping when necessary to permit documentation of the sewer’s condition. In no case will the television camera be pulled at a speed greater than 30 feet per minute. Manual winches, power winches, TV cable, power rewinds, or other devices that do not obstruct the camera view or interfere with proper documentation of the sewer conditions shall be used to move the camera through the sewer line. If, during the inspection operation, the television camera will not pass through the entire manhole section, the contractor shall set up his equipment so that the inspection can be performed from the opposite manhole or direction.(reverse-setup)
4. When manually operated winches are used to pull the television camera through the line, telephones, radios or other suitable means of communication shall be set up between the two manholes of the section being inspected to insure good communication between members of the crew.
5. The importance of accurate distance measurements is emphasized. The location of defects shall be within one foot.
6. During the internal inspection the television camera shall be temporarily stopped at each repair. The camera shall also be stopped at any unnoticed or non-repaired point source of infiltration.
3.04 SEWER BYPASSING AND DEWATERING
A. Contractor shall be responsible for bypassing sewer flow around his work and dewatering of sewer lines in accordance with the requirements of Section 01531. Where sags or submerged sections of the sewer are encountered during TV inspection, the contractor shall first complete inspection of the entire reach to determine the extent of such areas prior to dewatering the sewer. Dewatered sections of the sewer shall then be TV inspected.
B. On all sewer mains which have sags or dips, to an extent that the television camera lens becomes submerged during the television inspection, the contractor shall use a high pressure 323
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) cleaner to draw the water out of the pipe, or other means, to allow inspection of the pipe and identification of pipe defects, cracks, holes and location of service connections.
3.05 LINEAR MEASUREMENT
A. The CCTV camera location footage counter shall be zeroed at the beginning of each inspection. The survey unit location entered on the footage counter at the start of the inspection shall allow for the distance from the accepted start of the length of the sewer to the initial point of observation of the camera (pre-set footage). In the case of resuming an inspection at an intermediate point within a sewer reach, the footage counter shall be set to start at the distance from the upstream maintenance hole to that point, as previously recorded by the counter. The CONTRACTOR shall ensure that the footage counter starts to register immediately when the survey unit starts to move.
B. The lateral camera shall be pushed from cleanouts to the sewer main and be equipped with a footage counter to display and record inspection footage. Maximum rate of travel shall be 30 feet per minute when recording.
C. Prior to commencing inspections, the CONTRACTOR shall demonstrate compliance with the linear measurement tolerance specified below:
1. After the sewer line rehabilitation has been completed, the entire sewer line from manhole to manhole shall be televised. The post construction inspection shall be used to determine whether or not all of the approved sewer line defects and infiltration sources previously located have been fully repaired to the satisfaction of the City.
2. The camera shall be moved through the line in either direction at a moderate rate, stopping when necessary to permit documentation of the sewer’s condition. In no case will the television camera be pulled at a speed greater than 30 feet per minute. Manual winches, power winches, TV cable, power rewinds, or other devices that do not obstruct the camera view or interfere with proper documentation of the sewer conditions shall be used to move the camera through the sewer line. If, during the inspection operation, the television camera will not pass through the entire manhole section, the contractor shall set up his equipment so that the inspection can be performed from the opposite manhole or direction.(reverse-setup)
3.06 CCTV MONITOR DISPLAY
A. The images displayed on the CCTV monitors will be a view of the pipe above the water surface as seen by the CCTV camera as the unit is conveyed through the sewer.
B. The camera lighting shall be fixed in intensity prior to commencing the survey and the white balance set to the color temperature emitted. In order to ensure color constancy, no variation in illumination shall take place during the survey.
C. The video equipment shall be checked using an approved test card with a color bar prior to commencing each day's survey. The camera shall be positioned centrally and parallel to the test card at a distance where the full test card just fills the monitor screen. The card shall be illuminated evenly and uniformly without any reflection. 324
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3.07 DATA DISPLAYS
A. The CCTV images shall include an initial data display that identifies the sewer reach being surveyed and a survey status display that provides continuously updated information on the location of the survey unit as the survey is being performed. These data displays shall be in alphanumeric form. The size and position of the data shall not interfere with the main subject of the monitor picture.
B. The on-screen display should be white during inspections where the background behind the display is dark and, conversely, black where the background is light.
C. At the beginning of each reach of sewer being inspected, the following information shall be electronically generated and displayed on the CCTV monitors as well as included in the audio track:
1. Date of survey
2. Inspection company name and inspector
3. Street name or location
4. Manhole number to manhole number (in order of inspection)
5. Direction of survey (upstream or downstream)
6. Time of start of survey
D. During inspections, the following information shall be electronically generated, automatically updated, and displayed on the CCTV monitors:
1. Survey unit location in the sewer line in feet and tenths of feet from adjusted zero
2. Sewer diameter
3. Upstream and downstream manholes reference numbers as per approved drawings
3.08 MANHOLE NUMBERING AND DEFECT CODES
A. The Contractor will be required to use the manhole numbering as shown on the contract drawings.
B. The defect codes, inspection forms, inspection database and inspection protocols shall be in accordance with the National Association of Sewer Service Companies (NASSCO) Pipeline Assessment and Certification Program (PACP).
***END OF SECTION***
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 02770
SANITARY SEWER TESTING
PART 1 GENERAL
1.01 SUMMARY
A. Section Includes:
1. Testing of sanitary sewer systems.
B. Related Sections:
1. Section 02318 – Trenching.
2. Section 02700 – Polyvinyl Chloride (PVC) Pipe and Fittings
3. Section 02710 – High Density Polyethylene (HDPE) Pipe and Fittings
4. Section 02720 – Ductile Iron Pipe and Fittings
5. Section 02760 – Closed Circuit Television (CCTV) Inspection.
6. Section 03301 – Cast in Place Concrete
7. Section 03400 – Precast Concrete
1.02 REFERENCES
A. American Society for Testing and Materials (ASTM):
1. C 969 – Standard Practice for Infiltration and Exfiltration Acceptance Testing of Installed Precast Concrete Pipe Sewer Lines
2. C 1091-03a – Test Method for Hydrostatic Infiltration Testing of Vitrified Clay Pipe Lines
3. F 1417 – Standard Practice for Installation Acceptance of Plastic Non-pressure Sewer Lines Using Low-Pressure Air
4. F 2164 – Standard Practice for Field Leak Testing of Polyethylene (PE) and Crosslinked Polyethylene (PEX) Pressure Piping Systems Using Hydrostatic Pressure
5. D 3034 – Specification for Type PSM Poly (Vinyl Chloride) (PVC) Sewer Pipe and Fittings
6. F 1667 – Guide for Construction Procedures for Buried Plastic Pipe B. Uni-Bell PVC Pipe Association
1. B-6 – Recommended Practice for low Pressure Air Testing of Installed Sewer Pipe PART 2 PRODUCTS
2.01 GENERAL
A. Mandrels, temporary plugs, bypass pumping, low-pressure testing equipment and all other necessary materials shall be provided by the Contractor, subject to the City’s approval. All testing shall be performed by the Contractor in the presence of the City’s representative. No materials shall be used which would be injurious to the public, personnel, adjacent improvements or the pipeline.
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2.02 PRESUUSRE GAUGES
A. Pressure gauges shall be laboratory-calibrated test gauges and shall be recalibrated by a certified laboratory prior to the leakage test. Gauge shall be easy to read in no more than one (1) pound per square inch (psi) increments and have a maximum full-scale range of five (5) psi.
PART 3 EXECUTION
3.01 PIPE SHAPE AND DEFLECTION TESTING FOR GRAVITY SEWER A. Deflection testing shall be performed after the trench has been completely backfilled and compacted.
B. Newly installed pipe (8) inches in diameter or larger gravity sewer pipe shall be tested for deflection, joint displacement, or other obstruction by passing a rigid mandrel through the pipe.
C. The mandrel shall be a full circle, rigid, non-adjustable, an odd-numbered leg (9 leg minimum), approved by the Engineer as to design and manufacturer. Mandrel size shall meet the minimum requirements set forth in ASTM D 3034 and ASTM F 679. The circular cross section of the mandrel shall have a diameter of at least ninety five percent (95%) of the specified average inside diameter of the pipe and the minimum length of the circular portion of the mandrel shall be equal to the nominal diameter of the pipe.
D. Where obstructions and excessive deflection are encountered by the mandrel, the Contractor shall remove, replace, and retest the deficient section. Re-rounding will not be allowed.
3.02 LEAKAGE TESTING FOR GRAVITY SEWER
A. Pipe leakage testing shall be performed after the pipe has been installed and prior to replacing laterals.
B. Testing shall be performed in the presence and under the direction of the City or its appointed Representative, prior to re-connecting laterals.
C. All plugs shall be adequately braced and restrained to support the full load developed.
No workers shall be allowed in the excavation or manhole while the line is under pressure. The Contractor shall make provisions for reading the pressure at the ground surface and for safely releasing the air pressure without entering the manhole or excavation.
D. If any leaks are found, the air pressure shall be released, the leaks eliminated, and the test procedure re-started.
E. The following procedure shall be used for air testing:
1. Plug all pipe outlets with suitable test plugs. Brace each plug securely.
2. If the pipe to be tested is submerged in groundwater, insert a pipe probe by boring or jetting into the backfill material adjacent to the center of the pipe, and determine the pressure in the probe when air passes slowly through it. This is the backpressure due to groundwater submergence over the end of the probe. All gauge pressures in the test shall be increased by this amount. 327
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3. Add air slowly to the portion of the pipe being tested until the internal pressure is raised to 4.0 psig.
4. After an internal pressure of 4.0 psig is obtained, allow at least two (2) minutes for air temperature to stabilize, adding only the amount of air required to maintain pressure. After two (2) minute period, disconnect the air supply.
5. Check exposed pipe and plugs for abnormal leakage by coating with a soap solution. If any leakage is observed, bleed off air and make necessary repairs.
6. Begin the test period. In no case shall the air pressure within the line be less than four (4) pounds per square inch at the beginning of the test period.
7. Main Sewers:
a. If the pressure drop during the required test period equal to or less than 1 psi (6.9 kPa), the line has passed. If the pressure drop is greater than 1 psi (6.9 kPa) during the test time, the line has failed the test. b. The required test time shall be based on the diameter and length of pipe to be tested and in accordance with the following, or 10 minutes, whichever is greater:
Minimum Test Time for Various Sewer Main Pipe
Sizes
Nominal
Pipe Size
(inches)
Minimum
Time
(min:sec)
Length
for
Minimum
Time (ft)
Time for
Longer Length
(sec)
4 3:46 597 0.380L
6 5:40 398 0.854L
8 7:34 298 1.520L
10 9:26 239 2.374L
12 11:20 199 3.418L
15 14:10 159 5.432L
18 17:00 133 7.692L
21 19:50 114 10.470L
24 22:40 99 13.674L
L = Length in feet
c. At the City’s option, one half of the test time specified above may be used with a maximum pressure drop of 0.5 psi (3.45kPa).
F. TEST REPORT: Contractor shall prepare and submit a report detailing all pipes tested.
The report shall include the pipe location, pipe size, upstream and downstream manhole ID, testing date, testing pressure, pressure drop, test time, and test date. The report shall be submitted to the City within one week of performing the test. The City will review the report and if acceptable the City will sign the report for acceptance of the test.
3.03 ALLOWABLE PIPELINE SAG FOR GRAVITY SEWER
A. For new gravity sewer piping installed, if it is determined that a sag is present during the post-installation CCTV inspection and the sag depth is equal to or greater than ten (10) percent of the new pipe inside diameter, the contractor shall repair the sag at no additional cost to the City.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) B. The Contractor shall re-perform testing as specified herein and post-installation CCTV inspection after the pipeline sag has been repaired. All costs associated with re-testing and re-inspection of the pipeline shall be borne by the Contractor.
3.04 MANHOLE TESTING
A. All new concrete manholes shall be vacuum tested by the Contractor for leakage after installation and prior to backfilling. Testing shall be performed in the presence and under the direction of the City or its appointed Representative.
B. Prior to vacuum testing, all manholes shall be visually inspected. All defects shall be repaired by the Contractor, with grout, to the satisfaction of the City or the City’s Representative.
C. All pipes entering the manhole shall be sealed at a point outside the manhole walls so as to include testing of the pipe/manhole joints.
D. A vacuum of ten (10) inches of mercury shall be drawn on the manhole, the valve on the vacuum line of the test hood closed and the vacuum pump shut off. The manhole shall be deemed to have passed the test if the vacuum drop is less than one (1) inch of mercury during the required test period. The minimum duration of the test period shall be based on the inside diameter of the manhole and shall conform to the following table:
Vacuum Test Time for Manholes
Manhole Inside
Diameter
(inches)
Test Time
(seconds)
48 60
60 75
72 90
E. If the manhole does not pass the vacuum testing, then the Contractor shall either replace the manhole or make the necessary repairs and re-test at no additional Cost to the City.
F. TEST REPORT: Contractor shall prepare and submit a report detailing all manholes tested. The report shall include the manhole location, manhole ID, testing date, testing pressure, pressure drop, test time, and test date. The report shall be submitted to the City within one week of performing the test. The City will review the report and if acceptable the City will sign the report for acceptance of the test.
3.05 WET WELL TESTING
A. Precast concrete wet well shall be hydrostatically leak tested prior to acceptance and prior to coating as specified below:
1. Test Procedure:
a. Plug all inlets and outlets with temporary plugs
b. Fill structure with water
c. Let stand for 24 hours
d. Fill to rim of structure
e. Let stand for 2 hours
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) f. Calculate water loss. Leakage shall not exceed 0.1 gallon per hour per foot of water depth during the test.
2. Repair all structures which do not meet the test requirement. Re-test structure until it passes.
3.06 CCTV VIDEO INSPECTION
A. All new sewer gravity mains and force mains shall be visually inspected using CCTV video inspection in accordance with specification Section 02760.
3.07 FORCE MAIN TESTING
A. Testing of new force main carrier pipe shall be in accordance with ASTM F2164.
Contractor shall provide all equipment and personnel necessary to properly test. Testing shall be done in the presence of the City inspector.
B. Testing shall be done after the pipe has been fused, installed, and backfilled. Ensure thrust restraints have been installed and allow sufficient time for any required concrete thrust blocks to achieve required sufficient strength. Ensure fused joints have sufficiently cooled.
C. Testing shall not be done only when the temperature of pipe is 80 degree Fahrenheit or less.
D. Testing against closed valves is not allowed. Contractor shall install blind flanges for isolation.
E. Testing Procedure:
1. Fill the pipeline with water at a maximum velocity of 10-feet per minute and bleed off any trapped air (testing with air will not be acceptable).
2. Gradually increase the pressure so the lowest element in the system achieves a test pressure that is 1.5 times the pipe design pressure or 150 psi, whichever is less.
Monitor pipe for any leaks.
3. Provide additional water to maintain sufficient test pressure. After the pipe has been pressurized at test pressure for 4 hours, testing can begin.
4. To test, reduce test pressure by 10 psi and stop adding test liquid. Monitor the pressure for 1 hour. Test pressure shall remain within 5% of the target value, and no visual leakage shall occur. If pipe does not pass these requirements, contractor shall repair leaks and retest the pipe.
F. Under no circumstance shall the pipe be pressurized over the design pressure for more than 8 hours. If the test is not complete within this time limit, the pipeline shall be depressurized at or below the design pressure and allowed to “relax” for at least 8 hours before testing.
***END OF SECTION***
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CONCRETE CURBS, GUTTERS, AND SIDEWALKS 02772 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 02772
CONCRETE CURBS, GUTTERS, AND SIDEWALKS
PART 1 - GENERAL
1.01 SUMMARY
A. Section Includes: Concrete curbs, gutters, sidewalks, driveways, access ramps, and alley intersections to replace those demolished or damaged during construction B. Related Sections:
1. Section 02200 - Excavation and Backfill.
2. Section 02722 - Aggregate Base.
3. Section 03100 - Concrete Formwork and Accessories.
4. Section 03301 - Cast-In-Place Concrete.
1.02 SUBMITTALS
A. Product Data: Submit data completely describing all products to be used.
1.03 PROJECT CONDITIONS
A. Any concrete flatwork damaged during the course of construction, including transportation and delivery, shall be replaced to that flatwork’s pre-existing condition or better.
B. Contractor shall be responsible for all field measurements necessary to meet these specifications.
PART 2 PRODUCTS
2.01 MATERIALS
A. Concrete: Shall conform to the applicable requirements of Section 03301. All sidewalk and curb concrete shall contain 1 lb. of lamp black per cubic yard.
B. Curb Finishing Mortar: 1 part portland cement to 2 parts sand.
C. Form Release Material: Light oil or other releasing agent of concrete type that does not discolor concrete or interfere with the application of finishing mortar to curb tops and faces.
D. Joint Materials:
1. Expansion: Comply with requirements as specified in Section 03100.
2. Construction: Steel dividers or plastic inserts.
PART 3 - EXECUTION
3.01 EXAMINATION
A. Verification of Conditions:
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1. Verify field conditions, including subgrade condition and interferences, before beginning construction.
3.02 DEMOLITION
A. Concrete Removal:
1. Concrete shall be removed to neatly saw cut edges at the nearest existing score line unless directed otherwise by the Engineer.
3.03 PREPARATION
A. Surface Preparation:
1. Subgrade:
a. Construct and compact true to grades as specified in Section 02200. b. Remove soft or unsuitable material to depth of not less than 6 inches below subgrade elevation and replace with satisfactory material.
2. Forms and Subgrade: Water immediately in advance of placing concrete.
3.04 INSTALLATION
A. Special Techniques:
1. Contractor's Option:
a. Construct concrete curbs and gutters by conventional use of forms, or by means of curb and gutter machine when acceptable to the Engineer. b. When use of machines designed specifically for work of this Section are accepted by the Engineer, results must be equal to or better than those produced by use of forms.
c. Applicable requirements of construction that apply to use of forms also apply to use of machines.
d. Discontinue use of machines when results are not satisfactory to the Engineer.
B. Reinforcement:
1. Drill 5/8-inch diameter holes, 6-inches deep, on 24-inches on center along the face of the saw cut concrete and install 12-inch long #4 rebar into the drilled holes and secure with epoxy.
C. Forms:
1. Carefully set to line and grade and securely stake in position forms conforming to dimensions of items to be constructed.
2. Thoroughly clean prior to each use and coat with form releasing material.
D. Expansion and Contraction Joints:
1. Expansion Joints:
a. Construct vertically, and at right angles to centerline of street and match joints in adjacent pavement or sidewalks.
b. Constructed at radius points, driveways, alley entrances, and at adjoining structures.
c. Fill joints with expansion joint filler material.
2. Contraction Joints:
a. Constructed not more than 15 feet apart.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) b. Make joints of construction joint material, scoring or saw cutting to depth of not less than 1-1/2 inches and matching joints in adjacent pavement or sidewalk.
E. Wheelchair Ramps
1. All wheelchair ramp construction shall include new depressed curb and gutter, raised truncated dome pattern with yellow detectable warning surface, installing and compacting 6” of aggregate base and installing and compacting 6” thick AC plug.
F. Concrete:
1. Placing:
a. Thoroughly spade concrete away from forms so that no rock pockets exist next to forms and so that no coarse aggregate will show when forms are removed.
2. Compacting:
a. Compact by mechanical vibrators accepted by the Engineer. b. Continue tamping or vibrating until mortar flushes to surface and coarse aggregate is below concrete surface.
3. Form Removal:
a. Front Form Faces: Do not remove before concrete has taken initial set and has sufficient strength to carry its own weight.
b. Gutter and Rear Forms: Do not remove until concrete has hardened sufficiently to prevent damage to edges.
4. Finishing and Curing:
a. As soon as curb face forms are stripped, apply finishing mortar to the top and face of curb and trowel to a smooth, even finish. Finish with fine haired broom in direction of work.
b. Where curb is installed without integral gutter, extend finish 2 inches below grade.
c. Edge concrete at expansion joints to 1/4-inch radius. d. Flow lines of gutters shall be troweled smooth 4 inches out from curb face for integral curb and gutter and 4 inches on both sides of flowline 4 gutters without curbs.
G. Backfilling:
1. Unless otherwise specified, backfill behind curbs, gutters, or sidewalks with soil native to area.
3.05 FIELD QUALITY CONTROL
A. Tests:
1. Curbs and Gutters:
a. Test face, top, back, and flow line with 10-foot straightedge or curve template longitudinally along surface.
b. Correct deviations in excess of 1/4 inch.
2. Gutters:
a. Frequency of Testing: When required by the Engineer, where gutters have slope of 0.8 foot per hundred feet or less, or where unusual or special conditions cast doubt on capability of gutters to drain.
b. Test Method: Establish flow in length of gutter to be tested by supplying water from hydrant, tank truck, or other source.
c. Required Results:
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) 1) 1 hour after supply of water is shut off, inspect gutter for evidence of ponding or improper shape.
2) In event water is found ponded in gutter to depth greater than ½-inch or on adjacent asphalt pavement, correct defect or defects in manner acceptable to the Engineer without additional cost to the Contract.
3.06 ADJUSTING
A. Repair portions of concrete damaged while stripping forms or, when damage is severe, replace such work at no additional cost to the Contract. Evidence of repairs shall not be noticeable in the finished product.
B. Remove and replace sections of work deficient in depth or not conforming to requirements indicated herein at no additional cost to the Contract. Removal and replacement shall be the complete section between 2 joints.
***END OF SECTION***
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 02830
CHAIN LINK FENCING
PART 1 GENERAL
1.01 DOCUMENTS
The General Conditions and all other Contract Documents for this project are complementary and applicable to this Section of the Specifications.
1.02 SCOPE OF WORK
A. Install new chain link fencing in the locations shown on the plans.
B. The intent of this specification is to provide for a complete installation in a workmanlike and professional manner. Not all required materials, installation procedures, or hardware may be specifically referred to.
1.03 RELATED WORK SPECIFIED ELSEWHERE
A. Section 02200 - Excavation and Backfill.
B. Section 03301 - Cast in Place Concrete.
1.04 REFERENCE STANDARDS
A. American Society for Testing and Materials (ASTM):
1. A36 – Structural Steel
2. A53 – Pipe, Steel, Black, and Hot-Dipped, Zinc-Coated Welded and Seamless.
3. A123 – Zinc (Hot-Dipped Galvanized) Coatings on Iron and Steel Products.
4. A153 – Zinc Coating (Hot-Dip) on Iron and Steel Hardware.
5. A392 – Zinc-Coated Steel Chain-Link Fence Fabric
6. A817 – Metal-Coated Steel Wire for Chain-Link Fence Fabric and Marcelled Tension Wire.
7. F567 – Installation of Chain-Link Fence.
8. F626 – Fence Fittings,
9. F900 – Industrial and Commercial Swing Gates.
10. F1043 – Strength and Protective Coating on Metal Industrial Chain-Link Fence Framework.
11. F1083 – Pipe, Steel, Hot-Dipped Zinc-Coated (Galvanized) Welded, for Fence Structures
1.05 SUBMITTALS
A. Submit product data for all components and accessories.
1. Size, coatings, colors, etc.
2. Manufacturer’s Literature and Data: Chain link fencing, gates and all accessories
3. Manufacturer’s Certificates: Coating complies with specifications. 335
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) B. Submit shop drawings showing layout dimensions, spacing of components, post footing dimensions, and anchorage and installation details. Locations of post and gates shall be clearly indicated.
1.06 WARRANTY
A. Provide a 10-year warranty for factory finish against cracking, peeling, and blistering under normal use.
PART 2 PRODUCTS
2.01 MATERIALS
A. Posts and Rails: ASTM A53 steel hot-dipped galvanized.
B. Fabric: A392 knuckled top and bottom. Single width fabric to full height of fence. Nine (9) gauge finished wire size, mesh to match the existing, adjacent fence. Class 1 chain link fence fabric with 1.2 ounces of zinc coating per square foot of uncoated wire surface shall be used.
C. Truss Rods: 3/8" diameter, steel rod, galvanized with truss tightener.
D. Ties: 9 gauge galvanized wire.
E. Bars, Band, Clips, Bolts, Fittings, and Hardware: Galvanized.
F. Tension Wire: 7 gauge coil spring galvanized.
G. Malleable Tops: For all corner, gate and terminal posts, galvanized.
H. Accessories and Hardware: Galvanized.
I. Privacy Slats: Privacy slats shall be PVC or HDPE with UV inhibitors, provide 85% or greater privacy. Color shall be dark green.
PART 3 EXECUTION
3.01 PREPARATION
A. Prior to fabrication, field-verify required dimensions.
B. Fence manufacturer shall submit footing dimensions for approval.
1. Allow 8 inches minimum post embedment.
2. Allow 6 inches minimum concrete beneath post bottom.
C. Provide post holes to the depth and diameter shown on the manufacturer’s printed installation instructions. Clear loose material from post holes. 336
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3.02 INSTALLATION
A. Install fencing in accordance with manufacturer's installation instructions and approved shop drawings.
B. Install fence posts plumb and level by embedding post directly in concrete footing.
Temporarily brace fence posts with until concrete is set.
1. Concrete footings shall conform to Section 03301 - Cast-in-Place Concrete.
2. Thoroughly compact concrete so it is free of voids and finished in a slope or dome to divert water running down the post away from the footing.
3. Cure concrete a minimum of 72 hours before any further work is done on the posts.
C. Do not install bent, bowed, or otherwise damaged panels. Remove damaged components from site and replace.
D. Secure fence panels with stainless steel bolts to fence posts.
E. Securely install privacy slats to achieve 85% minimum privacy screening.
F. Do not install bent, bowed, or otherwise damaged panels. Remove damaged components from site and replace.
3.03 HANDLING
Care shall be taken in handling, transporting and placing fence materials to prevent damage. No damaged materials will be accepted until and unless the damage has been repaired to the satisfaction of the City. Damaged materials will be replaced at the City’s discretion.
** END OF SECTION **
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 03000
CONCRETE WORK - GENERAL
PART 1 GENERAL
1.01 APPLICABLE SECTION
A. Submit Shop Drawings, Product Data, Mill Certificates, and Samples required by other portions of Contract Documents. The requirements/provisions of the General and Supplementary Conditions shall apply to this section.
1.02 DESCRIPTION OF WORK
A. The work included under this section consists of furnishing all material, supplies, equipment, tools, transportation, and facilities, and performing all labor and services necessary for, required in connection with or properly incidental to furnishing, and installing concrete work as described in this section of the specifications, shown on the accompanying drawings, or reasonably implied therefrom, except as hereinafter specifically excluded.
B. Work Included:
1. All formwork, including any special forms necessary to produce architectural details and/or to accommodate the work of others and removal of forms.
2. All concrete reinforcement, placement, bending and forming thereof.
3. All concrete and cement finishing; all surface treatment and curing, including nonslip finishes and color work.
4. Installation of all reglets, bolts, anchors, cans, sleeves, column anchor bolts, etc., whether furnished under this section or by others (except cans and sleeves required under the Electrical and Mechanical Divisions).
5. The furnishing of all items required to be or shown on the drawings as embedded in concrete, which are not specifically required under other sections.
6. Setting headers and screeds. Curing and protecting concrete.
7. Inserts, sleeves, cans, etc. required under the Electrical and Mechanical Divisions.
PART 2 PRODUCTS
2.01 PRODUCTS
A. See specification Sections 03100, 03200, 03301, 03400, and 03600.
PART 3 EXECUTION
3.01 DEFECTIVE WORK
A. General: Work considered to be defective may be ordered by the Engineer to be replaced in which case the Contractor shall remove the defective work at his expense. Work considered to be defective shall include, but not be limited to, the following:
1. Reinforcing:
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) a. Kinks and bends therein which are not scheduled or indicated on the drawings; reinforcing improperly placed, or previously heated, or excessively cold worked reinforcing.
2. Concrete:
a. Concrete in which defective or inadequate reinforcing steel has been placed. b. Concrete incorrectly formed or not conforming to details and dimensions on the drawings or with the intent of these documents, or concrete the surfaces of which are out of plumb or level.
c. Concrete below specified strength.
d. Concrete not meeting the maximum allowable drying shrinkage requirements. e. Concrete containing wood, cloth, or other foreign matter, rock pockets, voids, honeycombs, cracks or cold joints not scheduled or indicated on the drawings.
3.02 CORRECTION OF DEFECTIVE WORK
A. The Contractor shall, at his expense, make all such corrections and alleviation measures as directed by the Engineer.
B. Concrete work containing rock pockets, voids, honeycombs, cracks or cold joints not scheduled or indicated on the drawings, shall be chipped out until all unconsolidated material is removed.
C. Secure approval of chipped-out areas before patching. Patch per ACI 301-89. **END OF SECTION**
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CONCRETE FORMING AND ACCESSORIES 03100 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 03100
CONCRETE FORMING AND ACCESSORIES
PART 1 GENERAL
1.01 SECTION INCLUDES
A. Formwork for concrete, with shoring, bracing and anchorage.
1.02 RELATED REQUIREMENTS
A. Section 03200 - Concrete Reinforcing
B. Section 03301 - Cast-in-Place Concrete
1.03 REFERENCE STANDARDS (Editions adopted by current governing California Building Code)
A. ACI 117 - Standard Specifications for Tolerances for Concrete Construction and Materials.
B. ACI 301 - Specifications for Structural Concrete for Buildings; American Concrete Institute.
C. ACI 318 - Building Code Requirements for Structural Concrete and Commentary; American Concrete Institute.
D. ACI 347 - Guide to Formwork for Concrete; American Concrete Institute.
E. ASTM C31 - Standard Practice for Making and Curing Concrete Test Specimens in the Field.
F. ASTM C39 - Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens.
G. ASTM D994 - Standard Specification for Preformed Expansion Joint Filler for Concrete (Bituminous Type).
H. ASTM D1751 - Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types).
1.04 SUBMITTALS
A. See Section 01300 – Contractor Submittals, for submittal procedures.
B. Product Data: Provide data on formwork release agent or form liner proposed for use with each formed surface.
C. Formwork Facing Materials: Data on form-facing materials proposed for smooth-form finish if different from that specified in Part 2.02.
D. Construction and Contraction Joints: Location of construction and contraction joints proposed if different from those indicated in the Contract Documents.
E. Shop Drawings
1. All of the following shop drawings and calculations shall be prepared, stamped, and signed by a registered Civil or Structural Engineer of the State of California.
2. Formwork
a. Submit shop drawings for fabrication and erection of forms for portions of the concrete surfaces, as indicated below:
1) For formwork over 12’ in height.
2) Show general construction of forms including size of members, bracing, jointing, 340
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) special form joint or reveals, location and pattern of form tie placement, and other items that affect the structural integrity of formwork or exposed concrete visually.
3. Falsework and Shoring Shop Drawings: The Contractor shall submit shop drawings and calculations of any required falsework, shoring. Shop drawings and calculations shall be prepared in accordance with the requirements of the ACI 318 and State of California Department of Transportation Standard Specifications, Section 48-2 - Falsework.
4. Reshoring and Backshoring Plans: When reshoring or backshoring is required or permitted, submit procedures and plans of operations, before use. Indicate on shop drawings the magnitude of construction loads permitted during reshoring or back-shoring.
F. Testing for Formwork Removal: Data on method for determining strength of concrete for removal of formwork when a method other than field-cured cylinders (ASTM C31 and ASTM C39) is proposed.
G. Formwork Removal Plans: Detail plans for formwork removal operations when removal of forms at concrete strengths lower than that specified in Part 3.08 is proposed.
1.05 QUALITY ASSURANCE
A. Codes and Standards: Comply with the provisions of the following codes, specifications, and standards, except where more stringent requirements are shown or specified.
1. California Building Code, current governing edition
2. ACI 318
3. ACI 347
PART 2 PRODUCTS
2.01 FORMWORK - GENERAL
A. Maximum deflection of facing materials reflected on concrete surfaces exposed to public view shall be 1/240 of the span between structural members of the formwork.
B. Formed Construction and Contraction Joints
1. Locate and form construction joints that least impair strength of the structure and meet the requirements of Section 03301.
2. Unless otherwise specified or permitted, locate and detail formed construction joints to the following requirements:
a. Locate construction joints within the middle third of the spans of slabs, beams, and girders. When a beam intersects a girder within this region, offset the joint in the girder a distance equal to or greater than twice the width of the beam; b. Locate joints in walls and columns at the underside of slabs, beams, or girders and at the tops of footings or slabs; and
c. Make joints perpendicular to the main reinforcement.
3. Provide keyways where indicated on Contract Documents. Unless otherwise specified, longitudinal keyways indicated on the Contract Documents, shall be a minimum of 1-1/2 in. deep in joints in walls and between walls and slabs or footings.
4. Provide construction and contraction joints where indicated on the Contract Documents.
Submit for acceptance the location of construction and contraction joints differing from those indicated on the Contract Documents.
2.02 FORM MATERIALS
A. Form-facing materials: Materials for form faces in contact with concrete shall meet the requirements of "Concrete Finishing" Section 03301 - Cast-in-Place Concrete and the following 341
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) requirements unless otherwise specified in Contract Documents.
1. For smooth-form finish, use plywood, tempered concrete-form-grade hardboard, metal, plastic, paper, or other acceptable materials capable of producing the desired finish for form-facing materials. Form-facing materials shall produce a smooth, uniform texture on the concrete. Do not use form-facing materials with raised grain, torn surfaces, worn edges, dents, or other defects that will impair the texture of concrete surfaces. Facing materials shall be supported with studs or other backing capable of maintaining deflections within the tolerances specified in Part 2.01.
2.03 FORMWORK ACCESSORIES
A. Use commercially manufactured accessories for formwork accessories that are partially or wholly embedded in concrete, including ties and hangers. Do not use nonfabricated wire form ties.
Where indicated in the Contract Documents, use form ties with integral water barrier plates in walls or other acceptable positive water barriers.
2.04 FORMWORK RELEASE AGENT
A. Use commercially manufactured formwork release agents that prevent formwork absorption of moisture, prevent bond with concrete, and do not stain the concrete surfaces.
2.05 EXPANSION JOINT FILLER
A. Premolded expansion joint filler shall conform to ASTM D994 or ASTM D1751.
2.06 FABRICATION AND MANUFACTURE
A. Formwork shall be tight to prevent loss of mortar from concrete.
B. Place 3/4 inch chamfer strips in the corners of formwork to produce beveled edges on permanently exposed surfaces unless otherwise specified. Do not bevel reentrant corners or edges of formed joints of concrete unless specified in the Contract Documents.
C. Inspect formwork and remove deleterious material immediately before concrete is placed.
Provide temporary openings where needed at the base of column and wall formwork to facilitate cleaning and inspection.
D. Fabricate form ties so ends or end fasteners can be removed with minimum spalling at the faces of concrete.
E. Locate waterstops in joints where indicated on Contract Documents. Use pieces of premolded waterstop with a maximum practicable length to create the minimum number of end joints. Make joints in waterstops in accordance with the manufacturer's recommendations. Ensure that joints develop effective watertightness equal to the continuous waterstop material, permanently develop not less than 50% of the strength of the parent section and permanently retain flexibility.
2.07 EPOXY ANCHORING SYSTEMS
A. Refer to Section 05501.
PART 3 EXECUTION
3.01 EARTH FORMS
A. Where sides of excavations have been cut neat and accurate to size for pouring of concrete directly against the excavation, forms for footings will not be required. Remove loose soil prior to placing concrete.
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3.02 CONSTRUCTION AND ERECTION OF FORMWORK
A. At construction joints, lap contact surface of the form sheathing for flush surfaces exposed to view over the hardened concrete in the previous placement. Ensure formwork is sealed against hardened concrete to prevent offsets or loss of mortar at construction joints and to maintain a true surface.
B. Provide positive means of adjustment (such as wedges or jacks) of shores and struts. Do not make adjustments in the formwork after concrete has reached its time of initial setting. Brace formwork securely against lateral deflection and lateral instability.
C. Fasten form wedges in place after final adjustment of forms and before concrete placement.
D. Anchor formwork to shores, supporting surfaces, or members to prevent upward or lateral movement of the formwork system during concrete placement. Form supports shall be placed on adequate foundations and have sufficient strength and bracing to prevent settlement or distortion from the weight of the concrete or other cause. Support shall rest on double wedged shim, or other approved means, so that the forms will be maintained at the proper grade.
E. Construct formwork for wall openings to facilitate removal and to counteract swelling of wood formwork.
F. Provide runways for moving equipment and support runways directly on the formwork or structural member without resting on the reinforcing steel.
G. All formed joints on concrete surfaces to be exposed shall be taped and shall align so joints will not be apparent on the concrete surfaces.
H. Any movement or bellying of forms during construction shall be considered just cause for their removal and, in addition, the concrete work so affected.
I. Bolts, rods, or other approved devices shall be used for internal form ties and shall be of sufficient quantities to prevent spreading of the forms. The ties shall be placed at least 1 inch away from the finished surface of the concrete. Bolts and rods that are to be completely withdrawn shall be coated with grease.
J. Boards or other form materials that have been damaged or checked or warped prior to placing of concrete shall be removed from the forms and replaced with approved materials or otherwise corrected to the satisfaction of the engineer.
K. Assign a sufficient number of men to keep watch on and maintain the forms during placing of concrete. Satisfactorily remedy any displacement or looseness of forms or reinforcement before placing of concrete. No form shall be moved or altered except as may be specifically directed.
L. Wall forms shall be set to account for movement of post-tensioned slabs that will occur due to long term shortening of slabs. The Engineer will establish the offsets at each level after the Contractor has submitted a detailed pour schedule.
3.03 APPLICATION - FORM RELEASE AGENT
A. Cover surfaces of formwork with an acceptable material that will prevent bond with the concrete.
A field-applied formwork release agent or a factory-applied liner may be used. If a formwork release agent is used, apply to the surfaces of the formwork in accordance with the manufacturer's recommendations before placing reinforcing steel. Do not allow formwork release agent to puddle in the forms. Do not allow formwork release agent to contact reinforcing steel or hardened concrete against which fresh concrete is to be placed. 343
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3.04 INSERTS, EMBEDDED PARTS, AND OPENINGS
A. Position and support expansion joint materials, waterstops, and other embedded items to prevent displacement. Fill voids in sleeves, inserts, and anchor slots temporarily with readily removable material to prevent entry of concrete into voids.
B. Place sleeves, inserts, anchors, and embedded items required for adjoining work or for support of adjoining work before concrete placement. Holes, notches, conduits, pipes, etc. are not allowed in concrete slabs, walls, members, etc. unless shown on the structural drawings or requested and specifically accepted by the Engineer.
3.05 FORM CLEANING
A. Clean surfaces of formwork and embedded materials of mortar, grout, and foreign materials before concrete is placed.
3.06 FORMWORK TOLERANCES
A. Unless otherwise specified in the Contract Documents, construct formwork so concrete surfaces conform to the tolerance limits of ACI 117. The class of surface shall conform to Part 2.02.
B. To maintain specified tolerances, camber formwork to compensate for anticipated deflections in formwork during concrete placement. Set formwork and intermediate screed strips for slabs accurately to produce designated elevations and contours of the finished surface before removal of formwork. Ensure that edge forms and screed strips are strong enough to support vibrating screeds or roller pipe screeds when the finish specified requires the use of such equipment.
C. When formwork is cambered, set screeds to the same camber to maintain specified concrete thickness.
3.07 FIELD QUALITY CONTROL
A. The Contractor shall hire the Engineer responsible for the design of formwork over 12' in height, falsework or shoring to inspect the work as detailed on the reviewed shop drawings.
B. The Contractor shall verify accuracy of items, furnished under other sections of these specifications and installed under this section.
3.08 FORM REMOVAL
A. Remove top forms on sloping surfaces of concrete as soon as removal will not allow concrete to sag. Perform needed repairs or treatment required at once and follow immediately with specified curing.
B. Do not damage concrete during removal of formwork for columns, walls, slabs, sides of beams, and other parts not supporting the weight of the concrete. Perform needed repair and treatment required on vertical surfaces at once and follow immediately with specified curing.
C. Leave formwork and shoring in place to support the weight of concrete in beams and joists for at least 14 days and in slabs for at least 10 days after the last concrete and until concrete has attained 3000 psi minimum per Part 3.08E and the Engineer responsible for design of shoring and falsework has approved removal.
D. Vertical forms shall remain on columns, walls, pilasters for at least seven 7 days after the last concrete and until concrete has attained 3000 psi minimum per Part 3.08E and the Engineer responsible for design of the formwork has approved removal.
E. Contractor shall request to have field cured compression test specimen taken where it is planned 344
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) to remove formwork and shoring sooner than indicated above and submit detailed plans for review and acceptance. Mold cylinders in accordance with ASTM C31, and cure them under the same conditions for moisture and temperature as used for the concrete they represent. Test cylinders in accordance with ASTM C39.
F. In removing plywood forms, no metal pinch bars shall be used and special care to be taken in stripping. Start at top edge or vertical corner where it is possible to insert wooden wedges.
Wedging shall be done gradually and shall be accompanied by light tapping of the plywood panels to crack them loose. Do not remove forms with a single jerk after it has been started at one end.
G. Nothing herein shall be construed as relieving the contractor of any responsibility of the safety of the structure.
END OF SECTION
345
CONCRETE REINFORCING 03200 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 03200
CONCRETE REINFORCING
PART 1 GENERAL
1.01 SECTION INCLUDES
A. Reinforcing steel for concrete, shotcrete and masonry.
B. Supports and accessories for steel reinforcement.
1.02 RELATED REQUIREMENTS
A. Section 03100 - Concrete Forming and Accessories.
B. Section 03301 - Cast-in-Place Concrete.
1.03 REFERENCE STANDARDS (Editions adopted by current governing California Building Code)
A. ACI 117 - Standard Specifications for Tolerances for Concrete Construction and Materials; American Concrete Institute International.
B. ACI 301 - Specifications for Structural Concrete for Buildings; American Concrete Institute International.
C. ACI 318 - Building Code Requirements for Structural Concrete and Commentary; American Concrete Institute International.
D. ACI SP-66 - ACI Detailing Manual; American Concrete Institute International.
E. ASTM A1064 - Standard Specification for Steel Wire, Plain, for Concrete Reinforcement.
F. ASTM A123 - Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
G. ASTM A185 - Standard Specification for Steel Welded Wire Reinforcement, Plain, for Concrete.
H. ASTM A615 - Standard Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement.
I. ASTM A 641 - Standard Specification for Zinc-Coated (Galvanized) Carbon Steel Wire.
J. ASTM A706 - Standard Specification for Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement.
K. ASTM A767 - Standard Specification for Zinc-Coated (Galvanized) Steel Bars for Concrete Reinforcement.
L. ASTM A780 - Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings.
M. ASTM E329 - Standard Specification for Agencies Engaged in Construction Inspection and/or Testing.
N. AWS D1.4 - Structural Welding Code - Reinforcing Steel; American Welding Society.
O. CRSI (DA4) - Manual of Standard Practice; Concrete Reinforcing Steel Institute. 346
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1.04 SUBMITTALS
A. See Section 01300 – Contractor Submittals, for submittal procedures.
B. Shop Drawings (Placing drawings)
1. Comply with requirements of ACI SP-66. Shop drawings shall also show details for congested areas and connections. Shop drawings used in field must be reviewed copies.
C. Product Data
1. Manufacturer's catalog sheets including instructions for use and description of application and ICC/IAPMO evaluation report shall be provided on each of the following items intended for use on project:
a. Mechanical anchorage devices for splices.
D. Mill Certificates
1. The Contractor shall provide Mill Certificates for each size of bar for each heat to be used on project and certify that reinforcing steel supplied for this project meet or exceed specified requirements.
2. Mill Certificates shall include name of mill, date of rolling, date of shipping to fabricator and shall be signed by fabricator certifying that each material complies with or exceeds the specified requirements. A Mill Certificate shall be furnished with each lot of material delivered to the project and the lot shall be clearly identified in the Certificate.
3. When Mill Certificates cannot be provided, the Contractor shall hire a professional testing laboratory to verify compliance and provide laboratory test reports. The Contractor shall pay for the cost of testing.
E. Laboratory Test Reports
1. Laboratory test reports shall be signed by a principal of the testing agency who is a registered Civil Engineer in the State of California.
2. When required by other portions of these specifications, laboratory test reports shall be submitted for each size of bar tested for each heat to show compliance with appropriate ASTM Standards and these specifications.
F. Welder's Certificates and WPS: Submit description of reinforcement weld locations, welding procedures, and welder certification when welding is permitted.
1.05 QUALITY ASSURANCE
A. Perform work of this section in accordance with the current governing edition of CBC, ACI 301, ACI SP-66, ACI 318, and AWS D1.4 except as modified by the contract documents.
B. Sampling and Testing:
1. General
a. If the Owner's agent, through oversight or otherwise, has accepted material or work which is defective or contrary to specifications, this material or work, regardless of state of completion, may be rejected.
b. Testing agencies shall meet the requirements of ASTM E329. Testing agencies shall be accepted by the Engineer before performing any work.
2. Testing responsibilities of Contractor:
a. Submit data on qualifications of proposed testing agency for acceptance. Use of testing services will not relieve the Contractor of the responsibility to furnish materials and construction in compliance with the Contract Documents. b. Cooperate with and notify owner's agent at least 24 hours in advance of inspections required and shall provide samples, test pieces, and facilities for inspection at no cost to 347
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c. Identify each lot of fabricated reinforcing steel to be shipped to the site by assigning an individual lot number that identifies steel by heat number and shall be tagged in such a manner that each such lot can be accurately identified at the job site. d. Remove all unidentified reinforcing steel, anchorage assemblies and bar couplers received at the site.
1.06 STORAGE OF MATERIALS
A. Store reinforcement during fabrication and at site to avoid excessive rusting or coating with grease, oil, soil, or other objectionable materials. Bundles shall not be dropped or dragged.
Reinforcing steel shall be transported and stored in a manner that will not damage any applied coating.
1.07 SEQUENCING AND SCHEDULING
A. Coordinate work with all trades so as not to interfere with the work of other trades. Bring interferences between trades to Engineer's attention and resolve before any concrete is placed.
PART 2 PRODUCTS
2.01 REINFORCING BARS
A. Reinforcing Steel:
1. Bars for reinforcement shall conform to the requirements of ASTM A706 ASTM A615, Grade 60 bars may be substituted to meet a through e above if the actual yield strength based on mill tests does not exceed the specified yield strength by more than 18,000 psi, the ratio of the actual ultimate tensile stress to the actual tensile yield strength is not less than 1.25, and the minimum elongation in 8 inches shall be at least 14% for #3 through #6, 12% for #7 through #11 and 10% for #14 and #18. This substitution must be verified by the special inspector prior to bundle tag removal.
2. Bars for reinforcement not noted above shall be deformed grade steel conforming to the requirements of ASTM A706 or A615, Grade 60.
3. Uncoated steel unless noted otherwise.
4. Galvanized in accordance with ASTM A767, Class II where required by Contract Documents chromate wash treated after fabrication and bending. Repair coating damage in accordance with ASTM A780.
2.02 WIRE
A. All wire for concrete reinforcement shall conform to ASTM A1064.
2.03 WELDED WIRE REINFORCEMENT
A. All wire fabric mesh shall conform to ASTM A185, plain welded wire mesh in flat sheets (not rolls), with welded intersections spaced not farther apart than 12 in. in the direction of principal reinforcement.
B. Use wire-reinforcement supports complying with Class 1, maximum protection, or Class 2, moderate protection, as indicated in Chapter 3 of the CRSI Manual of Standard Practice.
C. Use galvanized wire-reinforcement support or wire reinforcement support coated with plastic.
2.04 WELDING ELECTRODES
A. Welding electrodes shall be per Table 5-1 of AWS D1.4. 348
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2.05 MECHANICAL COUPLING DEVICES
A. Mechanical coupling devices shall develop 125 percent of the minimum yield strength of the bars spliced.
2.06 REINFORCEMENT ACCESSORIES
A. Chairs, Bolsters, Bar Supports, Spacers: Sized and shaped for adequate support of reinforcement during concrete placement. Reinforcement supports shall conform to the requirements of ACI 301.
2.07 OTHER MATERIALS
A. All other materials, not specifically described by these specifications but required for complete and proper placement of reinforcement shall be new, first quality of their respective kinds, and subject to the approval of the Engineer.
2.08 FABRICATION
A. Welding of reinforcement is permitted only with the specific approval of Engineer. Perform welding in accordance with AWS D1.4. Do not weld crossing bars (tack welds) for assembly of reinforcement, supports, or embedded items.
PART 3 EXECUTION
3.01 EXISTING CONDITIONS
A. Prior to all work of the section, carefully inspect the installed work of other trades and verify that all work is sufficiently complete to permit the start of work under this section and that the completed work of this section will be in complete accordance with the original design and the reviewed shop drawings. In the event of discrepancy, immediately notify the Engineer in writing.
B. In the event conduits, pipes, inserts, sleeves, or any other items interfere with placing the reinforcement as indicated on the drawings or approved shop drawings, or as otherwise required, immediately notify the
Engineer and obtain approval on procedure before placement of reinforcement is started.
3.02 BENDING
A. Bends for reinforcing steel shall be made in accordance with ACI 301 and ACI 318. Bend bar sizes No. 3 through 5 cold only one time, provided reinforcing bar temperature is above 32 degree F. Do not field bend reinforcing steel in a manner that will injure material, cause the bars to be bent on too tight a radius, or that is not indicated as allowed on drawings or permitted by Engineer. Do not straighten bent or kinked bars for use on project without permission of Engineer. Replace bars with kinks or bends not shown on the drawings.
3.03 PLACING
A. All reinforcement shall be placed in strict conformance with the requirements of the Contract Drawings, both as to location, position and spacing of members. It shall be supported and secured against displacement by the use of adequate and proper wire supporting and spacing devices, tie wires, etc. so that it will remain in its proper position in the finished structure.
Reinforcement may not be wet set in concrete pours.
B. Tolerances: Do not exceed the placing tolerances specified in ACI 318 and ACI 117, whichever is more stringent, before concrete is placed. Placing tolerances shall not reduce cover requirements 349
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C. Minimum concrete cover for reinforcement and couplers shall be as indicated in the Contract Drawings. Concrete cover is measured from the theoretical excavation line, not the line of any over excavation. Where less than 3 inches cover is noted and concrete will be placed against soil, increase the section thickness to attain 3 inches cover.
D. Preserve clear space between parallel bars of not less than 1-1/2 times the nominal diameter of round bars and in no case let the clear distance be less than 1-1/2 inches nor less than 1-1/3 times the maximum size of aggregate for concrete. Bars placed in shotcrete shall have a minimum clearance between bars of 2-1/2 inches for No. 5 and smaller and 6 bar diameters for bars larger than No. 5. When two curtains of steel are provided in shotcrete wall, the curtain nearer the nozzle shall have a minimum spacing equal to 12 bar diameters and the remaining curtain shall have a minimum spacing of six bar diameters.
E. For slabs on ground, extend welded wire reinforcement to within 2 in. of the concrete edge.
Reinforcement shall be lapped and tied around the perimeter of each sheet in order to maintain the proper positioning of the reinforcement. Lap splices shall have a minimum of two ties per spliced length. Do not place welded wire reinforcement on grade and subsequently raise into position in concrete.
F. Furnish and use templates for placement of column dowels unless otherwise permitted by engineer.
G. Lap splices shall be contact lap splices in accordance with ACI 318 unless noted otherwise on the Contract Drawings. Bars shall be wired together at laps. Wherever possible, stagger splices in adjacent bars. Splice bars in members such as spandrels, beams, etc, as follows: Top bars at centerline of span, bottom bars at the support. Make all splices in welded wire reinforcement at least 1-1/2 meshes wide or 12 inches, whichever is greater. When splicing in areas to receive shotcrete, lap splices shall be non-contact with at least 2 inches clearance between bars.
H. Butt splices shall be accomplished by mechanical anchorage devices. Stagger these devices 2 feet, unless noted otherwise on the Contract Documents.
I. Bars shall not be cut by gas torch.
3.04 CLEANING REINFORCEMENT
A. Take all means necessary to ensure that steel reinforcement, at the time concrete is placed around it, is completely free from rust, soil, loose mill scale, oil, paint and all coatings which will destroy or reduce the bond between steel and concrete.
END OF SECTION
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CAST-IN-PLACE CONCRETE
PART 1 GENERAL
1.01 SECTION INCLUDES
A. Requirements for cast-in-place concrete work.
1.02 REFERENCED SECTIONS
A. The following Section is referenced in this Section
1. Section 01300 – Contractor Submittals
1.03 SUBMITTALS
A. Comply with Section 01300.
B. Shop Drawings
1. Reinforcing Steel: Prepare shop fabrication and field installation drawings in accordance with CRSI Manual of Standard Practice and ACI SP.
2. Layout drawings for construction joints.
C. Product Data: Waterstops, curing compound data.
D. Concrete Mix Design: Data on the concrete mix, including aggregate gradations and admixtures, in accordance with ASTM C94.
E. Quality Control Submittals
1. Manufacturer’s application instructions for curing compound.
2. Ready-mix delivery tickets for each truck in accordance with ASTM C94.
1.04 QUALITY ASSURANCE
A. Supplier Qualifications: A minimum of 5 years’ experience manufacturing ready-mixed concrete and that complies with ASTM C94 for production facilities and equipment.
B. Source Limitations: Use the same brand of cement from the same manufacturer's plant, obtain aggregate from one source, and obtain admixtures through one source from a single manufacturer.
C. Concrete and Reinforcement: Unless otherwise specified, meet the requirements of ACI 301 and 318.
D. Hot Weather Concreting: Conform to ACI 305R.
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2.01 FORMWORK
A. Exposed Areas: Use hard plastic finished plywood.
B. Unexposed Areas: Use new ship lap or plywood.
C. Earth cuts may be used for forming footings.
2.02 CONCRETE
A. Ready-mixed meeting ASTM C94, Option A.
B. Portland Cement: ASTM C150, Type II.
C. Aggregates: Furnish from one source.
1. Natural Aggregates
a. Free from deleterious coatings and substances in accordance with ASTM C33, except as modified herein.
b. Free of materials and aggregate types causing pop outs, discoloration, staining, or other defects on surface of concrete.
2. Non-Potentially Reactive: In accordance with ASTM C33, Appendix XI, paragraph X1.1.
3. Aggregate Soundness: Test for fine and coarse aggregates in accordance with ASTM C33 and ASTM C88 using sodium sulfate solution.
4. Fine Aggregates
a. Clean, sharp, natural sand.
b. ASTM C33.
c. Materials Passing 200 Sieve: 4 percent maximum.
d. Limit deleterious substances in accordance with ASTM C33, Table 1 with material finer than 200 sieve limited to 3 percent, coal and lignite limited to 0.5 percent.
5. Coarse Aggregate
a. Natural gravels, combination of gravels and crushed gravels, crushed stone, or combination of these materials containing no more than 15 percent flat or elongated particles (long dimension more than five times the short dimension).
b. Materials Passing 200 Sieve: 0.5 percent maximum.
D. Admixtures: Do not use admixtures that contribute water-soluble chloride ions exceeding those permitted in hardened concrete. Do not use calcium chloride or admixtures containing calcium chloride.
1. Air-Entraining: ASTM C260.
2. Water-Reducing: ASTM C494, Type A or D.
3. Superplasticizers: ASTM C494, Type F or G.
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4. Fly Ash: ASTM C618, Class C or F.
5. Color Pigments: Inert mineral or metal oxide pigments, natural or synthetic; resistant to lime and other alkalies.
E. Concrete Mix Design
1. Minimum Compressive Field Strength at 28 days when cured and tested in accordance with ASTM C31 and C39: 4,000 psi for Reinforced Concrete and 2,500 psi for Unreinforced Concrete Fill.
2. Coarse Aggregate Size: 1-1/2 inches and smaller.
3. Slump Range: 3 to 5 inches.
4. Air Entrainment: Between 1 and 3 percent by volume.
5. Water Reducers: Use in concrete without plasticizers.
F. Proportions
1. Design mix to meet aesthetic and structural concrete requirements.
2. Water-cement ratio (water-cement plus fly ash ratio) shall control amount of total water added to concrete as follows:
a. Reinforced Concrete:
Coarse Aggregate Size W/C Ratio
1-1/2 inch 0.50
1 inch 0.45
b. Unreinforced Concrete Fill: 0.55 maximum.
3. Minimum Cement Content (Combined Cement Plus Fly Ash Content):
a. 541 pounds per cubic yard for Reinforced Concrete with 1½ inch maximum size aggregate.
b. 564 pounds per cubic yard for Reinforced Concrete with 1 inch maximum size aggregate.
c. 470 pounds per cubic yard for Unreinforced Concrete Fill.
4. Increase cement content (combined cement plus fly ash content), as required to meet strength requirements and water-cement ratio.
5. Fly Ash Content: minimum 20 percent, maximum 50 percent by weight of total cement content.
G. Mixing: Minimum 70 and maximum 270 revolutions of mixing drum. Non-agitating equipment is not allowed.
2.03 REINFORCING STEEL
A. Deformed Bars: ASTM A615, Grade 60. Reinforcing steel to be welded shall be ASTM A706, Grade 60.
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C. Bar Supports:
1. For Slab Rebar: Concrete blocks or plastic bar supports.
2. For Rebar in Walls, Beams, Columns, and Slabs Exposed to View:
Galvanized steel chairs with plastic tips or plastic bar supports and side form spacers.
2.04 ANCILLARY MATERIALS
A. Curing Compound
1. Material: Water-based product in accordance with ASTM C309, Type 1, Class A.
2. Manufacturers and Products: One of the following or equal:
a. W. R. Meadows, Inc.: 1300-CLEAR
b. Euclid Chemical Co.: Kurex DR VOX
B. Epoxy Bonding Agent and Adhesives (for Binding New Concrete to Existing Concrete)
1. Epoxies: Two component material for use on dry or damp surfaces and conforming to the requirements of ASTM C881, Type II, Grade 2, Class C.
2. Apply in accordance with manufacturer’s recommendations.
3. Manufacturers and Products: One of the following or equal:
a. Sika Corporation: Sikadur-2 Hi-Mod LPL
b. Euclid Chemical Co.: DURAL LPL MV
C. Waterstops
1. General: Place hydrophilic and/or rubber dumbbell type or center bulb type waterstops at construction joints and other joints as specified and indicated on the Drawings.
2. Hydrophilic Waterstops:
a. Use: For concrete repairs or when attaching new concrete to existing structures.
b. Manufacturers and Products: One of the following or equal:
1) Greenstreak, Hydrotite CJ
2) Tremco, Parastop II
c. Installation: As indicated on the Drawings and in accordance with manufacturer’s instructions.
3. Rubber Waterstops
a. Use: At new construction joints where indicated on the Drawings. b. Material: PVC or rubber waterstops manufactured by one of the following, or equal:
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2) Progress Unlimited
3) Williams Products
c. Size:
1) Construction and Contraction Joints: 6-inch flat dumbbell type.
2) Expansion Joints: 9-inch wide dumbbell with hollow center bulb.
D. Expansion Joint Filler: ASTM D994, 1/2-inch thick, or as shown.
E. Surface Hardener
1. Premixed, noncolored, nonmetallic Master Builders, Mastercron; Sonneborn, Harcol; A. C. Horn Inc., Durafax; Burke Company Non-Metallic Floor Hardner; or equal.
2. Apply in accordance with manufacturer's instructions.
F. Concrete for Electrical Conduits
1. Concrete encasement for electrical conduit shall contain 3 pounds of red oxide per sack of cement.
G. Vapor Barrier
1. Material: 15 mil, multilayer plastic, 0.01 minimum permeance rating.
2. Manufacturers and Products: One of the following or equal:
a. Stego Industries: StegoWrap
b. W. R. Meadows: Premoulded Membrane Vapor Seal with Plasmatic Core
H. Non-Shrink, Non-Metallic Grout
1. Material: Hydraulic cement-based mineral aggregate grout conforming to the requirements of ASTM C1107 and CRD-C 621.
2. Manufacturers and Products: One of the following or equal:
a. Sika Corporation: SikaGrout-928
b. Euclid Chemical Co.: Hi-Flow Grout
I. Controlled Low-Strength Material (CLSM)
1. General: Design mix in accordance with Section 19-3.02G “Controlled LowStrength Material” of the Caltrans Standard Specifications.
2. 28-Day Compressive Strength: 50 – 100 psi
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3.01 FORMWORK
A. Design, construct, erect, brace and maintain formwork in accordance with ACI 301.
B. Form Ties
1. Fixed conical or spherical type inserts that remain in contact with forming material and allow for dry packing of form tie holes.
2. Space ties to withstand pressures and to limit deflection of forms to acceptable limits.
3. Wire ties are not acceptable.
C. Construction
1. In accordance with ACI 347.
2. Make joints tight to prevent escape of mortar and to avoid formation of fins.
3. Brace as required to prevent distortion during concrete placement.
4. On exposed surfaces locate form ties in uniform pattern or as shown.
5. Construct so ties remain embedded in the wall with no metal within 1-inch of concrete surface when forms, inserts, and tie ends are removed.
D. Form Removal
1. Remove after concrete has attained 28 day strength, or approval is obtained in writing from Engineer.
2. Remove forms with care to prevent scarring and damaging the surface.
3.02 PLACING REINFORCING STEEL
A. Place reinforcing steel in accordance with CRSI Recommended Practice for Placing Reinforcing Bars.
B. Field bending or welding of reinforcing bars will not be allowed.
C. Bar Supports: Provide in sufficient quantity to prevent sagging and to support bars during concrete placement.
D. Splices and Laps
1. Top Bars: Horizontal bars placed such that 12 inches of fresh concrete is cast below in single placement.
2. Horizontal wall bars are considered top bars.
3. Bar lap splices shall conform to General Structural Notes on the Drawings.
4. Tie splices with 18-gauge annealed wire as specified in CRSI Standard. 356
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3.03 PLACING CONCRETE
A. Place concrete in accordance with ACI 301.
B. Before placing concrete:
1. Check reinforcing steel for proper placement and correct discrepancies.
2. Remove excessive rust, mill scale, dirt, oil and other material from rebar that may adversely affect bonding to concrete.
3. Remove water from excavation and debris and foreign material from forms.
C. Before depositing new concrete on existing concrete, clean surface using sandblast or other mechanical means to obtain a 1/4-inch rough profile, and apply epoxy bonding agent in accordance with the manufacturer’s instructions.
D. Place concrete as soon as possible after leaving mixer, without segregation or loss of ingredients, without splashing forms or steel above, and in layers not over 2 feet deep. Place within 1-1/2 hours after adding cement to mix.
E. Placement Limitations: 8 feet maximum vertical drop to final placement, when not guided with chutes or other devices to prevent segregation due to impact with reinforcing.
F. Hot Weather
1. Prepare ingredients, mix, place, cure, and protect in accordance with ACI 305R.
2. Maintain concrete temperature below 80 degrees F at time of placement, or furnish test data or provide other proof that admixtures and mix ingredients do not produce flash set plastic shrinkage, or cracking due to heat of hydration. Ingredients may be cooled before mixing to maintain fresh concrete temperatures at 80 degrees F or less.
3. Make provisions for windbreaks, shading, fog spraying, sprinkling, ice, or wet cover, or other means to provide concrete with temperature specified.
4. Maximum allowable temperature differential between reinforcing steel and concrete: Not greater than 20 degrees F at the time of concrete placement.
3.04 COMPACTION
A. Vibrate concrete as follows:
1. Apply approved vibrator at points spaced not farther apart than vibrator’s effective radius.
2. Apply close enough to forms to vibrate surface effectively but not damage form surfaces.
3. Vibrate until concrete becomes uniformly plastic.
4. Vibrator must penetrate fresh placed concrete and into previous layer of fresh concrete below.
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3.05 CONSTRUCTION JOINTS
A. Locate as shown or as approved.
B. Maximum Spacing Between Construction Joints: 40 feet, unless otherwise indicated.
3.06 CRACK CONTROL JOINTS
A. Provide crack control joints in concrete slabs on grade, curbs, gutters, sidewalks and other concrete flatwork as follows:
1. Install crack control joints by use of grooving tool on fresh concrete or sawcut by use of a saw designed for crack control joints as soon as the concrete hardens sufficiently to support the saw, however, no longer than 12 hours after concrete placement.
2. Depth: 1/4 the thickness of the slab.
3. Frequency: Unless otherwise indicated,
a. Maximum spacing of 2.5 times the slab thickness in feet (6-inch slab ≤ 15 feet on center).
b. Rectangular slabs: Maximum 1½ to 1 ratio of side lengths.
3.07 SLAB FINISHES
A. General
1. The finishes specified herein include surface finishes, treatments and toppings for floors and slabs. Floors shall be sloped to drain uniformly.
Unless otherwise specified, slope shall be minimum 1/8 inch per foot towards nearest drain. Where finish is not specified, floor slabs shall receive steel troweling. Dry cement shall not be used on new concrete surfaces to absorb excess moisture. Edges shall be rounded to a radius of 1/2 inch. Joints shall be grooved to a radius and depth of 1/2 inch each. Uneven-slope tolerance is 1/4-inch in 10 feet.
B. Float Finish
1. Conform to ACI 301, Section 11.7.2. Floating shall be performed with a hand or power-driven float. Floating of any one area shall be the minimum necessary to produce the finish specified. Floating shall compact and smooth the surface and close any cracks and checking of surfaces.
C. Broomed Finish
1. Conform to ACI 301, Section 11.7.4. Broomed finish shall be provided for walks, slabs on grade exposed to atmosphere, and where otherwise indicated or specified. Apply float finish, then a light broom finish to produce a profile that is parallel to the slab drainage.
D. Steel Trowel Finish
1. Conform to ACI 301, Section 11.7.3. Immediately after final troweling, the surface shall be cured and protected. Steel trowel finish shall be provided on 358
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3.08 FINISHING AND PATCHING FORMED SURFACES
A. Unexposed Surfaces: Provide rough-formed concrete texture as imparted by formfacing material, fill form tie holes with nonshrink grout and grind off projections, fins, and rough spots.
B. Exposed Surfaces: Provide smooth-formed concrete texture as imparted by formfacing material, arranged in an orderly and systematic manner with a minimum number of seams. Fill form tie holes with nonshrink grout and grind off projections, fins, and rough spots. Where scheduled, apply rubbed surface as follows:
1. Smooth Rubbed Finish: Not later than one day after form removal, moisten concrete surfaces and rub with carborundum brick or another abrasive to produce 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. a. 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.
b. 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. a. 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.
b. Compress grout into voids by grinding the concrete surface in a swirling motion, then finish the surface with a cork float.
C. Patching Defective Areas: Patch defective areas and repair rough spots resulting from form release agent failure or other reasons to provide smooth uniform appearance.
1. Cut out honeycombed and defective areas.
2. Cut edges perpendicular to surface at least 1-inch deep. Do not feather edges.
Soak area with water for 24 hours.
3. Finish surfaces to match adjacent concrete.
4. Keep patches damp for minimum 7 days or spray with curing compound to minimize shrinking.
3.09 PROTECTION AND CURING
A. Protect fresh concrete from direct rays of sunlight, drying winds, and wash by rain. 359
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C. Use curing compound only where approved by Engineer. Cure formed surfaces with curing compound applied in accordance with manufacturer’s directions as soon as forms are removed and finishing is complete.
1. Do not use curing compound on concrete surfaces that will be painted.
D. Remove and replace concrete damaged by freezing.
3.10 FIELD QUALITY CONTROL
A. Concrete Samples:
1. Provide concrete for making composite samples for testing slump, air content, and for making cylinders for determination of compressive strength.
2. Prepare samples in accordance with ASTM C172. Select trucks or batches of concrete on a random basis.
3. Samples may be obtained at the discharge chute of the truck or at the point of discharge into forms.
B. Sampling Frequency: One composite sample for each 100 cubic yards of structural concrete, or fraction thereof, of each concrete mixture placed in any one day.
C. Evaluation will be in accordance with ACI 301, Chapter 17 and Specifications.
D. Slump tests and concrete cylinders will be made by the Owner. Owner will handle cured test cylinders, transport to the testing laboratory and pay testing costs.
E. Enforcement of Compressive Strength Requirements:
1. Compressive strength of concrete will be considered acceptable if the following conditions are satisfied:
a. Averages of all sets of 3 consecutive strength test results are greater or equal to the specified compressive strength.
b. No individual strength test (average of 2 cylinders) falls below specified compressive strength by more than 500 pounds per square inch.
2. Whenever one, or both, of 2 conditions stated above is not satisfied, provide additional curing of affected portion of structure, then obtain test cores from the affected area.
a. Obtain 3 test cores in accordance with ASTM C 42 and ACI 318. b. Concrete will be considered acceptable if the average compressive strength of the 3 test cores is equal to at least 90 percent of the specified 28-day compressive strength and no single core is less than 80 percent of the specified 28-day compressive strength. c. Concrete will be designated as defective when the specified conditions are not achieved.
d. Fill core holes with concrete.
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3. Engineer may require the Contractor to strengthen defective concrete by means of additional concrete, additional reinforcing steel, or replacement of defective concrete, all of the Contractor's expense.
***END OF SECTION***
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PRECAST CONCRETE
PART 1 GENERAL
1.01 SUMMARY
A. Section Includes:
1. Precast concrete manholes, wet wells, valve vaults, inlets, pull boxes, and other precast concrete structures.
B. Related Sections:
1. Section 02200 – Excavation and Backfill
2. Section 03301 - Cast in Place Concrete.
1.02 REFERENCE STANDARDS
A. California Building Code, latest edition.
B. American Concrete Institute (ACI), Building Code Requirements for Reinforced Concrete.
C. Caltrans Standard Specifications.
D. Precast Concrete Institute (PCI)
E. National Precast Concrete Association (NPCA)
F. American Society for Testing and Materials (ASTM):
1. C150 - Portland Cement.
2. C478 – Precast Reinforced Concrete Manhole Sections
3. C858 - Underground Precast Concrete Utility Structures.
4. C913 – Precast Concrete Water/Wastewater Structures
1.03 SUBMITTALS
A. Standard manufacturer’s product data where applicable.
B. Concrete design, calculations, and shop drawings for all non-standard precast structures.
1. Concrete Mix Design
2. Design Calculations stamped and signed by a California licensed Civil or Structural Engineer.
3. Load Calculations stamped and signed by a California licensed Civil or Structural Engineer.
4. Shop drawings showing reinforcement, connections, embedded items, etc.
1.04 DELIVERY, STORAGE, AND HANDLING
A. All materials shall be delivered to the jobsite as a complete unit, clearly labeled with the manufacturer's product identification and printed instructions. 362
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C. All materials shall be handled and installed in accordance with the manufacturer's instructions.
PART 2 PRODUCTS
2.01 PRECAST CONCRETE STRUCTURES
A. Where shown on the plans, the Contractor may use reinforced concrete structures that are cast at an off-site location. In general these structures include vaults and electrical pull boxes. Precast concrete structures shall conform to ASTM C478, C858, and C913.
B. All precast concrete structures will be manufactured in a plant especially designed for that purpose. Standard products may be used wherever feasible.
C. Design of precast concrete structures is the responsibility of the Contractor and Contractor’s Engineer. Design Calculations shall be stamped and signed by a California licensed Civil or Structural Engineer. Design requirements are listed below:
1. Structures shall be designed to resist buoyant forces from groundwater assuming a depth of groundwater at finish grade.
2. Design loads shall consist of dead load, live load, impact load, full depth interior fluid, loads due to groundwater table at finish grade, seismic loads, and any other loads which may be imposed on the structure. Soil properties and loading values detailed in the project geotechnical report shall be used for the design of precast concrete structures.
3. Valve Vault and Wet Well – The bottom 3 feet of the wall riser shall be cast integrally with the bottom slab to eliminate a joint at the wall to base interface.
4. Individual riser sections shall be designed to utilize as few joints as possible.
Vertical joints are not allowed.
5. Precast structures shall be designed to be water tight and to limit movement and deflections.
D. The Contractor shall submit shop drawings showing reinforcement, connections, embedded items, etc. Pipe penetrations shall be formed or core drilled. Penetrations 4 inches in diameter or larger shall be formed at the precast concrete plant.
E. Hatches for precast structures shall be installed at the precast concrete plant. The size and position of hatches shall be as shown on the Plans. The hatches shall be as specified in Section 08310.
2.02 MATERIALS
A. Portland cement concrete shall conform to Section 03301, although concrete compressive strength and reinforcement yield strength may be at the discretion of the manufacturer. Lightweight concrete shall not be used.
B. Reinforcing steel shall conform to Section 03200.
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2.03 PRECAST MANHOLES AND INLETS
A. Where shown on the Plans, Contractor may use reinforced concrete structures that are cast at an off-site location.
1. Precast concrete manhole sections shall conform to ASTM C478, C858, and C913.
2. Precast concrete inlets shall conform to ASTM C858 and C913.
B. All precast concrete structures shall be manufactured in a plant especially designed for that purpose. Standard Products should be used wherever feasible.
C. Precast concrete manholes, inlets, frames, and covers shall be rated for H-20 traffic loading.
2.04 JOINT SEALERS, WATER STOPS
A. All joints between precast concrete sections shall be made water-tight by using a preformed plastic material that is permanently self-adhering and flexible. Compound shall be “Ram-Nek” as manufactured by K.T. Snyder Company, Houston, Texas or approved equal. (“Ram-Nek” is distributed locally by Hanson Concrete Products of Milpitas.) Follow manufacturer’s recommended installation procedures.
B. Where cast-in-place concrete is poured against an existing concrete structure, a preformed rubber hydrophilic water stop with adhesive back shall be installed on the precast side of the joint prior to the pour. Water stop shall be Adeka Ultra Seal MC2010M (Gates Unlimited, Santa Clara) or equivalent. Follow manufacturer’s recommended installation procedures.
C. Manhole pipe connection shall have an A-Lox X-Cel water stop or approved equal.
2.05 NON-SHRINK GROUT
A. Grout shall meet the requirements of Section 03600.
PART 3 EXECUTION
3.01 CASTING
A. No concrete shall be cast until all submittals have been favorably reviewed by the Engineer and returned to the Contractor.
B. Precast concrete structures shall be cast and cured at the plant following manufacturer’s procedures.
C. Structures shall not be shipped to the job site until fully cured.
3.02 STORAGE, HANDLING AND DELIVERY
A. Precast concrete structures shall be fully braced (with temporary struts if necessary) until delivered to the project site, installed, leveled and anchored into place as shown on the Plans.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) B. After cure, precast concrete structures may be stored on the project site in conformance with these specifications, at the Contractor’s own risk.
C. Contractor is responsible for coordinating the delivery of precast concrete structures and all trades required for their installation and anchorage.
3.03 INSTALLATION
A. Precast concrete structures shall be installed as shown on the Plans, according to the manufacturer’s recommendations.
B. Joint sealers shall be used as specified herein for a watertight installation.
3.04 TESTING
A. Manholes and wet wells shall be tested as specified in Section 02770.
3.05 DEFECTIVE CONCRETE AND REPAIRS
A. Concrete shall be considered defective for the following reasons:
1. Failure of finished concrete profiles to conform to the plans within tolerance.
2. Concrete showing cracks, rock pockets, voids, spalls, or defects that adversely affect the structural adequacy of the concrete.
B. Defective concrete that results from improper casting or curing shall be repaired or replaced at the plant prior to shipment; damaged concrete that results from transportation, handling, or storage after the piece leaves the plant shall be repaired or replaced at no expense to the City.
C. Repairing and Patching: When directed by the City, defective concrete may be repaired by chipping away the defective section and repairing it with concrete or mortar as directed by the City.
***END OF SECTION***
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SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 03600
GROUT
PART 1 GENERAL
1.01 SECTION INCLUDES
A. Grout for uses other than masonry.
1.02 REFERENCED SECTIONS
A. The following Sections are referenced in this Section
1. Section 01300 – Contractor Submittals
2. Section 03301 – Cast-In-Place Concrete
1.03 SUBMITTALS
A. Comply with Section 01300.
B. Manufacturer’s Data
1. Provided for the following:
a. Dry pack grout
b. Cement grout
c. Nonshrink grout, non-metallic
d. Nonshrink grout, metallic
e. Pressure grout
f. Epoxy grout
g. Polymer concrete
C. Laboratory Test Reposts
1. Test reports on previously tested materials shall be accompanied by the manufacturer's statement that the previously tested material is the same type, quality, manufacture, and make as that proposed for use in this project.
2. Test reports are required for the following:
a. Cement
b. Aggregates
c. Bonding compounds
d. Admixtures
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2.01 MATERIALS
A. Cement
1. Portland cement: ASTM C150 Type II or Type V, low alkali, containing less than 0.60 percent alkalis.
B. Aggregate
1. General
a. Nonreactive and washed before use.
b. When sources of aggregate are changed, provide test reports for the new material.
c. Perform the tests specified prior to commencing grout work.
2. Fine Aggregate
a. Hard, dense, durable particles of either sand or crushed stone regularly graded from coarse to fine and shall conform to ASTM C33 as modified herein.
b. When tested in accordance with ASTM C136, gradation shall be such that 100 percent by weight will pass a standard No. 8 mesh sleeve and no less than 45 percent by weight will pass a standard No. 40 mesh sieve.
3. Variation from the specified gradations in individual tests will be acceptable if the average of three consecutive tests is within the specified limits and the variation is within the permissible variation listed below:
US standard sieve size
Permissible variation in individual
tests, percent
30 or coarser 2.0
50 or finer 0.5
4. Other tests shall be in accordance with the following specifications:
C. Admixtures
1. General
a. Compatible with the grout.
Test Test Method Requirements
Organic Impurities ASTM C40 Color lighter than standard Amount of Material Passing
No. 200 Sieve ASTM C117 3% maximum by weight
Soundness ASTM C88 10% maximum loss with sodium sulfate Reactivity ASTM C289 Innocuous aggregate
Sand Equivalent ASTM D2419 Minimum 80
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SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) b. Calcium chloride or admixtures containing calcium chloride are not acceptable.
c. Used in accordance with the manufacturer's recommendations and added separately to the grout mix.
2. Water Reducing Retarder
a. ASTM C494 Type D.
b. Master Builders Pozzolith 300-R, Sika Corporation Plastiment, or equal.
3. Lubricant for Cement Pressure Grouting
a. Lubricant additive for cement pressure grouting shall be Intrusion Prepakt Intrusion Aid, Sika Intraplast N, or equal.
D. Water
1. Water for washing aggregate, for mixing and for curing shall be free from oil and deleterious amounts of acids, alkalis, and organic materials; shall not contain more than 500 mg/1 of chlorides as Cl, nor more than 800 mg/1 of sulfates as SO4; and shall not contain an amount of impurities that may cause a change of more than 25 percent in the setting time of the cement nor a reduction of more than five percent in the compressive strength of the grout at 14 days when compared with the result obtained with distilled water.
2. Additionally, water used for curing shall not contain an amount of impurities sufficient to discolor the grout.
2.02 GROUT
A. Drypack Grout
1. A mixture of approximately one part cement, 1-1/2 to 2 parts sand, water reducing retarder, and sufficient water to make a stiff workable mix.
B. Cement Grout
1. A mixture of one part cement, two parts sand, proportioned by volume, admixtures for pressure grouting, and sufficient water to form a workable mix.
C. Nonshrink Grout, Non-Metallic
1. Nonshrink, nonmetallic aggregate grout shall be Five Star Products, Inc., Five Star Grout; Sika Corporation, SikaGrout-928; Euclid Chemical Co., HiFlow Grout; or equal.
D. Nonshrink grout, Metallic
1. Nonshrink, metallic grout shall be Master Builders, MasterFlow 885; Euclid Chemical Co., Hi-Flow Metallic Grout; or equal.
E. Epoxy Grout for Crack Repair
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1. Except as noted below, epoxy grout shall be a high modulus, twocomponent, moisture insensitive, 100 percent solids, thermosetting modified polyamide epoxy compound.
a. The consistency shall be a paste form capable of not sagging in horizontal or overhead anchoring configurations.
b. Material shall conform to ASTM C881 Type 1, Grade 3, such as Master Builders MasterEmaco ADH 327, Sika Corporation Sikadur Hi-Mod Series, Adhesive Technology Corporation Solidbond 200 or equal, and shall have a heat deflection temperature in excess of 130 degrees F.
2. Epoxy for pressure grouting/crack injection shall be a two-component, moisture insensitive, high modulus, injection grade, 100 percent solids, blend of epoxy-resin compounds.
a. The consistency shall be as required to achieve complete penetration in hairline cracks and larger.
b. Material shall conform to ASTM C881 Type 1 Grade 1, such as Sika Corporation Sikadur 52, Master Builders MasterInject 1500, Adhesive Technology Corporation SLV 300 series, or equal.
F. Polymer Concrete (For Resurfacing or Patching)
1. Polymer concrete (for resurfacing or patching) shall consist of a liquid binder and dry aggregate mixed together to make a mortar or grout of a consistency as required for the application.
2. The liquid binder shall be a chemical and oil resistant, stress relieved, low modulus, moisture insensitive, two-component epoxy-resin compound.
3. The consistency shall be similar to lightweight oil for proper mixing with aggregate.
4. Material shall conform to ASTM C881 Type 3 Grade 1, such as Sika Corporation Sikadur Lo-Mod series, Master Builders MasterSeal 350, Adhesive Technology Corporation 400 series, or equal.
5. The aggregate shall be oven dry in sealed packages until time of mixing, and shall be of size and consistency compatible with recommendations of manufacturer of liquid binder for intended application.
2.03 PRESSURE GROUTING EQUIPMENT
A. Pressure grouting equipment shall include a mixer and holdover agitator tanks and shall be designed to place grout at pressures up to 50 psi.
B. Provide gages to indicate pressure used.
C. The mixer shall be provided with a meter capable of indicating to one-tenth of a cubic foot the volume of grout used.
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3.01 GENERAL
A. Bonding compound for use with grout is specified in Section 03301. Primer, if required for polymer concrete, shall be provided per manufacturer's recommendation.
3.02 DRYPACK GROUT
A. Use drypack grout for built-up surfaces, setting miscellaneous metal items and minor repairs.
B. Surfaces required to be built up with drypack grout shall be roughened by brushing, cleaned, and coated with the bonding compound specified in Section 03301 before the application of the grout.
C. Apply drypack grout immediately following the application of the bonding compound in bands or strips to form a covering of the required thickness. The covering shall be smooth.
D. Construction joints in the grout shall be sloped and shall be cleaned and wetted before application is resumed.
E. Cure drypack grout in accordance with Section 03301.
F. Grout shall not be placed during freezing weather unless adequate protection is provided.
3.03 CEMENT GROUT
A. Use cement grout for filling nonbearing portions of equipment pads and pressure grouting.
B. Except for the specialized equipment for pressure grouting, mixing and placing apparatus shall be similar to that normally used for cast-in-place concrete.
C. Mix grout for a period of at least 1 minute.
D. Agitate diluted grout to keep ingredients mixed.
3.04 NONSHRINK GROUT
A. Nonshrink, metallic aggregate grout shall be used for the bearing surfaces of machinery and equipment bases, column base plates and bearing plates at dry, interior locations.
B. Nonshrink, non-metallic aggregate grout shall be used for the bearing surfaces of machinery and equipment bases, column base plates, and bearing plates at damp or exterior locations as well as for setting handrail, guardrail, or fence posts in pipe sleeves.
Grout shall meet the requirements of CRD-C 621 and shall be placed in accordance with manufacturer's instructions.
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3.05 EPOXY GROUT
A. Epoxy grout shall be used for repairing cracks by pressure grouting or gravity flow and for repairing structural concrete.
B. Concrete shall be primed in accordance with the grout manufacturer's instructions.
3.06 PRESSURE GROUTING
A. Prior to grouting, systems and holes to be grouted shall be washed clean.
B. Washing is not required for grouting soil voids outside pipe cylinders or casing pipes.
C. Grouting, once commenced, shall be completed without stoppage.
D. In case of breakdown of equipment, wash out the grouting system sufficiently to ensure fresh grout and adequate bond and penetration will occur upon restarting the grouting operation.
E. Maintain grout pressure until grout has set.
***END OF SECTION***
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SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 04200
CONCRETE MASONRY UNITS
PART 1 GENERAL
1.01 SECTION INCLUDES
A. Concrete masonry units, mortar, grout, and reinforced masonry construction.
1.02 REFERENCED SECTIONS
A. The following Sections are referenced in this Section
1. Section 01300 – Contractor Submittals
2. Section 09900 – Coating Systems
1.03 SUBMITTALS
A. Comply with Section 01300.
B. Product Data: For each type of masonry unit, masonry accessory, and admixture to be incorporated into the Work.
C. Shop Drawings: Submit reinforcement placing drawings with details of bond beams and lintels. Comply with ACI 315, "Details and Detailing of Concrete Reinforcement." Show elevations of reinforced walls with locations of control joints and wall penetrations.
D. Samples for each type and color of exposed masonry units and colored mortars.
E. Material Certificates: For each type of product indicated. Include statements of material properties indicating compliance with requirements including compliance with standards and type designations within standards.
F. Mix Designs: For each type of mortar and grout. Include description of type and proportions of ingredients.
1.04 QUALITY ASSURANCE
A. Preconstruction Testing Service: Contractor shall engage a qualified independent testing agency to perform preconstruction testing indicated below. Payment for these services shall be made by Contractor.
1. Concrete Masonry Unit Test: For each type of unit required, per ASTM C140.
2. Mortar Test (Property Specification): For each mix required, per ASTM C780.
3. Grout Test (Compressive Strength): For each mix required, per ASTM C1019. 372
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SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) B. Sample Panels: Build sample panels to verify selections made under sample submittals and to demonstrate aesthetic effects. Build sample panels for typical exterior wall in sizes approximately 48 inches long by 48 inches high.
1.05 PROJECT CONDITIONS
A. Cold-Weather Requirements: Do not use frozen materials or materials mixed or coated with ice or frost. Do not build on frozen substrates. Remove and replace unit masonry damaged by frost or by freezing conditions. Comply with cold-weather construction requirements contained in ACI 530.1/ASCE 6/TMS 602.
B. Hot-Weather Requirements: Comply with hot-weather construction requirements contained in ACI 530.1/ASCE 6/TMS 602.
PART 2 PRODUCTS
2.01 CONCRETE MASONRY UNITS
A. General
1. Modular dimensions and air, water, or steam cured.
2. Surface Texture: Provide split-face, scored split-face, or ground-face blocks where indicated on the Drawings. At other locations, provide precision masonry units with comparatively smooth and uniform surface texture.
B. Hollow Load Bearing Concrete Masonry Units
1. Provide hollow load-bearing units conforming to ASTM C90, made with lightweight aggregate.
2. Provide load-bearing units unless otherwise specified.
3. Unit Compressive Strength: Provide units with minimum average net-area compressive strength of 2,000 psi.
4. Weight Classification: Light weight.
C. Special Shapes: Provide special shapes for lintels, corners, jambs, sashes, movement joints, headers, bonding, and other special conditions.
D. Size and Color: Nominal 16-inch long by 8-inch wide by 8-inch tall units arranged to form a running bond pattern as indicated on the Drawings. Color to be the Manufacturer’s standard Tan color or as selected by Construction Manager from submitted color palette.
E. Water Repellent and Anti-Graffiti Coatings: As indicated in Section 09900.
2.02 MORTAR MATERIALS
A. Cementitious Materials
1. Portland Cement: Conforming to ASTM C150, Type I or II. Type III may be used for cold-weather construction upon approval of the Engineer. 373
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2. Hydrated Lime: Conforming to ASTM C207, Type S.
3. Mortar Cement: Conforming to ASTM C1329.
B. Sand for Mortar: Conforming to ASTM C144.
1. For joints less than 1/4 inch thick, use aggregate graded with 100 percent passing the No. 16 sieve.
C. Water-Repellent Admixture: Liquid water-repellent mortar admixture intended for use with concrete masonry units and formulated to minimize efflorescence while enhancing the bond between the mortar and masonry units.
1. Products: One of the following, or equal:
a. Addiment Incorporated; Mortar Tite.
b. Grace Construction Products; Dry-Block Mortar Admixture. c. Master Builders, Inc.; Color Cure Mortar Admix or Rheomix Rheopel.
D. Water: Use potable water.
2.03 GROUT MATERIALS
A. Cementitious Materials
1. Portland Cement: Conforming to ASTM C150, Type I or II. Type III may be used for cold-weather construction upon approval of the Engineer.
2. Hydrated Lime: Conforming to ASTM C207, Type S.
B. Fine and Coarse Aggregates: Conforming to ASTM C404.
C. Water: Use potable water.
2.04 MORTAR AND GROUT MIXES
A. Mortar for Unit Masonry: Comply with ASTM C270, Property Specification, Type S.
B. Grout for Unit Masonry: Proportion by volume in accordance with ASTM C476 to achieve a minimum compressive strength of 2,500 psi.
1. Use grout of type indicated or, if not otherwise indicated, of type (fine or coarse) that will comply with Table 1.15.1 in ACI 530.1/ASCE 6/TMS 602 for dimensions of grout spaces and pour height.
2. Provide grout with a slump of 8 to 11 inches as measured according to ASTM C143.
C. Epoxy Pointing Mortar: Mix epoxy pointing mortar to comply with mortar manufacturer's written instructions.
2.05 REINFORCEMENT
A. Uncoated Steel Reinforcing Bars: Conforming to ASTM A615, Grade 60. 374
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1. Cold drawn steel wire conforming to ASTM A82, hot dipped galvanized after fabrication in accordance with ASTM A153.
2. Acceptable Configurations:
a. Truss type with two or more longitudinal wires welded to a continuous diagonal cross wire.
b. Ladder type with perpendicular cross wires not more than 1 inch on center.
3. Dimensions:
a. Provide in 10-foot long flat sections.
b. Preformed Tees and Corner reinforcement: Approximately 30 inches long.
c. Overall Width: Approximately 2 inches less than the nominal wall thickness.
2.06 MISCELLANEOUS MASONRY ACCESSORIES
A. Compressible Filler: Premolded filler strips complying with ASTM D1056, Grade 2A1; compressible up to 35 percent; formulated from neoprene.
B. Preformed Control-Joint Gaskets: Made from styrene-butadiene-rubber compound, complying with ASTM D2000, Designation M2AA-805 and designed to fit standard sash block and to maintain lateral stability in masonry wall.
C. Bond-Breaker Strips: Asphalt-saturated, organic roofing felt complying with ASTM D226, Type I (No. 15 asphalt felt).
2.07 MASONRY CLEANERS
A. Acidic Cleaner: Manufacturer's standard-strength cleaner designed for removing mortar/grout stains from new masonry without damaging masonry. Use product approved for intended use by cleaner manufacturer and manufacturer of masonry units being cleaned.
B. Manufacturers: One of the following or equal:
1. Diedrich Technologies, Inc.
2. EaCo Chem, Inc.
3. ProSoCo, Inc.
PART 3 EXECUTION
3.01 INSTALLATION, GENERAL
A. Use full-size units without cutting if possible. If cutting is required, cut units with motor-driven saws; provide clean, sharp, unchipped edges. Allow units to dry before 375
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B. Select and arrange units for exposed unit masonry to produce a uniform blend of colors and textures.
C. Comply with tolerances in ACI 530.1/ASCE 6/TMS 602 and with the following:
1. For conspicuous vertical lines, such as external corners, door jambs, reveals, and expansion and control joints, do not vary from plumb by more than 1/8 inch in 10 feet, 1/4 inch in 20 feet, or 1/2 inch maximum.
2. For conspicuous horizontal lines, such as lintels, sills, parapets, and reveals, do not vary from level by more than 1/8 inch in 10 feet, 1/4 inch in 20 feet, or 1/2 inch maximum.
3.02 LAYING MASONRY WALLS
A. Lay out walls in advance for accurate spacing of surface bond patterns with uniform joint thicknesses and for accurate location of openings, movement-type joints, returns, and offsets. Avoid using less-than-half-size units, particularly at corners, jambs, and, where possible, at other locations.
B. Bond Pattern for Exposed Masonry: Unless otherwise indicated, lay exposed masonry in running bond; do not use units with less than nominal 4-inch horizontal face dimensions at corners or jambs.
C. Step back unfinished walls for joining with new walls, toothing will not be permitted.
D. Built-in Work: Build in door and window frames, fan and louver openings, pipe and conduit sleeves, and other items as the masonry construction progresses. Fill in solidly with masonry around built-in items.
E. Fill space between steel frames and masonry solidly with mortar, unless otherwise indicated.
F. Completely fill all cores in hollow concrete masonry units with grout.
3.03 MORTAR BEDDING AND JOINTING
A. Lay hollow concrete masonry units as follows:
1. With face shells fully bedded in mortar and with head joints of depth equal to bed joints.
2. With webs fully bedded in mortar in grouted masonry, including starting course on footings.
B. Lay solid masonry units with completely filled bed and head joints; butter ends with sufficient mortar to fill head joints and shove into place. Do not deeply furrow bed joints or slush head joints.
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SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) C. Tool exposed joints slightly concave when thumbprint hard, using a jointer larger than joint thickness, unless otherwise indicated.
D. Cut joints flush for masonry walls to receive plaster or other direct-applied finishes (other than paint), unless otherwise indicated.
3.04 REINFORCED UNIT MASONRY INSTALLATION
A. Temporary Formwork and Shores: Construct formwork and shores as needed to support reinforced masonry elements during construction.
1. Construct formwork to provide shape, line, and dimensions of completed masonry as indicated. Make forms sufficiently tight to prevent leakage of mortar and grout.
Brace, tie, and support forms to maintain position and shape during construction and curing of reinforced masonry.
2. Do not remove forms and shores until reinforced masonry members have hardened sufficiently to carry their own weight and other temporary loads that may be placed on them during construction.
B. Placing Reinforcement: Comply with ACI 530.1/ASCE 6/TMS 602.
C. Grouting
1. Grout Types:
a. Use fine grout in grout spaces that are less than 2 inches in any horizontal dimension after deducting the thickness of horizontal reinforcement. b. Use fine grout in grout spaces where clearance between the reinforcing bars and the masonry is less than 3/4-inch.
c. Use coarse grout in all other locations.
2. Do not place grout until entire height of masonry to be grouted has attained enough strength to resist grout pressure.
3. Comply with requirements in ACI 530.1/ASCE 6/TMS 602 for cleanouts and for grout placement, including minimum grout space and maximum pour height.
4. Limit height of vertical grout pours to not more than 60 inches.
5. Place grout in a continuous pour and agitate to eliminate voids. If masonry units are dislodged or displaced by the grouting operation, remove masonry units and relay in alignment with fresh mortar.
3.05 TOLERANCES
A. Complete masonry work within the following tolerances:
1. Face of Concrete Masonry Unit: 1/16-inch from face of adjacent unit.
2. Variation from True Plane: 1/4-inch in 10 feet and 1/2-inch maximum in 20 feet or more.
3. Variation from Plumb: 1/4-inch in each story, noncumulative and 1/2-inch maximum in two stories or more.
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4. Variation from Level: 1/8-inch in 3 feet, 1/4-inch in 10 feet, and 1/2-inch maximum.
5. Variation in Wall Thickness: plus or minus 1/4-inch.
3.06 FIELD QUALITY CONTROL
A. Special Inspection and Testing of masonry construction shall be performed by the Owner’s Testing Laboratory. The Contractor shall allow inspectors access to scaffolding and work areas as needed to perform inspections.
B. Place grout only after inspectors have verified compliance of grout spaces and grades, sizes, and locations of reinforcement.
C. Masonry Work to Receive Special Inspection: All masonry work shall receive Special Inspection in accordance with the requirements of California Building Code. Bolts installed in masonry require Special Inspection. Review Inspection protocol with Construction Manager.
D. Three representative full-size sample masonry units showing full range of color, texture, finish, and dimensions are to be submitted for review.
E. Testing Frequency: One set of tests for each 5,000 sq. ft. of wall area or portion thereof.
F. Concrete Masonry Unit Test: For each type of unit provided, per ASTM C140.
G. Mortar Test (Property Specification): For each mix provided, per ASTM C780. Test mortar for mortar air content and compressive strength.
H. Grout Test (Compressive Strength): For each mix provided, per ASTM C1019.
3.07 CLEANING
A. In-Progress Cleaning: Clean unit masonry as work progresses by dry brushing to remove mortar fins and smears before tooling joints.
B. Final Cleaning: After mortar is thoroughly set and cured, clean exposed masonry as follows:
1. Test cleaning methods on sample wall panel; leave one-half of panel uncleaned for comparison purposes.
2. Protect adjacent surfaces from contact with cleaner.
3. Wet wall surfaces with water before applying cleaners; remove cleaners promptly by rinsing surfaces thoroughly with clear water.
4. Clean masonry by bucket-and-brush hand-cleaning method described in BIA Technical Notes 20.
5. Clean masonry with a proprietary acidic cleaner applied according to manufacturer's written instructions.
***END OF SECTION***
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SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 05400
COLD-FORMED METAL FRAMING
PART 1 GENERAL
1.01 SUMMARY
A. Section Includes
1. Fabricate and erect exterior load bearing and nonload bearing steel stud wall framing including crossbridging and bracing and bracketing to the building structure, complete in all respects, including runner tracks, headers, sills, z-furring and hat channels, jack studs, anchors and fastening devices, welding supplies and accessories, and other components required, all as indicated.
2. Hot-rolled and galvanized steel clip angles and shelf an- gles and framing members required at wall openings for louvers, doors and other openings at light gauge steel framing work, except items indicated or specified to be provided by other trade(s).
3. Anchorage system for securing to building structure.
4. Strapping over framing for attachment of metal panels.
5. Shop and field welding required for proper connecting, and for securing light gauge steel framing to the surrounding construction.
6. Touch-up painting of all shop and field welds.
B. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section.
C. Related Sections
1. Section 05500 – Miscellaneous Metal: Provision of non-structural steel framing.
2. Section 09290 - Gypsum Board: Provision of gypsum board.
3. Section 09900 - Painting and Coating: For finish painting.
1.02 REFERENCES
A. AISC - American Institute of Steel Construction
1. Code - Code of Standard Practice for Steel Buildings and Bridges.
2. Specification - Specification for the Design, Fabrication and Erection of Structural Steel for Buildings.
B. AISI - American Iron and Steel Institute
1. Specifications - Specification for the Design of Cold- Formed Steel Structural Members.
C. ASTM - American Society for Testing and Materials
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1. A36 - Specification for Structural Steel.
2. A653 - Standard Specification for Steel Sheet, Zinc- Coated (Galvanized) or ZincIron Alloy-Coated (Galvannealed) by the Hot-Dip Process.
3. A780 - Practice for Repair of Damaged Hot-Dip Galvanized Coatings.
D. AWS - American Welding Society
1. D1.3 - Structural Welding Code - Sheet Steel.
E. CBC - California Building Code, 2025 Edition
F. FS - Federal Specifications
1. TT-P-564 - Primer Coating, Synthetic, Rust-Inhibiting, Lacquer-Resisting.
G. ICC - International Code Council
1. ES - Evaluation Service
H. SSPC - The Society for Protective Coatings
1.03 SUBMITTALS
A. Product Data: For information only, submit manufacturer’s product data for all components to be used in the construction and anchoring of the light gauge steel framing. Include specifications, installation Instructions, and data substantiating that the materials comply with specified requirements.
B. Shop Drawings
1. Submit for the City’s approval complete shop drawings of all work of this Section, based on, and closely following, the layouts and details on the Drawings.
2. Shop drawings shall show complete elevations, plans and sections of all installation, including complete large scale details of all typical and special conditions of construction; clearly indicating materials, sizes, shapes, sections, gauges, thicknesses and finishes of all members; and clearly indicating all materials and methods used in the connection and anchoring of the work; locations and spacing of all shop and field welds; bracing and bracketing; anchorage; support framing; installation tolerance; electrolytic isolation; and all other pertinent details.
3. The Contractor shall engage the services of a professional engineer registered in the State of California to prepare and/or review all shop drawings and structural design computations specified herein, who shall, upon completion, stamp them with his/her professional seal. The shop drawings and structural design computations, with the engineer’s seal affixed thereto, shall be submitted to the City for approval.
C. Do not order materials or begin fabrication or installation until the City’s approval of submittals has been obtained.
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1.04 QUALITY ASSURANCE
A. Qualifications
1. Welders
a. Qualified for the work by tests as prescribed in AWS D1.3 and shall submit certification of such qualifications to the City prior to beginning of this work. b. Certificates of qualification of welders from a recognized agency whose test procedures and requirements are at least equal to those of AWS may be acceptable to the City.
c. Cost of certifying and/or qualifying of welders shall be borne by the Contractor.
2. Fabricator/Erector: The light gauge steel framing fabricator/erector shall have at least 3 years experience in the fabrication and erection of light gauge steel framing systems of scope and type similar to the required work.
B. Regulatory Requirements: Work shall comply with the governing laws and building code and applicable provisions of the following standards:
1. AlSC Specification.
2. AISC Manual.
3. AISC Code.
4. AWS D1.3.
5. AISI Specifications.
6. CBC Building Code, 2025 Edition.
7. SSPC Painting Manual.
C. Any material or workmanship which is rejected by the City and/or the Testing Agency in mill, shop, or field, shall be replaced promptly by the Contractor to the satisfaction of the City and/or the Testing Agency, and at the Contractor’s expense.
D. Acceptance of work in shop shall not prevent the final rejection of work at the job site, even after erection, if work is found to be defective in any way.
1.05 DELIVERY, STORAGE AND HANDLING
A. Acceptance at Site:Deliver to the fabrication site in manufacturer’s unopened containers or bundles, fully identified with name, brand, type and grade.
B. Storage and Protection
1. Store off the ground in a dry ventilated space or protect with suitable waterproof coverings and ventilate to avoid condensation.
2. Protect metal framing units from weather and damage. 381
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1.06 PROJECT CONDITIONS
A. Coordination: Examine all Drawings as to the requirements for accommodations and/or the installation of work of other Sections and provide holes and connections as required for such work and for site assembly of metal work. Holes shall be drilled or punched and reamed in the shop. Show sizes and locations of all such holes on the shop drawings.
1.07 WARRANTY
A. The Contractor shall obtain in the City’s name the standard written manufacturer’s warranty of all materials furnished under this Section where such warranties are offered in the manufacturer’s published product data. All these warranties shall be in addition to, and not in lieu of, other liabilities which the Contractor may have by law or other provisions of the Contract Documents.
PART 2 PRODUCTS
2.01 MANUFACTURERS
A. Acceptable Manufacturers: CEMCO; Wheeling Steel Co.; Dietrich; Safco, or equal.
2.02 MATERIALS
A. Materials shall be new, free from defects marring strength, durability, or appearance, and of best commercial quality for the purpose used. Take necessary measurements in field to assure exact fit of all components.
B. Steel Framing System: A complete proprietary framing system, consisting of cold rolled steel studs formed from steel, of gauge(s) indicated on the approved shop drawings, and of a minimum yield stress of 50 KSI conforming to ASTM A653 for 16 gauge and heavier members and of a minimum yield stress of 33 KSI conforming to ASTM A653 for 18 gauge and lighter members. The system shall include all steel channel head and sill runner tracks, deflection tracks, steel cross bridging and bracing, steel jack studs, anchors and fastening devices, welding supplies and accessories, and other items that are required for a complete installation. All steel members shall be G60 galvanized per ASTM A653 or shop primed with 1 coat of rust-inhibitive primer, conforming to FSTT-P-664.
C. Hot Rolled Steel Members: Provide all steel clip angles, shelf angles and other support and retention members indicated on the Drawings, except items specifically indicated or specified to be provided under other Sections. Steel shall conform to ASTM A36, of sizes and configurations indicated on the Drawings. All steel shapes provided under this Section shall conform to standards set forth under Section 05500.
2.03 FASTENERS
A. Fastening of 16 Gauge or Heavier Metal: Framing components shall be fastened to each other by welding only (unless otherwise indicated on the Drawings).
1. Welding: Welding standards shall conform to standards set forth in AISC and AWS reference standards specified hereinabove.
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2. Electrodes for welding shall conform to AWS requirements for welding low carbon steel. Manufacturer shall furnish instructions with each container of electrodes giving recommended voltage, amperage, polarity of direct current, for all uses and positions for which electrode is suitable.
B. Fastening of 18 Gauge Metal and Lighter: Framing components may be fastened to each other by screws.
C. Self-drilling fasteners shall be “TEKS” as manufactured by ITW Buildex, or equal.
Use length and type as indicated on the Drawings or as recommended by the manufacturer for the intended use.
D. Powder actuated fasteners shall be “X-U” shot pins as manufactured by Hilti, Inc., or equal. Fastener length shall be as indicated on the Drawings or as recommended by the manufacturer for the intended use. Fasteners shall be installed in accordance with the manufacturer’s recommendations and current ICC-ES evaluation reports.
2.04 MISCELLANEOUS MATERIALS
A. Galvanizing Repair Paint: High zinc dust content paint, with dry film containing not less than 94 percent zinc dust by weight, as manufactured by Parker Amchem, “Galvaprep SG”; Sherwin Williams, “Zinc Clad I”, or equal.
B. Thermal Insulation: None required.
2.05 FABRICATION
A. Light gauge steel framing shall be shop or field assembled.
B. Prior to commencement of fabrication, subcontractor shall submit fabrication and erection drawings for the City’
s approval as specified.
C. Contractor shall coordinate stud locations with the following:
1. Mechanical work.
2. Coordinate interface between light gauge steel framing and gypsum board studs and to ensure proper support for gypsum board and gypsum sheathing to be installed under Section 09290.
D. Metal framing shall be fabricated in accordance with manufacturer’s printed or written instructions unless otherwise indicated.
E. Framing components shall be straight and true prior to fabrication. Flattening or straightening of components shall be done by a process not injurious to materials.
F. Framing components shall be cut squarely (or on an angle as with bracing) to fit squarely against abutting members.
G. No splices will be allowed in studs. Stud tracks shall be continuous, with splices butt welded.
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SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) H. Provide lateral bracing and bridging to manufacturer’s specifications and recommendations as required by CBC.
I. Provide all angles, clips, and other miscellaneous pieces necessary to attach light gauge framing panels to building structure or to attach other materials to light gauge framing panels.
J. Cut all openings in light gauge framing required for ducts, grilles, pipes, etc.
K. Components shall be set square and in line and shall be held firmly in position until properly fastened.
L. Panel components shall be joined by welding.
1. Welders shall be grade certified for the weight and type of materials and the type of equipment being used.
2. Welding shall be done in accordance with AWS D1.3.
M. Finished assemblies shall be free from twists, bends, or open joints with all members straight, square and true to line.
2.06 SOURCE QUALITY CONTROL
A. Inspection
1. Inspection and testing of welded connections will be performed by an independent testing laboratory, under a separate contract with the City.
Welded connections shall be subjected to inspection and testing in shop and field by the City and/or testing laboratory. Such inspection and testing shall not relieve the Contractor of his/her responsibility to provide his/her own inspection, testing, and quality control as necessary to furnish workmanship in accordance with requirements of the Contract Documents.
2. Notify the City and testing laboratory prior to start of any fabrication, erection, or other phase of work requiring welded connections so as to afford them reasonable opportunity to inspect work.
3. Facilitate inspection and testing by testing laboratory. The Contractor shall, upon request and at his/her own expense, furnish testing laboratory with:
a. Complete sets of approved Shop Drawings and corrective work procedures at shop(s) and in field.
b. Representative sample pieces of materials requested for testing.
4. Testing laboratory will inspect welded connections for burned welds, adequate size and length of welds, and general appearance and integrity of welds as required by the City.
5. Do not remove any marks or tags applied by testing laboratory identifying rejected work.
6. Welded connections which have been rejected by the City and/or testing laboratory in shop or field shall be corrected without delay and at no expense to the City.
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SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) B. Acceptance of work in shop shall not prevent final rejection of work at job site, even after erection, if work is found to be defective in any way.
PART 3 EXECUTION
3.01 EXAMINATION
A. Examine supporting substrates and abutting structural framing for compliance with requirements, including installation tolerances and other conditions affecting performance of cold formed metal framing. Do not proceed with installation until unsatisfactory conditions have been corrected.
3.02 ERECTION
A. Light gauge steel framing shall be erected by approved methods using equipment of adequate capacity to safely perform the work.
B. Any damage to other building materials caused by erection of light gauge steel framing shall be repaired or replaced as directed by the City at this subcontractor’s expense.
C. Contractor shall be responsible for checking dimensions and assuring fit of all members and panels before erection begins.
D. Work shall be erected plumb, level and to dimensions and elevations indicated.
E. Do not install any member or panel which is bent or racked. Such panels shall be replaced.
F. During erection, install steel cables with turnbuckles in sufficient number to prevent distortion and damage to framing due to wind or erection forces until erection is complete. These cables may be used to plumb and line the work.
G. Tracks providing anchorage for studs shall be anchored to steel or concrete as required by CBC, but not over 24 inches. No piece of track shall have less than 2 anchors.
H. Where panels are attached to steel with a continuous attachment angle, the attachment angle shall be welded to each stud and shall be fastened to structural steel support as required by CBC, but not less than 24 inches on center.
I. Do not bridge building expansion and control joints with cold formed metal framing.
Independently frame both sides of joints.
J. Install insulation in built-up exterior framing members, such as headers, sills, boxed joists and double studs, inaccessible upon completion of framing work.
K. Fasten reinforcement plate over web penetrations that exceed size of manufacturer’s standard punched openings.
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COLD-FORMED METAL FRAMING 05400- 8
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) L. Erection Tolerances: Install cold formed metal framing to a maximum allowable tolerance variation from plumb, level, and true to line of 1/8-inch in 10 feet and as follows:
1. Space individual framing members no more than plus or minus 1/8-inch from plan location. Cumulative error shall not exceed minimum fastening requirements of sheathing or other finishing materials.
3.03 ADJUSTING
A. Galvanizing Repairs: Prepare and repair damaged galvanized coatings on fabricated and installed cold-formed metal framing with galvanizing repair paint, according to ASTM A780 and the manufacturer’s instructions.
3.04 PROTECTION AND CLEANING
A. During erection of the light gauge steel framing work, protect the work of other trades against damage or staining by the exercise of reasonable care and precautions. Repair or replace any work so damaged.
1. Upon completion of this work, remove all rubbish, debris, and tools from the work area and leave the premises broom clean.
***END OF SECTION***
386
MISCELLANEOUS METAL 05500- 1
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 05500
MISCELLANEOUS METAL
PART 1 GENERAL
1.01 SECTION INCLUDES
A. Furnishing material, supplies, equipment, tools, transportation and facilities and performing labor and services necessary for, required in connection with or properly incidental to furnishing and installing miscellaneous metal, as described in this Section of the Specifications, shown on the accompanying Plans, or reasonably implied therefrom.
1.02 REFERENCED SECTIONS
A. The following Sections are referenced in this Section
1. Section 01300 – Contractor Submittals
2. Section 09900 – Coating Systems
1.03 SUBMITTALS
A. Comply with Section 01300.
B. Certified test reports: Before delivery of any miscellaneous metalwork, provide certificates which attest to material compliance with these specifications.
C. Layout or installation shop drawings for all miscellaneous metals, including but not limited to, seat angles, brackets, flashing, pipe supports.
PART 2 PRODUCTS
2.01 MATERIALS
A. Structural Steel Wide Flange Beams: ASTM A992.
B. Structural Steel Shapes (other than Wide Flange Beams) and Plates: ASTM A36.
C. Structural Steel Tubing (HSS): ASTM A500, Grade B.
D. Structural Steel Pipe: ASTM A53, Grade B or ASTM A501.
E. Stainless Steel Tubing (HSS): ASTM A554, Type 316, unless noted otherwise.
F. Stainless Steel Shapes and Plates: ASTM A276, Type 316, unless noted otherwise.
G. Machine Bolts, Nuts, and Washers: ASTM A307.
H. Threaded Rods: ASTM F1554, Grade 36, unless noted otherwise. 387
MISCELLANEOUS METAL 05500- 2
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) I. High Strength Bolts: ASTM A325 bearing-type connections, unless noted otherwise.
J. Hardened Steel Washers: ASTM F436.
K. Heavy Hex Nuts: ASTM A563.
L. Stainless Steel Bolts and Threaded Rods: ASTM F593, Alloy Group 2, Condition A.
M. Stainless Steel Nuts: ASTM F594, Alloy Group 2, Condition A.
N. Welded Headed Studs: ASTM A108.
O. Welding Materials: AWS D1.1, D1.3 or D1.6; type required for materials being welded.
P. Cold-Formed Steel
1. Framing including stud and track sections, clips, light gauge angles and break shapes.
2. Material shall be supplied by a manufacturer who is a member of the Steel Stud Manufacturer’s Association (SSMA) and shall be ASTM A 653 Grade 33 for 18 GA and thinner material and ASTM A 653 Grade 50 for 16 GA and thicker material.
3. Wood Construction Connectors and Fasteners: Simpson Strong-Tie Company Inc. or approved equal.
4. Self-Drilling Sheet Metal Fasteners: Tek Screws by ITW Buildex or equal.
5. Powder Actuated Fasteners: ‘X-U’ Shot Pins by Hilti or equal.
Q. Steel Bar Grating: Steel bar grating shall be as manufactured by Grating Pacific, Inc. or approved equal. Bar depth, width and spacing shall be as shown on the Plans. All grating sections shall be banded. Steel bar grating shall be hot dip galvanized.
R. Metal Strut, Fasteners and Accessories: Cooper B-Line, Unistrut or equal.
2.02 FABRICATION
A. Fabricate structural steel members in accordance with AISC Specification.
B. Conform to Chapter 22, California Building Code (CBC), latest Edition.
C. Welding
1. Welder qualification requirements, welding procedures, etc. according to AWS D1.1 and D1.3. Employ only certified welders.
2. Butt welds: Full penetration welds unless otherwise noted.
3. Arc welding electrodes: E70 Series.
4. All welds on hand and guardrails are to be ground smooth.
5. Tie plates: Welded as shown on the Plans.
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MISCELLANEOUS METAL 05500- 3
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) D. Holes for bolts or rivets shall be punched or drilled 1/16-inch larger than normal bolt.
Holes in column base plates may be 5/16-inch larger than anchor bolt diameter only if washers field welded to the base plate are provided under the nuts.
E. Zinc coating material: As specified in ASTM A153.
F. Zinc dust-zinc oxide coating: Conform to MILLSPEC DOD-P-20135.
G. Coating: As manufactured by Z.R.C. Chemical Products Co., Galvicon Co., or equal.
2.03 MISCELLANEOUS STEEL METALWORK
A. Other miscellaneous steel metalwork including embedded and non-embedded steel metalwork, hangers, and inserts shall be as specified on the Plans and shall be hot-dip galvanized after fabrication unless otherwise specified.
2.04 COATING REQUIREMENTS
A. Hot-dip galvanize fabricated material where specified on the Plans and in this Section of the Specifications.
B. Clean, prepare and shop prime other steel work in accordance with Section 09900.
C. Do not prime surfaces to be field welded.
D. Touch-up primer in the field after welding is complete. Apply finish coats in the field in accordance with Section 09900.
E. Coatings in contact with potable water shall be NSF-61 approved for potable water applications.
PART 3 EXECUTION
3.01 STEEL ERECTION
A. Erect structural steel in accordance with AISC Specification.
B. Make provision for erection loads, and for sufficient temporary bracing to maintain structure safe, plumb and in true alignment until completion of erection and installation of permanent bracing.
C. Do not field cut or alter structural members without approval of Engineer.
D. After erection, prime welds, abrasions, and surfaces not shop primed, galvanized, except surfaces to be in contact with concrete. Use a primer consistent with shop coat. Use primer recommended for galvanized surfaces.
E. Bolting: Securely bolt or weld the work as erection progresses to provide for all dead load, lateral forces and erection stresses.
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3.02 MISCELLANEOUS METALWORK
A. General
1. Fieldwork shall not be permitted on galvanized items. Drilling of bolts or enlargement of holes to correct misalignment will not be allowed.
2. Protect dissimilar metals from galvanic corrosion by means of pressure tapes, coatings or isolators. Protect aluminum in contact with concrete or grout with a heavy coat of bituminous paint.
3. Metalwork to be embedded in concrete:
a. Placed accurately and held in correct position while the concrete is placed or, if specified, recesses or blockouts shall be formed in the concrete. b. The surfaces of metalwork in contact with or embedded in concrete shall be thoroughly cleaned.
c. If accepted, recesses may be neatly cored in the concrete after it has attained its design strength and the metalwork grouted in place.
B. Seat Angles, Supports, and Guides
1. Set seat angles for grating and supports for floor plates so that they are flush with the floor and also maintain the grating and floor plates flush with the floor.
C. Fabrication
1. Holes shall be punched 1/6-inch larger than the nominal size of the bolts, unless otherwise specified. Whenever needed, because of the thickness of the metal, holes shall be subpunched and reamed or shall be drilled.
2. Fabrication including cutting, drilling, punching, threading and tapping required for miscellaneous metal or adjacent work shall be performed prior to hot-dip galvanizing.
3.03 FABRICATIONS REQUIREMENTS
A. Steel members, fabrications and assemblies: Galvanized after fabrication in accordance with ASTM A123.
B. Steel items weighing 100 pounds or less: Hot-dip zinc coated.
C. Anchor bolts and nuts 5/8 inch and larger: Hot-dip zinc coated in accordance with ASTM A153.
D. Anchor bolts and nuts smaller than 5/8-inch and all other bolts, screws, nuts, washers and other minor steel fasteners: Mechanically zinc coated.
E. Fabrication practices for products to be galvanized: In accordance with applicable portions of ASTM A143, A384 and A385.
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SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
3.04 REPAIR OF DEFECTIVE GALVANIZED COATING
A. Where zinc coating has been damaged after installation, substrate surface shall be first cleaned and then repaired with zinc dust-zinc oxide coating in accordance with ASTM A780. Application shall be as recommended by the zinc dust-zinc oxide coating manufacturer. Coating shall consist of multiple coats to dry film thickness of eight mils.
B. Remove items not physically damaged, but which have insufficient or deteriorating zinc coatings, and items damaged in shipment or prior to installation from the project site for repair by the hot-dip zinc coating method.
3.05 CLEANING
A. After installation, damaged surfaces of shop primed metals shall be cleaned and touched up with the same material used for the shop coat.
***END OF SECTION***
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ANCHOR BOLTS 05501- 1
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 05501
ANCHOR BOLTS
PART 1 GENERAL
1.01 SECTION INCLUDES
A. Anchor bolts complete with washers and nuts. Type 316 stainless steel, unless otherwise specified.
1.02 REFERENCED SECTIONS
A. The following Sections are referenced in this Section
1. Section 01300 – Contractor Submittals
2. Section 03301 – Cast-In-Place Concrete
3. Section 11002 – Equipment Mounting
1.03 SUBMITTALS
A. Comply with Section 01300 and include the following information:
1. Data indicating load capacities.
2. Chemical resistance.
3. Temperature limitations.
4. Installation instructions.
5. Evaluation Report for expansion type anchors as specified in Paragraph 3.04.
6. Design calculations in accordance with Paragraph 2.03.
7. Manufacturer’s data and catalog numbers.
PART 2 PRODUCTS
2.01 GENERAL
A. Anchor bolt holes in equipment support frames shall not exceed the bolt diameters by more than 25 percent up to a limiting maximum oversizing of 1/8-inch. Minimum anchor bolt diameter shall be 1/2-inch. Anchor bolts for equipment mounting shall be provided as specified in Section 11002.
B. Tapered washers shall be provided where mating surface is not square with the nut.
C. Expansion or adhesive anchors set in holes drilled in the concrete after the concrete is placed will not be permitted in substitution for anchor bolts except where otherwise specified. Upset threads shall not be acceptable.
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SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
2.02 MATERIALS
A. Anchor bolt materials: as specified below unless otherwise specified.
B. All equipment anchor bolts and anchor bolts that are submerged or above the water surface shall be Type 316 stainless steel.
Material Specification
Carbon steel bolts:
Structures ASTM A307, Grade A, hot-dip galvanized
Equipment ASTM A449, Type 1, hot-dip galvanized
Stainless steel bolts, nuts, washers ASTM A320 Type 316 Expansion anchors (concrete) Simpson Strong-Bolt 2, Hilti Kwik Bolt TZ2, or equal Expansion anchors (masonry) Simpson Strong-Bolt 2, Hilti Kwik Bolt TZ2, or equal Adhesive anchors (concrete) Simpson SET-3G, Hilti HIT-RE 500 V3, or equal Adhesive anchors (masonry) Simpson SET-3G, Hilti HIT-HY 200 V3, or equal Screw anchors (concrete) Simpson Titen HD, Hilti KH-EZ, or equal
2.03 DESIGN
A. Design anchor bolts for equipment frames and foundations in accordance with the CBC for Seismic Design Category F and Site Class CD.
1. This force shall be considered acting at the center of gravity of the piece under consideration.
2. A basic wind speed of 105 miles per hour, Exposure Category C, shall be used if applicable.
B. Submit calculations and shop drawings with the equipment submittal in accordance with Paragraph 1.03 and Section 01300 for all anchorage details.
1. All calculations shall be prepared and signed by a civil or structural engineer currently registered in the State of California.
PART 3 EXECUTION
3.01 GENERAL
A. Fieldwork, including cutting and threading, shall not be permitted on galvanized items.
B. Dissimilar metals shall be protected from galvanic corrosion by means of pressure tapes, coatings or isolators.
C. All stainless steel anchor bolts and fasteners shall be assembled with a stainless steel anti-seize compound such as molycote.
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SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
3.02 CAST-IN-PLACE ANCHOR BOLTS
A. Anchor bolts to be embedded in concrete and concrete unit masonry shall be placed accurately and held in correct position while the concrete or grout is placed or, if specified, recesses or blockouts shall be formed in the concrete and the metalwork shall be grouted in place in accordance with Section 03301.
B. The surfaces of metalwork in contact with concrete shall be thoroughly cleaned.
3.03 ADHESIVE ANCHOR BOLTS
A. Use shall be limited to locations where exposure, on an intermittent or continuous basis, to acid concentrations higher than ten percent, to chlorine gas, or to machine or diesel oils, is extremely unlikely.
B. Use shall be limited to applications where exposure to fire or exposure to concrete or rod temperature above 120 degrees F is extremely unlikely. Overhead applications (such as pipe supports) because of the above concerns, shall be disallowed.
C. Approval from Engineer for specific application and from supplier of equipment to be anchored, if applicable.
D. Anchor diameter and grade of steel shall be per contract documents or per equipment supplier specifications. Anchor shall be threaded or deformed full length of embedment and shall be free of rust, scale, grease, and oils.
E. Embedment depth shall be as specified on the Drawings.
F. All installation recommendations by the anchor system manufacturer shall be followed carefully, including maximum hole diameter.
G. Holes shall have rough surfaces, such as can be achieved using a rotary percussion drill.
H. Holes shall be blown clean with compressed air and be free of dust or standing water prior to installation.
I. Anchor shall be left undisturbed and unloaded for full adhesive curing period.
J. Concrete temperature (not air temperature) shall be compatible with curing requirements of adhesives per adhesive manufacturer. Anchors shall not be placed in concrete below 25ºF.
3.04 EXPANSION ANCHORS
A. Use of expansion type anchors shall be subject to Conditions B-C and F-H specified in Paragraph 3.03 and approval by the Engineer.
B. The Contractor shall supply the Engineer with the current evaluation report from the International Code Council – Evaluation Service for the particular brand of expansion anchors to be used.
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SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
3.05 SCREW ANCHORS
A. Use of screw anchors shall be subject to Conditions B-C and F-H specified in Paragraph
3.03 and approval by the Engineer.
B. The Contractor shall supply the Engineer with the current evaluation report from the International Code Council – Evaluation Service for the particular brand of screw anchors to be used.
***END OF SECTION***
395
ROUGH CARPENTRY 06100- 1
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 06100
ROUGH CARPENTRY
PART 1 GENERAL
1.01 SECTION INCLUDES
A. Furnishing all material, supplies, equipment, tools, transportation and facilities and performing all labor and services necessary for, required in connection with or properly incidental to furnishing and installing rough carpentry, as described in this section of the specifications, shown on the accompanying drawings, or reasonably implied therefrom.
B. Work Included
1. Furnishing and installing wood framing including furring, blocking and manufactured roof trusses.
2. Furnishing and installing plywood sheathing.
3. Furnishing and installing light gage metal connectors.
4. Furnishing and installing bolts, lag screws, washers and nails necessary for connecting wood framing and sheathing.
5. Installing miscellaneous metal connectors.
1.02 REFERENCED SECTION
A. The following Section is referenced in this Section
1. Section 01300 – Contractor Submittals
1.03 QUALITY ASSURANCE
A. Codes and Standards
1. Comply with all Federal, State and Local Codes and Safety Regulations.
2. In addition, comply with the provisions of the following codes, specifications, and standards, except where more stringent requirements are shown or specified:
a. “California Building Code”, 2025 Edition (CBC).
b. National Forest Products Association, “National Design Specification for Wood Construction”.
c. American Plywood Association, “U.S. Product Standard PS 1”.
B. Grade Marks
1. All framing lumber shall be identified by the grade stamp of the West Coast Lumber Inspection Bureau.
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SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
2. All plywood shall be identified as to species, grade, and glue type and shall bear the identification grade mark of the American Plywood Association. All gluedlaminated beams shall be stamped with an AITC product quality mark.
C. Certificates of Conformance
1. The Contractor shall provide AITC Certificate of Conformance for gluedlaminated beams.
1.04 SUBMITTALS
A. General Requirements
1. Comply with Section 01300.
2. Construction of wood framing and sheathing shall not begin until Contractor has received submittals reviewed by Engineer governing all aspects of the intended work.
B. Shop Drawings
1. Submit shop drawings for the wood roof trusses to be installed as shown on the Contract Drawings, including layout, size of members, and connection details.
2. Submit calculations showing all stresses and deflections caused by dead, live, and lateral loads for review.
3. Also submit shop drawings for the wood trusses to the City Building Inspection Division. Make this submittal prior to requesting a framing inspection.
4. Drawings and calculations shall be signed by a Civil Engineer currently registered in the State of California.
C. Product Data
1. Provide manufacturer’s catalog sheets including instructions for use and description of application on each of the eight gage metal connectors.
1.05 DELIVERY STORAGE AND HANDLING
A. Deliver and store lumber on sleepers and cover for protection. See general conditions for additional delivery and storage requirements.
1.06 SEQUENCING AND SCHEDULING
A. Obtain information and instructions from other trades and suppliers in ample time to schedule and coordinate the installation of items furnished by them to be installed prior to or in conjunction with rough carpentry so provisions for their work can be made without delaying the project.
1. Do any cutting and repairing made necessary by failure or delay in complying with these requirements, at no cost to City.
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ROUGH CARPENTRY 06100- 3
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) PART 2 PRODUCTS
2.01 FRAMING
A. Framing Lumber: Douglas Fir Coast Region, conforming to West Coast Lumber Inspection Bureau Standard Grading and Dressing Rule No. 17.
B. Dressed, S4S.
C. Sizes two inches or less in nominal thickness: Seasoned lumber with 19 percent maximum moisture content at time of dressing and shipment.
1. 2x, 3x, 4x, plates, rafters, joists, beams, blocking, outriggers, and braces, No. 1 (1,000F-b), Para. 123-b, unless noted otherwise on the drawings.
2. 2x4, 3x4, 4x4, studs, furring and blocking, construction grade, (1,000F-b), Para. 122-b.
3. 2x fascias shall be California Redwood No. 2 conforming to the Standard Specifications for grades of California Redwood lumber of the Redwood Inspection Service, as amended to date.
2.02 PLYWOOD
A. Roof Plywood
1. Conform to U.S. Product Standard PS 1-09, American Plywood Association.
Each sheet shall be stamped with the PS and/or APA grade mark.
2. Five-ply exposure 1 type, CDX, Group Identification Index 32/16, Species Group 2 or better.
B. Wall Plywood
1. Conform to U.S. Product Standard PS 1-09, American Plywood Association.
Each sheet shall be stamped with the PS and/or APA grade mark.
2. Four-ply exterior type, select veneer siding, Group Identification Index 24/0, Species Group 2 or better.
2.03 ROOF TRUSSES
A. Design wood roof trusses to support the following minimum loads:
1. Top Chord Dead Load: 8 psf (+ self-weight)
2. Top Chord Live Load: 20 psf
3. Bottom Chord Dead Load: 6 psf (+ self-weight)
4. Bottom Chord Live Load: 10 psf (Non-concurrent with top chord LL)
5. Wind Loads: 23 psf (vertical), 8 psf (horizontal). Apply loads concurrently and in worst-case direction.
6. Seismic Loads: as shown on the Contract Drawings.
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ROUGH CARPENTRY 06100- 4
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
2.04 LIGHT GAGE METAL CONNECTIONS
A. Simpson Company Strong-Tie Connectors installed per manufacturer’s recommendations.
2.05 NAILS
A. Bright common wire nails, galvanized for exterior work; conform to Federal Specification FF-N-105B.
2.06 BOLTS
A. Conform to ASTM A307, Manufacturer to American Standard bolt and nut dimensions with “Free Fit – Class 2” threads.
2.07 SCREWS
A. Lag screws shall be ASTM A307 fasteners. Lead holes shall be drilled as follows: for a depth equal to the unthreaded portion of the shank, the lead hole shall be the same diameter as the shank; for the threaded portion, the diameter shall be 40% to 70% of the diameter of the shank to the specified depth of penetration. Lead holes shall be lubricated prior to installation.
B. ‘SD’ and ‘SDS’ screws by Simpson Strong-Tie. Screw size: As shown on the drawings.
2.08 WEATHER-RESISTIVE BARRIER
A. Tyvek HomeWrap by Dupont or approved equal. Install per manufacturer’s recommendations.
PART 3 EXECUTION
3.01 GENERAL REQUIREMENTS
A. Conform all framing operations to the requirements of the CBC.
B. Set all framing members level and true.
1. Do not notch, bore or cut members for pipes, ducts, conduits, or other reasons.
2. Make all bearings full and all blocking solid unless otherwise indicated on the drawings.
3. Finish all bearing surfaces on which structural members are to rest so as to give sure and even support.
4. Where framing members slope, cut or notch the ends as required to give uniform bearing surface.
399
ROUGH CARPENTRY 06100- 5
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) C. Place solid blocking at ends of spans and over supports. Cross-Bridging or solid blocking in spans shall not exceed 8 feet or less if shown on structural drawings.
D. Remove all wood, including form lumber, scrap lumber, shavings and sawdust in contact with ground. Leave no wood buried in any fill or backfill.
E. Provide framing of openings through roof for roof vents. Provide 2x4 blocking around openings; no roof framing or trusses shall be cut
F. Center joints of plywood accurately over supports and nail into solid wood. Protect all plywood from moisture by use of all required waterproof covering until the plywood has in turn been covered by the next succeeding component or finish.
G. Remove lumber not grade stamped and lumber of improper grade from the job site, and immediately replace with grade stamped lumber of the proper grade.
H. Other Materials
1. All other lumber materials, not specifically described but required for the proper completion of the work, shall be new, first quality of their respective kinds and subject to the approval of the Engineer.
3.02 EXAMINATION OF SURFACE CONDITIONS
A. Prior to the work of this section, carefully inspect the installed work of other trades and verify that all such work has been so installed as to allow rough carpentry to produce surfaces to the required design.
3.03 WORKMANSHIP
A. All rough carpentry shall produce joints true, tight, and well nailed with all members assembled in accordance with the drawings and with all pertinent regulations.
B. Cut all wood members to fit. Do not shim.
C. Erect all members straight, plumb and accurately located.
D. Carefully select all structural members.
1. Select individual pieces so that knots and obvious defects will not interfere with making proper connections.
2. Lumber may be rejected by the Engineer, whether or not it has been installed, for excessive warp, twist, bow, or crook, or for mildew, fungus or mold as well as for improper cutting or fitting.
3. Cut out and discard all defects which render a piece unable to serve its intended function.
3.04 ERECTION
A. Erect the wood framing true to line and grade.
400
ROUGH CARPENTRY 06100- 6
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) B. Temporary Bracing and Shoring
1. Temporarily brace the wood framing in both directions and maintain walls, joists, beams, and other framing members plumb until the final connections of the framework and construction of diaphragms are complete.
2. Provide such temporary shoring and additional bracing of wood framing as required to adequately and safely support any or all loads imposed upon the structure during construction.
3.05 CLEAN UP
A. In addition to the requirements of General Conditions, keep premises clean and clear of debris caused from this portion of the work.
3.06 FIELD QUALITY CONTROL
A. Framing and Plywood Nailing Inspection
1. City’s agent will inspect the completed framing, the plywood nailing, and connector installation to ensure that rough carpentry work is in accordance with the Contract Documents.
***END OF SECTION***
401
METAL DOORS AND FRAMES 08110- 1
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 08110
METAL DOORS AND FRAMES
PART 1 GENERAL
1.01 SECTION INCLUDES
A. Steel doors and steel door frames.
1.02 REFERENCED SECTIONS
A. The following Sections are referenced in this Section
1. Section 01300 – Contractor Submittals
2. Section 08710 – Finish Hardware
1.03 QUALITY ASSURANCE
A. Certificates of Compliance
1. Provide manufacturer’s certificates attesting that doors, frames, and accessories meet the specified requirements.
2. Include the grade and model number of each door.
1.04 SUBMITTALS
A. Comply with Section 01300 and include the following items:
1. Shop drawings containing the following information:
a. Elevations of each door type
b. Size of doors and frames
c. Metal gages
d. Details of door and frame construction
e. Methods of anchorage
f. Provisions for and location of hardware
g. Details of installation
h. Schedule showing location of each door, frame, and swing of door
2. Detail specifications and instructions for installation, adjustments, cleaning, and maintenance.
1.05 DELIVERY AND STORAGE
A. Doors, frames, and accessories shall be delivered undamaged and with protective wrappings or packaging.
402
METAL DOORS AND FRAMES 08110- 2
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) B. Doors and frames shall be stored on platforms under cover in clean, dry, ventilated, and accessible locations, with 1/4-inch airspace between doors.
C. Remove damp or wet packaging immediately wipe dry affected surfaces.
D. Replace damaged materials with new.
PART 2 PRODUCTS
2.01 STEEL DOORS
A. General
1. 1-3/4 inches thick, 16 gage, and conform to ANSI 100 unless otherwise specified.
2. Composite construction prepared to receive hardware specified in Section 08710.
B. The internal construction of the doors shall conform to one of the following methods, in accordance with the manufacturer’s standard practice:
1. Vertical and/or horizontal steel, rigidly formed members shall have sound deadening applied to the inside to eliminate metallic sound incident to normal door operation.
2. Honeycomb, polyurethane, or solid structural mineral core bonded to the inside of both faces of the door.
3. Other methods of reinforcing may be used, provided they achieve the same degree of flatness, rigidity, sound deadening and strength as the methods listed above.
2.02 STANDARD STEEL FRAMES
A. General
1. Steel frames shall conform to ANSI 100, shall be of the sizes and shapes specified, and unless otherwise specified, shall be fully welded unit type frames. Steel frames shall be provided for doors, sidelites, and transoms.
B. Welded Frames
1. Frame faces shall be continuously welded at corner joints.
2. Stops and rabbets shall be mechanically interlocked or continuously welded.
3. All welds shall be ground smooth.
4. Frames shall be mortised and reinforced with heavy gage reinforcements for hinges and lock strikes.
5. Steel spreaders to ensure proper alignment of the frame shall be used and shall remain in place until the adjacent wall construction is complete.
C. Anchors
403
METAL DOORS AND FRAMES 08110- 3
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
1. General
a. Provide steel anchors to secure the frame to adjoining construction. b. Anchors shall be zinc-coated or painted with rust-inhibitive paint, not lighter than 18 gage.
2. Wall Anchors
a. Provide a minimum of four anchors for each jamb.
b. Locate anchors opposite top and bottom hinges and at equal spaces in between.
1) Anchors for masonry work shall be corrugated or perforated steel straps or 3/16-inch diameter steel wire, adjustable or T-shaped.
2) Anchors for stud partitions shall be welded or otherwise securely fastened to backs of frames.
a) Anchors shall be designed and fastened to wood
studs with nails, to closed steel studs with sheet
metal screws, and to open steel studs by wiring or
welding.
3) Frames shall be secured to previously placed concrete or masonry with expansion bolts in accordance with SDI 111-F. 4) Anchors for solid plaster partitions shall be secured solidly to back of frames and tied into the lath.
a) Adjustable top strut anchors shall be provided on
each side of frame for fastening to structural
members or ceiling construction above.
b) Size and type of strut anchors shall be as
recommended by the frame manufacturer.
3. Floor Anchors
a. Provide at bottom of each jamb member, drilled for 3/8-inch anchor bolts.
b. Where floor fill occurs, bottom of frames shall be terminated at the indicated finished floor levels and supported by adjustable extension clips resting on and anchored to the structural slabs.
2.03 INSULATED ROLL-UP DOORS
A. General
1. Doors shall be spring loaded, hand chain operated, coiling doors with steel hood and hand chain lock.
2. Coiling doors shall be Atlas Door, Cornell Iron Works, or approved equal.
3. Provide doors, guides, and accessories from one manufacturer.
4. Provide locking slide bolts on door interior.
B. Material
404
METAL DOORS AND FRAMES 08110- 4
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
1. Galvanized steel interlocked curtain with baked-on epoxy modified polyester finish. Color to be selected by the Owner.
2. Design door and structural steel angles and guides for wind load per ASCE 7-22. A basic wind speed of 105 miles per hour and Exposure Category C shall be used.
3. Spring counter balance housed in a steel pipe with 24 gauge galvanized steel hood.
C. Insulated Door Slat Material Requirements
1. Flame Spread Index of zero and a Smoke Developed Index of 10 as tested per ASTM E84.
2. Minimum Sound Transmission Class (STC) rating of 26 as tested per ASTM E90.
3. Minimum R-value of 8.0 (U-factor of 0.125) as calculated using the ASHRAE Handbook of Fundamentals.
4. Insulation to be CFC Free with an Ozone Depletion Potential (ODP) rating of zero.
D. Weather Stripping
1. Bottom Bar: Replaceable, bulb-style, compressible EDPM gasket extending into guides.
2. Hood: Neorenet/rayon baffle to impede air flow above coil.
2.04 ASTRAGALS
A. Pairs of exterior steel doors which will not have aluminum astragals or removable mullions shall have overlapping steel astragals provided with the doors.
2.05 WEATHER STRIPPING
A. As specified in Section 08710.
2.06 HARDWARE PREPARATION
A. Doors and frames to receive finish hardware shall be reinforced, drilled, and tapped for hardware in accordance with the applicable requirements of SDI 107 and ANSI A115.1 and A115.4.
B. Drilling and tapping for surface-applied hardware shall be done in the field, but additional reinforcing for surface-applied hardware shall be built into the door at the factory.
C. Hardware shall be located in accordance with the requirements of ANSI 100, as applicable.
2.07 FINISHES
A. Hot-Dip Zinc-Coated and Factory-Primed Finish
405
METAL DOORS AND FRAMES 08110- 5
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
1. Doors and frames shall be fabricated from galvanized steel, ASTM A653, Coating Designation G60 or A60 (galvannealed).
2. Damaged zinc-coated surfaces shall be repaired by the application of zinc dust paint conforming to DOD-P-21035.
3. Zinc-coated surfaces shall be phosphate treated and factory primed as specified in ANSI 100.
2.08 FABRICATION AND WORKMANSHIP
A. Finished doors and frames shall be strong and rigid, neat in appearance, and free from defects, waves, scratches, cuts, dents, ridges, holes, warp, and buckle.
B. Molded members shall be clean cut, straight, and true, with joints coped or mitered, well formed, and in true alignment.
C. Exposed welded and soldered joints shall be ground smooth.
D. Door frame sections shall be designed for use with the wall construction specified.
E. Corner joints shall be well formed and in true alignment.
F. Conceal fastenings where practicable.
G. On wraparound frames for masonry partitions, a throat opening shall be provided 1/8 inch larger than the actual masonry thickness.
H. Frames in exposed masonry walls or partitions shall be designed to allow sufficient space between the inside back of trim and masonry to receive caulking compound.
2.09 PRODUCT DATA
A. Certificates of compliance specified in paragraph 1.03 shall be provided as product data in accordance with Section 01300.
PART 3 EXECUTION
3.01 INSTALLATION
A. Frames
1. Set frames in accordance with SDI 105, and plumbed, aligned, and braced securely until permanent anchors are set.
2. Anchor bottoms of frames with expansion bolts or powder-actuated fasteners.
3. Wall anchors shall be built in or secured to adjoining construction.
4. Anchor frames to the struts or bracing where frames require ceiling struts or overhead bracing.
5. Backfill frames with mortar.
406
METAL DOORS AND FRAMES 08110- 6
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
6. When an additive is provided in the mortar, inside of frames shall be coated with corrosion-inhibiting bituminous material.
7. For frames to be installed in exterior walls and to be filled with mortar or grout, the stops shall be filled with strips of rigid insulation to keep the grout out of the stops and to facilitate installation of stop-applied head and jamb seals.
B. Doors
1. Hang doors in accordance with clearances specified in ANSI 100.
2. Clean and adjust hardware after erection and glazing.
3.02 PROTECTION
A. Doors and frames shall be protected from damage, and damaged doors and frames repaired prior to completion and acceptance of the project or replaced with new, as directed.
B. Rusted frames shall be wire brushed until all rust is removed, cleaned thoroughly, and applied with an all-over coat of rust-inhibitive paint of the same type used for shop coat.
3.03 CLEANING
A. Thoroughly clean exposed surfaces of doors and frames upon completion.
B. Mastic smears and other unsightly marks shall be removed. ***END OF SECTION***
407
ACCESS DOORS 08310 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 08310
ACCESS DOORS
PART 1 GENERAL
1.01 SUMMARY
A. Section Includes: Access doors for pump station valve vault and wet well.
1.02 SUBMITTALS
A. Product Data.
B. Shop Drawings: Show the following:
1. Access door attachment to structure in each typical condition.
2. Locations of access doors.
1.03 DELIVERY, STORAGE, AND HANDLING
A. Identify type and size of each door in way not to damage finish prior to delivery.
B. Deliver products only after proper facilities are available.
C. Deliver and store packaged products in original containers with seals unbroken and labels intact until time of use.
D. Handle carefully to prevent damage and store on clean concrete surface or raised platform in safe, dry area. Do not dump onto ground.
E. Protect access doors during shipment and storage to prevent warping, bending, and corrosion.
PART 2 PRODUCTS
2.01 FLOOR HATCHES
A. H20 Unintended Traffic Rated Hatches: Hatches rated for incidental H20 Traffic loading.
1. H20 rated hatches shall be designed for 16,000 lb. point loads + 30% impact.
2. Hatches shall be manufactured by EJ, USF Fabrication, or approved equal.
3. Door leaf shall be anodized aluminum ¼” diamond pattern.
4. Maximum deflection under the specified loading shall be 1/150th of the span.
5. Channel frame shall be extruded aluminum, to match the hatch material, cast into the new concrete structure.
6. Hinges: Heavy forged aluminum hinges, each having a minimum 1/4" (6.3 mm) diameter Type 316 stainless steel pin, shall be provided, and shall pivot so the cover does not protrude into the channel frame. Shall be specifically designed for horizontal installation and shall be through bolted to the cover with tamper-proof Type 316 stainless steel lock bolts and shall be through bolted to the frame with Type 316 stainless steel bolts and locknuts.
408
ACCESS DOORS 08310 - 2
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
7. Drain Coupling: Provide a 1-1/2" (38mm) drain coupling located in the right front corner of the channel frame (away from the hinges). Frame shall drain to the wet well or vault.
8. Lift Assist: Hatch shall be supplied with heavy duty stainless steel pneu-spring for smooth, easy, and controlled door operation throughout the entire arc of opening and closing. Spring shall consist of a minimum ½” stainless steel shaft which slides into a minimum 1” stainless steel tube. Spring shall be charge with an inert gas (nitrogen). Mechanical, torsion, or coil type springs shall not be accepted as equal.
9. Hatch shall be equipped with an aluminum lift handle. Handle shall be flush with the top of the ¼” diamond plate.
10. Hatch shall be supplied with a 316 stainless steel slam lock, with key way projected by a threaded plug. Plug shall be flush with the top of the ¼” diamond plate.
11. Cover shall be equipped with a hold open arm which automatically locks the cover in the open position. A Type 316 stainless steel snap lock with fixed handle shall be mounted on the underside of the cover.
12. Hardware shall be anticorrosion throughout.
B. Clear open spaces indicated on the drawings shall be provided for all hatches.
C. Fall Through Protection: Hatches shall have integral fall through protection.
1. The Safety Grate shall be made of 6061-T6 aluminum and designed per the Specifications for Aluminum Structures by the Aluminum Association, Inc. 5th Edition, Dec. 1986 for “Bridge Type Structures”.
2. Design shall combine covering of the opening, fall through protection per OSHA Standard 1910.23 and controlled confine space entry per OSHA Standard 1910.146.
3. The grating shall be designed to withstand a minimum live load of 300 pounds per square foot using 17,300 psi as the design stress for the aluminum. Deflection shall not exceed 1/150" of the span.
4. Grate openings shall allow for visual inspection, limited maintenance and float adjustments while the safety grate fall through protection is left in place. Each grate shall be provided with a permanent hinging system, which will lock the grate in the 90° position once opened. Grates in the open position create a visual barrier around the opening, alerting passing pedestrians.
5. Each aluminum safety grate shall be coated with a safety orange color, promoting visual awareness of the hazard, by a powder coat system, applied by the electrostatic spray process. The coating is a thermosetting powder coat finish with a minimum thickness of 2 mils-4 mils and shall be baked at 350°-375°F until cured.
D. Manufacturer shall guarantee against defects in hatch material or workmanship for a period of ten years.
E. Contractor shall ensure that the fall protection grates and mounting hardware will not interfere with the placement of the pump guiderails or removal of the pumps from the pump station wet well. Access hatch hinge and mounting brackets shall not be placed above, or within 2 inches of the pump guide rails. The Contractor shall ensure that the pumps can be easily removed and replaced.
409
ACCESS DOORS 08310 - 3
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
2.02 FINISHES
A. Floor Access Doors:
1. Aluminum: Anodized finish, diamond plate for top wearing surface.
2. Aluminum in Contact with Dissimilar Metals and Concrete: Manufacturer’s standard bituminous coating.
3. Steel: Manufacturer’s standard red oxide primer.
PART 3 EXECUTION
3.01 EXAMINATION
A. Examine construction to receive access door and verify correctness of dimensions and other supporting or adjoining conditions.
B. Contractor shall replace any defective or damaged equipment at no additional cost to the City.
3.02 PREPARATION
A. Coordinate details with other work supporting, adjoining, or requiring access doors.
B. Verify dimensions, profiles, and fire-resistive rating for each opening.
C. Verify that location will serve portion of work to which access is required. Where proposed functional location conflicts with other work, notify the Engineer before installation.
3.03 INSTALLATION
A. Install access doors in accordance with manufacturer's instructions.
B. Ensure correct types and adequate sizes at proper locations.
C. Securely attach frames to supporting work and ensure doors, frames and hardware operate smoothly and are free from warp, twist, and distortion.
D. See 2.01-E above.
E. Access hatches shall be cast into precast concrete structures, see Section 03400.
3.04 ADJUSTING
A. Adjust doors, frames, and hardware to operate smoothly, freely, and properly, without binding.
3.05 CLEANING
A. Thoroughly clean surfaces of grease, oil, or other impurities, touch-up abraded prime coat.
END OF SECTION
410
FINISH HARDWARE 08710- 1
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 08710
FINISH HARDWARE
PART 1 GENERAL
1.01 SECTION INCLUDES
A. Furnish and install all necessary architectural finish hardware to complete the Project.
Furnish templates for door and frame preparation.
1.02 REFERENCED SECTIONS
A. The following Section is referenced in this Section.
1. Section 01300 – Contractor Submittals
1.03 REFERENCES
A. DHI: Door and Hardware Institute
B. NAAMM: National Association of Architectural Metal Manufacturers C. NFPA 101: Life Safety Code
1.04 SUBMITTALS
A. Comply with Section 01300.
B. Provide product data on specified hardware. Indicate locations and mounting heights of each type of hardware.
C. Submit manufacturer’s parts lists, templates, and installation instructions.
1.05 DELIVERY, STORAGE, AND HANDLING
A. Deliver hardware with items packed separately, complete and ready for installation with necessary fittings, trim, fasteners, and accessories. Mark packages clearly for identification in accordance with Hardware Schedule. Deliver hardware so that work may progress without delay or interruption.
B. Upon delivery of the finish hardware to the job site, the Contractor shall be responsible for all material. Protect hardware from damage at all times prior to and after its installation.
1.06 COORDINATION
A. Coordinate work of this Section with other directly affected Sections involving manufacturer of any internal reinforcement for door hardware. 411
FINISH HARDWARE 08710- 2
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) B. Hardware shall be manufactured to template. Provide templates and, if necessary, the physical hardware to fabricator of doors and frames in ample time to facilitate the work.
1.07 MAINTENANCE MATERIALS
A. Provide special wrenches and tools applicable to each different or special hardware component.
PART 2 PRODUCTS
2.01 MANUFACTURERS
A. Equivalent products by the other named manufacturers in the list below and within the hardware group listings are also acceptable except for locksets and cylinders.
1. Butts and Hinges: Ives, McKinney, Stanley.
2. Locksets and Latchsets: Schlage.
3. Cylinders: Schlage.
4. Panic Hardware: Von Duprin, Sargent.
5. Slide Bolts and Foot Bolts: McKinney, Stanley.
6. Weather Stripping, Thresholds and Door Bottom Sweeps: Pemko.
7. Stops/Holders: Rockwood, Quality.
8. Closers: LCN Series 4010 (pull side) or Series 4110 (push side) as required.
9. Lock Guards: Ives.
10. Silencers: Glynn-Johnson.
2.02 HINGES
A. Provide butt hinges of the five-knuckle, full mortise type, having two or four ball or oilite bearings as noted, stainless steel pins, and complying with ANSI A156.1.
B. Provide all out swinging doors to the exterior with butt hinges of the stainless steel or non-ferrous material, with non-removable pins of the set screw type. Ives 5BB1HW NRP, or equal.
C. Hinge Size:
1. Doors 1-3/4” in thickness to 37” in width shall be provided with 4-1/2” x 4- 1/2” butt hinges provided with at least two ball or oilite bearings; wider and heavier doors with 5” x 5” extra heavy butt hinges provided with four ball or oilite bearings.
2. Butt hinges for doors thicker than those noted above or with unusual trim conditions which would interfere with the full opening of the door shall be provided with hinges of sufficient size to support the door weight adequately, and of sufficient width to clear adjacent trim.
D. Number of Hinges per Door Leaf:
412
FINISH HARDWARE 08710- 3
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
1. Provide two hinges per door leaf for doors up to 60” high; three hinges per leaf for doors up to 90” high; one additional butt hinge for each additional 30” in height, or fraction thereof.
2.03 LATCHSETS AND CYLINDERS
A. Design: Provide Schlage Model ND94RD at exterior doors, Schlage Model ND10S at interior passage doors, and Schlage Model ND40S at interior restroom doors. All levers shall be Sparta style.
B. Provide Large Format Interchangeable Cores.
C. Strikes: Provide each lockset, latchset, or deadlock with a box strike. Provide standard type strikes with extended lips where required to protect adjacent trim from being marred by latch bolt. Verify cutout types provided in metal frames.
D. Deadbolts: Provide keyed deadbolts, double cylinder, at each exterior door, minimum 1-1/2-inch throw, Schlage B562P.
E. Panic Hardware: Exit devices shall be UL listed panic hardware with heavy-duty push pads as manufactured by Von Duprin, 98/99 Series.
2.04 DOOR BOTTOM SWEEPS, THRESHOLDS AND WEATHER STRIPPING A. All exterior doors shall be fitted with door bottom sweep, threshold set in sealant, and weather stripping.
B. Door bottoms shall be designed to seal space below door and prevent entry of wasps and other pests.
2.05 STOPS/HOLDERS
A. Provide each door leaf with a door stop and latch holder mounted on outside concrete surface with concrete expansion anchors. Provide stops of proper size and height to prevent doors from hitting walls or fixed objects. Omit door stops and holders on fire-rated doors.
2.06 LOCK GUARDS
A. Provide lock guards on all exterior doors. Construct of stainless steel, with 626 brushed chrome finish, with no exposed fasteners on face of unit.
2.07 SILENCERS
A. Provide each door with a press-metal frame with rubber silencers. Provide each single door with three silencers, each pair of doors with four.
2.08 KEYS AND KEYING
A. Provide a construction keying system for Contractor’s and/or City’s use during construction. Contractor shall retain construction keys and inserts and turn over to the City upon completion of construction.
413
FINISH HARDWARE 08710- 4
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) B. Coordinate the changeover to permanent keyways with the City at completion of station commissioning.
2.09 FINISH
A. All hardware shall have brushed chrome finish (626) for interior and exterior installations typically, unless noted otherwise.
1. Provide over steel base metal (BHMA 626), typical, where required by code.
2.10 HARDWARE SCHEDULE
A. Door hardware sets shall conform to the following schedule. Numbers and references in hardware schedule establish quality to be furnished and installed. Suitable types having similar quality and operation as finish hardware specified may be furnished when approved by the City.
1. Door Hardware Type A: Each door shall have:
3 Hinges
1 Lockset
1 Strike
1 Door Stop/Holder
1 Closer
1 Threshold
1 set Weather Stripping
1 Door Bottom Sweep
1 set Silencers
1 Deadbolt
2. Door Hardware Type B: Each pair of doors shall have:
6 Hinges
1 Lockset
1 Strike
2 Door Stops/Holders
2 Closers
2 Thresholds
2 sets Weather Stripping
2 Door Bottom Sweeps
2 sets Silencers
1 Deadbolt
1 set Slide Bolts
1 set Foot Bolts
1 Astragal
3. Door Hardware Type C: Each door shall have:
3 Hinges
1 Latchset
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FINISH HARDWARE 08710- 5
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) 1 Strike
1 Door Stop/Holder
1 set Silencers
PART 3 EXECUTION
3.01 PACKING AND MARKING
A. Package all items of hardware in its individual container marked with the manufacturer’s name, type number, and name of item.
B. Each item shall be complete with necessary fastenings, wrenches, spanners, etc., installation instructions, and templates, indelibly, legibly, and carefully marked with an item number corresponding to the room name and hardware group number as indicated on the Plans and hardware schedule provided by supplier.
3.02 EXAMINATION
A. Inspect all doors, frames, and other surfaces to receive items or finish hardware and report all defects which might adversely affect the installation or function of the hardware. Commencement of work will imply acceptance of surfaces as being satisfactory and adequate.
B. Coordinate and be responsible for the proper fabrication of all work or material to receive hardware. No extra cost will be allowed because of changes or corrections necessary to facilitate the proper installation and operation of the hardware.
3.03 INSTALLATION
A. Install hardware in accordance with manufacturer’s instructions and requirements of ANSI/NFPA 80, and DHI. Use the templates provided by the hardware item manufacturer.
B. Conform to handicap requirements for positioning requirements for the handicapped.
C. Provide architectural finish hardware with all necessary (plus prudent spares) screws, bolts, or other devices or fastenings of suitable size and type to secure the hardware in position for heavy use and long life, harmonizing as to material and finish. Secure all hardware to concrete with expansion sleeve anchors as indicated by best current practice. All screws normally exposed to view, including all screws for butt hinges, shall have “Phillips” heads, finished to match hardware.
D. Keying
1. Remove construction plugs and install permanent cylinders as required.
2. The master key chart will be provided by the City.
3. The Contractor is responsible for all keying and permanent keys.
4. Provide construction cylinders and keys as required during construction and rekey permanent locksets as directed by City.
415
FINISH HARDWARE 08710- 6
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) ***END OF SECTION***
416
GYPSUM BOARD 09290- 1
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 09290
GYPSUM BOARD
PART 1 GENERAL
1.01 SECTION INCLUDES
A. Gypsum wallboard.
1.02 REFERENCED SECTION
A. The following Section is referenced in this Section
1. Section 01300 – Contractor Submittals
1.03 SUBMITTALS
A. Comply with Section 01300.
B. Provide manufacturer’s complete product data sheets.
PART 2 PRODUCTS
2.01 GYPSUM WALLBOARD
A. Gypsum wallboard shall be tapered edge sheets, fire resistant with moisture and mold resistance, conforming to ASTM C36, of 5/8-inch thickness unless otherwise shown.
1. Gypsum wallboard shall be USG Sheetrock Brand Mold Tough Panels Firecode X or approved equal.
2. The tape, adhesive and reinforcement shall be standard products recommended by the manufacturer of the gypsum wallboard used in the work.
B. Framing components shall conform to ASTM A653, Grade A, G60 galvanized roll formed channel tracks “C” type studs, flanges minimum 1-5/8” wide with rigid attachment to structure.
1. Wire ties to be 18 ga. soft annealed, galvanized. Provide gauge of studs to meet horizontal loads.
PART 3 EXECUTION
3.01 INSTALLATION
A. Wallboard
417
GYPSUM BOARD 09290- 2
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
1. Except as may be modified by these specifications and by applicable laws and ordinances at the place of building, all work shall be installed to conform to the requirements of ASTM C840.
2. Space fasteners 12 inches on center in the field and eight inches on center staggered along abutting edges and at 12 inches on center for ceilings.
3. Place fasteners no closer than 3/8 inch from ends or edges of wallboard.
4. Apply a three-inch wide uniform coating of adhesive centered over the joint.
5. Center tape over the joint and embed into the adhesive.
6. When dry, sand the joint smooth.
7. Apply two coats of adhesive over the tape, extending each coat slightly beyond the preceding one.
8. Allow each coat to dry and sand smooth.
9. Treat nail dimples in a like manner.
***END OF SECTION***
418
COATING SYSTEM 09800 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 09800
COATING SYSTEMS
PART 1 GENERAL
1.01 DOCUMENTS
The General Conditions and all other Contract Documents for this project are complementary and applicable to this section of the Specifications.
1.02 SCOPE OF WORK
A. Work Included
Paint, protective coatings, and finishes for pipes, exposed metal, equipment, floors, walls, and ceilings.
B. Related Work Specified Elsewhere
1. Ductile Iron Pipe: Section 02720.
2. Submersible Pumps: Section 11312.
3. Valves: Section 15110.
1.03 REFERENCE STANDARDS
Standards listed below are a part of this section as specified and modified. In case of conflict between the requirements of this section and those of listed standards, the requirements of this section shall prevail. Where two or more standards are at variance, the most restrictive requirement shall apply.
A. AWWA C105 Polyethylene Encasement for Ductile-Iron Pipe Systems B. AWWA C210 Liquid Epoxy Coating Systems for the Interior and Exterior of Steel Water Pipelines
B. AWWA C213 Fusion-Bonded Epoxy Coating for the Interior and Exterior of Steel Water Pipelines
C. SSPC PA2 Measurement of Dry Paint Thickness with Magnetic Gauges D. SSPC SP1 Solvent Cleaning
E. SSPC SP5 White Metal Blast Cleaning
F. SSPC SP6 Commercial Blast Cleaning
G. SSPC SP7 Brush-off Blast Cleaning
H. SSPC SP8 Pickling
I. SSPC SP10 Near-white Blast Cleaning
419
COATING SYSTEM 09800 - 2
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
1.04 SUBMITTALS
A. Data Sheets:
a. Paint System Data Sheet
b. Technical Data Sheets:
i. Solids Content
ii.Ingredient Analysis
iii. VOC Content
iv.Chemical Resistance
v.Temperature Resistance
vi.Typical Exposures and limitations
c. Manufacturer Instructions:
i. Special requirements for transportation and storage
ii. Mixing Instructions
iii. Shelf Life
iv. Pot life of materials
v. Precautions for application free of defects.
vi. Surface preparation.
vii.Method of application.
viii.Recommended number of coats.
ix.Recommended thickness of each coat.
x.Recommended total thickness.
xi. Drying time for each coat, including prime coat.
xii.Required prime coat.
xiii.Compatible and non-compatible prime coats.
xiv.Recommended thinners, when recommended.
xv.Limits of ambient conditions during and after application. xvi.Time allowed between coats.
xvii.Required protection from sun, wind, and other conditions. xviii.Touch-up requirements and limitations.
d. Paint Colors available
e. Maintenance and repair instructions
f. Regulatory Requirements: VOC compound limitations, coatings containing lead compounds, abrasive, abrasive blast cleaning techniques, and disposal B. Samples: For building floor, walls, and ceiling applications a. Unless otherwise specified, before painting work is started, prepare minimum 8- by 10-inch samples with type of paint and application specified on similar substrate to which paint is to be applied.
b. Furnish additional samples as required until colors, finishes, and textures are approved.
c. Retain approved samples to be used as the quality standard for final finishes.
C. Quality Control:
a. Applicator's Experience: List of references substantiating the requirement as specified.
1.05 PRODUCT, DELIVERY STORAGE, AND HANDLING
420
COATING SYSTEM 09800 - 3
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) A. Deliver paint to project site in unopened containers that plainly show at time of use, the designated name, date of manufacture, color, and name of manufacturer B. Store paints in a suitable protected area that is heated or cooled as required to maintain temperatures within the range recommended by the paint manufacturer.
C. Shipping:
a. Where pre-coated items are to be shipped to the jobsite, protect coating from damage. Batten coated items to prevent abrasion
b. Use nonmetallic or padded slings and straps in handling c. Items will be rejected for excessive damage
PART 2 PRODUCTS
2.01 GENERAL
A. Primer, intermediate, and finish coats shall be of same manufacturer B. Products shall meet federal, state, and local requirements limiting the emission of volatile organic compounds. Specific information may be secured through the office of the Bay Area Air Quality Management District (BAAQMD).
C. Coatings in contact with potable water shall be certified by the National Sanitation Foundation in accordance with ANSI/NSF Standard 61.
D. Protective interior coatings for valves and hydrants shall conform to the requirements of American Water Works Association coating standard C550.
E. Coating systems also apply to recoating of existing surfaces if specified to be recoated on the Drawings and/or in this specification.
F. Formulate with colorants free of lead, lead compounds, or other materials which might be affected by presence of hydrogen sulfide or other gases at the project site.
G. Liquid-epoxy coating for the interior and exterior of steel water pipelines shall conform to the requirements of American Water Works Association coating standard C210.
2.02 PIPE AND FITTINGS COATING SYSTEMS
A. Pipe and Fittings: Reference section 02720.
2.03 FERROUS METAL COATINGS FOR NON-IMMERSION SERVICE
A. Ferrous Metals for Non-Immersion Service: Exposed metals including steel bollards, steel air ducting, associated appurtenances, and miscellaneous ferrous metal not called out elsewhere shall be lined and/or coated with the following system, following manufacturer’s recommendations:
1. Surface Preparation: Sandblast to SSPC 6 (commercial blast cleaning).
2. Prime Coat: Blasted surfaces shall be coated with a 2.5 to 3.5 mil d.f.t. coat of zincrich aromatic urethane, such as Tnemec Series 90-97 Tneme-Zinc, or approved equal.
3. Intermediate Coat: Primed surfaces shall be coated with a 4 to 6 mil d.f.t. coat of polyamidoamine epoxy, such as Tnemec Series N69 High-Build Epoxoline II, or approved equal.
421
COATING SYSTEM 09800 - 4
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
4. Top Coat: A 2 to 3 mil d.f.t. coat of semi-gloss aliphatic acrylic polyurethane such as Tnemec Series 73 Endura-Shield shall be applied.
B. All prime and intermediate coats shall be compatible. City shall select finished top coat color from manufacturer’s standard colors. Prime and intermediate coat colors shall be compatible as recommended by the manufacturer.
2.04 BUILDING COATINGS
A. Floor: Sikagard 664 or approved equal, with silica sand anti slip aggregate applied at one pound per 1 gallon of topcoat or as recommended by the manufacturer.
B. Masonry Walls: 1 Coat of Loxon Acrylic Block Surfacer and 2 Coats of SuperPaint Exterior Latex or H&C COLORTOP water-based solid color concrete stain applied at 100- 150 sq ft/gal or approved equal.
C. Gypsum Ceiling and Walls: 1 Coat of PVA Primer and 2 Coats of SuperPaint Exterior Latex or 1 Coat ProMar 200 Zero V.O.C. Primer and 1 Coat of Pro Industrial DTM Acrylic coating or approved equal.
D. Doors and Gutters: 2 Coats of Superpaint Exterior Latex or approved Equal.
E. Colors and Shein:
1. Floor: Grey.
2. Walls and Ceiling: Tan Eg-Shel or Flat
3. Trim and Doors: Brown Flat or Semi-Gloss
PART 3 EXECUTION
3.01 GENERAL
A. All materials shall be delivered to the site in the manufacturer's sealed containers. Each container shall be labeled by the manufacturer, and the label shall be intact upon delivery.
Labels shall give the manufacturer's name, brand, type of paint, batch number, color of paint and instructions for reducing. Materials shall not be delivered until the Engineer's written approval has been received.
B. Each coat of paint shall be of the consistency as supplied by the manufacturer, or thinned if necessary, and applied in accordance with the manufacturer's written instructions. Work shall be free from "runs", "bridges", "shiners", or other imperfections due to faulty intervals. Care shall be taken to obtain a uniform, unbroken coating over all bolts, threads, nuts, welds, edges, and corners. Further, all weld splatter shall be removed and all welds neutralized with thinner.
C. Care shall be exercised not to damage adjacent work during sandblasting operations.
Stainless steel need not be sandblasted. Blasted surfaces shall be coated within four hours of being sandblasted. All dust shall be removed from the surfaces prior to painting.
3.02 ENVIRONMENTAL CONDITIONS
422
COATING SYSTEM 09800 - 5
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) A. Paint shall not be applied in extreme heat, nor in dust or smoke laden air, nor in damp or humid weather, nor when the air temperature and/or the temperature of the surface to be painted is below 50o F or within 10o F of the dew point. The Contractor shall provide temporary heat as required to maintain 50o F temperature and 10o F above the dew point day and night until painting is complete and the paint is dry.
B. Paint shall not be applied to surfaces hotter than 120o F.
3.03 GENERAL SURFACE PREPARATION
A. All surfaces to be coated or painted shall be in the specified condition to receive the material before any coating or painting is performed. No more sandblasting or surface preparation than can be coated or painted in a normal working day will be permitted. All sharp edges, burrs, and weld spatter shall be removed.
1. White Metal Blast Cleaning (SSPC SP5): Removal of all visible rust, mill scale, paint, and foreign matter by blast cleaning by wheel or nozzle using sand, grit, or shot.
2. Near-White Blast Cleaning (SSPC SP10): Blast cleaning nearly to White Metal Cleanliness, until at least 95% of each element of surface area is free of all visible residues.
3. Commercial Blast (SSPC SP6): Blast cleaning until at least 67% of each element of surface area is free of all visible residues.
4. Brush-off Blast Cleaning (SSPC SP7): Blast cleaning of all except tightly adhering residues of mill scale, rust and coatings, exposing numerous evenly distributed flecks of underlying metal.
5. Solvent Cleaning (SSPC SP1): Removal of all grease, oil, and dirt.
3.04 INSPECTION AND GUARANTEE
A. During and after final application of protective coatings, all metal surfaces shall be checked mechanically with an Elcometer, Mikrotest or other approved dry film thickness gage to insure that the specified dry film thickness has been attained.
B. Coating testing and repair of damages, flawed areas, holidays, or mishaps shall conform to applicable AWWA standards.
C. The Contractor shall guarantee all coating work for a period of one year following the date of final acceptance by the City and is hereby notified that the City will inspect the project prior to the expiration of the guarantee period. The Contractor will be notified of the eleventh month inspection by certified letter and asked to attend. Defects in workmanship and materials shall be repaired by the Contractor at no cost to the City.
3.05 PAINT SCHEDULE
A. Items for Coating: Items shall be coated as specified herein.
B. Factory Painted Equipment: Except as otherwise noted in the specifications, the following shall receive final finish coats at the factory. Paint shall conform to these specifications for appropriate service. Any areas damaged during shipment, installation, or initial testing shall be refinished as the original at no extra cost to the City. Factory painted items shall be of a color approved by the City.
423
COATING SYSTEM 09800 - 6
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) ⋅ Pump Station Control Panels
⋅ Pump Termination Cabinet
C. Items Field Painted: Following shall be painted in the Field ⋅ Ground level floors
⋅ Above ground level walls and foundation
⋅ Ceilings
⋅ Soffit
⋅ Exposed conduits and piping
⋅ Doors
⋅ Gutters and downspouts
C. Items Not Painted: Unless otherwise specified, the following items shall not be painted:
⋅ Encased piping or conduit
⋅ Plastic pipe and conduit
⋅ Galvanized and Stainless steel framing and plates
⋅ Nameplates
⋅ Serial numbers
⋅ Warning or operating instruction labels
⋅ Gages
⋅ Steel encased in concrete or masonry
** END OF SECTION **
424
WASTEWATER STRUCTURES COATING 09900 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 09900
WASTEWATER STRUCTURES COATING
PART 1 GENERAL
1.01 SUMMARY
A. Section Includes:
1. Coating of sanitary sewer manholes, wet wells, and valve vaults as indicated on the contract drawings.
B. Related Sections
1. Section 03301 - Cast In Place Concrete.
2. Section 03400 - Precast Concrete.
3. Section 03600 - Grouts
1.02 REFERENCE STANDARDS
A. American Society for Testing and Materials (ASTM)
1. D570 - Standard Test Method for Water Absorption of Plastics
2. D638 - Standard Test Method for Tensile Properties of Plastics
3. D695 - Standard Test Method for Compressive Properties of Rigid Plastics
4. D790 - Standard Test Method for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials
5. D4258 - Standard Practice for Surface Cleaning Concrete for Coating
6. D4259 - Standard Practice for Abrading Concrete
7. D7234 - Standard Test Method for Pull-Off Adhesion Strength of Coatings on Concrete Using Portable Pull-Off Adhesion Testers
B. National Association of Corrosion Engineers (NACE)
C. Society for Protective Coatings (SSPC):
1. SP1 - Solvent Cleaning
2. SP13 - Surface Preparation of Concrete
D. American Concrete Institute (ACI)
1. RAP-3 – Spall Repair by Low Pressure Spraying
2. 546R – Concrete Repair Guide
1.03 SUBMITTALS
A. The Contractor shall furnish detailed data pertaining to the surfaces of the structure(s) to be rehabilitated, the rehabilitation product, surface preparation, and installation for review.
B. Letter from the Coatings Manufacturer certifying the Coatings Installer as factory trained and qualified.
425
WASTEWATER STRUCTURES COATING 09900 - 2
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) C. Test reports from an independent testing laboratory confirming chemical resistance of coating for chemicals common to wastewater facilities.
PART 2 PRODUCTS
2.01 CEMENTITIOUS COATING
A. Both a cementitious and epoxy coating system shall be applied to manholes, wetwells, and valve vault as indicated to be coated on the project plans.
Cementitious coating shall be compatible with the epoxy coating.
B. Products:
1. Parson Environmental: Parson MH Liner or Parson CA Liner 100
2. Raven Lining System: Raven 705CA or Raven 755
3. Madewell: Mainstay ML-72 or ML-CA
4. Or Approved Equal
2.02 EPOXY COATINGS
A. Epoxy Coatings shall be used on all manholes, wet well, and valve vault where indicated to be coated on the project plans.
B. Epoxy coatings shall meet the following physical properties:
1. Compressive strength: > 16,000 psi per ASTM D695
2. Flexural strength: > 12,000 psi per ASTM D790
3. Tensile strength: > 7,500 psi per ASTM D638
C. Products:
1. Parson Environmental: Parsonpoxy SEL-80
2. Raven Lining Systems: Raven 405
3. Madewell: Mainstay DS-5
4. Or Approved Equal
PART 3 EXECUTION
3.01 GENERAL
A. All materials shall be delivered to the site in the manufacturer's sealed containers.
Each container shall be labeled by the manufacturer, and the label shall be intact upon delivery.
B. Installation shall be in conformance with the manufacturer’s recommendations unless otherwise noted herein.
C. All protective coating materials shall be used within the manufacturer's recommended shelf life.
D. Storage: Coating materials shall be protected from exposure to inclement weather, and shall be thoroughly stirred, strained, and kept at a uniform consistency during application.
426
WASTEWATER STRUCTURES COATING 09900 - 3
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) E. Mixing:
1. Coatings of different manufacturers shall not be mixed together.
2. Mixing of multi-component coating systems shall be performed in accordance with Manufacturer’s recommendations. Components must be mixed in complete batches only and used immediately.
3.02 SURFACE PREPARATION
A. Remove roots.
B. All oil, grease, and form release and curing compounds shall be removed by detergent cleaning in accordance with SSPC-SP1 before abrasive blast cleaning.
Surface preparation shall be performed in accordance with the latest editions of the following standards:
1. ASTM D4258: Standard Practice for Surface Cleaning Concrete for Coating
2. ASTM D4259: Standard Practice for Abrading Concrete
C. Concrete surfaces and deteriorated concrete surfaces to be coated or lined shall be abrasive blast cleaned in accordance with SSPC-SP13 to remove existing coatings, laitance, deteriorated concrete, and to roughen the surface equivalent to the surface of the No. 60 grit flint sandpaper (surface profile of 2.5 to 4 mils).
D. Repair any cracks, bug holes, spalled areas, holes, leaks, or evidence of leaks with mortar or grout as recommended by the epoxy coating manufacturer.
E. Unless required for proper adhesion, surfaces shall be dry prior to coating. The presence of moisture shall be determined with a moisture detection device such as Delmhorst Model DB, or equal.
F. All surfaces to be coated shall be completely dry, clean, and contaminant-free prior to application.
G. Additional surface preparation per the epoxy coating manufacturer’s recommendations.
3.03 APPLICATION OF MATERIALS
A. Coating shall be applied by a Manufacturer approved installer.
B. Coating shall be applied by spray methods in accordance with the manufacturer requirements and as follows:
1. Material shall not be applied to frozen surfaces or surfaces that may freeze within 24 hours of application
2. Application shall be at an angle as near perpendicular to the sub-surface as practicable with the application nozzle held 1 foot from the sub-surface. If nozzle flow is non-uniform and slugs, sand spots and wet sloughs result, the nozzle shall be directed away from the work area until the faulty conditions are corrected.
C. Coatings shall be applied to all walls, benches, and inverts. 427
WASTEWATER STRUCTURES COATING 09900 - 4
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
3.04 Field Testing
A. Proper, safe access shall be provided in locations where requested by the Engineer to facilitate inspection. Additional illumination shall be furnished when the Engineer requests. Proper ventilation and atmospheric monitoring shall be provided as well as all other safety equipment and precautions required by OSHA for a safe inspection in all areas.
B. The Engineer will conduct wet-film thickness testing. Contractor shall recoat any areas found deficient in thickness.
C. Holiday Testing:
1. Engineer will visually inspect coverage for blisters, sags, and holidays.
Contractor shall repair areas identified by this inspection prior to conducting holiday test.
2. Contractor shall holiday test, in the presence of the Engineer, all coated surfaces.
a. Holiday testing equipment and procedures shall be done in strict accordance with the latest edition of the NACE “Discontinuity (Holiday) Testing of Protective Coatings.”
b. Areas that contain holidays shall be marked and repaired or recoated in accordance with the coating manufacturer's printed instructions and then retested.
3. Holiday detectors shall be of the following type:
a. High voltage pulse-type holiday detector such as Tinker & Rasor Model AP-W, D.E. Stearns Co. Model 14/20, or equal shall be used. The unit shall be adjusted to operate at a voltage of at least 110 volts/mil desired thickness.
D. Adhesion Testing:
1. Adhesion testing will be performed by an independent inspector hired and paid for by the City as deemed necessary by the City. The adhesion testing will be conducted after the coating system has cured per manufacturer instruction and in accordance with ASTM D7234.
2. The Contractor shall schedule adhesion testing with the City a minimum of one week prior to the desired testing date. The pull tests shall meet or exceed 200 psi and shall include subbase adhered to the back of the dolly or no visual signs of coating material in the test hole.
3. Pull tests with the results between a minimum 150 psi and 200 psi shall be acceptable if more than 50% of the subsurface adhered to the back of the dolly.
If any test fails, a minimum of three additional locations in the section of the failure will be tested.
4. If any of the retests fail, all loosely adhered or unadhered liner in the failed area, as determined by the Engineer, shall be removed and replaced at the Contractor’s expense. The costs for testing all reapplied coatings shall be paid for by the Contractor.
5. Adhesion testing is destructive and removes lining material. The Contractor shall repair all disturbed and removed areas of the lining material per the manufacturer’s recommendations after testing is complete. 428
WASTEWATER STRUCTURES COATING 09900 - 5
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) E. Any damaged areas, faulty areas, or discontinuities (pinholes) found during quality control inspection shall be repaired in accordance with the Manufacturer’s recommendations.
** END OF SECTION **
429
EQUIPMENT MOUNTING 11002- 1
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 11002
EQUIPMENT MOUNTING
PART 1 GENERAL
1.01 SECTION INCLUDES
A. Equipment mounting requirements, including fabricated steel equipment bases, concrete equipment pads, supports, anchorage, and accessories.
1.02 REFERENCED SECTIONS
A. The following Sections are referenced in this Section
1. Section 01300 – Contractor Submittals
2. Section 01611 – Seismic Design Requirements
3. Section 05501 – Anchor Bolts
4. Section 09800 – Coating Systems
1.03 QUALITY ASSURANCE
A. Provide supports, anchorage, and equipment mounts that are sized and designed to resist the calculated forces and that are in accordance with the manufacturer’s recommendations, the current California Building Code (CBC), and industry standards requirements.
1.04 DESIGN REQUIREMENTS
A. Design equipment mounts and anchorages to resist the minimum lateral force required by Section 01611 and the latest edition of the CBC.
B. Equipment anchor bolt sizes shown on the Drawings are the minimum required size.
C. Equipment anchorage design and calculations shall be prepared and signed by a civil or structural engineer currently registered in the state where equipment is installed.
1.05 MOUNTING REQUIREMENTS
A. Mount equipment and driver on a common fabricated steel baseplate with ample rigidity to support equipment and maintain shaft alignment without excessive deflection.
B. Mount equipment baseplates on concrete equipment pads.
1.06 SUBMITTALS
A. Comply with Section 01300.
B. Shop Drawings: Provide drawings of equipment bases and anchorage details. 430
EQUIPMENT MOUNTING 11002- 2
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) C. Anchorage Calculations: Submit stamped and signed anchor bolt sizing calculations.
PART 2 PRODUCTS
2.01 ANCHOR BOLTS AND CONCRETE ANCHORS
A. Provide anchor bolts and concrete anchors in accordance with Section 05501.
2.02 CONCRETE EQUIPMENT PADS
A. Construct concrete pedestals at least 6 inches wider and longer than the steel or cast base so that the distance between the anchor bolts and the edge of concrete is at least 3 inches.
B. Unless otherwise shown or specified, all conduits, piping connections, drains, etc. shall be enclosed by the concrete base.
C. Shape concrete pedestals to drain away from the base.
D. Allow concrete to cure 21 days or until the concrete has cured to 75 percent of its specified compressive strength before placing equipment on the concrete pedestal.
E. Do not start equipment placed on the concrete pedestal until the concrete has cured for 28 days or to 100 percent of its specified compressive strength.
2.03 STRUCTURAL STEEL EQUIPMENT BASES
A. Provide structural steel bases with thickened steel pads for doweling.
1. Fabricate equipment base using continuous welds to seal seams and contact edges between steel members.
2. Grind welds smooth.
B. Design equipment bases with perimeter steel beams, intermediate stiffeners and baseplate.
1. Provide perimeter steel beams with minimum depth equal to 1/10th of the longest dimension of the base.
2. Beam depth need not exceed 14 inches provided that the baseplate deflection is kept within acceptable limits to minimize misalignment, as determined by the manufacturer.
C. Provide grout holes for the bases of equipment where vibration isolation is not specified.
D. Provide minimum 1-inch thick steel mounting baseplate for equipment with drivers 20 horsepower and larger.
E. Shop-apply prime coat prepared in accordance with the requirements of Section 09900 and compatible with the finish coatings.
431
EQUIPMENT MOUNTING 11002- 3
SAN JUAN PUMP STATION AND FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) PART 3 EXECUTION
3.01 GENERAL
A. Connect piping to equipment with flexible connections and/or expansion joints such that the intended uses of these joints is maintained in the piping system.
B. Coordinate the location of electrical conduit and piping penetrations within the concrete pad and equipment base.
1. Stub-up penetrations on the same side of the equipment as required for connection to the equipment.
2. Locate equipment drains for proper drainage away from equipment.
3.02 EQUIPMENT MOUNTING
A. Mount equipment on equipment baseplates using stainless steel shims so that equipment and driver are level in both directions and mounted within machined areas on baseplate.
Do not use wedges to obtain level and alignment.
B. Utilize templates for placement of anchor bolts prior to placing concrete for equipment pad.
C. Apply a non-seize or non-galling compound on the threads of anchor bolts and concrete anchors.
3.03 SHAFT ALIGNMENT
A. After the complete unit has been installed on the equipment pad and leveled, check the factory shaft alignment by disassembling coupling and measuring angular and parallel orientations.
B. Use reverse-indicator dial or laser type alignment equipment to align shafts to within the manufacturer’s required tolerance. Allow for thermal expansion, spacer coupling length and other factors that affect proper shaft alignment.
3.04 GROUTING EQUIPMENT BASES
A. After alignment has been completed, tighten anchor bolts and grout between equipment base and equipment pad. Use non-shrink and non-ferrous grout no less than 7/8 inch and no more than 1-5/8 inches thick unless otherwise shown.
B. Allow 48 hours for grout to harden and then remove jacking screws. Re-check torque on anchor bolts and re-check shaft alignment, making corrections as necessary. ***END OF SECTION***
432
SUBMERSIBLE DIRECT DRIVE MIXER 11220 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 11220
SUBMERSIBLE DIRECT DRIVE MIXER
PART 1 GENERAL
1.01 SCOPE
A. Furnish and install a heavy duty, direct drive submersible mixer for use within sanitary sewer wetwells as specified herein.
1.02 QUALITY ASSURANCE
A. The equipment specified in this Section shall be furnished, coordinated, serviced, and guaranteed by a supplier experienced in the design, manufacture, coordination, installation, and servicing of equipment of the type, size, and complexity specified in this Section. The supplier shall be capable of providing fully knowledgeable, experienced service personnel and replacement parts at the Project site not later than 24 hours after telephone notification by the Owner.
1.03 SUBMITTALS
A. Materials and Shop Drawings: Copies of all materials required to establish compliance with these specifications shall be submitted in accordance with the provisions of the Section 01300: Submittals, and the General Conditions. Submittals shall include at least the following:
1. Equipment catalog cut sheets.
2. Outline dimensions of all equipment.
3. Cross sectional drawings of all equipment with parts identification and materials specifications.
4. Fabrication and erection drawings.
5. Motor nameplate data and specifications sheet for all electric motors.
6. Bill of material.
7. List of spare parts.
8. Electrical schematics and interconnecting wiring diagrams showing extent of factory prewiring and details of control panels.
9. Manufacturer's drawings with parts list for all accessory equipment.
10. Shop painting specification(s) for ferrous surfaces.
11. Test data for equipment as specified herein.
12. Handling and storage instructions.
13. Operation and maintenance manuals.
14. A complete set of reproducible as-built Shop Drawings for all equipment furnished.
15. Certification by the manufacturer of the output rating of the rotor-impeller mixer selected, including all ratings for the gear drive and the mechanical adjustable speed drive unit.
B. Operating Instructions:
1. Six (6) copies of an operating and maintenance manual shall be furnished. The manual shall be prepared specifically for this installation and shall include all required catalog cuts, drawings, equipment lists, descriptions, and necessary 433
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) information that are required to instruct operating and maintenance personnel unfamiliar with all of the equipment specified herein. A complete, corrected and approved copy of the shop drawing submittal shall be included with each manual provided.
2. A factory representative who has a complete knowledge of proper operation and maintenance requirements for the equipment shall be provided for a minimum of one (1) eight-hour working day to instruct representatives of the Owner on proper operation and maintenance of the equipment. Provide at least ten (10) days advance notice to the Owner before scheduling the instruction day. The operation and maintenance manuals shall be provided at a time in advance of the instruction/training period that is approved by the Owner.
C. Equipment Certification:
1. The Contractor shall submit to the Engineer six (6) copies of a certified report from the factory service representative certifying that the submersible mixer equipment has been properly installed and operates satisfactorily under the specified operating conditions.
1.04 REFERENCES
A. American Society for Testing and Materials (ASTM):
1. A 36 – Standard Specification for Carbon Structural Steel
2. A48 - Standard Specification for Gray Iron Castings.
3. A 123 - Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products.
4. A 320 – Standard Practice for Preparation of Iron Casting for Electroplating
5. A 666 – Standard Specification for Annealed or Cold-Worked Austenitic Stainless Steel Sheet, Strip, Plate, and Flat Bar
6. B 209 – Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate
7. B 221 – Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes
8. B 308 – Standard Specification for Aluminum-Alloy 6061-T6 Standard Structural Profiles
9. F 593 – Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs
10. F 594 – Standard Specification for Stainless Steel Nuts
1.05 WARRANTY AND GUARANTEES
A. All equipment supplied under this Section shall be warranted for a period of two (2) years by the manufacturer and Contractor. The warranty period shall commence upon Owner acceptance as outlined in the General and Supplementary Conditions.
B. The equipment shall be warranted to be free from defects in workmanship, design, and materials. If any part of the equipment should fail during the warranty period, it shall be replaced at no expense to the Owner.
C. The manufacturer's warranty period shall run concurrently with the Contractor's warranty period. No exception to this provision shall be allowed. 434
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1.06 SHIPPING REQUIREMENTS
A. All fabricated steel assemblies shall be shipped in convenient sections, or as specified herein and permitted by carrier regulations, properly match-marked and identified for ease of field erection.
B. All equipment shall be handled during delivery, storage, and installation in a manner to prevent damage of any nature in accordance with the manufacturer's approved instructions.
C. All electrical controls and equipment shall be stored in a clean, dry, weather-tight building upon delivery to the Project site.
1.07 MANUFACTURER REQUIREMENTS
A. The mixer shall be Flygt Model 4620 having the characteristics specified herein. The Contractor shall furnish Flygt mixers; no other manufacturers will be accepted.
PART 2 PRODUCTS
2.01 GENERAL
A. The mixer(s) shall be capable of handling raw sewage. The mixer(s) shall be able to be raised and lowered and shall be easily removed for inspection or service without the need for personnel to enter the wetwell.
B. The mixer shall operate with the starting and stopping of the pumps. A disconnect switch shall be included in the motor control center to manually turn off the mixer.
C. The mixer shall be mounted on a square guide bar system. A sliding guide bracket shall be an integral part of the mixer unit. The entire weight of the mixer unit shall be guided by a single bracket which must be able to handle all thrust created by the mixer. The standard mixer, with its appurtenances and cable, shall be capable of continuous submergence under water, without loss of watertight integrity, to a depth of 130 ft. Guide bar, bracket, hardware, and appurtenances shall be 316 Stainless Steel.
1. Each unit shall be fitted with at least 25 ft. of stainless steel lifting cable of adequate strength to permit raising and lowering the mixer.
D. The unit provided shall be manufactured to the dimensions shown on the Drawings and as specified herein. Each mixer shall be of the integral design, close coupled, submersible type.
All components of the mixer, including motor, shall be capable of continuous underwater operation. Major mixer components shall be of 316L Stainless Steel construction. The oil housing cover plate shall be of corrosion resistant composite (4610/20 utilize a vinyl ester composite motor cover). All exposed fasteners shall be of stainless steel. The motor housing exterior shall be made of 316 Stainless Steel. All metal surfaces coming into contact with the mixed media, other than stainless steel, shall be protected by a factory applied spray coating of acrylic dispersion zinc phosphate primer with an epoxy finish coat on the exterior of the mixer.
E. The unit shall be furnished and installed complete with all mechanical equipment required for proper operation, including complete drive units, mounting brackets, hardware, guide rail 435
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) system, and other metal construction indicated by the Drawings, and any additional materials or construction required by the manufacturer's design.
2.02 MATERIALS
A. Structural Steel: ASTM A36
B. Steel Galvanizing: ASTM A123
C. Structural Aluminum: ASTM B209, ASTM B221, ASTM B308, Alloy 6061-T6 D. Structural Stainless Steel: Type 316
E. Castings: ASTM A48, gray iron having a minimum tensile strength of 20,000 pounds per square inch (psi)
F. Bolting Materials:
1. Anchor Bolts or High Strength Bolting Requirements; ASTM A320, B8M, Class 2, Type 316 stainless steel, high strength bolts.
2. Commercial Strength Bolting Requirements: ASTM F593, Type 316 stainless steel bolts and ASTM F594, Type 316 stainless steel nuts
3. Washers: Type 316 stainless steel
4. All nuts and bolts shall be coated with Xylan Fluoropolymer coating.
G. Elastomers
1. All mating surfaces where watertight sealing is required shall be machined and fitted with a double set of Nitrile rubber or Viton O-rings. Fitting shall be such that sealing is accomplished by metal-to-metal contact between machined surfaces.
This will result in controlled compression of the O-rings without requiring a specific torque limit. No secondary sealing compounds, rectangular gaskets, elliptical O-rings, grease or other devices shall be used.
H. Mixer & Propeller
1. The propeller shall be of 316 stainless steel dynamically balanced, non-clogging backward curved design. Each blade shall be laser cut and welded to the hub to ensure that the propeller is properly balanced.
2. The propeller shall be capable of handling solids, fibrous materials, heavy sludge, and other matter found in normal sewage applications.
3. The propeller shall be Flygt propeller code 042113SJ and be capable of a nominal thrust of 295 N with a propeller speed 1675 rpm and propeller diameter 8-9/32 inches and a shaft horsepower not to exceed 2.3 BHP in clear water.
4. The mixer shall draw 18 Amps maximum when operating at the specified BHP.
Total input power shall not exceed 1.55 kW. The mixer shall be designed for continuous duty in handling mixed media of a maximum temperature of 311 ̊F.
I. Jet Ring Assembly
1. The mixer assembly shall incorporate a jet ring a full 360 degrees around the propeller.
436
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) J. Cable Entry
1. The cable entry housing shall consist of a compressible rubber bushing to seal off motor area and relieve strain on the cable. Cable entry housing shall be constructed of vinylester for shock and chemical resistance.
K. Bearings
1. All bearings shall have a minimum B-10 or L-10aa rated life of 100,000 hours and shall have inner and outer races of metal construction. The shaft shall be supported by a single row angular contact ball bearings and single row cylindrical roller bearing, plus a heavy duty single row angular contact ball bearing on the propeller side.
L. Oil Housing
1. The oil housing shall contain two compartments consisting of an inner and an outer section with four ports to connect and facilitate oil flow. In the event that the mixed media bypasses the other seal, this design will allow the outer compartment to collect the heavier (denser) fluids by means of a simple gravity process.
M. Mechanical Seals
1. Each mixer shall be provided with two sets of lapped end face type mechanical seals running in oil reservoirs for cooling and lubrication.
2. The standard inner mechanical seal is corrosion resistant Tungsten Carbide/Aluminum Oxide.
3. The outer seal faces are Tungsten Carbide/Tungsten Carbide. One face of the inner seal ring pair shall have spiral grooves laser etched in it, to provide a pumping action to move leakage from the stator housing back into the oil chamber. In order to avoid seal failure due to sticking, clogging, and misalignment from elements contained in the mixed media, only the seal faces of the outer seal assembly and its retaining clips shall be exposed to the mixed media.
N. Spare Parts
1. A selection of spare parts shall be included with each mixer. The minimum spare parts included shall be bearings, seals, and o-rings.
2.03 ELECTRIC MOTOR
A. Mixer and motor shall be explosion-proof and rated for Class I, Division 1 hazardous locations.
B. The motor shall be directly connected to the propeller (gearbox designs are not acceptable) to produce a propeller speed of 1675 RPM. The mixer motor shall be squirrel cage, induction, shell type design, housed in an air filled, watertight chamber. The stator winding shall be insulated with moisture resistant Class F insulation which will resist a temperature of 155°C (311°F). The stator shall be insulated by the trickle impregnation method resulting in a winding fill factor of at least 95%. The motor shall be designed for continuous duty, capable of sustaining a maximum of at least thirty (30) evenly spaced starts per hour. The rotor bars and short circuit rings shall be made of aluminum.
C. Thermal sensors shall be used to monitor stator temperatures. The stator shall be equipped with three (3) thermal switches embedded in the end coils of the stator winding and set for 284°F (140°C).
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1. The thermal switch and leakage sensor shall be connected to a Flygt Mini CAS control and status monitoring unit. The Flygt Mini CAS unit shall be designed to be mounted within the pump station motor control center.
D. Performance Requirements:
1. Motors shall be rated for operation on 3 phase, 240-volt power supply.
2. Motor shall be 2.3 HP, LSPM (line-started permanent-magnet) submersible electric motor connected for operation on 230 Volts, 3 Phase, 60 Hertz service.
3. Each motor shall have a 1.15 service factor and a 1.0 service factor for inverter duty rated motors.
4. Motors shall be free of objectionable noise and vibration. Units shall operate with a maximum sound level not to exceed 85 dBA as measured 5 feet from any surface.
5. The mixer- motor shall be inverter duty rated for a 4 to 1 turndown and shall be compatible with the VFD unit provided by the Contractor to drive the mixer.
PART 3 EXECUTION
3.01 INSTALLATION
A. Installation shall be as shown on the Drawings and in accordance with the manufacturer's recommendations and erection drawings. Erection drawings shall be submitted and approved prior to shipment of equipment. Mechanism parts shall be securely anchored to the wet well and grout filled by stainless steel fastening hardware furnished by the manufacturer, as shown on the Drawings.
B. All necessary bolts, nuts, washers, hanger rods, clips, and other hardware items for the anchoring and erection of the units shall be included. The manufacturer shall ship anchor bolts, bolting template drawings, and accurate bolt setting patterns to the Contractor in advance of shipping fabricated items and other equipment.
C. Edge Grinding. Sharp corners of cut or sheared edges and corners shall be rounded to a smooth contour by grinding.
D. Fabrication. All welds shall be continuous seal welds. All welds shall be in accordance with current AWS Standards.
3.02 INSPECTION AND TESTING
A. The submersible mixer supplier’s bid shall include the furnishing of the services of a fully qualified and experienced manufacturer’s representative to provide all specified services for inspection and testing of the completed mixer unit. Upon completion of installation, the Contractor, in the presence of the Owner and a qualified manufacturer's representative, shall perform a preliminary test on the submersible mixer to ensure the functioning of all component parts to the satisfaction of the Owner. The Contractor shall furnish all labor, equipment, water, and power required to perform each test.
B. Approval of the preliminary test by the Owner shall not constitute final acceptance of the equipment furnished.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) C. Upon approval of the preliminary test, the Contractor, in the presence of the Owner and a qualified manufacturer's representative, shall perform a field test to demonstrate the ability to meet or exceed the specified design criteria and proper function for the purpose intended.
D. The field tests on the submersible mixer shall be undertaken with water in the wet well filled up to the lead pump on water elevation shown on the Drawings. The Contractor shall be responsible for providing sufficient water for filling the wet well for the test runs. The test runs on the unit shall determine acceptable normal running noise, vibration, speed, and direction.
E. In the event of improper installation, the Contractor and the submersible mixer manufacturer shall be responsible for supervising the correction of the work and performing subsequent field tests until all defects are corrected.
3.03 MIXER TEST
A. The mixer manufacturer shall perform the following inspections and tests on each mixer before shipment from the factory:
1. Propeller, motor rating, and electrical connections shall first be checked for compliance to the customer's purchase order.
2. A dielectric test shall be carried out in accordance to IEC 60034-1 (two times rated voltage plus 1000 V). This test shall be done after assembly but before any performance tests. No records shall normally be provided.
3. Prior to shipment, the mixer shall be run dry to establish correct rotation and mechanical integrity.
B. A written report stating the foregoing steps have been done may be supplied with each mixer at the time of shipment (upon request).
**END OF SECTION**
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 11312
SUBMERSIBLE PUMPS
PART 1 GENERAL
1.01 SUMMARY
A. Section Includes: Requirements for provision of pump systems including submersible non-clog motor-driven pumps for service in raw sewage.
B. Related Sections:
1. Section 15050 – Basic Mechanical Materials and Methods.
1.02 REFERENCES
A. American Bearing Manufacturers Association (ABMA):
1. 9 - Load Ratings and Fatigue Life for Ball Bearings.
2. 11 - Load Ratings and Fatigue Life for Roller Bearings.
B. American Society for Testing and Materials (ASTM):
1. A 48 - Standard Specification for Gray Iron Castings.
2. A 108 - Standard Specification for Steel Bars, Carbon, Cold-Finished, Standard Quality.
3. A 167 - Standard Specification for Stainless and Heat-Resisting ChromiumNickel Steel Plate, Sheet, and Strip.
4. A 176 - Standard Specification for Stainless and Heat-Resisting Chromium Steel Plate, Sheet and Strip.
5. A 276 - Specification for Stainless Steel Bars and Shapes.
6. A 283 - Specification for Low and Intermediate Tensile Strength Carbon Steel Plates.
7. A 532 - Specification for Abrasion-Resistant Cast Irons.
8. A 576 - Specification for Steel Bars, Carbon, Hot Wrought, Special Quality.
9. A 582 - Specification for Free-Machining Stainless and Heat-Resisting Steel Bars.
10. A 743 - Specification for Castings, Iron-Chromium, Iron-Chromium-Nickel, Corrosion-Resistant, for General Application.
11. B 148 - Specification for Aluminum-Bronze Sand Castings.
12. B 505 - Specification for Copper-Base Alloy Continuous Castings.
13. B 584 - Specification for Copper Alloy Sand Castings for General Applications.
14. E 10 - Test Method for Brinell Hardness of Metallic Materials.
15. E 18 - Test Methods for Rockwell Hardness and Rockwell Superficial Hardness of Metallic Materials.
16. F 593 - Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs.
17. F 594 - Specification for Stainless Steel Nuts.
C. American National Standards Institute/Hydraulic Institute (ANSI/HI):
1. 1.1-1.5 - Centrifugal Pumps - Nomenclature, Definitions, Application, and Operation.
2. 1.6 - Centrifugal Pump Tests.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
3. 9.1-9.5 - General Pump Standards for Types, Definitions, Application, and Sound Measurements.
4. 9.6.4 – Rotodynamic Pumps for Vibration Measurements and Allowable Values
1.03 DEFINITIONS
A. Pump head (Total Dynamic Head, TDH), flow capacity, pump efficiency, net positive suction head available (NPSHa), and net positive suction head required (NPSHr): As defined in ANSI/HI 1.1-1.5, 1.6 and 9.1-9.5 and as modified in the Specifications.
B. Suction Head: Gauge pressure available at pump intake flange or bell in feet of fluid above atmospheric; average when using multiple suction pressure taps, regardless of variation in individual taps.
C. Tolerances: As defined in ANSI/HI 1.6 and 2.6, or more restrictive tolerances specified herein.
1.04 SYSTEM DESCRIPTION
A. Submersible Pumps with Components: Submersible pump, motor driver, bearings, seals, supports, electrical cable, necessary controls and instrumentation, taps, lifting eyes, lifting chain and similar type items as specified and as required for complete operational units ready for use as specified and installed as indicated on the Drawings.
B. Pump Types: Pumps supplied and installed shall be, rail-mounted submersible, centrifugal, Flygt pumps having the general characteristics as tabulated below. The Contractor shall furnish Flygt pumps; no other pump manufacturers will be accepted.
1. Flygt Model NP3315 HT
a. Maximum Rotative Speed (rpm) 1775
b. Shutoff Head (feet) 217
c. Max. Motor Horse Power 130
d. Motor Voltage (3 phase) 460
e. Rated Current (Amperes) 152
f. Starting Current (Amperes) 260
g. Power Factor at Full Load 0.89
h. Discharge Size (inches) 6
i. Impeller (in) 15.35 (390 mm)
j. Pump Curve:
0 gpm 292 ft.
115 gpm 290 ft.
230 gpm 284 ft.
345 gpm 278 ft.
460 gpm 273 ft.
575 gpm 268 ft.
690 gpm 263 ft.
805 gpm 257 ft.
920 gpm 252 ft.
1035 gpm 247 ft.
1150 gpm 242 ft.
1265 gpm 236 ft.
1380 gpm 231 ft.
1495 gpm 226 ft.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
1.05 SUBMITTALS
A. The manufacturer shall submit to the Engineer for approval, certified performance curves, and shop and assembly drawings. The drawings shall show the dimensions, ratings, component parts, arrangements, and materials of construction for all items covered under this section. The performance curves shall be based on data secured during actual tests run at the factory on the pump model proposed for installation, and signed by a responsible manufacturer's representative. The curves shall show the make, model, size, and trim of the impeller, the developed head, brake horse power, NPSHre, and efficiency at intervals of 50 gpm in capacity for the model operating at the specified rotative speed over the operating range of the pump.
B. Manufacturer shall supply six (6) sets of its standard submittals which shall contain the following:
1. Pump Outline Drawings
2. Motor Performance Data
3. Cable and Protective Device Data
4. Typical Installation Guides
5. Certified Pump Performance Curves
6. Detailed Description and Dimensions of All Accessories
7. Detailed Electrical Data
8. Control Drawings and Data
9. Technical Manuals
10. Parts Lists
11. Printed Warranty
1.06 QUALITY ASSURANCE
A. General: Pumps shall be suitable for pumping municipal wastewater and shall be designed and fully guaranteed for this use. Motors supplied with submersible pumps under this specification shall be suitable for continuous operation under submerged, partially submerged, or dry conditions. Motors shall be non-overloading throughout the full range of pump operation, as established by the pump model performance curve.
B. Standards: Equipment furnished and installed by the contractor shall be in full conformity and harmony with the intent to secure the best standard of construction and equipment as a whole or in part. Pumps shall be installed in strict accordance with manufacturer specifications, standard drawings, and installation instructions.
C. Submittals: Submittal data provided shall be of sufficient depth to illustrate compliance with these specifications, the plans, and other specifications that may influence the proper operation of this pump. No pump equipment shall be shipped until the required drawings and curves have been submitted to and acknowledged by the Engineer as being of general compliance and conformance with the information in the contract documents.
D. Testing: Model pumps shall be factory tested to determine head versus capacity, efficiencies, and kilowatt draw required for the operating points specified. All tests shall be run in accordance with the latest edition of the American Hydraulic Institute Standards. The actual pumps furnished shall also be tested for:
1. Impeller, propeller, motor rating, and electrical connections tests shall be run for compliance with specification requirements.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
2. Motor and cable insulation test for moisture content or insulation defects shall be performed with a 500 volt DC megger.
3. After a submerged test run of 30 minutes under 6 feet of water, Test 2 shall be repeated.
4. If any deviation of the above tests is found, that pump shall be rejected.
E. Operation and Maintenance Manuals: The pump supplier shall provide operation and maintenance manuals for all equipment and accessories furnished. The manuals shall be original (no photocopies) and contain at least the following:
1. Identification stating the general nature of the manual, which appears on or is readable through the front cover.
2. Neatly typewritten index near the front of the manual, furnishing immediate information as to location in the manual of all emergency data regarding the equipment.
3. Complete and detailed instructions regarding operation and maintenance of all equipment involved.
4. Complete nomenclature of all replaceable parts, their part numbers, current cost, list of recommended spare parts to be kept on hand, and name, address and telephone number of nearest vendor of parts.
5. Copies of all guaranties and warranties issued.
6. Copies of the favorably reviewed shop drawings with all data concerning changes made during construction.
7. Where content of manuals includes manufacturers' catalog pages, clearly indicate the precise items included in this installation.
F. Guarantee: Products furnished and installed under this section shall be guaranteed for a minimum period of five (5) years. Parts and labor for the first year of this guaranty period shall be provided in full, at no additional cost.
1.07 DELIVERY, STORAGE, AND HANDLING
A. As specified in Section 15050.
1.08 PROJECT CONDITIONS
A. Install pumps as indicated on the drawings.
1.09 SEQUENCING AND SCHEDULING
A. The specified pumps may have significantly long lead times. Contractor is responsible for expediting the submittal and material procurement process as necessary to complete the work within the contract time provided.
PART 2 PRODUCTS
2.01 MANUFACTURERS
A. Pump: Named manufacturer only. No other manufacturer is acceptable for City maintenance standardization:
1. ITT Flygt, NP series as specified herein.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
2.02 SUBMERSIBLE PUMPS AND MOTORS
A. Pumps shall be designed for municipal wastewater. Pump characteristics shall be such that the motor nameplate rating is not exceeded at any point on the operating curve.
B. Pumps shall have a discharge suitable for wet-pit installation. Pump and motor shall be explosion-proof (X Designation).
C. Pump and motor characteristics; including pump design and construction, cable seal, cooling system, wear rings, seals, impellers, bearings and motors; shall strictly meet Flygt’s published Performance Specification (latest release).
D. Pump motors shall be the squirrel-cage induction type, housed in a NEMA B air filled, watertight chamber, rated for continuous full load operation. The stator windings shall be insulated with moisture resistant Class H insulation rated for 180°C (356°F). The motor shall be inverter duty rated in accordance with NEMA MG1, Part 31. The stator shall be heat-shrink fitted into the cast iron stator housing. Motors shall be capable of withstanding up to 15 starts per hour and shall have a minimum 1.15 service factor.
E. The impeller shall be of ASTM A-532 (Alloy III A) 25% chrome cast iron dynamically balanced, semi-open, multi-vane, back swept, screw-shaped, non-clog design. The impeller leading edges shall be mechanically self-cleaned automatically upon each rotation as they pass across a spiral groove located on the volute suction. The screwshaped leading edges of the gray iron impeller shall be hardened to Rc 60 and shall be capable of handling solids, fibrous materials, heavy sludge, and other matter normally found in wastewater. The screw shape of the impeller inlet shall provide an inducing effect for the handling of up to 5% sludge and rag-laden wastewater. The impeller to volute clearance shall be readily adjustable by the means of a single trim screw. The impellers shall be locked to the shaft, held by an impeller bolt and shall be coated with alkyd resin primer.
F. The pump volute shall be a single piece gray cast iron, ASTM A-48, Class 35B, nonconcentric design with smooth passages of sufficient size to pass any solids that may enter the impeller. Minimum inlet and discharge size shall be as specified. The volute shall have a replaceable suction cover insert ring in which are cast spiral-shaped, sharpedged groove(s). The spiral groove(s) shall provide trash release pathways and sharp edge(s) across which each impeller vane leading edge shall cross during rotation so to remain unobstructed. The insert ring shall be cast of ASTM A-532 (Alloy III A) 25% chrome cast iron and provide effective sealing between the multi-vane semi-open impeller and the volute housing.
G. Nameplates: Motors shall have a stainless steel plate showing the motor connection diagram and a stainless steel nameplate indicating type, frame, insulation class, full load current, horsepower, full load minimum guaranteed efficiency and nominal power factor, rpm, degree rise in Celsius, maximum ambient temperature rating in degrees Celsius, manufacturer's name, serial number, model, voltages, locked motor Kva code and bearing numbers.
2.03 ACCESSORIES
A. Pump accessories shall be furnished as required and be compatible with each of the submersible pumps and the conditions of their installation. 444
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) B. All accessory hardware including anchor bolts, lifting chain and cable brackets shall be Type 316 stainless steel.
C. Accessories for each submersible pump and motor to be installed at the Pump Station:
1. Self-aligning discharge connection.
2. Stainless steel guide rails and mounting accessories as recommended by the pump manufacturer for pump removal and installation without the need to enter the wet well.
3. Intermediate guide bar brackets for guide rails.
4. Discharge Elbow.
5. At least 40 LF of submersible motor cable or as necessary to complete the installation.
6. Cable holder.
7. At least 25 LF of stainless steel lifting chain.
8. Lifting eye compatible with the pump.
9. Dual moisture sensing probe system to detect the entrance of moisture and provide an alarm. The moisture detection system shall be designed to detect the entrance of moisture in the high heat transfer fluid reservoir and the air-filled motor stator housing.
10. A316 stainless steel anchor bolts as recommended by the pump supplier and any other miscellaneous supplies required to complete the installation.
11. Contractor shall provide spare parts as recommended by the manufacturer. The minimum spare parts included shall be bearings, mechanical seals, o-rings, and wear rings.
2.04 COATINGS
A. Equipment shall receive final finish coats at the factory. Each coat of paint shall be of the consistency as supplied by the paint manufacturer, or thinned if necessary, and applied in accordance with the manufacturer's written instructions. Work shall be free from “runs”, “bridges”, “shiners”, or other imperfections. Care shall be taken to obtain a uniform, unbroken coating over welds, edges, and corners. Weld splatter shall be removed and all welds neutralized with thinner. Blasted surfaces shall be coated within four hours of being sandblasted. All dust shall be removed from surfaces prior to coating.
B. All surfaces to be coated or painted shall be in the specified condition to receive the material before any coating or painting is performed. Follow manufacturer's instructions. During and after final application of protective coatings, all metal surfaces shall be checked mechanically with an Elcometer, Mikrotest, or other approved dry film thickness gage to insure that the specified dry film thickness has been attained.
Coating testing and repair of damages, flawed areas, holidays, or mishaps shall conform to applicable AWWA standards.
C. Care shall be taken to prevent damage to coated surfaces during shipment. Any coatings damaged during shipment shall be refinished as the original at no extra cost to the City.
D. Coatings shall be guaranteed for a period of one year following the date of final acceptance.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
2.05 PROTECTIONS
A. Provide normally closed thermal switch in stator housing for thermal protection.
B. Provide leakage sensor in stator housing for moisture protection.
C. The thermal switch and leakage sensor shall be connected to a Flygt Mini CAS control and status monitoring unit. The Flygt Mini CAS unit shall be designed to be mounted within the pump station motor control center.
PART 3 EXECUTION
3.01 INSTALLATION
A. Pumps shall be installed in strict accordance with the manufacturer’s requirements B. Anchor bolts for the pump pedestals shall be drilled and epoxied into place after the pumps and discharge piping are set.
3.02 FIELD QUALITY CONTROL
A. Witnessing: All field testing shall be witnessed by the Engineer. Contractor shall notify the City a minimum of 48-hours prior to field testing.
B. Inspection and Check-out: As specified in Section 15050.
C. Equipment Performance Test: Test pump operations using automatic level controls as scheduled with the City and described herein.
D. All water and electricity required for field testing shall be provided at Contractor’s sole expense.
E. Operational Testing:
1. After installation, equipment shall be tested in the presence of the Engineer by an authorized pump manufacturer representative who shall certify, in writing, that the pumps are operating in compliance with these specifications and are free from binding, scraping, overloading, vibration or other defects. a. Vibration at any point of pump operation shall not exceed the upper limits of the Hydraulic Institute Standards. Vibration testing is only required if noticeable vibration occurs during pump operation. If necessary, vibration testing shall be completed per ANSI/HI 9.6.4.
2. Each pumping unit shall be run and monitored for a minimum duration of one (1) hour during the test period. A minimum of 6 pump cycles shall occur during pump testing. Motor running current readings shall be taken for each phase.
Coordinate testing with the City.
3. The manufacturer’s representative shall perform the following:
a. Check motor stator and power cables.
b. Check seal lubrication.
c. Check for proper rotation.
d. Check power supply voltage.
e. Measure motor operating load and no load current for each phase. f. Check level control operation and sequence.
446
SUBMERSIBLE PUMPS 11312 - 8
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
3.03 MANUFACTURER'S FIELD SERVICES
A. Require manufacturer to inspect system before initial start-up and certify that system has been correctly installed and prepared for start-up as specified in this section and Section 15050.
B. The manufacturer’s service representative shall review recommended operation and maintenance procedures with City personnel.
**END OF SECTION**
447
PRESSURE FIELD INSTRUMENTS 11424 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 11424
PRESSURE FIELD INSTRUMENTS
PART 1 GENERAL
1.01 SUMMARY
A. Section Includes: Permanently installed field pressure indicators with integral instrumentation devices.
B. Related Sections:
1. Section 02720 - Ductile Iron Pipe and Fittings.
1.02 SUBMITTALS
A. Product Data.
B. Shop Drawings:
1. Connection diagram.
2. Factory calibration data sheets for instruments and devices requiring set-up and calibration.
C. Manufacturer's Installation Instructions: Include mounting details.
D. Field Calibration Data Sheets: Include for instruments and devices requiring set-up and calibration.
1.03 MAINTENANCE
Not Used.
PART 2 PRODUCTS
2.01 PRESSURE SENSORS
A. Provide flanged bolt-through pressure sensors at the locations shown on the Drawings. Flanges shall be Type 316 stainless steel. Pressure shall be sensed using a captive fluid displaced through a flexible Buna-N sleeve to the instrument’s Bourdon tube.
B. Pressure sensors shall be Ashcroft Series 80, or approved equal.
C. The pressure-sensing ring shall measure pressure for 360 degrees around the full inside circumference of the pipeline. The sensing ring shall also be clamped into the body for the full radial width of the sensor. Pressure shall be transmitted to the gauge by a locked in and sealed fluid such as ethylene glycol or silicone oil. 448
PRESSURE FIELD INSTRUMENTS 11424 - 2
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
2.02 PRESSURE GAUGES
A. Pressure gauges shall be Ashcroft 1279, Ametek Solfrunt Series 1900, or Equal.
B. Pressure range shall be 0 to 160 psi.
C. Sensing element shall be bourdon tube with welded, stress-relieved joints. Sensing element material shall be as recommended by the manufacturer and as indicated in the data sheet. Gauges shall have an accuracy of plus and minus 1/2-percent of full scale.
D. Body material shall be as recommended by the manufacture and as indicated in the data sheet.
E. Gauge shall be either dry or liquid-filled.
F. Gauges shall be provided with a 316 stainless steel pulsation dampener (snubber), unless otherwise noted in the data sheet. The pulsating dampener shall absorb system pressure pulses.
PART 3 EXECUTION
3.01 INSTALLATION
A. Install instruments in accordance with manufacturer's instructions.
3.02 TESTING
A. Contractor shall hydrostatically pressure test the gauge prior to installation. Pressure test to 120 psi and maintain pressure for at least 5 minutes. Record pressure of the gauge and a separate gauge. Notify Engineer if difference in pressure measured is 5 psi or greater.
END OF SECTION
449
MAGNETIC FLOW METERS 13421 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 13421
MAGNETIC FLOW METERS
PART 1 GENERAL
1.01 DESCRIPTION
Work under this Section includes all labor and materials which are required to furnish and install magnetic flow meters as indicated and as specified. Work includes flow meters, appurtenant hardware, and accessories as necessary to furnish and install functioning flow meters.
1.02 RELATED SECTIONS
A. Section 15052 Basic Piping and Methods
1.03 REFERENCE STANDARDS
A. Design, fabricate and test flow meters and materials in accordance with manufacturer’s recommended procedures and the following codes and standards:
1. ASTM A105 – Standard Specification for Carbon Steel Forgings in Piping Applications
2. ASTM A193 – Standard Specification for Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications
3. ASTM A194 – Standard Specification for Carbon Steel, Alloy Steel, and Stainless Steel Nuts for Bolts for High Pressure or High Temperature Service, or Both
1.04 SUBMITTALS
A. Comply with requirements of Section 01300, Contractor Submittals.
B. Submit the following for review:
1. Technical data and shop drawings
a. Showing all critical dimensions.
b. Showing principal parts and materials.
2. Materials lists
3. Installation guides
4. Operation and maintenance instructions
5. Detailed description and dimensions of all accessories
6. Anchor Bolts and Nuts
C. Submittal data provided shall be of sufficient depth to illustrate compliance with these Specifications, the plans and other Specifications that may influence the proper operation of the flow meters.
D. Contractor shall submit to the Engineer for review, certified shop, and assembly plans. The plans shall show the dimensions, ratings, component parts, arrangements, and materials of construction for all items covered under this Section. Such review does not relieve the Contractor from responsibility for executing the work in accordance with the Contract 450
MAGNETIC FLOW METERS 13421 - 2
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) Documents.
E. No equipment shall be ordered until the required data have been submitted to and acknowledged by the Engineer as being of general compliance and conformance with the information in the Contract Documents.
F. Operation and Maintenance Manuals: Provide operation and maintenance manuals for all equipment and accessories furnished. Clearly indicate the precise items included in this installation where the content of the manual includes manufacturers' catalog pages. The manuals shall be original (no photocopies) and contain at least the following:
1. Identification stating the general nature of the manual, which appears on or is readable through the front cover.
2. Neatly typewritten index near the front of the manual, furnishing immediate information as to location in the manual of all emergency data regarding the equipment.
3. Detailed instructions regarding operation and maintenance of all equipment.
4. Complete nomenclature of all replaceable parts, their part numbers, current cost, list of recommended spare parts to be kept on hand, and name, address and telephone number of nearest vendor of parts.
5. Copies of all guarantees and warranties issued.
6. Copies of the favorably reviewed shop plans with all data concerning changes made during construction.
7. Factory calibration report
8. Field calibration report
1.05 DELIVERY, STORAGE, AND HANDLING
A. Ship all flow meters with suitable packaging to protect products form damage.
B. Protect threads, flanges, stems and meters from damage.
1.06 QUALITY ASSURANCE
A. General: Flow meters shall be suitable for use with raw sanitary sewage force mains located within underground vaults as shown on the plans, and shall be designed and fully guaranteed for this use.
B. Standards: Equipment furnished shall be in full conformity and harmony with the intent to secure the best standard of construction and equipment as a whole or in part. This Specification shall be regarded as a minimum standard for design and fabrication of equipment.
1.07 GUARANTEE
Parts and labor for the first two years of this guarantee period shall be provided by Manufacturer in full, at no cost to the Owner.
PART 2 PRODUCTS
451
MAGNETIC FLOW METERS 13421 - 3
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
2.01 MAGNETIC FLOWMETER
A. The magnetic flowmeter shall be of the electromagnetic design and shall produce a DC voltage signal that is linear with the liquid flow rate. Meter accuracy shall be ±0.5 percent of the actual rate of flow from 0.2 to 32 feet per second.
B. Changes in conductivity, density, viscosity, temperature, and/or pressure shall not affect the accuracy of the flowmeter.
1. Limits for accuracy shall be at least:
a. Operating Temperature: -4° F to 140 °F
b. Operating Pressure: 0.15 to 232 psi
C. The liner shall be neoprene. The liner shall be compatible with the chemical, temperature, and abrasion characteristics of the municipal raw sewage and sludge solutions.
D. The electrodes shall be made of Type 316 stainless steel and shall be of the self-cleaning type. The electrodes shall be of the high impedance type to aid in prevention of errors due to coatings.
E. The meter enclosure shall be a NEMA 4X design and suitable for Class 1, Division 2, Groups C, and D classified (hazardous) areas.
F. The meter shall be rated for continuous submergence to 30 feet. The conduit entries of the sensor remote junction box shall be properly sealed to prevent water ingress. The use of sealed IP68 approved cable glands, conduit connections and/or conduit plugs shall be used to create a water tight installation.
G. The meter tube shall be made of Type 304 stainless steel with 150 lbs. ANSI flanges.
H. The sensing head must be completely interchangeable with any magnetic flowmeter transmitter without losing stated accuracy and without having to recalibrate. Clam shell design type will not be acceptable.
I. Electronic components, magnetic driver, or any part requiring field adjustments and calibration shall not be mounted on the flowmeter.
J. The magnetic flowmeter shall be furnished with a built-in grounding rings and straps which are constructed from Type 316 stainless steel. The grounding of the flowmeter shall be provided as required by the flowmeter manufacturer. All cables required to connect the flowmeter to the transmitter shall be furnished by the manufacturer.
K. The magnetic flowmeter shall be suitable for raw sewage and sludge applications.
L. The magnetic flowmeter and transmitter shall operate satisfactorily when located near electric motors controlled by variable frequency drive systems. A certificate documenting a list of successful installations and operation of the proposed magnetic flowmeter in high electromagnetic field and radio frequency interference (EMF & RFI) environment shall be submitted to the Engineer. If the proposed magnetic flowmeter has any case of operational problems in the sewage solution application and EMF RFI environments, the meter will not be acceptable.
452
MAGNETIC FLOW METERS 13421 - 4
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) M. The magnetic flowmeter shall be a Siemens Sitrans F M MAG 5100 DN300 electromagnetic flowmeter with a Siemens Sitrans F M MAG 5000 transmitter. The Contractor shall furnish the make and model specified; no other pump manufacturers will be accepted.
2.02 MAGNETIC FLOWMETER TRANSMITTER
A. The transmitter shall energize the coils in the primary head of the magnetic flowmeter with a pulsed DC current and convert the low level high impedance DC signal from the flowmeter to a proportional 4-20 ma DC signal for transmission.
B. The transmitter shall be of all microprocessor based, solid-state construction employing electromagnetic and electrostatic shielding techniques. The transmitter shall be capable of automatic range change, automatically switched as a function of flow rate with programmable range ratio. The transmitter shall have data retention for a minimum of ten (10) years, galvanic isolation between all output circuits and between these and the input circuit (electrodes), active status indication output to signal directions automatic or trip point.
C. Span shall be continuously adjustable between 1 to 40 feet per second flow velocity by means of pushbuttons. The transmitter accuracy shall be included in the overall system accuracy of at least plus or minus 0.2 percent. The repeatability shall be plus or minus 0.02 percent of full scale. The signal output shall be 4-20 ma DC into 1,000 ohms. No nulling or pre-calibrated adjustments shall be necessary. The transmitter shall be furnished with a digital readout which shows flow rate or totalized value in engineering units. The transmitter shall be capable of monitoring forward or reverse flow condition. The transmitter shall operate on 120 volt, 60 Hertz power source.
D. The transmitter shall operate at 30 Hertz for high stability and fast response. The transmitter shall have programmable digital filter to eliminate automatically noise spikes for both amplitude and time domain duration.
E. The transmitter shall have the ability to adjust the gain automatically as the flow rate varies.
It shall also be capable of manually setting the gain at low flow, medium flow and high flow.
F. The transmitter shall have adjustable features for both damping and rate limiting functions.
The transmitter shall have a self-diagnostic feature to monitor continuously for abnormal conditions and provide alarm annunciation and contact output.
G. The transmitter shall have a low flow cutout feature and shall lock the transmitter output signal at minimum value adjustable from 0 to 20 percent when the flow drops below an adjustable minimum value. The transmitter shall also be able to zero-clamp or signal lock with a contact input.
H. The transmitter shall have communication capabilities for HART.
I. The transmitter shall be housed in a NEMA 4X enclosure suitable for surface mounting. A small type enclosure type, similar to the meter mounted type, will not be acceptable. The conduit entries of the sensor remote junction box shall be properly sealed to prevent water ingress. The use of sealed IP68 approved cable glands, conduit connections and/or conduit plugs shall be used to create a water tight installation. 453
MAGNETIC FLOW METERS 13421 - 5
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) J. The transmitter shall be as manufactured by the same company as the magnetic flowmeter.
Substitutions will not be allowed to standardize on equipment and to maintain interchangeability of parts at the City’s pump stations.
2.03 SPARE PARTS
A. Contractor shall provide spare parts as recommended by the manufacturer. The minimum spare parts included shall be cable glands, sealing screw, terminal box, and terminal box lid.
PART 3 EXECUTION
3.01 MANUFACTURER’S INSTRUCTIONS
A. Comply with manufacturer’s product data, including technical bulletins, catalog installation instructions, and product carton instructions for installation.
3.02 PREPARATION
A. Verify that dimensions are correct for device installation, including dimensions and connection to the force main.
B. Verify that conditions are acceptable for product installation in accordance with the manufacturer’s recommended installation procedures.
C. The Contractor shall review the proposed installation and conditions and verify the manufacturers’ details for accuracy to fit the application and dimensions prior to ordering.
3.03 INSTALLATION
A. Coordinate the installation of equipment with other related and adjacent work. Installation shall not start until construction has progressed to a point where remaining construction operations will not damage new equipment.
B. Thoroughly clean and remove all shipping materials prior to setting.
C. Protect metal, painted, and rubber finish surfaces from damage during construction.
D. Comply with manufacturers’ installation instructions.
E. If the location of the flow meter is adjusted in the field during construction it is the Contractor’s responsibility to ensure that the flow meter is located a minimum of 5 pipe diameters downstream and 3 pipe diameters upstream of the nearest bend, valve, or fitting.
3.04 CLEANING
A. Repair or replace damaged installed products. Clean installed products in accordance with the manufacturer’s instructions.
B. Remove construction debris from site and legally dispose of the debris in conformance with Specifications.
454
MAGNETIC FLOW METERS 13421 - 6
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
3.05 TESTING AND CALIBRATION
A. Flow meter sensors shall be wet calibrated at the factory. The factory calibration report shall be shipped with the flow meter, and submitted to the City.
B. Contractor shall complete all installation, testing, and calibration procedures recommended by the flow meter manufacturer.
3.06 FIELD CALIBRATION
A. Once the flow meter has been installed and the pipe is returned to service the Contractor shall perform all field testing and calibration per the manufacturer’s instructions for testing and calibration. Testing and calibration procedures and results shall be submitted to the City in writing upon completion.
***END OF SECTION***
455
BASIC MECHANICAL MATERIALS AND METHODS 15050 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 15050
BASIC MECHANICAL MATERIALS AND METHODS
PART 1 GENERAL
1.01 SUMMARY
A. Section Includes: Basic design and performance requirements for mechanical equipment.
1.02 REFERENCES
A. American Society of Mechanical Engineers (ASME):
1. ASME PTC 8.2 - Performance Test Code for Centrifugal Pumps.
2. ANSI/ASME PTC 10 - Performance Test Code - Compressors and Exhausters.
3. ANSI/ASME PTC 17 - Performance Test Code - Reciprocating Internal-Combustion Engines.
4. ANSI/ASME PTC 11 - Performance Test Code - Measurement of Shaft Horsepower - Instruments and Apparatus.
B. American Bearing Manufactures Association (ABMA) Standards:
1. ABMA 9 - Load Ratings and Fatigue Life for Ball Bearings.
2. ABMA 11 - Load Ratings and Fatigue Life for Roller Bearings.
C. American Society for Testing and Materials (ASTM):
1. A 36 - Standard Specification for Structural Steel.
2. A 48 - Standard Specification for Gray Iron Castings.
3. A 526 - Standard Specification for Steel Sheet, Zinc Coated by the Hot Dip Process, Commercial Quality.
4. B-61 - Standard Specification for Steam or Valve Bronze Castings.
5. B 62 - Standard specification for Composition Bronze or Ounce Metal Castings.
6. E 527 - Standard Practice for Numbering Alloys and Metals (UNS).
D. American National Standards Institute/Hydraulic Institute Standards (ANSI/HI):
1. ANSI/HI 1.1-1.5 - Centrifugal Pumps - Nomenclature, Definitions, Application, and Operation.
2. ANSI/HI 1.6 - Centrifugal Pump Tests.
1.03 DEFINITIONS
A. Special Tools: Tools that have been specifically made for use on unit of equipment for assembly, disassembly, repair, or maintenance.
B. Resonant Frequency: That frequency at which a small driving force produces an everlarger vibration if no dampening exists.
C. Rotational Frequency: The revolutions per unit of time usually expressed as revolutions per minute.
D. Critical Frequency: Same as resonant frequency for the rotating elements or the installed machine and base.
456
BASIC MECHANICAL MATERIALS AND METHODS 15050 - 2
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) E. Peak Vibration Velocity: The root mean square average of the peak velocity of the vibrational movement times the square root of 2 in inches per second.
F. Rotational Speed: Same as rotational frequency.
G. Maximum Excitation Frequency: The excitation frequency with the highest vibration velocity of several excitation frequencies that are a function of the design of a particular machine.
H. Critical Speed: Same as critical frequency.
I. Free Field Noise Level: Noise measured without any reflective surfaces (an idealized situation); sound pressure levels at 3 feet from the source unless specified otherwise.
1.04 SYSTEM DESCRIPTION
A. General:
1. Provisions specified under each technical equipment specification prevail over and supersede conflicting provisions as specified in this Section.
2. Provide equipment and parts that are suitable for stresses which may occur during fabrication, transportation, erection, and operation.
3. Provide equipment that has not been in service prior to delivery, except as required by tests.
4. Like parts of duplicate units are to be interchangeable.
5. When two or more units of equipment for the same purpose are required, provide products of same manufacturer.
6. Equipment manufacturer's responsibility extends to selection and mounting of gear drive units, motors or other prime movers, accessories, and auxiliaries required for proper operation.
7. When necessary, modify manufacturer's standard product to conform to specified requirements or requirements indicated on the Drawings and contained in Laws and Regulations.
B. Material Requirements:
1. Materials: Suitable for superior corrosion resistance and for services under conditions normally encountered in similar installations.
2. Dissimilar Metals: Separate contacting surfaces with dielectric material.
C. Vibration:
1. Resonant Frequency: Ensure there are no natural resonant torsional, radial, or axial frequencies within 25 percent above or below the operating rotational frequencies or multiples of the operating rotational frequencies that may be excited by the equipment design.
D. Equipment Mounting and Anchoring:
1. Mount equipment on cast iron or welded steel bases with structural steel support frames. Utilize continuous welds to seal seams and contact edges between steel members. Grind welds smooth.
2. Provide bases and supports with machined support pads, dowels for alignment or mating of adjacent items, adequate openings to facilitate grouting, and openings for electrical conduits.
3. Provide jacking screws in bases and supports for equipment weighing over 1,000 pounds.
457
BASIC MECHANICAL MATERIALS AND METHODS 15050 - 3
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
4. Anchor equipment base to concrete pad. Determine number, size, type, and location of bolts, anchor bolts, or other connections.
5. Provide bolt sleeves for anchor bolts for heavy equipment. Adjust bolts to final location and fill sleeve with non-shrink grout.
E. Structural Design:
1. For equipment with operating weight of 400 pounds or more provide calculations for:
a. Determination of operating weight and centroid of equipment. 1) Operating weight is to be weight of unit plus weight of fluids or solids normally contained in unit during operation.
b. Determination of seismic forces and overturning moments. c. Determination of shear and tension forces in connections. d. Design of connection details based on calculated shear and tension forces.
F. Equipment Units Weighing 50 Pounds or More: Provide with lifting lugs or eyes to allow removal with hoist or other lifting device.
1.05 SUBMITTALS
A. Product Data:
1. For each item of Equipment:
a. Design features.
b. Load capacities.
c. Efficiency ratings.
d. Material designations by UNS alloy number or ASTM Specification and Grade.
e. Data needed to verify compliance with the Specifications. f. Catalog data.
g. Name plate data.
h. Clearly mark submittal information to show specific items, materials and accessories or options being furnished.
B. Shop Drawings:
1. Drawings for Equipment:
a. Drawings that include outline drawings, cut-away drawings, parts lists, material specification lists, and other information required to substantiate that proposed equipment complies with specified requirements.
2. Outline drawings showing equipment, driver, driven equipment, pumps, seal, motor(s) or other specified drivers, variable frequency drive, shafting, U-joints, couplings, drive arrangement, gears, baseplate or support dimensions, anchor bolt sizes and locations, bearings, and other furnished components.
3. Installation and checkout instructions including leveling and alignment tolerances, grouting, lubrication requirements, and initial start-up procedures.
4. Wiring, control schematics, control logic diagrams and ladder logic or similar for computer based controls.
5. Recommended or normal operating parameters such as temperatures and pressures.
6. Alarm and shutdown set points for all controls furnished. 458
BASIC MECHANICAL MATERIALS AND METHODS 15050 - 4
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) C. Calculations:
1. Calculations and other information to substantiate base plates, supports, and anchor bolts meet minimum design strength requirements and seismic design.
2. Calculations and other information to substantiate that operating rotational frequencies meet the requirements of this Section.
3. Torsional Analysis of Power Transmission Systems: When torsional analysis specified in the equipment Sections, provide:
a. Sketch of system components identifying physical characteristics including mass, diameter, thickness, and stiffness.
b. Results of analysis including first and second critical frequencies of system components and complete system.
D. Quality Control Submittals:
1. Source quality control reports and certified test data.
2. Submit factory test reports before shipment.
3. Certified static and dynamic balancing reports for rotating equipment.
4. Field quality control reports and test data.
5. Submit material test reports a specified in the equipment sections.
E. Operation and Maintenance Manuals:
1. Submit prior to training of City's personnel.
2. Make available at project site complete copy of manuals for use by field personnel and Engineer during start-up and testing of equipment.
3. Include manufacturer and model number of every bearing; include calculated ball pass frequencies of the installed equipment for both the inner and outer raceways.
4. Include motor rotor bar pass frequencies.
1.06 QUALITY ASSURANCE
A. Qualifications: Equipment manufacturer and system component manufacturers to have a minimum of 5 years experience in the design, manufacture, and assembly of the specified equipment and components with an established record of successful operation of such equipment and components.
B. References: Provide references from a minimum of 3 installations currently operating the same model equipment in continuous service for a minimum of 2 years under similar operating conditions. Reference information shall include location, service, contact person, and contact phone number.
C. Manufacturer's Field Service:
1. Furnish services of authorized representative specially trained in installation of equipment.
a. Visit project site and perform tasks necessary to certify installation.
1.07 DELIVERY, STORAGE, AND HANDLING
A. Packing and Shipping:
1. Equipment: Pack in boxes, crates, or otherwise protect from damage and moisture, dust, or dirt during shipment, handling, and storage.
2. Bearings: Separately pack or otherwise suitably protect during transport.
3. Spare Parts: Deliver in boxes labeled with contents, equipment to which spare parts belong, and name of Contractor.
459
BASIC MECHANICAL MATERIALS AND METHODS 15050 - 5
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) B. Storage:
1. Equipment Having Bearings: Store in enclosed facilities. Rotate units at least once per month or more often as recommended by the manufacture to protect rotating elements and bearings.
2. Gear Boxes: Oil filled or sprayed with rust preventive protective coating.
C. Protection:
1. Equipment: Protect equipment from deleterious exposure.
2. Painted Surfaces: Protect against impact, abrasion, discoloration, and other damage.
1.08 PROJECT CONDITIONS
A. Environmental Requirements:
1. Equipment for project is to be suitable for performance in a wastewater pumping plant environment and under following conditions:
a. Ambient Temperatures: freezing to 95 degrees Fahrenheit. b. Relative Humidities: 60 to 100 percent.
c. Other: Coastal fog.
1.09 SEQUENCING AND SCHEDULING
A. Equipment Anchoring: Obtain from equipment manufacturers' anchoring material and templates or setting drawings in time for anchors to be cast-in-place when concrete is placed.
B. Coordinate details of equipment with other related parts of the Work, including verification that structures, piping, wiring, and equipment components are compatible.
C. General Start-up and Testing of Equipment:
1. Perform general start-up and testing procedures after operation and maintenance manuals for equipment have been received.
2. Conduct functional testing of mechanical or electrical systems when each system is substantially complete and after general start-up and testing procedures have been successfully completed.
1.10 WARRANTY
A. Warranty: Where no specific term of warranty is provided in a technical specification, warrant equipment free of defects in material and workmanship for one year from the date of acceptance or date of first beneficial use of the equipment by the City; cover parts and labor.
B. Where a warranty exceeds one year, manufacturer’s warranty shall be issued in the City’s name.
1.11 MAINTENANCE
A. Special Tools:
1. When specified, provide special tools required for operation and maintenance.
2. Mark or tag and list such tools in maintenance and operations instructions.
Describe use of each tool.
460
BASIC MECHANICAL MATERIALS AND METHODS 15050 - 6
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) B. Spare Belts:
1. When spare belts are specified, furnish 1 spare belt for every different type and size of belt-driven unit.
a. Where 2 or more belts are involved, furnish matched sets. b. Identify as to equipment, design, horsepower, speed, length, sheave size, and use.
c. Package in boxes labeled with identification of contents.
C. Spare Parts:
1. Assume responsibility until turned over to City.
2. Store in enclosed facilities.
3. Furnish itemized list and match identification tag attached to every part.
4. List parts by generic title and identification number.
5. Furnish name, address, and telephone number of supplier and spare parts warehouse.
PART 2 PRODUCTS
2.01 MATERIALS
A. Ferrous Materials:
1. Steel for Members used in Fabrication of Assemblies: ASTM A 36.
2. Iron Castings: ASTM A 48, tough, close-grained gray iron, free from blowholes, flaws, and other imperfections.
3. Galvanized Steel Sheet: ASTM A 526, minimum 0.0635 inch (16 gauge).
4. Expanded Metal: ASTM A 36, 13-gauge, 1/2-inch flat pattern expanded metal.
B. Nonferrous Materials:
1. Stainless Steel: Type 304 or 316 as specified; provide L grade where welding required.
2. Bronze in Contact with Liquid: Composition of not more than 2 percent aluminum nor more than 6 percent zinc; UNS Alloy C83600, C92200, or C92700 in accordance with ASTM B 62, B-61, B-505, or B-584, when not specified otherwise.
C. Dielectric Materials for Separation of Dissimilar Metals:
1. Neoprene, bituminous impregnated felt, heavy bituminous coatings, nonmetallic separators or washers, or other materials.
D. Non-Shrink Grout: As specified in Section 03600.
2.02 BEARINGS
A. Type: Oil or grease lubricated, ball or roller antifriction type, of standard manufacture.
B. Oil Lubricated Bearings: Provide either pressure lubricating system or separate oil reservoir splash type system.
1. Oil Lubrication Systems: Sized to safely absorb heat energy normally generated in bearings under maximum ambient temperature of 15-degree Fahrenheit above the specified maximum ambient temperature specified under article, Project Conditions; provide external cooler when required, air cooled if water cooling 461
BASIC MECHANICAL MATERIALS AND METHODS 15050 - 7
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) source not indicated on the Drawings. Equip with filler pipe and external level gauge.
C. Grease Lubricated Bearings, Except Those Specified to Be Factory Sealed: Fit with easily accessible grease supply, flush, drain, and relief fittings.
1. Lubrication Lines and Fittings:
a. Lines: Minimum 1/4-inch diameter stainless steel tubing. b. Multiple Fitting Assemblies: Mount fittings together in easily accessible location.
c. Use standard hydraulic type grease supply fittings.
1) Manufacturers: One of the following or equal:
a) Alenite
b) Zurk.
D. Ratings: Rated in accordance with ABMA 9 or ABMA 11 for L10 rating life of not less than 50,000 hours.
1. Higher ratings, when specified in other Sections, supersede preceding requirement.
2.03 FABRICATION
A. Nameplates: Engraved or stamped on Type 304 stainless steel and fastened to equipment at factory in an accessible and visible location.
1. Indicate Following Information as Applicable:
a. Manufacturer's name.
b. Equipment model number and serial number.
c. Maximum and Normal rotating speed.
d. Horsepower.
e. Rated capacity.
f. Service class per applicable standards.
2. Nameplates for Pumps: Include:
a. Rated total dynamic head in feet of fluid.
b. Rated flow in gallons per minute.
c. Impeller, gear, screw, diaphragm, or piston size.
3. Gear Reduction Units: Include:
a. AGMA Class of service.
b. Service factor.
c. Input and output speeds.
B. Bolt Holes in Equipment Support Frames: Do not exceed bolt diameter by more than 25 percent, up to limiting maximum diameter oversize of 1/4 inch.
C. Shop Finishing:
1. Provide factory and field coating.
a. Bases and Support Frames in Contact with Concrete or Other Material: Paint contacting surfaces with minimum of 2 coats of zinc chromate primer before installation or grouting.
b. Shop Primer for Steel and Iron Surfaces, Unless Specified Otherwise:
1) Manufacturers: One of the following or equal:
a) Ameron, Amercoat 185 Universal Primer.
b) Cook, 391-N-167 Barrier Coat.
c) Kop-Coat, Pug Primer.
462
BASIC MECHANICAL MATERIALS AND METHODS 15050 - 8
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) d) Tnemec, 37-77 Chem-Prime.
e) Valspar, 13-R-28 Chromox Primer.
c. Coat machined, polished, and nonferrous surfaces which are not to be painted with rust-preventive compounds.
1) Manufacturers: One of the following or equal:
a) Houghton, Rust Veto 344.
b) Rust-Oleum, R-9.
d. Coating for Ferrous Metal Surfaces, Except Stainless Steel: High solids polyamine epoxy.
e. Finish Painting of Motors: Shop finish paint with manufacturer's standard coating, unless otherwise specified.
2.04 SOURCE QUALITY CONTROL
A. As specified in the individual equipment sections of the Specifications.
PART 3 EXECUTION
3.01 EXAMINATION
A. Inspect all components for shipping damage, conformance to specifications, and proper torques and tightness of fasteners.
3.02 PREPARATION
A. Metal Work Embedded in Concrete:
1. Accurately place and hold in correct position while concrete is being placed.
2. Clean surface of metal in contact with concrete immediately before concrete is placed.
B. Concrete Surfaces Designated to Receive Grout:
1. Give surfaces heavy sandblasting treatment.
2. Clean surfaces of sandblasting sand, grease, oil, dirt, and other foreign material that may reduce bonding of grout.
3. Concrete Saturation: Saturate concrete with water. Concrete surface shall be damp concrete at time grout is placed.
C. Field Measurements:
1. Prior to fabrication of equipment, take measurements for installation of equipment and verify dimensions indicated on the Drawings. Ensure equipment and ancillary appurtenances fit within available space.
3.03 INSTALLATION
A. Install equipment in accordance with manufacturer's installation instructions and recommendations.
B. Lubrication Lines and Fittings:
1. Lines from Fittings to Point of Use: Support and protect.
2. Fittings:
463
BASIC MECHANICAL MATERIALS AND METHODS 15050 - 9
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) a. Bring fittings to outside of equipment in manner such that they are readily accessible from outside without necessity of removing covers, plates, housings, or guards.
b. Mount fittings together wherever possible using factory-mounted multiple fitting assemblies securely mounted, parallel with equipment lines, and protected from damage.
c. Fittings for Underwater Bearings: Bring fittings above water surface and mount on edge of structure above.
C. Alignment of Drivers and Equipment:
1. Where drive motors or other drivers are connected to driven equipment by flexible coupling, disconnect coupling halves and align driver and equipment after complete unit has been leveled on its foundation.
2. Comply with procedures of appropriate Hydraulic Institute Standards, AGMA Standards, alignment tolerances of equipment manufacturers and the following requirements to bring components into angular and parallel alignment:
a. Maximum Total Coupling Offset (not the per plane offset): Not to exceed
0.5 mils per inch of coupling length for spacer couplings based on coupling length (not dial separation).
b. Utilize jacking screws, wedges, or shims as recommended by the equipment manufacturer and as specified in the equipment sections.
3. Use Reverse-indicator Arrangement Dial Type or Laser Type Alignment Indicators: Mount indicators on the driver/coupling flange and equipment/coupling flange. Alignment instrumentation accuracy to be sufficient to read angular and radial misalignment at 10 percent or less of the manufacturer's recommended acceptable misalignment.
4. Alignment and calculations to include measurement and allowance for thermal growth, spacer coupling length, indicator separation, and axial spacing tolerances of the coupling.
5. When alignment satisfies most stringent tolerance of system components, tighten anchor bolts and grout between base and foundation. Allow minimum 48 hours for grout to harden. After grout hardens, remove jacking screws, fully tighten anchor bolts, and recheck alignment. Correct alignment as required.
6. After operational testing is complete, dowel motor or drivers and driven equipment. Comply with manufacturer's instructions.
D. Grouting Equipment Bases:
1. Comply with manufacturer's installation instructions for grouting spaces, type of grout, and tolerances for level and alignments, both vertical and horizontal.
2. Grout base when piping connections are complete and in alignment with no strain transmitted to equipment.
3. Grout base when equipment is leveled and in alignment.
4. Place grout, filling voids under equipment bases including recesses between anchor bolts and sleeves.
a. Extend grout to edge of bases or bedplates and bevel at 45 degrees around units.
b. Finish surfaces with slope that prevents ponding water within grouted areas.
E. Special Techniques: Use applicable special tools and equipment, including precision machinist levels, dial indicators, and gauges as required in equipment installations. 464
BASIC MECHANICAL MATERIALS AND METHODS 15050 - 10
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) F. Completed Equipment Installations: Comply with requirements for intended use and specified vibration and noise tolerances.
G. Warning Signs: Mount securely with stainless fasteners at equipment which can be started automatically or from remote locations.
3.04 FIELD QUALITY CONTROL
A. Test equipment as required by product manufacturer.
3.05 MANUFACTURER'S REPRESENTATIVE
A. Field Checkout: Before field testing and start-up, provide services of factory-trained field service representative to certify the equipment has been installed, aligned and checked in accordance with the manufacturers instructions and the Specifications.
B. Testing: Provide services of factory trained representative to observe and advise the Contractor during field quality control testing.
C. Training: When training is specified, provide services of factory-trained representative to perform training.
**END OF SECTION**
465
BASIC PIPING MATERIALS AND METHODS 15052 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 15052
BASIC PIPING MATERIALS AND METHODS
PART 1 GENERAL
1.01 SUMMARY
A. Section Includes: Basic piping materials and methods.
B. Related Sections:
1. Section 02700 – Polyvinyl Chloride (PVC) Pipe and Fittings
2. Section 02710 – High Density Polyethylene (HDPE) Pipe
3. Section 02720 – Ductile Iron Pipe
4. Section 02770 – Sanitary Sewer Testing.
1.02 REFERENCES
A. American National Standards Institute
1. B 1.20.1 - Specifications of International Thread Standards B. American Society of Testing and Materials (ASTM):
1. A 53 - Standard Specification for Pipe, Steel, Black, and Hot-Dipped, ZincCoated Welded and Seamless.
2. A 106 - Specification for Seamless Carbon Steel Pipe for High-Temperature Service.
3. A 262 – Standard Practices for Detecting Susceptibility to Intergranular Attack in Austenitic Stainless Steels
4. A 351 - Standard Specification for Castings, Austenitic, for PressureContaining Parts
5. B 62 - Standard Specification for Composition Bronze or Ounce Metal Castings
6. D 1784 - Standard Specification for Rigid Poly(Vinyl Chloride) (PVC) Compounds and Chlorinated Poly(Vinyl Chloride) (CPVC) Compounds
7. D 1785 - Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40, 80, and 120
8. D 2240 - Test Method for Rubber Property - Durometer Hardness.
9. D 2564 - Specification for Solvent Cements for Poly (Vinyl Chloride) (PVC) Plastic Piping Systems
10. D 2672 - Standard Specification for Joints for IPS PVC Pipe Using Solvent Cement
11. B 42 - Standard Specification for Seamless Copper Pipe, Standard Sizes 466
BASIC PIPING MATERIALS AND METHODS 15052 - 2
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
12. B 88 - Standard Specification for Seamless Copper Pipe Water Tube C. American Water Works Association
1. AWWA C115 - Flanged Ductile Iron Pipe with Ductile Iron or Gray Iron Threaded Flanges
2. AWWA C116 - Protective Fusion-bonded Epoxy Coatings for the Interior and Exterior Surfaces of Ductile Iron and Gray Iron Fittings
3. AWWA C207 - Steel Pipe Flanges for Waterworks Service
1.03 DEFINITIONS
A. Aboveground Piping: Piping within buildings, tunnels, or other structures without regard to elevation of piping, or exposed piping outside buildings and structures.
B. Underground Piping: Piping buried in soil or cast in concrete.
C. Underwater Piping: Piping below tops of walls in basins or concrete tanks containing water.
D. Wet Wall: Wall with water on at least one side.
1.04 SYSTEM DESCRIPTION
A. Piping Drawings:
1. Except in details, piping is indicated diagrammatically. Not every offset and fitting, or structural difficulty that may be encountered has been indicated on the Drawings. Sizes and locations are indicated on the Drawings.
2. Perform minor modifications to piping alignment where necessary to avoid structural, mechanical, or other type of obstructions that cannot be removed or changed.
a. Modifications are intended to be of minor scope, not involving a change to the design concept or a change to the Contract Price or Contract Times.
B. Performance Requirements:
1. Restraining Piping:
a. Restrain piping at valves and at fittings where piping changes direction, changes sizes, and at ends.
1) When piping is underground use mechanical restraints. 2) When piping is aboveground or under water, use mechanical or structural restraints.
3) Determine thrust forces by multiplying the nominal cross sectional area of the piping by 2.5 times the pump shutoff head.
467
BASIC PIPING MATERIALS AND METHODS 15052 - 3
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) b. Provide underground mechanical restraints at all valves, fittings, and where specified in the Piping Schedule or shown on the Drawings.
C. Connections to Existing Piping:
1. Expose existing piping to which connections are to be made with sufficient time to permit, where necessary, field adjustments in line, grade, or fittings. a. Provide sleeves, flanges, nipples, couplings, adapters, and other fittings needed to install or attach new fittings to existing piping and to make connections to existing piping.
D. Connections at Dissimilar Metals:
1. Connect ferrous and nonferrous metal piping, tubing, and fittings with dielectric couplings especially designed for the prevention of chemical reactions between dissimilar metals.
2. Nonferrous metals include aluminum, copper, and copper alloys.
E. Piping Alternatives:
1. Provide piping in accordance with this Section, unless indicated on the Drawings or specified otherwise.
2. Alternative Pipe Ratings: Piping with greater pressure rating than specified may be substituted in lieu of specified piping without changes to the Contract Price. Piping of different material may not be substituted in lieu of specified piping.
3. Valves in Piping Sections: Valves shall have the same pressure rating as the adjacent piping.
4. For flanged joints, where one of the joining flanges is raised face type, provide a matching raised face type flange for the other joining flange.
PART 2 PRODUCTS
2.01 LINK TYPE SEALS
A. Manufacturers: One of the following or equal:
1. Calpico, Inc.
2. Thunderline Corporation, Link-Seal.
B. Characteristics:
1. Modular mechanical type, consisting of interlocking neoprene or synthetic rubber links shaped to continuously fill the annular space between the pipe and wall opening.
2. Assemble links solely with stainless steel bolts and nuts to form a continuous rubber belt around the pipe.
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BASIC PIPING MATERIALS AND METHODS 15052 - 4
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
3. Provide a stainless steel or glass reinforced nylon pressure plate under each bolt head and nut. Isolate pressure plate from contact with wall sleeve.
2.02 GASKETS
A. Gaskets for Steel Piping:
1. Suitable for pressures equal to and less than 150 pounds per square inch gauge, temperatures equal to and less than 250 degrees Fahrenheit, and raw sewage service.
2. Gasket Material:
a. Neoprene elastomer with minimum Shore A hardness value of 70. b. Reinforcement: Inserted 13 ounce nylon fabric cloth for pipes 20 inch or larger.
c. Thickness: Minimum 3/32 inch thick for less than 10 inch pipe; minimum 1/8 inch thick for 10 inch and larger pipe.
3. Manufacturers: One of the following or equal:
4. Pipe 20 inches in Diameter and Larger:
a. Garlock, Style 8798.
b. John Crane, similar product.
5. Pipe less than 20 inches in Diameter:
a. Garlock, Style 7797.
b. John Crane, similar product.
B. Gaskets for Flanged Joints in Polyvinyl Chloride and Polyethylene Piping:
1. Suitable for pressures equal and less than 150 pounds per square inch gauge, with low flange bolt loadings, temperatures equal and less than 120 degrees Fahrenheit, polymer, chlorine, caustic solutions, and other chemicals, except chemicals which liberate free fluorine including fluorochemicals and gaseous fluorine.
2. Material: Viton Rubber; 0.125 inch thick.
3. Manufacturers: One of the following or equal:
a. Garlock.
b. John Crane, similar product.
2.03 PIPE AND FITTINGS
A. Sewer PVC Pipe and Fittings: Refer to Section 02700.
B. Ductile Iron Pipe and Fittings: Refer to Section 02720 C. Water service piping:
1. Copper tubing Type K, soft, conforming to ASTM B88.
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BASIC PIPING MATERIALS AND METHODS 15052 - 5
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) D. Stainless steel pipe shall be seamless conforming to ASTM A262. Stainless steel shall be 316 unless otherwise noted.
E. Ball Valve: Refer to Section 15110.
F. Cam-lock Fitting:
1. Stainless steel 316 manufactured by Dixon or approved equal.
2. Metal coupling shall be able to withstand 75 psi minimum of working pressure
3. The body of the fitting shall meet material requirements included in ASTM A351.
4. Fitting shall be electrical isolated from dissimilar material by use of Nitrile (NBR) gasket or approved equal.
PART 3 EXECUTION
3.01 EXAMINATION
A. Verification of Existing Conditions:
1. Locate and expose existing structures, piping, conduits, and other facilities and obstructions that may affect construction of underground piping before starting excavation for new underground piping and appurtenances.
2. Verify sizes, elevations, locations, and other relevant features of existing facilities and obstructions. Determine conflicts for the construction of the new underground piping and appurtenances.
3. Make piping location and grade adjustments to resolve conflicts between new piping and existing facilities and obstructions.
3.02 WALL AND SLAB PENETRATIONS
A. Provide sleeves for piping penetrations through concrete walls, floors, ceilings, roofs, pilasters, columns, piers, and beams unless specified or otherwise indicated on the Drawings.
B. For piping 1 inch in nominal diameter and larger, provide sleeves with minimum inside diameters of 1 inch plus outside diameter of piping. For piping smaller than 1 inch in nominal diameter, provide sleeve of minimum twice the outside diameter of piping.
1. Arrange sleeves and adjacent joints so piping can be pulled out of sleeves and replaced without disturbing the structure.
2. Cut ends of sleeves flush with surfaces of concrete, masonry, or plaster. 470
BASIC PIPING MATERIALS AND METHODS 15052 - 6
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
3. Conceal ends of sleeves with escutcheons where piping runs through floors, walls, or ceilings of finished spaces within buildings.
4. Seal spaces between pipes and sleeves with link-type seals when not otherwise specified or indicated on the Drawings.
C. Cast couplings or wall pieces in walls for penetrations of buried rigid piping including steel and vitrified clay through structures.
1. Provide couplings or wall pieces with mechanical push-ons, or similar flexible joints at outside faces of walls.
2. Provide additional similar joints in piping at transition points between trenches and structure excavations.
3. For steel piping, single joints may be used in lieu of 2 joints. Locate single joints outside within 2 feet from outside faces of walls. Link Seal: Use 2 link seals where seal is used to seal at wet wall sleeves. Mount one seal on the inside face of the wall and the other on the outside face of the wall.
Coordinate the inside diameter of the wall sleeve with the size of the seal to provide watertight sealing.
D. Where not indicated on the Drawings, penetrations for conditions other than those specified under the preceding subparagraphs shall be 1 of the 3 types specified in such subparagraphs found by Engineer to be the most suitable for the particular conditions.
3.03 EXPOSED PIPING
A. Install exposed piping in straight runs parallel to the axes of structures, unless indicated otherwise.
1. Install piping runs plumb and level, unless otherwise indicated on the Drawings. Slope plumbing drain piping with 1/8 inch per foot downward in the direction of flow. Slope digester gas piping to drip traps or low-point drains at minimum 1/2 inch per foot where condensate flows against the gas, or 1/4 inch per foot where condensate flows with gas.
B. Install exposed piping after installing equipment and after piping and fitting locations have been determined.
C. Do not transfer pipe loads and strain to equipment.
D. In addition to the joints indicated on the Drawings, provide unions, flexible couplings, flanged joints, and other types of joints or means which are compatible with and suitable for the piping system, and necessary to allow ready assembly and disassembly of the piping.
471
BASIC PIPING MATERIALS AND METHODS 15052 - 7
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) E. Assemble piping without distortion or stresses caused by misalignment.
1. Match and properly orient flanges, unions, flexible couplings, and other connections.
2. Do not subject piping to bending or other undue stresses when fitting piping.
Do not correct defective orientation or alignment by distorting flanged joints or subjecting flange bolts to bending or other undue stresses.
3. Flange bolts, union halves, flexible connectors, and other connection elements shall slip freely into place.
4. Alter piping assembly to fit when proper fit is not obtained.
5. Install eccentric reducers or increasers with the top horizontal for pump suction piping.
3.04 BURIED PIPING
A. Bury piping with minimum 3-foot cover without air traps, unless otherwise indicated on the Drawings.
B. Where 2 similar services run parallel to each other, piping for such services may be laid in the same trench. Lay piping with sufficient room for assembly and disassembly of joints, for thrust blocks, for other structures, and to meet separation requirements of public health authorities having jurisdiction.
C. Laying Piping:
1. Lay piping in finished trenches free from water or debris. Begin at the lowest point with bell ends up slope.
2. Place piping with top or bottom markings with markings in proper position.
3. Lay piping on an unyielding foundation with uniform bearing under the full length of barrels.
4. Where joints require external grouting, banding, or pointing, provide space under and immediately in front of the bell end of each section laid with sufficient shape and size for grouting, banding, or pointing of joints.
5. At the end of each day's construction, plug open ends of piping temporarily to prevent entrance of debris or animals.
D. Buried metallic pipe, fittings, and valves shall be wrapped with polyethylene as specified in Section 02720.
3.05 CLEANING
A. Piping Cleaning:
1. Upon completion of installation, clean piping interior of foreign matter and debris. Perform special cleaning when required by the Contract Documents. 472
BASIC PIPING MATERIALS AND METHODS 15052 - 8
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
3.06 PIPING SCHEDULE
A. Abbreviations:
1. Abbreviations to designate piping include the following:
BF Butt fusion
BS Bell and spigot
CI Cast iron
CL Class, followed by the designation
DIP Ductile iron piping
FL Flanged
Ga Gauge, preceded by the designation
GE Grooved end joint
HDPE High Density Polyethylene
NPS Nominal pipe size, followed by the number in inches, pounds per square inch, or pounds per square inch, gauge.
PEE Polyethylene encasement
PVC Polyvinyl Chloride
SCH Schedule, followed by the designation
SCRD Screwed
SS
SSFM
STL
Stainless steel, Sanitary Sewer
Sanitary Sewer Force Main
Steel
SW Solvent Weld
VCP Vitrified clay piping
WLD Weld
**END OF SECTION**
473
PIPE SUPPORTS 15061 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 15061
PIPE SUPPORTS
PART 1 GENERAL
1.01 SUMMARY
A. Section Includes: Supports for pipe, fittings, valves, and appurtenances.
B. Related Sections:
1. Section 05501 – Anchor Bolts
2. Section 05505 – Miscellaneous Metals.
3. Section 09800 – Coating Systems.
4. Section 15052 - Basic Piping Materials and Methods.
1.02 REFERENCES
A. American National Standard Institute or Manufacturer's Standardization Society (ANSI/MSS):
1. SP-58 - Standard for Pipe Hangers and Supports - Materials, Design, and Manufacture.
2. SP-69 - Standard for Pipe Hangers and Supports - Selection and Application.
1.03 SUBMITTALS
A. Shop Drawings: Include schedule, indicating where supports will be installed, and drawings of pipe support system components.
PART 2 PRODUCTS
2.01 PIPE SUPPORTS
A. Standard U-bolt: ANSI/MSS SP-69 Type 24.
1. Manufacturers: One of the following or equal:
a. Anvil, Figure 137.
b. Bergen-Paterson, Part 6510.
c. B-Line Systems, Inc., Figure B3188.
B. Pipe Clamps: ANSI/MSS SP 69 Type 4.
1. Manufacturers: One of the following or equal:
a. Anvil, Figure 212.
b. Bergen-Paterson, Part 6100.
c. B-Line Systems, Inc., Figure B3140.
d. Unistrut.
C. Clevis Hangers: ANSI/MSSS SP 69 Type 1
1. Manufacturers: one of the following or equal:
a. Anvil, Figure 590.
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PIPE SUPPORTS 15061 - 2
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) D. Anchor Bolts, Flush Shells, Powder Actuated Fasteners, and Concrete Anchors: As specified in Section 05501.
2.02 MATERIALS
A. Pipe Supports:
1. Stainless Steel (Type 316): Use in all submerged locations, above water level but below top of wall inside water bearing structures and where specifically indicated on the Drawings.
2. Hot-dip Galvanized Steel: Use in areas other than above and where specifically indicated on the Drawings. Hot-dip galvanize pipe support after fabrication.
3. Plastic, Aluminum, FRP and Other Miscellaneous Materials: Use where specifically indicated on the Drawings.
B. Fasteners:
1. As specified
PART 3 EXECUTION
3.01 INSTALLATION
A. Properly support, suspend, or anchor exposed pipe, fittings, valves, and appurtenances to prevent sagging, overstressing, or movement of piping; and to prevent thrusts or loads on or against connected pumps, blowers, and other equipment.
B. Carefully determine locations of inserts. Anchor to formwork prior to placing concrete.
C. Use flush shells only where indicated on the Drawings.
D. Do not use anchors relying on deformation of lead alloy.
E. Do not use stud type powder actuated fasteners for securing metallic conduit or steel pipe larger than 1 inch to concrete, masonry, or wood.
F. Suspend pipe hangers from hanger rods. Secured with double nuts.
G. Install continuously threaded hanger rods only where indicated on the Drawings.
H. Use adjustable ring hangers; or adjustable clevis hangers, for 6 inch and smaller diameter pipe.
I. Use adjustable clevis hangers for pipe larger than 6 inches in diameter.
J. Secure pipes with galvanized double nutted U-bolts or suspend pipes from hanger rods and hangers.
K. Support Spacing:
1. Support 2 inch and smaller piping on horizontal and vertical runs at maximum 4 feet on center, unless otherwise specified.
2. Support larger than 2 inch piping on horizontal and vertical runs at maximum 6 feet on center, unless otherwise specified.
475
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
3. Support exposed polyvinyl chloride and other plastic pipes at maximum 5 feet on center, regardless of size.
L. Install Supports at:
1. Horizontal bends.
2. Both sides of flexible pipe connections.
3. Base of risers.
4. Floor penetrations.
5. Connections to pumps, blowers and other equipment.
6. Valves and appurtenances.
M. Securely anchor plastic pipe, valves, and headers to prevent movement during operation of valves.
N. Anchor plastic pipe between expansion loops and direction changes to prevent axial movement through anchors.
O. Support base fittings with metal supports or when indicated on the Drawings, concrete piers.
P. Size hanger rods, supports, clamps, anchors, brackets, and guides in accordance with ANSI/MSS SP 58 and SP 69.
Q. Do not use chains, plumbers' straps, wire, or similar devices for permanently suspending, supporting, or restraining pipes.
R. Support plumbing drainage and vents in accordance with California Plumbing Code.
S. Supports, Clamps, Brackets, and Portions of Support System Bearing Against Copper Pipe:
Copper plated, copper throughout, or isolated with neoprene or polyvinyl chloride tape.
T. Where pipe is insulated, install over-sized supports and hangers.
U. Install insulation shield in accordance with ANSI/MSS SP 69, Type 40. Shield shall be galvanized steel unless specified elsewhere.
V. Install riser clamps at floor penetrations and where indicated on the Drawings.
W. Provide dielectric protection whenever fastening dissimilar metals.
X. Paint or Coat support system components as specified in Sections 09800.
END OF SECTION
476
VALVES 15110 - 1
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 15110
VALVES
PART 1 - GENERAL
1.01 DOCUMENTS
The General Conditions and all other Contract Documents for this project are complementary and applicable to this section of the Specifications.
1.02 SCOPE OF WORK
A. Work Included: All work necessary to furnish and install all valves as shown on the drawings and specified herein.
B. Related Work Specified Elsewhere
1. Ductile Iron Pipe: Section 02720.
2. Sanitary Sewer Testing: Section 02770.
3. Coating Systems: Section 09800.
4. Basic Piping Materials and Methods: Section 15052.
1.03 REFERENCE STANDARDS
Standards listed below are a part of this section as specified and modified. In case of conflict between the requirements of this section and those of listed standards, the requirements of this section shall prevail. Where two or more standards are at variance, the most restrictive requirement shall apply.
A. ANSI B16.1 - Cast Iron Pipe Flanges and Flanged Fittings B. ASTM A536 - Specification for Ductile Iron Castings
C. AWWA C110 - Ductile Iron and Gray Iron Fittings, 3-inch through 48-inch D. AWWA C509 - Resilient-Seated Gate Valves for Water and Sewerage Systems E. AWWA C550 - Protective Epoxy Interior Coatings for Valves and Hydrants
1.04 QUALITY ASSURANCE
A. Acceptable Manufacturers: The Contractor shall provide valves with the manufacturer’s name and pressure rating clearly marked on the outside of the body of the same manufacturer where possible.
B. Valve Connections: Suitable valves shall be provided to connect to adjoining piping as specified for pipe joints.
477
VALVES 15110 - 2
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
1.05 SUBMITTALS
A. Product Data: The Contractor shall submit shop plans, manufacturer's product data, and installation instructions demonstrating that the proposed valves are in compliance with the referenced standards as well as the intended service. If plans are returned disapproved or not stamped, they shall be revised or corrected as necessary and resubmitted for review, approval, and stamping.
B. Operation and Maintenance Data: Furnish bound sets of installation, operation, and maintenance instructions for each type of valve 4 inch in nominal size and larger. Include information on valve operators in operation and maintenance instruction manual.
C. Certification: Certified test reports with each delivery that the valve(s) comply with this specification.
PART 2 - PRODUCTS
2.01 GATE VALVES
A. Gate valves shall be non-rising stem resilient wedge gate valves meeting AWWA C509 standards with flanged ends drilled to ANSI B16.1 Class 125 standards.
B. Provide a removable hand wheel for each non-buried gate valve.
C. Resilient wedge gate valves shall have a cast iron wedge fully encapsulated in molded rubber complying with ASTM D2000, with extended wedge guides molded as part of the wedge.
Resilient seat shall affect a bubble-tight seal across the wedge at a full differential of 200 psi.
The wedge shall be designed to minimize solids build-up and stem binding. Internal working parts shall be corrosion resistant and accessible without removing the main body from the discharge line.
D. Valves shall be epoxy lined and coated per Section 09800 and in conformance with AWWA C550. Lining materials shall not be applied to valve stems, wedges or wedge seats; nor build up in thickness to interfere with joint assembly or with the operation of the lined unit.
E. Buried valves shall be wrapped with polyethylene per Section 02720.
F. Valve, Gate, and Operator Bolts and Nuts:
1. Fabricated of Type 316 stainless steel for the following installation conditions:
a. Submerged in sewage or water.
b. In an enclosed space above sewage or water.
c. In structures containing sewage or water, below top of walls. d. At openings in concrete or metal decks.
e. Buried.
2. Where dissimilar metals are being bolted, use stainless steel bolts with isolation bushings and washers.
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2.02 CHECK VALVES
A. Where check valves are indicated on the contract drawings, ball type check valves shall be used.
B. Valves shall be designed for horizontal installation with a sinking ball.
C. Ball shall be aluminum core with vulcanized Nitrile rubber covering.
D. Valves shall be flanged.
E. Valves shall be epoxy lined and coated per Section 09800 and in conformance with AWWA C550. Lining materials shall not be applied to ball; nor build up in thickness to interfere with joint assembly or with the operation of the lined unit.
F. Ball check valves shall be Flygt Type 5087 or approved equal.
2.03 UNDERGROUND VALVES
A. Provide underground valves with flanged, mechanical, or other type of joint required for the type of pipe to which the valve is to be connected.
B. Coating and Wrapping:
1. After installation, wrap valves with polyethylene as specified for ductile iron piping in Section 02720.
a. Contractor shall ensure and confirm that polyethylene wrapping does not affect operation of valve.
2.04 BALL VALVES
A. Where indicated on the plans, new ball valves shall be used.
1. Ball valves shall conform to ASTM A351.
2. Type 316 stainless steel
3. NPT Female Threaded end
4. Locking handle
5. Full port
6. 1,000 psi minimum pressure rating
7. Sharpe Series 5303 or approved equal
PART 3 - EXECUTION
3.01 PREPARATION
Foreign material, scale, and dirt, inside and outside, shall be removed from valve materials before assembly.
3.02 CONNECTIONS
A. Valve connections shall be made in accordance with applicable standards and manufacturer's recommendations.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) B. Non-conducting connections shall be provided wherever jointing dissimilar metals.
3.03 INSTALLATION
A. General: Valves shall be installed in accordance with good trade practice to insure that after installation and testing they are in good condition. Should damage occur to pipe, valves, fittings, or equipment, repairs satisfactory to the City shall be made prior to final acceptance at no additional cost to the City.
B. Handling and Storage of Valves: During loading, transportation, and unloading, every precaution shall be taken to prevent valve damage. Any damaged valves shall be replaced or repaired to the satisfaction of the City.
C. Provide incidental work and materials necessary for installation of valves including flange gaskets, flange bolts and nuts, valve boxes and covers, concrete bases, blocking, and protective coating.
D. Where needed, furnish and install additional valves for proper operation and maintenance of equipment and plant facilities under the following circumstances:
1. Where such additional valves are required for operation and maintenance of the particular equipment furnished by CONTRACTOR.
2. Where such additional valves are required as a result of a substitution or change initiated by CONTRACTOR.
E. Install Valves with their stems in vertical position above the pipe, except as follows:
1. Butterfly valves, gate valves aboveground, globe valves, ball valves, and angle valves may be installed with their stems in the horizontal position.
2. Buried plug valves with geared operators shall be installed with their stems in a horizontal position.
F. Install valves so that handles clear obstructions when the valves are operated from fully open to fully closed.
G. Place top of valve boxes flush with finish grade or as otherwise indicated on the Drawings.
H. Valves with Threaded Connections:
1. Install valves by applying wrench on end of valve nearest the joint to prevent distortion of the valve body.
2. Apply pipe joint compound and Teflon tape on external (male) threads to prevent forcing compound into valve seat area.
I. Valves with Flanged Connections:
1. Align flanges and gasket carefully before tightening flange bolts.
2. When flanges are aligned, install bolts and hand tighten.
3. Tighten nuts opposite each other with equal tension before moving to next pair of nuts.
J. Valves with Soldered Connections:
1. Do not overheat connection to prevent damage to resilient seats and metal seat rings.
2. Position valves in full open position before starting soldering procedure.
3. Apply heat to piping rather than to valve body.
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3.04 TESTING
A. Valves shall be tested at the same time that the adjacent pipeline is tested. Joints shall show no visible leakage under test. Joints that show signs of leakage shall be repaired prior to final acceptance. If there are any special parts of control systems or operators that might be damaged by the pipeline test, they shall be properly protected. The Contractor shall be held responsible for any damage caused by the testing.
B. If requested by the City, the valve manufacturer shall furnish an affidavit stating that the materials and options furnished comply with these specifications. ** END OF SECTION **
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 16010
ELECTRICAL GENERAL
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The following list of components and areas of work is a summary of the work required in the electrical and controls portion of the Drawings and Specifications. The list is not comprehensive of the total work required nor is it in any specific order. It is merely being provided as an aid to the bidder. Work not listed herein, but described in the plans or Specifications, is also part of the overall scope of work.
1. Power Distribution Equipment
a. Utility Metering Switchboard with main disconnect
b. ATS (4 pole) and Distribution Switchboard (3ph, 4w)
c. Low voltage panelboard, and transformer.
2. Motor Controls:
a. Systems Integrator to provide detailed shop-level design submittal, furnish equipment, assemble, wire, test, and complete all test forms pertaining to motor controls as part of their scope of work. b. Pump control panels with solid state starters.
c. Mixer Control Panel.
3. Control panel(s):
a. Systems Integrator to provide detailed shop-level design submittal, furnish equipment, assemble, wire, test, and complete all test forms pertaining to control panels as part of their scope of work. b. System Integrator to perform factory and field testing as required for this project. Instrumentation calibrations and I/O checkout must be complete prior to Operational Testing.
c. System Integrator to coordinate, configure, and place communications system(s) into operation during pre-operational testing of system hardware.
4. PLC, OI, and SCADA Applications Programming.
a. Customized Nexicon PLC software code
b. Flygt Cloud SCADA
5. Instrumentation
a. Systems Integrator to select, furnish, configure, test, and complete test forms pertaining to instrumentation as part of their scope of work. b. Furnish NSF/ANSI 61 certified products that have undergone testing for any device, valve, instrument, or assembly that will come into contact with drinking water.
c. Furnish mounting supports or other accessories as detailed and as recommended by the instrument manufacturer for the application.
6. Conduit, junction boxes, pull boxes, wire, and grounding system, for equipment interconnection, and operation.
a. Contractor to perform termination of all field wiring and internal wiring for equipment that required dis-assembly for shipping.
b. Contractor to label conduits, wire, and equipment per specifications. 482
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7. Furnish and install process piping, shut off, sample and calibration valves, drains, pressure reducers and calibration equipment for connection of instrumentation as defined in manufacturer installation instructions or as indicated.
8. Trenching, backfilling, compaction and resurfacing for all new underground conduit routes, concrete pads, and pull boxes.
9. Coordination and equipment for connection of power utility and telephone services per utility Drawings and standards.
10. Site electrical devices, lights and receptacles.
11. Seismic Anchorage Design Calculations and conforming installation.
12. System startup, calibration, testing and documentation.
13. Demolition of existing equipment as noted in the drawings.
B. Electro-mechanical equipment to be installed in this project may be specified in other divisions but will interface to equipment provided under Electrical Specifications. Obtain submittals for those devices, review, coordinate and provide all interfacing equipment, software, communications, I/O, and testing to integrate the equipment to the extent possible and as intended.
C. Install electrical and control portion of electro-mechanical equipment specified in other sections. Reference those Specifications, pertinent details, and follow all manufacturer instructions to erect, install and commission equipment. Furnish all electrical equipment, interconnecting wire, and make connections to place equipment in operation.
D. All electrical equipment and materials, and methods - including installation, calibration, and testing - shall conform to the applicable codes and standards listed in this and other Sections. All electrical materials and work shall conform to published standards of the National Electric Code (NEC) current issue, Institute of Electrical and Electronic Engineers (IEEE), and Underwriters Laboratories Inc (UL).
1.02 RELATED SPECIFICATIONS
A. The following specification sections are part of the [Electrical Specifications].
Section Description
16110 Conduit and Boxes
16120 Low Voltage Wire and Data Cable
16250 Automatic Transfer Switch
16430 Low Voltage Switchboard
16450 Grounding
16470 Panelboard and Power Transformer
16482 Solid State Soft Starter
16600 Factory and Field Testing
16905 Control Panels
16910 PLC & OI Hardware
16915 PLC & OI Applications Programming
16940 Instrumentation
483
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) B. Owner, Engineer, Construction Manager, and City are used within Electrical Specifications and are interchangeable. They are all representatives of the Owner, in this case, the City of Belmont.
1.03 QUALIFICATIONS AND REQUIRED WORK SCOPE
A. Electrical Contractor / Certified Electrician
1. Management and installation of the entire electrical and control system required for this project shall be by an Electrical Contractor or Certified Electrician (EC/CE) meeting qualifications as defined herein.
2. EC/CE shall select, furnish, and install all commodity electrical materials (conduit, wire, supports, fittings, ductbanks, etc) that are generally not “custom” or uniquely manufactured for this project. Custom electrical panels, controls, and instrumentation shall be furnished by Systems Integrator but installed by EC/CE.
3. The EC/CE shall meet the following minimum qualifications:
a. Has a current C10 Electrical Contractor’s License and/or project Foreman who is a California Certified Electrician issued by the State of California Department of Industrial Relations.
b. EC/CE shall comply with State law which requires that all personnel installing electrical components are certified by the State of California as “Electrician” or “Electrician Trainee.” Trainees may install electrical components only under direct supervision of a certified Electrician. c. EC/CE shall have sufficient qualified personnel to staff the project and meet the construction schedule as defined by the Contract requirements or as approved during the submittal process.
d. EC/CE shall be regularly engaged in similar industrial power and controls electrical work.
e. EC/CE shall have successfully performed work of similar or greater complexity (as measured in contract value on industrial power and controls projects) on at least three (3) previous projects. f. EC/CE must be competent in performance, supervision and coordination of work required and performed by equipment suppliers or other specialty subcontractors.
g. EC/CE shall be capable of looking at electrical equipment submittals, prior to installation, comparing hookup requirements to the Drawings, and notifying Engineer of any deficiencies.
h. EC/CE shall be competent in methods and materials execution and selection associated in the type of electrical and instrumentation work indicated in Drawings and specified in this Division.
i. EC/CE shall be familiar with and understand codes and requirements from NFPA70, NFPA110, and all other governing national or local codes.
j. EC/CE shall know and understand common terms and abbreviations used in this Industry. Not all terms and abbreviations will be defined in the Drawings and Specifications.
4. If the EC/CE does not meet the qualifications, the EC/CE may be stopped from doing further work, rejected, removed, and/or required to meet qualifications prior to the resumption of work.
B. System Integrator
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1. Systems Integrator shall be a supplier to the Electrical Contractor or Certified Electrician and must be competent in performance, supervision and coordination of work required in this contract.
2. This includes, but is not limited to, all work necessary to finish design, select, furnish, construct, supervise installation, configure, calibrate, test, and place into operation all transmitters, instruments, programmable controllers, control panels, motor controls, alarm equipment, communications, monitoring equipment, and accessories.
3. The System Integrator shall provide a Project Engineer with one year (minimum) prior experience on similar sized projects. This Project Engineer shall coordinate the technical aspects of this project and prepare the shop level equipment design submittals and drawings. The Project Engineer shall attend coordination meetings when specifically requested by the Engineer.
4. The System Integrator (SI) shall meet the following minimum qualifications:
a. SI shall be regularly engaged providing electrical and control systems for industrial projects.
b. Manufacturing facility within 200 road miles of project location. c. SI shall be capable of labeling all electrical panels as manufactured or customized by the System Integrator with appropriate Underwriters Laboratories (UL) label prior to factory testing or shipment to project site.
d. SI shall have successfully completed work of similar or greater complexity and on similar facilities on at least 5 previous projects under the present company name.
e. SI shall be actively engaged in the following disciplines for the last 5 consecutive years.
1) Design and manufacturing of custom Control Panels, Motor Controls, and associated devices and equipment as specified in this division.
2) Programming and commissioning of SCADA, PLC and Operator Interface hardware.
3) Instrumentation - selection, purchase, calibration, start-up and commissioning.
4) Testing, calibration, start-up, and commissioning of control systems.
f. SI shall have a staffed and equipped service facility with personnel and equipment required to provide on-site field service to troubleshoot, diagnose, and repair the control system.
C. Application Programmer
1. The Applications Programmer will be furnished by System Integrator or by Contractor.
2. Applications Programmer must be competent in performance, supervision, and coordination of work required in this contract in order to facilitate construction and not cause delays to the main construction contract.
3. This includes, but is not limited to, all work necessary to configure, test, troubleshoot, and place into operation SCADA system, Operator Interface, and programmable controller.
a. Nexicon PLC custom programming for site I/O, function, alarms, communications, and interface to SCADA.
b. Flygt Cloud SCADA system to coordinate and interface to the site PLC. 485
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4. The Application Programmer shall have on staff a PLC Programmer with no less than seven (7) years prior experience performing new installation PLC programming on water and wastewater projects.
5. The Application Programmer shall have on staff a SCADA Programmer with no less than five (5) years prior experience performing new installation SCADA configuration and programming on water and wastewater projects.
6. The Application Programmer (AP) shall meet the following minimum qualifications:
a. AP shall be regularly engaged providing electrical and control systems for the Municipal Water and Wastewater Industry.
b. AP shall be registered in the State of California as a Professional Electrical Engineer.
c. AP shall have successfully completed work of similar or greater complexity and on similar facilities. Project References may be requested prior to starting work.
d. AP shall be actively engaged in the following disciplines:
1) Programming and commissioning of SCADA, PLC and Operator Interface hardware.
2) Testing, calibration, start-up, and commissioning of control systems as applied to the Water and Wastewater industry. e. AP project staff shall be based from a location within 300 miles of the project site with personnel and equipment required to maintain, repair and calibrate the PLC, OI, and SCADA system.
7. If the Applications Programmer does not meet the requirements above and cannot demonstrate through submittal process that he is (they are) qualified, then the Application Programmer will be rejected and a replacement Application Programmer must be submitted.
1.04 CONTRACT DOCUMENTS
A. The resolution of conflicting information within the contract electrical documents shall put precedence on electrical Drawings over that of electrical Specifications.
B. The Drawings and Specifications are intended to be descriptive of the type of electrical system to be provided with sufficient detail to construct. Minor omission of detail shall not relieve a qualified contractor from the obligation to provide a complete operational system if it can be determined that the particular detail is usual and customary for similar systems.
C. The following Specifications may incorporate specific equipment or materials that do not have equal equipment listed. These items are standards because of their familiarity, serviceability, and/or spare parts inventory. However, equal alternate equipment or materials (noted in the submittal cover letter) will be considered for use on this project if submitted. The Engineer may reject said equipment for the purpose of adherence to standards.
D. Contract Drawings are diagrammatic and indicate general arrangement of systems and equipment.
1. Exact locations and layouts of electrical products shall be defined during submittal, assembly, or field fit during construction. Field measurements take precedence over dimensioned drawings. Drawing intent is to show initial size, 486
ELECTRICAL GENERAL 16010 - 6
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) capacity, approximate location, orientation, and general relationship of equipment in area shown but may not show exact detail or arrangement.
2. However, when materials, locations, sizes, or methods are specifically dimensioned, detailed or noted, the Drawings shall take precedence over electrical Specifications in the event of conflict. In no case, is NEC, UL, or other applicable governing standards to be overridden.
E. The Contractor shall examine the architectural, mechanical, structural, and electrical and instrumentation submittals and equipment furnished under other Specifications divisions in order to determine conduit routing, stub-up locations, and final terminations for all conduits and cables. Conduits shall be stubbed up as near as possible to equipment electrical terminals. The exact locations and routing of cables and conduits shall be governed by structural conditions, physical interferences, and the physical location of wire terminations on equipment.
F. All equipment shall be installed and located so that it can be readily accessed for operation and maintenance. If accessibility appears to be compromised, the location of equipment or stub ups shall be modified to the extent possible.
G. Where conduits are shown on the Drawings, or stated to be furnished but not explicitly shown, as part of the scope of work; the Contractor shall provide all fittings, boxes, wiring, etc. as required for completion of the raceway system in compliance with the NEC and the applicable Specifications in this Section.
H. No changes from the Drawings or Specifications shall be made without written approval of the Engineer. Should there be a need to deviate from the Contract documents, submit written details and reasons for all changes to the Engineer for review.
I. The Contractor shall maintain a neatly and accurately marked full size set of Contract Drawings recording the as built locations and layout of all electrical and instrumentation equipment, routing of raceways, junction and pull boxes, and other diagram or drawing changes. Drawings shall be kept current weekly, with all "change orders", submittal modifications, and construction changes shown. Drawings shall be subject to the inspection by the Engineer at all times, progress payments or portions thereof may be withheld if Drawings are not accurate or current.
J. When documents are changed, they shall be marked with erasable colored pencils or PDF markup tools using the following coloring scheme:
1. Additions - Blue
2. Deletions - red
K. Prior to acceptance of the work, the Contractor shall deliver to the Engineer one set of record full size drawings neatly marked accurately showing the information required above.
1.05 UTILITY COORDINATION AND FEES
A. All fees and charges of the Power Utility, Pacific Gas & Electric (PG&E), for design and final connection will be paid by others.
B. Coordinate all work with the Utility for the work shown on Contract Drawings. 487
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
1. Unless already completed, apply for electric service within 10 working days from Notice to Proceed.
2. Coordinate and meet with the Utility’s Representative at the project site(s) within 30 days after award of contract.
3. Discuss specific installation and comply with Utility requirements. Contact Engineer in the event that Utility requirements far exceed allowances in the plans and Specifications. Provide an itemized list of deviations and potential costs or credits.
4. Contractor may be required to be certified by the Utility prior to installation.
Check Utility website and obtain certification as required.
5. Coordinate and obtain required inspections prior to backfill. Make corrections to installation as required by Utility.
6. Coordinate connection and date of service with Utility. Utility back-charges due to mis-coordination or installation problems will be Contractor responsibility to pay and correct.
C. Furnish and install electric service in accordance with the serving Utility's requirements.
1. The contract plans show the preliminary design for the Utility installation. Slight changes required by the Utility do not constitute extra work unless cost impacts in material and labor exceed $5000. In that event, the agreed excess amount will be allowed as a change order.
2. The Contractor shall provide and install service entrance equipment, all material, conduits, wiring, pull ropes, pole risers, transformer pads, bollards, etc. as shown on Utility design drawings and standards for new power service. Utility standards are available upon request from the Utility or for download from the Utility’s website.
3. The Utility will furnish primary wire, transformer, meter, and connections.
D. Following award of Contract, schedule all service installations and connections with utilities. Construction or start-up delays as a consequence to lack of documented effort by the Contractor which delay the project completion due to lack of Utility services will not be considered valid and Contract liquidated damages may be assessed.
1.06 PROJECT COORDINATION
A. Prior to submittal, the Electrical Contractor shall coordinate with equipment suppliers to verify sizes, mounting, connections, storage, and delivery of equipment. If there are any issues whereby the solution will be in conflict with plans and Specifications, or that are undefined and need direction, they shall be brought to the attention of the Engineer or Construction Manager via the RFI process.
1.07 SUPERVISION
A. The Contractor shall schedule all activities, manage all technical aspects of the project, coordinate submittals and drawings, and attend all project meetings associated with this Section. The Contractor shall coordinate and confirm that the project schedule is being adhered to and all work is being completed within the scheduled time frames.
B. The Contractor shall supervise all work in this Section, including the electrical system general construction work, from the beginning to completion and final acceptance. 488
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) C. The Contractor shall coordinate, obtain, prepare, and/or complete the documentation required within this division. All documentation shall be complete and delivered prior to final acceptance.
1.08 INSPECTIONS
A. General
1. Contract work or materials shall be subject to inspection at any time by the Engineer. If equipment, material, or installation method does not conform to the Contract documents, or does not have a favorably reviewed submittal status and has been determined to be unsatisfactory by the Engineer, then the Contractor shall remove said material from the premises; and if said material has been installed, the entire expense of removing and replacing same, including any cutting and patching that may be necessary, shall be borne by the Contractor.
2. The Engineer may inspect and test the fabricated equipment at the factory before shipment to job site. See Electrical Specifications [Factory and Field Testing] for requirements.
3. Work shall not be closed in or covered over before inspection and approval by the Engineer. All costs associated with uncovering and making repairs where non-inspected work has been performed shall be borne by the Contractor.
4. The Contractor shall cooperate with the Engineer and provide assistance at all times for the inspection of the electrical system under this Contract. The Contractor shall remove covers, provide access, operate equipment, and perform other reasonable work which, in the opinion of the Engineer, will be necessary to determine the quality of the work.
B. Milestones requiring inspection and signoff.
1. Underground conduit and grounding system complete. Do not cover any portion of conduit prior to inspection. Conduits must be labeled with temporary tags per Electrical Specifications [Conduit and Boxes] and [Grounding].
2. Factory testing. Coordinate test date with Engineer 2 weeks prior to test scheduled date.
3. Installation of electrical equipment. Equipment is anchored in place, conduit connections are complete, no wire is yet pulled into conduit. Permanent conduit tags must be in place per Electrical Specifications [Conduit and Boxes] and [Grounding].
4. Wire termination complete. Do not energize equipment. All wire tags must be installed and wires terminated per Electrical Specifications [Low Voltage Wire and Data Cable]. Pre-energization testing to commence after inspection.
5. Testing per Electrical Specifications [Factory and Field Testing]. All testing per Electrical Specifications [Factory and Field Testing] shall be witnessed unless specifically declined by the Engineer. Schedule tests with Engineer 2 weeks prior to test date.
6. Start-up per Electrical Specifications [Factory and Field Testing]. Schedule tests with Engineer 2 weeks prior to test date.
7. Punch list – final inspection. Schedule final walkthrough with Engineer one week prior to intended project completion date. All items on punchlist must be complete prior to scheduling walk-through.
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1.09 JOB CONDITIONS
A. Construction Power and Telephone Service
1. The Contractor shall coordinate, furnish and install, temporary utility services required during construction of the project, such as temporary electrical power and telephone service. Temporary services shall be installed in accordance with the applicable codes and regulations of the serving utilities.
2. Upon completion of the project, remove temporary services. All equipment and material shall be the property of the Contractor.
B. Equipment Storage
1. The Contractor shall provide adequate protection for all equipment and materials during shipment, storage and construction.
2. Equipment and materials shall be completely and sufficiently sealed and covered and set on a pallet above grade so that they are protected from weather, wind, dust, water, or construction operations.
3. Equipment shall not be stored outdoors. Where equipment is stored or installed in an area with susceptibility to moisture, such as unheated buildings, untested piping, etc., provide an acceptable means to prevent moisture damage, such as plastic cover and a uniformly distributed heat source to prevent condensation.
C. The project site is located where outside temperatures vary between 10 deg F. to 110 deg F. Humidity in this area will range from 10% to 100%.
1.10 AREA CLASSIFICATIONS
A. Area classifications are shown on the site electrical plans. The area enclosed by walls or the entire drawing area shall be classified as shown unless otherwise described in notes.
B. All electrical equipment, enclosures, conduit, and supports shall be formally rated for or, at minimum, meet the intent of the rating as interpreted by Engineer.
C. If no area classification rating is shown on the Drawings, classification shall default to a NEMA 12 rating for indoors, and NEMA 4 rating for outdoors (non corrosive) and NEMA 4X for corrosive areas both indoors and outdoors.
1.11 SUBMITTAL REQUIREMENTS
A. General
1. Requirements described herein are specific to electrical submittals and are secondary to those described in other general Specifications sections. Any additional requirements described here that are beyond those described in those sections shall be provided as described. Conflicts shall be resolved by giving priority to general Specifications.
2. Contractor and System Integrator to complete application engineering, confirmation of products and associated applications, provide detailed shop-level design submittal, furnish equipment, assemble, wire, test, and complete all test forms pertaining to motor controls as part of their scope of work.
3. The Contractor shall ensure that the System Integrator and/or equipment suppliers provide the submittal documentation required in this section. Submittals shall be neat, orderly, complete (without un-needed parsing), and indexed. 490
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) a. Like equipment shall be submitted complete in a single submittal. For instance, all general electrical materials shall be in a single submittal.
All instrumentation, all control panels, or all MCCs and so on shall be submitted complete where possible.
b. Submittals that are broken down without sufficient cause will be rejected for future inclusion into a combined submittal.
c. Do not separate submittals by area.
d. Do not separate submittals by specification division unless agreed to in advance.
e. Submittals for work scope covered in this contract are expected to be as follows. This list is intended to be a guideline and not to be specific of all submittals required. Project circumstances or leadtimes or availability will each impact the order and division of submittals.
1) General electrical materials – conduit, wire, labels, etc. 2) Power Distribution and Motor Controls
3) PLC and Control Panels
4) Seismic Calculations
5) Instrumentation
6) PLC Programming
7) SCADA Application Programming
8) Factory and Field Testing forms and procedures
9) Interconnection Diagrams
10) O&M Manuals
4. The Contractor shall coordinate submittals with the work so that project will not be delayed. This coordination shall include scheduling the different categories of submittals, so that one will not be delayed for lack of coordination with another.
Time extensions will not be allowed due to failure to properly schedule submittals.
5. No material or equipment shall be delivered to the job site until the submittal for such items has been reviewed by the Engineer and marked "no exceptions noted" or "make corrections noted".
6. The equipment Specifications have been prepared on the basis of the equipment first named in the Specifications. The Contractor shall note that the second named equipment, if given, is considered acceptable and equal equipment, but in some cases additional design, options, or modifications may be required to meet Specifications or functional installation.
7. Exceptions to the Specifications or Drawings or equipment or procedures submitted as “equal” to specified equipment shall be clearly identified in a letter at the front of the submittal. Submittal data for “equal” equipment or procedures shall contain sufficient details so a proper evaluation may be made by the Engineer. The Contractor is responsible for verifying proper application/operation of substituted equipment.
8. The opinion of the Engineer will be the final determination whether a substitution request meets the design intent.
9. Deviations from the Contract documents shall not be incorporated into the work without prior written approval of the Engineer. A "Change Order" directive from the Engineer is required prior to incorporating any deviation from the Contract documents that has costs associated. The cost differential associated with this change order must be negotiated with the Owner to amend the Contract to reflect the costs or savings.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) B. Submittal Procedures
1. Identify all submittals by submittal number on letter of transmittal. Submittals shall be numbered consecutively and resubmittals shall have a letter suffix. For example:
a. 1st submittal: 1
b. 1st resubmittal: 1A
c. 2nd resubmittal: 1B, etc.
2. The reviewed submittals will be annotated "Make Corrections Noted", "No Exceptions Noted", "Revise and Resubmit Noted Items", or "Rejected without Review." The following actions shall then be taken by the Contractor:
a. "No Exceptions Noted" - The Contractor may proceed with the work covered in this submittal. No resubmission is necessary. b. “Make Corrections Noted” - The Contractor may proceed with the work covered in this submittal incorporating the changes noted. However, the Contractor shall revise the submittal in accord with the changes noted and resubmit six (6) copies of drawings, bill of materials, and catalog data denoting changes within 14 calendar days when requested by the Engineer for record keeping purposes.
c. "Revise and Resubmit Noted Items" - The Contractor shall not proceed with the work covered in this submittal. The Contractor shall revise and correct the submittal in accordance with the comments and resubmit six (6) copies within 14 calendar days for approval.
d. "Rejected without Review" submittal - The Contractor shall not proceed with the work covered in this submittal. The submittal did not address the work scope as defined by the submittal’s title or the previous submittal comments have not been addressed in full. The Contractor shall revise and correct the submittal in accordance with the Specifications, and resubmit six (6) copies within calendar 14 days for approval.
3. Resubmittals shall address all comments by the Engineer. A submittal response letter shall be submitted that addresses each comment by the Engineer with a standardized response of “revised” or with a written explanation. Partial resubmittals (that do not address all comments) may be returned without review at the discretion of the Engineer.
4. The Contractor shall be responsible for the Engineer's review cost for each resubmittal in excess of the second resubmittal. These costs will be back-charged to the Contractor and will be deducted from his progress payments.
C. Electrical Equipment -- Submittal data shall be grouped by equipment type. Each submittal shall be as complete as possible covering the entire project and scope of supply.
Drawings or equipment submitted individually that are not on the critical path will not be accepted for individual review. The electrical submittals shall include (as a minimum):
1. Table of Contents
2. Comment Letter: The Project Engineer of the System Integrator shall note all deviations from Contract Documents and the reason(s) for the deviation. They may use this forum to inform the Engineer or installing Contractor of important information related to the project. RFIs must be submitted separately. Resubmittals shall include written responses to every comment provided by the Engineer during the previous review.
3. Bill of Materials: The Contractor and System Integrator each shall provide Bill of Material for electrical components formatted as shown below. Generic names 492
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) or part numbers as defined by a distributor or Integrator are not acceptable. Only the originating manufacturer’s name and part number shall be listed. Provide separate bill of materials for each panel, MCC, instrument list, etc.
Bill of Material
Item # Qty Tag# Description Manufacturer Part #
4. Catalog Data shall include the following: (features and options shall be highlighted, circled, or “arrowed.”)
a. Instrumentation data summary sheets (by Contractor)
b. Manufacturer’s technical information brochure
c. Physical size and mounting details and illustrations d. Calibration Range
e. Input/output signals
f. Electric power, air, and/or water supply requirements. g. Options selected and available (Cross out items not included) h. Materials of construction of components
5. Program Software Documentation
a. Programming documentation
b. Programming code native files
D. Shop Drawings Shop drawings shall be furnished for each electrical panel even if one was not shown explicitly on the Drawings. Shop drawings shall be numbered in sequence. Blank drawings or drawings that contain no specific project data will not be accepted for review.
1. Shop Drawings shall be generated with a computer utilizing AutoCAD or similar drafting program. Drawings shall be no smaller than 11" x 17". The lettering shall be legible and no smaller than 0.75 inch in height.
2. Shop Drawings shall be custom prepared for this project and shall have borders and a title block identifying the project, manufacturer, system or location, drawing number, drawing title, AutoCAD file name, project engineer, date, revisions, and type of drawing. Diagrams shall carry a uniform and coordinated set of wire colors, wire numbers, and terminal block numbers. The shop drawings shall include the following as a minimum:
3. Electrical one-line diagrams detailing all devices associated with the power distribution system. The following applicable information or data shall be shown on the one- or three- line diagram: location, size and amperage rating of bus; size and amperage rating of wire or cable; breaker ratings, number of poles, and frame sizes; power fail and other protective devices; fuse size and type.
4. Detailed analog and digital I/O diagrams showing the wiring requirements for each instrument or device connection. Reference the Drawings for an example of each I/O card drawing requirements. If one is not included in the Drawings, then one may be obtained from the Engineer upon request.
5. Elementary (wiring) diagrams shall be provided for all relay logic, programmable logic controls, motor controls, power supplies, and other wiring. All elementary (wiring) diagrams shall be drawn in JIC EMP/EGP format and standards showing ladder rung numbers and coil and contact cross referencing numbers.
6. Equipment exterior and interior scaled drawings of front, side, elevation, deadfront, front panel devices, and backpan components. Show fabrication 493
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) methods and details; including material of construction, paint color, door latch and lock, and ventilation system. Show shipping split locations and offloading information. Submit base plan showing allowed conduit entrance areas and bolt hole locations.
7. Drawings shall show UL required information as needed to UL label the equipment in accordance with UL procedures for label applied.
8. Submit full size drawing of all nameplates and tags, as specified herein, to be used on project. Submittal to include the following:
a. Dimensions of nameplate.
b. Exact lettering and font for each nameplate.
c. Color of nameplate.
d. Color of lettering.
e. Materials of construction.
f. Method and materials for attachment.
g. Drawing showing location of nameplates on each, panel and enclosure.
E. Interconnection Diagrams Interconnection diagrams shall be furnished for each electrical and instrumentation system, even if one was not shown explicitly on the Drawings. Reference the Drawings for an example of interconnection drawing requirements. If one is not included in the Drawings, then one may be obtained from the Engineer upon request. Each interconnection diagram shall include the following as a minimum:
1. The diagrams shall show connection point descriptions and field routing only.
This includes, but is not limited to, terminal blocks, field wiring with numbers, junction boxes, conduit material with sizes, and conduit numbers.
2. Each conduit in the Conduit and Wire Schedule shall be shown on at least one interconnection diagram. Multiple conduits may be shown on a single interconnect and a conduit may appear on multiple interconnects.
3. Interconnect diagrams shall be based on connected equipment, ie.
Interconnection diagram for Pump 1. All components connected to the MCC cubicle for Pump 1 shall be shown on a single interconnect.
4. All terminations points on the diagram shall be shown with the actual equipment identification terminal number or letter.
5. Interconnections between equipment shall be shown terminal to terminal with conduit lines in between. Wires within the same conduit shall be bundled and shown as a single line and labeled with the conduit name and wire fill. If not all wires within a conduit are used on a particular interconnection diagram, then the fill shall be noted as XX of XXX wires.
6. Conduit shall be shown as routed through junction boxes and pull boxes. Wire fill leading into a pull box shall be equal to the combined outgoing conduit wire fill.
7. Each wire and color code shall be shown connected to a terminal block. Spare wires may be shown as a list of wire numbers located near the end point of the wire.
8. Schematic symbols shall be used for field devices showing electrical contacts.
Circuit polarities shall be shown where applicable.
9. The diagrams shall show all other Contract and shop drawing numbers, for reference, that are associated with each device that is interconnected. Attached with each interconnect, a copy of all the support documents used in preparing interconnects. This includes current issues of panel schematics, connection diagrams, terminal block diagrams, submittals, contract Drawings, vendor 494
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) drawings and all other data used to develop the interconnection diagram as noted in the “Reference Documents” corner of interconnect drawings.
10. Provide a notes section on each interconnect drawing. In the note section list any variances from the Contract conduit schedule necessary for completing the interconnections. Change orders regarding wire fill, conduit schedule and errors in plans regarding conduits and wires may not be processed until interconnect drawings have been received for such work.
11. The interconnection drawings shall be As-Built by the Contractor after start-up and prior to project completion. All deletions and additions of equipment, wire and cables shall be clearly shown. Interconnects shall include list of all applicable field instructions and change orders.
12. The diagrams shall be utilized by the electrician during all phases installation and connection of all conductors to ensure coordination of equipment interconnect.
13. Field wiring shall not start before the interconnection drawing have been submitted by the Contractor and approved by the Engineer.
14. The Contractor shall not pull in any wires into conduits that do not have approved interconnects. If the Contractor pulls and/or terminates wire without approved interconnect drawings, the Contractor will not be reimbursed for labor for re-pulling/replacing wires even if there was an error in wire fill or sizing in the “Wire and Conduit Schedule”. If the Contractor pulls and/or terminates wire without approved associated interconnect drawings, then all progress payments for that particular area of work will be withheld until approved interconnect drawings are in use.
F. Seismic Anchor Design Calculations
1. All switchgear, motor controls centers, transformers, cabinets, raceways, supports, and electrical materials shall be so installed as to remain in a secure and captive position when subjected to a horizontal force in accordance with the current, applicable, and more stringent of current California Building Code (CBC) or International Building Code (IBC) requirements. Method of securing shall constrain equipment against both vertical and horizontal forces and overturning forces.
2. Calculations as prepared by a civil engineer registered in the State of California shall be submitted in accordance with current code requirements for earthquakes forces on all specified equipment. Calculations shall include wind loading forces for equipment installed outdoors. Use seismic and wind factors based on the project location and exposure. The risk Category is IV.
3. Provide a submittal, minimum 3 weeks prior to equipment installation, of calculations, materials needed, and supporting drawings and details for installation by Contractor.
1.12 OPERATING AND MAINTENANCE INFORMATION
A. Operational Training
1. At time of completion, the Contractor shall provide a period of not less than 6 hours training for instruction of operation and maintenance personnel in the use of systems. Instruct all personnel at one time in one session. Make necessary arrangements with manufacturer's representative. Provide product literature and application guides for user's reference during instruction.
B. Operations and Maintenance Manuals
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1. Provide Operation and Maintenance manuals per Specifications as described in “Submittal Requirements” in this section with the following additional requirements:
a. A comprehensive index.
b. A complete "Record" set of favorably reviewed electrical submittals as provided under subsection “Submittal Requirements” illustrating all components, piping, and electrical connections.
c. A complete list of the equipment supplied, including serial numbers, ranges, catalog cuts, and pertinent data.
d. Full Specifications on each item.
e. Detailed service, maintenance and operation instructions for each item supplied. Schematic diagrams of all electronic devices shall be included.
A complete parts list with stock numbers shall be provided for the components that make up the assembly. All of these shall be originals, no copies.
f. Special maintenance requirements particular to this system shall be clearly defined, along with special calibration and test procedures. g. Shop drawings in native file format and updated to reflect as-built conditions.
h. Application programs, configurations, calculations, documents or other computer electronic files prepared for this project. Provide all files in native file format such as .dwg, .rss, .xls, .doc, etc.
2. Submit electronic readable PDF file format (email with attachments or download links) of the proposed O&M manuals for review by the Engineer. Submittals shall be delivered timely to the Engineer to allow for review period, corrections, and re-submissions as necessary.
a. General Contractor supervision must not be circumvented by sending submittals direct to Engineer.
C. At the end of the project hard copy and soft copy electronic PDF files, shall be updated to "as-built" conditions.
PART 2 PRODUCTS
2.01 QUALITY
A. All equipment and materials shall be new, in current production, and the products of reputable suppliers having adequate experience in the manufacture of these particular items. For uniformity, only one manufacturer will be accepted for each type of product.
B. Products specified that have become obsolete (out of current manufacturing, or have been superseded by another product) shall be cross-referenced to a replacement product(s) and provided in lieu of the specified product(s) for no additional cost. Under no conditions, shall products be submitted or furnished that are known (on manufacturer’s list of obsolescence) and expected to be removed from current production within 12 months after project submittal. Products found to have been furnished this way will be removed and replaced at Contractor’s expense.
C. All equipment shall be designed for the service intended and shall be of rugged construction, of ample strength for all stresses which may occur during fabrication, 496
ELECTRICAL GENERAL 16010 - 16
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) transportation, erection, and continuous or intermittent operation. All equipment shall be adequately braced and anchored and shall be installed in a neat and workmanlike manner.
Appearance and safety, as well as utility, shall be given consideration in the design of details. All components and devices installed shall be standard items of industrial grade, unless otherwise noted, and shall be of sturdy and durable construction suitable for long, trouble free service. Light duty, fragile and competitive grade devices of questionable durability shall not be used.
D. The Contractor should expect that there will be occasional freezing conditions at the project site in outdoor locations. Instrument valves, tubing, instrumentation, and other components which are outdoors and susceptible to damage if frozen, must be provided with internal or external protection. Freeze protection can consist of internal or external active heaters with thermostats and/or passive insulation systems. Active systems can be powered from a nearby receptacle or via the conduit intended for the device.
E. Products that are specified and include a manufacturer, trade name or catalog number are intended to establish a standard of quality, performance, warranty and service. Products that are specified “or equal,” do not prohibit the use of equal products of other manufacturers provided they are submitted, identified and promoted as equal, and favorably reviewed by the Engineer prior to procurement and installation.
F. Products submitted as “equal” to the named products will be reviewed for conformance with the Specifications and in comparison with the first named product. If the equal product meets Specifications, but does not have a feature or performance characteristic that is available with the first named product, and that feature or performance is required for this project, then the submitted equal product may be rejected on those grounds.
G. In the event that some claims of the manufacturer of submitted “equal” product are called into question by the Engineer, the Contractor, may be required to prove those claims either prior to installation or during startup of product. If the product does not meet the claims made or Specifications, the product may be rejected by the Engineer and a replacement product must be submitted by the Contractor in its place. All cost for the rejected product, installation, testing, and removal will be the responsibility of the Contractor.
H. Underwriters Laboratories (UL) listing is required for all substituted equipment when such a listing is available for the first named equipment. Extra parts, labor, panel space, power supplies, circuit breakers, and/or GFIC devices shall be provided as necessary for incorporation of specified non-UL components.
I. When required herein or requested by the Engineer, the Contractor shall submit equipment or material samples for test or evaluation. The samples shall be furnished with information as to their source and prepared in such quantities and sizes as may be required for proper examination and tests, with all freight and charges prepaid. All samples shall be submitted before shipment of the equipment or material to the job site and in ample time to permit the making of proper tests, analyses, examinations, rejections, and resubmissions before incorporated into the work. 497
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
2.02 NAMEPLATES & TAGS
A. Equipment exterior nameplates Nameplate material shall be rigid laminated black plastic with beveled edges and white lettering; except for caution, warning, and danger nameplates the color shall be red with white lettering. The size of the nameplate shall be as shown on the Drawings. No letters are allowed smaller than 3/16". All nameplates located outdoors shall be UV resistant. Securely fasten nameplates in place using two stainless steel screws, type 316L, if the nameplate is not an integral part of the device.
Epoxy cement or glued on nameplates will not be acceptable. Engrave the nameplates with the inscriptions as approved by the Engineer in the submittal.
1. For each major piece of electrical equipment provide a manufacturer's nameplate showing the Contract specified name and number designation, and pertinent ratings such as voltage, # of phases, ratings, etc.
2. For each device with a specific identity (pushbutton, indicator, instrument, etc.) mounted on the exterior or deadfront of a piece of equipment provide a nameplate with the inscription as shown on the Drawings and described herein.
3. Where required by code, provide nameplates denoting information required. For example:
a. Transformers not in sight of disconnect, furnish nameplate denoting location of feeding circuit breaker or disconnect.
b. Motor controls without door interlock or disconnecting circuit breaker; furnish nameplate denoting location or feeding circuit breaker or disconnect.
4. Where no inscription is indicated on the Drawings or described herein, furnish nameplates with an appropriate inscription providing the name and number of device.
5. Install Safety Signs in accordance with the latest OSHA requirements. a. Entrances to electrical rooms and stations: Danger Sign requirements, ELECTRICAL ROOM, HIGH VOLTAGE (define voltage, example 480 VAC) KEEP OUT, AUTHORIZED PERSONNEL ONLY.
b. Equipment enclosures, cable tray and wireway where 120 VAC or higher and 50 V DC and higher exist: Danger Sign requirements, HIGH VOLTAGE (define voltage, example 480 VAC) AUTHORIZED
PERSONNEL ONLY.
c. Equipment such as motor control centers, control panels, etc., where more than one source may be present in an enclosure or cubicle: Danger Sign requirements, VOLTAGE (define voltage, example 120 VAC control voltage or 480 VAC power) FROM MULTIPLE SOURCES IN THIS ENCLOSURE.
d. Equipment such as switchboards, switchgear, panelboards and motor control centers: Warning Sign requirements, WARNING, SERVICE ENTRANCE DISCONNECT FOR 1 OF ___ (define quantity)
SERVICES TO THIS BUILDING. OTHER SERVICE ENTRANCE
DISCONNECTS ARE LOCATED AT (define locations).
6. Caution, warning and danger nameplates shall be red with white lettering B. Equipment Interior Nameplates Nameplate material shall be clear plastic with black machine printed lettering as produced by a KROY or similar machine; except caution, warning, and danger nameplates shall have red lettering. The size of the nameplate tape shall be no smaller than 1/2” in height with 3/8" lettering unless otherwise approved by the Engineer. Securely fasten nameplates in place on a clean surface using the adhesion 498
ELECTRICAL GENERAL 16010 - 18
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) of the tape. For each device with a specific identity (relay, module, power supply, fuse, terminal block, etc.) mounted in the interior of a piece of equipment provide a nameplate with the inscription as shown on the Drawings and described herein. Where no inscription is indicated on the Drawings or described herein, furnish nameplates with an appropriate inscription providing the name and number of device used on the submittal drawings. Stamp the nameplates with the inscriptions as approved by the Engineer in the submittal.
C. Equipment Tags When there is no space or it is impractical to attach an engraved plastic nameplate with screws, as is the case with most field devices and instruments, the Contractor shall attach a tag to the equipment with the same inscriptions as specified above in paragraph A. The tag shall be made from stainless steel material and the size of the nameplate shall be no smaller than 3/8"h x 2"w with 3/16" machine printed or engraved lettering unless otherwise approved by the Engineer. The tag shall be attached to the equipment with stainless steel wire of the type normally used for this purpose.
2.03 FASTENERS
A. Fasteners for securing equipment to walls, floors, or ceilings, shall be stainless steel. The minimum size fastener shall be 3/8 inch diameter.
B. Voltage Monitor Relay (VMR)
1. The voltage monitor relay (VMR) shall continuously monitor the three phases for power loss, low voltage, phase loss, and phase reversal. The VMR shall interface to the control circuit with DPDT contacts rated for 4 Amps at 120 VAC. The VMR shall have a drop out voltage adjustment, time delay adjustment, and status indicating LEDs. Voltage monitor relay shall be Time Mark 2652, or equal.
2.04 MOTOR CONTROL ACCESSORIES
A. Control Power Transformer:
1. Control power transformer shall be epoxy encapsulated for dust and moisture protection. The internal wiring shall be copper and have 105 deg. C insulation rating. The unit shall feature barriered screw terminals for connection to electrical circuits. Provide with time-delay, slow-blow secondary fuse rated to protect the transformer and interrupt 10,000 amperes at 120VAC. Two primary fuses rated for 480 VAC and AIC as shown in the Drawings shall be provided.
Transformer minimum size and voltage ratings shall be as shown on Contract Drawings. Control power transformer shall be Micron Impervitran, Cutler Hammer MTE or equal.
B. Moisture Over-temp Relay:
1. Provide new MiniCAS-120 relay, no equal. Provide Omron P3GA-11 reverse relay socket no equal. This item may be furnished with the pump. Coordinate with Contractors/suppliers.
2.05 DEVICES
A. Switches
1. General purpose commercial grade switches shall be manufactured in accordance with UL 20. Switches shall be one pole, brown, 20 amps at 277 VAC, 1HP at 120 499
ELECTRICAL GENERAL 16010 - 19
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) VAC, 2 HP at 240 VAC. Switches shall have copper alloy contact arm with silver cadmium oxide contacts. Switches shall have slotted terminal screws and a separate green grounding screw. Provide Leviton, Hubbel, or equal.
B. Receptacles
1. General purpose receptacles shall be commercial grade, duplex and rated 20 amps, 120 VAC, 2 pole, 3 wire grounding, NEMA 5-20R configuration, specification grade, and side wired to screw terminals. Face color shall be brown when paired with stainless steel covers. General purpose receptacles shall be specification grade Leviton, Hubbel, or equal.
2. GFI receptacles shall be commercial grade, duplex, brown, 20A, 120V, back and side wired, with "test" and "reset" buttons. “Daisy Chain” connecting multiple receptacles from one GFI unit is not acceptable. GFI receptacles shall be Leviton, Hubbel, or equal.
3. Boxes shown in NEMA 3R environments and outdoor locations shall be weatherproof while in-use. Furnish in-use weatherproof covers and weatherproof boxes for these areas. Receptacles, plugs, and housings shall be fabricated of impact resistant plastic with o-rings and gaskets to prevent the entrance or water, vapors, and chemicals when unplugged or plugged.
2.06 POWER MONITORING
A. Power Monitor
1. General:
a. Microprocessor based multifunction power and energy meter b. Designed for multifunction electrical power, voltage, and current measurement on 3 phase power systems.
c. Measured parameters: voltage, current, frequency, unbalance, kW, KVAR, KVA, power factor, kWh.
d. Support for 3-Element Wye, 2.5 Element Wye, 2 Element Delta, 4 wire Delta systems.
e. 200 ms update for power measurement, 100ms update for voltage, current, Hz.
f. Din rail mounting
g. 85 to 264 VAC control power, 5W.
2. Voltage Inputs
a. Configurable to potential transformer ratio.
b. Input impedance of 1 Mega Ohm, 0.014W at 120 Volts.
c. Direct voltage input range
1) 347 Volts Line to Neutral
2) 600 Volts Line to Line.
d. 2500V withstand.
3. Current Inputs:
a. Configurable to current transformer (CT) ratio 1A or 5A input. b. Burden 0.05VA, Impedance 0.002 ohms
c. Meter shall have a maximum burden of 0.005VA per phase, at the maximum of 15 Amperes continuous input.
d. Fault current withstand shall be 200 Amps for 1/2 second.
4. Digital I/O:
a. Two status inputs 24VDC dry contact.
b. Two assignable digital relay outputs
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
5. Accuracy
a. Revenue meter accuracy
b. +/- 1% or better for volts and amps
c. +/- 1% for power and energy functions.
d. True RMS measurements
6. Communications
a. Ethernet - 100BaseT Ethernet IP Allen Bradley protocol b. Modbus TCP
7. Display:
a. 4 Line backlit LCD display to display real time measured parameters including voltage, current, power, and power factor.
8. Acceptable Products
a. Electro Industries Shark 200 with Ethernet
b. Or Equal
B. CT Shorting Terminal Block
1. Panel mount inside control equipment with front screw terminal connections.
Inserting a thumb screw shall short terminals to a top mounted ground bar.
Provide quantity of terminal poles as required for function and as shown in Drawings. Furnish Flex Core 170xSC or equal.
C. Current Transformers
1. Furnish mounted (preferable) or unmounted current transformers based on space allocated and installation requirements. The current transformer shall have wire leads or binding posts and ratio as shown on the Drawings. The accuracy shall be metering accuracy class 0.6 at a minimum burden at 60 hz shall be 2.5 VA and as required to meet specified accuracy of device(s) fed.
PART 3 EXECUTION
3.01 CONSTRUCTION METHODS
A. Equipment shall be assembled and wired by the manufacturer prior to shipment. Field modifications or changes are not allowed without a written "change order" to the Contract. Field changes, however large or small, shall be executed using the components, materials, wiring, labeling, and assembly methods identical to that of the original supplied equipment.
B. Factory as-built Drawings for each custom manufactured control panel or MCC shall be shipped with the equipment and placed inside in waterproof envelopes.
3.02 EQUIPMENT FABRICATION
A. All electrical equipment, including custom manufactured equipment, shall meet the requirements of Underwriters Laboratories (UL) and bear the appropriate label. Panels shall be affixed with UL label prior to shipment and be built in accordance with the UL guidelines and procedure that corresponds to the UL label. Custom control panels shall bear a UL-508A label for general use, minimum, with additional UL labels as required per intended service.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
1. Design and furnish a Low Voltage Limited Energy Circuit for any device(s) not bearing a UL listing or registration that are required to be installed into a UL labeled panel.
2. Revise voltages for any electrical parts and equipment that are specified that do not bear the UL listing or registration.
B. Panel cutouts for devices (i.e. indicating lights, switches) shall be cut, punched, or drilled and smoothly finished with rounded edges. Exposed metal from cutouts that are made after the final paint finish has been applied shall be touched up with a matching paint prior to installing device.
C. Equipment doors shall swing freely and close and latch with proper alignment.
D. Component within the electrical equipment shall be securely mounted on an interior subpanel or backpan and arranged for easy servicing. Mounting bolts and screws shall be front mounted for device removal without special tools or removal of entire mounting panel.
E. A ground bus shall be provided in each enclosure or cabinet. It shall have provisions for connecting a minimum of ten grounding conductors. Screw type lugs shall be provided for connection of grounding conductors. All grounding conductors shall be sized as shown on plans or in accordance with NEC Table 250 95, whichever is larger.
F. Bolts and screws for mounting devices on doors shall have a flush head which blends into the device or door surface. No fastening devices shall project through the outer surfaces of equipment.
3.03 WORKMANSHIP
A. All work in this division shall conform to the codes and standards outlined herein.
B. Installation shall be performed by qualified personnel providing first class workmanship per Electrical Specifications [Electrical General, Qualifications].
C. Maintain equipment installed (or to be installed) in new condition. Protect equipment from damage while in Contractor care from dust, water, or mishaps that are typical to construction sites
D. Confirm that equipment and materials are correct for their intended duty and will be installed per manufacturer guidelines. Equipment and components found to be installed inconsistent with manufacturer guidelines and/or these Specifications will not be acceptable and subject to removal and replacement.
E. Upon completion of daily work, remove excess materials, scraps, and debris from the work area and from the inside of equipment.
F. Upon notification, stop work on any portion of the installation that is determined to be non-compliant with contract or being installed by unqualified personnel.
G. Perform all work to correct improper installations at no additional cost to the owner. 502
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) H. Equipment furnished under this contract or provided to Contractor for installation shall be installed in accordance with manufacturer's instructions, installation calculations, and contract documents.
3.04 EQUIPMENT SHIPMENT AND STORAGE
A. Shipment -- Any equipment whose destination (jobsite) is more than 25 miles from the factory shall be carefully protected for shipping. All openings shall be protected by plywood securely fastened to the framework of the equipment. Equipment shall be adequately covered during local delivery.
B. Storage -- From the time of receipt until the equipment is installed and energized, the equipment shall be considered in storage. While in storage, a 120V, 1 phase source of power shall be made available and connected to space heaters in all items of equipment so equipped. Equipment not provided with space heaters shall be provided with a light bulb or electric heater while in storage to prevent moisture condensation. Unless stored indoors, it shall be a least 1 foot above grade covered with at least 2 layers of heavy polyethylene plastic sheets and anchored to prevent damage by high winds. All equipment shall be protected from dust and moisture prior to and during construction.
3.05 DAMAGED PRODUCTS
A. Damaged products that cannot be repaired to new condition shall be replaced with new products. All equipment and materials shall be in like-new condition at start-up and commissioning.
B. Existing equipment to be reused shall be repaired or replaced if damaged while in the Contractor’s care. The Contractor shall pay for the parts and/or services of the original equipment manufacturer (OEM) to troubleshoot, asses, and repair damaged equipment.
C. Minor cosmetic damage shall be repaired by spray painting, after properly preparing the surface, all scratches or defects in the finish of the equipment. Only identical paint furnished by the equipment manufacturer shall be used for such purposes.
3.06 INSTALLATION
A. General
1. Install all products per manufacturer's recommendations and the Drawings.
2. Provide all necessary hardware, conduit, wiring, fittings, and devices to connect the electrical equipment provided under other Sections.
3. Furnish and install wiring between adjacent equipment sections that are not completed at factory. Install 1-1/2” minimum diameter insulated chase nipples with lock rings and insulated bushings for thru wiring.
4. Protect wiring insulation from wear by installing rubber cushions, bushings, or strip insulation, or by fastening the wiring to a rigid surface with zip ties and anchors.
5. Provide additional devices, wiring, conduits, relays, signal converters, isolators to complete interfaces of the electrical and instrumentation system.
6. Changing normally open contacts to normally closed contacts or vice versa
7. Adding additional relays to provide more contacts as necessary. 503
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
8. All programmable devices (not specifically excluded herein) shall be programmed, set-up and tested by the Contractor prior to startup. Programming and set-up parameters shall be adjusted or changed as directed by the Engineer during start-up and throughout the warranty period.
9. Coordinate with the Engineer and setup all alarm, process, and operation setpoints.
10. Keep a copy of the manufacturer’s installation instructions on the jobsite available for review at all times prior to and during the installation of the associated equipment.
B. Panels and enclosures:
1. Install panels and enclosures at the location shown on the Plans or approved by the Engineer.
2. Install level and plumb.
3. Anchored to pad or wall as defined herein or as defined in approved seismic calculations. Assumes 4500 psi strength concrete and 3” minimum from edge of 6” depth concrete pad.
a. Pad mounted equipment up to 90” height: minimum1/2” 316SS concrete anchors with 5” minimum embedment into 4000 psi concrete. Locate anchors at each of 4 corners per equipment section.
b. Wall mounted equipment up to 400 lbs and mounted into reinforced concrete filled cinder block walls: minimum 3/8” 316SS concrete anchors with 3.5” minimum embedment. Locate anchors at each of 4 corners per panel.
4. Seal all enclosure openings to prevent entrance of insects and rodents.
5. Clearance about electrical equipment shall meet the minimum requirements of NEC 110.26
C. Electrical receptacles, plugs, and switches
1. Electrical plugs, receptacles, cords, and connectors required to power or interface the equipment and panels shall be furnished and installed by the Contractor.
2. Ground fault circuit interrupter receptacles shall be used where noted as GFI on plan or where in outdoor NEMA 3R locations, or in areas that are indoor and in same room as water pipe.
3. Boxes shown in NEMA 3R environments and outdoor locations shall be weatherproof while in-use. Furnish in-use weatherproof covers and weatherproof boxes for these areas.
4. Definite purpose receptacles and plugs in NEMA 4 or 4X environments where a receptacle is shown and a device is to be connected continuously, shall be listed as UL type 4, 4X, (Plug) and NEMA 3R (flip cover).
D. Conduits and Ducts:
1. Install all conduits and ducts per Electrical Specifications [Conduit and Boxes] and [Grounding].
2. Minimum wire bending space at terminals and minimum width of wiring gutters shall comply with NEC tables 312-6 (a) & (b).
E. Wiring, Grounding, and Shielding:
1. Observe proper grounding and shielding practices as this application environment is generally noisy. The shield of shielded cables shall be terminated 504
ELECTRICAL GENERAL 16010 - 24
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) to ground at one end only, the origination end. The shield at the other end shall be encased in an insulated material to isolate it from ground.
F. Cutting and Patching:
1. The Contractor shall do all cutting and patching required for installing his work.
Any cutting which may impair the structure shall require prior approval by the Engineer. Cutting and patching shall be done only by skilled labor of the respective trades. All surfaces shall be restored to their original condition after cutting and patching.
G. Cleaning and Touch up:
1. At the completion of the work, all parts of the installation, including all equipment, exposed conduit, and fittings, shall be thoroughly cleaned of grease and metal cuttings. Any discoloration or other damage to parts of the building, the finish, or the furnishings, due to the Contractor's failure to properly clean the system, shall be repaired by the Contractor.
2. The Contractor shall thoroughly clean any of his exposed work requiring same.
3. Vacuum and clean the inside of all electrical and instrumentation enclosures prior to applying power.
4. The Contractor shall paint scratched or blemished surfaces with the necessary coats of quick drying paint to match existing color, texture and thickness. This shall include all prime painted electrical equipment including but not limited to enclosures, poles, boxes, devices etc.
3.07 APPLICATION OF POWER
A. The Engineer will direct the energization and de-energization of all existing and new equipment. The Contractor is not authorized to energize or de-energize any equipment unless they have been given written permission to do so or while in the presence of the Engineer.
1. Any equipment that is under repair, demolition or installation shall be locked off and tagged out of service with Contractor supplied padlocks and tags.
2. The Contractor is required to comply with NFPA 70E and specifically in regards to safety when working on live equipment. Obtain work permits when needed to do live work.
B. The Contractor is responsible for grounding of high and medium voltage cabling and/or bus during installation and removal of equipment. The contractor is responsible for complying with all California Electrical Safety Orders (ESO) and Occupational Safety and Health Act (OSHA) safety requirements and procedures while working in or near medium voltage equipment.
3.08 WARRANTY
A. The Contractor shall warrant all electrical and instrumentation equipment & software for a period of 1 year from date of final acceptance. Standard published warranties of equipment which exceed the preceding specified length of time shall be honored by the manufacturer or supplier.
B. The Contractor shall have a staff of experienced personnel available to provide on-site warranty service on 2 working days notice during the warranty period. Such personnel 505
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) shall be capable of fully testing and diagnosing hardware & software and implementing corrective measures.
3.09 FINAL ACCEPTANCE
A. Final acceptance will be given by the Engineer after the equipment testing is complete, each deficiency has been corrected, final documentation has been provided, and all the requirements of Contract documents have been fulfilled.
B. At the end of the project, following the completion of the field tests, and prior to final acceptance, the Contractor shall provide the following:
1. Each "operation and maintenance" manual shall be modified or supplemented to reflect all field changes and as built conditions.
2. Two (2) disk copies of all final documentation to reflect as-built conditions.
C. Keys: Submit two sets of all keys for locks supplied on this project. Wire all keys for each lock securely together. Tag and plainly mark with lock number or equipment identification, and indicate physical location, such as panel or switch number.
END OF SECTION
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 16110
CONDUIT AND BOXES
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Labor, materials, equipment, tools, safety gear, test equipment, incidentals, services, and transportation for a complete electro-mechanical installation as shown on the Drawings, included in these Specifications, or as can be reasonably implied from project descriptions.
B. The scope of work includes:
1. Furnish and install conduits, wireways, raceways, cable trays, junction boxes, pull boxes, and associated hardware. Provide conduit, fittings, hardware, hangars, mounting channel, and other parts for a complete raceway installation.
2. Replacement of liquid tight flex conduit that is sun exposed for any conduit that is getting new conductors.
3. Demolishing conduit and conductors for demolished equipment.
4. Furnish and install grounding system required by drawings, or if not shown or defined, as required by Article 250 of the NEC.
5. Installations shall be designed and installed with components meeting the NEMA area designation.
C. Work includes that specified in Electrical Specifications [Electrical General].
1.02 REFERENCES
A. Electrical Specifications [Electrical General]
B. Electrical Specifications [Low Voltage Wire & Data Cable] C. Electrical Specifications [Grounding]
D. Project Drawings
1.03 QUALIFICATIONS
A. Material furnished under this specification shall be installed by qualified installers meeting requirements specified in Electrical Specifications [Electrical General, Qualifications].
1.04 SUBMITTAL REQUIREMENTS
A. Provide submittals and drawings as specified in Electrical Specifications [Electrical General, Submittal Requirements].
PART 2 PRODUCTS
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2.01 CONDUIT, RACEWAYS AND WIREWAYS
A. GENERAL - Conduit, raceways, and wireways, wiring methods, materials, installation shall meet all requirements of the NEC, be UL labeled for the application, and meet the minimum following specifications.
1. All wiring shall be installed in conduits, raceways, or wireways when interconnecting equipment and devices.
a. The minimum size conduit shall be 3/4-inch unless indicated otherwise on the Drawings or for special connections to equipment. b. Provide cords and cord seals for devices or instrumentation requiring waterproof seal to maintain NEMA 4 or 4X ratings. Example devices include lighting and pipe mounted instruments that are located below grade.
2. Conduits may connect into junction boxes or wireways as shown in the drawings or as requested by Contractor and approved by Engineer. Junction boxes (circle with J in drawings) can be as simple as a condulet or JIC box, or larger box as determined by contractor and needed for the installation. Drawing may or may not depict junction box requirements that may be required by code. Wireways or junction boxes shall be rated for area (as noted in the Drawings), or furnish minimum NEMA 4 if not noted.
3. The Contractor shall use conduit material types (SPEC per conduit schedule) as defined below or as otherwise shown in the contract drawings or as specifically called out in the conduit schedule.
a. Non-exposed underground portions of conduit run shall be PVC-40 for all signals and voltages unless otherwise shown in the conduit schedule. b. Exposed conduit material (not underground and beyond transition) shall be per the following table unless specifically noted otherwise in the plan drawings. The conduit schedule denotes the conduit type for nonexposed (under-ground, in-concrete, etc.) and does not apply or coordinate with this table. Exposed condulets, elbows, fittings, device boxes, and hardware shall be of the same material and finish as the adjacent conduit.
Location Material
NEMA 1 or 12 Galvanized rigid steel (GRS)
NEMA 3R Galvanized rigid steel (GRS)
NEMA 4 PVC-Coated Steel (GRS-PVC)
NEMA4X PVC-Coated Steel (GRS-PVC)
Class 1 Div 1 or 2 hazardous PVC-Coated Steel (GRS-PVC)
4. Conduit stubs and transitions:
a. Conduit transitions shall be GRS-PVC for 6” on either side of the mtransition point (minimum) or as shown in drawing details. Conduit transition is defined as conduit sections emerging from or through concrete or earth or from below to above grade or through walls or vaults, non-exposed to exposed.
b. Beneath pad mounted electrical equipment, where not exposed, shall be installed or trimmed to 2” or less above slab and have bushing or end bell 508
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) installed. Overall height of conduit entering into the base of equipment shall be enough for bushings/bells to be installed but be high enough for conduit tags to be installed.
c. Uniform in height for each panel or section. Conduits end bushings/bells shall not vary in height above slab more than ½” from lowest to highest. d. Conduits shall be spaced apart such that bushings and end bells may be installed without interfering with the adjacent conduits. e. Transitions to PVC shall include PVC coated locknuts to shield exposed steel pipe threads.
f. Through walls – shall protrude approximately 2” and include end bell or bushing. Pack space around conduit with non-shrink grout if the thruhole was core drilled. g. From hazardous locations – shall include seal off and/or conduit cable seals as required per NEC.
h. Conduits for future use shall be capped with coupling and plug. Identify each end with conduit labels.
i. Existing conduits that are no longer able to be used due to removal of equipment or shown demolished, shall have flexible conduit removed, wires removed or pulled back to the nearest pullbox, coiled and labeled at each end. Disconnect wires at each end.
5. Conduit Tags
a. All conduits listed in the “Conduit and Wire Routing Schedule” shall have conduit tags at both ends of each conduit run with tag number from schedule identified. This shall include ends within underground pull boxes.
b. All underground conduits shall have conduit tags at both ends of each conduit run. This shall include ends within underground pull boxes. c. Tags on each conduit shall denote destination of conduit (acronym) and a unique number. Use tags such as 01 and RTU, 02 and MCC, 03 and LP, 05 and P1, 06 and PIT-61, etc. Tag destination acronym shall reverse at the other end of conduit but the number shall stay the same. Two tags may be used if placed back-to-back.
d. All conduits shall have temporary tags during construction. Temporary tags may be made from duct tape with hand written ink marking or suitable equivalent. Temporary tags shall be removed by Contractor at time of installation of permanent tags.
e. Tag material shall be rigid laminated red plastic with white lettering.
The size of the tag shall be ¼” thick by 1” round or ¾” x 1” rectangle minimum.
f. Letter height shall be 3/8” minimum. Engrave the tags with the conduit number or acronym. Labeling shall be neatly installed for visibility and shall be clearly legible. Securely fasten tags in place using 20ga stainless steel tie wire through a pilot hole on the tag.
g. Conduit tags shall be Custom manufactured per specification.
6. Supports
a. Cross section of a single channel shall be 1-5/8" x 1-5/8" and crosssection of a double channel shall be 1-5/8" x 3-1/4". The channel wall thickness shall be 12 gauge as applicable.
b. One-Hole clamps shall be intended for pipe mounting on support channels and equipped with clamp-backs. The clamps shall be Efcor, Thomas and Betts, Appleton or equal
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) c. Spacers, provided to support underground conduits in concrete encasements, shall be plastic. The spacers shall be Carlon, JohnsManville, Underground Products or equal d. Anchors shall be expansion type for securing equipment to concrete foundations, floors and walls. Anchors shall have length identification mark on the exposed end of the bolt. Provide Hilti Kwik Bolt TZ, or equal.
e. Stanchions shall be provided as needed to mount equipment and electrical components. Stanchions shall be shop fabricated from welded 4” c-channel, 12” x 12” x ¼” steel base plate, coated with a rust inhibiting primer and top coat of gray polyurethane gloss paint. Attach equipment to the stanchion direct or on a ¼” aluminum sheet sized for the equipment supported.
f. Conduit Hangers shall be trapeze construction, with double channel, 3/8- inch rods and nuts. Suspend from suitable structural support. g. Support material and finish shall be per the following table unless otherwise noted in the drawings. Brackets, fittings and hardware shall be of the same material and finish.
Location Material
Indoors NEMA 12 Galvanized steel
Outdoors NEMA 3R Galvanized steel
Outdoors NEMA 4 Stainless Steel type 316
Corrosive areas
NEMA4X
PVC bonded, 40 mil, factory applied
h. Equipment mounting racks shall be designed by installer for rigid equipment and conduit mounting. Racks shall be bolted or welded construction and sized for equipment or as shown on the drawings. i. Strut channels shall be used for mounting equipment to walls and for supporting conduit runs. Double strut channel type shall be used for fabricating equipment mounting racks as required and/or as detailed on the drawings. Add additional supports to rigid mounting locations as needed to prevent wobbling and to meet seismic requirements. All field cut surfaces of the strut channels shall be deburred and coated to prevent rust.
B. Galvanized Rigid Steel Conduit - (GRS)
1. Manufactured from high-strength steel and hot dipped zinc galvanized inside and out. Conduit and fittings shall meet UL 514B, UL 6, and conform to NEMA RN
2. Conduit shall be capable of being used as an equipment grounding conductor per NEC 250.
2. Provide factory radius elbows where 90 degree bends are required within a GRS conduit run.
3. Cast fittings and device boxes shall be malleable iron or aluminum. Appleton type FS/FD or equal.
4. In hazardous locations, fittings shall meet and be listed UL 886.
5. All fittings, hubs, couplings, pulling elbows and connectors shall be threaded-type. Set-screw type and compression-type are not acceptable. All thread conduit is not allowed over 1/2” exposed length. Cover plates shall be cast iron with sealing gasket in NEMA 3R locations.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
6. Conduits entering enclosures shall be fitted with insulated grounding bushing; O-Z "HBLG", Appleton "GIB", or approved equal. All grounding bushings shall be tied to the grounding system with properly sized bonding conductors per the NEC code.
7. Combination expansion-deflection fittings installed exposed shall be Type XD as manufactured by Crouse-Hinds Co.; Type DX as manufactured by O.Z. Gedney Co.; Type DF as manufactured by Appleton Electric Co., or equal C. Galvanized Rigid and Coated Steel Conduit (GRS-PVC)
1. Galvanized Rigid Steel conduit with a 40-mil thick polyvinylchloride exterior coating and a 2-mil urethane interior coating meeting NEMA RN-1, UL-6 and ETL PVC-001. The bond of the PVC to the zinc coated pipe must be stronger than the tensile strength of the PVC.
2. Provide factory radius elbows where 90 degree bends are required within a GRSPVC conduit run.
3. Cast fittings and device boxes shall be malleable iron or aluminum with a 40-mil thick PVC coating meeting the same.
4. In hazardous locations, fittings shall meet and be listed UL 886.
5. Provide PVC coated threaded-type fittings, hubs, pulling elbows, couplings, and connectors; set-screw type and compression-type are not acceptable. Form 8 conduit fittings, ½” through 4”, must have a tongue-in-groove gasket to effectively seal out the corrosive elements. Covers shall be supplied with plastic encapsulated stainless steel cover screws. Form 8 fittings shall be UL and type 4X and IP69 listed.
6. A PVC Coated Sealing Locknut shall be used on all exposed male threads transitioning into female NPT threads which do not have sealing sleeves, including transitions from PVC couplings/female adapters to PVC Coated GRC elbows in direct burial applications. “PVC Coated Sealing Locknuts” are not to be used in place of a Myers hub
7. A PVC sleeve extending one pipe diameter or two inches, whichever is less, shall be formed at every female fitting opening except unions. The inside sleeve diameter shall be matched to the outside diameter of the conduit.
8. All junction and metal pull boxes shall be galvanized with exterior surfaces PVC coated to 40 mils thickness.
9. Unistrut, strut clamps, pipe straps, and clamp back spacers, shall have 40 mil thick PVC coating. All mounting anchors shall be stainless steel.
10. Conduits entering enclosures shall be fitted with insulated grounding bushing.
All grounding bushings shall be tied to the grounding system with properly sized bonding conductors per the NEC code.
11. GRS-PVC conduit to be Robroy Plasti-bond, Perma-Cote, KorKap, T&B OCAL or equal.
D. PVC Conduit, Schedule 40 or 80 (PVC-40, PVC-80)
1. Shall be high impact schedule 40 or 80 polyvinylchloride suitable for use underground, direct burial and for use with 90 C wires, and shall conform to UL 651. Shall be UL listed and labeled for "direct" burial.
2. Elbows, and risers shall be per exposed conduit transition detail. PVC conduit is not allowed above ground or in exposed locations except where specifically indicated.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
3. Custom bends (44 deg maximum) shall only be allowed in horizontal underground locations. Custom bends shall be neat, orderly, full diameter, and parallel with other conduits.
4. PVC fittings shall have solvent-weld-type conduit connections. Fittings and device boxes shall be PVC with factory fabricated conduit connections. Provide Carlon or equal.
5. Conduits entering enclosures shall be fitted with a glued male adapter, lock ring and bushing to prevent wire chafing. Conduits entering panels through concrete to an open bottom or entering a pull box shall have a glued end bell fitting.
6. PVC conduit shall be stored on a flat surface and shielded from the sun.
E. Liquid Tight Flexible Metal Conduit (above 2-1/2”) - (FLEX)
1. Liquid Tight Flexible Metal conduit shall be moisture and oil-proof with PVC jacket extruded over a galvanized flexible steel conduit.
2. Liquid Tight Flexible Metallic Conduit shall be sunlight, oil, and flame resistant and approved for the installation of electrical conductors in indoor and outdoor applications.
3. Liquid Tight Flexible Nonmetallic Conduit shall be listed to UL standard UL 360.
4. Liquid Tight flexible metallic conduit shall be installed in accordance with Article 350 of the National Electrical Code (NEC) and other applicable sections of the NEC and/or local electrical codes.
5. Liquid Tight Fittings shall be listed for the use with Liquid tight Flexible Metallic Conduit and conform to UL514B.
a. Outdoors when extension of GRS-PVC: PVC coated galvanized steel with insulated bushings.
b. Outdoors when extension of GRS: Galvanized steel with insulated bushings.
c. Indoors or outdoors when extension of stainless steel: 316 stainless steel with sealing ring and insulated bushing.
d. Indoors: Galvanized steel with insulated bushings.
6. Flexible Metallic Conduit shall be Electri-Flex Liquatite type LA or equal.
2.02 CONDUIT SEALING BUSHINGS
A. Conduit Sealing Bushings shall provide a positive gas and fluid seal for all styles of conduits, including aluminum, galvanized rigid steel, and PVC.
B. Sizes available range from 3/4” thru 6” in both solid and split styles and available as blank, single, two and three conductors.
C. Seal conduits where indicated within underground pullboxes with conduit cable seals to prevent gasses or liquids from entering pullboxes.
D. Furnish Roxtec RS UG, Crouse Hinds, OZ Gedney, or equal.
2.03 DEVICE BOXES
A. Boxes
1. Device boxes shall be of zinc-galvanized malleable iron or cast aluminum with shape and size best suited for the particular application, rated for the location 512
CONDUIT AND BOXES 16110 - 7
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) installed, and shall be supported directly to structure by means of screws, anchors, or bolts.
2. Box dimensions shall be in accordance with size, quantity of conductors, and conduit clearances per NEC articles 314 requirements.
3. Boxes exposed to the weather or in moist locations shall be weatherproof (WP) by means of gasketing under a weatherproof cover.
4. Boxes connected to GRS-PVC conduit runs shall be PVC coated with 40 mil coating.
B. Device Plates and Covers
1. Indoor general purpose device plates and covers shall be stainless steel. Plates or covers shall be attached with stainless steel screws. An engraved plastic label denoting circuit breaker number and panelboard name shall be affixed to each cover with #4 stainless steel screws.
2. Weatherproof switch, outlet, and receptacle boxes shall be fitted with gasketed covers rated for wet locations. Each access cover shall have a padlockable cover to maintain security and weatherproof integrity even when a plug is connected to the receptacle. Screws and hinge springs shall be stainless steel. Weatherproof access covers shall be Leviton 5977-CL, Cooper 4966, or equal.
2.04 PULL BOXES
A. Junction Boxes
1. Where required for best installation or where specifically called out in the Drawings, junction boxes shall have JIC type construction with hinged door, type NEMA 4X type 304 stainless steel, or as otherwise shown and compliant with the indicated NEMA area rating. Door shall be fastened with clamps and stainless steel screws. No devices, screws, rivets, or bolts shall protrude through the exterior surface unless specifically shown on the Drawings. Boxes shall be Hoffman, Circle AW, or equal.
B. Underground Boxes
1. Underground pull boxes shall be prefabricated “Christy Box” size and type as noted in the Drawings or equal. Size shall be as shown or dimensioned on the Drawings. Provide larger boxes as needed to meet code or as determined in field to allow for adequate pull area at Contractor discretion. Extension sections shall be provided as necessary to reach the depth of underground conduits with maximum depth of 48”. All boxes shall have galvanized steel hold down bolts and hardware. Boxes shall be H/20 loading rated and have traffic rated covers.
Steel covers or lids shall be galvanized and grounded with bonding jumper to the local grounding circuit per NEC. Pull box covers shall be labeled electrical, signal, utility, and telephone, whichever applies. Pull boxes shall be Christy Concrete Products, Brooks or equal.
C. Pull Box and Vault Identification
1. Engrave or bead weld box covers with minimum thickness of ¼” x 1” lettering with pullbox name (i.e. PBX-XXX) and purpose (electrical, signal, fiber, telephone, etc.). Provide an additional identifier “high voltage” for boxes with 600 volts or higher.
2. Utility pull boxes shall be labeled per Utility Company standards. 513
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
2.05 HOLE PLUGS
A. General
1. Designed to seal unused pushbutton holes, conduit openings and knockout holes against dust, oil and water when modifying existing enclosures.
2. Hammond Manufacturing, or equal
B. Steel Hole Plug
1. 2 color options - ANSI 61 gray or RAL7035 Light Gray
2. Oil resistant gasket.
3. Secured with an 10-24 x 0.55" threaded stud and plated wing nut.
4. Suitable for Type 1, 3, 3R, 4, 12, painted steel or non-metallic.
C. Stainless Steel Hole Plugs
1. Cupped cap to protect rubber gasket and seal.
2. Finished in brushed natural 304 stainless steel finish.
3. Oil resistant gasket.
4. Secured with an 10-24 x 0.55" threaded stud and plated wing nut.
5. Suitable for 4X and stainless steel panels.
2.06 BACKFILL MATERIAL
A. Controlled Low Strength Material:
1. Backfill material shall be CLSM (Controlled low strength material) or sand slurry cement mix with 1000 to 1200 psi compressive strength.
2. Colored red with fifteen (15) pounds of red iron oxide No. 188 per cubic yard of concrete.
PART 3 EXECUTION
3.01 WORKMANSHIP
A. All work in this Section shall conform to the codes and standards specified in Electrical Specifications [Electrical General, Workmanship].
3.02 INSTALLATION
A. System:
1. Install all products per Electrical Specifications [Electrical General, Installation].
B. Rigid Conduits and Ducts:
1. Exposed conduits shall be neatly arranged with runs perpendicular or level and parallel to walls. Bends shall be concentric.
2. Except as expressly indicated or approved, all conduits shall be surface mount on block walls, concealed behind gypsum walls, and buried to required depth below floor slabs.
3. Pipe threads shall be treated with conductive thread compound.
4. Installation of the GRS-PVC conduits must be in accordance with the manufacturer’s installation procedures using recommended tools. 514
CONDUIT AND BOXES 16110 - 9
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) a. Apply touch up compound at each fitting sealing sleeve edge to improve watertight seal.
b. To ensure compliance, the installer(s) must be “manufacturer certified” before installation can proceed.
c. Certification available by contacting manufacturer’s representative and attending a brief instructional course. Valid and unexpired certification card shall be available for review per installer.
5. Repair GRS-PVC coating utilizing a touch-up compound as provided by the manufacturer of the conduit of the same material as the coating. Overlap beyond the damaged area to cover the PVC coating. Contact from touchup compound to PVC is required to maintain integrity. The entire conduit shall be replaced if the repair exceeds 1” combined length.
6. A maximum of three equivalent 90 degree elbows are allowed in any continuous run. Install pull boxes where required to limit bends in conduit runs to not more than 270 degrees or where pulling tension would exceed the maximum allowable for the cable.
7. Route all above grade conduits parallel or perpendicular to structure lines and/or piping. Conduits installed above grade shall be braced in place with stanchions.
Expansion joints shall be installed every 100 feet. Bends shall be concentric. a. Combination expansion-deflection fittings installed exposed shall be Type XD as manufactured by Crouse-Hinds Co.; Type DX as manufactured by O.Z. Gedney Co.; Type DF as manufactured by Appleton Electric Co., or equal
b. Conduit unions shall be provided in GRS-PVC and GRS runs to enable conduit assembly and disassembly.
8. Care shall be exercised to avoid interference with the work of other trades. This work shall be planned and coordinated with the other trades to prevent such interference. Process Pipe, mechanical and HVAC shall have precedence over conduits for routing and space requirements.
9. Seal each bottom entrance conduit into the MCC and other electrical enclosures with pliable plugging compound sealant to prevent the entrance of gasses, insects and rodents. Plugging compound sealant shall be Gardner Bender Duct Seal or equal.
10. Seal conduits where indicated from sewer wetwells in underground pullboxes with conduit cable seals. Furnish Roxtec RS UG, Crouse Hinds, or equal.
11. Exposed conduit stubs for future use shall be capped with coupling and plugged.
Drill hole in plug for pull rope as necessary.
12. Explosion proof seal-off fittings shall be provided on all conduits that enter or leave hazardous areas per requirements of the National Electrical Code, Chapter 5 and UL 886. The seal-off fitting shall prevent hazardous gases and/or flames from passing from one type area to another through the conduit system. Ceramic or other non-asbestos fiber material and sealing compound shall be placed in the fitting to complete the seal.
13. Hazardous location conduit outlet boxes shall be used in hazardous locations for change in direction, access to conductors and as pull and splice boxes.
14. All spare conduits shall have 1/8" nylon pull ropes installed.
C. Flexible Conduit and Cords
1. Final connections to vibrating equipment such as motors, heaters and fans shall be made with liquid tight flexible conduit.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
2. Flexible conduit lengths shall not be greater than 36 inches for sizes up to 2 ½” and 48 inches for 3” and larger conduit.
3. Flexible conduit shall include a ground conductor for equipment bonding in circuits over 30 VDC or as shown in the conduit schedule.
4. Flexible conduit shall only be installed in exposed or accessible locations.
5. Where equipment is cord connected, submersible rated, and conduit connections are not possible without modification, devices and equipment may be free-air cord connected in lieu of flexible conduit. Connection to adjacent rigid conduit shall be through liquid-tight cord connector fitting specifically designed for the purpose and sized appropriately for the cord. Cord connectors shall be rated similar to the adjacent conduit they are connected to: Stainless steel, galvanized or plastic.
D. Excavation and Layout:
1. Trenches for conduit below floor slabs and other underground electrical conduit shall be excavated to the required depths per utility requirements or specific detail. Conduits under floor slabs shall have minimum trench depth to contain bends without any portion of the radius visible at finished grade.
2. Provide minimum 1” space between conduits and lay conduits parallel to each other to the extent possible unless otherwise indicated in drawings and details.
3. Install spacers to support underground conduits. Horizontal and vertical separation shall be maintained by plastic spacers set every four feet. Spacers shall be Carlon Snap-Loc or equal.
4. Underground conduits outside of structures, excluding utility conduits, shall have a minimum cover of 24 inches except under roadways where minimum cover shall be 30 inches or as otherwise shown in the Contract Drawings. Back filling shall be done only after conduits have been inspected.
5. Excavation and back fill of conduits shall conform to the requirements herein and as indicated in drawing details unless otherwise noted. Conduits for other entities (Utilities, etc.) shall be as required and inspected by the governing entity.
6. At all times during the installation of the electrical system, the Contractor shall provide barricades, fences, guard rails, etc., to safeguard all personnel, including small children, from excavated trenches.
E. Backfill Material:
1. Backfill material shall be free of rocks greater than 1” in diameter and as noted in the drawing details or notes as indicated. If no backfill requirements are noted, then backfill shall be CLSM (Controlled low strength material) or sand slurry cement mix with 1000 to 1200 psi compressive strength.
2. Colored red with fifteen (15) pounds of red iron oxide No. 188 per cubic yard of concrete.
F. Underground pullboxes:
1. Pullboxes shall be located in areas that will experience the least traffic loading and in the general vicinity as shown in the Drawings. Boxes in pavement shall be set at final grade and boxes in planter areas shall be set 1” above final grade.
Boxes shall not be buried by landscape material.
2. Steel pull box lids shall be grounded per NEC 250.4(A)(5) and 314.4.
3. Boxes shall be set on compacted base and base rock to minimize settling of the box over time. If the box is located in a paved traffic area, a 6” x 6” concrete ring shall be poured around the box below the pavement. 516
CONDUIT AND BOXES 16110 - 11
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) G. Device Mounting Heights:
1. Mounting heights of fixtures and devices shall be as follows unless otherwise indicated or when height has to be adjusted to be over or under counter tops. a. Wall switches => 48 inches
b. Convenience outlets => 18 inches
c. Telephone outlets => 18 inches
d. Bracket fixtures => 7 feet 6 inches
H. Cutting, Coring, Patching and Repairing:
1. The Contractor shall do all cutting and patching required to install his work. Any cutting which may impair the structure will require prior approval. Cutting and patching shall be done only by skilled labor of the respective trades. Where it is becomes necessary to cut into existing work for the purpose of making electrical installations, locate existing post tension cables, rebar and electrical services prior to core drilling using ground penetrating radar or similar technologies. All surfaces shall be restored to their original condition after cutting and patching.
3.03 FIELD ASSISTANCE
A. General: Provide all equipment and supplies necessary to perform all testing. The Owner shall have the option to witness and participate in the on-site tests performed by the installer.
B. Per Electrical Specifications [Factory and Field Testing].
3.04 WARRANTY
A. Provide warranty as specified in Electrical Specifications [Electrical General, Warranty].
END OF SECTION
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) SECTION 16120
LOW VOLTAGE WIRE & DATA CABLE
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Labor, materials, equipment, tools, safety gear, test equipment, incidentals, services, and transportation for a complete electro-mechanical installation as shown on the Drawings, included in these Specifications, or as can be reasonably implied from project descriptions.
B. The scope of work includes:
1. Furnish and install wire, splices, lugs, or other miscellaneous devices as defined in this specification.
2. End to end wiring and terminations for each system, device, instrument, and piece of equipment shown in the Drawings as new, or rehabilitated, or reconnected.
3. Testing of conductors and completed wired systems.
4. Installations shall be designed and installed with components meeting the NEMA area designation.
C. Work includes that specified in Electrical Specifications [Electrical General].
1.02 REFERENCES
A. Electrical Specifications [Electrical General]
B. Electrical Specifications [Conduit and Boxes]
C. Electrical Specifications [Grounding]
D. Project Drawings
1.03 QUALIFICATIONS
A. Material furnished under this specification shall be installed by qualified installers meeting requirements specified in Electrical Specifications [Electrical General, Qualifications].
1.04 SUBMITTALS AND DRAWINGS
A. Provide submittals and drawings as specified in Electrical Specifications [Electrical General, Submittal Requirements].
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) PART 2 PRODUCTS
2.01 WIRING AND ELECTRICAL DEVICES
A. General
1. General
a. Provide wiring and electrical devices specified herein and install field and internal panel wiring as shown on the Contract Drawings. b. This section applies to all wires or conductors used internal (non-field) to electrical equipment or external for field wiring.
c. Field wire quantity and size shall be per “Conduit and Wire Routing Schedule.”
2. Analog Signals
a. Analog signal transmission between electric or electronic instruments shall be 4-20 milliamperes and shall operate at 24 volts DC unless otherwise specified. Milliampere signals shall be current regulated and shall not be affected by changes in load resistance within the unit's rating.
b. Provide powered current isolators wherever the loops’ load resistance exceeds the originating current signal transmitter's rating. Associated shunt resistors shall be located on rail-mounted terminal blocks.
Exposed resistor leads shall be insulated with heat-shrink tubing.
B. Low Voltage Wire and Cable (through 600V except instrument signals)
1. General: Low voltage conductors shall be used for power, control, lighting and miscellaneous circuits. This Section applies to all wires or conductors used internal for all electrical equipment or external for field wiring. Wire shall be new, plainly marked with UL label, gauge, voltage, type of insulation, and manufacturer's name.
a. Conductors shall be copper with a minimum of 98% conductivity. b. Control and instrument wiring shall have tinned copper conductors. c. Class C stranding. Solid conductors may be used for lighting and receptacle circuits.
d. Wire shall be rated 600 volt (min).
e. Size all conductors per NEC minimum and as shown on the drawings. 1) Minimum #12 AWG for wires used in power transmission circuits or as defined on the drawings.
2) Minimum #14 AWG for wires used in signal transmission circuits or as defined on the drawings.
2. Wire colors and sizes shall not change within the circuit.
3. Wire shall be properly fused or breaker protected at or below the maximum amperage rating allowed by the NEC.
4. Control and Power Wiring:
a. Field wire in conduit:
1) Type XHHW-2, XLPE insulation, color coded, rated 90 °C in wet or dry locations, oil resistant, UL44.
a) Use for power circuits carrying voltages higher than 200 volts phase to ground.
b) Color coded by phase and voltage per NEC and table
herein.
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) 2) Type THHN / THWN, nylon insulation with thermoplastic jackets, rated 90 °C in dry locations and 75 °C in wet locations, oil resistant, UL83 and UL1063.
a) Use for power circuits with voltages below 200 volts phase to ground, or control circuits.
b) Color coded by phase and voltage per NEC and table
herein.
3) Minimum #12 AWG for wires used in power transmission circuits or as defined on the drawings.
4) Minimum #14 AWG for wires used in signal transmission circuits or as defined on the drawings.
b. Non-field control panel or factory installed equipment internal wiring:
1) Insulation - PVC jacket, type TEW, MTW, color coded, UL1015 with tinned copper.
2) Option: Insulation – Nylon (polyamide) with thermoplastic cover, color coded, type THHN, THWN, MTW, UL 1063
3) Minimum #14 AWG for wires used for individual conductor circuits 100 volts and above.
4) Minimum #18 AWG for wires used for individual conductor circuits below 100 volts.
c. Field wire in tray (Tray Cable type TC):
1) Individual cables - Insulation type THHN/THWN, rated 90 °C in dry locations and 75 °C in wet locations, oil resistant, UL83. 2) 3 or more conductor plus ground wire in a single cable. 3) UL Listed as sunlight resistant, direct burial, and open wiring. 4) Conductor sizing per ICEA Publication P-54-440 for cable tray and ICEA P-46-426 for conduit
5) Minimum #12 AWG for wires used in power transmission circuits or as defined on the drawings.
6) Minimum #14 AWG for wires used in signal or control
transmission circuits or as defined on the drawings.
d. Power cord
1) Flexible wire cord shall be type SOW, SOOW, or G and be provided in 2, 3, or 4 conductor plus ground as required for connected load.
2) EPR insulation, 90 deg C rating, oil and abrasion resistant., overall jacket plus individual conductor jackets. 600V rated 3) Conductors shall be stranded copper.
4) Cord shall be installed with cord grips on each end where it enters termination enclosures.
5. Instrument wiring:
a. Field: Instrument cables shall have 600V tray cable rated insulation and 100% individual shielded twisted pair #18 (or #16 conductors) with drain wire. Single twisted shielded pair (TSPR) cables shall be Belden 9341 (or 9342), or approved equal. Three wire twisted shielded cables (#18 TS3W) shall be Belden 1036A, 1119A, or equal. See drawings for cable size required.
b. Non-Field: Instrument cables shall have 300V rated insulation and 100% individual shielded twisted pair #18 conductors with drain wire. Single twisted shielded pair (TSPR.) cables shall be Belden 8760, or approved equal. Three wire shielded cable shall be Belden 8770 or equal. 520
LOW VOLTAGE WIRE & DATA CABLE 16120 - 4
SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) c. Field multi-pair instrument cable as required per conduit schedule shall have 300V rated insulation and 100% individual shielded twisted pair #18 conductors with drain wire. Multiple twisted shielded pair (T.S.PR.) cables shall be Belden 9773 thru 9777, or equal.
d. Multi-pair cable is not allowed (unless specifically called out in conduit schedule or on plans) for use in field or non-field applications. One T.S.PR cable is required for each signal.
6. Manufacturer Supplied Cables
a. Cables and wiring for special systems provided by the manufacturer with the equipment shall be installed per the manufacturer's recommendations.
7. Data Cable
a. Data network category 6 cable (indoor) shall consist of 4 pair unshielded twisted pair #23 awg solid copper conductors. The cable shall be rated by IEEE for service intended – plenum and dry.
1) Cable: IEEE Category 6, various manufacturers.
2) Connectors: Standard RJ-45 with boot.
b. Data network cable (outdoor) shall consist of 4 pair foil and braid shielded twisted pair #24 awg solid copper conductors with anti-crosstalk divider, and drain wire. Rated Level 2 Category 6+ Outdoor Carrier by IEEE for use in plenum, conduit, wet or dry.
1) Cable: IEEE Category 6, Belden 2149a, or equal
2) Connectors: Grounded RJ-45 with drain wire crimp.
8. Temporary motor or panel hook-up
a. Temporary cable may be cord without conduit or PVC conduit with wiring. In either case, the cabling must be protected from damage during construction. Sections may be located out of harms way, buried, or sleeved in steel conduit as needed.
b. Power Circuits: Provide 2, 3, or 4 conductor plus ground power supply cable(s) for temporary pump connections or electrical power circuits.
Cables shall be sized for breaker rating amperage, (minimum). c. Provide multi-conductor (TC) cables for digital control circuits. Provide quantity of conductors as needed.
d. Provide instrument wiring for 4-20 ma instrumentation. e. Voltage drop in power circuits shall not exceed 15% during motor start and 5% during operation.
C. Color Code
1. All wires #8 and below shall have wire insulation the color specified. Wires #6 and larger may be black with color electrical tape at termination points.
2. No other colors shall be used without prior approval.
3. Color code color code of all wire shall conform with the following table:
WIRE COLOR CODE TABLE
Description Phase/Code
Letter
Field wire or tape color Non-Field Wire
Color
480V, 3 Ph A Brown Brown
B Orange Orange
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) C Yellow Yellow
240V or 208V, 3 Ph A Black -
B Red (Orange if high leg) -
C Blue -
Neutral White White
240 / 120 V, 1 Ph L1 Black Black
L2 Red -
24V Positive 24+ Blue Pink
24V Negative 24- Gray Gray
12V Positive 12+ Blue Red
12V Negative 12- Black Black
AC Control Red Red (Yellow for
foreign circuits)
DC Control Blue Blue
Ground G Green Green
Shielded Pair + Red, Clear, or White Clear or White
- Black Black
2.02 WIRE MARKING
A. All panel, enclosure and field wiring shall have wire labels on both ends of each wire.
Labeling shall be neatly installed for visibility and shall be clearly legible. Each conductor of instrument shielded signal wiring shall be labeled. Wire labels shall be machine printed with on white heat shrinkable tubing. Each label shall fit a minimum 23 characters, 3/16” in height before shrink. Tubing shall be oversized for the wire and shrunk into place using an electric heat gun. The “shrunk” label shall have just enough give to allow the label to be rotated. Hand lettered wire labels are not acceptable and shall be replaced at the Contractor's expense. Provide Brady “PermaSleeve” or equal.
1. Node Style Wire Identification All wires that are electrically the same (connected to common termination points) and do not pass through a contact or other switching device shall have the same wire identification. The wire labeling code for each end of the same wire shall be identical.
a. The wire identification code for internal panel wiring shall be the number/letter as designated on the Drawing elementary and/or approved shop drawings.
b. Wire labeling for field wiring shall contain the field equipment name/tag as a prefix and the pupose. (I.E. FIT071-+ and FIT071-- or P10-124) where + or 124 are the field device terminal block name or purpose. The hierarchy of prefix label names is 1) Instrument Tag, 2) Electrical panel or equipment name, and 3) Equipment name. Therefore, wires from MCC50 P10 cubicle to PLC10 will be labeled MCC50-P10-xx where xx is the terminal number or the purpose. Wires from field pressure switch 522
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645) PSH10 to MCC50 P10 will be labeled PSH-10-xx where xx is the PSH terminal block name.
c. Wire labels shall be per control panel submittal and/or interconnection submittal drawings using rules described above – Wire labels must be documented prior to printing and before they are applied. Abbreviations may be used in the wire label as long as they are consistent and understandable.
d. Wire labels for lighting and receptacle circuits shall consist of the panel board and circuit number and a unique node number. (I.E. LP#3-A, LP#3-B, LP#3-N)
e. Wire labels may be omitted on “neutral jumpers” less than 8” in length. f. Wire labelling shall be documented and revised on drawings to as-built conditions.
2.03 ELECTRICAL TAPE / SHRINKABLE INSULATORS
A. Vinyl tape shall be 7 mil, 600 volt rated, flame retardant, hot and cold weather resistant conforming to UL510. Provide 3M Scotch Super 33+ vinyl tape or equal
1. Vinyl tape for color coding shall be 7 mil, ¾” width, vinyl tape conforming to UL 510. Provide 3M Scotch 35 vinyl tape or equal.
B. Rubber Tape: EPR rubber, 90 deg C continuous rated. Provide 3M 130C rubber tape or equal.
C. Varnished Cambric Tape: Adhesive backed, 7 mil, bias cut cotton tape, coated with yellow insulating varnish. Provide 3M Scotch 2510 or equal.
D. Shrinkable insulators shall be heat shrinkable, polyolefin thick wall sleeves, end caps and cable repair sleeves are designed for use in splicing, sealing and re-jacketing of direct bury secondary cables. The insulators shall comply with UL 486D and be rated up to 1000 Volts. They shall provide long-term reliable performance overhead, underground or submerged with mechanical and environmental protection. Shrinkable insulators shall be 3M ITCSN or 3M IMCSN per manufacturer instructions for the application or equal.
PART 3 EXECUTION
3.01 WORKMANSHIP
A. All work in this Section shall conform to the codes and standards specified in Electrical Specifications [Electrical General, Workmanship].
B. Perform work to remedy non-compliant installations after inspection.
C. Upon notification, stop work on any portion of the installation that is determined to be substandard or being installed by unqualified personnel.
3.02 FABRICATION AND INSTALLATION
A. System:
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SAN JUAN PUMP STATION & FORCE MAIN REHABILITATION PROJECT (CCN 2026-645)
1. Install all products specified in Electrical Specifications [Electrical General, Installation].
2. Panels shall be completely factory wired and tested before shipment.
3. All spare PLC input / output points shall be wired to terminal blocks.
4. A minimum of 20% spare unwired terminals shall be provided in each panel.
B. Wiring Methods:
1. Wiring Separation: Wires carrying 100 volts and above shall be physically separated from lower voltage wiring by using separate bundles or wire ways with sufficient distance to minimize the introduction of noise, crossing only at 90 degree angles.