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B. Store concrete reinforcement material at the site to prevent damage and accumulation of dirt or excessive rust. Store on heavy wood blocking so that no part of it will come in contact with the ground.
PART 2 - PRODUCTS
2.1 MATERIALS
A. Reinforcing Bars: Provide ASTM A615 Grade 60 for all bars except for welded bars which shall conform to ASTM A706.
B. Steel Wire: ASTM A82.
C. Welded Smooth Wire Fabric: ASTM A185.
1. Furnish in flat sheets, not rolls.
D. Supports for Reinforcement: Bolsters, chairs, spacers and other devices for spacing, supporting and fastening reinforcement in place.
1. Use wire bar type supports complying with CRSI recommendations, except as specified below. Do not use wood, brick, or other unacceptable materials.
2. For slabs on grade, use precast concrete blocks.
3. For all concrete surfaces, where legs of supports are in contact with forms, provide supports complying with CRSI "Manual of Standard Practice", with either hot-dip galvanized, plastic protected or stainless steel legs.
2.2 FABRICATION
A. General: Fabricate reinforcing bars to conform to required shapes and dimensions, with fabrication tolerances complying with CRSI, Manual of Standard Practice. In case of fabricating errors, do not re-bend or straighten reinforcement in a manner that will injure or weaken the material.
B. Unacceptable Materials: Reinforcement with any of the following defects will not be permitted in the Work:
1. Bar lengths, bends, and other dimensions exceeding specified fabrication tolerances.
2. Bends or kinks not shown on approved Shop Drawings.
3. Bars with reduced cross-section due to excessive rusting or other cause.
PART 3 - EXECUTION
3.1 INSPECTION
A. CONTRACTOR and his installer shall examine the substrate and the conditions under which concrete reinforcement is to be placed, and notify CONSTRUCTION MANAGER
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in writing of unsatisfactory conditions. Do not proceed with the Work until unsatisfactory conditions have been corrected in a manner acceptable to CONSTRUCTION MANAGER.
3.2 INSTALLATION
A. Placing: Reinforcing steel shall be accurately positioned as shown on the Drawings, and shall be supported and wired together to prevent displacement, using annealed iron wire ties or suitable clips at intersections. All reinforcing steel shall be supported by concrete or metal supports, spacers or metal hangers. Where concrete is to be placed on the ground, supporting concrete blocks (or dobbies) shall be used, in sufficient numbers to support the continuous length of the steel. For concrete over formwork, the CONTRACTOR shall furnish concrete, metal, plastic, or other acceptable bar chairs and spacers.
B. Where the concrete surface will be exposed to the weather in the finished structure or where rust would impair architectural finishes, the portions of all accessories in contact with the formwork shall be galvanized or shall be made of plastic.
C. Tie wires shall be bent away from the forms in order to provide the specified concrete coverage. Bars additional to those shown on the Drawings which may be found necessary or desirable by the CONTRACTOR for the purpose of securing reinforcement in position shall be provided by the CONTRACTOR at its own expense.
D. Placing Tolerances: Unless otherwise specified, reinforcement placing tolerances shall be within the limits specified in Section 7.5 of ANSI/ACE 318 except where in conflict with the requirements of the Building Code.
E. Bars may be moved as necessary to avoid interference with other reinforcing steel, conduits, or embedded items. If bars are moved more than one bar diameter, or enough to exceed the above tolerances, the resulting arrangement of bars shall be acceptable to the CONSTRUCTION MANAGER.
F. Welded wire fabric reinforcement placed over horizontal forms shall be supported on slab bolsters having gray, plastic-coated standard type legs. Slab bolsters shall be spaced not less than 30 inches on centers, shall extend continuously across the entire width of the reinforcing mat, and shall support the reinforcing mat in the plane shown on the Drawings.
G. Bar Tying: Bars shall be tied sufficiently often to prevent shifting. There shall be at least three ties in each bar length (this shall not apply to dowel laps or to bars shorter than 4 feet, unless necessary for rigidity). Slab bars shall be tied at every intersection around the periphery of the slab. Wall bars and slab bar intersections shall be tied at not less than every fourth intersection, but at not greater than the following maximum spacing:
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Slab Bars Wall Bars
(inches) (inches)
Bars No. 5 and smaller 60 48
Bars No. 6 through No. 9 96 60
Bars No. 10 through No. 11 120 96
H. Where concrete surfaces shall be core-drilled to install sockets for handrail, reinforcing steel shall be placed to coordinate with handrail socket locations.
3.3 SPACING OF BARS
A. The clear distance between parallel bars (except in columns and between multiple layers of bars in beams) shall be not less than the nominal diameter of the bars nor less than 1- 1/3 times the maximum size of the coarse aggregate, nor less than one inch.
B. Where reinforcement in beams or girders is placed in 2 or more layers, the clear distance between layers shall be not less than one inch.
C. In spirally-reinforced and in tied columns, the clear distance between longitudinal bars shall be not less than 1-1/2 times the bar diameter, nor less than 1-1/2 times the maximum size of the coarse aggregate, nor less than 1-1/2 inches.
3.4 SPLICING
A. General: Reinforcing bar splices shall only be used at locations shown on the Drawings.
When it is necessary to splice reinforcement at points other than where shown, the character of the splice shall be acceptable to the CONSTRUCTION MANAGER.
Welded splices shall conform to the requirements of Part 4 of this Section.
B. Splices of Reinforcement: The length of lap for reinforcing bars, unless otherwise shown on the Drawings shall be in accordance with ACI 318.
C. When shown on the Drawings, welded splices and mechanical connections shall develop at least 125 percent of the specified yield strength of the bar in tension.
D. Laps of welded wire fabric shall be in accordance with the ACI 318. Adjoining sheets shall be securely tied together with No. 14 tie wire, one tie for each 2 running feet. Wires shall be staggered and tied in such a manner that they cannot slip.
E. Splices in column spiral reinforcement, when necessary, shall be made by welding or by a lap of 1-1/2 turns.
F. Bending or Straightening: Reinforcing shall not be straightened or rebent in a manner, which will injure the material. Bars with kinks or bends not shown on the Drawings shall not be used. All bars shall be bent cold, unless otherwise permitted by the CONSTRUCTION MANAGER. No bars partially embedded in concrete shall be fieldPage 301 of 1513 Section 03200
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bent except as shown on the Drawings or specifically permitted by the CONSTRUCTION MANAGER.
3.5 CONCRETE COVER
A. On all formed surfaces there shall be a nominal cover over the steel of two (2) inches minimum.
B. Unless otherwise specified in these specifications or shown on the Drawings, all reinforcing steel facing subgrades in footing and floors for concrete construction shall be given a nominal protective cover of three (3) inches.
C. No ìburyî or ìcarrierî bars will be allowed unless specifically approved by the CONSTRUCTION MANAGER.
3.6 CLEANING AND PROTECTION
A. Reinforcing steel shall at all times be protected from moisture until concrete is placed around it.
B. The surfaces of all reinforcing steel and other metalwork to be in contact with concrete shall be thoroughly cleaned of all dirt, grease, loose scale and rust, grout, mortar and other foreign substances immediately before the concrete is placed. Where there is delay in depositing concrete, reinforcing shall be reinspected and, if necessary recleaned.
3.7 INSPECTION OF REINFORCEMENT
Concrete shall not be placed until the reinforcing steel is inspected and permission for placing concrete is granted by the CONSTRUCTION MANAGER. All concrete placed in violation of this provision will be rejected.
3.8 MECHANICAL COUPLERS
A. Mechanical couplers shall be provided where shown and where approved by the CONSTRUCTION MANAGER. The couplers shall develop a tensile strength, which exceeds 125 percent of the yield strength of the reinforcement bars being spliced at each splice.
B. Where the type of coupler used is composed of more than one component, all components required for a complete splice shall be supplied. This shall apply to all mechanical splices, including those splices intended for future connections.
C. The reinforcement steel and coupler used shall be compatible for obtaining the required strength of the connection. Straight threaded type couplers shall require the use of the next larger size reinforcing bar or shall be used with reinforcing bars with specially forged ends which provide upset threads which do not decrease the basic cross section of the bar.
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PART 4 - APPENDIX TO SECTION 03200
These specifications shall apply to the welding of reinforcing steel for splices, steel connection devices, inserts, anchors and anchorage details, as well as any other welding of reinforcing steel both in the fabricating shop and in the field. When welding reinforcing steel to primary structural members, the provisions of AWS D1.1 shall also be fully satisfied. Reinforcing steel may be subject to cracking the embrittlement when welded, and special procedures are needed to minimize this problem. These are minimum specifications and shall not supersede any more restrictive specifications shown on the approved plans.
4.1 STANDARDS FOR WELDING
A. The details, procedures, workmanship and technique of reinforcing steel welding shall be in accordance with the requirements of the Reinforcing Steel Welding Code, AWS D1.4- 98 as published by the American Welding Society.
B. All welding shall be performed in accordance with the requirements of an approved procedure specification.
4.2 APPROVED PROCEDURES
A. Each joint welding procedure for reinforcing bar splices, bar connections, and insert connections that are to be employed shall be established in a procedure specification and shall be qualified prior to use by tests as prescribed in AWS D1.4-98.
B. Procedure qualification tests shall be witnessed by a registered special inspector in structural steel assembly and tested by an approved testing agency. The results of successful procedure qualification tests and the approved procedure specifications shall be submitted to the CONSTRUCTION MANAGER.
C. The approved procedure specifications shall be made available at the site where welding is performed.
4.3 WELDER QUALIFICATION
A. All welders to be employed in welding reinforcing bars shall have been qualified by tests as prescribed in AWS D1.4-98, unless evidence of previous qualification is accepted by the CONSTRUCTION MANAGER and the Registered Special Inspector.
B. Welder qualification tests shall be witnessed by a Registered Special Inspector in structural steel assembly.
C. Upon request of the Registered Special Inspector or the CONSTRUCTION MANAGER, welders shall provide evidence of qualification for each process, position and type of weld to be performed.
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4.4 SPECIAL INSPECTION (PERFORMED BY THE OWNER)
A. Special inspection for reinforcing steel welding shall be provided by a special inspector certified to inspect structural steel assembly.
B. The special inspector shall provide continuous inspection for all reinforcing steel welding.
C. Special inspection is required for reinforcing steel welding performed on the site (field) and off site (shop).
4.5 GENERAL
A. Arc strikes on reinforcing steel outside the area of permanent welds shall be avoided.
B. Tack welds shall be made using preheat and quality requirements applicable to permanent welds. Tack welds that do not become a part of permanent welds are prohibited. Under no circumstances should stressed bars be tack welded along their length. ** END OF SECTION **
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SECTION 03251
CONCRETE JOINTS
PART 1 - GENERAL
1.1 WORK OF THIS SECTION
A. Scope
1. CONTRACTOR shall provide all labor, materials, equipment and incidentals as shown, specified and required to furnish and install concrete joints.
2. The types of concrete joints required include the following:
a. Construction joints.
b. Waterstops.
B. General: All joints subject to hydrostatic pressure shall be provided with continuous waterstop.
C. Related Sections:
1. Section 03100, Concrete Form Work.
2. Section 03300, Cast-In-Place Concrete.
1.2 QUALITY ASSURANCE
A. Reference Standards: Comply with applicable provisions and recommendations of the following, except as otherwise shown or specified:
1. ACI 301, Specifications for Structural Concrete.
2. ACI 318, Building Code Requirements for Structural Concrete
3. ACI 350, Code Requirements for Environmental Engineering Concrete Structure
4. ASTM A 36, Structural Steel.
5. ASTM D 1752, Preformed Expansion Joint Fillers for Concrete Paving and Structural Construction.
6. CRD-C572, Corps of Engineers Specifications for Polyvinyl- Chloride Waterstop.
7. ASTM Cellular Elastomeric Preformed Gasket and Sealing Materials.
B. Waterstop Inspection: It is required that all waterstop field joints shall be subject to rigid inspection, and no such work shall be scheduled or started without having made prior arrangements with the CONSTRUCTION MANAGER to provide for the required inspections. Not less than 24 hoursí notice shall be provided to the CONSTRUCTION MANAGER for scheduling such inspections.
C. All field joints in waterstops will be subject to rigid inspection for misalignment, bubbles, inadequate bond, porosity, cracks, offsets, and other defects which would reduce the
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potential resistance of the material to water pressure at any point. All defective joints shall be replaced with material which will pass said inspection, and all faulty material shall be removed from the site and disposed of by the CONTRACTOR at its own expense.
D. The following defects represent a partial list of defects, which shall be grounds for rejection:
1. Offsets at joints greater than 1/32 inch or 15 percent of material thickness, at any point, whichever is less.
2. Exterior crack at joint, due to incomplete bond, which is deeper than 1/32 inch at any point.
3. Any combination of offset or exterior crack which will result in a net reduction in the cross section of the waterstop in excess of 1/32 inch or 15 percent of material thickness at any point, whichever is less.
4. Misalignment of joint, which result in misalignment of the waterstop in excess of ½ inch in 10 feet.
5. Porosity in the welded joint as evidenced by visual inspection.
6. Bubbles or inadequate bonding, which can be detected with a penknife test. (If, while prodding the entire joint with the point of a penknife, the knife breaks through the outer portion of the weld into a bubble, the joint shall be considered defective).
E. Waterstop Samples: Prior to use of the waterstop material in the field, a sample of a fabricated mitered cross and a tee constructed of each size or shape of material to be used shall be submitted to the CONSTRUCTION MANAGER for review. These samples shall be fabricated so that the material and workmanship represent in all respects the fittings to be furnished under this contract. Field samples of fabricated fittings (crosses, tees, etc.) will be selected at random by the CONSTRUCTION MANAGER for testing by a laboratory at the OWNERís expense. When tested, they shall have a tensile strength across the joints equal to at least 600 psi.
F. Construction Joint Sealant: The CONTRACTOR shall prepare adhesion and cohesion test specimens as specified herein, at intervals of 5 working days while sealants are being installed.
G. The sealant material shall show no signs of adhesive or cohesive failure when testing in accordance with the following procedure in laboratory and field tests:
1. Sealant specimen shall be prepared between 2 concrete blocks (1-inch by 2-inch by 3-inch). Spacing between the blocks shall be ½-inch. Coated spacers (2-inch by 1 ½-inch by ½-inch) shall be used to insure sealant cross-sections of ½-inch by 2- inches with a width of ½-inch.
2. Sealant shall be cast and cured according to manufacturerís recommendations except that curing period shall not exceed 24 hour.
3. Following curing period, the gap between blocks shall be widened to 1 inch.
Spacers shall be used to maintain this gap for 24 hours prior to inspection for failure.
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H. All manufactured items shall be installed in accordance with manufacturer's instructions.
1.3 SUBMITTALS
A. Samples: Submit for approval the following:
1. Polyvinyl chloride waterstops for joints, including a fabricated mitered cross and a tee constructed of each size or shape of material to be used.
2. Preformed plastic adhesive waterstop.
3. Construction joint sealant.
4. Field samples of fabricated fittings (crosses, tees, etc.) selected at random by the CONSTRUCTION MANAGER for testing by a laboratory at the OWNERís expense (Minimum tensile strength across the joint equal to at least 600 psi).
B. Shop Drawings: Submit for approval the following:
1. Manufacturer's specifications and installation instructions for all materials required.
2. Layout of all construction joint locations prior to the submittal of steel reinforcing drawings.
C. Certifications: Submit the following:
1. Certified test reports from the sealant manufacturer on the actual batch of material being supplied indicating compliance with the above requirements shall be furnished the CONSTRUCTION MANAGER before the sealant is used on the job.
2. Shipping Certification: The CONTRACTOR shall provide written certification from the manufacturer as an integral part of the shipping form, to show that all of the material shipped to this project meets or exceeds the physical property requirements of the Contract Documents. Supplier certificates are not acceptable.
1.4 TYPES OF JOINTS
A. Construction Joints: When fresh concrete is placed against a hardened concrete surface, the joint between the two pours is called a construction joint. When required on the Drawings, such a joint will be provided with a waterstop and/or sealant groove of the shape specified and detailed on the Drawings. The surface of the first pour may also be required to receive a coating of bond breaker as called for on the detail Drawings.
B. Weakened Plane Joints: The function of the weakened plane joint is to provide a weaker plane in the concrete, where shrinkage cracks will probably occur. A groove, of the shape and dimensions shown on the Drawing, is formed or saw-cut in the concrete. This groove is afterward filled with a joint sealant material as specified in Subsection 2.6 ìJoint Sealant.î
1.5 GUARANTEE
The CONTRACTOR shall provide a 5-year written guarantee of the entire sealant installation against faulty and/or incompatible materials and workmanship, together with
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a statement that it agrees to repair or replace, to the satisfaction of the OWNER, at no additional cost to the OWNER, any such defective areas which become evident within said 5-year guarantee period.
PART 2 - PRODUCTS
2.1 GENERAL
All joint materials specified herein shall be classified as acceptable for potable water use by the Environmental Protection Agency, within 30 days of application.
2.2 WATERSTOPS
A. General: Waterstops shall be extruded from an elastomeric polyvinylchloride compound containing the plasticizers, resins, stabilizers, and other materials necessary to meet the requirements of these Specifications. No reclaimed or scrap material shall be used. The CONTRACTOR shall obtain from the waterstop manufacturer and shall furnish to the CONSTRUCTION MANAGER for review, current test reports and a written certification of the manufacturer that the material to be shipped to the job meets the physical requirements as outlined in the U.S. Army Corps of Engineers Specification CRD-C572 and listed in Paragraph E, below.
B. Flatstrip Waterstops: Flatstrip waterstops shall be as detailed and as manufactured by:
Kirkhill Rubber Co., Brea, California; Water Seals, Inc., Chicago, Illinois; Progress Unlimited, Inc., New York, New York; Vinylex Corporation; Greenstreak, or equal; provided, that at no place shall the thickness of flatstrip waterstops be less than 3/16 inch.
C. Preformed Plastic Adhesive Waterstop: Preformed plastic adhesive waterstops shall be used where indicated. Waterstop shall be as detailed and manufactured by SYNKOFLEX or SIKA.
D. Waterstop Testing Requirements: When tested in accordance with the specified test standards, the waterstop material shall meet or exceed the following requirements:
Physical Property, Sheet Material Value ASTM Std.
Tensile Strength-min (psi)
Ultimate Elongation-min (percent)
Low Temp. Brittleness-Max
(degrees F)
Stiffness in Flexure-min (psi)
2000
350
-35
400
D 638-82a, Type IV
D638-82a, Type IV
D 746-79
D 747-70 (1981)
Accelerated Extraction (CRD-C572)
Tensile Strength-min (psi)
Ultimate Elongation-min (percent)
1500
300
D 638-82a, Type IV
D 638-82a, Type IV
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Effect of Alkalies (CRD-C572)
Change in Weight (percent) +0.25/-0.10 -----
Finish Waterstops
Tensile Strength (psi)
Ultimate elongation (percent)
Shore hardness
Specific gravity
Stiffness in flexure (psi)
Cold brittleness (F)
Water absorption: 48 hours
Tear resistance (lb/in)
2,000
350
75 5
1.3 1300
-35°
.32% max.
290
(ASTM D-412)
(ASTM D-412)
(ASTM D-2240)
(ASTM D-792)
(ASTM D-747)
(ASTM D-746)
(ASTM D-570)
(ASTM D-624)
2.3 NOT USED
2.4 CONCRETE CONSTRUCTION JOINT ROUGHENER
A. Provide a water-soluble non-flammable, surface-retardant roughener.
B. Product and Manufacturer: Provide one of the following:
1. Rugasol-S by Sika Corporation for horizontal joints only.
2. EAC-S by Preco Industries, Ltd. for horizontal joints only.
3. Tuf-Cote (Deep Etch) by Preco Industries Ltd. for vertical joints.
4. Or equal.
2.5 EPOXY BONDING AGENT
A. Where indicated, provide an epoxy-resin bonding agent, two-component type.
B. Product and Manufacturer: Provide one of the following:
1. Sikadur 32 Hi-Mod LPL by Sika Corporation.
2. Eucopoxy LPL by the Euclid Chemical Company.
3. Or equal.
2.6 JOINT SEALANT
A. Joint sealant shall be polyurethane polymer designed for bonding to concrete which is continuously submerged in potable water. No material will be acceptable which has an unsatisfactory history as to bond or durability when used in the joints of water retaining structures.
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B. Joint sealant material shall meet the following requirements:
Work Life @ 75° 4 hours
Cure Time @ 40° 5 days maximum
w/ primer
Ultimate Hardness 30 - 40 Shore "A"
Tensile Strength 150 psi, minimum
Ultimate Elongation 500 percent, minimum
Tear Resistance (Die C 75 pounds per inch of
ASTM D 624) thickness, minimum
Color Light Gray
C. All polyurethane sealants for waterstop joints in concrete shall conform to the following requirements:
1. Sealant shall be 2-part polyurethane with the physical properties of the cured sealant conforming to or exceeding the requirements of ANSI/ASTM C 920 or Federal Specification TT-S-00227 E(3) for 2-part material, as applicable.
2. For sloping joints, vertical joints and overhead horizontal joints, only ìnon-sagî compounds shall be used; all such compounds shall conform to the requirements of ANSI/ASTM C 920 Class 12-1/2, or Federal Specification TT-S-0027 E(3), Type II.
3. For plane horizontal joints, the self-leveling compounds which meet the requirements of ANSI/ASTM C 920 Class 25, or Federal Specification TT-S-0027 E(3), Type I shall be used. For joints subject to either pedestrian or vehicular traffic, a compound providing non-tracking characteristics, and having a Shore ìAî hardness range of 25 to 35, shall be used.
4. Primer materials, if recommended by the sealant manufacturer, shall conform to the printed recommendations of the sealant manufacturer.
D. All sealants, wherever shown on the Drawings or required hereunder shall be Rubbercalk 2101 or 220 as manufactured by Products Research Company; GS 102 or GS 1102 as manufactured by Federal Sealants Corp.; Pacific Polymers Elasto-Thane Type 227R, or equal.
2.7 BACKING ROD
Backing rod, where indicated, shall be an extruded closed-cell, polyethylene foam rod.
The material shall be compatible with the joint sealant material used and shall have a tensile strength of not less than 40 psi and a compression deflection of approximately 25 percent at 8 psi. The rod shall be 1/8-inch larger in diameter than the joint width except that a one-inch diameter rod shall be used for a 3/4-inch wide joint.
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2.8 BOND BREAKER
Bond breaker shall be Super Bond Breaker as manufactured by Burke Company, San Mateo, California; Hunt Process 225-TU as manufactured by Hunt Process Company, Santa Fe Springs, California; Select Cure CRB as manufactured by Select Products Co., Upland, California; or equal. It shall contain a fugitive dye so that areas of application will be readily distinguishable.
PART 3 - EXECUTION
3.1 GENERAL
A. Unless otherwise shown on the Drawings, waterstops of the type specified herein shall be embedded in the concrete across joints as shown. All waterstops shall be fully continuous for the extent of the joint. Splices necessary to provide such continuity shall be accomplished in conformance to printed instructions of manufacturer of the waterstops. The CONTRACTOR shall take suitable precautions and means to support and protect the waterstops during the progress of the WORK and shall repair or replace at its own expense any waterstops damaged during the progress of the WORK. All waterstops shall be stored so as to permit free circulation of air around the waterstop material.
B. When any waterstop is installed in the concrete on 1 side of a joint, while the other half or portion of the waterstop remains exposed to the atmosphere for more than 2 days, suitable precautions shall be taken to shade and protect the exposed waterstop from direct rays of the sun during the entire exposure and until the exposed portion of the waterstop is embedded in concrete.
3.2 SPLICES IN WATERSTOPS
A. Splices in waterstops shall be performed by heat-sealing the adjacent waterstop sections in accordance with the manufacturerís printed recommendations. It is essential that:
1. The material not be damaged by heat sealing.
2. The splices have a tensile strength of not less than 60 percent of the unspliced materialís tensile strength.
3. The continuity of the waterstop ribs and of its tubular center axis be maintained.
B. Butt joints of the ends of 2 identical waterstop sections may be made while the material is in the forms.
C. All joints in waterstop involving more than 2 ends to be jointed together, and all joints which involve an angle cut, alignment change, or the joining of 2 dissimilar waterstop sections shall be prefabricated by the CONTRACTOR prior to placement in the forms, allowing not less than 24-inch long strips of waterstop material beyond the joint. Upon being inspected and approved, such prefabricated waterstop joint assemblies shall be
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installed in the forms and the ends of the 24-inch strips shall be butt welded to the straight run portions of waterstop in place in the forms.
3.3 JOINT CONSTRUCTION
A. Setting Waterstops: In order to eliminate faulty installation that may result in joint leakage, particular care shall be taken of the correct positioning of the waterstops during installation. Adequate provisions must be made to support the waterstops during the progress of the WORK and to insure the proper imbedment in the concrete. The symmetrical halves of the waterstops shall be equally divided between the concrete pours at the joints. The center axis of the waterstops shall be coincident with the joint openings. Maximum density and imperviousness of the concrete shall be insured by thoroughly working it in the vicinity of all joints.
B. In placing flat-strip waterstops in the forms, means shall be provided to prevent them from being folded over by the concrete as it is placed. Horizontal waterstops shall be held in place with continuous supports to which the top edge of the waterstop shall be tacked.
Unless otherwise shown, vertical waterstops shall be held in place with light wire ties on 12-inch centers, which shall be passed through the edge of the waterstop and tied to the curtain of reinforcing steel. In placing concrete around waterstops, concrete shall be worked under the waterstops by hand so as to avoid the formation of air and rock pockets.
C. Joint Preparation: Construction joints shall be provided where shown on the Drawings.
Special care shall be used in preparing concrete surfaces at joints where bonding between 2 sections of concrete is required. Unless otherwise shown on the Drawings, such bonding will be required at all horizontal joints in walls. Surfaces shall be prepared in accordance with the requirements of Section 03300 ìCast-in-Place Concrete.î Except on horizontal wall construction joints, wall to slab joints or where otherwise shown or specified, at all joints where waterstops are required, the joint face of the first pour shall be coated with a bond breaker as specified herein.
D. Adequate means shall be provided for anchoring the waterstop in concrete. Waterstops shall be positioned so that they are equally embedded in the concrete on each side of the joint.
E. Sealant application shall be in accordance with the manufacturerís printed instructions.
The surfaces of the groove for the sealant shall not be coated. Concrete next to waterstops shall be placed in accordance with the requirements of Section 03300 ìCastin-Place Concrete.î F. Construction Joint Sealant: Where shown, construction joints in floor slabs shall be provided with tapered grooves, which shall be filled with a construction joint sealant.
The material used for forming the tapered grooves shall be left in the grooves until just before the grooves are cleaned and filled with joint sealant. After removing the forms from the grooves, all laitance and fins shall be removed, and the grooves shall be sandblasted. The grooves shall be allowed to become thoroughly dry, after which they
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shall be blown out; immediately thereafter, they shall be primed and filled with the construction joint sealant. The primer used shall be supplied by the same manufacturer supplying the sealant. No sealant will be permitted to be used without a primer. Care shall be used to completely fill the sealant grooves. Areas designated to receive a sealant filler shall be thoroughly cleaned, as outlined for the tapered grooves, prior to application of the sealant.
G. The primer and sealant shall be placed strictly in accordance with the printed recommendations of the manufacturer, taking special care to properly mix the sealant prior to application. All sealant shall cure at least 7 days before the structure is filled with water.
H. All sealant shall be installed by a competent waterproofing specialty contractor who has a successful record of performance in similar installations. Before work is commenced, the crew doing the WORK shall be instructed as to the proper method of application by a representative of the sealant manufacturer.
I. Thorough, uniform mixing of 2-part, catalyst-cured materials is essential; special care shall be taken to properly mix the sealer before its application. Before any sealer is placed, the CONTRACTOR shall arrange to have the crew doing the WORK carefully instructed as to the proper method of mixing and application by a representative of the sealant manufacturer.
J. Any joint sealant which, after the manufacturerís recommended curing time for the job conditions of the WORK hereunder, fails to fully and properly cure shall be completely removed; the groove shall be thoroughly sandblasted to remove all traces of the uncured or partially cured sealant and primer, and shall be re-sealed with the specified joint sealant. All costs of such removal, joint treatment, re-sealing, and appurtenant work shall be at the expense of the CONTRACTOR.
** END OF SECTION **
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SECTION 03300
CAST-IN-PLACE CONCRETE
PART 1 - GENERAL
1.1 WORK OF THIS SECTION
A. Scope:
1. CONTRACTOR shall provide all labor, materials, equipment and incidentals as shown, specified and required to furnish and install cast-in-place concrete.
2. The Work includes providing concrete consisting of Portland cement, fine and coarse aggregate, water, and approved admixtures; combined, mixed, transported, placed, finished and cured. The Work also includes:
a. Providing openings in concrete to accommodate the Work under this and other Sections and building into the concrete all items such as sleeves, frames, anchor bolts, inserts and all other items to be embedded.
B. Coordination:
1. Review installation procedures under other Sections and coordinate the installation of items that must be installed in the concrete.
C. Related Sections:
1. Section 03100, Concrete Formwork.
2. Section 03200, Concrete Reinforcement.
3. Section 03251, Concrete Joints.
1.2 QUALITY ASSURANCE
A. Reference Standards: Comply with the applicable provisions and recommendations of the following, except as otherwise shown or specified.
1. ACI 211.1, Recommended Practice for Selecting Proportions for Normal and Heavyweight Concrete.
2. ACI 214, Recommended Practice for Evaluation of Compression Test Results of Field Concrete.
3. ACI 301, Specifications for Structural Concrete.
4. ACI 304, Recommended Practice for Measuring, Mixing, Transporting and Placing Concrete.
5. ACI 305, Recommended Practice for Hot Weather Concreting.
6. ACI 306, Recommended Practice for Cold Weather Concreting.
7. ACI 309, Recommended Practice for Consolidation of Concrete.
8. ACI 311, Recommended Practice for Concrete Inspection.
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9. ACI 318, Building Code Requirements for Reinforced Concrete.
10. ACI 350R, Environmental Engineering Concrete Structures.
11. AASHTO M 182, Burlap Cloth Made From Jute or Kenaf.
12. The California Building Code (CBC) of the International Conference of Building Officials (ICBO), latest edition.
13. ACI 315, Details and Detailing of Concrete Reinforcement.
14. ACI 347, Recommended Practice for Concrete Formwork.
15. ACI 117, Standard Tolerances for Concrete Construction and Materials.
B. Concrete Testing Service
1. CONTRACTOR shall employ, at his own expense, a testing laboratory experienced in design and testing of concrete materials and mixes to perform material evaluation tests and to design concrete mixes.
a. Testing agency shall meet the requirements of ASTM E 329. b. Selection of a testing laboratory is subject to CONSTRUCTION MANAGER'S approval.
c. Submit a written description of the proposed concrete testing laboratory giving qualifications of personnel, laboratory facilities and equipment, and other information that may be requested by CONSTRUCTION MANAGER.
2. Materials and installed Work may require testing and retesting, as directed by CONSTRUCTION MANAGER, at any time during the progress of the Work.
Allow free access to material stockpiles and facilities at all times. Tests not specifically indicated to be done at OWNER'S expense, including the retesting of rejected materials and installed Work, shall be done at CONTRACTOR'S expense.
C. Qualifications of Water-Reducing Admixture Manufacturer:
1. Water-reducing admixtures shall be manufactured under strict quality control in facilities operated under a quality assurance program. CONTRACTOR shall furnish copy of manufacturer's quality assurance handbook to document the existence of the program. Manufacturer shall maintain a concrete testing laboratory which has been approved by the Cement and Concrete Reference Laboratory at the Bureau of Standards, Washington, D.C.
2. When requested by CONSTRUCTION MANAGER, provide a qualified concrete technician employed by the admixture manufacturer to assist in proportioning the concrete for optimum use of the admixture. The concrete technician, when requested, shall advise on proper addition of the admixture to the concrete and on adjustment of the concrete mix proportions to meet changing jobsite conditions.
D. Tests for Concrete Materials:
1. Submit written reports to CONSTRUCTION MANAGER, for each material sampled and tested, prior to the start of Work. Provide the Project identification name and number, date of report, name of CONTRACTOR, name of concrete testing service, source of concrete aggregates, material manufacturer and brand
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name for manufactured materials, values specified in the referenced specification for each material, and test results. Indicate whether or not material is acceptable for intended use.
1.3 SUBMITTALS
A. Samples: Submit samples of materials as specified and as otherwise may be requested by CONSTRUCTION MANAGER, including names, sources and descriptions.
B. Shop Drawings: Submit for approval the following:
1. Manufacturer's specifications with application and installation instructions for proprietary materials and items, including admixtures and bonding agents.
2. List of concrete materials and concrete mix designs proposed for use. Include the results of all tests performed to qualify the materials and to establish the mix designs.
3. The following information, if ready-mixed concrete is used. a. Physical capacity of mixing plant.
b. Trucking facilities available.
c. Estimated average amount, which can be produced and delivered to the site during a normal 8-hour day, excluding the output to other customers.
C. Laboratory Test Reports: Submit copies of laboratory test reports for concrete cylinders, materials and mix design tests. CONSTRUCTION MANAGER'S review will be for general information only. Production of concrete to comply with specified requirements is the responsibility of CONTRACTOR.
D. Submit notarized certification of conformance to referenced standards when requested by CONSTRUCTION MANAGER.
E. Delivery Tickets: Furnish to CONSTRUCTION MANAGER copies of all delivery tickets for each load of concrete delivered to the site. Provide items of information as specified in ASTM C 94.
1.4 PRODUCT DELIVERY, STORAGE AND HANDLING
A. All materials used for concrete must be kept clean and free from all foreign matter during transportation and handling and kept separate until measured and placed in the mixer. Bins or platforms having hard clean surfaces shall be provided for storage. Suitable means shall be taken during hauling, piling and handling to insure that segregation of the coarse and fine aggregate particles does not occur and the grading is not affected.
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PART 2 - PRODUCTS
2.1 CONCRETE MATERIALS
A. Cement:
1. Portland cement, ASTM C 150, Type V, blended with ASTM C618 pozzolan or fly ash.
2. The pozzolan or fly ash content shall not exceed 25 percent by weight of the total cementitious material.
3. Use Portland cement made by a well-known acceptable manufacturer and produced by not more than one plant. A single brand of cement shall be used throughout the Work.
4. Do not use cement which has deteriorated because of improper storage or handling.
B. Aggregates: ASTM C 33 and as herein specified.
1. Do not use aggregates containing soluble salts or other substances such as iron sulfides, pyrite, or other materials that can cause stains on exposed concrete surfaces.
2. Fine Aggregate: Clean, sharp, natural sand free from loam, clay, lumps or other deleterious substances.
a. Dune sand, bank run sand and manufactured sand are not acceptable.
3. Coarse Aggregate: Clean, uncoated, processed aggregate containing no clay, mud, loam, or foreign matter, as follows:
a. Crushed stone, processed from natural rock or stone. b. Washed gravel, either natural or crushed. Use of slag and pit or bank run gravel is not permitted.
C. Water: Clean, free from injurious amounts of oils, acids, alkalis, organic materials or other substances that may be deleterious to concrete or steel.
2.2 CONCRETE ADMIXTURES
A. Provide admixtures produced by established reputable manufacturers, and use in compliance with the manufacturer's printed instruction. Do not use admixtures, which have not been incorporated and tested in the accepted mixes, unless otherwise authorized in writing by CONSTRUCTION MANAGER.
B. Air-Entraining Admixtures: ASTM C 260.
1. Product and Manufacturer: Provide one of the following:
a. SIKA AER, as manufactured by Sika Chemical Corporation. b. MB-VR, as manufactured by Master Builders Company.
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c. Daravair, as manufactured by W.R. Grace & Company.
d. Or equal.
2. Sufficient air-entraining agent shall be used to provide a total air content of 3 to 5 percent; provided that, when the main daily temperature in the vicinity of the worksite falls below 40 degrees F for more than one day, the total air content provided shall be 5 to 7 percent. The air-entraining agent shall be added to the batch in a portion of the mixing water. The solution shall be batched by means of a mechanical batcher capable of accurate measurement. Air content shall be tested at the point of placement.
C. Water-Reducing Admixture: ASTM C 494, Type A.
1. Proportion all concrete with non-air entraining, normal setting, water-reducing, aqueous solution of a modification of the salt of polyhydroxylated organic acids.
The admixture shall not contain any lignin, nitrates or chlorides added during manufacture. The required quantity of cement shall be used in the mix regardless of an admixture.
2. Product and Manufacturer: Provide one of the following:
a. Eucon WR-75, as manufactured by The Euclid Chemical Company. b. Pozzolith 322N, as manufactured by Master Builders Company. c. WRDA, as manufactured by W.R. Grace & Company.
d. PRO-KRETE-R, as manufactured by Protex Industries.
e. Plastiment, as manufactured by Sika Chemical Corporation. f. Or equal.
D. Calcium Chloride: Do not use calcium chloride in concrete. Do not use admixtures containing calcium chloride.
E. Fly ash or pozzalan shall conform to ASTM C618, Class F.
2.3 PROPORTIONING AND DESIGN OF MIXES
A. Proportioning:
1. Concrete shall be composed of cement, admixtures, aggregates, and water. These materials shall be on the qualities specified. The exact proportions in which these materials are to be used for different parts of the Work shall be determined by the CONTRACTOR and submitted to the CONSTRUCTION MANAGER for review prior to use in the Work. In general, the mix shall be designed to produce a concrete capable of being deposited so as to obtain maximum density and minimum shrinkage and, where deposited in forms, to have maximum smoothness of surface. Mix designs with more than 41 percent of sand of the total weight of fine and coarse aggregate shall not be permitted. The proportions shall be changed whenever necessary or desirable to meet the required results at no additional cost to the OWNER. All changes shall be reviewed by the CONSTRUCTION MANAGER.
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2. The minimum compressive strength and cement content of concrete shall be not less than that shown in the following tabulation. The CONSTRUCTION MANAGER may order the cement content for any class of concrete to be increased over the quantity specified in the tabulation if he or she determines that such increase is necessary to attain the required strength. Such increased quantities of cement, if so ordered, shall be furnished by the CONTRACTOR at no additional cost to the OWNER.
Concrete Min.
28-day
Compressive Strength
(psi)
Max.
Size Aggregate
(in.)
Min. Cement
per cu yd
(lbs)
Max. W/C Ratio
(by weight)
4,500 1 658 0.45
B. Use an independent testing facility acceptable to CONSTRUCTION MANAGER for preparing and reporting proposed mix designs.
1. The testing facility shall not be the same as used for field quality control testing.
C. Proportion mixes by either laboratory trial batch or field experience methods, using materials to be employed on the Project for concrete required. Comply with ACI 211.1 and report to CONSTRUCTION MANAGER the following data:
1. Complete identification of aggregate source of supply.
2. Tests of aggregates for compliance with specified requirements.
3. Scale weight of each aggregate.
4. Absorbed water in each aggregate.
5. Brand, type and composition of cement.
6. Brand, type and amount of each admixture.
7. Amounts of water used in trial mixes.
8. Proportions of each material per cubic yard.
9. Gross weight and yield per cubic yard of trial mixtures.
10. Measured slump.
11. Measured air content.
12. Compressive strength developed at 7 days and 28 days, from not less than 3 test cylinders cast for each 7-day and 28-day test, and for each design mix.
D. Submit written reports to CONSTRUCTION MANAGER of proposed mix of concrete at least 15 days prior to start of Work. Do not begin concrete production until mixes have been approved by CONSTRUCTION MANAGER.
E. Laboratory Trial Batches: When laboratory trial batches are used to select concrete proportions, prepare test specimens and conduct strength tests as specified in ACI 301.
However, 4,500 psi concrete mixes need not be designed for greater than 5,000 psi regardless of the production facilities standard deviation.
1. The trial batch shall be prepared using the aggregates, cement and admixture proposed for the project. The trial batch shall be of a quantity such that the testing
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laboratory can obtain 3 drying shrinkage and 6 compression test specimens from each batch.
2. Three compression test cylinders shall be tested at 7 days and 3 at 28 days. The average compressive strength for the 3 cylinders prepared for any given trial batch shall be not less than 125 percent of the specified compressive strength.
F. Shrinkage Tests:
1. Drying shrinkage tests will be made for the trial batch and during construction to ensure continued compliance with these Specifications. One set of 3 specimens shall be taken from the first pour of each class of concrete having a 28-day strength of 4,500 psi or higher, and additional set of 3 specimens of each type shall be taken during construction, as required by the CONSTRUCTION MANAGER.
2. The maximum concrete shrinkage for specimens cast in the laboratory from the trial batch, as measured at 21-day drying age or at 28-day drying age shall be 0.036 percent or 0.042 percent, respectively. The CONTRACTOR shall only use a mix design for construction that has first met the trial batch shrinkage requirements.
3. If the required shrinkage limitation is not met during construction, the CONTRACTOR shall be required to take any or all of the following actions, at no additional cost to the OWNER, for securing the specified shrinkage requirements.
These actions may include changing the source of aggregates, cement and/or admixtures; reducing water content; washing of aggregate to reduce fines; increasing the number of construction joints; modifying the curing requirements; or other actions designed to minimize shrinkage or the effects of shrinkage.
G. Adjustment to Concrete Mixes: Mix design adjustments may be requested by CONTRACTOR when characteristics of materials, job conditions, weather, test results, or other circumstances warrant; at no additional cost to the OWNER and as accepted by CONSTRUCTION MANAGER. Laboratory test data for revised mix designs and strength results must be submitted to and accepted by CONSTRUCTION MANAGER before using the revised mixes.
H. Admixtures:
1. Use air-entraining admixture in all concrete, except interior slabs subject to abrasion, unless otherwise shown or specified. Add air-entraining admixture at the manufacturer's prescribed rate to result in concrete at the point of placement having air content within the prescribed limits.
2. Use amounts of admixtures as recommended by the manufacturer for climatic conditions prevailing at the time of placing. Adjust quantities and types of admixtures as required to maintain quality control.
I. Slump Limits:
1. Use of a high-range water reducer is permitted and is required for walls and columns.
Slump limits for concrete with high-range water reducer are 8 inches
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maximum and 5 inches minimum. The product shall be manufactured by one of the following:
a. Daracem 100 or WRDA 19 by W.R. Grace.
b. Sikament FF or Sikament 86 by Sika Corporation.
c. Rheobuild 1000 or Rheobuild 716 by Master Builders.
d. Or equal.
2.4 EPOXY BONDING AGENT
A. Where indicated, provide an epoxy-resin bonding agent, two component, polysulfide type, for bonding freshly-mixed plastic concrete to hardened concrete.
B. Product and Manufacturer: Provide one of the following:
1. Sikadur 32, Hi-Mod LPL, as manufactured by Sika Chemical Corporation.
2. Eucopoxy LPL, as manufactured by the Euclid Chemical Company.
3. Epoxtite Binder (Code #2390) by A.C. Horn, Incorporated.
4. Or equal.
2.5 CONCRETE CURING MATERIALS
A. Absorptive Cover: Burlap cloth made from jute or kenaf, weighing approximately 10 ounces per square yard and complying with AASHTO M182, Class 3.
B. Moisture-Retaining Cover: One of the following, complying with ASTM C 171.
1. Waterproof paper.
2. Polyethylene film.
3. White burlap-polyethylene sheet.
C. Curing Compound: ASTM C 309 Type 1-D (water retention requirements):
1. Product and Manufacturer: Provide one of the following:
a. Super Aqua Cure VOX, as manufactured by The Euclid Chemical Company. b. Sealtight 1100, as manufactured by W.R. Meadows, Incorporated. c. Mastercure, as manufactured by Master Builders.
d. Hunt Process clear ARB as manufactured by Hunt Process Co. e. Select Cure CRB as manufactured by Select Products Co. f. Or equal.
2. The product shall meet volatile organic compound restrictions of C.A.R.B.
3. Provide fugitive dye.
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2.6 EMBEDDED ITEMS
A. Items such as plates, angles, inserts, bolts and similar items not specified elsewhere shall be provided and installed under this Section. All embedded items shall be hot dip galvanized after fabrication. After galvanizing, coat with zinc chromate paint. Stainless steel items shall not be galvanized.
PART 3 - EXECUTION
3.1 INSPECTION
A. CONTRACTOR and his/her installer shall examine the substrate and the conditions under which Work is to be performed and notify CONSTRUCTION MANAGER of unsatisfactory conditions. Do not proceed with the Work until unsatisfactory conditions have been corrected in a manner acceptable to CONSTRUCTION MANAGER. Provide 24 hours notice to CONSTRUCTION MANAGER of intended concrete placements.
3.2 CONCRETE MIXING
A. General:
1. Concrete may be produced at batch plants or it may be produced by the ready-mixed process. Batch plants shall comply with the recommendations of ACI 304, and shall have sufficient capacity to produce concrete of the qualities specified, in quantities required to meet the construction schedule. All plant facilities are subject to testing laboratory inspection and acceptance of CONSTRUCTION MANAGER.
2. Mixing:
a. Mix concrete with an approved rotating type batch machine, except where hand mixing of very small quantities may be permitted.
b. Remove hardened accumulations of cement and concrete frequently from drum and blades to assure acceptable mixing action.
c. Replace mixer blades when they have lost 10 percent of their original height. d. Use quantities such that a whole number of bags of cement is required, unless otherwise permitted.
B. Ready-Mix Concrete:
1. Comply with the requirements of ASTM C 94, and as herein specified. Proposed changes in mixing procedures, other than herein specified, must be accepted by CONSTRUCTION MANAGER before implementation.
a. Plant equipment and facilities: Conform to National Ready- Mix Concrete Association "Plant and Delivery Equipment Specification". b. Mix concrete in revolving type truck mixers which are in good condition and which produce thoroughly mixed concrete of the specified consistency and strength.
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c. Do not exceed the proper capacity of the mixer.
d. Mix concrete for a minimum of two minutes after arrival at the job site, or as recommended by the mixer manufacturer.
e. Do not allow the drum to mix while in transit.
f. Mix at proper speed until concrete is discharged.
g. Maintain adequate facilities at the job site for continuous delivery of concrete at the required rates.
h. Provide access to the mixing plant for CONSTRUCTION MANAGER at all times.
C. Maintain equipment in proper operating condition, with drums cleaned before charging each batch. Schedule rates of delivery in order to prevent delay of placing the concrete after mixing, or holding dry- mixed materials too long in the mixer before the addition of water and admixtures.
3.3 TRANSPORTING CONCRETE
A. Transport and place concrete not more than 90 minutes after water has been added to the dry ingredients.
B. Take care to avoid spilling and separation of the mixture during transportation.
C. Do not place concrete in which the ingredients have been separated.
D. Do not re-temper partially set concrete.
E. Use suitable and approved equipment for transporting concrete from mixer to forms.
3.4 CONCRETE PLACEMENT
A. General: Place concrete continuously so that no concrete will be placed on concrete, which has hardened sufficiently to cause the formation of seams or planes of weakness within the section. If a section cannot be placed continuously, provide construction joints as specified in Section 03251 of these Specifications and approved in writing by the CONSTRUCTION MANAGER. Deposit concrete as nearly as practical in its final location to avoid segregation due to rehandling or flowing. Do not subject concrete to any procedure, which will cause segregation.
1. Screed concrete, which is to receive other construction to the proper level to avoid excessive skimming or grouting.
2. Do not use concrete which becomes non-plastic and unworkable, or does not meet the required quality control limits, or which has been contaminated by foreign materials. Do not use retempered concrete. Remove rejected concrete from the job site and dispose of it in an acceptable location.
3. Do not place concrete until all forms, bracing, reinforcement, and embedded items are in final and secure position.
4. Unless otherwise approved, place concrete only when CONSTRUCTION MANAGER is present.
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5. Allow a minimum of 3 days before placing concrete against a slab or wall already in place.
6. In order to minimize the effects of shrinkage, concrete shall be placed in units as bounded by construction joints shown on the Contract Drawings. The placing of units shall be done by placing alternate units in a manner such that each unit placed shall have cured for at least seven (7) calendar days before a contiguous unit or units are placed, except that the corner sections of vertical walls shall not be placed until all the adjacent wall panels have cured at least fourteen (14) calendar days.
B. Concrete Conveying:
1. Handle concrete from the point of delivery and transfer to the concrete conveying equipment and to the locations of final deposit as rapidly as practical by methods, which will prevent segregation and loss of concrete mix materials.
2. Provide mechanical equipment for conveying concrete to ensure a continuous flow of concrete at the delivery end. Provide runways for wheeled concrete conveying equipment from the concrete delivery point to the locations of final deposit. Keep interior surfaces of conveying equipment, including chutes, free of hardened concrete, debris, water, snow, ice and other deleterious materials.
3. Do not use chutes for distributing concrete unless approved in writing by CONSTRUCTION MANAGER.
a. Provide sketches showing methods by which chutes will be employed when requesting such approval.
b. Design chutes, if permitted, with proper slopes and supports to permit efficient handling of the concrete.
4. Pumping concrete is permitted, however do not use aluminum pipe for conveying.
C. Placing Concrete into Forms:
1. Deposit concrete in forms in horizontal layers not deeper than 18 inches and in a manner to avoid inclined construction joints. Where placement consists of several layers, place concrete at such a rate that concrete which is being integrated with fresh concrete is still plastic.
2. Do not permit concrete to free-fall within the form from a distance exceeding 4 feet.
Windows shall be placed in the forms at four 4 feet on center for the full height of the wall.
3. Remove temporary spreaders in forms when concrete placing has reached the elevation of such spreaders.
4. Consolidate concrete placed in forms by mechanical vibrating equipment supplemented by hand spading, rodding or tamping. Use equipment and procedures for consolidation of concrete in accordance with the applicable recommended practices of ACI 309. Vibration of forms and reinforcing will not be permitted, unless otherwise accepted by CONSTRUCTION MANAGER.
5. Do not use vibrators to transport concrete inside of forms. Insert and withdraw vibrators vertically at uniformly spaced locations not farther than the visible
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effectiveness of the machine. Place vibrators to rapidly penetrate the layer of concrete and at least 6 inches into the preceding layer. Do not insert vibrators into lower layers of concrete that have begun to set. At each insertion, limit the duration of vibration to the time necessary to consolidate the concrete and complete embedment of reinforcement and other embedded items without causing segregation of the mix.
6. Do not place concrete in beam and slab forms until the concrete previously placed in columns and walls is no longer plastic.
7. Force concrete under pipes, sleeves, openings and inserts from one side until visible from the other side to prevent voids.
8. CONTRACTOR shall provide illumination into bottom of wall forms.
D. Placing Concrete Slabs:
1. Deposit and consolidate concrete slabs in a continuous operation, within the limits of construction joints, until the placing of a panel or section is completed.
2. Consolidate concrete during placing operations using mechanical vibrating equipment, so that concrete is thoroughly worked around reinforcement and other embedded items and into corners.
3. Consolidate concrete placed in beams and girders of supported slabs, and against bulkheads of slabs on ground, as specified for formed concrete structures.
4. Bring slab surfaces to the correct level. Smooth the surface, leaving it free of humps or hollows. Do not sprinkle water on the plastic surface. Do not disturb the slab surfaces prior to beginning finishing operations.
E. Bonding for Next Concrete Pour: Roughen surfaces of set concrete at all joints, except where bonding is obtained by use of a concrete bonding agent. Construction joints shown on the Drawings are specified in Section 03251 of these Specifications. Clean surfaces of laitance, coatings, loose particles, and foreign matter. Roughen surfaces in a manner to expose bonded aggregate uniformly and to not leave laitance, loose particles of aggregate, or damaged concrete at the surface.
1. Prepare for bonding of fresh concrete to new concrete that has set but is not fully cured, as follows:
a. Thoroughly wet the surface but allow no freestanding water. b. For horizontal surfaces place a 2-inch layer of mortar, 1-part sand and 1-part cement with water, over the hardened concrete surface.
c. Place fresh concrete before the mortar has attained its initial set.
2. Bonding of fresh concrete to fully cured hardened concrete or existing concrete, and horizontal surfaces, which will receive a topping, shall be accomplished as indicated.
F. Quality of Concrete Work:
1. Make all concrete solid, compact and smooth, and free of laitance, cracks and cold joints.
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2. All concrete for liquid retaining structures, and all concrete in contact with earth, water, or exposed directly to the elements shall be watertight.
3. Cut out and properly replace to the extent ordered by CONSTRUCTION MANAGER, or repair to the satisfaction of Construction Manager, surfaces which contain cracks or voids, are unduly rough, or are in any way defective. Thin patches or plastering will not be acceptable.
4. All leaks through concrete, and cracks, holes or other defective concrete in areas of potential leakage, shall be repaired and made watertight by CONTRACTOR.
5. Repair, removal, and replacement of defective concrete as ordered by CONSTRUCTION MANAGER shall be at no additional cost to OWNER.
G. Cold Weather Placing:
1. Protect all concrete Work from physical damage or reduced strength, which could be caused by frost, freezing actions, or low temperatures, in compliance with the requirements of ACI 306 and as herein specified.
2. When the air temperature has fallen to or may be expected to fall below 40 F, provide adequate means to maintain the temperature, in the area where concrete is being placed, at between 50 F and 70 F for at least seven days after placing.
Provide temporary housings or coverings including tarpaulins or plastic film.
Maintain the heat and protection, if necessary, to insure that the ambient temperature does not fall more than 30 F in the 24 hours following the seven-day period.
Avoid rapid dry-out of concrete due to overheating, and avoid thermal shock due to sudden cooling or heating.
3. When air temperature has fallen to or is expected to fall below 40 F, uniformly heat all water and aggregates before mixing as required to obtain a concrete mixture temperature of not less than 55 F and not more than 85 F at point of placement.
4. Do not use frozen materials containing ice or snow. Do not place concrete on frozen subgrade or on subgrade containing frozen materials. Ascertain that forms, reinforcing steel, and adjacent concrete surfaces are entirely free of frost, snow and ice before placing concrete.
5. Do not use salt and other materials containing antifreeze agents or chemical accelerators, or set-control admixtures, unless approved by CONSTRUCTION MANAGER, in mix designs.
H. Hot Weather Placing:
1. When hot weather conditions exist that would seriously impair the quality and strength of concrete, place concrete in compliance with ACI 305 and as herein specified.
2. Cool ingredients before mixing to maintain concrete temperature at time of placement below 85 F when the temperature is rising and below 85 F when the temperature is falling. Mixing water may be chilled, or chopped ice may be used to control the concrete temperature provided the water equivalent of the ice is calculated in the total amount of mixing water.
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3. Cover reinforcing steel with water-soaked burlap if it becomes too hot, so that the steel temperature will not exceed the ambient air temperature immediately before embedment in concrete.
4. Wet forms thoroughly before placing concrete.
5. Do not place concrete at a temperature so as to cause difficulty from loss of slump, flash set, or cold joints.
6. Do not use set-control admixtures unless approved by CONSTRUCTION MANAGER in mix designs.
7. Obtain CONSTRUCTION MANAGER'S approval of other methods and materials proposed for use.
3.5 FINISH OF FORMED SURFACES
A. Rough Form Finish:
1. Standard rough form finish shall be the concrete surface having the texture imparted by the form material used, with tie holes and defective areas repaired and patched with mortar of 1 part cement to 1 ½ parts sand and all fins and other projections exceeding 1/4 inch in height rubbed down or chipped off.
2. Use rough form finish for the following:
a. Exterior vertical surfaces up to 1 foot below grade. b. Interior exposed vertical surfaces of liquid containers up to 1 foot below liquid level.
c. Interior and exterior exposed beams and undersides of slabs. d. Other areas shown.
B. Smooth Form Finish:
1. Produce smooth form finish by selecting form materials which will impart a smooth, hard, uniform texture. Arrange panels in an orderly and symmetrical manner with a minimum of seams. Repair and patch defective areas as above with all fins or other projections completely removed and smoothed.
2. Use smooth form finish for surfaces that are to be covered with a coating material.
The material may be applied directly to the concrete or may be a covering bonded to the concrete such as waterproofing, dampproofing, painting or other similar system.
C. Smooth Rubbed Finish:
1. Provide smooth rubbed finish to concrete surfaces which have received smooth form finish as follows:
a. Rubbing of concrete surfaces not later than the day after form removal. b. Moistening of concrete surfaces and rubbing with carborundum brick or other abrasive until a uniform color and texture is produced. Do not apply cement grout other than that created by the rubbing process.
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2. Except where surfaces have been previously covered as specified above, use smooth rubbed finish for the following:
a. Interior exposed walls and other vertical surfaces.
b. Exterior exposed walls and other vertical surfaces down to 1 foot below grade. c. Interior and exterior horizontal surfaces, except exterior exposed slabs and steps.
d. Interior exposed vertical surfaces of liquid containers down to 1 foot below liquid level.
e. Other areas shown.
D. Related Unformed Surfaces:
1. At tops of walls, horizontal offsets, and similar unformed surfaces occurring adjacent to formed surfaces, strike off smooth and finish with a texture matching the adjacent formed surfaces. Continue the final surface treatment of formed surfaces uniformly across the adjacent unformed surfaces, unless otherwise shown.
3.6 MONOLITHIC SLAB FINISHES
A. Float Finish:
1. After placing concrete slabs, do not work the surface further until ready for floating.
Begin floating when the surface water has disappeared or when the concrete has stiffened sufficiently. Check and level the surface plane to a tolerance not exceeding 1/4 inch in 10 feet when tested with a 10 foot straightedge placed on the surface at not less than 2 different angles. Cut down high spots and fill all low spots.
Uniformly slope surfaces to drains. Immediately after leveling, refloat the surface to a uniform, smooth, granular texture.
2. Use float finish for the following:
a. Interior exposed horizontal surfaces of liquid containers except those to receive grout topping.
b. Exterior below grade horizontal surfaces.
B. Trowel Finish:
1. After floating, begin the first trowel finish operation using a power-driven trowel.
Begin final troweling when the surface produces a ringing sound as the trowel is moved over the surface.
2. Consolidate the concrete surface by the final hand troweling operation. Finish shall be free of trowel marks, uniform in texture and appearance, and with a surface plane tolerance not exceeding 1/8 inch in 10 feet when tested with a 10-foot straight edge.
Grind smooth surface defects, which would telegraph through applied floor covering system.
3. Use trowel finish for the following:
a. Interior exposed slabs unless otherwise shown or specified.
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b. Slabs to receive resilient floor finishes.
C. Non-Slip Broom Finish:
1. Immediately after float finishing, slightly roughen the concrete surface by brooming in the direction perpendicular to the main traffic route. Use fiber-bristle broom unless otherwise directed. Coordinate the required final finish with CONSTRUCTION MANAGER before application.
2. Use Non-Slip Broom Finish for the following:
a. Exterior exposed horizontal surfaces subject to light foot traffic. b. Interior and exterior concrete steps and ramps.
c. Horizontal surfaces which will receive a grout topping or a concrete equipment base slab.
3.7 CONCRETE CURING AND PROTECTION
A. General:
1. Protect freshly placed concrete from premature drying and excessive cold or hot temperature, and maintain without drying at a relatively constant temperature for the period of time necessary for hydration of the cement and proper hardening of the concrete.
2. Start initial curing after placing and finishing concrete as soon as free moisture has disappeared from the concrete surface. Keep continuously moist for not less than 72 hours.
3. Begin final curing procedures immediately following initial curing and before the concrete has dried. Continue final curing for at least 7 days and in accordance with ACI 301 procedures. For concrete sections over 30 inches thick and formed walls, continue final curing for an additional 7 days, minimum. Avoid rapid drying at the end of the final curing period.
B. Curing Methods:
1. Perform curing of concrete by moist curing, or by moisture- retaining cover curing.
Use curing compound only in cold weather and only when permitted by CONSTRUCTION MANAGER.
a. For curing, use water that is free of impurities which could etch or discolor exposed, natural concrete surfaces.
2. Provide moisture curing by any of the following methods:
a. Keeping the surface of the concrete continuously wet by covering with water. b. Continuous water-fog spray.
c. Covering the concrete surface with the specified absorptive cover, thoroughly saturating the cover with water, and keeping the absorptive cover continuously wet with sprinklers or porous hoses. Place absorptive cover so as to provide
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coverage of the concrete surfaces and edges, with a 4-inch lap over adjacent absorptive covers.
3. Provide moisture-retaining cover curing as follows:
a. Cover the concrete surfaces with the specified moisture- retaining cover for curing concrete, placed in the widest practical width with sides and ends lapped at least 3 inches and sealed by waterproof tape or adhesive. Immediately repair any holes or tears during the curing period using cover material and waterproof tape.
4. Provide liquid curing compound as follows:
a. Apply the specified curing compound to all concrete surfaces when permitted by CONSTRUCTION MANAGER. Slabs to receive terrazzo floors, chemical resistant heavy-duty concrete topping or ceramic tile, shall not be cured with liquid curing compound, but shall be moisture cured. The compounds shall be applied immediately after final finishing in a continuous operation by power spray equipment in accordance with the manufacturer's directions. Recoat areas, which are subjected to heavy rainfall within 3 hours after initial application. Maintain the continuity of the coating and repair damage to the coat during the entire curing period. For concrete surfaces, which will be in contact with potable water, the manufacturer shall certify that the curing compound used is EPA and NSF approved.
C. Curing Formed Surfaces:
1. Cure formed concrete surfaces, including the undersides of girders, beams, supported slabs and other similar surfaces by moist curing with the forms in place for the full curing period or until forms are removed. If forms are removed, continue curing by methods specified above, as applicable.
D. Curing Unformed Surfaces:
1. Initially cure unformed surfaces, such as slabs, floor topping, and other flat surfaces by using the appropriate method specified above.
2. Final cure unformed surfaces, unless otherwise specified, by utilizing methods specified above, as applicable.
E. Temperature of Concrete During Curing:
1. When the atmospheric temperature is 40 F and below, maintain the concrete temperature between 50 F and 70 F continuously throughout the curing period.
When necessary, make arrangement before concrete placing for heating, covering, insulation or housing as required to maintain the specified temperature and moisture conditions continuously for the concrete curing period. Provide cold weather protection complying with the requirements of ACI 306.
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2. When the atmospheric temperature is 80 F and above, or during other climatic conditions which will cause too rapid drying of the concrete, make arrangements before the start of concrete placing for the installation of wind breaks or shading, and for fog spraying, wet sprinkling, or moisture-retaining covering. Protect the concrete continuously for the concrete curing period. Provide hot weather protection complying with the requirements of ACI 305, unless otherwise specified.
3. Maintain concrete temperature as uniformly as possible, and protect from rapid atmospheric temperature changes. Avoid temperature changes in concrete which exceed 5° F in any one hour and 50° F in any 24 hour period.
F. Protection from Mechanical Injury:
1. During the curing period, protect concrete from damaging mechanical disturbances including load stresses, heavy shock, excessive vibration, and from damage caused by rain or flowing water. Protect all finished concrete surfaces from damage by subsequent construction operations.
3.8 FIELD QUALITY CONTROL
A. Field quality control testing shall be performed by the OWNER. CONSTRUCTION MANAGER will make slump tests and will direct the number of tests and cylinders required. The OWNER will make standard compression test cylinders and entrained air tests as specified below. CONTRACTOR shall furnish all necessary assistance required by CONSTRUCTION MANAGER. The CONTRACTOR shall be charged for the cost of any additional tests and investigation on work performed which does not meet the specifications.
3.9 MISCELLANEOUS CONCRETE ITEMS
A. Curbs:
1. Provide monolithic finish to interior curbs by stripping forms while concrete is still green and steel-troweling surfaces to a hard, dense finish with corners, intersections, and terminations slightly rounded.
2. Exterior curbs shall have rubbed finish for vertical surfaces and a broomed finish for top surfaces.
B. Equipment Bases:
1. Unless specifically shown otherwise, provide concrete bases for all pumps and other equipment. Construct bases to the dimensions shown, or as required to meet manufacturers; requirements and Drawing elevations. Where no specific elevations are shown, bases shall be 6-inches thick and extend 3-inches outside the metal equipment base or supports. Bases to have smooth trowel finish, unless a special finish such as terrazzo, ceramic tile or heavy-duty concrete topping is required. In those cases, provide appropriate concrete finish.
2. Include all concrete equipment base work not specifically included under other Sections or other contracts.
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3. In general, place bases up to 1 inch below the metal base. Properly shim equipment to grade and fill 1-inch void with non-shrink grout as specified in Section 03600, Grout.
3.10 CONCRETE REPAIRS
A. Repair of Formed surfaces:
1. Repair exposed-to-view formed concrete surfaces, that contain defects, which adversely affect the appearance of the finish. Surface defects that require repair include color and texture irregularities, cracks, spalls, air bubbles, honeycomb, rock pockets, and holes left by the rods and bolts; fins and other projections on the surface; and stains and other discolorations that cannot be removed by cleaning.
2. Repair concealed formed concrete surfaces that may contain defects that adversely affect the durability of the concrete. Surface defects that require repair include cracks in excess of 0.01-inch wide, cracks of any width and other surface deficiencies which penetrate to the reinforcement or completely through nonreinforced sections, honeycomb, rock pockets, holes left by tie rods and bolts, and spalls except minor breakage at corner.
3. Repair structural cracks and cracks in water-holding structures.
B. Method of Repair of Formed Surfaces:
1. Repair and patch defective areas with cement mortar immediately after removal of forms and as directed by CONSTRUCTION MANAGER.
2. Cut out honeycomb, rock pockets, voids over ½-inch diameter, and holes left by tie rods and bolts, down to solid concrete but, in no case, to a depth of less than 1 inch.
Make edges of cuts perpendicular to the concrete surface. Before placing the cement mortar, thoroughly clean, dampen with water, and brush-coat the area to be patched with the specified bonding agent.
a. For exposed-to-view surfaces, blend white Portland cement and standard Portland cement so that, when dry, the patching mortar color will match the color of the surrounding concrete. Contractor shall impart texture to repaired surfaces to match texture of existing adjacent surfaces. Provide test areas at inconspicuous locations to verify mixture, texture and color match before proceeding with the patching. Compact mortar in place and strike off slightly higher than the surrounding surface.
3. Cracks which require repair shall be pressure grouted using one of the following.
Apply in accordance with the manufacturer's directions and recommendations. a. Sikadur Hi-Mod and Gel, as manufactured by Sika Chemical Company. b. Euco Epoxy #452 Epoxy System, as manufactured by The Euclid Chemical Company.
c. Or equal.
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4. Fill holes extending through concrete by means of a plunger- type gun or other suitable device from the least exposed face, using a flush stop held at the exposed face to ensure completely filling.
5. Waterblast exposed-to-view surfaces that require removal of stains, grout accumulations, sealing compounds, and other substances marring the surfaces.
C. Repair of Unformed Surfaces:
1. Test unformed surfaces, such as monolithic slabs, for smoothness and to verify surface plane to the tolerances specified for each surface and finish. Correct low and high areas as herein specified.
2. Test unformed surfaces sloped to drain for trueness of slope, in addition to smoothness, using a template having the required slope. Correct high and low areas as herein specified.
3. Repair finish of unformed surfaces that contain defects which adversely affect the durability of the concrete. Surface defects, as such, include crazing, cracks in excess of 0.01-inch wide or which penetrate to the reinforcement or completely through non-reinforced sections regardless of width, spalling, popouts, honeycomb, rock pockets, and other objectionable conditions.
4. Repair structural cracks and cracks in water-holding structures.
D. Methods of Repair of Unformed Surfaces:
1. Correct high areas in unformed surfaces by grinding, after the concrete has cured sufficiently so that repairs can be made without damage to adjacent areas.
2. Correct low areas in unformed surfaces during, or immediately after completion of surface finishing operations by cutting out the low areas and replacing with fresh concrete. Finish repaired areas to blend into adjacent concrete. Use one of the following. Apply in accordance with the manufacturer's directions and recommendations.
a. Poly-Patch, as manufactured by The Euclid Chemical Company. b. Sikatop, as manufactured by Sika Chemical Company.
c. Or equal.
3. Repair defective areas, except random cracks and single holes not exceeding 1-inch diameter, by cutting out and replacing with fresh concrete. Remove defective areas to sound concrete with clean, square cuts, and expose reinforcing steel with at least 3/4-inch clearance all around. Dampen all concrete surfaces in contact with patching concrete and brush with the specified bonding agent. Place patching concrete before grout takes its initial set. Mix patching concrete of the same materials and proportions to provide concrete of the same type or class as the original adjacent concrete. Place, compact and finish as required to blend with adjacent finished concrete. Cure in the same manner as adjacent concrete.
4. Repair isolated random cracks, and single holes not over 1-inch diameter, by the drypack method. Groove the top of cracks, and cut out holes to sound concrete and clean of dust, dirt and loose particles. Dampen all cleaned concrete surfaces and
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brush with the specified bonding agent. Place dry-pack before the cement grout takes its initial set. Mix dry-pack, consisting of 1 part Portland cement to 2-1/2 parts fine aggregate passing a No. 16 mesh sieve, using only enough water as required for handling and placing. Compact dry-pack mixture in place and finish to match adjacent concrete. Keep patched areas continuously moist for not less than 72 hours.
5. Cracks which require repair shall be pressure grouted using one of the following.
Apply in accordance with the manufacturer's directions and recommendations. a. Sikadur Hi-Mod L.V. and Gel, as manufactured by Sika Chemical Company. b. Euco Epoxy #452 Epoxy System, as manufactured by The Euclid Chemical Company.
c. Or equal.
6. Assure that surface is acceptable for flooring material to be installed in accordance with manufacturer's recommendations.
E. Other Methods of Repair:
1. Repair methods not specified above may be used if approved in writing by CONSTRUCTION MANAGER.
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SECTION 03490
PRE-CAST CONCRETE TRENCH
PART 1 - GENERAL
1.1 SCOPE
A. The Contractor shall furnish and install a precast concrete underground utility trench system and accessories for electrical cabling and hydraulic hoses as indicated on the Contract Drawings and specified herein.
1.2 DESIGN
A. The precast components shall be designed to conform to requirements stated in ASTM C857 "Practice for Minimum Structural Design Loading for Underground Precast Concrete Utility Structures, ASTM C858 "Specifications for Underground Precast Concrete Utility Structures" and ACI-318 "Building Code Requirements for Structural Concrete and Commentary on Building Code Requirements in Structural Concrete".
B. The precast trench system shall be designed so that supplemental support such as protection rods or cross supports are not required.
1.3 SUBMITTALS
A. The Contractor shall submit information in accordance with Section 01300, Submittals, to substantiate compliance with this specification. In addition, the following specific information shall be submitted.
1. Product Technical Data
a. Acknowledgement that products submitted meet requirements of standards referenced.
b. Product details, catalog cut sheets.
c. Manufacturerís installation instructions.
2. Fabrication Drawings and Calculations: The CONTRACTOR shall submit shop drawings and calculations for all pre-cast concrete items and trench lids signed and stamped by a civil engineer registered in California. Submitted drawings shall show all dimensions, reinforcement, lifting inserts, openings, and all other inserts.
PART 2 - PRODUCTS
2.1 GENERAL
A. The trench system shall consist of precast concrete U-shaped base units and removable covers, as manufactured by Trenwa Inc. of Fort Thomas, Kentucky or an approved equal.
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B. All sections of trench shall be designed to carry HS20, 32,000 pounds axle loading and shall be furnished in standard 10-foot lengths, except that special lengths shall be furnished where required by the layout.
C. Trench base units shall have galvanized steel impact angles embedded along the top edges for durability.
D. The interior clear trench dimensions shall be as shown on the Contract Drawings.
E. The lids for the road crossing trench shall be made of FRP Monolithic Composite designed to carry HS20, 32,000 pounds axle loading as manufactured by Fibrelite or an approved equal.
2.2 MATERIALS
A. Cement shall conform to ASTM C150/C150M, "Specification for Portland Cement".
B. Fine and coarse aggregates shall conform to ASTM C33/C33M, "Specification for Concrete Aggregates".
C. Chemical Admixtures shall conform to ASTM C260/C260M "Air-Entraining Admixtures for Concrete and ASTM C494/C494M "Chemical Admixtures for Concrete".
D. Steel reinforcing bars shall conform to ASTM A615 "Specification for Deformed and Plain Carbon Steel Bars for Concrete Reinforcement".
E. Steel reinforcing wires shall conform to ASTM A496 "Specification for Steel Wire, Deformed, for Concrete Reinforcement".
F. Steel reinforcing welded wire mats shall conform to A1064 Standard Specification for Carbon-Steel Wire and Welded Wire Reinforcement, Plain and Deformed, for Concrete".
G. Embedded steel shapes and plates shall conform to ASTM A36/C36M "Standard Specification for Carbon Structural Steel".
2.3 CONCRETE
A. Batching, mixing and placing of concrete shall conform to ACI A301 "Specifications for Structural Concrete" and ASTM C94/C94M "Specification for Ready-Mix Concrete" and ACI 304 "Guide for Measuring, Mixing, Transporting and Placing Concrete". All materials shall be pre-weighed prior to mixing.
B. Concrete shall obtain a minimum compressive strength of 5,000 psi at 28 days of age.
C. Concrete shall contain 6% entrained air by volume (plus or minus 1%).
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2.4 REINFORCEMENT
A. Fabrication and placement shall conform to ACI-318 "Building Code Requirements for Structural Concrete".
2.5 ACCESSORIES
A. The Manufacturer shall provide the following accessories:
1. EPDM corner guards for all tís, crosses, transitions, and mitered corners 45 degrees and higher to prevent abrasion to cables pulled around the corners.
2. Two (2) manual lifting tools for trench lids.
B. The Contractor shall provide the following accessories:
1. FRP trench dividers as shown on the Contract Drawings.
PART 3 - EXECUTION
3.1 INSTALLATION
A. The trench system and accessories shall be installed by the Contractor per the manufacturerís recommendations unless otherwise required by the plans.
B. Trenches shall be installed level and flush with the adjacent finished surface.
C. A crushed rock base shall be installed as shown on the drawings.
D. Trench base units shall be backfilled with crushed aggregate base or SE-30 sand compacted to 95% relative compaction.
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SECTION 03600
GROUT
PART 1 - GENERAL
1.1 WORK OF THIS SECTION
A. Work of this Section shall include:
1. Grouting of equipment baseplates
2. Patching cavities in concrete
3. Other grouting specified or indicated on Drawings
1.2 RELATED SECTIONS
A. The Work of the following Sections applies to the Work of this Section, Other Sections, not referenced below, shall also apply to the extent required for proper performance of this Work.
1. Division 1
2. Section 03300, Cast-in-Place Concrete
3. Section 05503, Anchor Bolts, Adhesive Anchors, Expansion Anchors, and Concrete Inserts
1.3 QUALITY ASSURANCE
A. Applicable Standards
1. Corps of Engineering Specification CRD-C 621 - Specification for Non-Shrink Grout
PART 2 - PRODUCTS
2.1 MATERIALS
A. Non-Shrinking Non-Metallic Grout: Master Builders "Special LL-713 Grout," Sauereisen Cements "F-100 Level Fill Grout," U.S. Grout "Five Star Grout," The Upco Corp "Upcon," or equivalent
B. Epoxy Grout:
1. Adhesive: Ceilcote "HT648 Grout," Exxon Chem Co. "Escoweld 2505," Sika "Sikadur Hi-Mod," or equivalent
2. Aggregate: Ceilcote "HT648," Exxon Chem Co. "Escoweld 2510," Sika "Colma Quartzite Aggregate," or equivalent
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C. Water: Clean and free from deleterious substances
2.2 MANUFACTURE
A. Non-Metallic Non-Shrinking Grout: Factory pre-mixed requiring only water addition in the field
B. Epoxy Grout
1. Three component epoxy resin system
a. Two liquid epoxy components
b. One inert aggregate filler component
2. Each component furnished in separate package for mixing at jobsite PART 3 - EXECUTION
3.1 PREPARATION
A. Non-Shrinking Non-Metallic Grout
1. Clean concrete surface to receive grout
2. Saturate concrete with water for 24 hours prior to grouting B. Epoxy Grout: Apply only to clean, dry, sound surface
3.2 APPLICATION
A. Non-Shrinking Non-Metallic Grout
1. Mix in a mechanical mixer
2. Use no more water than necessary to produce flowable grout
3. Place in accordance with manufacturer's instructions
4. Completely fill all spaces and cavities below the top of baseplates
5. Provide forms where baseplates and bedplates do not confine grout
6. Where exposed to view finish grout edges smooth
7. Except where a slope is indicated on the Drawings, finish edges flush at the baseplate, bedplate, member or piece of equipment
8. Protect against rapid moisture loss by covering with wet rags or polyethylene sheets
9. Wet cure grout for 7 days, minimum
B. Epoxy Grout
1. Mix and place in accordance with manufacturer's instructions
2. Completely fill all cavities and spaces around dowels and anchors without voids
3. Grout base and bedplates as specified for non-shrinking, non-metallic grout
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4. Obtain manufacturer's field technical assistance as required to ensure proper placement
3.3 SCHEDULE
A. Non-Shrinking Non-Metallic Grout: General use
B. Epoxy Grout
1. Patching cavities in concrete
2. Grouting of dowels and anchor bolts into concrete
3. Other uses indicated on Drawings
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SECTION 05500
MISCELLANEOUS METALS
PART 1 - GENERAL
1.1 WORK OF THIS SECTION
A. The CONTRACTOR shall provide miscellaneous metals and appurtenances, complete, in accordance with the Contract Documents.
B. Work Included in this Section. Principal items are:
1. Shop/erection drawings and samples.
2. Iron castings.
3. Steel channels and/or angle frames and thresholds with anchors.
4. Welding electrodes.
5. Shop prime paint.
6. Guard post assemblies of removable and stationary types.
7. Miscellaneous iron and steel items indicated, specified, or required for completion of the Contract, unless included under other Sections.
8. Galvanizing and shop primer finishes, including field touch-up.
1.2 RELATED SECTIONS
A. The Work of the following Sections apply to the Work of this Section. Other, not referenced below, shall also apply to the extent required for proper performance of this Work.
1. Section 03200, Concrete Reinforcement.
2. Section 03300, Cast-in-Place Concrete.
3. Section 03600, Grout.
4. Section 05503, Anchor Bolts, Adhesive Anchors, Expansion Anchors and Concrete Inserts.
1.3 REFERENCE SPECIFICATIONS, CODES AND STANDARDS
A. The current edition of the Uniform Building Code (UBC).
B. Except as otherwise indicated, the current editions of the following Federal Specifications apply to the Work of this Section:
1. QQ-F-461 Floor Plate, Steel, Rolled
2. MIL-G-18015 A (Ships) Aluminum Planks. (6063-T6)
3. MIL-A-907E Antiseize Thread Compound, High Temperature
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C. Except as otherwise indicated, the current editions of the following commercial standards apply to the Work of this Section:
1. Commercial Standards:
AA-M32C22A41 Aluminum Association
AASHTO Standard Specification for Highway Bridges
AISC Specification for Design, Fabrication and Erection of Structural Steel for Buildings with Commentary and Code of Standard Practice for Steel Buildings and Bridges
AISC Manual of Steel Construction
AISI Design of Light Gauge, Cold-Formed Steel Structural Members
AWS B2.1 Welding Procedures and Performance Qualifications AWS D1.1 Structural Welding Code - Steel
AWS D1.2 Structural Welding Code - Aluminum
AWS QC1 Standard for AWS Certification of Welding Inspectors NFPA 101 Life Safety Code
NAAMM National Association of Architectural Metal Manufacturers Metal Stairs Manual
AWS-AS Welding of Stainless Steel with Electrodes and Techniques
2. ASTM Standards in Building Codes:
ASTM A36 Specification for Structural Steel
ASTM A48 Specification for Gray Iron Castings
ASTM A53 Specification for Pipe, Steel, Black and Hot-Dipped, ZincCoated Welded and Seamless ASTM A123 Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
ASTM A125 Specification for Steel Springs, Helical, Heat Treated ASTM A153 Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware
ASTM A167 Specification for Stainless and Heat-Resisting ChromiumNickel Steel Plate, Sheet and Strip ASTM A193 Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service
ASTM A194 Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure and High-Temperature Service
ASTM A276 Specification for Stainless Steel Bars and Shapes ASTM A283 Specification for Low and Intermediate Tensile Strength Carbon Steel Plates
ASTM A307 Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile
ASTM A320 Specification for Alloy-Steel Bolting Material for LowTemperature Service ASTM A325 High Strength Bolts for Structural Steel Joints
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ASTM A424 Specification for Steel, Sheet, for Porcelain Enameling ASTM A500 Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes
ASTM A536 Specification for Ductile Iron Casting
ASTM A563 Specification for Carbon and Alloy Steel Nuts ASTM A569 Specification for Steel, Carbon (0.15 Maximum Percent), Hot Rolled Sheet and Strip Commercial Quality
ASTM A575 Specifications for Steel Bars, Carbon, Merchant Quality, M-Grades ASTM A786 Specification for Rolled Steel Floor Plates
ASTM A992 Steel for Structural Shapes for Use in Building Framing ASTM B98 Specification for Copper-Silicon Alloy Rod, Bar, and Shapes ASTM B210 Specification for Aluminum and Aluminum-Alloy Drawn Seamless Tubes
ASTM B221 Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Shapes, and Tubes
ASTM B438 Specification for Sintered Bronze Bearings (Oil-Impregnated)
3. Trade Standards
Welded Austenitic Chromium-Nickel Stainless Steel Technique and Properties, as Published by the International Nickel Company, Inc., New York, New York.
Porcelain Enamel Institute, Inc.
1.4 CONTRACTOR SUBMITTALS
A. Shop Drawings: Shop drawings shall be submitted in accordance with Division 1 of the Specifications.
B. Layout Drawings: Layout drawings for grating shall be submitted showing the direction of span, type and depth of grating, size and shape of grating panels, seat angle details, and details of grating hold down fasteners. Load and deflection tables shall be submitted for each style and depth of grating used.
C. Product List and Product Data Sheets: Protective Coating, a product list shall be submitted with product data sheets of intended shop coats.
1.5 QUALITY ASSURANCE
A. Miscellaneous metals shall be fabricated and erected in accordance with the latest edition of the AISC "Specification for the Design, Fabrication and Erection of Steel for Buildings", and "Code of Standard Practice for Steel Buildings and Bridges", except whenever there is a discrepancy between the design drawings and this specification, the Drawings shall govern.
B. Aluminum work shall be fabricated and erected in conformance with applicable requirements of the UBC and referenced standards of the Aluminum Association.
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C. Continuous Inspections: All welding and high strength bolting of structural steel assemblies shall be conducted under the continuous inspection of an International Conference of Building Officials (ICBO) certified "Special Inspector" selected by the OWNER with costs borne by the OWNER. Should such fabrication be performed in the shop of a licensed fabricator approved by the governing building official and certified by the ICBO Evaluation Services, Inc. Only the field welding and high strength bolting of structural steel assemblies will be required to be performed under continuous inspection of the ICBO-certified "Special Inspector." The OWNER shall be notified at least 24 hours in advance of needed inspections. Copies of inspection reports for shall be provided for the OWNER, CONTRACTOR, and governing building official.
PART 2 - PRODUCTS
2.1 MATERIALS
A. Steel: Steel shall conform to the following requirements:
1. Shapes, Plates, Bars ASTM A 36 or ASTM A992.
2. Pipe, Pipe Columns, Bollards ASTM A 53, Type E or S, Grade B Schedule 40, unless noted otherwise.
3. Tubes ASTM A 500, Grade B
B. Aluminum: Aluminum structural shapes shall be new and conform to applicable Federal Specification for 6061-T6 alloy, unless otherwise noted. Aluminum Pipe shall conform to Schedule 40, or greater.
C. Stainless Steel: Unless otherwise designated or approved, stainless steel alloy types shall conform to ASTM A167 and ASTM A276 as follows:
1. Stainless steel plates, pipe and structural shapes: Type 316L.
2. Stainless steel bolts, nuts and washers: Type 316L where connecting or bearing on aluminum.
D. Cast Iron: Cast iron shall conform to ASTM A48, except as otherwise noted.
E. Ductile Iron: Ductile iron shall conform to ASTM A536, using Grade 60-40-18 or better, except as otherwise noted.
2.2 STEEL PIPE HANDRAILS
Steel pipe handrails, including brackets and related hardware, which may be partially or wholly submerged, or which are located inside a hydraulic structure, shall be entirely of Type 316L stainless steel. All other steel pipe handrails shall be standard 1-inch black steel pipe made up by welding. All steel pipe handrail shall be picked at fabrication plant and shall be hot-dip galvanized after fabrication.
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2.3 CHECKERED PLATE
A. Checkered Plate: Checkered plate shall conform to Federal Specification QQ-F461.
Checkered plate shall be not less than1/4-inch thick, and shall have a pattern of raised lugs on one face and shall be smooth on the opposite face. Lugs shall be a minimum of one inch in length and raised a minimum of 0.050-inch above the surface. The lugs shall be located in a pattern in which the lugs are oriented at 90 degrees from the adjacent lugs in two orthogonal directions. The rows of lugs shall be oriented at 45 degrees from the edges of the plates.
B. Plate Material: Where no plate material is indicated, aluminum shall be provided.
Unless indicated otherwise, the minimum plate thickness shall be as required to limit deflection, resulting from a live load of 100 psf, to1/4-inch or the span divided by 240, whichever is less.
2.4 IRON CASTINGS
A. General: Iron castings shall be of uniform quality, free from blowholes, porosity, hard spots, shrinkage, distortion, or other defects. They shall be smooth and well cleaned by shotblasting.
B. Covers and Grates: Covers and grates shall fit together evenly, so that the cover fits flush with the surrounding surface and so that the cover does not rock or rattle when loading is applied. Round covers and frames shall have machined bearing surfaces.
C. Design Loads: Covers and grates with matching frames shall be designed to support the following loadings:
1. Where located within a structure, the design loading shall match that required for the adjacent floor area, or, if no loading is given, a minimum of 300 pounds per square foot, unless indicated otherwise.
2. Exterior covers and grates shall be designed for AASHTO HS-20 loading unless indicated otherwise.
2.5 GALVANIZING
A. Galvanizing for Iron and Steel: Galvanizing for iron and steel shall conform to ASTM A123, with the average weight of 2.0 ounces per square foot, and not less than 1.8 ounces per square foot.
B. Ferrous Metal Hardware Items: Ferrous metal hardware items shall conform to ASTM A153, with average coating weight of 1.3 ounces per square foot.
2.6 WELDING ELECTRODES
A. Steel Electrodes: Welding electrodes shall conform with AWS D1.1, except E7024 rods or electrodes shall not be used.
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B. Aluminum Electrodes: Contingent upon alloys being welded, all welds shall conform to the requirements of AWS D1.2.
C. Stainless Steel Electrodes: Welding of stainless steel with electrodes and techniques shall conform to the pertinent AWS A5 series specification, and as recommended in Welded Austenitic Chromium-Nickel Stainless Steel Techniques and Properties as published by the International Nickel Company, Inc., New York, New York.
2.7 BOLTS
A. Bolt Requirements: Bolts shall comply with the following:
1. Nuts shall be capable of developing the full strength of the bolts. Threads shall be Coarse Thread Series conforming to the requirements of the American Standard for Screw Threads. Bolts and cap screws shall have hexagon heads and nuts shall be Heavy Hexagon Series.
2. The length of all bolts shall be such that after joints are made up, each bolt shall extend through the entire nut, but in no case more than 1/2-inch beyond the nut.
B. Standard Service Bolts (Not Buried or Inside Tanks or Channels): Except where otherwise indicated, bolts and nuts shall be steel and shall be galvanized after fabrication.
Threads on galvanized bolts and nuts shall be formed with suitable taps and dies such that they retain their normal clearance after hot-dip galvanizing. Except as otherwise indicated herein, steel for bolts, anchor bolts and cap screws shall be in accordance with the requirements of ASTM A325, or threaded parts of ASTM A36. ASTM A325 bolts and nuts shall not be galvanized.
C. Bolts Buried or Inside Tanks or Channels: Unless otherwise indicated, bolts, anchor bolts, nuts and washers which are buried, submerged, or below the top of the wall inside any hydraulic structure shall be of Type 316 stainless steel.
2.8 SHOP PRIME PAINT
To ensure compatibility with deferred field-applied paint or coating systems, for ferrous metals other than stainless steel, galvanized steel and cast iron, provide surface preparations, and use shop prime paint product and manufacturer as painting, or protective coating system intended for field application specified in Section 09800, Protective Coatings. Shop prime shall not be provided on portions of work immediately adjacent to intended field welds, nor portions intended for embedment.
2.9 MANUFACTURERS
A. Products of the type or model (if any) indicated shall be manufactured by one of the following (or equal):
1. Floor and Cover Plates:
a. Alcoa C-102 Aluminum Tread Plate.
b. Reynolds Diamond Tread Plate.
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2. Field Repairs to Galvanizing:
a. ìGalvinoxî.
b. ìGalvo-Weldî.
PART 3 - EXECUTION
3.1 FABRICATION AND INSTALLATION REQUIREMENTS
A. Fabrication and Erection: Except as otherwise indicated, the fabrication and erection of structural steel shall conform to the requirements of the American Institute of Steel Construction "Manual of Steel Construction."
1. The Work of this Section shall be coordinated with related trades. Particular attention is required for items to be embedded in concrete work. All punchings and drillings, indicated or required, shall be provided for attachment of other work to that of this Section.
2. Compliance with Safety Requirements. Dimensions required for the fabrication and installation of handrails, ladders, grating, plate, pipe hangers and etc. which are not shown on the Drawings, shall conform to the Division of Occupational Health and Safety, General Industrial Safety Orders, State of California.
B. Protection: The CONTRACTOR shall provide and be responsible for protection and repair of adjacent surfaces and areas which may become damaged as a result of work in this Section. Work performed hereunder shall be protected until completion and final acceptance of project by the OWNER. The CONTRACTOR shall repair or replace all damaged or defective work to original specified condition at no additional cost to the OWNER.
1. Finished floor surfaces and adjacent work shall be protected from damage.
Concrete floors shall not be overloaded. Mobile equipment used in placing steel shall have pneumatic tires. Steel members shall not be placed directly on floors; pads of timber or other material shall be used for cushioning.
2. Where welding is done in proximity to glass or finished surfaces, such surfaces shall be protected from damage due to weld sparks, spatter or tramp metal.
C. Pipe Rails and Railings: Pipe rails and railing shall be fabricated complete with stanchions, toe plates, welded and bolted fittings, attachments and expansion/contraction provisions true to size configurations to meet or exceed the requirements of CAL/OSHA, and as shown on the Drawings. The CONTRACTOR shall grind and polish welds flush and smooth. Curves, where indicated or necessary, shall be bent on a radius of not less than 5 inches.
1. Safety chains shall be 1/2-inch link chain of same material as the railing with stainless steel harness-type snap to meet or exceed the requirements of CAL/OSHA.
2. Provisions shall be made to drain water from rail systems by drilling weep holes in concealed locations at the lowest possible elevations.
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D. Pipe and Conduit Supports and Bracing: Supports and bracing for pipe and conduit shall be fabricated and installed as detailed on the Drawings, in a fully coordinated manner with the Work of other trades. Where shown or indicated, hot-dip galvanized shall be provided after fabrication, with touch-up of abraded or burned galvanizing using materials specified in this Section. Unless otherwise indicated, members shall be shop primed with a rust-inhibitive primer conforming with requirements of Section 09800, Protective Coating.
E. Embedded Steel Channel and Angle Frames: Embedded steel channel and angle frames shall have continuously welded joints. Exposed welds shall be ground flush. Hot-dip galvanizing shall be provided after fabrication.
3.2 WELDING
A. Welding Steel: Welding shall be performed in accordance with the "Structural Welding Code-Steel", AWS D1.1, and current revisions, except where the Gas Metal Arc Welding (GMAW) process is used, the short-circuited mode shall only be used for light gauge material (12 gauge and lighter). Welders shall be qualified by tests in accordance with AWS B2.1.
3.3 GALVANIZING
All structural steel plates shapes, bars and fabricated assemblies required to be galvanized shall, after the steel has been thoroughly cleaned of rust and scale, be galvanized in accordance with the requirements of ASTM A 123. Any galvanized part that becomes warped during the galvanizing operation shall be straightened. Bolts, anchor bolts, nuts and similar threaded fasteners, after being properly cleaned, shall be galvanized in accordance with the requirements of ASTM A 153. Field repairs to galvanizing shall be made using "Galvinox," "Galvo-Weld," or equal.
3.4 PAINTING
One or more shop coats of paint shall be given on all ferrous metals, except cast-iron, ductile iron, stainless steel and galvanized metals. Before priming, surfaces shall be thoroughly cleaned. Shop coats shall be allowed to dry before materials are loaded for delivery to the job site. After erection, all areas shall be painted where the shop coats have been rubbed off or omitted, and all field bolting and welding areas as specified for shop priming. See Section 09800, Protective Coating for surface preparation, prime coatings, finish painting and coatings.
3.5 ISOLATION OF DISSIMILAR METALS
Aluminum members shall be isolated from contact with dissimilar metals, concrete and masonry to provide protection from electrolytic deterioration. The CONTRACTOR shall use non-absorptive tape or gaskets, a heavy brush coat of approved zinc chromate primer made with a synthetic resin vehicle, or a heavy coat of approved alkali, resistant bituminous paint.
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SECTION 05503
ANCHOR BOLTS, ADHESIVE ANCHORS, EXPANSION ANCHORS, AND CONCRETE
INSERTS
PART 1 - GENERAL
1.1 WORK OF THIS SECTION
A. CONTRACTOR shall provide all labor, materials, equipment and incidentals as shown, specified and required to furnish and install anchor bolts, adhesive anchors, expansion anchors and concrete inserts as shown and specified.
B. This Section includes all bolts, anchors and inserts required for the Work, but not specified under other Sections.
C. The types of Work using the bolts, anchors and inserts include, but are not limited to the following:
1. Rails.
2. Hangers and brackets.
3. Equipment.
4. Piping.
5. Grating and floor plate.
6. Electrical and Plumbing Work.
7. Wood and plastic fabrications.
8. Partitions and ceilings.
1.2 RELATED SECTIONS
A. The Work of the following Sections apply to the Work of this Section. Other Sections, not referenced below, shall also apply to the extent required for proper performance of the Work.
1. Section 05500, Miscellaneous Metal.
2. Division 11, Equipment.
1.3 REFERENCE SPECIFICATIONS, CODES AND STANDARDS
A. The current edition of the Uniform Building Code (UBC).
B. Comply with the applicable provisions and recommendations of the following, except as otherwise shown or otherwise specified.
1. ASTM A 307 Carbon Steel Externally and Internally Threaded Standard Fasteners
2. ASTM A 320 Alloy-Steel Bolting Materials for Low-Temperature Service
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C. Adhesive anchors, expansion anchors and inserts shall be UL or FM approved.
1.4 SUBMITTALS
A. Shop Drawings: Submit for approval in accordance with the requirements of Division 1 of the Specifications, the following:
1. Setting drawings and templates for location and installation of anchorage devices.
2. Copies of manufacturerís specifications, load tables, dimension diagrams and installation instructions for the devices.
B. Load and anchoring calculations signed and sealed by a California Registered Civil Engineer as specified in Paragraph 2.1. All required calculations and certifications by a California Registered Professional Engineer shall be at the CONTRACTORís expense and shall be included with the CONTRACTORís bid.
1.5 QUALITY ASSURANCE
Manufacturers and suppliers of the materials specified herein shall be required to review and satisfy all relevant requirements of the Contract Documents. The CONTRACTOR, manufacturer, supplier, fabricator and/or subcontractors furnishing and/or installing equipment, materials, services and specialties associated with this Section shall fully coordinate their efforts to avoid potential claims that are based on failure to review relevant Contract Documents.
PART 2 - PRODUCTS
2.1 DESIGN CRITERIA
A. When the size, length or load carrying capacity of an anchor bolt, expansion anchor, or concrete insert is not specified or not shown on the Drawings, provide the size, length and capacity required to carry the design load times a minimum safety factor of four.
B. Determine design loads as follows:
1. For equipment anchors, use the design load recommended by the manufacturer and approved by the CONSTRUCTION MANAGER.
2. For pipe hangers and supports, use one half the total weights of pipe, fittings, valves, accessories and water contained in pipe, between the hanger and support in question and adjacent hangers and supports on both sides.
3. Allowances for vibration are included in the safety factor specified above.
C. Seismic design loads shall be based on Seismic Zone 4 conditions.
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2.2 MATERIALS
A. Anchor Bolts
1. Provide bolts complying with ASTM A 307, unless otherwise specified or otherwise shown.
2. In enclosed process areas, corrosive areas, outdoor areas, buried or submerged locations, provide stainless steel bolts complying with ASTM A 320, Type 316.
3. In ferric chloride storage and feed areas, and the acid waste storage and feed area, coat all 317 SS bolts after installation with vinylester, by Tnemec Company, Inc., or equal.
B. Adhesive Anchors: Unless otherwise shown or specified, all drilled, concrete or masonry anchors shall be adhesive anchors. No material substitutions will be considered unless accompanied with ICBO report verifying strength and arterial equivalency.
1. Epoxy adhesive anchors are required for drilled anchors where exposed to weather, in submerged, wet, splash, overhead, and corrosive conditions, and for anchoring handrails, pumps, mechanical equipment, and reinforcing bars. Epoxy systems shall be Sika/F1 System with Sikadur Injection Gel Epoxy or Masterbuilders Concresive Epoxy Cartridge Dispensing System and Concresive Paste LPL, or equal. Threaded rod shall be Type 316 stainless steel.
2. Unless otherwise shown, glass capsule, polyester resin adhesive anchors will be permitted in locations not specified above and shall be Hilti HVA, Molly Parabond, or equal. Threaded rod shall be galvanized steel.
C. Expansion Anchors
1. Provide Type 316 stainless steel as specified or as shown. Anchors shall be Type 316 stainless steel and of the size required for the concrete strength specified.
Provide stud type (male thread) or flush type (female thread), as required.
2. Manufacturer: Provide anchors as manufactured by one of the following:
a. Molly division of USM Corporation.
b. Hilti, Incorporated.
c. Or equal.
D. Concrete Inserts
1. For piping, grating and floor plate provide Type 316 stainless steel inserts. Provide those recommended by the manufacturer for the required loading.
2. Manufacturer: Provide inserts as manufactured by one of the following:
a. ITT Grinnell.
b. Hohmann and Barnard, Inc.
c. Hilti, Incorporated.
d. Or equal.
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E. Power actuated fasteners and other types of bolts and fasteners not specified herein shall not be used unless approved by the CONSTRUCTION MANAGER.
PART 3 - EXECUTION
3.1 INSPECTION
A. CONTRACTOR shall examine areas and conditions under which anchor bolts, expansion anchors, adhesive anchors and concrete insert Work is to be installed, and notify the CONSTRUCTION MANAGER in writing of conditions detrimental to proper and timely completion of Work. Do not proceed with Work until unsatisfactory conditions have been corrected in a manner acceptable to the CONSTRUCTION MANAGER.
3.2 INSTALLATION
A. Drilling equipment used and installation of expansion anchors shall be in accordance with manufacturerís instructions.
B. Assure that embedded items are protected from damage and are not filled in with concrete.
C. Expansion anchors may be used for hanging or supporting pipe 2-inches diameter and smaller. Expansion anchors shall not be used for larger pipe, unless otherwise shown or approved by the CONSTRUCTION MANAGER.
D. Use concrete inserts for pipe hangers and supports for the pipe size and loading recommended by the insert manufacturer.
E. Unless otherwise shown or approved by the CONSTRUCTION MANAGER, conform to the following for expansion anchors:
1. Minimum embedment depth in concrete: 6 diameters.
2. Minimum anchor spacing on centers: 12 diameters.
3. Minimum distance to edge of concrete: 6 diameters.
Increase dimensions above if required to develop the required anchor load capacity.
F. For the adhesive anchors and adhesive material, CONTRACTOR shall comply with the manufacturerís installation instructions on the hole diameter and depth required to fully develop the tensile strength of the anchor or reinforcing bar. CONTRACTOR shall properly clean out the hole utilizing a wire brush and compressed air to remove all loose material from the hole, prior to installing adhesive capsules or material.
G. Adhesive anchor manufacturerís representative shall observe and demonstrate the proper installation procedures for the adhesive anchors and adhesive material at no additional expense to OWNER. Each installer shall be certified, in writing, by the manufacturer to be qualified to install the adhesive anchors.
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3.3 CLEANING
After embedding concrete is placed, remove protection and clean bolts and inserts.
3.4 FIELD QUALITY CONTROL
A. CONTRACTOR shall employ a testing laboratory to perform field quality testing of installed anchors. The CONSTRUCTION MANAGER is to determine the level of testing which is required for the various types of expansion anchors and bolts. A minimum of 10 percent of the adhesive anchors and reinforcing bars are to be tested to 50 percent of the ultimate tensile capacity of the anchor or reinforcing bar.
B. If failure of any of the adhesive anchors or reinforcing bars occurs, CONTRACTOR will be required to pay for the costs involved in testing the remaining 90 percent.
C. CONTRACTOR shall correct improper workmanship, remove and replace, or correct as instructed by the CONSTRUCTION MANAGER, all anchors or bars found unacceptable or deficient, at no additional cost to the OWNER.
D. CONTRACTOR shall pay for all corrections and subsequent tests required to confirm the integrity of the anchor or bar.
E. The independent testing and inspection agency shall complete a report on each area. The report should summarize the observations made by the inspector and be submitted to the CONSTRUCTION MANAGER.
F. Provide access for the testing agency to places where Work is being produced so that required inspection and testing can be accomplished.
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SECTION 07900
SEALANTS AND CAULKING
PART 1 - GENERAL
1.1 WORK OF THIS SECTION
A. Scope: Furnish and install all caulking and sealant shown on the Drawings, specified herein and not specified under other sections
1. Seal all openings shown on the Drawings and at other locations requiring caulking to seal visually and against infiltration from air and water, including, but not limited to the following
a. Control joints and expansion joints in masonry and concrete construction b. Flashing retainers
c. Isolation joints between structure and other elements d. Joints at penetrations of walls, decks, and floors by piping and other service and equipment
e. Joints between items or equipment and other construction f. Joints between door frames and adjacent materials, exterior and interior g. Bedding for all door thresholds and floor-mounted hardware h. Open joints between dissimilar materials; joints around door frames, louvers, and other penetrations in the interior or exterior walls as detailed or specified i. Joints between foundation and interior floor slabs or exterior flatwork j. Other joints as detailed
1.2 RELATED SECTIONS
A. The Work of the following Sections applies to the Work of this Section. Other Sections, not referenced below, shall also apply to the extent required for proper performance of this Work.
1. Division 1.
2. Section 03251, Concrete Joints
3. Section 03300, Cast-in-Place Concrete
4. Section 05503, Anchor Bolts, Adhesive Anchors, Expansion Anchors and Concrete Inserts
5. Section 09800, Protective Coating
1.3 QUALITY ASSURANCE
A. Applicator Qualifications: All caulking shall be by a sealant contractor, recognized as such, and in business for at least five years prior to this installation, employing skilled tradesmen for the Work
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1.4 SUBMITTALS
A. In accordance with Division 1 of the Specifications.
B. Color Samples: Submit color chart for each type of sealant for Owner's color selection.
C. Product Data: Submit product data for each material intended for use and location of application.
D. Warranty: Submit warranty specified under Section 1.7.
1.5 DELIVERY, STORAGE, AND HANDLING
Deliver product in original, unopened containers and store in an area not subject to extreme heat or cold.
1.6 JOB CONDITIONS
A. Environmental Conditions
1. Do not apply exterior sealants during wet weather and when the outside temperature is below 40°F
2. Do not apply interior sealants when the inside temperature is below 60°F
1.7 WARRANTY
A. Furnish a five-year written warranty to replace any or all joints which failed during the warranty period at no additional cost to the OWNER.
B. Submit two copies of written guarantee agreeing to repair or replace sealants which fail to perform as airtight and watertight joints; or fail in joint adhesion, cohesion, abrasion resistance, weather resistance, extrusion resistance, migration resistance, stain resistance, or general durability; or appear to deteriorate in any other manner, not clearly specified as an inherent quality of the material by submitted manufacturer's data.
C. Warranty shall date from final acceptance of the project by the OWNER.
PART 2 - PRODUCTS
2.1 JOINT BACKING MATERIAL
A. General
1. Size joint backing material for minimum 30% compression when inserted in the joint.
2. Material shall be round rod or semicircular type
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B. Manufacturers
1. Dow Chemical Company, Ethafoam
2. Sonneborn, Sonofoam
3. Schlegel Manufacturing Company, Schlegelfoam
4. Denver Foam
5. Equivalent products of other manufacturers may be accepted subject to compliance with design, function, materials, and performance of the specified items.
2.2 SEALANT MATERIAL
A. Manufacturers
1. DAP, Inc.
2. Sika Corporation
3. Pecora Corporation
4. Products Research and Chemical Corporation
5. Sonneborn Building Products
6. Tremco Manufacturing Company
7. Mameco International
8. Equivalent products of other manufacturers may be accepted subject to compliance with design, function, materials, and performance of the specified items.
B. Acceptable Materials
1. Interior and under thresholds: Latex acrylic
2. Sealant at concrete slabs: Two component self-leveling urethane
3. All other caulking: One or two component polysulfide, Type 1, Class B nonsag
4. Primer: As recommended by the sealant manufacturer
5. Plastic joint sealer, where indicated on the drawings or specified a. Horizontal application: Pecora "Urexpan NR-200" or equivalent b. Vertical application: Pecora "Dynatrol II" or equivalent
6. Sealant at foundations: Sika Corporation "Sikaflex 1a" or equivalent
2.3 BOND BREAKER TAPE
A. Polyethylene tape or other plastic tape as recommended by the sealant manufacturer to be applied to sealant contact surfaces where bond to the substrate or joint filler must be avoided for proper performance of sealant.
B. Provide self-adhesive tape where applicable.
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PART 3 - EXECUTION
3.1 INSPECTION
A. Inspect all areas to receive caulking and sealant prior to application of such.
B. If any joint or space to receive caulking or sealant is not according to detail and cannot be put into proper condition to receive the work by specified methods, notify CONSTRUCTION MANAGER in writing, or assume responsibility for and rectify any unsatisfactory caulking and sealing which results.
3.2 PREPARATION
A. Preparation of Surfaces
1. Clean all surfaces in accordance with manufacturer's recommendations.
2. Mask edges if required to protect adjoining surfaces and produce a straight finish line.
3. Clean joint surfaces immediately before installation of sealant or caulking compound. a. Remove dirt, insecure coatings, moisture, oil, grease, form release compounds, concrete curing compound, and other substances which would interfere with bond of sealant or caulking compound.
4. Do not proceed with installation of sealant over joint surfaces which have been painted, lacquered, waterproofed, or treated with water repellent or other treatment or coating.
a. Remove coating or treatment at joint surfaces before installing sealant
5. Etch concrete masonry joint surfaces to remove excess alkalinity unless sealant manufacturer's printed instruction indicates that alkalinity does not interfere with sealant bond and performance.
a. Etch with 5% solution of muriatic acid, neutralize with diluted ammonia solution, rinse thoroughly with water and allow to dry before sealant installation.
B. Priming
1. If required, prime all surfaces which are to be caulked with manufacturer's recommended or standard primer after the surfaces have been prepared as specified.
2. Before use, check all primers for discoloration and dirt pick up on adjacent surfaces. a. If staining occurs after exposure, take adequate measures to prevent the primer from being applied over the face of adjacent porous materials by masking or other suitable measures.
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C. Joint Backing
1. All joints which are to be caulked shall be of depth necessary to provide for the specified allowable thickness of sealant and also the required backing where specified.
a. Backing shall be to extent and type as specified and needed to provide for the allowable depth of the sealant.
2. Backup materials for sealants shall be non-staining, compatible with the sealant and primer, shall be of a resilient nature and as recommended by the manufacturer of the sealant.
a. Size and shape of the backing shall be as required by the width of the joint and/or specified.
b. Do not use materials impregnated with oil, solvents, or bituminous materials.
3. Compress backing material a minimum of 30% when inserted in the joint a. Backing material for the upper portion of joints shall be round rod or semicircular in cross section with the arc in contract with the sealant.
4. Install bond breaker tape wherever required by manufacturer's recommendations to ensure that elastomeric sealants will perform properly.
3.3 APPLICATION
A. Exterior Metal Sills: Set in full bed of polysulfide sealant.
B. Thresholds: Set in full bed of acrylic sealant.
C. Caulk Joints
1. Apply sealants in continuous beads without open joints, voids, or air pockets, using a ratchet handgun or mechanical powered gun.
2. Confine sealants to joint areas with masking tape or other precautions. a. Apply compounds in concealed compression joints accurately so that excess compound will not extrude from joints.
3. Remove excess compound or sealant promptly as work progresses, and clean adjoining surfaces.
4. In rough surfaces or joint of uneven widths install sealant well back into joint (recess equal to width of joint, or 3/8" minimum at masonry).
5. Anti-tack agent shall be used where necessary to protect freshly applied sealant from dirt.
6. Joints shall be slightly recessed as to facilitate a painter's line.
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a. All joints throughout construction shall be hand-tooled and finished
7. All work shall be done according to manufacturer's printed instructions and specifications.
D. Concrete Slab Control Joints: Pour joints full, but not overflowing E. Workmanship
1. Employ only proven installation techniques which will ensure that sealants will be deposited in uniform, continuous ribbons without gaps or air pockets, with complete "wetting" of the joint bond surfaces equally on opposite sides.
2. Except as otherwise indicated, fill sealant rabbet to a slightly concave surface, slightly below adjoining surfaces.
3. Where horizontal joints are between a horizontal surface and a vertical surface, fill joint to form a slight cove, so that joint will not trap moisture and dirt.
F. Joint Sizes: Install sealants to depths as recommended by the sealant manufacturer but within the following general limitations
1. For normal moving joints sealed with elastomeric sealants but not subject to traffic, fill joints to a depth equal to 50% of joint width, but not more than ½" deep or less than º" deep.
2. For joints sealed with non-elastomeric sealants and caulking compounds, fill joints to a depth in the range of 75% to 125% of joint width.
G. Spillage
1. Do not allow sealants or compounds to overflow or spill onto adjoining surfaces or to migrate into the voids of adjoining surfaces.
2. Use masking tape or other precautionary devices to prevent staining of adjoining surfaces by either the primer/sealer or the sealant/caulking compound.
3. Remove excess and spillage of compounds promptly as the work progresses
4. Clean the adjoining surfaces by whatever means may be necessary to eliminate evidence of spillage.
5. Do not damage the adjoining surfaces or finishes.
3.4 FIELD QUALITY CONTROL
A. Where directed by the CONSTRUCTION MANAGEER, cut out and remove a total of three samples consisting of the undisturbed sealant and back-up material from the joint
1. Samples to be 6 inches in length
2. Reseal cut out areas with the same materials
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3.5 CURING, PROTECTION, AND CLEANING
A. Cure sealants and caulking compounds in compliance with manufacturer's instructions and recommendations, to obtain high early bond strength, internal cohesive strength, and surface durability.
B. The installer shall advise the contractor of procedures required for the protection of sealants and caulking compounds during the construction period, so that they will be without deterioration or damage (other than normal weathering) at the time of acceptance.
C. Protect all surfaces from damage.
1. Clean soiled surfaces immediately
2. Replace with new material any damaged material which cannot be cleaned ** END OF SECTION **
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SECTION 09800
PROTECTIVE COATINGS
PART 1 - GENERAL
1.1 WORK OF THIS SECTION
A. The CONTRACTOR shall provide protective coatings, complete and in place, in accordance with the Contract Documents.
B. Definitions
1. The term "paint," "coatings," or "finishes" as used herein, shall include surface treatments, emulsions, enamels, paints, epoxy resins, and all other protective coatings, excepting galvanizing or anodizing, whether used as a pretreatment, primer, intermediate coat, or finish coat.
2. The term "MDFT" means minimum dry film thickness.
C. The following surfaces shall not be protective coated unless specifically indicated in other Sections or on the Drawings.
1. Concrete.
2. Stainless steel.
3. Machined surfaces.
4. Grease fittings.
5. Glass.
6. Equipment nameplates.
7. Platform gratings, stair treads, door thresholds, and other walking surfaces.
8. Plastic and fiberglass surfaces.
9. Embedded steel in concrete.
10. Factory pre-finished surfaces with baked-on enamel, porcelain, polyvinyldiene fluoride or other similar heat-applied factory finish.
11. Submerged or intermittently submerged concrete unless otherwise specified.
D. The coating system schedules summarize the surfaces to be coated, the required surface preparation, and the coating systems to be applied. Coating notes on the Drawings are used to show exceptions to the schedules, to show or extend the limits of coating systems, or to clarify or show details for application of the coating systems.
1.2 RELATED SECTIONS
A. The following section applies to the work of this Section. Other Sections of the Specifications, not referenced below, shall also apply to the extent required for proper performance of this work.
1. Division 1, General Requirements.
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1.3 REFERENCE SPECIFICATIONS, CODES AND STANDARDS
A. Except as otherwise indicated, the current editions of the following apply to the Work of this Section:
1. References herein to "SSPC Specifications" or "SSPC" shall mean the published standards of SSPC, the Society for Protective Coatings.
2. References herein to "NACE" shall mean the published standards of the National Association of Corrosion Engineers.
3. References herein to ANSI/AWWA shall mean the published standards of the American Water Works Association including:
a. ANSI/AWWA C205 Cement-Mortar Protective Lining and Coating for Steel Water Pipe B 4 in. (100mm) and Larger B Shop Applied b. ANSI/AWWA C209 Cold-Applied Tape Coatings for the Exterior of Special Sections, Connections, and Fittings for Steel Water Pipelines c. ANSI/AWWA C210 Liquid Epoxy Coating Systems for the Interior and Exterior of Steel Water Pipelines
d. ANSI/AWWA C213 Fusion-Bonded Epoxy Coating for the Interior and Exterior of Steel Water Pipelines
e. ANSI/AWWA C214 Tape Coating Systems for the Exterior of Steel Water Pipelines
f. ANSI/AWWA C217 Cold-Applied Petrolatum Tape and Petroleum Wax Tape Coatings for Exterior of Special Sections, Connections, and Fittings for Buried Steel Water Pipelines
4. Federal Specifications:
a. OSHA 1910.144 Safety Color Code for Marking Physical Hazards
5. National Sanitation Foundation NSF
a. NSF Standard 61 for Contact with Drinking Water.
6. ASTM Standards:
a. C-309 Liquid Membrane-Forming Compounds for Curing Concrete
7. Regulatory Agency Requirements: Coatings for surfaces in contact with raw or potable water shall impart no taste or odor to the water nor result in any organic or inorganic content in excess of the maximum contaminant level established by applicable laws or regulations including NSF Standards. All coatings shall be approved by the San Diego Air Pollution Control District. The CONTRACTOR shall revise painting systems specified herein to provide manufacturerís regulatory agency approved coating system where required. All painting systems shall be VOC compliant.
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B. The Work of this Section shall comply with the current edition of the Uniform Building Code as adopted by the City of El Centro.
C. Inspection records of shop or field-applied coatings and linings for buried or submerged items shall be submitted within 15 days after the work has been accepted.
1.4 CONTRACTOR SUBMITTALS
A. General: Submittals shall be furnished in accordance with Division 1 of the Specifications unless indicated otherwise below.
1. A copy of this specification section, with addendum updates included, and all referenced and applicable sections, with addendum updates included, with each paragraph check-marked to indicate specification compliance or marked to indicate requested deviations from specification requirements. Check marks (3) shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated, and therefore requested by the CONTRACTOR, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph, referenced to a detailed written explanation of the reasons for requesting the deviation. The CONSTRUCTION MANAGER shall be the final authority for determining acceptability of requested deviations. The remaining portions of the paragraph not underlined will signify compliance on the part of the CONTRACTOR with the specifications. Failure to include a copy of the marked-up specification sections, along with justification(s) for any requested deviations to the specification requirements, with the submittal shall be sufficient cause for rejection of the entire submittal with no further consideration.
B. Submittals shall include the following information and be submitted at least 30 days before protective coating work:
1. Coating Materials List: Eight copies of a coating materials list showing the Manufacturer and the coating number, keyed to the coating systems herein. The list shall be submitted before or at the time of submittal of samples.
2. Paint Manufacturer's Information: For each coating system to be used, the following data:
a. Paint manufacturer's data sheet for each product proposed, including statements on the suitability of the material for the intended use. b. List of material surfaces to be coated for each coating system. c. Technical and performance information that demonstrates compliance with the system performance and material requirements.
d. Paint manufacturer's instructions and recommendations on surface preparation and application.
e. Proposed application techniques including proof of the acceptability of the proposed technique for each coating.
f. Colors available for each product (where applicable). g. Compatibility of shop and field applied coatings (where applicable).
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h. Material Safety Data Sheet for each product used.
1.5 SPECIAL CORRECTION OF DEFECTS REQUIREMENTS
A. Warranty Inspection: A warranty inspection may be conducted during the eleventh month following completion of all coating and painting work. The CONTRACTOR and a representative of the coating material manufacturer shall attend this inspection. All defective work shall be repaired in accordance with these Specifications and to the satisfaction of the OWNER. The OWNER may, by written notice to the CONTRACTOR, reschedule the warranty inspection to another date within the 2-year correction period, or may cancel the warranty inspection altogether. If a warranty inspection is not held, the CONTRACTOR is not relieved of its responsibilities under the Contract Documents.
1.6 SERVICES OF MANUFACTURER
A. For submerged and severe service coating systems, the CONTRACTOR shall require the paint manufacturer to furnish the following services:
1. The manufacturer's representative shall furnish at least 6 hours of on-site instruction in the proper surface preparation, use, mixing, application and curing of the coating systems.
2. The manufacturer's representative shall personally observe the start of surface preparation, mixing, and application of the coating materials.
3. The manufacturer's representative shall provide technical support in the field to resolve field problems associated with manufacturer's products furnished under this Contract or the application thereof.
1.7 SAFETY AND HEALTH REGULATIONS
A. General: In accordance with the requirements of OSHA Safety and Health Standards for Construction (29CFR1926) and the applicable requirements of regulatory agencies having jurisdiction, as well as manufacturerís printed instructions and appropriate technical bulletins and manuals, the CONTRACTOR shall provide and require use of personnel protective lifesaving equipment for persons working in or about the project site.
B. Head and Face Protection and Respiratory Devices: Equipment shall include protective helmets which shall be worn by all persons while in the vicinity of the Work. In addition, workers engaged in or near the work during sandblasting shall wear OSHA approved eye and face protection devices and air purifying, half-mask or mouthpiece respirators.
Barrier creams shall be used on any exposed areas of skin.
C. Ventilation: Where ventilation is used to control hazardous exposure, all equipment shall be explosion-proof. Forced air ventilation shall be provided to reduce the concentration of air contaminant to a safe limit. Air circulation and exhausting of solvent vapors shall be continued until coatings have fully cured.
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D. Sound Levels: Whenever the occupational noise exposure exceeds maximum allowable sound levels, the CONTRACTOR shall implement furnish and require the use of approved ear protective devices.
E. Illumination: Adequate illumination shall be provided while Work is in progress, which may include explosion-proof lights, scaffolding and electrical equipment. Whenever required by the CONSTRUCTION MANAGER, the CONTRACTOR shall provide additional illumination to cover all areas to be inspected. The level of illumination for inspection purposes shall be determined by the CONSTRUCTION MANAGER.
F. Temporary Ladders and Scaffolding: All temporary ladders and scaffolding shall conform to applicable safety requirements. They shall be erected where requested by the CONSTRUCTION MANAGER to facilitate inspection and shall be moved by the CONTRACTOR to locations as requested by the CONSTRUCTION MANAGER.
PART 2 - PRODUCTS
2.1 GENERAL
A. Suitability: Use suitable coating materials as recommended by the Manufacturer.
B. Compatibility: In any coating system only compatible materials from a single Manufacturer shall be used in the Work. Particular attention shall be directed to compatibility of primers and finish coats. If necessary, a barrier coat shall be applied between existing prime coat and subsequent field coats to ensure compatibility.
C. Containers: Coating materials shall be sealed in containers that plainly show the designated name, formula or specification number, batch number, color, date of manufacture, and name of manufacturer, all of which shall be plainly legible at the time of use.
D. Colors: All colors and shades of colors of all coats of paint shall be as indicated or selected by the CONSTRUCTION MANAGER. Each coat shall be of a slightly different shade, to facilitate inspection of surface coverage of each coat. Finish colors shall be as selected from the manufacturer's standard color samples by the CONSTRUCTION MANAGER.
E. Substitute or "Or-Equal" Products
1. To establish equality under Division 1 of the Specifications, the CONTRACTOR shall furnish satisfactory documentation from the manufacturer of the proposed substitute or equal product that the material meets the indicated requirements and is equivalent or better in the following properties:
a. Quality.
b. Durability.
c. Resistance to abrasion and physical damage.
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d. Life expectancy.
e. Ability to recoat in future.
f. Solids content by volume.
g. Dry film thickness per coat.
h. Compatibility with other coatings.
i. Suitability for the intended service.
j. Resistance to chemical attack.
k. Temperature limitations in service and during application. l. Type and quality of recommended undercoats and topcoats. m. Ease of application.
n. Ease of repairing damaged areas.
o. Stability of colors.
2. Protective Coating Materials shall be standard products produced by recognized manufacturers who are regularly engaged in production of such materials for essentially identical service conditions. Where requested, provide the CONSTRUCTION MANAGER with the names of not less than 10 successful applications of the proposed manufacturer's products which comply with these requirements.
3. The cost of all testing and analyzing proposed substitute products which may be required by the CONSTRUCTION MANAGER shall be paid by the CONTRACTOR at no additional cost to the OWNER. If a proposed substitution requires changes in the Work, bear all such costs involved and the costs of allied trades affected by the substitution at no additional cost to the OWNER.
2.2 INDUSTRIAL COATING SYSTEMS
A. Material Sources: Each of the following manufacturers is capable of supplying many of the industrial coating materials indicated herein. Where manufacturers and paint numbers are listed, it is to show the type and quality of coatings that are required.
Proposed substitute materials will be considered as indicated above. All industrial coating materials shall be materials that have a record of satisfactory performance in industrial plants, manufacturing facilities, and water and wastewater treatment plants.
1. Ameron International.
2. Carboline Coatings Company.
3. Tnemec Company.
4. Or approved equal.
2.3 COLORS AND FINISHES
A. Surface treatments and finishes are shown under îCoating Systemsî below. All substrates scheduled under ìCoating Systemsî shall be coated whether or not shown on the Drawings or in the Coating System Schedule, unless an item is specifically scheduled as not requiring one of the coating systems described in this Section.
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B. Color Selection: In general, all color coding of piping, ducts and equipment shall comply with applicable standards of ANSI A13.1 and OSHA 1910.144. Piping colors shall conform to the requirements of Section 15060, Pipe and Pipe Fittings.
C. The CONSTRUCTION MANAGER will provide final acceptance of colors based on samples applied on the job. After approval of submittals but before the CONTRACTOR starts the coating work, the CONSTRUCTION MANAGER will furnish color schedules for surfaces to be coated in accordance with this Section. The CONSTRUCTION MANAGER reserves the right to select non-standard colors for all coating systems specified within the ability of the manufacturer to produce such non-standard colors.
Selection of non-standard colors shall not be cause for CONTRACTOR rejecting the CONSTRUCTION MANAGERís color selections and CONTRACTOR shall supply such colors at no additional expense to OWNER.
D. Color Pigments: Color pigments shall be pure, nonfading, applicable types to suit the substrates and service indicated. Lead content shall not exceed amount permitted by federal, state and local government laws and regulations.
2.4 COATING SYSTEMS
A. Interior and Exterior Systems
1. System No. 1 Aliphatic Polyurethane: Two component aliphatic acrylic polyurethane coating material shall provide superior color and gloss retention, resistance to splash from acid and alkaline chemicals, resistance to chemical fumes and severe weathering and with a minimum solids content of 58 percent by volume.
Primer shall be a rust inhibitive two-component epoxy coating with a minimum solids content of 68 percent by volume.
a. Prime coat DFT = 4 mils, Ameron 385, Carboline 893, Tnemec N69, or equal. b. Finish coat (1 or more, DFT = 3 mils), Ameron Amershield, Carboline 134 HG, Tnemec 1074, or equal.
c. Total system DFT = 7 mils.
d. More than one finish coat shall be applied as necessary to produce a finish with uniform color and texture.
2. System No. 2 Epoxy, Equipment and Piping: Two-component, rust inhibitive polyamide cured epoxy coating material shall provide a recoatable finish that is available in a wide selection of colors. The coating material shall have a minimum solids content of 66 percent by volume and be resistant to service conditions of condensing moisture, splash and spillage of lubricating oils, and frequent washdown and cleaning.
a. Prime coat DFT = 3 mils, Ameron 385, Carboguard 890, Tnemec N69, or equal.
b. Prime coat, where shop applied. (DFT = 3 mils), Ameron 185 HS, Carboguard 150, Tnemec 50 330 or 161, or equal.
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c. Finish coats (2 or more, DFT = 6 mils), Ameron 385, Carboguard 890, Tnemec N69, or equal.
d. Total system DFT = 9 mils.
B. Submerged and Severe Service Coating Systems
1. Materials Sources: The manufacturers' products listed in this paragraph are materials which satisfy the material descriptions of this paragraph and have a documented successful record for long term submerged or severe service conditions.
Proposed substitute products will be considered as indicated above.
2. System No. 3 Amine-Cured Epoxy: High build, amine-cured, epoxy resin shall have a solids content of at least 80% by volume, and shall be suitable for long-term immersion service in potable water. For potable water service, the coating material shall be listed by the NSF International as in compliance with NSF Standard 61 Drinking Water System Components Health Effects.
a. Prime coat and finish coats (3 or more, DFT = 16 mils), Ameron 395, Carboguard 891, Tnemec Pota-Pox 80, or equal.
b. For coating of valves and nonsubmerged equipment, DFT = 12 mils.
3. System No. 4 - Cold-Applied Tape: Tape coating materials and procedures shall be in accordance with ANSI/AWWA C209. The system shall consist of a primer layer, inner layer tape (35 mils), and an outer layer tape (35 mils). Total system DFT = 70 mils. Prefabricated tape shall be Type II for fittings and ANSI/AWWA C214 tape for piping.
4. System No. 5 - Polyamide-Cured Epoxy: High build, polyamide epoxy resin shall have a solids content of at least 56% by volume, and shall be suitable for long-term immersion in potable water. For potable water service, the coating material shall be listed by NSF International as in compliance with NSF Standard 61. a. Prime coat and finish coats (3 or more, DFT = 12 mils), Carboguard 888, Tnemec Pota-Pox 80, Ameron 83HS, or equal.
5. System No. 6 - Fusion Bonded Epoxy: The coating material shall be a 100% powder epoxy applied in accordance with the ANSI/AWWA C213 - Fusion-Bonded Epoxy Coating for the Interior and Exterior of Steel Water Pipelines, except that the surface preparation shall be as specified in the coating system schedule of this Section. The coating shall be applied using the fluidized bed process. a. Liquid Epoxy: For field repairs, the use of a liquid epoxy will be permitted, applied in not less than three coats to provide a DFT of 15 mils. The liquid epoxy shall be a 100 percent solids epoxy recommended by the powder epoxy manufacturer and per AWWA C210.
(i) Coating DFT = 16 mils, Scotchkote 134 or 206N, or equal. (ii) Total system DFT = 16 mils.
(iii) For coating of valves, DFT = 12 mils.
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6. System No. 7 - Epoxy, Concrete: The coating material shall be an amine-cured epoxy material suitable for long-term immersion in water and for service where subjected to occasional splash and spillage of water treatment chemicals. The finish coating material shall have a minimum solids content of 80% by volume. If used for potable water service the finish coating material shall be listed by the NSF International as in compliance with NSF Standard 61, and shall conform with state and local health regulations and policies for service in potable water. The fillersealer shall be a 100 percent solids amine-cured epoxy material with silica and inert fillers. A 100 percent solids epoxy surface shall be used to fill holes and patch the concrete surface after abrasive blasting.
a. Prime coat (filler-sealer), applied in two coats to the entire surface using a squeegee to achieve a smooth, void-free surface, Carboguard 501, Tnemec Series 218 Mortar Clad, Ameron Nu-Klad 105A followed by Nu-Klad 114A (two coats) or equal.
b. Finish coats (2 or more, DFT = 12 mils), Carboguard 891, Tnemec Pota-Pox 80 Ameron 395, or equal. On walking surfaces, use a nonskid additive sieve size 70-100 silica broadcast and back rolled into the final coat.
C. Special Coating Systems
1. System No. 8 - Cold-applied Petrolatum/Wax Tape Coating: Materials and procedures shall be in accordance with ANSI/AWWA C217. The system shall consist of a primer (DFT = 3 mils) and a tape layer (40 mils minimum thickness).
2. System No. 9 - Rich Portland Cement Mortar: Rich Portland cement mortar coating shall have a minimum thickness of 1/8 inch, followed by enclosure in an 8-mil thick polyethylene sheet with all joints and edges lapped and sealed with tape.
3. System No. 10 Cement Mortar Coating: Cement mortar coating materials and procedures shall conform to the requirements of ANSI/AWWA C205. A 1 1/4 inch minimum thickness mortar coating shall be provided. The mortar coating shall be reinforced with wire fabric. The cement mortar shall contain no less than one part Type V cement to three parts sand. The cement mortar shall be cured by a curing compound meeting the requirements of "Liquid Membrane Forming Compounds for Curing Concrete," ASTM C 309, Type II, white pigmented, or by enclosure in an 8 mil thick polyethylene sheet with all edges and joints lapped by at least 6 inches.
Sheeting shall be removed before backfilling.
4. System No. 11 - Tape and Cement Mortar Coating: A flexible pipe dielectric coating system (polyethylene tape) and cement mortar protective overcoat (rock shield) shall be provided. Polyethylene tape requirements shall conform to the requirements of ANSI/AWWA C214. A 3/4-inch minimum thickness mortar coating (rock shield) shall be provided and shall be reinforced with welded wire fabric conforming to the requirements of ANSI/AWWA C205. Cement mortar shall conform to the requirements of ANSI/AWWA C205, and cement for mortar shall be Type V.
5. System No. 13 - Acrylic Latex Coating for Exposed PVC Piping: Exterior surfaces of PVC piping exposed to sunlight shall be completely coated with a single component, water-based acrylic latex with a fungicide additive. Exposed PVC
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piping in interior, non-submerged applications shall be color-coded using a single component, water-based acrylic latex. The acrylic latex shall have a minimum solids content of 35 percent by volume. The prime coat shall be as recommended by the manufacturer. The coating material shall be available in ANSI safety colors.
The system shall include a prime coat (DFT = 2 mils) as recommended by the manufacturer. The system shall include two or more finish coats (DFT = 6 mils) of Amerguard 220, Carboline 3359, Tnemec Cryl Series 6, or equal. The total system DFT = 8 mils.
2.5 COATING SYSTEM SCHEDULE
Item Surface Prep. System No.
All ferrous surfaces indoors and
outdoors, exposed or covered,
except those included below.
Commercial blast
cleaning SSPC-SP6
(1) aliphatic
polyurethane
Surfaces of piping and equipment
and ferrous surfaces submerged or
intermittently submerged in potable
water and all surfaces inside
enclosed hydraulic structures and
vents (excluding shop-coated
valves, couplings, pumps).
White metal blast
cleaning SSPC-SP5
(3) amine-cured
epoxy
Buried steel pipe 3-inch diameter
and smaller.
Removal of dirt,
grease, oil
(4) cold applied
tape
Where indicated, ferrous surfaces
in water passages of all valves
4-inch diameter and larger, exterior
surfaces of submerged or buried
valves.
White metal blast
cleaning SSPC-SP5
(5) polyamidecured epoxy
Where indicated, ferrous surfaces
in water passages and submerged
surfaces of all pumps which have
discharge diameter of 4 inches or
larger.
White metal blast
cleaning SSPC-SP5
(3) amine-cured
epoxy
Ferrous surfaces of sleevecouplings and exposed piping inside buildings/vaults.
White metal blast
cleaning SSPC-SP5
(6) fusion-bonded
epoxy
Buried surfaces that are not
indicated to be coated elsewhere.
Removal of dirt,
grease, oil
(4) cold applied
tape
Above-grade or below-grade
concrete, submerged and nonPer paragraph 3.7 (7) epoxy, concrete
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Item Surface Prep. System No.
submerged
Below-grade concrete, submerged,
potable water
Per paragraph 3.7 (7) epoxy,
concrete
Galvanized surfaces where
indicated
Sweep blast
cleaning SSPC-SP7
(2) epoxy
Buried pipe couplings, valves, and
flanged joints, including epoxycoated surfaces
As specified by
reference
specification
(8) petrolatum /
wax tape
Buried plastic pipe couplings,
valves, fittings, and flanged joints
(where piping is plastic)
Removal of dirt,
grease, oil
(9) rich Portland
cement mortar
Buried steel pipe and fittings As specified by
reference
specification
(11) tape and
cement mortar
(10) cement
mortar
Buried ductile or cast iron pipe and
fittings
As specified by
manufacturer for
polyurethane
coating; as specified
by reference
specification for
epoxy coatings
(12) polyurethane
Exposed PVC piping Solvent-cleaned
SSPC-SPI
(13) acrylic latex
PART 3 - EXECUTION
3.1 WORKMANSHIP
A. Skilled craftsmen and experienced supervision shall be used on all Work.
B. Coating shall be done in a workmanlike manner so as to produce an even film of uniform thickness. Edges, corners, crevices, and joints shall receive special attention to insure thorough cleaning and an adequate thickness of coating material. The finished surfaces shall be free from runs, drops, ridges, waves, laps, brush marks, and variations in color, texture, and finish. The hiding shall be so complete that the addition of another coat would not increase the hiding. Special attention shall be given to insure that edges, corners, crevices, welds, and similar areas receive a film thickness equivalent to adjacent
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areas, and installations shall be protected by the use of drop cloths or other precautionary measures.
C. All damage to surfaces resulting from the Work shall be cleaned, repaired, and refinished to original condition.
3.2 STORAGE, MIXING, AND THINNING OF MATERIALS
A. Manufacturer's Recommendations: Unless otherwise indicated, the coating manufacturer's printed recommendations and instructions for thinning, mixing, handling, applying, and protecting its coating materials, for preparation of surfaces for coating, and for all other procedures relative to coating shall be strictly observed.
B. All protective coating materials shall be used within the manufacturer's recommended shelf life.
C. Storage and Mixing: Coating materials shall be stored under the conditions recommended by the Material Safety Data Sheets, and shall be thoroughly stirred, strained, and kept at a uniform consistency during application. Coatings of different manufacturers shall not be mixed together.
3.3 PREPARATION FOR COATING
A. General: All surfaces to receive protective coatings shall be cleaned as indicated before application of coatings. Examine all surfaces to be coated, and correct surface defects before application of any coating material. All marred or abraded spots on shop-primed and on factory-finished surfaces shall receive touch-up restoration before any coating application. Surfaces to be coated shall be dry and free of visible dust.
B. Protection of Surfaces Not to be Coated: Surfaces which are not to receive protective coatings shall be protected during surface preparation, cleaning, and coating operations.
C. All hardware, lighting fixtures, switchplates, machined surfaces, couplings, shafts, bearings, nameplates on machinery, and other surfaces not to be painted shall be removed, masked or otherwise protected. Drop cloths shall be provided to prevent coating materials from falling on or marring adjacent surfaces. The working parts of all mechanical and electrical equipment shall be protected from damage during surface preparation and coating operations. Openings in motors, including moisture weep holes, shall be masked to prevent entry of coating or other materials.
D. Care shall be exercised not to damage adjacent work during blast cleaning operations.
Spray shall be conducted under carefully controlled conditions. The CONTRACTOR shall be fully responsible for and shall promptly repair any and all damage to adjacent work or adjoining property occurring from blast cleaning or coating operations.
E. Protection of Painted Surfaces: Cleaning and coating shall be coordinated so that dust and other contaminants from the cleaning process will not fall on wet, newly coated surfaces.
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3.4 SURFACE PREPARATION STANDARDS
A. The following referenced surface preparation specifications of SSPC: The Society for Protective Coatings shall form a part of this specification:
1. Solvent Cleaning (SSPC SP1): Removal of oil, grease, soil, salts, and other soluble contaminants by cleaning with solvent, vapor, alkali, emulsion, or steam.
2. Hand Tool Cleaning (SSPC SP2): Removal of loose rust, loose mill scale, loose paint, and other loose detrimental foreign matter, by hand chipping, scraping, sanding, and wire brushing.
3. Power Tool Cleaning (SSPC SP3): Removal of loose rust, loose mill scale, loose paint, and other loose detrimental foreign matter, by power tool chipping, descaling, sanding, wire brushing, and grinding.
4. White Metal Blast Cleaning (SSPC SP5): Removal of all visible rust, oil, grease, soil, dust, mill scale, paint, oxides, corrosion products and foreign matter by blast cleaning.
5. Commercial Blast Cleaning (SSPC SP6): Removal of all visible oil, grease, soil, dust, mill scale, rust, paint, oxides, corrosion products, and other foreign matter, except that staining shall be limited to no more than 33 percent of each square inch of surface area.
6. Brush-Off Blast Cleaning (SSPC SP7): Removal of all visible oil, grease, soil, dust, loose mill scale, loose rust, and loose paint.
7. Near-White Blast Cleaning (SSPC SP10): Removal of all visible oil, grease, soil, dust, mill scale, rust, paint, oxides, corrosion products, and other foreign matter, except that staining shall be limited to no more than 5 percent of each square inch of surface area.
8. Surface Preparation of Concrete (SSPC-SP13): Concrete surface shall be free of contaminants, laitance, loosely adhering concrete and dust, and should provide a sound, uniform substrate suitable for the application of protective coating or lining systems.
3.5 METAL SURFACE PREPARATION (UNGALVANIZED)
A. The minimum abrasive blasting surface preparation shall be as indicated in the coating system schedules included at the end of this Section. Where there is a conflict between these Specifications and the coating manufacturer's printed recommendations for the intended service, the higher degree of cleaning shall apply.
B. Workmanship for metal surface preparation shall be in conformance with the current SSPC Standards and this Section. Blast cleaned surfaces shall match the standard samples available from the National Association of Corrosion Engineers, NACE Standard TM 01 70 Visual Standard for Surfaces of New Steel Airblast Cleaned with Sand Abrasive and TM 01 75 Visual Standard for Surfaces of New Steel Centrifugally Blast Cleaned with Steel Grit.
C. All oil, grease, welding fluxes, and other surface contaminants shall be removed by solvent cleaning per SSPC SP1 Solvent Cleaning before blast cleaning.
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D. All sharp edges shall be rounded or chamfered and all burrs, and surface defects and weld splatter shall be ground smooth before blast cleaning.
E. The type and size of abrasive shall be selected to produce a surface profile that meets the coating manufacturer's recommendation for the particular coating and service conditions.
Abrasives for submerged and severe service coating systems shall be clean, hard, sharp cutting crushed slag. Automated blasting systems shall not be used for surfaces that will be in submerged service. Metal shot or grit shall not be used for surfaces that will be in submerged service, even if subsequent abrasive blasting is planned to be one with hard, sharp cutting crushed slag.
F. The abrasive shall not be reused unless an automated blasting system is used for surfaces that will be in nonsubmerged service. For automated blasting systems, clean oil-free abrasives shall be maintained. The abrasive mix shall include at least 50 percent grit.
G. Comply with the applicable federal, state, and local air pollution control regulations for blast cleaning.
H. Compressed air for air blast cleaning shall be supplied at adequate pressure from wellmaintained compressors equipped with oil and moisture separators which remove at least 95% of the contaminants.
I. Surfaces shall be cleaned of all dust and residual particles of the cleaning operation by dry air blast cleaning, vacuuming, or another approved method before painting.
J. Enclosed areas and other areas where dust settling is a problem shall be vacuum cleaned and wiped with a tack cloth.
K. Damaged or defective coating shall be removed by the specified blast cleaning to meet the clean surface requirements before recoating.
L. If the specified abrasive blast cleaning will damage adjacent work, the area to be cleaned is less than 100 square feet, and the coated surface will not be submerged in service, then SSPC SP2 Hand Tool Cleaning or SSPC SP3 Power Tool Cleaning, may be used.
M. Shop-applied coatings of unknown composition shall be completely removed before the indicated coatings are applied. Valves, castings, ductile or cast iron pipe, and fabricated pipe or equipment shall be examined for the presence of shop-applied temporary coatings. Temporary coatings shall be completely removed by solvent cleaning per SSPC SP1 before the abrasive blast cleaning work has been started.
N. Shop primed equipment shall be solvent cleaned in the field before finish coats are applied.
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3.6 SURFACE PREPARATION FOR GALVANIZED FERROUS METAL
A. Galvanized ferrous metal shall be alkaline cleaned per SSPC SP1 to remove oil, grease, and other contaminants detrimental to adhesion of the protective coating system to be used.
B. Pretreatment coatings of surfaces shall be in accordance with the printed recommendations of the coating manufacturer.
3.7 SURFACE PREPARATION FOR CONCRETE SURFACES
A. Prepare surfaces of concrete to be painted by removing all efflorescence, chalk, dust, dirt, grease, oils, with soap and water.
B. Determine the alkalinity and moisture content of the surfaces to be painted by performing appropriate tests in accordance with SSPC-SP13. If the surfaces are found to be sufficiently alkaline to cause blistering and burning of the finish paint, correct this condition before application of paint in accordance with the coating manufacturerís recommendations. Provide suitable testing materials and carry out alkalinity and moisture tests.
C. Do not paint over surfaces where the moisture content exceeds 8%, unless otherwise permitted in the manufacturerís printed directions.
D. Surface preparation and acceptance criteria shall be in accordance with methods described in SSPC-SP13, except acid etching and flame cleaning will not be permitted.
3.8 SHOP COATING REQUIREMENTS
A. Unless otherwise indicated, all items of equipment, or parts of equipment which are not submerged or buried in service, shall be shop primed and then finish coated in the field after installation with the indicated or selected color. The methods, materials, application equipment and all other details of shop painting shall comply with this Section. If the shop primer requires topcoating within a specified period of time, the equipment shall be finish coated in the shop and then touchup painted after installation.
B. All items of equipment or parts and surfaces of equipment which are submerged or inside an enclosed hydraulic structure when in service, with the exception of pumps and valves, shall have all surface preparation and coating work performed in the field.
C. The interior surfaces of steel water reservoirs, except for Part A surfaces, shall have all surface preparation and coating work performed in the field.
D. For certain pieces of equipment, it may be undesirable or impractical to apply finish coatings in the field. Such equipment may include engine generator sets, equipment such as electrical control panels, switchgear or main control boards, submerged parts of pumps, ferrous metal passages in valves, or other items where it is not possible to obtain the indicated quality in the field. Such equipment shall be primed and finish coated in the
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shop and touched up in the field with the identical material after installation. The CONTRACTOR shall require the manufacturer of each such piece of equipment to certify as part of its shop drawings that the surface preparation is in accordance with these Specifications. The coating material data sheet shall be submitted with the shop drawings for the equipment.
3.9 APPLICATION OF COATINGS
A. The application of protective coatings to steel substrates shall be in accordance with SSPC-PA1 - Paint Application Specification No. 1.
B. Cleaned surfaces and all coats shall be inspected before each succeeding coat. Schedule such inspection with the CONSTRUCTION MANAGER in advance.
C. Blast cleaned ferrous metal surfaces shall be painted before any rusting or other deterioration of the surface occurs. Blast cleaning shall be limited to only those surfaces that can be coated in the same working day.
D. Coatings shall be applied in accordance with the manufacturerís instructions and recommendations, and this Section, whichever has the most stringent requirements.
E. Special attention shall be given to edges, angles, weld seams, flanges, nuts and bolts, and other places where insufficient film thicknesses are likely to be present. Use stripe painting for these areas.
F. Special attention shall be given to materials which will be joined so closely that proper surface preparation and application are not possible. Such contact surfaces shall be coated before assembly or installation.
G. Finish coats, including touch-up and damage repair coats shall be applied in a manner which will present a uniform texture and color matched appearance.
H. Coatings shall not be applied under the following conditions:
1. Temperature exceeding the manufacturerís recommended maximum and minimum allowable.
2. Dust or smoke laden atmosphere.
3. Damp or humid weather.
4. When the substrate or air temperature is less than 5 degrees F above dewpoint.
5. When air temperature is expected to drop below 40 degrees F or less than 5 degrees F above the dewpoint within 8 hours after application of coating.
6. When wind conditions are not calm.
I. Dewpoint shall be determined by use of a sling psychrometer in conjunction with U.S.
Department of Commerce, Weather Bureau psychometric tables.
J. Unburied steel piping shall be abrasive blast cleaned and primed before installation.
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3.10 CURING OF COATINGS
A. Maintain curing conditions in accordance with the conditions recommended by the coating material manufacturer or by this Section, whichever is the most stringent, before placing the completed coating system into service.
B. In the case of enclosed areas, forced air ventilation, using heated air if necessary, may be required until the coatings have fully cured.
3.11 SHOP AND FIELD INSPECTION AND TESTING
A. General: Furnish the CONSTRUCTION MANAGER a minimum of 3 daysí advance notice of the start of any field surface preparation work or coating application work, and a minimum of 7 daysí advance notice of the start of any shop surface preparation work.
B. All inspection, testing, and operation of inspection tools for field-applied coatings and linings shall be performed only in the presence of the CONSTRUCTION MANAGER, unless the CONSTRUCTION MANAGER has granted prior approval to perform such Work in its absence. NACE Level III Coating Inspectors shall be provided for all coatings in immersion service, as directed by the CONSTRUCTION MANAGER.
C. Inspection by the CONSTRUCTION MANAGER, or the waiver of inspection of any particular portion of the Work, shall not relieve the CONTRACTOR of its responsibility to perform the Work in accordance with these Specifications.
D. For external or internal application of lining or coating materials for buried or submerged piping systems, the CONTRACTOR shall supply inspection procedures for use by the CONSTRUCTION MANAGER. Procedures shall be supplied in advance of starting work.
E. Inspection Devices: Furnish, until final acceptance of such coatings, inspection devices in good working condition for the detection of holidays and measurement of dry-film thicknesses of protective coatings. Dry-film thickness gauges shall be made available for the CONSTRUCTION MANAGER's use at all times while coating is being done, until final acceptance of such coatings. Furnish the services of a trained operator of the holiday detection devices until the final acceptance of such coatings. Holiday detection devices shall be operated only in the presence of the CONSTRUCTION MANAGER by NACE Level III Coating Inspectors, as determined to be necessary by the CONSTRUCTION MANAGER.
F. Holiday Testing: Holiday test all coated ferrous surfaces inside a steel reservoir, other surfaces which will be submerged in water or other liquids, or surfaces which are enclosed in a vapor space in such structures and surfaces coated with any of the submerged and severe service coating systems. Areas which contain holidays shall be marked and repaired or recoated in accordance with the coating manufacturer's printed instructions and then retested. Electrical inspection for linings and coatings shall be in accordance with applicable NACE standards RPO 188 and/or RPS 274.
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1. Coatings with Thickness Exceeding 20 Mils: For surfaces having a total dry film coating thickness exceeding 20 mils: 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 the voltage required to cause a spark jump across an air gap equal to twice the specified coating thickness.
2. Coatings with Thickness of 20 Mils or Less: For surfaces having a total dry film coating thickness of 20 mils or less: Tinker & Rasor Model M1 nondestructive type holiday detector, K D Bird Dog, or equal shall be used. The unit shall operate at less than 75 V. For thicknesses between 10 and 20 mils, a nonsudsing type wetting agent, such as Kodak Photo Flo, or equal, shall be added to the water before wetting the detector sponge.
G. Film Thickness Testing: On ferrous metals, the dry film coating thickness shall be measured in accordance with the SSPC "Paint Application Specification No. 2" using a magnetic-type dry film thickness gauge such as Mikrotest model FM, Elcometer model 111/1EZ, or equal. Each coat shall be tested for the correct thickness. No measurements shall be made until at least 8 hours after application of the coating. On nonferrous metals and other substrates, the coating thicknesses shall be measured at the time of application using a wet film gauge.
H. Surface Preparation: Evaluation of blast cleaned surface preparation work will be based upon comparison of the blasted surfaces with the standard samples available from the NACE, using NACE standards TM 01 70 and TM 01 75.
3.12 PROTECTION
A. Protect work of other trades, whether to be painted or not, against damage by the painting and finishing Work. Leave all such work undamaged. Correct all damages by cleaning, repairing or replacing, and repainting, as acceptable to the CONSTRUCTION MANAGER.
B. Provide ìWet Paintî signs as required to protect newly painted finishes. Remove all temporary protective wrappings provided for protection of this Contract and other contracts after completion of painting operations.
3.13 CLEAN-UP
A. During the progress of Work, remove from the site all discarded paint materials, rubbish, cans and rags at the end of each work day.
B. Upon completion of painting Work, clean window glass and all other paint-spattered surfaces. Remove spattered paint by proper methods of washing and scraping, using care not to scratch or otherwise damage finished surfaces.
C. At the completion of Work of other trades, touch up and restore all damaged or defaced painted surfaces as determined by the CONSTRUCTION MANAGER.
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SECTION 10441
WARNING SIGNS
PART 1 - GENERAL
1.1 WORK OF THIS SECTION
This section specifies informational and accident prevention signs.
1.2 OPERATING AND DESIGN REQUIREMENTS
A. General: Accident prevention signs shall conform as to design with OSHA Section 1910.145 of Subpart J, Part 1910, Chapter XVII, Title 29 of the Code of Federal Regulations. Exit signs shall conform with Section 1910.37(g) of the OSHA Safety and Health Standard for General Industry, Article 10, Section 10.113 of the Uniform Fire Code, and where applicable with local fire regulations.
B. Design Requirements
1. Size: Sign size shall be as follows:
A ñ 14-inch x 20-inch
B ñ 10-inch x 14-inch
C ñ 7-inch x 10-inch
2. Languages: English and Spanish
3. Type
a. The English sign type shall be as follows:
Type Message
I CAUTION--AUTOMATIC EQUIPMENT MAY START AT
ANY TIME
II DANGER--480 VOLTS
III CAUTION--CORROSIVE CHEMICALS
IV NOTICE--NON-POTABLE WATER--DO NOT DRINK
V NO SMOKING
VI EMERGENCY EYEWASH AND SAFETY SHOWER
VII DANGER--KEEP OUT
VIII DANGER--HIGH VOLTAGE
IX DANGER--CONFINED SPACE ENTRY
X DANGER--CONFINED SPACE--HAZARDOUS
ATMOSPHERE
XI EAR PROTECTION REQUIRED BEYOND THIS POINT
XII CAUTION--HIGH TEMPERATURE
XIII RESTRICTED AREA-AUTHORIZED PERSONNEL ONLY
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Type Message
XIV RADIATION HAZARD
XV HARD HAT AREA
XVI LOCK OUT SWITCH BEFORE WORKING ON EQUIPMENT
XVII NO SWIMMING
XVIII CAUTION--____-FOOT VERTICAL DROP
XIX CAUTION--AUTOMATIC DOOR
XX DO NOT STARE AT WELDING FLAME
XXI CAUTION--PROTECTIVE GEAR REQUIRED WHILE
SERVICING
XXII CAUTION--MOVING MACHINERY
XXIII TRIP MAIN BREAKER INSIDE BUILDING PRIOR TO
WORKING ON TRANSFORMER
XXIV EXIT
b. The Spanish sign type shall be as follows:
Type Message
I PRECAUCION--EQUIPO AUTOMATICO PUEDE PONERSE
EN MARCHA EN CUALQUIER HORA
II PELIGRO--480 VOLTIOS
III PRECAUCION--QUIMICOS CORROSIVOS
IV ADVERTENCIA--AGUA NO POTABLE--NO BEBER
V NO FUMAR
VI REGADERA DE EMERGENCIA Y LAVABO DE OJOS
VII PELIGRO--ALEJESE
VIII PELIGRO--ALTO VOLTAJE
IX PELIGRO--ENTRADA ESTRECHA
X PELIGRO--ESPACIO REDUCIDO--ATMOSFERA
PELIGROSA
XI PROTECCION DE OIDOS REQUERIDA DESPUES DE ESTE
PUNTO
XII PRECAUCION--TEMPERATURA ALTA
XIII AREA RESTRINGIDA--SOLO PERSONAL AUTORIZADO
XIV RADIACION PELIGROSA
XV AREA DE CASCOS
XVI PONER CANDADO AL INTERRUPTOR ANTES DE
TRABAJAR EN EL EQUIPO
XVII PROHIBIDO NADAR
XVIII PRECAUCION--CAIDA VERTICAL DE ____-PIEZ
XIX PRECAUCION--PUERTA AUTOMATICA
XX NO SE LE QUEDE MIRANDO A LA LLAMA DE SOLDAR
XXI PRECAUCION--EQUIPO DE PROTECCION ES
REQUERIDO MIENTRAS TRABAJA
XXII PRECAUCION--MAQUINARIA EN MOVIMIENTO
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Type Message
XXIII APAGAR EL INTERRUPTOR PRINCIPAL ADENTRO DEL
EDIFICIO ANTES DE TRABAJAR EN EL
TRANSFORMADOR
XXIV SALIDA
PART 2 - PRODUCTS
2.1 GENERAL
Sign lettering shall be single stroke and shall contrast in color with the background. For those messages for which there are international symbols, the international symbols shall be used. Chain mounted signs shall have lettering on both sides.
2.2 MATERIALS
Signs shall be 0.100-inch thick fiberglass with embedded fade-proof legends.
PART 3 - EXECUTION
3.1 LOCATION
A. Signs shall be placed next to the equipment and distributed as follows:
Type Message
I CAUTION--AUTOMATIC EQUIPMENT MAY START AT
ANY TIME
V NO SMOKING
VIII DANGER--HIGH VOLTAGE
XIII RESTRICTED AREA-AUTHORIZED PERSONNEL ONLY
XVI LOCK OUT SWITCH BEFORE WORKING ON EQUIPMENT
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SECTION 11000
EQUIPMENT GENERAL PROVISIONS
PART 1 - GENERAL
1.1 WORK OF THIS SECTION
A. The DESIGN-BUILDER shall provide all tools, supplies, materials, equipment, and all labor necessary for the furnishing, construction, installation, testing, and operation of all equipment and appurtenant Work, complete and operable, in accordance with the Contract Documents.
B. The provisions of this Section shall apply to all equipment specified under this Contract and where referred to, except where otherwise indicated.
C. Unless Otherwise Noted: Pumps, electric motors, compressors, and similar equipment and all outdoor equipment shall be designed, or modified, to operate satisfactory for the following conditions:
1. Outside ambient air conditions: Outdoor daily range (min. to max.): 0-120 degrees F.
1.2 RELATED SECTIONS
A. The Work of the following Sections applies to the Work of this Section. Other Sections, not referenced below, shall also apply to the extent required for proper performance of this Work.
1. Section 05500, Miscellaneous Metals.
2. Section 09800, Protective Coatings.
1.3 REFERENCE SPECIFICATIONS AND STANDARDS
A. Commercial Standards: All equipment, products, and their installation shall be in accordance with the following standards, as applicable, and as indicated in each Section:
1. American Society for Testing and Materials (ASTM).
2. American Public Health Association (APHA).
3. American National Standards Institute (ANSI).
4. American Society of Mechanical Engineers (ASME).
5. American Water Works Association (AWWA).
6. American Society of Heating, Refrigerating, and Air Conditioning Engineers (ASHRAE).
7. American Welding Society (AWS).
8. American Gear Manufacturers Association (AGMA).
9. American Iron and Steel Institute (AISI).
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10. National Fire Protection Association (NFPA).
11. Federal Specifications (FS).
12. National Electrical Manufacturers Association (NEMA).
13. Antifriction Bearing Manufacturers Association (AFBMA).
14. Mechanical Power Transmission Association (MPTA).
15. Rubber Manufacturers Association (RMA).
16. Sheet Metal and Air Conditioning Contractorís National Association (SMACNA).
17. Hydraulic Institute Standards (HYI).
18. Institute of Electrical and Electronic Engineers (IEEE).
19. Instrument Society of America (ISA).
20. Manufacturerís published recommendations and specifications.
21. General Industry Safety Orders (CAL OSHA).
B. The following standards have been referred to in this Section:
1. ANSI B16.1 Cast Iron Pipe Flanges and Flanged Fittings Class 25, 125, 250, and 800
2. ANSI B16.5 Pipe Flanges and Flanged Fittings, NPS through NPS 24
3. ANSI B46.1 Surface Texture (Surface Roughness, Waviness, and Lay)
4. ANSI S12.6 Methods for Measuring the Real-Ear Attenuation of Hearing Protectors
5. ANSI/ASME B1.20.1 General Purpose Pipe Threads (Inch)
6. ANSI/ASME B31.1 Power Piping
7. ANSI/AWWA D100 Welded Steel Tanks for Water Storage
8. AWWA C206 Field Welding of Steel Water Pipe
9. ASTM A 48 Specification for Gray Iron Castings
10. ASTM A 108 Specification for Steel Bars, Carbon, Cold-Finished, Standard Quality
1.4 CODES
A. The Work of this Section shall comply with the current editions of the following codes as adopted by the authority having jurisdiction over the Work:
1. Uniform Mechanical Code.
2. Uniform Plumbing Code.
3. Uniform Fire Code.
4. National Electrical Code.
5. Uniform Building Code.
1.5 SUBMITTALS
A. Shop Drawings: The DESIGN-BUILDER shall furnish complete shop drawings for all equipment specified in other Sections, together with all materials, fabrication, assembly, foundation, and installation drawings in accordance with Division 1 of the Specifications.
B. Tools: The DESIGN-BUILDER shall obtain from the manufacturer a list of special wrenches and other special tools necessary for the assembly, adjustment, and dismantling
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of the equipment. All tools shall be of best quality hardened steel forgings with bright finish. Wrench heads shall have work faces dressed to fit nuts. All tools shall be suitable for professional work and manufactured by a recognized supplier of professional tools such as Snap On, Crescent, Stanley, or equal. After approval, DESIGN-BUILDER shall furnish such tools neatly mounted in a labeled toolbox of suitable design provided with a hinged cover.
C. Spare Parts: In accordance with Division 1 of the Specifications, the DESIGN-BUILDER shall obtain from the manufacturer and submit to the OWNER REPRESENTATIVE a list of suggested spare parts for each piece of equipment. After approval, the DESIGNBUILDER shall furnish such spare parts suitably packaged, identified with the equipment number, and labeled. DESIGN-BUILDER shall also furnish the name, address, and telephone number of the nearest distributor for each piece of equipment. All spare parts are intended for use by the OWNER, only, after expiration of the correction period.
D. Operation and Maintenance Information: The DESIGN-BUILDER shall submit operations and maintenance information for each piece of equipment. The following shall be included in compliance with Division 1 of the Specifications:
1. Manufacturer's catalog including installation instructions.
2. Manufacturer's operating and maintenance procedures including lubricating instructions.
3. Manufacturer's certification that products comply with the indicated requirements.
4. Certification that products have been factory-tested.
5. Certification that the equipment has been field-tested and the equipment complies with the indicated requirements.
6. Equipment tolerances and required clearances.
7. Electrical data including control and wiring diagrams.
8. Warranty information, address and telephone number of local service representative.
E. Torsional Analysis: The DESIGN-BUILDER shall submit to the OWNER REPRESENTATIVE a torsional and lateral vibration analysis of the following equipment, in accordance with Division 1 of the Specifications. The analysis must be performed by a State of California Registered Professional Mechanical Engineer experienced in this type of Work and approved in advance by the OWNER REPRESENTATIVE.
1. All engine drives.
2. All blowers and compressors with drives of 100 horsepower and over.
3. All vertical pumps with universal joints and extended shafts.
4. All synchronous motor driven trains.
5. All electric motor with variable frequency drive (VFD) trains.
6. All other equipment where indicated.
Excitation of the following frequencies shall be evaluated:
1. Train with gear 1 and 2 x RPM of either shaft
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2. Engine drive n x RPM
3. Synchronous motor n x slip frequency, 1 and 2 x line frequency
4. VFD n x RPM, 1 and 2 line frequency
where:
RPM = Rotor speed
n = an integer determined by the drive manufacturer
- for engines: derived from the number of power strokes per revolution - for motors: derived from the number of poles
Note: The excitation frequencies for motor drives shall include transient and steady state conditions.
F. The undamped torsional natural frequencies of the complete train shall be at least 10 percent above or 10 percent below any possible (steady state) excitation frequency within the specified operating speed range (from minimum to maximum continuous speed). The manufacturer shall furnish a detailed report of the analysis including the following:
1. A description of the method used to calculate the natural frequencies.
2. A diagram of the mass elastic system.
3. A table of the mass moment and torsional stiffness of each element of the mass elastic system.
4. A Campbell diagram.
5. A mode shape diagram with peak stresses shown for each resonant frequency.
G. Vibration Analysis: In his bid price the DESIGN-BUILDER shall include at least two site visits of the abovementioned specialist, during construction and testing of the equipment, to analyze and measure the amount of equipment vibration and make his written recommendation for keeping the vibration at a safe limit.
H. Earthquake Design and Restraint: All manufactured equipment supplied under this contract shall be designed, constructed and attached to resist stresses produced by seismic forces specified in this Section. Equipment that does not vibrate during normal operation shall be rigidly attached. Equipment that vibrates during normal operation shall be attached by means of isolators with mechanical stops that limit movement in all directions, unless it can be demonstrated by calculations that such stops are not required.
Equipment or portions of equipment that move during normal operation shall be restrained with mechanical devices that prevent displacement unless it can be demonstrated by calculations that such restraints are not required.
1. Work Included: The requirements specified in this Article apply to all machinery, mechanical and electrical equipment, instrumentation panels, and electrical panels, including but not limited to:
a. All pumps.
b. All compressors.
c. All tanks.
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d. Engine generators.
e. Heat exchangers.
f. Water treatment systems
g. HVAC equipment.
h. Engine cooling equipment.
i. All electrical equipment and panels, including battery racks. j. All instrumentation panels.
2. Minimum Earthquake Forces: Except as provided herein, the minimum design earthquake forces shall be those prescribed for Essential Facilities by the latest edition of the California Building Code.
3. Submit shop drawings, details and data required in this Section.
1.6 QUALITY ASSURANCE
A. Inspection, Startup, and Field Adjustment: The DESIGN-BUILDER shall demonstrate that all equipment meets the specified performance requirements. CONTRACTOR shall provide the services of an experienced, competent, and authorized service representative of the manufacturer of each item of major equipment who shall visit the site to perform the following tasks:
1. Assist the CONTRACTOR in the installation of the equipment.
2. To inspect, check, adjust if necessary and approve the equipment installation.
3. To start-up and field-test the equipment for proper operation, efficiency, and capacity.
4. To perform necessary field adjustments during the test period until the equipment installation and operation are satisfactory to the OWNER REPRESENTATIVE.
5. To instruct the OWNER's personnel in the operation and maintenance of the equipment. Instruction shall include step-by-step trouble shooting procedures with all necessary test equipment.
B. Costs: The costs of all inspection, startup, testing, adjustment, and instruction Work performed by said factory-trained representatives shall be paid for by the DESIGNBUILDER at no additional cost to the OWNER. The OWNER will pay for costs of power and water. When available, the OWNER's operating personnel will provide assistance for field testing and startup.
C. Tolerances: Tolerances and clearances shall be as shown on the shop drawings and shall be closely adhered to. Machine Work shall in all cases be of high-grade workmanship and finish, with consideration to the special nature or function of the parts. Members without milled ends and which are to be framed to other steel parts of the structure may have a variation in the detailed length of not greater than 1/16-inch for members 30 feet or less in length, and not greater than 1/8-inch for members over 30 feet in length.
D. Machine Finish: The type of finish shall be the most suitable for the application and shall be shown in micro-inches in accordance with ANSI B46.1. The following finishes shall be used:
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1. Surface roughness not greater than 63 micro-inches shall be required for all surfaces in sliding contact.
2. Surface roughness not greater than 250 micro-inches shall be required for surfaces in contact where a tight joint is not required.
3. Surface roughness not greater than 500 micro-inches shall be required for other machined surfaces.
4. Contact surfaces of shafts and stems which pass through stuffing boxes and contact surfaces of bearings shall be finished to not greater than 32 micro-inches.
E. Manufacturer's Experience: Unless otherwise directed by the OWNER REPRESENTATIVE, all equipment furnished from each manufacturer shall have a record of at least 5 years of successful, trouble free operation in similar applications of similar equipment from the same manufacturer.
F. Warranty: Unless otherwise specified, all equipment shall have a minimum one year full parts and service warranty from the date of installation and acceptance in the Work.
1.7 TOOLS AND SPARE PARTS
A. All special tools and the manufacturerís standard set of spare parts required for the normal operation and maintenance of respective items of equipment in Divisions 2, 3, 9, 11, 13, 15, and 16 shall be furnished with those items of equipment by the manufacturer.
This includes special tools, instruments, accessories required for proper ìin-plantî adjustment, maintenance, overhaul, and operation. Tools shall be high-grade, smooth, forged, alloy tool steel.
B. Special tools are considered to be those tools, which because of their limited use are not normally available, but which are necessary for the particular equipment, whether they are identified in the manufacturerís standard manual or not.
C. All spare parts shall be carefully packed in cartons and all tools packed in metal tool boxes with locking clasps, each labeled with indelible markings, and shall be adequately treated for a long period of storage. Complete ordering information including manufacturerís name and address, part ordering information including manufacturer, part number, part name, and equipment name and number(s) for which the part is to be used shall be supplied with the required spare parts. The tools and spare parts shall be delivered and stored in a location directed by the OWNER REPRESENTATIVE no later than 30 days prior to scheduled field testing. A list of spare parts shall be placed in each storage container respectively, and a duplicate list shall be included with the operations and maintenance manuals.
D. Additional and specific spare parts and tools for certain equipment provided have been specified in the pertinent Sections of the Specifications. The DESIGN-BUILDER shall collect and store all spare parts so required in an area to be designated by the OWNER REPRESENTATIVE. In addition, the DESIGN-BUILDER shall furnish to the OWNER REPRESENTATIVE an inventory listing all spare parts, the equipment they are associated with, the name and address of the supplier, and the delivered cost of each item.
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Copies of the actual invoice for each item shall be furnished with inventory to substantiate the delivery.
E. Special tools and spare parts shall be new and shall not be utilized by the DESIGNBUILDER. The DESIGN-BUILDER shall replace any special tools or spare parts used in the construction, testing, or warranty service provided during the term of this Contract at no additional cost to the OWNER.
PART 2 - PRODUCTS
2.1 GENERAL REQUIREMENTS
A. These Specifications call attention to certain features, but do not purport to cover all details of construction of the units. However, the DESIGN-BUILDER shall furnish and install the mechanisms and/or systems complete in all details and ready for operation when external connections are made. Where components standard with the manufacturer are not specifically mentioned, such components shall be provided and incorporated in the work as if they had been completely described or detailed, at no additional expense to the OWNER.
B. The structural drawings show the primary structure and its framing members. Where materials or equipment not part of the primary structure are to be supported by it, and where the method of attachment is not shown or specified elsewhere, the DESIGNBUILDER shall provide all members and connection details necessary to transfer the loads of the materials and equipment to the primary structural frame. Subframing necessary for this purpose shall be designed by a Civil or Structural Engineer registered in California, and shall be adequate for all loads caused by the weight and operation of the equipment and other loads required by the Codes used for the design of the structure involved. The designer shall provide the OWNER REPRESENTATIVE with the design and calculations, and shall specifically reference the resulting loads to be transferred at each connection to the primary frame. Where connections are made to roof framing, penetrations of the waterproof roof covering shall be kept to a minimum, and the steel decking shall not be used to support the loads. The framing provided will be rejected if the OWNER REPRESENTATIVE determines that it will in any way damage any members of the primary structural frame or any other elements of the building or structure.
C. All steel members used in the fabrication of the equipment shall conform to the requirements of "Specifications for Structural Steel", ASTM A36.
D. Fabrication of structural steel members shall be in accordance with the latest edition of AISC "Specifications for the Design, Fabrication, and Erection of Structural Steel for Buildings". Zinc Coating (hot dip) for Steel Shapes, Bars, Plates and Strip shall be in accordance with the latest edition of ASTM A123. Zinc Coating (hot dip) for Iron and Steel Hardware shall be in accordance with the latest edition of ASTM A153. All welding shall conform to the latest standards of the American Welding Society.
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E. All parts shall be amply proportioned for all stresses that may occur during fabrication, erection, and operation. All parts of the same size and type shall be identical.
F. Manufacturers: Products shall be new, of current manufacture, and shall be the products of reputable manufacturers specializing in the manufacture of such products.
G. Products: Materials shall be suitable for the intended purpose and free of defects and shall be recommended by the manufacturer for the application indicated.
H. High Noise Level Locations: The DESIGN-BUILDER shall provide one personal hearing protection station, as indicated herein, at each high noise level location. Said locations are defined as follows:
1. Outdoor Location: Any single equipment item or any group of equipment items that produce noise exceeding OSHA noise level requirements for a 2-hour exposure.
Where such equipment is separated by a distance of more than 20-feet, measured between edges of footings, each group of equipment shall be provided with a separate hearing protection station.
2. Indoor Location
a. Any single equipment item, or any group of equipment items, located within a single room not normally occupied, which produces noise exceeding OSHA noise level requirements for a 2-hour exposure.
b. Any single equipment item, or any group of equipment items, located within a single room normally occupied by workers, which produces noise exceeding OSHA noise level requirements for an 8-hour exposure.
3. Personal Hearing Protection Station: At each station, the DESIGN-BUILDER shall supply, in their original unopened packaging, three pairs of high attenuation hearing protectors. The ear protectors shall be capable of meeting the requirements of ANSI S12.6 and shall produce a noise level reduction of 25-dBA at a frequency of 500- Hz. The hearing protectors shall have fluid filled ear cushions and an adjustable, padded headband. The protectors shall be stored in a weatherproof, labeled, steel cabinet, furnished by the DESIGN-BUILDER and mounted in an approved location near the noise protection station.
I. Service Factors: Service factors shall be applied in the selection or design of mechanical power transmission components. Unless otherwise calculated, the minimum service factor shall be 1.25. Unless otherwise indicated, the following load classifications shall apply in calculating service factors:
Type of Equipment Load Classification
Pump:
Centrifugal or Rotary Uniform
Reciprocating Moderate Shock
Fan/Blower Moderate Shock
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Crane or Hoist Moderate Shock
J. Welding: Unless otherwise indicated, all welding shall conform to the following:
1. Latest revision of ANSI/AWWA D100.
2. Latest revision of AWWA C206.
3. All composite fabricated steel assemblies which are to be erected or installed inside a hydraulic structure, including any fixed or movable structural components of mechanical equipment, shall have continuous seal welds to prevent entrance of air or moisture.
4. All welding shall be by the metal-arc method or gas-shielded arc method as described in the American Welding Society's "Welding Handbook" as supplemented by other pertinent standards of the AWS. Qualification of welders shall be in accordance with the AWS Standards governing same.
5. In assembly and during welding, the component parts shall be adequately clamped, supported, and restrained to minimize distortion and for control of dimensions.
Weld reinforcement shall be as specified by the AWS code. Upon completion of welding, all weld splatter, flux, slag, and burrs left by attachments shall be removed.
Welds shall be repaired to produce a workmanlike appearance, with uniform weld contours and dimensions. All sharp corners of material to be painted or coated shall be ground to a minimum of 1/32-inch on the flat.
K. Protective Coating: All equipment shall be painted or coated in accordance with Section 09800, Protective Coatings, unless otherwise indicated. Nonferrous metal and corrosionresisting steel surfaces shall be coated with grease or lubricating oil. Coated surfaces shall be protected from abrasion or other damage during handling, testing, storing, assembly, and shipping.
L. Protection of Equipment: All equipment shall be boxed, crated, or otherwise protected from damage and moisture during shipment, handling, and storage. All equipment shall be protected from exposure to corrosive fumes and shall be kept thoroughly dry at all times. Fans, blowers, pumps, motors, drives, electrical equipment, and other equipment having anti-friction or sleeve bearings shall be stored in weather-tight storage facilities before installation. For extended storage periods, plastic equipment wrappers should be avoided, to prevent accumulation of condensate in gears and bearings.
M. Identification of Equipment Items: Each item of equipment shipped shall have a legible identifying mark corresponding to the equipment number indicated for the particular item.
N. Vibration Level: All reciprocating equipment shall be provided with restrained spring-type vibration isolators or pads per manufacturer's written recommendations.
O. Shop Fabrication: Shop fabrication shall be performed in accordance with the Contract Documents and the approved shop drawings.
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2.2 EQUIPMENT ANCHORAGE REQUIREMENTS, DESIGN AND ENGINEERING
CALCULATIONS
A. All equipment designed to be fixed in position shall be securely fastened in place. For all equipment with (1) an operating weight of 400 pounds (181 kilograms) or more, or (2) specifically identified in the specifications for anchorage calculations, detailed engineering anchorage calculations and figures shall be submitted to the OWNER REPRESENTATIVE. For other equipment weighing less than 400 pounds (181 kilograms), the equipment manufacturer shall provide recommended anchorage information to the DESIGN-BUILDER for use in the installation of the equipment.
B. It shall be the responsibility of the equipment manufacturer/supplier to provide the engineering anchorage calculations and figures to the DESIGN-BUILDER for submission to the OWNER REPRESENTATIVE. As a minimum, the equipment manufacturer/supplier shall determine the number, dimensions, material, location, embedment, and installation conditions of all anchor bolts to be set in concrete in accordance with these Specifications and Drawings. At the option of the DESIGNBUILDER, the DESIGN-BUILDER or equipment manufacturer/supplier shall furnish the anchor bolts and associated hardware as specified herein and as determined by engineering anchorage calculations for installation by the DESIGN-BUILDER.
C. Engineering anchorage calculations and figures shall be prepared, stamped, and signed by a Professional Civil Engineer registered in the State of California. Calculations shall include the following steps as a minimum:
1. Determination of the operating weight and centroid of the equipment.
2. Determination of the shear and overturning forces at each anchorage due to the force determined, as specified below, being applied at the equipment's centroid.
3. Determination of the shear and tension forces which must be developed by the anchorage at each support to resist the forces calculated.
4. Selection of anchorage details based upon the maximum shear and tension forces calculated above. As a minimum, details shall include number of bolts, materials, diameter, total length, embedded length, required edge distance, and bolt dimensions.
5. The design for cast-in anchor bolts shall be in accordance with the Uniform Building Code Section 1923. The design of adhesive bolts shall be in accordance with the applicable ICBO report. Design shall be based on installation in concrete with a 28-day compressive strength of 4,000 psi. The use of expansion anchor is not permitted.
6. All anchorage for equipment shall, as a minimum, be designed to comply with the requirements of Section 1630 of the Uniform Building Code.
7. Anchorage shall be designed to resist the minimum lateral force in the direction of each principal horizontal axis using Section 1632 of the Uniform Building Code and the following parameters:
p
r
x
p
pap
w
h
h
R
ICa
Fp
31
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Where
ap = Numerical Coefficient Specified in Table
16-0, (UBC 97) Minimum = 1.0.
Ca = Seismic Coefficient for the El Centro WTP
Site Specific PGA is 0.44.
Ip = Importance Factor Specified in Table 16-K,
(UBC 97)
Use 1.5
Rp = Numerical Coefficient Specified in Table
16-0, (UBC 97)
hr = Roof Elevation with respect to grade
hx = The element or component attachment
elevation with respect to grade. hr shall not
be taken less than 0.0.
Wp = The weight of an element or component
8. In addition to the lateral force, anchorage shall be designed to resist a vertical force, Ev. Shall be applied to the equipment
Ev = 0.5 Cavo I D
D = Dead load. May be taken as zero for
allowable stress
design.
Cavo = Seismic coefficient for the El Centro WTP
site specific PGA is 0.44.
9. Anchorage for equipment shall be designed to resist seismic forces occurring at each of the three principal directions separately as well as simultaneously. When combining seismic forces in orthogonal directions simultaneously, the combination of 100 percent Fh1 plus 30 percent of Fh2 plus 30 percent of Fv shall be used.
Where inclusion of vertical loads results in a less conservative design, vertical effects shall be neglected.
10. Alternatively, the orthogonal effects may be combined on a square root of the sum of the squares (SRSS) basis, using 100 percent of the forces in three directions.
D. Provide a heavy cast-iron or welded steel base for each item of equipment which is to be installed on a concrete foundation.
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1. Mount equipment assemblies on a single, heavy-cast-iron or welded steel bedplate unless otherwise specified or shown on the Drawings.
2. Provide bases and bedplates with machined support pads, tapered dowels for alignment of mating, or adjacent items, adequate openings to facilitate grouting, and openings for electrical conduits.
3. All seams and contact edges between steel plates and shapes shall be continuously welded and ground smooth.
4. Plates shall have a minimum thickness of 1/4-inch.
5. Include a drip lip and provision for directing accumulated gland leakage to a single disposal drain point.
E. Pipe all accumulated gland and seal water leakage and spent cooling water to a floor drain provided by DESIGN-BUILDER adjacent to each piece of equipment.
1. A single floor drain may be provided for more than one piece of equipment provided that the equipment drain line does not create a safety or tripping hazard.
2. If drain piping creates a hazard, provide an additional floor drain adjacent to the equipment at no additional cost to the OWNER.
F. Equipment Foundations: Equipment foundations shall be in accordance with manufacturer's written recommendations. All mechanical equipment, tanks, and control cabinets shall be mounted on concrete bases as shown on standard structural details.
G. Shop Drawings: Shop drawings shall be submitted to the OWNER REPRESENTATIVE for review in accordance with the requirements of Division 1 of the Specifications. Shop drawings will be considered incomplete unless clear, concise calculations are presented showing equipment anchorage forces and the capacities of the anchorage elements provided by the DESIGN-BUILDER.
2.3 PIPE HANGERS, SUPPORTS, AND GUIDES
All pipe connections to equipment shall be supported, anchored, and guided to avoid stresses and loads on equipment flanges and equipment.
2.4 FLANGES AND PIPE THREADS
All flanges on equipment and appurtenances provided under this Section shall conform to ANSI B16.1, Class 125; or B16.5, Class 150, unless otherwise indicated. All pipe threads shall be in accordance with ANSI/ASME B1.20.1, and with requirements of Section 15000, Piping Components.
2.5 NOT USED
2.6 FLEXIBLE COUPLINGS
A. Flexible element couplings shall be provided between the driver and the driven equipment to accommodate slight angular misalignment, parallel misalignment, end float, and to cushion shock loads. Where required for vertical shafts driven by solid shaft
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drivers, the coupling shall be a spacer type. The spacer shall be of sufficient length to permit seal replacement without removal of the driver.
B. The DESIGN-BUILDER shall have the equipment manufacturer select or recommend the size and type of coupling required to suit each specific application.
C. Couplings shall be keyed to the shaft. Keys, keyways, and fits shall conform to ISO/R773. Flexible couplings with cylindrical bores shall have interference fits as specified in ISO/R286. Coupling hubs shall be furnished with tapped puller holes.
D. Where universal type couplings are specified, they shall be of the needle bearing type construction, equipped with commercial type grease fittings.
E. Jacking Screws and Anchor Bolts
1. Provide jacking screws in the equipment bases and bedplates to aid in leveling before grouting.
2. Equipment suppliers shall furnish anchor bolts, nuts, washers and sleeves of adequate design as required for proper anchorage of the bases and bedplates to the concrete bases.
a. Sleeves shall be a minimum of 1.5 times the diameter of the anchor bolts. b. Unless otherwise shown or specified, anchor bolts for items of equipment mounted on baseplates shall be long enough to permit 1-inch of grout beneath the baseplate and to provide adequate anchorage into structural concrete. c. Anchor bolts, together with templates or setting drawings, shall be delivered sufficiently early to permit setting the anchor bolts when the structural concrete is placed.
d. Anchor bolts shall be 316 stainless steel for all equipment except for pumps which will be Type 416 stainless steel which conform to ASTM A167 and ASTM A276.
2.7 ELECTRIC MOTOR DRIVES
DESIGN-BUILDER must coordinate the work of all trades and the national safety code requirements for each installation in order to comply with these specifications.
2.8 SHAFTING
A. General: All shafting up to ten feet in length shall be continuous between bearings and shall be sized to transmit the power required. Keyways shall be accurately cut in line.
Shafting shall not be turned down at the ends to accommodate bearings or sprockets whose bore is less than the diameter of the shaft. All shafts shall rotate in the end bearings and shall be turned and polished, straight, and true.
B. Materials: Shafting materials shall be appropriate for the type of service and torque transmitted. Environmental elements such as corrosive gases, moisture, and fluids shall
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be taken into consideration. Materials shall be as indicated unless furnished as part of an equipment assembly.
1. Cold-rolled steel shafting shall conform to AISI 4140 (A434 CL BB).
2. Corrosion-resistant shafting shall be AISI grade Type 316 stainless steel or Monel, whichever is most suitable for the intended service.
C. Differential Settlement: Where differential settlement between the driver and the driven equipment may be expected, a shaft of sufficient length with two sets of universal type couplings shall be provided.
2.9 BEARINGS
A. General Rotating Element Type: Bearings shall conform to the standards of the AntiFriction Bearing Manufacturers Association, Inc. (AFBMA).
B. To assure satisfactory bearing application, fitting practice, mounting, lubrication, sealing, static rating, housing strength, and other important factors shall be considered in bearing selection.
C. All bearings that may be lubricated shall be equipped with a hydraulic grease fitting in an accessible location and shall have sufficient grease capacity in the bearing chamber.
D. All lubricated-for-life bearings shall be factory-lubricated with the manufacturer's recommended grease to insure maximum bearing life and best performance.
E. Bearing Life: Except where otherwise indicated, all bearings shall have a minimum L-10 life expectancy of 10 years or 100,000 hours, whichever occurs first.
F. Bearing housings shall be of cast iron, ductile iron, or steel and bearing mounting arrangement shall be as indicated, or as recommended in the published standards of the manufacturer if not indicated. Split-type housings may be used to facilitate installation, inspection, and disassembly.
G. Sleeve-type bearings shall have a Babbitt or bronze liner.
2.10 GEARS AND GEAR DRIVES
A. Unless otherwise indicated, gears shall be of the helical or spiral-bevel type, designed and manufactured in accordance with AGMA Standards, with a minimum service factor of
1.7, a minimum L-10 bearing life of 60,000 hours and a minimum efficiency of 94 percent. Worm gears shall not be used unless specifically approved by the OWNER REPRESENTATIVE.
B. All gear speed reducers or increasers shall be of the enclosed type, oil- or greaselubricated and fully sealed, with a breather to allow air to escape but keep dust and dirt out. The casing shall be of cast iron or heavy-duty steel construction with lifting lugs and
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an inspection cover for each gear train. An oil level sight glass and an oil flow indicator shall be provided and installed for easy reading.
C. Gears and gear drives as part of an equipment assembly shall be shipped fully assembled for field installation.
D. Material selections shall be left to the discretion of the manufacturer, provided the above AGMA values are met. Input and output shafts shall be adequately designed for the service and load requirements. Gears shall be computer-matched for minimum tolerance variation. The output shaft shall have two positive seals to prevent oil leakage.
E. Oil level indicators and drain shall be easily accessible. Oil coolers or heat exchangers with all required appurtenances shall be furnished when necessary.
F. Where gear drive input or output shafts have to connect to couplings or sprockets supplied by others, the DESIGN-BUILDER shall have the gear drive manufacturer supply matching key taped to the shaft for shipment.
2.11 DRIVE CHAINS
A. Power drive chains shall be commercial type roller chains and meet ANSI Standards.
B. A chain take-up or tightener shall be provided in every chain drive arrangement to provide easy adjustment.
C. A minimum of one connecting or coupler link shall be provided with each length of roller chain.
D. Chain and attachments shall be of the manufacturer's best standard material and suitable for the process fluid.
2.12 SPROCKETS
A. General: Sprockets shall be used in conjunction with all chain drives and chain-type material handling equipment.
B. Materials: Unless otherwise indicated, materials shall be as follows:
1. Sprockets with 25 teeth or less, normally used as a driver, shall be made of medium carbon steel in the 0.40 to 0.45 percent carbon range.
2. Type A and B sprockets with 26 teeth or more, normally used as driven sprockets, shall be made of minimum 0.20 percent carbon steel.
3. Large diameter sprockets with Type C hub shall be made of cast iron conforming to ASTM A 48, Class 30.
C. All sprockets shall be accurately machined to ANSI Standards. Sprockets shall have deep hardness penetration in tooth sections.
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D. Finish bored sprockets shall be furnished complete with keyseat and set screws.
E. To facilitate installation and disassembly, sprockets shall be of the split type or shall be furnished with taper-lock bushings as required.
F. Idler sprockets shall be furnished with brass or Babbitt bushings, complete with oil hole and axial or circumferential grooving. Steel collars with set screws may be provided in both sides of the hub.
2.13 V-BELT DRIVES
A. V-belts and sheaves shall be of the best commercial grade and shall conform to ANSI, MPTA, and RMA Standards.
B. Unless otherwise indicated, sheaves shall be machined from the finest quality gray cast iron.
C. All sheaves shall be statically balanced. In some applications where vibration is a problem, sheaves shall be dynamically balanced. Sheaves operating at belt speeds exceeding 6,500 fpm may be required to be of special materials and construction.
D. To facilitate installation and disassembly, sheaves shall be furnished complete with taperlock or QD bushings as required.
E. Finish bored sheaves shall be furnished complete with keyseat and set screws.
F. Sliding motor bases shall be provided to adjust the tension of V-belts.
2.14 DRIVE GUARDS
All power transmission, prime movers, machines, shaft extensions, and moving machine parts shall be guarded to conform with the OSHA Safety and Health Standards (29CFR1910, as adopted and amended by the State of California). The guards shall be constructed of minimum 10-gauge expanded, flattened steel with smooth edges and corners, galvanized after fabrication and securely fastened. Where required for lubrication or maintenance, guards shall have hinged and latched access doors.
2.15 FLEXIBLE CONNECTORS
Flexible connectors shall be installed in all piping connections to engines, blowers, compressors, and other vibrating equipment and in piping systems in accordance with Section 15000, Piping Components.
2.16 NOT USED
2.17 GASKETS AND PACKINGS
A. Gaskets containing asbestos will not be permitted.
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B. Packing around valve stems and reciprocating shafts shall be of compressible material, compatible with the fluid being used. Chevron-type "V" packing shall be Garlock No. 432, John Crane "Everseal," or equal.
2.18 NAMEPLATES
Equipment nameplates of Type 316 stainless steel shall be engraved or stamped and fastened to the equipment in an accessible location with No. 4 or larger oval head Type 316 stainless steel screws or drive pins. Nameplates shall contain the manufacturer's name, model, serial number, size, characteristics, and appropriate data describing the equipment performance ratings.
2.19 SAFETY REQUIREMENTS
Where Work areas are located within a flammable or toxic gas environment, suitable gas detection, ventilating, and oxygen deficiency equipment shall be provided. Workers shall be equipped with approved breathing apparatus.
2.20 EQUIPMENT MOUNTS, GROUTING AND VIBRATION ISOLATION A. Equipment mountings shall be as shown on the Drawings. Where a steel or cast base is shown between the equipment and a concrete pedestal, it shall be painted after fabrication in conformance with applicable provisions of Division 9. It also shall be equipped with drain pans and drain connections, including piping, where applicable.
B. All concrete plan dimensions for bases or pedestals shall be at least 2 inches larger in each dimension than the steel or cast base installed thereon. Dimensions shall be increased as required to obtain the minimum edge distance for anchorage. Conduits, piping connections, drains, etc., shall be installed as shown on the Drawings, or if not shown, as acceptable to the OWNER REPRESENTATIVE.
C. Where specified or noted in the Drawings, the equipment, including the base, shall be mounted on or suspended from vibration isolators to prevent the transmission of vibration and mechanically transmitted sound to the supporting structure. Vibration isolation available internally in the equipment unit is not equivalent and shall not be provided when vibration isolation as specified herein by these Specifications. Normally provided internal vibration isolators need to be replaced with rigid supports in such cases.
D. Where required for certain units of mechanical equipment, details of the vibration isolators are included in the Specifications for furnishing and installing those units.
E. The DESIGN-BUILDER shall furnish the necessary materials and construct suitable raised, reinforced concrete foundations for all installed equipment, even though such foundations may not be indicated on the Drawings. The tops of foundations shall be at such elevations as will permit grouting as specified in this Paragraph 2.9.
F. In setting pumps, motors, and other items of equipment customarily grouted, the DESIGN-BUILDER shall make an allowance of at least one (1) inch for grout under the
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equipment bases. All shims shall be removed. Unless otherwise approved, all grout shall be non-shrink grout, acceptable to the CONSTRUCTION MANAGER.
G. Grout shall be mixed and placed in accordance with Section 03600. Where practicable, the grout shall be placed through the grout holes in the base and worked outward and under the edges of the base and across the rough top of the concrete foundation to a peripheral form so constructed as to provide a suitable chamfer around the top edge of the finished foundation.
H. Where such procedure is impractical, the method of placing grout shall be as acceptable to the CONSTRUCTION MANAGER. After the grout has hardened sufficiently, all forms, hoppers and excess grout shall be removed, and all exposed grout surfaces shall be patched in an acceptable manner to the CONSTRUCTION MANAGER, and if necessary, given a burlap rubbed finish, and painted with at least two coats of paint, as noted in Division 9.
2.21 OVERLOAD PROTECTION
A. General: Unless otherwise indicated in individual equipment Sections, all equipment drives incorporating overload protection shall be provided with an overload protection device as follows:
1. Mechanical System: The overload protection shall be a mechanical device to provide for reliable protection in the event of excessive overload. It shall be a ball detent type designed for long-term repeatability and life. It shall be infinitely adjustable by a single adjusting nut. Once set it shall be tamperproof, and incorporate a torque monitoring and control system. It shall activate an alarm set for 85 percent, and a motor cutout switch set for 100 percent of maximum continuous running torque. A visual torque indication shall be provided and oriented so that it may be read from the walkway. The dial shall be calibrated from 0 to 100 percent of maximum continuous running torque. The design of the torque limiter should initiate the mechanical disengagement of the drive upon overload.
Each unit shall be suitable for outdoor/corrosive environments with a protective finish, corrosion inhibiting lubricants and a Type 316 stainless steel cover.
2. Electronic System: As an alternative to the mechanical system, the overload protection may be an Electronic Torque Monitoring Control System capable of displaying torque, rpm's, one level of overload, and two levels of overload of the drive system. It shall incorporate a time-delay for start-up and a voltage monitoring and compensation circuit for up to +15 percent variation.
3. The overload device shall be housed in an enclosure with NEMA rating in accordance with the area designations of Section 16050, Basic Electrical Materials and Methods. A visual torque dial shall be provided and oriented so that it can be easily read from the walkway.
4. The torque monitoring system shall be calibrated to: alarm and shut down the system in the event the torque drops to 50 percent of normal running; alarm at 85 percent of maximum continuous running torque and shut down the motor at maximum continuous running torque of the equipment. The system shall be
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calibrated at the factory of the equipment manufacturer and it shall be capable of monitoring twice the maximum continuous running torque of the equipment.
B. Manufacturers, or equal:
1. American Autogard Corporation.
2. Ferguson Enterprises, Inc.
2.22 LIFTING LUGS
Lifting lugs or lifting eyebolts shall be provided for all equipment or any component weighing 50 pounds or more, for setting of units or future removal. They shall be galvanized or zinc plated steel.
2.23 NOISE REQUIREMENTS
A. General
1. In an attempt to limit off-site noise, it has been established that each piece of equipment must be limited as to its "free field" noise level. Therefore, unless otherwise specified, the maximum permissible "free field" noise level for a complete piece of equipment shall not exceed 85 dBA at a distance of 3 feet from the equipment and 5 feet from the floor with the equipment operating at any load point up to and including rated load in accordance with the specification and not exceed 50 dBA at a distance of 25 feet from the equipment, and 5 feet from the floor. For the purposes of this Paragraph, "free field" shall be the noise level measured when the equipment shall include the driver, driven equipment and any intermediate couplings, gears and auxiliaries. For a complete piece of mechanical equipment located outside of a structure, the maximum permissible noise level shall comply with the requirements of the CAL-OSHA Standard Specifications.
2. Maximum permissible noise levels are in decibels as read on the "A" weighting network of a standard sound level meter (dBA); all measurements are made in relation to a reference pressure of .0002 microbar. Measurements of emitted noise levels shall be made on a sound level meter meeting at least the Type II requirements as set forth in ANSI S1.4 "Specification for General Purpose Sound Level Meters". The sound level meter shall be set on the "A" scale and to slow response. Unless changed in the specific section relating to a particular piece of equipment, the point of measurement of sound level shall be made at the specified distance from any major surface along the entire perimeter and at mid-height of the piece of equipment. If mid-height is not easily determinable, then line of measurement shall be at a height level with the apparent noise source. To assure accuracy, the sound level meter shall be acoustically calibrated with an appropriate instrument, prior to test measurement.
B. Testing
1. The DESIGN-BUILDER shall furnish for each piece of rotating/moving equipment prior to shipment to the job site, a certified factory noise test report on the actual
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equipment to be provided or an unconditional guarantee that the equipment when operating under design conditions will not produce noise exceeding the permissible levels specified.
2. Noise measurements shall be accomplished at the factory or at such other location approved by the CONSTRUCTION MANAGER. These measurements shall be accomplished prior to shipment of any equipment to the job site. The measurements shall take place in a reverberant or semi-reverberant condition, with equipment sitting on a hard reflective surface or conditions identical to the operating conditions of the equipment on this project.
3. Noise level measurements shall be taken or observed by an independent acoustical laboratory or consultant retained and paid for by the DESIGN-BUILDER. Such independent acoustical laboratory or consultant shall be qualified by experience in the acoustical field to take such measurement and shall be responsible for conducting the acoustical sampling in accordance with accepted procedures for the measurement of sound. The laboratory or consultant shall be acceptable to the CONSTRUCTION MANAGER. The person responsible for the tests shall certify the maximum noise levels emanating from the equipment, its operating conditions, the environment in which tests were conducted, a list of the acoustical instruments used, and the points at which the measurements were taken. The description shall be sufficiently detailed to permit the test to be repeated, and shall include a sketch of the item being measured which shows the points of measurement and the point of maximum encountered noise level on the measurement.
4. If the DESIGN-BUILDER provides an unconditional guarantee, the CONSTRUCTION MANAGER may perform field tests for noise generation, which shall be conducted by an independent acoustical laboratory or consultant acceptable to the OWNER. If the noise levels are in excess of the allowable limits, appropriate field noise reduction measures shall be undertaken to reduce the noise to the allowable limits. If the noise level is within the allowable limits the OWNER will pay the DESIGN-BUILDER only for all reasonable expenses directly incurred in conducting the test. Delay, incidental, or extended overhead expenses or claims will not be paid by OWNE. All field noise reduction measures shall be accomplished at the DESIGN-BUILDER's expense, and shall be acceptable to the CONSTRUCTION MANAGER prior to installation. Rated capacities, operational and normal maintenance procedures of the equipment shall not be affected by the noise reduction measures.
(Note: Noise and vibration tests can be performed by the manufacturer's representatives if they are so qualified).
2.24 PROTECTION AGAINST ELECTROLYSIS
Where dissimilar metals are used in conjunction with each other, suitable insulation acceptable to the CONSTRUCTION MANAGER shall be provided between adjoining surfaces to eliminate direct contact and any resultant electrolysis. The insulation shall be bituminous impregnated felt, heavy bituminous coatings, nonmetallic separators or washers, or other acceptable materials.
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2.25 PROVISION FOR TEMPORARY PRESSURE GAUGE CONNECTION
Where pressure gauges are not shown on the suction and discharge piping of pumps, compressors, and blowers, the DESIGN-BUILDER shall make provision for the temporary connection of pressure gauges by providing a connection and tee handle isolation ball valves or corporation stops.
PART 3 - EXECUTION
3.1 PROTECTION
A. Box, crated, or otherwise completely enclosed and protected during shipment, handling and storage in accordance with the manufacturerís recommendations.
1. Protect equipment from exposure to the elements. Keep thoroughly dry and clean at all times.
2. Store pumps, blowers, motors, electrical equipment, and other equipment having anti-friction or sleeve bearings in weather-tight storage facilities such as warehouses. Turn shafts during storage as recommended by the manufacturer to prevent bearing set.
3. Clean and restore all materials and equipment showing evidence of rust, dirt contamination, or other surface or subsurface deterioration to the satisfaction of the CONSTRUCTION MANAGER before installation.
B. Protect painted surfaces against impact, abrasion, discoloration, and other damage.
1. Repaint and repair damaged surfaces to the satisfaction of the CONSTRUCTION MANAGER before acceptance in accordance with the requirements of Section 09800, Protective Coatings.
C. Protect electrical equipment, controls, and insulation against moisture or water damage.
D. The DESIGN-BUILDER shall maintain equipment storage facilities in accordance with the provisions of Division 1 of the Specifications.
E. Store all equipment in the designated storage facilities from delivery until installation.
F. Periodically exercise all mechanical equipment, whether in the DESIGN-BUILDERís designated storage facility before final installation, or whether installed, but not yet placed into service or accepted by the OWNER, in accordance with procedures prescribed by each manufacturer.
3.2 EQUIPMENT INSTALLATION
A. Install all equipment in full accordance with the equipment manufacturerís recommendations and good practice.
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1. Where specified in other sections of this specification, factory-trained service personnel shall be on-site to supervise the installation.
2. Sufficient notice shall be given to the CONSTRUCTION MANAGER before equipment installation so that the CONSTRUCTION MANAGER or his representative may be present during installation.
B. General installation requirements:
1. Examine equipment for damage in shipping and handling. The examination shall include checking for corrosion, poor workmanship, dirt or deleterious substances, and poor fits.
2. Level the base plate or bedplate.
3. Install equipment.
4. Check alignment of couplings.
5. If grout has been used, check alignment and levelness after the grout has set.
6. Check direction of rotation and correct, if necessary, to insure proper operation.
7. Provide drain lines from all equipment gland leakage housings, seal water openings, spent cooling water outlets, and strainers to nearest floor drain or point of disposal.
Blow-down valves shall be provided on all strainers whether or not shown on the drawings.
8. Ensure that all submerged or intermittently submerged powered equipment does not have power and control cable splices of any kind inside wells or pits.
9. Include oil and grease for equipment lubrication in initial operation.
3.3 PLACING EQUIPMENT IN OPERATION
A. Before being placed in operation, equipment shall be inspected by the manufacturerís factory-trained personnel.
1. Correct all defects discovered during this inspection before initial equipment startup.
2. Remove internal coatings applied at the factory if required.
3. Lubricate equipment per manufacturerís recommendations and ensure operating levels are correct.
B. Conduct full-load operational tests in the presence of the CONSTRUCTION MANAGER. The results of such tests shall be recorded.
1. Unsatisfactory performance shall be corrected and tests shall be repeated until the equipment performance meets the Specifications.
2. The DESIGN-BUILDER shall furnish all power, materials, services, test equipment and labor required to successfully complete all full load equipment testing specified.
3. The DESIGN-BUILDER shall certify in writing to the CONSTRUCTION MANAGER, in triplicate, that all tests were conducted in accordance with these Specifications and that all components within each system successfully functions as required.
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C. The DESIGN-BUILDER shall notify the CONSTRUCTION MANAGER 10 calendar days in advance of the time when the equipment will be placed into operation.
D. During the course of initial operation, the DESIGN-BUILDER shall instruct the OWNERís personnel in the proper operation and maintenance of the equipment, as specified herein.
3.4 COUPLINGS
The DESIGN-BUILDER shall have the equipment manufacturer select or recommend the size and type of coupling required to suit each specific application; installation shall be per equipment manufacturer's printed recommendations.
3.5 INSULATING CONNECTIONS
All insulating connections shall be installed in accordance with the manufacturer's printed instructions.
3.6 PIPE HANGERS, SUPPORTS, AND GUIDES
Hangers, supports, seismic bracing and guides shall be spaced in accordance with ANSI/ASME B.31.1 standard.
3.7 PACKAGED EQUIPMENT
When any system is furnished as pre-packaged equipment, the DESIGN-BUILDER shall coordinate with subcontractors all necessary space and structural requirements, clearances, utility connections, signals, and outputs.
3.8 INSTALLATION CHECK
A. Provide an experienced, competent, and authorized representative of the manufacturer or supplier of each major item of equipment, as specified in Divisions 11, 13, and 16 of these specifications, to check adjust if necessary, and approve the equipment installation.
1. In each case, the equipment supplierís representative shall be present when the equipment is placed in operation.
2. The DESIGN-BUILDER shall have the equipment supplierís representative revisit the job site as often as necessary until all problems are corrected and the equipment installation and operation is satisfactory to the CONSTRUCTION MANAGER.
B. Each equipment supplierís representative shall furnish through the DESIGN-BUILDER a written report certifying that the equipment:
1. has been properly installed and lubricated;
2. is in accurate alignment;
3. is free from all stress imposed by connecting piping or anchor bolts;
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4. has been operated successfully under full load conditions for a 24-hour period without interruption; and
5. is ready for continuous operation under specified conditions.
C. Equipment manufacturers shall furnish the services of competent, factory-trained personnel during the warranty period specified to inspect, service, and repair the equipment where required.
1. Service requests shall be answered and acted upon promptly.
2. This requirement shall not include normal maintenance and service of equipment, which will be the responsibility of the OWNER.
D. All costs for this work shall be included in the price bid by the DESIGN-BUILDER, and no additional compensation shall be made by the OWNER.
** END OF SECTION **
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SECTION 11001
GENERAL REQUIREMENTS FOR EQUIPMENT
PART 1 - GENERAL
1.1 WORK OF THIS SECTION
This section specifies general requirements which are applicable to all mechanical equipment.
The Contractor is responsible for ensuring that all mechanical equipment meets the requirements of this section in addition to the specific requirements of the individual equipment specification section.
1.2 RELATED SPECIFICATION SECTIONS
A. The following specification sections are listed as a reference to the Contractor of requirements specified elsewhere that are most pertinent to equipment items. All equipment furnished shall comply with the provisions of these listed sections in addition to the remainder of the contract documents.
1. Division 1, General Requirements.
2. Section 05500, Miscellaneous Metals
3. Section 05503, Anchor Bolts
4. Section 09800, Protective Coatings
5. Section 10441, Warning Signs
6. Section 11002, Equipment Mounting
1.3 GENERAL REQUIREMENTS
A. All equipment shall be of new sturdy construction of ample strength for all stresses which may occur during fabrication, transportation, erection and during continuous or intermittent operations and shall be adequately stayed, or braced and anchored, and shall be installed in a neat and workmanlike manner. Appearance as well as utility shall be given consideration in the design of details.
B. All equipment shall include all production line improvements made up to the delivery or contract date.
C. The furnishing and installation of equipment shall include testing, painting, checking levels and alignment, furnishing and placing of lubricants of whatever type, and furnishing of factory trained service mechanics or engineers where called for. All equipment when finally installed shall be complete and ready for operation without binding or overloading of critical components or motors. The Contractor shall furnish at no extra cost to the Owner all appurtenances, piping, valves, fittings, wiring, supports, hangers, etc. as are required to place the equipment in first class operating condition and in a neat and workmanlike manner.
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D. All fasteners for aluminum shall be stainless steel. All steel other than stainless steel shall be isolated from aluminum with stainless steel, neoprene, or other approved material.
1.4 QUALITY ASSURANCE
A. Arrangement
The arrangement of equipment shown on the plans is based upon information available at the time of design and is not intended to show exact dimensions peculiar to a specific manufacturer. The plans are, in part, diagrammatic, and some features of the illustrated equipment installation may require revision to meet actual equipment installation requirements. Structural supports, foundations, connected piping and valves shown may have to be altered to accommodate the equipment provided. No additional payment will be made for such revisions and alterations which shall be accomplished by the Contractor and approved by the Construction Manager.
B. Motors and Control Devices
1. Control Devices: Control devices, wiring, starters, and other electrical items provided with mechanical equipment shall be as specified in Division 16 and the particular equipment section.
C. Unit Responsibility
Equipment systems made up of two or more components shall be provided as a unit by the responsible manufacturer. Unless otherwise specified, the Contractor shall obtain each system from the supplier of the driven equipment, which supplier shall provide all components of the system to enhance compatibility, ease of construction and efficient maintenance. Contractor is responsible to the Owner for performance of all systems.
D. References
This section references the following documents. They are a part of this section as specified and modified. The latest version in effect at the time of bid shall apply. In case of conflict between the requirements of this section and those of the listed documents, the requirements of this section prevail.
Reference Title
AFBMA Std 9 Load Ratings and Fatigue Life for Ball Bearings AFBMA Std 11 Load and Fatigue Life for Roller Bearings
ANSI B1.1 Unified Screw Threads
ANSI B2.1 Pipe Threads (Except Dupeal)
ANSI B16.1 Cast Iron Pipe Flanges and Flanged Fittings, Class 125
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ANSI B16.5 Steel Pipe flanges, Flanged Valves and Fittings, Class 150 ANSI B18.2.1 Square and Hex Bolts and Screws, Including Askew Head Bolts, Hex Cap Screws, and Log Screws
ANSI B18.2.2 Square and Hex Nuts
ASTM A449 Standard Specification for Quenched and Tempered Steel Bolts and Studs
1.5 SUBMITTALS
Submittals shall be made as specified for each equipment item or group of related equipment items. Submittals shall be in accordance with Division 1 of the Specifications, and shall identify the equipment by the number listed in the specification section, manufacturer and type designation.
1.6 OPERATION AND MAINTENANCE MANUALS
The Contractor shall furnish operation and maintenance manuals for each equipment system in accordance with Division 1 of the Specifications.
1.7 PROTECTION DURING SHIPMENT
A. Shipping
1. Equipment shall be shipped in sealed, weather-tight, enclosed conveyances and protected against damaging stresses during transport and handling.
2. Bearing housings shall be wrapped or otherwise sealed to prevent contamination by grit and dirt; and ventilation and other types of openings shall be taped closed.
3. Damage shall be corrected to conform to the requirements of the contract before the assembly is incorporated into the work. The Contractor shall bear the costs arising out of dismantling, inspection, repair and reassembly.
B. Factory Applied Coatings
Unless otherwise noted, each item of equipment shall be shipped to the site of the work with a shop applied prime coating meeting the requirements of Section 09800, PROTECTIVE COATINGS. The prime coating shall be applied over clean, dry, surfaces prepared in accordance with Section 09800, PROTECTIVE COATINGS. The prime coating will serve as a base for field applied finish coats.
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PART 2 - PRODUCTS
2.1 FLANGES AND PIPE THREADS
A. Flanges on equipment and appurtenances provided under this section shall conform in dimensions and drilling to ANSI B16.1, Class 125 or ANSI B16.5, Class 150, as applicable.
Pipe threads shall conform in dimension and limits of size to ANSI B1.1, coarse thread series, Class 2 fit.
B. Threaded flanges shall have a standard taper pipe thread conforming to ANSI B1.20.1. Unless otherwise specified, flanges shall be flat faced.
C. Flange assembly bolts shall be heavy pattern, hexagonal head carbon steel machine bolts, ASTM A449, with heavy pattern, hot pressed hexagonal nuts conforming to ANSI B18.2.1 and ANSI B18.2.2. Submerged equipment shall have Type 316 stainless steel, ASTM A193, Grade B8M bolts and Type 316 stainless steel ASTM A194 hexagonal nuts conforming to ANSI B18.2.1 and ANSI B18.2.2. Threads shall be Unified Screw Threads, Standard Coarse Thread Series, Class 2A and 2B, ANSI B1.1.
2.2 BEARINGS
A. Unless otherwise specified, equipment bearings shall be oil or grease lubricated, ball or roller type, designed to withstand the stresses of the service specified. Each bearing shall be rated in accordance with the latest revisions of AFBMA Methods of Evaluating Load Ratings of Ball and Roller Bearings. Unless otherwise specified, equipment bearings shall have a minimum L1O rating life of 50,000 hours. The rating life shall be determined using the maximum equipment operating speed.
B. Grease lubricated bearings, except those specified to be factory sealed and lubricated, shall be fitted with easily accessible grease supply, flush, drain and relief fittings. Extension tubes shall be used when necessary. Grease supply fittings shall be standard hydraulic Alemite type.
C. Oil lubricated bearings shall be equipped with either a pressure lubricating system or a separate oil reservoir type system. Each oil lubrication system shall be of sufficient size to safely absorb the heat energy normally generated in the bearing under a maximum ambient temperature of 60°C and shall be equipped with a filler pipe and an external level indicator gage.
2.3 SEALS
A. Mechanical
1. Unless otherwise specified in the equipment sections, rotating shafts shall be provided with mechanical seals and stuffing boxes tapped for flushing seal faces. Seals shall be factory installed. Seals shall be internal, single or double as specified, and unbalanced; except balanced seals shall be provided when shaft speed is greater than 3,600 rpm or when pressures are greater than shown in the following table.
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Seal Inside Diameter Shaft Speed Sealing Pressure
(inches) (rpm) (psig)
1/2" to 2" Up to 1,800 100
1,801 to 3,600 50
Over 2" up to 4" Up to 1,800 50
1,801 to 3,600 25
2. Single unbalanced seals shall be Crane 8-1, Durametallic RO, or equal unless specified otherwise. Single balanced seals shall be Chesterton 880, Crane 8B-I, or equal. Double seals shall be Chesterton 241, Durametallic RO/RD, or equal unless specified otherwise.
3. To maintain the necessary minimum or maximum pressure across the seal faces, spring pressure shall be uniformly distributed to the sealing faces by a coil spring or multiple springs. The rotating seal element shall be clamped to the shaft and provided with an Oring seal. The stationary seal element shall be sealed with O-ring or gasket material.
4. Seal faces shall be either tungsten carbide, carbon, silicon carbide or ceramic.
Elastomeric materials shall be Viton. Metal parts shall be Type 316 stainless steel.
B. Shaft Packing
Where shaft packing is specified, stuffing boxes shall be tapped to permit introduction of seal liquid and shall hold a minimum of five rows of packing and a bronze lantern ring. Packing shall be die-molded graphite impregnated non-asbestos packing rings of material suitable for the intended service and as recommended by the manufacturer. Lantern rings shall be of twopiece construction and shall be provided with tapped holes to facilitate removal.
2.4 COUPLINGS
A. Unless otherwise specified in the particular equipment sections, equipment with a driver greater than 1/2 hp, and where the input shaft of a driven unit is directly connected to the output shaft of the driver, shall have its two shafts connected by a flexible coupling which can accommodate angular misalignment, parallel misalignment, end float, and which cushions shock loads and dampens torsional vibrations. The flexible member shall consist of a tire with synthetic tension members bonded together in rubber. The flexible member shall be attached to flanges by means of clamping rings and cap screws, and the flanges shall be attached to the stub shaft by means of taperlock bushings which shall give the equivalent of a shrunk-on fit.
There shall be no metal-to-metal contact between the driver and the driven unit. Each coupling shall be sized and provided as recommended by the coupling manufacturer for the specific application, considering horsepower, speed of rotation, and type of service.
B. Where torque or horsepower capacities of couplings of the foregoing type is exceeded, Thomas-Rex, Falk Steel Flex, or equal, couplings will be acceptable provided they are
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sized in accordance with the equipment manufacturer's recommendations and sizing data are submitted. They shall be installed in conformance with the coupling manufacturer's instructions.
C. The use of mechanical couplings as specified above shall not relieve the Contractor of his responsibility for precise alignment of all driver and driven units.
D. All metal parts shall be Type 316 stainless steel.
2.5 GUARDS
Exposed moving parts shall be provided with guards which meet the requirements of OSHA.
Guards shall be fabricated of 14 gage steel, 1/2-13-15 expanded metal screen to provide visual inspection of moving parts without removal of the guard. Guards shall be galvanized after fabrication and painted with the equipment. Guards shall be designed to be readily removable to facilitate maintenance of moving parts. Provisions shall be made to extend lube fittings through guards. Any holes in the guards shall be reinforced.
2.6 CAUTION SIGNS
A. Equipment with guarded moving parts which operate automatically or by remote control shall be identified by signs reading "CAUTION AUTOMATIC EQUIPMENT MAY START AT ANY TIME".
B. Signs shall be constructed of corrosion proof material. Signs shall be installed near guarded moving parts. Signs shall be in accordance with Section 10441, WARNING SIGNS.
2.7 PRESSURE TAPS, TEST PLUGS AND GAGES
Pressure taps shall be provided on the suction and discharge sides of all pumps, blowers and compressors. Pressure and vacuum test plugs and gages shall be provided where specified.
2.8 NAMEPLATES
Nameplates shall be provided on each item of equipment and shall contain the specified equipment name or abbreviation and equipment number. Equipment nameplates shall be engraved or stamped on stainless steel and fastened to the equipment in an accessible location with stainless steel screws or drive pins.
2.9 LUBRICANTS
The Contractor shall provide for each item of mechanical equipment a supply of the lubricant required for the commissioning period. Lubricants shall be of the type recommended by the equipment manufacturer. The Contractor shall limit the various types of lubricants by consolidating them, with the equipment manufacturer's approval, into the least number of different types. Not less than 90 days before the date shown in
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his construction schedule for starting, testing and adjusting equipment, the Contractor shall provide the Owner's Representative with 3 copies of a list showing the required lubricants, after consolidation, for each item of mechanical equipment. The list shall show estimated quantity of lubricant needed for a full year's operation, assuming the equipment will be operating continuously.
2.10 SPARE PARTS
A. Where spare parts are required by the specifications, the spare parts for each separate piece of equipment shall be packed in a heavily constructed painted wood box with hinged cover and a locking clasp. The top of the cover shall be painted with the words "SPARE PARTS" followed by the name and number of the piece of equipment involved.
B. Each part shall be individually wrapped in a waterproof container and tagged. Spare bearings shall be encapsulated in an airtight plastic film.
C. Spare parts shall not be used by the contractor during the startup and commissioning of equipment.
2.11 SPECIAL TOOLS AND ACCESSORIES
Any and all tools, instruments or accessories of a special nature which are required to assemble, disassemble, maintain or repair any item of equipment shall be furnished by the Contractor with that piece of equipment. Special tools shall be tagged and well-marked indicating their service and the piece of equipment for which their use is intended. Operation and maintenance manuals shall contain a list and description or pictorial representation of all special tools required for a given piece of equipment.
2.12 LIFTING EYES
Lifting eyes shall be provided on all equipment weighing over 80 lb.
PART 3 - EXECUTION
3.1 GENERAL
Equipment shall be provided and tested within the tolerances recommended by the equipment manufacturer. In addition, equipment provided under the specification sections listed in Paragraph 1.4, Quality Assurance, of this section shall be installed and tested under the direction of installers who have been trained by the equipment manufacturer. This requirement, however, shall not be construed as relieving the Contractor of his overall responsibility for this portion of the work.
3.2 INSTALLATION AND TESTING
The Contractor shall cause each item of equipment to be installed, aligned and tested under the direction of installation engineers who have been factory trained by the
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equipment manufacturer. Upon completion of the project and as a condition precedent to final acceptance, the Contractor shall furnish written certification from the equipment manufacturers that each item has been installed, aligned and tested correctly and that the installation meets all of the manufacturer's requirements for efficient, trouble-free operation.
This provision, however, shall not be construed as relieving the Contractor of his responsibility for this portion of the work. The Contractor shall furnish all fuel, lubricants, and other required materials for testing and shall perform all work, all in accordance with manufacturers' recommendations.
** END OF SECTION **
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JUNE 2024 11002-1
SECTION 11002
EQUIPMENT MOUNTING
PART 1 - GENERAL
1.1 WORK OF THIS SECTION
This section specifies equipment mounting consisting of equipment bases, vibration isolation, and seismic restraint applicable to all equipment.
1.2 QUALITY ASSURANCE
Support, anchorage, and mounting of all tanks, piping, and equipment shall be provided by the Contractor according to the Uniform Building Code and the manufacturer's recommendations, unless otherwise specified. All elements required to resist the calculated forces described herein or required by the equipment manufacturer shall be provided by the Contractor.
1.3 SUBMITTALS
A. Calculations and shop drawings for all of the work required above shall be provided in accordance with Division 1 of the Specifications. Anchor bolt, vibration isolation and seismic restraint design shall be made and signed by a civil or structural engineer currently registered in the State of California.
B. Inasmuch as all anchorage of equipment is to be made of poured-in-place concrete elements, it is imperative that types of anchorage be coordinated with the concrete construction so that anchorage may be installed at time of pouring. If calculations and anchorage details are not submitted prior to pouring of concrete, the Contractor shall become responsible for any strengthening of concrete elements because of superimposed seismic loading.
PART 2 - PRODUCTS
2.1 GENERAL
Unless the equipment incorporates unit construction using an integral rigid frame, or is specified otherwise, each item of mechanical equipment, together with its driver, shall be mounted on a rigid steel or cast iron base. Cast iron bases are acceptable only if the equipment is not furnished with a vibration isolation system. Steel or cast bases shall be hot-dip galvanized after fabrication and rigidly grouted into place with non-shrink grout. (Finish painting shall be in accordance with Section 09800, Protective Coatings). Motor mounting hardware for any belt driven configuration shall allow for belt tension adjustment.
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2.2 ANCHOR BOLTS
Anchor and assembly bolts shall be of ample size and strength for the purposes intended as determined by the equipment manufacturer in accordance with the requirements of this section. Anchor bolts shall be designed for lateral and pullout forces as specified in Subsection 3.01 below and in accordance with Section 05503. Anchor bolt material shall be as specified in the individual equipment specifications. If material is not specified in the individual equipment section, material shall be per Section 05503. In case of conflict, the individual equipment section shall prevail.
2.3 STRUCTURAL STEEL BASE
Structural steel bases shall be rectangular in shape for all equipment other than centrifugal refrigeration machines and pump bases, which may be "T" or "L" shaped where shown. Pump bases for split case pumps shall include supports for suction and discharge base ells. All perimeter members shall be beams with a minimum depth equal to one tenth of the longest dimension of the base. Beam depth need not exceed 14 in., provided that the deflection and misalignment is kept within acceptable limits as determined by the manufacturer. Grout holes shall be provided for the bases of all equipment where vibration isolation is not specified. Where vibration isolation is required, height saving brackets shall be employed in all mounting locations to provide a base clearing of 1 in. Structural steel bases shall be hot dip galvanized after fabrication and finish painted in accordance with Section 09800, Protective Coatings.
2.4 CAST IRON BASES
Cast iron bases located within a building do not require galvanizing but must be sealed in accordance with the requirements for bleeding surfaces specified in Section 09800, Protective Coatings, prior to grouting. All fasteners requiring connections to the base shall be terminated by nuts welded to the bottom side of the base and plugged with cork, plastic plugs or grease, or acorn nuts. In no case shall the fastener terminate only into the metal base.
2.5 CONCRETE PEDESTALS
All equipment, including bases, shall be mounted on a concrete pedestal. Concrete pedestals shall be at least 3 in. larger than the steel or cast base and shall be adequately doweled into the floor slab. All conduits, piping connections, drains, etc. shall be enclosed by the concrete base. Unless otherwise shown or specified, no related conduits, piping connections, drains, etc. shall be accepted which rise directly from the floor.
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PART 3 - EXECUTION
3.1 INSTALLATION
A. Equipment
1. Each piece of equipment shall be anchored to resist a minimum lateral force required by the UBC, the manufacturer of the equipment, or a lateral seismic force of 60% of the operating weight of the equipment, whichever is greater. This force shall be considered acting at the center of gravity of the piece under consideration.
No equipment shall be anchored to vertical structural elements without written approval of the Owner's Representative.
2. Equipment which is not vibration isolated shall be anchored directly to the supporting floor system. In addition to the anchorage, all such equipment shall be internally designed so that all static and moving parts are anchored to the supporting framework to resist the imposed seismic force. All forces must be transmitted to the base in order to be anchored as required. Vibration isolated equipment shall be specially designed to meet these same requirements.
B. Piping
1. All piping, raceways, accessories, and appurtenances furnished with equipment shall be anchored to resist a lateral seismic force of 60% of its operating weight without excessive deflection. This force shall be considered acting at the center of gravity of the piece under consideration.
2. Piping with flexible connections and/or expansion joints shall be anchored such that the intended uses of these joints are maintained in the piping system.
C. Ductwork
All ductwork for both heating and ventilating and for mechanical equipment shall be anchored to the floor system(s), walls, or to the roof as shown. ** END OF SECTION **
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SECTION 11010
ULTRAVIOLET DISINFECTION SYSTEM
PART 1 - GENERAL
1.1 SCOPE
A. The City has procured equipment from a Manufacturer for an open channel, gravity flow, and low-pressure high intensity ultraviolet lamp (UV) disinfection system with an automatic chemical/mechanical cleaning system and variable output lamp drivers. This system will be capable of disinfecting effluent to meet the water quality standards listed in this section.
B. The Contractor shall coordinate with the City and the Manufacturer and shall install all equipment, materials, and appurtenances supplied by the Manufacturer. The Contractor shall also furnish and install any additional materials, equipment, or appurtenances and shall provide all labor required to provide a complete and operational UV system in accordance with this section and the contract documents.
C. The UV disinfection system manufacturer is Trojan Technologies (Manufacturer).
1.2 RELATED SECTIONS:
A. The Work of the following Sections applies to the Work of this Section. Other Sections of the Specifications, not referenced below, shall also apply to the extent required for proper performance of this Work.
1. Division 1 ñ General Requirements
2. Section 03300, Cast In Place Concrete
3. Section 03490, Pre-cast Concrete Trench
4. Section 03600, Grout
5. Section 05503, Anchor Bolts, Adhesive Anchors, Expansion Anchors, and Concrete Inserts
6. Section 09800, Protective Coatings
7. Section 13121, Pre-engineered Metal Building
8. Division 11 - Equipment
9. Division 16 ñ Electrical
10. Appendix A ñ TrojanUV Layout Drawings, Revision D
11. Appendix B ñ TrojanUV Submittal, Revision C
1.3 DESIGN CRITERIA:
A. The UV equipment shall disinfect effluent with the following characteristics:
1. Peak Flow Per Channel: 8.0 MGD
2. Average Flow Per Channel: 3.3 MGD
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3. Minimum Flow Per Channel: 0.9 MGD
4. Total Suspended Solids: 30 mg/L, 30 Day Average grab samples
5. Effluent Temperature Range: 33 to 85 F (1 to 30 °C)
6. Ultraviolet Transmittance @ 253.7 nm: 62%, minimum
7. Effluent standards to be achieved: 200 Fecal Coliform/100 ml* *Based on a 30-day Geometric Mean of daily samples for the effluent standard as specified in 1) through 6). Effluent standards shall be guaranteed regardless of influent count to UV system.
B. The UV system shall be installed in 2 open channels as shown on the Plans.
C. The UV system configuration will be as follows:
1. Number of Channels: 2
2. Number of Banks per Channel: 3
3. Lamps per Bank: 8
4. Total Number of Lamps in the UV System: 48
5. Number of System Control Centers: 1
6. Number of UV Sensors: 1 per bank
7. Number of Power Distribution Centers: 2
8. Number of Hydraulic System Centers: 2
D. Performance Requirements:
1. The UV disinfection system shall be complete with UV Banks and lifting mechanism, System Control Center (SCC), Power Distribution Centers (PDCs), and Hydraulic System Centers (HSCs) as shown on the contract drawings and as specified herein.
2. The UV disinfection system shall produce an effluent conforming to the following discharge permit: 200 Fecal Coliform/100 ml, based on a 30-day Geometric Mean.
Grab samples will be taken in accordance with the Microbiology Sampling Techniques found in Standard Methods for the Examination of Water and Wastewater, 21st Ed.
3. The UV disinfection system will be designed to deliver a minimum MS2 RED of 30 mJ/cm2 at peak flow, in effluent with a UV Transmission of 62% at end of lamp life (EOLL) after reductions for quartz sleeve fouling. The basis for evaluating the RED will be the independent third-party bioassay, without exception. Bioassay validation methodology to follow applicable protocols described in 2006 USEPA UVDGM.
4. The RED will be adjusted using an end of lamp life factor of 0.5 to compensate for lamp output reduction over the time period corresponding to the manufacturerís lamp warranty. The use of a higher lamp aging factor will be considered only upon review and approval of independent third party verified data that has been collected and analysed in accordance with protocols described in the NWRI Ultraviolet Disinfection Guidelines for Drinking Water and Water Reuse.
5. The RED will be adjusted using a quartz sleeve fouling factor of 0.8 to compensate for quartz sleeve transmission reduction due to wastewater effluent fouling. The use of a higher quartz sleeve fouling factor will be considered only upon review and
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approval of independently verified data that has been collected and analysed in accordance with protocols described in the NWRI Ultraviolet Disinfection Guidelines for Drinking Water and Water Reuse. The data recorded for the determination of the validated fouling factor must be obtained by testing in secondary wastewater effluent utilizing the same lamp, quartz sleeve and cleaning system proposed by the UV manufacturer.
6. Independent validation for use of higher factors (lamp aging and sleeve fouling) must be submitted to the Engineer for consideration a minimum of fifteen (15) days prior to bid. The independent validation shall have oversight by a qualified registered professional engineer with knowledge and experience in testing and evaluation of UV systems as defined in the EPA UVDGM (Appendix C, Section C.3.3)
7. The system will be designed for complete outdoor installation.
1.4 SUBMITTALS
The Manufacturer has provided submittals for the UV disinfection system, which are included in Appendix A (TrojanUV Layout Drawings, Revision D) and Appendix B (TrojanUV Submittal, Revision C) of the technical specifications. The Contractor shall thoroughly review these documents and if necessary, the Contractor shall coordinate with the Manufacturer to provide any supplemental documentation needed to install or operate the UV disinfection system. Any supplemental or revised documentation provided by the Manufacturer to the Contractor shall be submitted to the Engineer for review and approval.
1.5 MANUFACTURERíS SCOPE OF SUPPLY:
A. The Manufacturer shall supply the following:
1. Six (6) UV Banks (3 per channel). Each bank includes eight (8) UV lamps and quartz sleeves, one (1) UV intensity sensor, one (1) bank-in-place proximity sensor, one (1) chemical-mechanical wiping system, and one (1) automatic bank lifting mechanism.
2. Four (4) UV Bank Frames (2 per channel).
3. One (1) System Control Center (SCC)
4. Two (2) Power Distribution Centers (PDCs)
5. Two (2) Hydraulic System Centers (HSCs)
6. Two (2) Low Water Level Sensors
7. Two (2) Low Water Level Sensor Control Boxes
8. UV lamp cables (between UV bank and PDC)
9. UV intensity sensor cables (between UV bank and PDC)
10. UV proximity sensor cables (between UV bank and PDC)
11. Hydraulic hoses and connectors (between UV bank and HSC)
12. Two (2) Warning Signs
13. One (1) Operator Kit
14. Spare parts:
a. Eight (8) 1000W Solo Lamps
b. Four (4) 2kW Solo Lamp Drivers
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c. Four (4) Solo Sleeves
d. One (1) Signa UV Sensor
e. Eight (8) Signa 2 Row Wiper Seals
f. One (1) Signa Bank Control Board
1.6 CONTRACTOR SCOPE OF SUPPLY:
A. The Contractor shall supply the following:
1. Electrical conduit, wiring, junction boxes, and distribution panels
2. Controls/communications conduit, wiring, and junction boxes
3. Two (2) level control weirs (304 Stainless Steel, 137î Weir Length) manufactured by Trojan Technologies or an approved equal.
4. Concrete
5. Grout
6. Anchor bolts
7. FRP grating and covers
8. Any additional materials, equipment, or appurtenances required to provide a complete and operational UV system
PART 2 - PRODUCTS
2.1 MANUFACTURER
A. The procured UV disinfection system is TrojanUVSignaô, as manufactured by Trojan Technologies, London, Ontario, Canada.
PART 3 - EXECUTION
3.1 INSTALLATION
A. The Contractor shall install the UV disinfection system in accordance with the contract drawings, manufacturers' shop drawings, instructions, and installation checklist. The Contractor Installation Checklist shall be completed and returned to the Manufacturer at least two (2) weeks prior to date requested for commissioning. Photographs illustrating site readiness are required. The Contractor assumes all responsibility for the installation readiness of the UV system.
B. All labor, materials, and test apparatus necessary for completing the installation shall be furnished by the Contractor at no additional cost to the City or the Manufacturer.
C. The equipment and materials supplied by the Manufacturer are being stored in a secure location at the Cityís El Centro Wastewater Treatment Plant. Prior to construction, the Contractor shall take inventory and verify that all equipment and materials are present and undamaged. The Contractor shall immediately notify the City and the Manufacturer of any missing or damaged items.
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D. The Contractor shall be responsible for transporting and handling all equipment and materials supplied by the Manufacturer between the storage location and the project site.
Any equipment or materials damaged by the Contractor during transportation or installation shall be replaced by the Contractor at no additional cost to the City or the Manufacturer. Costs for insurance of equipment and materials during construction shall be included in the Contractorís bid, at the Contractor's discretion.
3.2 MANUFACTURER'S SERVICES
A. The Manufacturer will provide remote installation assistance by phone or email via the Technical Assistance Center at 1-866-388-0488 or [email protected]. Onsite installation assistance will not be provided.
B. Start-up and field-testing (Commissioning):
1. Onsite inspection: For each UV unit, the Manufacturer will provide 1 day of onsite inspection of the installation immediately prior to start-up.
2. Start-up and field-testing: For each UV unit, the Manufacturer will provide up to 3 working days of onsite start-up and field-testing services.
3. Onsite inspection, start-up, and field testing (2 trips, 4 working days each trip) will only be scheduled upon written request. Contractor shall notify the Manufacturer of schedule requirements at least two (2) weeks in advance. Upon arrival to commission the equipment, if the Manufacturerís Certified Service Technician determines the Contractor work is not complete and the start-up cannot be completed in the allotted time, a return visit will be scheduled at the Contractors expense. Contractor shall issue a purchase order to the Manufacturer for the return trip and additional time required at no additional cost to the City.
C. Operator Training:
1. Contractor shall coordinate with the City and shall schedule training for City Operators during the commissioning time allocated.
D. Warranty Service: As outlined in the warranty agreement included in the Manufacturerís submittal.
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SECTION 13121
PRE-ENGINEERED BUILDING
PART 1 - GENERAL
1.1 SCOPE
Design, fabricate, furnish, and install two (2) pre-engineered metal buildings as indicated on the plans and herein specified. Coordinate the building structural design with the foundation construction, electrical and mechanical requirements and other incidental or related work. The General Requirements of Division 1 shall apply to the work of this Section as if fully repeated herein.
1.2 QUALITY ASSURANCE
A. Like items of metal building materials specified herein shall be the end products of a single manufacturer.
B. Erector's Qualifications: The erector of the work specified in this section must be approved in writing by the pre-engineered metal building manufacturer.
1.3 SUBMITTALS
Submittals shall be in accordance with Section 01300, SUBMITTALS.
A. Provide manufacturer's literature and technical data indicating any deviation from the plans and Specifications required for complete installation of the proposed building.
B. Submit the required sets of coordinated Shop Drawings showing all components, including doors and other accessories and complete structural calculations for the building and foundation. Shop Drawings must be approved by the Owner prior to placing order for fabrication.
C. Shop Drawings must include, at the minimum:
1. Drawings showing slab, structural components and dimensions for this project.
2. Foundation anchor bolt plan with anchor bolt, shear angle and baseplate details for this project.
3. Calculations developed specifically for this project by a structural ENGINEER registered in the State of California.
4. Include all door, window and other openings and accessories details and specifications for painting system, including paint manufacturer's name, product trade-name and preparation for shop or field coats.
D. Submit written certification of compliance to these specifications on manufacturer's letterhead, identifying project name, location and date.