Vallejo City Council
February 24, 2026

High-Performance Coatings
09960-10 201631 September 2025
pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/09960 (BidSet) ASTM D4541, ASTM D4787, ASTM D5162, ASTM D7234, SSPC-PA 1, SSPC-PA 2, SSPC-PA 9, and other pertinent standards and recommended practices.

I. Inspection at Hold Points:

1. Coatings application: At the beginning of coating system application, measure, record, and confirm acceptability of surface and ambient air temperature and humidity. Inspect applicator's equipment for serviceability and suitability for coatings application:
a. Observe conditions during the Pre-application Meeting.

1.07 PRODUCT DELIVERY, STORAGE, AND HANDLING
A. Deliver, store, and handle products as specified in Section 01601 - Product Requirements.

B. Immediately remove unspecified and unapproved coatings from Project site.

C. Deliver new labeled, unopened containers:

1. Do not deliver materials after manufacturer's expiration date or over 12 months from manufacturing date, whichever is more stringent. Store materials in well-ventilated enclosed structures and protect from weather and excessive heat or cold in accordance with the CSM’s recommendations:
a. Store flammable materials in accordance with federal, state, and local requirements.
b. Store rags and cleanup materials appropriately to prevent fire and spontaneous combustion.

2. Store and dispose of hazardous waste in accordance with federal, state, and local requirements. This requirement specifically applies to waste solvents and coatings.

3. Container labels shall show the following:
a. Brand name or product title.
b. CSM's batch number.
c. CSM's manufacture date.
d. CSM's name.
e. Generic material type.
f. Application and mixing instructions.
g. Hazardous material identification label.
h. Shelf life expiration date.
i. Color.
j. Mixing and reducing instructions.

4. Clearly mark containers to indicate safety hazards associated with the use of or exposure to materials.

1.08 PROJECT CONDITIONS
A. Apply coatings to dry surfaces:

1. Surface moisture: Comply with manufacturer's requirements or as specified in this Section:
a. Plaster and gypsum wallboard: 12 percent.
b. Masonry and concrete block: 12 percent.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/09960 (BidSet) c. Interior located wood: 15 percent.
d. Concrete floors: Moisture vapor transmission rate of no more than

3.0 pounds per 1,000 square feet per 24 hours in accordance with ASTM F1869 or relative humidity no greater than 80 percent if tested in accordance with ASTM F2170 unless the CSM's recommendations are more restrictive.
e. Concrete structures: Negative results from Plastic Sheet Test in accordance with ASTM D4263, and maximum of 80 percent relative humidity in accordance with ASTM F2170.

B. Do not apply coatings when the following conditions exist. If such conditions exist, provide containment, covers, environmental controls, and other necessary measures:

1. During rainy, misty, or damp weather, or to surfaces with frost or condensation.

2. When the surface temperature is below 10 degrees Fahrenheit above the dew point.

3. When ambient or surface temperature:
a. Is less than 55 degrees Fahrenheit unless manufacturer allows a lower temperature.
b. Is less than 65 degrees Fahrenheit for clear finishes, unless manufacturer allows a lower temperature.
c. Exceeds 90 degrees Fahrenheit, unless manufacturer allows a higher temperature.
d. Exceeds manufacturer's recommendation.

4. When relative humidity is higher than 85 percent.

5. Under dusty or adverse environmental conditions.

6. When light on surfaces measures less than 15 foot-candles.

7. When wind speed exceeds 15 miles per hour.

C. Apply coating only under evaporation conditions rather than condensation:

1. Use dehumidification equipment, fans, and/or heaters inside enclosed areas to maintain required atmospheric and surface temperature requirements for proper coating application and cure.

2. Measure and record relative humidity and air and surface temperatures at the start and end of each shift to confirm proper humidity and temperature levels inside the work area:
a. Submit test results.

D. Continuously ventilate, dehumidify, and heat enclosed spaces with high humidity during surface preparation, coating application, and curing:

1. Maintain minimum air temperature of 55 degrees Fahrenheit and 10 degrees Fahrenheit above the dew point.

2. Maintain dew point of at least 10 degrees Fahrenheit less than the temperature of the coldest part of the structure where work is performed.

3. Reduce dew point temperature in conditioned space by at least 10 degrees Fahrenheit within 20 minutes.

4. Seal work areas and maintain positive pressure per dehumidification equipment supplier's recommendations.

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5. Maintain these conditions before, during, and after application to ensure proper adhesion and cure of coatings for no less than:
a. Entire curing period.
b. 8 hours after coating.

E. Systems:

1. Site electrical power availability as specified in Section 01500 - Temporary Facilities and Controls.

2. Internal combustion engine generators may be used:
a. Obtain required permits and provide air pollution and noise control devices on equipment as required by permitting agencies require. b. Comply with state, federal, and local fire and explosion protection measures when locating and operating generator.
c. Locate engine generator outside hazardous classified areas per NFPA 820.
d. Provide daily fuel service for generator for duration of use.

3. Dehumidification:
a. Provide desiccant or refrigeration drying.
b. Use only desiccant types with a rotary desiccant wheel capable of continuous operation.
c. Liquid, granular, or loose lithium chloride drying systems are not acceptable.

4. Heating:
a. Use electric, indirect combustion, or steam coil.
b. Direct-fired combustion heaters are not acceptable heat sources during abrasive blasting, coating application, or coating cure.

5. Filters:
a. Use a filtration system for dust removal designed to not interfere with dehumidification equipment’s ability to control dew point and relative humidity inside the reservoir.
b. Do not allow air from the working area or dust filtration equipment to recirculate through thein dehumidifier during coating application or when solvent vapors are present.

6. Design and submittals:
a. Prepare and submit dehumidification and heating plan, including all equipment and operating procedures.
b. Suppliers of services and equipment shall have at least 3 years of experience in similar applications.

F. Provide containment and ventilation system components in accordance with SSPC-Guide 6, Level 3 and as required for hazardous materials.

1.09 MAINTENANCE
A. Provide table of products applied organized by surface type. List coating manufacturer, color, color formulation, distributor name, telephone number, and address.

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1.10 CTR RESPONSIBILITIES
A. General:

1. Attend pre-installation conference.

2. Perform onsite application training.

3. Periodically inspect coating system application.

B. Coating system installation training:

1. Provide a minimum of 8 hours of classroom and off-site training for application personnel and supervisory personnel in one of the following ways:
a. Train a minimum of 2 supervisory personnel and 2 application personnel. b. Submit a letter from the CSM stating that CSM approves the supervisory and application personnel, listed by name and responsibility, and no additional training is required.

2. CTR can train up to 14 application personnel and 3 supervisory personnel at a time.

3. Minimum training requirements:
a. Explain in detail the mixing, application, curing, and termination requirements.
b. Provide hands-on demonstration of coating system mixing. c. Explain in detail the ambient condition requirements for temperature and humidity.
d. Explain in detail the surface preparation requirements. e. Explain in detail the re-coat times, cure times, and related ambient condition requirements.
f. Write a letter stating that training was satisfactorily completed by the personnel, listed by name and responsibility.

4. Provide special training as specified in the Coating Detail Sheets.

C. Coating system inspection:

1. CTR inspection is in addition to the CSA's inspection as specified in this Section.

2. Be on-site to oversee:
a. Coating application at least once a week.
b. End of surface preparation.
c. During coating application.
d. Post-cure inspection.

3. Routinely inspect and verify in writing that application personnel have successfully performed surface preparation, filler/surfacer application, coating system application, and Quality Control Inspection in accordance with this Section and to warrantable quality.

4. Perform the following activities to confirm conformance with the specifications:
a. Inspect ambient conditions during coating system installation at Hold Points for conformance with the specified requirements. b. Inspect each coated surface type and coating system applied to verify the following:
1) Cleanliness.
2) Surface pH for concrete substrates.
3) Confirm surface preparation of substrates where coating system will terminate or will be applied for conformance to the specified application criteria.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/09960 (BidSet) c. Verify surface profile of substrates by completing the following:
1) Inspect preparation and application of coating detail treatment at terminations, transitions, metal embedments in concrete, and joints and cracks in substrates.
2) Inspect application of filler/surfacer materials for concrete and masonry substrates.
3) Verify proper mixing of coating materials.
4) Inspect application of primers and finish coats, including wet and dry film thickness.
5) Inspect coating systems for proper cure times and conditions. d. Review adhesion testing of cured coating systems.
e. Review coating system continuity testing.
f. Inspect and record representative-localized repairs. g. Conduct final review of completed coating system installation. h. Prepare and submit site visit reports after each site visit to document that the coating work is in accordance with the CSM’s Recommendations.

D. Final report:

1. Prepare a final report, after coating work ends, summarizing each day's test data, observations, drawings, and photographs. Include substrate conditions, ambient conditions, and application procedures observed during the CTR's site visits. Include a statement that completed work was performed in accordance with the requirements of the CSM’s recommendations.

PART 2 PRODUCTS

2.01 DESIGN AND PERFORMANCE CRITERIA
A. Coating materials shall be formulated for environments encountered in water and wastewater treatment processes.

B. Coating materials that come in contact with water distributed as potable water shall be certified in accordance with NSF 61.

2.02 MATERIALS
A. General:

1. Product requirements as specified in Section 01601 - Product Requirements.

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2.03 COATING SYSTEMS IDENTIFICATION
A. Naming Conventions: Coating Systems Identifications contain the elements defined in Table 1.

Table 1 Coating System Identification Elements
First Element - Second Element - Third Element - Fourth Element (optional)
3 or 4 alpha
characters
1-3 alpha
characters
1 number 3 or 4 alpha characters
Coating Type Substrate System Number Additional Substrate or Special Condition
Example: EPX - C - 6 - BSC

1. First element identifies the coating type using the following abbreviations:
a. ACR: Acrylic.
b. CTE: Coal tar epoxy.
c. ELA: Elastomeric acrylic.
d. EPU: Epoxy-polyurethane.
e. EPX: Epoxy.
f. POL: Polyurethane.
g. SIL: Silicone.
h. SILX: Siloxane or silane.
i. VE: Vinyl ester.

2. Second element identifies the substrate using the following abbreviations:
a. C: Concrete or masonry.
b. F: Concrete flooring.
c. FRP: Fiber-reinforced plastic.
d. GM: Galvanized metal.
e. M: Metal.
f. PVC: Polyvinyl chloride, chlorinated polyvinyl chloride.

3. Third element identifies the sequential system number. a. For example, EPX-C-2 is the second standard epoxy coating system for concrete substrates.

4. Fourth element is optional and identifies the additional substrate or special condition with the following abbreviations:
a. PWS: Potable water service applications (NSF-61 approved). b. BSC: Biogenic sulfide corrosion-resistant applications in wastewater. c. BG: Below grade or buried.
d. OZ: Organic zinc primer, epoxy polyurethane system.
e. SC: Secondary containment.

2.04 PRODUCTS FOR COATING SYSTEMS
A. Products: As specified in Attachment B - Coating Detail Sheets.

B. Cleaning solvents:

1. Requirements for solvent wash, solvent wipe, or cleaner used, including, but not limited to, those used for surface preparation in accordance with SSPC-SP 1:
a. Emulsifying type.
b. Containing no phosphates.

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d. Does not damage zinc.
e. Compatible with the specified primer.
f. Complying with applicable air-quality control board requirements.

2. Use clean white cloths and clean fluids in solvent cleaning.

PART 3 EXECUTION

3.01 GENERAL PROTECTION REQUIREMENTS
A. Protect adjacent coated surfaces from coatings and damage associated with coating work. Repair damage resulting from inadequate or unsuitable protection.

B. Use drop cloths and other coverings to protect adjacent surfaces not to be coated against spatter and droppings.

C. Mask off surfaces of items not to be coated or remove items from area.

D. Furnish and deploy sufficient drop cloths, shields, and protective equipment to prevent spray or droppings from fouling surfaces not being coated and, in particular, surfaces within storage and preparation areas.

E. Place coating waste, cloths, and material that may pose a fire hazard in closed metal containers and remove daily from site.

F. Remove electrical plates, surface hardware, fittings, and fasteners before coating application. Carefully store, clean, and replace items after completing coating in each area. Do not use solvent or degreasers to clean hardware that may remove permanent lacquer finishes.

G. Erect and maintain protective enclosures in accordance with SSPC-Guide 6.

H. Protect the following surfaces from abrasive blasting by masking or by other means:

1. Threaded portions of valve and gate stems, grease fittings, and identification plates.

2. Machined surfaces for sliding contact.

3. Surfaces to be assembled against gaskets.

4. Surfaces of shafting where sprockets will be fit.

5. Surfaces of shafting where bearings will be fit.

6. Machined bronze surfaces, including slide gates.

7. Cadmium-plated items, except cadmium-plated, zinc-plated, or sherardized fasteners used to assemble equipment requiring abrasive blasting.

8. Galvanized items, unless scheduled to be coated.

I. Protect installed equipment, mechanical drives, and adjacent coated equipment from abrasive blasting to prevent damage caused by spent abrasive blast media, dust, or dirt entering such equipment.

High-Performance Coatings
09960-17 201631 September 2025
pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/09960 (BidSet) J. Schedule cleaning and coating to keep dust and spray from the cleaning process from falling on wet, newly coated surfaces:

1. Whenever possible, coordinate with other trades and complete surface preparation and coating work before installing hardware, hardware accessories, nameplates, data tags, electrical fixtures, and similar uncoated items that will be in contact with coated surfaces. Mask machined surfaces, sprinkler heads, and other small items that will not be coated.

2. After completing coating, reinstall removed items.

3. Disconnect and move equipment adjacent to walls to clean and coat equipment and walls. Replace and reconnect equipment after coating.

3.02 GENERAL SURFACE PREPARATION REQUIREMENTS
A. Prepare surfaces in accordance with CSM's instructions unless more stringent requirements are specified in this Section.

B. Coating detail sheets in Attachment B - Coating Detail Sheets include additional surface preparation requirements.

C. Follow more stringent requirement if information conflicts.

D. Where required by the City’s representative, a NACE International certified coatings inspector, provided by the City, will inspect and approve surfaces to be coated before applying a coating:

1. CSA shall coordinate coating inspections:
a. Identify coating inspection Hold Points during the pre-installation conference.
b. Provide at least 2 days' notice before inspection.

2. Contractor shall correct surface defects identified by the inspector at no additional cost to City.

3.03 MECHANICAL AND ELECTRICAL EQUIPMENT PREPARATION
A. Identify equipment, ducting, piping, and conduit as specified in Section 15050 - Common Work Results for Mechanical Equipment, Section 02003 - Pipe Identification, and Section 16075 - Identification for Electrical Systems.

B. Remove grilles, covers, and access panels for mechanical and electrical system and coat separately.

C. Prepare and finish coat equipment primed by the manufacturer using specified intermediate and top coats, as applicable, and color selected by the City.

D. Prepare, prime, and coat both insulated and bare pipes, conduits, boxes, insulated and bare ducts, hangers, brackets, collars, and supports, except where items are covered with material not requiring coating, or with a prefinished coating.

E. Replace identification markings on mechanical or electrical equipment when coated over or spattered.

High-Performance Coatings
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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/09960 (BidSet) F. Prepare and coat interior surfaces of air ducts and convector and baseboard heating cabinets visible through grilles and louvers with 1 coat of flat black paint to limit of sight line.

G. Prepare and coat dampers exposed immediately behind louvers, grilles, and convector and baseboard heating cabinets to match face panels.

H. Prepare and coat exposed conduit and appurtenances occurring in finished areas with color and texture to match adjacent surfaces.

I. Prepare and coat sides' front, back, and edges of plywood backboards for electrical equipment before installing backboards and mounting equipment on them.

J. Color code equipment, piping, conduit, and exposed ductwork and apply color banding and identification, such as flow arrows, naming, and numbering, in accordance with the Contract Documents.

3.04 CLEANING OF NEW AND PREVIOUSLY COATED OR NEW SURFACES A. Utilize cleaning agent to remove soluble salts, such as chlorides, from concrete and metal surfaces:

1. Cleaning agent: Biodegradable non-flammable and containing no VOC.

2. Manufacturers: The following or equal:
a. CHLOR*RID International, Inc.:
1) Complete soluble salt removal with steam or warm water cleaning.

3. Test cleaned surfaces to ensure removal of soluble salts. Carry out additional cleaning as needed.

4. Complete final surface preparation before applying new coating system in strict accordance with CSM's printed instructions.

3.05 BLAST CLEANING
A. Surface preparation requirements:

1. Do not reuse spent blast abrasive.

2. Ensure that filter compressed air used for blast cleaning is free of condensed water and oil. Clean moisture traps at least once every 4 hours or more frequently, as required, to prevent moisture from entering the abrasive blasting equipment air supply. Check blast air for moisture and oil after each cleaning in accordance with ASTM D4285.

3. Install oil separators just downstream of compressor discharge valves and at the discharge point of blast pot discharges. Check separators on the same frequency as the moisture traps.

4. Keep regulators, gauges, filters, and separators on compressor air lines to blasting nozzles operational at all times.

5. Install an air dryer or desiccant filter drying unit to dry the compressed air before blast pot connections. Use and maintain the dryer throughout surface preparation work.

6. Use a venturi-type, or other high velocity-type, abrasive blast nozzles supplied with at least 100 pounds per square inch gauge air pressure at the nozzle and enough volume to obtain appropriate blast cleaning production rates and surface cleanliness.

High-Performance Coatings
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7. Provide airborne particulate evacuation and filtering that meets OSHA safety standards. Maintain optimal visibility both to clean and provide the specified surface profile and to allow inspection of the substrate during surface preparation work.

8. If prepared and cleaned metallic substrates become contaminated between final surface preparation work and coating system application, or if the prepared substrate darkens or changes color, re-clean by water blasting, or abrasive blast cleaning as appropriate until the specified degree of cleanliness is restored.

B. Water jetting or water blasting:

1. Use water jetting or water blasting for recoating or relining where an adequate surface profile exists.

2. Perform water jetting or water blasting in accordance with SSPC-SP 13 and SSPC-WJ-1, WJ-2, WJ-3, WJ-4.

3.06 PREPARATION REQUIREMENTS FOR CONCRETE SURFACES
A. Cure for at least 28 days before coating.

B. Remove degraded concrete using abrasive blast cleaning or high or ultra-high-pressure water jetting, chipping, or other abrading tools until achieving a sound, clean substrate. Remove all bruised or cracked concrete.

C. Prepare substrate cracks and areas requiring resurfacing; perform detail treatment, including, but not limited to, terminating edges per the CSM's recommendations and as indicated on the Drawings:

1. Prepare concrete surfaces in accordance with SSPC-SP 13.

D. Prepare concrete surfaces in accordance with SSPC-SP 13:

1. Inspect concrete surfaces to select appropriate surface preparation method to provide a suitable substrate for the specified coating system.

2. Use blast cleaning or other means to expose the complete perimeter of air voids or bug holes. Do not leave shelled over, hidden air voids beneath the exposed concrete surface.

3. Repair concrete defects and physical damage.

4. Clean concrete surfaces of dust, mortar, formwork, fins, loose concrete particles, form release materials, oil, and grease.

5. Fill voids to provide surface as specified in Section 03366 - Concrete Finishes.

E. Provide clean substrate visually free of calcium sulfate, loose, coarse, or fine aggregate, laitance, loose hydrated cement paste, and otherwise harmful substances:

1. Confirm concrete surface minimum pH of 9.0 with surface pH testing.

2. If after surface preparation the surface pH remains below 9.0, perform additional water blasting, cleaning, or abrasive blast cleaning until additional pH testing indicates an acceptable pH level.

High-Performance Coatings
09960-20 201631 September 2025
pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/09960 (BidSet) F. Prepare concrete surface for coating in accordance with SSPC-SP 13:

1. Provide ICRI 310.2 minimum No. 3 concrete surface profile (CSP) or as specified on Coating Detail Sheets.

2. Evaluate profile of the prepared concrete using ICRI 310.2 surface profile replicas.

G. Blast clean cementitious repair mortars or grouts to the same profile and degree of cleanliness requirements required for concrete substrates.

H. Blast clean polymer-based surfacers or waterborne modified cementitious surfaces only if they have exceeded the CSM's recommended recoat time.

I. Vacuum all concrete surfaces before coating application, leaving a dust free, sound concrete substrate:

1. Thoroughly clean concrete surfaces to be coated to remove loose dirt and spent abrasive.

2. Remove debris produced by blast cleaning from the structures to be coated, and legally dispose of it off-site.

J. Test moisture content of concrete to be coated:

1. Conduct ASTM D4263 plastic sheet test at least once for every 500 square feet of surface area to be coated:
a. Any moisture on plastic sheet after test period constitutes a non-acceptable test, and the concrete must be dried further.

2. Conduct ASTM F1869 test at least once for every 1,000 square feet of concrete floor surface area to be coated.

3. Conduct ASTM F2170 one relative humidity moisture test at least once for each 500 square feet of non-floor concrete surface area where the opposite side is exposed to soil or water:
a. Waterproof surfaces exposed to soil or water where specified in Section 07110 - Dampproofing.

4. Comply with specified minimum moisture content and CSM’s written recommendations for moisture vapor transmission rates or relative humidity values.

K. Masonry surfaces:

1. Cure for at least 28 days before coating.

2. Prepare masonry surfaces to remove chalk, laitance, loose dirt, dried mortar splatter, dust, peeling, or loose existing coatings, or otherwise deleterious substances to leave a clean, sound substrate.

3. Wash and scrub masonry surfaces with clear water. Do not use muriatic acid.

4. Seal or fill masonry surfaces with a sealer or block filler compatible with the specified primer after cleaning.

5. Confirm that masonry surfaces are dry before coating application:
a. If using pressure washing or low-pressure water blast cleaning for preparation, allow the masonry to dry for at least 5 days under dry weather conditions or until the minimum ambient temperature is 70 degrees Fahrenheit before coating.

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3.07 GENERAL PREPARATION REQUIREMENTS FOR METALLIC SURFACES A. Remove rust, scale, and welding slag and spatter:

1. Remove and grind smooth all excessive weld material and weld spatter on metal surfaces before blast cleaning in accordance with NACE SP0178, Appendix C, Level C.

2. Grind sharp edges on metal substrate to approximately 1/16-inch radius before abrasive blast cleaning.

B. Prepare metallic surfaces in accordance with applicable portions of surface preparation specifications of the SSPC specified for each coating system:

1. Remove grease and oil in accordance with SSPC-SP 1.

2. Use solvent as recommended by the CSM.

3. Measure profile depth of the surface to be coated in accordance with Method C of ASTM D4417. Contractor shall select blast particle size and gradation to produce the specified surface profile.

4. Constantly monitor and maintain ambient environmental conditions to ensure cleanliness and that no “rust back” occurs before coating material application.

C. Prepare metallic surfaces by blast cleaning in accordance with SSPC-VIS 1 (ASTM D2200). Prepare abrasive blast representative areas for the City’s representative to inspect on the first day of cleaning.

D. Unless otherwise specified, the requirements for blast cleaning steel, ductile iron, and stainless steel substrates are as follows:

1. Ferrous metal surfaces not to be submerged: Abrasive blast in accordance with SSPC-SP 10 unless blasting may damage adjacent surfaces, is prohibited, or is specified otherwise. Where abrasive blasting is not possible, clean surfaces to bare metal with power tools in accordance with SSPC-SP 11.

2. Ferrous metal surfaces to be submerged: Abrasive blast in accordance with SSPC-SP 5, unless specified otherwise, to clean and provide roughened surface profile with a depth between 2 and 4 mils.

3. Remove traces of grit, dust, dirt, rust scale, friable material, loose corrosion products, or embedded abrasive from substrate before coating application.

4. When abrasive blasted surfaces rust or discolor before coating, abrasive blast clean surfaces again.

E. Field preparation of shop-primed surfaces:

1. Smooth welds and prominences with power tools before applying field-applied coatings.

2. Clean and dry shop-primed ferrous metal surfaces and fabricated assemblies before applying field coats.

3. Prepare shop epoxy primed surfaces with light abrasive blasting or abrading and then vacuum before applying finish coats:
a. Follow CSM instructions for surface preparation when the primer recoat limit has been exceeded.

4. Non-immersion service: Clean in accordance with SSPC-SP 2 (Hand Tool Cleaning) or SSPC-SP 3 (Power Tool Cleaning) and uniformly roughen.

5. Immersion, BSC, and SC service: Remove shop primer in accordance with SSPC-SP 5 (Near-White Blast Cleaning).

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09960-22 201631 September 2025
pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/09960 (BidSet) F. Damaged shop primer or rust bleeding:

1. Ferrous metals: Clean in accordance with SSPC-SP 1 (Solvent Cleaning) and spot blast in accordance with SSPC-SP 10 (Near-White Metal Blast Cleaning) to achieve a uniform surface profile between 2.0 and 2.5 mils before recoating.

2. Reject galvanized steel with rust bleeding.

G. Damaged coating: Repair by abrasive blast cleaning surfaces as specified for the coating system; feather to a smooth transition before touching up.

3.08 PREPARATION REQUIREMENTS BY SURFACE TYPE
A. Galvanized steel and non-ferrous metal surfaces:

1. Degrease or solvent clean (SSPC-SP 1) to remove oily residue.

2. Abrasive blast clean in accordance with SSPC-SP 16:
a. If abrasive blast cannot be performed, abrade in accordance with SSPC-SP 3 (Power Tool Cleaning).

3. Apply metal pretreatment within 24 hours before coating galvanized surfaces that cannot be thoroughly abraded, such as bolts, nuts, or preformed channels.

4. Test surface for contaminants using copper sulfate solution.

B. Stainless-steel surfaces:

1. Abrasive blast clean in accordance with SSPC-SP 16 to leave a clean, uniform appearance with surface profile between 1.5 and 2.5 mils.

C. Ductile iron pipe and fittings to be lined or coated: Abrasive blast clean in accordance with NAPF 500-03.

D. Sherardized, aluminum, copper, and bronze surfaces:

1. Abrasive blast clean in accordance with SSPC-SP 16.

2. Prepare in accordance with CSM's instructions.

E. Cadmium-plated, zinc-plated, or sherardized fasteners:

1. Abrasive blast in the same manner as uncoated metal when assembling equipment designated for abrasive blasting.

F. PVC and FRP surfaces:

1. Lightly sand surfaces to be coated:
a. Sand to remove gloss and establish uniform surface profile.

2. Vacuum to remove loose dust, dirt, and other materials.

3. Solvent clean with clean white rags and allow solvent to evaporate completely before applying coating materials.

3.09 APPLICATION REQUIREMENTS
A. Apply coatings in accordance with manufacturer's instructions.

B. Empty aboveground piping to be coated of contents when applying coatings.

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09960-23 201631 September 2025
pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/09960 (BidSet) C. Mechanical equipment shop primed by the manufacturer:

1. Pumps and valves: Shop coat with manufacturer's highest quality coating system meeting the project specifications:
a. Contractor shall provide CTR shop coating reports.

2. Non-immersed equipment: Touch up shop primer, and coat in the field with specified coating system after installation:
a. If project requires equipment removal and reinstallation, complete touch-up coating after final installation.

3. Immersed equipment not shop coated: Remove shop primer before surface preparation and field apply coating.

D. Verify surface preparation immediately before applying coating in accordance with SSPC-SP COM and the SSPC visual standard for the specified surface preparation method.

E. Allow surfaces to dry, except where coating manufacturer requires surface wetting before coating.

F. Wash coat and prime sherardized, aluminum, copper, and bronze surfaces, or prime with manufacturer's recommended special primer.

G. Do not apply coatings to a surface until it has been prepared as specified.

H. Use equipment designed to apply materials specified:

1. Use compressors with moisture traps and filters that remove water and oils from the air:
a. Perform a paper blotter test at the Engineer's request to verify air is sufficiently free of oil and moisture. Do not allow the amount of oil and moisture to exceed CSM-recommended amount.

2. Equip spray equipment with properly sized mechanical agitators, pressure gauges, pressure regulators, and spray nozzles.

I. Where 2 or more coats are required, tint prime coat intermediate coats as necessary to distinguish each coating and to help indicate coverage:

1. Do not use color additives with chromium, lead or lead compounds that hydrogen sulfide, other corrosive gases, might destroy or alter. Apply the specified number of coats.

J. Apply coating by brush, roller, trowel, or spray unless a specific application method is required by coating manufacturer's instructions or these Specifications:

1. Apply primer or first coat by brush to power tool cleaned ferrous surfaces.

2. Brush or spray-apply coats for blast-cleaned ferrous surfaces and subsequent coats for non-blast cleaned ferrous surfaces.

3. After prime coat dries, mark, repair, and retest pinholes and holidays before intermediate or top coats are applied.

K. Spray application:

1. With a brush, stripe coat edges, welds, corners, nuts, bolts, and difficult-to-reach areas, as necessary, before spray application to ensure specified coating thickness along edges.

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2. When using spray application, apply each coat to thickness no greater than recommended in coating manufacturer's instructions.

3. Use airless spray method unless air spray method is required by CSM's instruction or these Specifications.

4. Conduct spray coating under controlled conditions. Protect adjacent construction and property from coating mist, fumes, or overspray.

L. Lightly sand and thoroughly clean surfaces to receive high-gloss finishes unless CSM instructs otherwise.

M. Remove all dust on coatings between coats.

N. Shop and field coats:

1. Prime coat: Shop-apply or field-apply prime coats as specified. Use shop-applied primer compatible with the specified field coating system and apply at the minimum dry film thickness recommended by the finish coat CSM:
a. Provide data sheets identifying the shop primer to on-site coating application personnel.
b. Perform adhesion tests on the shop primer.
c. Remove and recoat damaged, deteriorated, and poorly applied shop coatings.
d. If shop primer coat meets this Section's requirements, spot prime exposed metal of shop-primed surfaces before spray applying primer over the entire surface.

2. Field coats: Apply field coats with 1 or more prime coats and finish coats to build up coating to dry film thickness specified for the coating system:
a. Do not apply finish coats until other work in the area is complete and previous coats are inspected.

3. Adhesion confirmation: Perform adhesion tests after proper coating cure in accordance with ASTM D3359. Demonstrate that:
a. Prime coat adheres to the substrate.
b. Coatings adhere to the prime and intermediate coats:
1) Coating 5 mils or more DFT: Achieve adhesion test result of 5A on immersed surfaces and 4A or better on other surfaces.
2) Coating less than 5 mils DFT: Achieve adhesion test results of 5B on immersed surfaces and 4B or better on other surfaces.

O. Brush, roll, trowel, or spray and back roll coats for concrete and masonry.

P. Plural component coating application:

1. Premix contents of component drums if required by the CSM each day.

2. Before starting application:
a. Verify gauges are working properly.
b. Complete ratio checks.
c. Sample the mix on plastic sheeting to ensure set time is appropriate and complete.
d. Label and retain all spray samples. Submit to Engineer when requested.

High-Performance Coatings
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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/09960 (BidSet) Q. Drying and recoating:

1. Provide fans, heating devices, or other means to prevent condensate or dew on substrate surface or between coats and during curing after applying the last coat.

2. Allow each coat to cure or dry thoroughly, in accordance with if required in CSM’s printed instructions, before recoating.

3. Use CSM's printed instructions and the requirements specified in this Section to determine minimum required drying time:
a. Do not allow excessive drying time or exposure, which may impair bond between coats.
b. Recoat all coatings within time limits recommended by CSM. c. If time limits are exceeded, abrasive blast clean and de-gloss clean before applying another coat.

4. If limitations on time between abrasive blasting and coating are not met before attaching components to surfaces that cannot be abrasive blasted, coat components before attachment.

5. Ensure primer and intermediate coats of coating are unscarred and completely integral when applying each succeeding coat.

6. Touch up suction spots between coats and apply additional coats where required to produce finished surface of solid, even color, free of defects.

7. Leave no holidays. Repair all holidays in accordance with the requirements on pertinent Coating Detail Sheets or as recommended by the CSM.

8. Sand and feather in to a smooth transition and recoat scratched, contaminated, or otherwise damaged coating surfaces so repairs are invisible to the naked eye.

9. For submerged service or highly corrosive headspace service, provide a letter to the Engineer stating that the lining system is fully cured and ready to be placed into service.

R. Workmanship:

1. Ensure that coated surfaces are free from runs, drips, ridges, waves, laps, and brush marks. Coats shall be applied to produce a smooth, even film of uniform thickness completely coating corners and crevices.

2. Coat surfaces without drops, overspray, dry spray, excessive runs, ridges, waves, holidays, laps, or brush marks.

3. Remove splatter and droppings after coating work is completed.

4. Evenly apply each coat of material and sharply cut to a line created with masking tape or other suitable materials.

5. Avoid over spraying or spattering paint on surfaces not to be coated. Protect glass, hardware, floors, roofs, vehicles, and other adjacent areas and installations by taping, drop cloths, or other suitable measures.

6. When coating complex steel shapes, stripe coat welds, edges of structural steel shapes, metal cut-outs, pits in steel surfaces, or rough surfaces with the primer before overall coating system application:
a. Brush apply stripe coat to ensure proper coverage.
b. Do not stripe coat with spray or roller.

7. Ensure that finish coat, including repairs, has a uniform color and gloss.

S. Coating properties, mixing, and thinning:

1. Thin prime coat and apply as recommended by the CSM. Thinned coating must comply with prevailing air pollution control regulations.

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2. If maximum recoat time is exceeded, prepare surface with solvent washing, light abrasive blasting, or other procedures per CSM’s instructions.

3. Allow adequate drying time between coats as instructed by the CSM, adjusted as necessary for the site conditions.

4. Ensure that coatings, when applied, provide a satisfactory film and a smooth even surface. Lightly sand glossy undercoats to provide a surface suitable for proper application and adhesion of subsequent coats. Thoroughly stir and strain coating materials during application and maintain uniform consistency.

5. Mix coatings with 2 or more components in accordance with CSM’s instructions.

6. Where necessary to suit conditions of the surface, temperature, weather, and method of application, thin the coating per CSM's recommendations:
a. Ensure that volatile organic content (VOC) of the thinned coating complies with prevailing air pollution control regulations.
b. Thin coatings to only what is necessary to obtain proper application characteristics.
c. Use a thinner recommended by the CSM.

T. Film thickness and continuity:

1. Apply coating to the specified thicknesses:
a. Apply additional coats when necessary to achieve specified thicknesses, especially at edges and corners.

2. Verify WFT of the coating system first coat and after applying each subsequent coat.

3. Do not allow the minimum thickness at any point to deviate more than 25 percent from the required average.

4. Do not allow the surface area covered per gallon of coating for various types of surfaces to exceed those recommended by the CSM:
a. Provide coating coverage worksheets listing the maximum and minimum coverage for each unit volume of coating for concrete surfaces.

5. Apply additional coats to achieve the specified dry film thickness if brush or roller application methods cannot achieve the specified film thicknesses per coat.

U. Protecting coated surfaces:

1. Do not handle, work on, or otherwise disturb coated items until the coating is completely dry and hard.

2. After installation, recoat shop-coated surfaces with specified coating system as necessary to match surrounding surfaces, and to coordinate with the specified color identification requirements.

V. Special requirements:

1. Before erection, apply all but the final finish coat to interior surfaces of roof plates, roof rafters and supports, pipe hangers, piping in contact with hangers, and contact surfaces inaccessible after assembly. Apply final coat after erection.

2. Coat structural slip-critical connections and high strength bolts and nuts after erection.

3. Areas damaged during erection:
a. Prepare surface for spot repairs as specified for the coating system. b. Recoat with prime coat before applying subsequent coats.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/09960 (BidSet) c. Touch up surfaces after installation.
d. Clean and dry surfaces to be coated at time of application.

4. Coat underside of equipment bases and supports not galvanized with at least 2 coats of primer specified before setting the equipment in place.

5. Coat aluminum in contact with concrete.

3.10 APPLICATION REQUIREMENTS FOR CONCRETE COATING SYSTEMS A. Apply filler/surfacer as recommended by CSM to fill bug holes and air voids in concrete or block texture in CMU, leaving a uniformly filled surface that does not produce blowholes or outgassing causing the coating system to pinhole:

1. Allow filler/surfacers to cure sufficiently before applying prime coat as required by the CSM. Use the CSM-recommended drying time between coats.

B. Apply surfacer or filler and let dry before coating application:

1. Use the drying time between filler/surfacer and coating system specified by the CSM for the site conditions:
a. Let concrete substrate dry before applying filler/surfacers or coating system materials.

2. If the maximum recoat time is exceeded, prepare surfaces by solvent washing, light abrasive blasting, and other procedures per CSM's instructions.

3. Apply a complete parge coat of the specified filler/surfacer material over the entire substrate before applying the coating system:
a. Scrub filler/surfacer into the substrate to completely fill open air voids and bug holes.
b. Completely cover the substrate, unless otherwise specified, above such filled voids by 1/8 inch of thickness.
c. Provide relatively flat, uniformly even surface before coating application.

4. Secondary containment: Place surfacer or filler 1/16 inch thick above concrete plane to create a monolithic surface free of pinholes:
a. Floor surfaces: Broadcast with aggregate to create a non-slip surface texture.
b. Remove excess aggregates and apply base coat to encapsulate embedded non-slip aggregate.

C. Concrete substrate temperatures:

1. Apply filler/surfacers and the coating system when temperatures are falling, typically late afternoon or evening:
a. Do not coat concrete with rising concrete substrate surface temperatures or substrates in direct sunlight, to minimize outgassing from the substrate and formation of pinholes, and/or blistering.

2. Should bubbles, pinholes, or other discontinuities form in the applied coating system material, they shall be repaired:
a. Should discontinuities develop in the filler/surfacer material or in the first coat of the coating material, repair them before the next coat. b. When discontinuities occur, open the air void behind or beneath the discontinuities and completely fill with specified coating material. Then, abrade the coated area around the discontinuities repair reapply coating over that area.

High-Performance Coatings
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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/09960 (BidSet) D. Perform application detail work in accordance with these Specifications, the CSM’s current written recommendations, and drawings, whichever is stricter.

E. Concrete coating systems application requirements:

1. Concrete coating minimum dry film thickness excludes parge coat, block filler, and sealer.

3.11 COATING SYSTEM SCHEDULE
A. Attachment A - Schedule of Surfaces to be Field Coated specifies surfaces to be coated in the field with the coating systems required.

3.12 SURFACES NOT REQUIRING COATING
A. Stainless steel piping, valves, pipe supports, instrument sunshades.

B. Sliding surfaces on expansion joints, motor and pump shafts, machined surfaces at bearings and seals, grease fittings, etc.

C. Galvanized structural steel framing, galvanized roof decking, galvanized pipe supports.

D. Copper and brass pipe, fittings, valves, etc.

E. Bronze valves, bearings, bushings, and fasteners.

F. Corrosion resistant special alloys: Inconel, Alloy 20, Hastelloy, etc.

G. Exterior Concrete.

H. Plastic surfaces except coat PVC, CPVC, and other plastic piping system exposed to sunlight.

I. Buried Piping that is encased in concrete or cement mortar.

3.13 QUALITY CONTROL
A. City-provided inspection or inspection by others does not limit the Contractor’s or CSA’s responsibilities for quality workmanship or quality control as specified or as required by the CSM’s instructions. City inspection is in addition to any inspection required of the Contractor.

B. City may perform, or contract with an inspection agency to perform, quality control inspection and testing of the coating work covered by this Section. These inspections may include the following:

1. Inspect materials upon receipt to ensure that the CSM supplied them.

2. Verify that specified storage conditions for the coating system materials, solvents, and abrasives are provided.

3. Inspect and record findings for substrate cleanliness.

4. Inspect and record pH of concrete and metal substrates.

5. Inspect and record substrate profile (anchor pattern).

6. Measure and record ambient air and substrate temperature.

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7. Measure and record relative humidity.

8. Check for substrate moisture in concrete.

9. Verify that mixing of coating system materials is in accordance with CSM’s instructions.

10. Inspect, confirm, and record that coating system materials' "pot life" is not exceeded during installation. Inspect to verify that recoat limitations for coating materials are not exceeded.

11. Perform adhesion testing.

12. Measure and record the coating system's thickness.

13. Verify proper curing of the coating system in accordance with the CSM's instructions.

14. Holiday or continuity testing in accordance with NACE SP0188 for coatings that will be immersed or exposed to aggressively corrosive conditions.

C. Contractor shall perform holiday testing in accordance with NACE SP0188 to identify holidays or pinholes needing repair for coating over 100 percent of surfaces:

1. Coated steel that will be immersed or exposed to aggressively corrosive conditions.

2. Coated concrete.

3. Perform holiday tests after proper application and coating system cure.

3.14 CORRECTIVE MEASURES
A. Repair pinholes or holidays identified by Holiday Testing as follows:

1. Remove the coating system with a grinder or other suitable power tool.

2. Remove coating system at all pinholes and holidays at least 2 inches diameter around the defect back to expose substrate.

3. Concrete voids: chip back to expose entire cavity in all directions:
a. Completely fill void with approved filler/surfacer material using a putty knife or other suitable tool and strike off. Cure per CSM’s recommendations.

4. Aggressively abrade or sand the intact coating system surface at least 3 inches beyond the removal area in all directions to produce a uniform 6- to 8-mil profile in the intact coating system.

5. Vacuum the prepared area to remove all dust, dirt, etc., leaving clean, sound surfaces.

6. Tape to mask the periphery of the prepared intact coating area to prevent coating repair application onto the prepared area.

7. Apply the coating system with enough coats to achieve the specified finish coat thickness over the defect and coating removal area. Feather the coating onto the abraded coated surfaces around the removal area to avoid a lip and to achieve a neat repair outline.

8. Follow curing time between coats as specified by CSM for the site conditions.

Solvent wash and abrasive blast per CSM's instructions, if the maximum recoat time is exceeded.

9. Apply coating at specified dry film thickness.

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3.15 CLEANUP
A. Remove surplus materials, protective coverings, and accumulated rubbish after completing coating. Thoroughly clean surfaces and repair overspray or other coating-related damage.

3.16 FINAL INSPECTION
A. Conduct final inspection of coating system work to determine whether it meets specifications requirements.

B. Conduct subsequent final inspection with Engineer to ensure work conforms to contract documents requirements.

C. Mark any rework required:

1. Re-clean and repair, as specified, at no additional cost to the City.

END OF SECTION

High-Performance Coatings
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ATTACHMENT A - SCHEDULE OF SURFACES TO BE COATED

A.

EPU-M-1 Metals, exterior, non-immersed
EPU-GM-1 Exterior galvanized metal
EPX-GM-1 Interior galvanized metal
EPX-M-2-PWS
Metals: immersed and in contact with water being treated for domestic use (potable water).

EPX-M-5
Aluminum surfaces in contact with concrete or masonry.

Locations where Alkali-resistant bitumastic is specified.

EPX-M-6-BG Below grade or buried pipes, valves, and appurtenances. 1: Non-immersed ferrous metal surfaces include:
a. Doors, doorframes, ventilators, louvers, grilles, exposed sheet metal, and flashing. b. Pipe, valves, pipe hangers, supports and saddles, conduit, cable tray hangers, and supports. c. Motors and motor accessory equipment.
d. Drive gear, drive housing, coupling housings, and miscellaneous gear drive equipment. e. Valve and gate operators and stands.
f. Structural steel.
g. Crane and hoist rails.
h. Exterior of tanks and other containment vessels.
i. Mechanical equipment supports, drive units, and accessories. j. Bare electrical equipment: boxes, exposed conduit, and accessories. k. Pumps not submerged.
l. Other miscellaneous metals.
2: Immersed ferrous metal surfaces include:
a. Interior surfaces of ferrous metal tanks.
b. Field priming of ferrous metal surfaces with defective shop-prime coat; including nonsubmerged service. c. Bell rings, underside of manhole covers and frames.
d. Sump pumps, including underside of base plates and submerged suction and discharge piping.
e. Exterior of submerged piping and valves other than stainless steel or PVC piping. f. Submerged pipe supports and hangers.
g. Stem guides.
h. Other submerged iron and steel metal unless specified otherwise.

ATTACHMENT A
The following schedule is incomplete. Coat unlisted surfaces with same coating system as similar listed surfaces. Contact Engineer for clarification.

Schedule of Surfaces to be Coated
Notes:
09960-1

Coating System
Coating Material
Substrate
Products: One of the following or equal: Primer Intermediate Coat Finish Coat Carboline Carboguard 890 Carboguard 890 Carbothane 134 VOC International Paint Devran 224V Devran 224V Devthane 379H PPG Amerlock 2VOC Amerlock 2VOC Amershield VOC
Sherwin Williams Macropoxy 646 100 Macropoxy 646 100 Hi Solids Polyurethane 250 Tnemec Series 69 Series 69 Series 1095
Service Condition
Surface Preparation
General
Ferrous Metal
Nonferrous Metal
Galvanized Metal
Surface profile
Ferrous Metal
Nonferrous Metal
Galvanized Metal
System Thickness (Dry Film)
Total
Primer
Intermediate Coat
Finish Coat
Application
Special CTR Training Not required.
4 to 5 mils
4 to 5 mils
2 to 3 mils

1.5 to 2.0 mils

1.5 to 2.0 mils
10 to 13 mils
SSPC-SP16, Brush Blast Cleaning.

SSPC-SP16, Brush Blast Cleaning. Test for surface contaminants.

2.5 to 3.0 mils
Metal
Interior or Exterior, subject to direct sunlight. Non-immersion.

Prepare surfaces as specified in this Section and as follows.

Bare surfaces: SSPC-SP10, Near-White Blast Cleaning.

Shop primed surfaces: SSPC-SP2, Hand Tool Cleaning or SSPC-SP3, Power Tool Cleaning.

Damaged primer or rust: SSPC-SP10, Near White Blast Cleaning and spot prime.

Attachment B
Coating Detail Sheet
EPU-M-1
Two coats epoxy with polyurethane finish coat
09960-2

Coating System
Coating Material
Substrate
Products: One of the following or equal: Primer Intermediate Coat Finish Coat Carboline Carboguard 890 None Applied Carbothane 134 VOC International Paint Devran 224V None Applied Devthane 379H PPG Amerlock 2VOC None Applied Amershield VOC
Sherwin Williams Macropoxy 646 100 None Applied Hi Solids Polyurethane 250 Tnemec Series 69 None Applied Series 1095
Service Condition
Surface Preparation
General
Galvanized Metal
Surface profile
Galvanized Metal
System Thickness (Dry Film)
Total
Primer
Finish Coat
Application
Special CTR Training Not required.
2 to 3 mils

1.5 to 2.0 mils
6 to 8 mils
4 to 5 mils
Galvanized Metal
Interior or Exterior, subject to direct sunlight. Non-immersion.

Prepare surfaces as specified in this Section and as follows.

SSPC-SP16, Brush Blast Cleaning. Test for surface contaminants.

Attachment B
Coating Detail Sheet
EPU-GM-1
Epoxy with polyurethane finish coat
09960-3

Coating System
Coating Material
Substrate
Products: One of the following or equal: Primer Intermediate Coat Finish Coat Carboline Carboguard CM94 None applied Carboguard CM94
International Paint Devran 201V None applied Devran 224V PPG Amerlock 2/400 Series None applied Amerlock 2/400 Series Sherwin Williams Macropoxy 646 None applied Macropoxy 646 Tnemec Series V69 None applied Series V69
Service Condition
Surface Preparation
General
Galvanized Metal
Surface profile
Galvanized Metal
System Thickness (Dry Film)
Total
Primer
Finish Coat
Application
Special CTR Training Not required.

Galvanized Steel
Interior, moderately corrosive.

Prepare surfaces as specified in this Section and as follows.

SSPC-SP16, Brush Blast Cleaning. Test for surface contaminants. 3 to 4 mils
5 to 8 mils
3 to 4 mils

1.5 to 2.0 mils
Attachment B
Coating Detail Sheet
EPX-GM-1
Epoxy
09960-4

Coating System
Coating Material
Substrate
Products: One of the following or equal: Primer Intermediate Coat Finish Coat Carboline Plasite 4500 None Applied Plasite 4500
International Paint No product specified No product specified No product specified PPG No product specified No product specified No product specified Sherwin Williams Sher-Plate None Applied Sher-Plate
Tnemec Series 22 None Applied Series 22
Service Condition
Surface Preparation
General
Ferrous Metal
Surface profile
Ferrous Metal
Primed surfaces
System Thickness (Dry Film)
Total
Application
Special CTR Training Required.
16 to 25 mils

2.0 to 2.5 mils

1.0 to 1.5 mils on the intact primer.

Metal
Immersed, moderately corrosive environment in contact with Potable Water.

Prepare surfaces as specified in this Section and as follows.

Bare surfaces: SSPC-SP5, White Metal Blast Cleaning.

Shop primed surfaces: SSPC-SP7, Brush-Off Blast Cleaning.

Damaged primer or rust: SSPC-SP5, White Metal Blast Cleaning and spot prime.

Attachment B
Coating Detail Sheet
EPX-M-2-PWS
Ultra-high Solids Epoxy
09960-5

Coating System
Coating Material
Substrate
Products: One of the following or equal: Primer Intermediate Coat Finish Coat Carboline CSM recommended None applied Carbomastic 15
International Paint CSM recommended Bar-Rust 231LV Bar-Rust 231LV PPG No product specified No product specified No product specified Sherwin Williams CSM recommended No product specified No product specified Tnemec CSM recommended Series 135 Series 135
Service Condition
Surface Preparation
General
Ferrous Metal
Nonferrous Metal
Surface profile
Ferrous Metal
Nonferrous Metal
System Thickness (Dry Film)
Total
Primer
Finish Coat
Application
Special CTR Training

2.0 to 2.5 mils
15 to 19 mils
2 to 4 mils
15 mils
Not Required.

1.0 to 1.5 mils
Prepare surfaces as specified in this Section and as follows.

Bare surfaces: SSPC-SP11, Power to Cleaning to Bare Metal.

Shop primed surfaces: SSPC-SP3, Power Tool Cleaning.

Damaged primer or rust: SSPC-SP11, Power to Cleaning to Bare Metal.

SSPC-SP16, Brush-Off Blast Cleaning.

Attachment B
Coating Detail Sheet
EPX-M-5
Epoxy mastic
Metal
Interior, corrosive environment, confined enclosures, where minimal surface preparation is possible. 09960-6

Coating System
Coating Material
Substrate
Products: One of the following or equal: Primer Intermediate Coat Finish Coat Carboline Carboguard 890 Carboguard 890 Carboguard 890
International Paint Bar-Rust 236 Bar-Rust 236 Bar-Rust 236 PPG Amerlock 400 Amerlock 400 Amerlock 400
Sherwin Williams No product specified No product specified No product specified Tnemec Series 69 Series 69 Series 69
Service Condition
Surface Preparation
General
Ferrous Metal
Nonferrous Metal
Galvanized Metal
Surface profile
Ferrous Metal
Nonferrous Metal
Galvanized Metal
System Thickness (Dry Film)
Total
Primer
Intermediate Coat
Finish Coat
Application
General
Special CTR Training
4 to 6 mils
Fill all bugholes with a filler/surfacer compatible with the coating.

Not Required.
16 mils
4 to 6 mils
4 to 6 mils

1.5 to 2.0 mils

2.5 to 3.0 mils

1.5 to 2.0 mils
SSPC-SP16, Brush-Off Blast Cleaning.

SSPC-SP16, Brush-Off Blast Cleaning.

Metal
Below grade in contact with soil.

Prepare surfaces as specified in this Section and as follows.

SSPC-SP10, Near White Metal Blast Cleaning.

Attachment B
Coating Detail Sheet
EPX-M-6-BG
Epoxy
09960-7

Coating System
Coating Material
Substrate
Products: One of the following or equal: Primer Intermediate Coat Finish Coat Carboline Carboguard 890 Carboguard 890 Carboguard 890
International Paint Bar-Rust 236 Bar-Rust 236 Bar-Rust 236 PPG Amerlock 400 Amerlock 400 Amerlock 400
Sherwin Williams Tank Clad HS Tank Clad HS Tank Clad HS Tnemec Series 69 Series 69 Series 69
Service Condition
Surface Preparation
General
Surface profile
Concrete
Existing Coated Concrete
System Thickness (Dry Film)
Total
Primer
Intermediate Coat
Finish Coat
Application
General
Special CTR Training
Fill all bugholes with a filler/surfacer compatible with the coating.

Not Required.
4 to 6 mils
16 mils
4 to 6 mils
4 to 6 mils
ICRI CSP 3.

ICRI CSP 3.

Attachment B
Coating Detail Sheet
EPX-C-7-BG
Polyamidoamine epoxy or epoxy coating type with similar performance Concrete
Below grade in contact with soil.

Prepare surfaces as specified in this Section and as follows. 09960-8

Painting Prestressed Concrete Water Tanks
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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/09986 (BidSet) SECTION 09986

PAINTING PRESTRESSED CONCRETE WATER TANKS
PART 1 GENERAL

1.01 SUMMARY
A. Section includes: Painting and coatings for prestressed concrete water tanks.

1.02 REFERENCES
A. Society for Protective Coatings (SSPC):

1. SP 1 - Solvent Cleaning.

1.03 SUBMITTALS
A. Product data.

B. Quality control submittals.

1.04 QUALITY ASSURANCE
A. Qualifications for concrete water tank painter shall match the qualifications for Coatings System Applicator as described in Section 09960 – High-Performance Coatings.

1.05 PROJECT CONDITIONS
A. Environmental requirements:

1. In accordance with paint system manufacturer’s recommendations.

PART 2 PRODUCTS

2.01 MATERIALS
A. A decorative coating shall be applied to the above grade exterior wall surfaces using two coats of a non-cementitious, high build, 100 percent acrylic resin polymer.

One of the following products, or equal:

1. Sherwin Williams Loxon XP WP.

2. Tnemec Envirocrete 156.

B. Exterior color shall be Sherwin Williams “Dapper Tan” or approved equal.

1. Submit coating manufacturer standard color charts for final approval.

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3.01 PREPARATION
A. Surface preparation: For surfaces designated to be painted:

1. General: Prepare surfaces in accordance with manufacturer’s installation instructions.

Surface
Preparation
Number Surface Preparation Process
SP 1 Painting Concrete and Shotcrete: Remove form release agents from poured or precast surfaces by sandblasting or as recommended by paint manufacturer.

3.02 FIELD FINISHING
A. Painting:

1. Painting concrete and shotcrete:
a. Exterior above grade concrete and shotcrete exposed to view surfaces (including 6 inches below finish grade on structures): Paint structures as listed on Painting Schedule.

2. Exterior walls below grade: Paint exterior concrete walls below finish grade on structures listed on Painting Schedule.

3. Submerged concrete and shotcrete:
a. Typical: Treat items as submerged if they are to be at any time underwater, are in structures which normally contain water or are below tops of walls of water containing structures.
b. Except as otherwise noted on Painting Schedule, specified, or indicated on the Drawings, do not paint submerged concrete and shotcrete.

3.03 FIELD QUALITY CONTROL
A. In accordance with the requirements of Section 09960 – High-Performance Coatings, Paragraph 3.13.

3.04 PAINTING SCHEDULE:

A. Shotcrete and concrete surfaces:

Paint System Location or Item
PS-1: Finish Surface Preparation SP 1. Apply two coats of non-cementitious, high build, 100 percent acrylic resin polymer. Total dry film thickness: 16 to 18 mils.

END OF SECTION

Potable Water Tank Mixer
11122-1 201631 September 2025
pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/11122 (BidSet) SECTION 11122

POTABLE WATER TANK MIXER
PART 1 GENERAL

1.01 SUMMARY
A. Section includes:

1. Submersible tank mixing systems intended for continuous use while submersed in potable water storage tanks.

1.02 REFERENCES
A. National Electrical Manufacturers Association (NEMA):

1. 250 - Enclosures for Electrical Equipment (1,000 V Maximum).

B. NSF International (NSF):

1. Standard 61 - Drinking Water System Components-Health Effects.

1.03 SUBMITTALS
A. Furnish Submittals as specified in Section 01330 - Submittal Procedures.

B. Product Submittals:

1. As specified in Section 01601 - Product Requirements.

2. A qualification statement demonstrating compliance with the Quality Assurance section.

3. Shop Drawings for the mixer.

4. Manufacturer's literature, illustrations, and specification sheets defining materials of construction, dimensions, and weights.

5. A CFD model demonstrating that the mixer will provide the degree of mixing specified in a tank of the actual dimensions indicated on the Drawings.

6. Control panel construction and wiring details.

C. Commissioning Submittals:

1. As specified in Section 01756 - Commissioning, including the following:
a. Manufacturer’s representative qualifications.
b. Certificates.
1) Requirements as specified in this Section.
c. Test Plans.
1) Test requirements as specified in this Section.
d. Test Reports.
e. Manufacturer’s representatives field notes and data. f. City training.

Potable Water Tank Mixer
11122-2 201631 September 2025
pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/11122 (BidSet) D. Final Submittals shall include:

1. Each mixing system shall be tested prior to deployment according to standard engineering practices at the factory testing facilities. Certification of this completed testing shall accompany mixer installation documentation.

E. Operation and maintenance manuals:

1. As specified in Section 01782 - Operation and Maintenance Manuals.

1.04 QUALITY ASSURANCE
A. As specified in Section 15050 - Common Work Results for Mechanical Equipment and Section 16050 - Common Work Results for Electrical.

B. The mixing equipment shall be the design and fabrication by a single manufacturer, which shall have sole source responsibility for the equipment.

C. The mixer shall have no visual defects, and shall have high quality welds, assembly, and corrosion resistant finish.

D. The manufacturer of the mixer shall have at least 5 years of experience in the production of such equipment for mixing in water storage tanks.

E. The furnished model shall have been in continuous service under similar service conditions for at least 5 years:

1. Provide references for a minimum of 5 installations.

1.05 DELIVERY, STORAGE, AND HANDLING
A. As specified in Section 01601 - Product Requirements, and the manufacturer’s instructions.

1.06 WARRANTY
A. As specified in Section 01783 - Warranties and Bonds.

B. Special warranty:

1. Mixer shall be warranted to be free of defects in materials and workmanship for a period of 2 years.

1.07 MAINTENANCE
A. Spare parts: Provide 1 set of the following items for each type and size required by the units:

1. O-rings.

2. Bearings.

3. Mechanical seals.

4. Power cable grommet.

B. Special tools: Provide 1 set of special tools of each type and size required by the units.

Potable Water Tank Mixer
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2.01 GENERAL
A. As specified in Section 01601 - Product Requirements.

B. The complete mixing system shall be NSF Standard 61 and NSF Annex G listed for safe contact with potable water.

2.02 MANUFACTURERS
A. One of the following, no equals:

1. Big Wave Water Technologies, Model TWM15-230-33-V3R075-3.

2. PAX Water Technologies, Model PWM500.

2.03 DESIGN AND PERFORMANCE CRITERIA
A. Design requirements:

1. Number of units required and water storage tank data:

Mixer
Qty
Tank Capacity
(MG)
Inside Tank
Diameter
(ft)
Tank Side Wall
Height
(ft)
Tank Overflow
Height
(ft)
1 6 172 45 37.5

2. Each mixer shall have the ability to function continuously on a year-round basis, regardless of tank drain and fill cycles.

3. Each mixer shall consist of a submersible motor, mixer element, submersible housing, and an exterior mounted control panel.

4. The mixer shall operate normally with no scheduled lubrication required.

5. Mixer shall be self-orienting when installed at bottom of tank.

B. Performance requirements:

1. The subject tank will be completely mixed by the mixer. In continuous operation of the mixer:
a. At least once per 24 hours, water temperatures within the tank shall converge to within 0.8 degrees Celsius.
b. At least once per 24 hours, chlorine concentrations within the tank shall converge to within 0.20 milligrams per liter.

2. Mixer shall not damage tank interior coating during operation.

2.04 MATERIALS
A. The mixer and motor shall be constructed Type 304 or 316 stainless steel with a Type 316 stainless steel retrieval chain.

B. Other non-metallic parts will be polyethylene and EPDM.

Potable Water Tank Mixer
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2.05 EQUIPMENT
A. Motor:

1. Direct drive, with no gearbox and no lubrication maintenance required.

2. Designed for continuous submersible operation without overheating or compromising motor life expectancy.

3. The motor cable shall be armored, waterproof and terminated at the motor with waterproof fittings and strain relief:
a. Cable length to reach from the motor to the junction box mounted on the tank roof plus 15 feet. No splices shall be permitted.

4. Motor shall have a service factor of 1.15 under all operating conditions.

5. Motor power: 0.5 horsepower, minimum.

6. Motor Voltage: 120 Volt, single phase.

PART 3 EXECUTION

3.01 INSTALLATION
A. Install products in accordance with manufacturer's instructions and as specified in Section 15050 - Common Work Results for Mechanical Equipment.

3.02 COMMISSIONING
A. As specified in Section 01756 - Commissioning.

B. Source Testing (Factory Acceptance Tests):

1. Not witnessed.

2. Propeller, motor rating, and electrical connections shall be checked for compliance to the specifications.

3. Mixers shall be vacuum tested to establish sealing integrity.

4. Mixers shall be run determine correct shaft rotation, thrust direction, and power consumption.

5. After immersion test(s), mixers shall be inspected for water infiltration, insulation defect(s), and motor resistance (ohms).

6. Furnish test reports and Manufacturer’s Certificate of Source Testing.

C. Installation Verification:

1. Furnish Manufacturer’s Certificate of Installation Verification.

D. Functional Testing:

1. Witnessed.

2. Test for complete mixing as specified in this Section and Section 15958 - Mechanical Equipment Testing.

3. Furnish Manufacturer’s Certificate of Functional Compliance.

E. City Training:

1. Not required.

Potable Water Tank Mixer
11122-5 201631 September 2025
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3.03 FIELD SERVICES
A. The start-up shall be performed by full-time factory employees trained in the operation of the potable water mixer.

END OF SECTION

Submersible Sump Pumps
11312J-1 201631 September 2025
pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/11312J (BidSet) SECTION 11312J

SUBMERSIBLE SUMP PUMPS
PART 1 GENERAL

1.01 SUMMARY
A. Section includes:

1. Requirements for submersible sump pump systems including pumps, and level controls.

B. Tag numbers: As specified in the Pump Schedule.

1.02 REFERENCES
A. ASTM International (ASTM):

1. A48 - Standard Specification for Gray Iron Castings.

2. A276 - Standard Specification for Stainless Steel Bars and Shapes.

3. D2000 - Standard Classification System for Rubber Products in Automotive Applications.

B. Hydraulic Institute (HI):

1. 9.1-9.5 - Pumps - General Guidelines.

2. 11.6 - Rotodynamic Submersible Pump Tests.

3. 14.1-14.2 - Rotodynamic Pumps for Nomenclature and Definitions.

4. 14.3 - Rotodynamic Pumps for Design and Application.

C. National Electrical Manufacturers Association (NEMA).

1.03 TERMINOLOGY
A. The words and terms listed below are not defined terms that require initial capital letters, but, when used in this Section have the indicated meaning.

1. Allowable Operating Region (AOR): The region over which the service life of the pump is not seriously compromised by hydraulic loads, vibration, or flow separation where the pump’s vibration, noise, and cavitation are within acceptable limits.

2. Preferred Operating Region (POR): The region over which the service life of the pump will not be significantly affected by hydraulic loads, vibration, or flow separation where the pump’s vibration, noise, and cavitation are within acceptable limits.

3. Pump head (Total Dynamic Head, TDH), flow capacity, pump efficiency, net positive suction head available (NPSHa), and net positive suction head required (NPSHr): As defined in HI 9.1-9.5, 11.6, 14.1-14.2, 14.3, and as modified in this Section.

4. Suction head: Gauge pressure available at pump intake flange or bell in feet of fluid above atmospheric; average when using multiple suction pressure taps, regardless of variation in individual taps.

Submersible Sump Pumps
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1.04 DELEGATED DESIGN
A. Anchoring and bracing.

1.05 SUBMITTALS
A. Furnish Submittals as specified in Section 01330 - Submittal Procedures.

B. Delegated Design:

1. Anchoring and bracing: Provide project-specific calculations based on support conditions and requirements to resist loads specified in Section 01850 - Design Criteria:
a. To structures for equipment installed in structures designated as seismic design category C, D, E, or F.
b. For equipment installed outdoors.
c. For wall mounted equipment weighing 125 pounds or more.

C. Commissioning Submittals:

1. As specified in Section 01756 - Commissioning, including the following:
a. Manufacturer’s representative qualifications.
b. Certificates:
1) Requirements as specified in this Section.
c. Test Plans:
1) Test requirements as specified in this Section.
d. Test Reports.
e. Manufacturer’s representatives field notes and data. f. City Training.

D. Product Submittals:

1. As specified in Section 01601 - Product Requirements.

2. Product data:
a. Include pump curves.

3. Shop Drawings.

4. Manufacturer’s instructions.

5. Calculations.

6. Schedules.

E. Operation and maintenance manuals:

1. As specified in Section 01782 - Operation and Maintenance Manuals.

1.06 DELIVERY, STORAGE, AND HANDLING
A. As specified in Section 01601 - Product Requirements, Section 15050 - Common Work Results for Mechanical, and the manufacturer’s instructions.

1.07 WARRANTY
A. Provide warranty as specified in Section 01783 - Warranties and Bonds.

Submersible Sump Pumps
11312J-3 201631 September 2025
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2.01 GENERAL
A. As specified in Section 01601 - Product Requirements.

B. Factory finish:

1. Exterior cast iron parts:
a. Water-thinned industrial enamel.
b. 3 to 4 mils.

2. Manufacturer to supply touch-up paint for field use.

2.02 DESIGN AND PERFORMANCE CRITERIA
A. As specified Section 01850 - Design Criteria and in the Pump Schedule.

B. Design working pressure: Minimum 1.5 times shut off pressure.

2.03 TYPE 1: SUMP PUMP, GENERAL SERVICE
A. Sump pump suitable for continuous operation:

1. With pump unit dry or unsubmerged at ambient temperature rating.

2. When immersed in water up to 104 degrees Fahrenheit.

B. Manufacturers: One of the following, or equal:

1. Barnes, SE series.

2. ITT Goulds, WS series.

3. Pentair Hydromatic, SKHS series.

C. Housing:

1. Cast iron: In accordance with ASTM A48, Class 30.

2. Inlet: Open and clear, without screening, capable of passing 2-inch spheres.

3. 3-inch NPT vertical discharge connection.

4. External mating parts shall be machined and Buna N, O-ring sealed.

5. Fasteners exposed to the pumped liquid: Type 316 stainless steel.

D. Impeller:

1. Cast iron: In accordance with ASTM A48, Class 30.

2. 2-vane; semi-open.

3. Pump-out vanes on backside.

4. Mechanically locked to shaft.

E. Bearings:

1. Upper radial and lower thrust bearings required.

2. Single row; oil lubricated.

3. Permanently sealed.

4. Shaft seal:
a. Type 21 mechanical seal:
1) Carbon versus ceramic faces.

Submersible Sump Pumps
11312J-4 201631 September 2025
pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/11312J (BidSet) 2) Elastomer:
a) Buna N in accordance with ASTM D2000.
3) Hardware:
a) Type 316 stainless steel in accordance with ASTM A276.

F. Motor:

1. Oil-filled, NEMA B with horsepower as scheduled:
a. 1 phase, 120 volts.
b. 1.15 service factor.
c. Integral motor capacitor-starting.

2. Shaft: Type 416 stainless steel in accordance with ASTM A276.

3. Insulation:
a. 1.5 horsepower and above: Class B.
b. Under 1.5 horsepower: Class F.

G. Power cable:

1. STW sized for motor and length requirements, 16 gauge minimum.

2. Length to reach connection (junction box) indicated on the Drawings plus 10 feet.

H. Factory inspection and test each pump:

1. Visual inspect for imperfections.

2. Check ground continuity.

3. High potential test (Hipot).

4. Air pressure test of housings for motor and volute.

5. Test run to:
a. Monitor voltage and current.
b. Detect excessive noise.

2.04 LEVEL SWITCHES
A. Type: Integral to the pump.

B. Cable length: Per pump manufacturer.

2.05 ACCESSORIES
A. Lifting cables:

1. Material: Type 304 or 316 stainless steel.

2. Attached to balance point of pump.

3. Suitable for lifting pump from sump.

4. Extend from pump attachment to hanger.

B. Lifting hangars:

1. Material: Type 304 or 316 stainless steel.

2. Suitable to provide storage of extra lift cable and electrical cables at wall sump.

2.06 SPARE PARTS AND SPECIAL TOOLS
A. As specified in Section 01601 - Product Requirements.

Submersible Sump Pumps
11312J-5 201631 September 2025
pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/11312J (BidSet) B. Special tools: For each type or size of pump, provide 1 set.

C. Touch-up paint: 1 pint of finish coating paint.

PART 3 EXECUTION

3.01 PREPARATION
A. Anchoring and bracing to structures:

1. Prepare equipment anchor setting template(s) and use to position anchors during construction of supporting structure(s).

2. Install anchors of type and material indicated on approved anchoring designs.

3. Install anchors with embedment indicated on approved anchoring designs.

3.02 INSTALLATION
A. Install the equipment in accordance with the accepted installation instructions and anchorage details.

B. In accordance with manufacturer’s instructions.

C. Install lifting hanger 3 feet 6 inches above floor.

D. Remove any extra length of power and control cables at connection point (panel, junction box, or receptacle).

E. Repair damaged finish with manufacturer’s supply of touch up paint.

3.03 PUMP SCHEDULE
A. Attributes:

Tag Numbers SMP-01
Sump Pump Type Type 1
Total Head, feet 18
Minimum flow, gpm 65
Maximum, hp 0.5

END OF SECTION

Cathodic Protection
13100-1 201631 September 2025
pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13100 (BidSet) SECTION 13100

CATHODIC PROTECTION
PART 1 GENERAL

1.01 THE REQUIREMENT
A. The Contractor shall furnish all materials, install all equipment and provide all labor necessary to complete the work shown on the Drawings and or/listed below and all other work and miscellaneous items not specifically mentioned but reasonably inferred, including all accessories and appurtenances required for a complete system. The intent of this specification is to provide for a complete, functional cathodic protection system for the Skyview Reservoir Replacement Project for the City of Vallejo.

B. Work included in this section consists of all components of the corrosion control and cathodic protection system; including insulating joints, test stations, anodes, bonding, cables, special backfill and any other work necessary to complete the installation. Work on this project includes the following items:

1. Ductile Iron Piping:
a. Cathodic protection system for all new buried ductile iron piping. b. Bonding of flanges, flexible couplings and other non-welded fittings. c. Coating of all buried ductile iron yard piping with 8-mil minimum thickness polyethylene encasement, except for buried ductile iron pipe connected to concrete encased pipe. Coating of buried ductile iron pipe connected to concrete encased pipe with wax tape coating.
d. Installation of magnesium anodes, cables, insulating joints, coatings for buried insulating joints, test stations, and coating for buried pipe connected to concrete encased pipe.
e. Backfill and compaction of backfill.
f. Provide shop Drawings, reports, permits, and obtain City’s approval where required.
g. Correction of all deficiencies.
h. The work shall include the provisions of all materials, equipment, and apparatus not specifically mentioned herein or noted on the plans, but which are obviously necessary to complete the work specified.

1.02 REFERENCE SPECIFICATIONS
A. This section contains references to the following documents. They are a part of this section as specified and modified. In case of a conflict between the requirements of this section and those of the listed documents, the requirements of this section shall prevail:

1. American Society of Testing and Materials (ASTM).

2. National Electrical Manufacturers Association (NEMA).

3. American Water Works Association (AWWA).

4. National Association of Corrosion Engineers (NACE).

5. American National Standards Institute (ANSI).

Cathodic Protection
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1.03 CODES AND REGULATIONS
A. All materials, workmanship, and installation shall conform to all requirements of the legally constituted authority having jurisdiction. These authorities include, but are not limited to, the latest revision of the State of California, Department of Industrial Relations, Division of Industrial Safety Orders of the Industrial Accident Commission, and all other applicable State, County, or City codes and regulations.

Nothing in the Drawings or specifications is to be construed to permit work not conforming to these regulations and codes. Where larger size or better grade materials than required by these regulations and codes are specified, the specifications and Drawings shall have precedence.

1.04 CONTRACTOR SUBMITTALS
A. Submittals shall be furnished in accordance with Section 01330 - Submittal Procedures and Section 01331 - Submittal Forms.

B. A complete list of equipment and material, including name and manufacturer, catalog number, size, finish, and any other pertinent data necessary for proper identification.

PART 2 PRODUCTS

2.01 GENERAL
A. All materials shall conform to the requirements set forth herein or as designated on the Drawings, unless otherwise specified. All materials must be new, free from defects, and shall be of the best commercial quality for the purpose specified. The Contractor shall furnish all necessary items and accessories not shown on the Drawings or specified herein, but which are required to fully carry out the specified intent of the work, without additional cost to the City.

2.02 MAGNESIUM GALVANIC ANODES
A. Magnesium anodes shall be of the high potential alloy as indicated below. Each anode shall be cast with a steel core and the core shall protrude from one end and shall be of sufficient length to permit attachment of a lead wire. Each anode shall conform to the following chemical composition and dimensions:

1. Chemical Composition:

Element Range
Aluminum 0.010%
Manganese 0.50 – 1.30 %
Copper 0.02 % Max.

Nickel 0.001% Max.

Iron 0.03% Max.

Other Impurities 0.05% each or 0.3% Max Total.

Magnesium Balance

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2. Bare Anode Dimensions:

Nominal Wt. Bare (lbs) Height (in.) Width (in.) Length (in.) 32 5 5 21
B. Anode Core Strap: Galvanized steel, with one end of anode recessed to provide access to the rod for connection of the lead wire.

C. Lead Wire: No. 10 AWG, Type THHN (Black) silver brazed to the rod, making a mechanically secure connection.

D. Soldered Connection and Core: Seal entirely with electrical potting compound.

E. Magnesium Anode Packaging: Prepackaged in a cloth bag containing low resistivity backfill consisting of 75 percent hydrated gypsum, 20 percent bentonite, and 5 percent sodium sulfate.

F. Manufacturers, or equal:

1. Farwest Corrosion.

2. Corrpro Companies.

2.03 CABLES
A. All underground cables utilized for drain and bonding cables shall be single conductor, stranded copper, Type CP, insulated for 600 volts with High Molecular Weight Polyethylene (HMWPE) in accordance with the requirements of ASTM D1248, Type 1, Class C, Category 5, Grades E-4 and E-5.

B. All cables for galvanic anodes and test stations shall be Type THHN, solid, copper, sized as shown on the plans, and shall conform to Federal Specifications JC-30B.

C. Test Leads and Anode Leads: Extend 18 inches minimum above grade after connection to test station panel board.

2.04 EXOTHERMIC WELD EQUIPMENT
A. The cable connections to the fittings and steel pipe shall be accomplished utilizing an exothermic welding process as shown on the Drawings. Each cable shall be fitted with a copper sleeve for accomplishing the weld and cartridge, sleeves and molds for each weld shall be furnished by the same manufacturer. All materials for welding shall be sized and in accordance with recommendations in manufacturers' literature.

B. Manufacturers, or equal:

1. “Cadweld" by Erico Products, Inc.

2. "Thermoweld" by Continental Industries, Inc.

2.05 CABLE-TO-PIPE COATING MATERIAL
A. Epoxy shall be used for sealing the cable to pipe connections.

Cathodic Protection
13100-4 201631 September 2025
pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13100 (BidSet) B. Subject to Compliance with the Contract Documents the following products and Manufacturers are acceptable:

1. Aquatapoxy® A-6, manufactured by Cohesant Materials.

2. ProPoxy® 20, manufactured by Hercules.

3. Durcon-164, by Duriron Company.

4. Scotchcast Resin No. 4, by 3-M Company.

5. CC-1 Potting Compound, by OSI Products.

6. Or approved equal.

2.06 FLUSH GRADE TEST STATION
A. Flush grade test stations shall be traffic boxes with cast iron cover as shown on the Drawings. Terminal boxes shall be locking type, constructed of high-impact, molded Lexan plastic. The test box shall be provided with sufficient hardware and binding post terminals for each cable as shown on the Drawings. All test station hardware, including nuts, bolts and shorting straps shall be nickel plated brass.

B. Manufacturers, or equal:

1. Christy G5 traffic box with a cast iron lid as shown on the Drawing. The cover shall be manufactured with "CP-TEST" markings for easy identification.

2. Terminal Boxes shall be Model "T-3" by Tinker & Rasor.

3. Anode metering shunts shall be 0.01 ohm, 8 amp capacity, with 1 percent accuracy by Tinker & Rasor.

2.07 CABLE WARNING TAPE
A. All buried test station cables shall have plastic warning tape installed a minimum of 12 inches above the top of the cables for the entire buried length of the cables. The warning tape shall be 3 inches wide and shall be yellow with black lettering with the legend "CAUTION, CATHODIC PROTECTION CABLES BURIED BELOW" in 2 inches high lettering printed at a minimum of seven-foot intervals along the entire buried length of the cable.

2.08 CABLE IDENTIFICATION TAG
A. All cables in the terminal boxes shall be identified. The identification tags shall be white plastic "zip-tie" type straps with a plastic tab of sufficient size to allow the pipeline station to be written on the tab with a permanent felt tip marker.

2.09 INSULATING JOINTS
A. Insulating Flange:

1. Each insulating flange set shall consist of a full-face central gasket, a full-length sleeve for each flange bolt, and two insulating washers with two steel washers for each bolt. The ring-type central gasket shall be 1/8-inch thick sheet packing, having a dielectric constant of 300 volts per mil, minimum. The insulating flange gasket shall be G-10 material with EPDM seals. Bolt sleeves shall be mylar, and insulating washers shall be constructed of G-10. The complete assembly shall have an ANSI pressure rating equal to that of the flanges between which it is installed.

Cathodic Protection
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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13100 (BidSet) B. Insulating Restraints:

1. Insulating elements shall be installed to electrically isolate the water pipeline from existing pipelines. The insulating elements shall consist of a full-face central gasket, two sleeves for each end of the flange bolt, and two insulating washers with two steel washers for each bolt. The ring-type central gasket shall be 1/8-inch thick sheet packing, having a dielectric constant of 300 volts per mil, minimum. Bolt sleeves shall be mylar, and insulating washers shall be constructed of G-10. The complete assembly shall have an ANSI pressure rating equal to that of the flanges between which it is installed.

2.10 BURIED FLEXIBLE COUPLING & INSULATING JOINT COATING A. Coatings for buried insulating flanges and insulating couplings shall consist of a non-conductive, petrolatum-based coating system, such as Trenton Wax Tape #1 by The Trenton Corporation, or equal. The coating system shall consist of a prime coat as an initial surface preparation to displace moisture on the surface and to improve adhesion of the wax tape. A wax tape wrap material shall be used to provide a smooth contour on the surface of the joint as well as for protection of the substrate. An over wrap shall be used as a final coating to provide increased mechanical strength of the coating. The prime coat shall be a petrolatum material with corrosion inhibitors and plasticizers. The wrap coat shall be a synthetic fabric saturated with a blend of petroleum wax, plasticizers and corrosion inhibitors. The outerwrap shall be a moisture cured “hard-shell” fiberglass wrap:

1. Cold applied tape system shall include a nonstitched, synthetic fabric tape applied over a microcrystalline wax-based coating primer. Primer shall be Tempcoat 3000 by Trenton, Denso Paste, or SCC PRIME GUARD 250. Tape shall be #2 Wax Tape by Trenton, Densyl Tape or SCC CORRGUARD B.

2. Contractor shall apply the wax tape with minimum of 1-inch overlap. Primer thickness shall be applied per manufacture requirements.

3. The outerwrap shall be a moisture cured “hard-shell” wrap of quick curing resins impregnated into a fiberglass fabric. The outerwrap shall be black in color only. The outerwrap shall be Trenton MCO110 Outerwrap, manufactured by Trenton Corporation or approved equal.

2.11 RIGID PVC CONDUIT AND FITTINGS
A. Rigid polyvinylchloride (PVC) conduit and fittings shall be Schedule 40, manufactured to NEMA TC-2 and WC-1094 specifications and shall be U.L. approved.

2.12 BITUMASTIC
A. Coating for all buried bolts, nuts and metallic washers shall be Bitumastic 300M, coal tar mastic coating, as manufactured by Carboline or approved equal.

Cathodic Protection
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3.01 MATERIAL DELIVERY, STORAGE AND PROTECTION
A. All materials and equipment to be used in construction shall be stored in such a manner to be protected from detrimental effects from the elements. If warehouse storage cannot be provided, materials and equipment shall be stacked well above ground level and protected from the elements with plastic sheeting or other method as appropriate.

3.02 GENERAL
A. All materials, workmanship and installation shall conform to all requirements of the legally constituted authority having jurisdiction. These authorities include, but are not limited to, the latest revision of the State of California, Department of Industrial Relations, Division of Industrial Safety, Electrical Orders; The National Electric Code, General Construction Safety Orders of the Industrial Accident Commission; and all other applicable State, County, or City codes and regulations. Nothing in the Drawings or specifications is to be construed to permit work not conforming to these regulations and codes. Where larger size or better grade materials than required by these regulations and codes are specified, the Specifications and Drawings shall have precedence.

3.03 GALVANIC ANODES
A. Galvanic anodes shall be installed in the trench horizontally in native soil, after excavation to proper depth, equal to the bottom of the pipeline or fitting, a minimum of 3 feet from fittings and a minimum of 5 feet from the pipelines. Spacing between anodes shall be a minimum of 10 feet, if multiple anodes are installed at a single test station location. Prior to placing anodes in the trench or hole, paper or plastic bags shall be removed, but the cloth bag shall remain around the anode. Care shall be exercised during installation to prevent damage to the cloth bag and loss of backfill material. After placing anodes in the trench, native soil, free of rocks and other foreign objects shall be placed around the anode to a minimum cover of one foot above the anode. Flood the anode hole with 10 gallons of fresh water when the backfill reaches one foot above the anode. Remainder of the trench shall then be backfilled with native soil. During installation, anodes shall not be supported or handled by use of attached wires.

B. The number of anodes to be installed at each test station is designated on the Drawings.

3.04 CABLES
A. Cables buried in the ground shall be direct buried and shall be laid straight, without kinks. The cable shall have a minimum cover of 30 inches. Each cable run shall be continuous in length and free of joints or splices. Care shall be exercised during installation to avoid punctures, cuts, and similar damage to insulation. Any damage to insulation will require replacement of the entire cable length. Backfill surrounding the cables shall be native soil free of foreign materials. Cable warning tape shall be installed 12-inches above the entire buried length of the cable.

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3.05 EXOTHERMIC WELDS
A. Cable-to-pipe connections shall be installed in the manner and at the locations shown on the Drawings. Coating materials shall be removed from the pipe surface over an area just sufficient to make the connections. The surface shall be cleaned to white metal by grinding or filing prior to welding the conductor. Grinding with resin impregnated wheels shall not be allowed. The conductor shall be welded to the pipe by the exothermic process with a copper sleeve fitted over the conductor, and only sufficient insulation shall be removed from the conductor to allow placing in welding mold. After the weld has cooled, all slag shall be removed and the weld shall be tested with a sharp blow from a 16-ounce hammer to assure proper metallurgical bond. All defective welds shall be removed and replaced.

B. All exposed surfaces of copper and steel shall be covered with a minimum thickness of 1/4-inch of insulating materials as shown on the Drawings.

3.06 TEST STATIONS
A. Test stations shall be installed at locations designated on the Drawings and at any additional locations where ductile iron valves are installed. The test station shall be located directly above the pipe or fitting. Exact locations of test stations shall be determined by the Construction Manager in the field. The terminal end of each cable shall be identified with the structure identification using the permanent cable identification tags.

B. The test station leads shall be tested by the Contractor and results approved by the Construction Manager prior to backfill.

3.07 JOINT BONDING
A. All non-welded rubber gasket joints, mechanical joints, flange joints and threaded joints shall be bonded with an insulated copper cable, sized as shown on the Drawings. The overall length of the conductor shall permit maximum movement of the pipe joint without transferring any tensile stress to the cable, per pipe manufacturer’s recommendations.

3.08 INSULATING FLANGED JOINTS
A. All insulating components of the insulating flanged gasket set shall be cleaned of all dirt, grease, oil and other foreign materials immediately prior to assembly. Bolt holes in mating flanges shall be properly aligned at the time bolts and insulating sleeves are inserted to prevent damage to the insulation. After flanged bolts have been tightened, each insulating washer shall be inspected for cracks or other damage. All damaged washers shall be replaced. After assembly, resistance between each bolt and flange shall be measured with an approved ohmmeter, and the minimum resistance shall be 50,000 ohms. Where the insulating joint is assembled in the shop and shipped as a unit, resistance shall be measured in the shop between the flanges and between each bolt and flange and shall meet the above requirements.

All insulating flanged joints shall be coated as shown on the Drawings and specified below.

Cathodic Protection
13100-8 201631 September 2025
pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13100 (BidSet) B. The testing shall be conducted in the presence of the City’s representative and approved by him prior to final acceptance.

3.09 FIELD COATING OF BURIED FLANGE HARDWARE
A. All buried nuts and bolts shall be coated with bitumastic prior to polyethylene encasement. After flange hardware is installed use wire brush, power brush or an abrasive cleaning pad to remove all loose material, dirt and grime from substrate to a minimum cleanliness of SSPC SP2. Apply Bitumastic coating liberally with a medium bristle brush to the extent that all surfaces are completely covered with no bare spots visually evident. Coat exposed surfaces of bolts, washers and nuts, giving special attention to the bottom-side surfaces. Follow the manufacturer’s recommendations for drying times required before polyethylene encasement and backfill.

3.10 FIELD COATING OF BURIED FLEXIBLE COUPLINGS & INSULATING FLANGES A. Surfaces shall be cleaned of all dirt, grease, oil and other foreign materials immediately prior to coating. Remove loose rust, paint and other foreign matter in accordance with SSPC SP2 or SP3. A prime coating shall be applied in a uniform coating over the entire surface to be wrapped. A liberal coating shall be applied to threads, cavities, shoulders, pits and other irregularities. A fill coating with a minimum 1/4-inch thickness shall be molded and packed onto irregular surfaces such as flanges, valves or flexible couplings to create a smooth profile prior to wrapping. The wax tape coating shall be spirally wrapped using a minimum of 55 percent overlap to ensure a double thickness of material. At the completion of each roll the overlaps shall be smoothed by hand in the direction of the spiral to ensure sealing of the overlap. A 2-inch overlap shall be maintained when overlapping one roll with the end of a new roll. Overlap shall occur on the top half of the pipeline. The outerwrap coating shall be spirally over-wrapped using a 55 percent overlap to ensure a double coating. In cases where the coating system does not terminate at the face of concrete, the outerwrap shall extend 4 to 6 inches beyond the wax tape end seam.

3.11 SYSTEM COMMISSIONING
A. After installation of the cathodic protection facilities, the system shall be tested, and adjusted by the City’s corrosion engineer, to assure conformance with the Specifications. Testing shall include a determination of proper installation of each component, adequacy of test stations and insulating joints, anodes, dielectric insulation and electrical continuity of bonded pipe fittings. Upon completion of tests, a detailed report will be submitted describing any deficiencies detected. Any and all deficiencies shall be corrected by the Contractor and site conditions restored prior to final acceptance. All retesting shall be at the Contractor’s expense.

B. The Contractor shall notify the City 48 hours prior to installation of any cathodic protection components so that inspections can be scheduled. Phone messages left with others will not be considered adequate notification. The Contractor shall not backfill any cathodic protection components prior to inspection and approval by the City.

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3.12 QUALITY ASSURANCE
A. All work shall be performed to the satisfaction of the City.

B. The Contractor shall not substitute for the specified materials unless approved by the City.

C. Compaction of backfill and trenches shall match the existing conditions and shall be approved by the City.

3.13 INTERFERENCE AND EXACT LOCATIONS
A. The Contractor shall coordinate and properly relate this work to the site and to the work of all trades. The general locations of the facilities are shown on the Drawings.

However, the Contractor shall visit the premises and thoroughly familiarize himself with all details of the work and working conditions, verify existing conditions in the field, determine the exact locations of existing pipelines and structures and advise the City of any discrepancy that may prevent or hinder the specified work from being completed. The Contractor shall be solely responsible for location and marking underground structures so as to avoid damage during construction.

3.14 GPS COORDINATES
A. The “as-built” GPS coordinates of all components such as test stations, anode beds, etc., shall be mapped by the Contractor and provided in tabular form and also as an electronic file.

END OF SECTION

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) SECTION 13207

STRAND-WOUND CIRCULAR PRESTRESSED CONCRETE TANK WITH A TYPE I

CORE WALL AND FLAT ROOF

TABLE OF CONTENTS
PART 1 GENERAL.................................................................................................................2

1.01 SUMMARY ...................................................................................................................2

1.02 REFERENCES.............................................................................................................2

1.03 SUBMITTALS...............................................................................................................4

1.04 NON-RESPONSIVE BID..............................................................................................6

1.05 QUALITY ASSURANCE...............................................................................................6

1.06 DESIGN CRITERIA......................................................................................................8

1.07 PRODUCT DELIVERY, STORAGE, AND HANDLING ..............................................13

1.08 PROJECT CONDITIONS ...........................................................................................13

1.09 SEQUENCING AND SCHEDULING ..........................................................................13

1.10 GUARANTEE .............................................................................................................14 PART 2 PRODUCTS ............................................................................................................15

2.01 MATERIALS ...............................................................................................................15

2.02 SOURCE QUALITY CONTROL .................................................................................23 PART 3 EXECUTION ...........................................................................................................24

3.01 SUPERVISION...........................................................................................................24

3.02 INSTALLATION..........................................................................................................24

3.03 FLOOR .......................................................................................................................25

3.04 CONCRETE ...............................................................................................................25

3.05 SEISMIC CABLES......................................................................................................27

3.06 PRESTRESSING .......................................................................................................27

3.07 ABRASIVE BLASTING...............................................................................................31

3.08 SHOTCRETING .........................................................................................................31

3.09 CLEANING .................................................................................................................34

3.10 FILLING AND WATERTIGHTNESS TESTING ..........................................................35

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1.01 SUMMARY
A. Work includes:

1. This section specifies the design and construction of an AWWA D110, Type 1, strand-wrapped circular prestressed concrete tank, furnishing, installation, and testing. The tank shall consist of: foundation, underdrain system, concrete membrane floor slab, cast-in-place concrete core wall, cast-in-place concrete flat roof with column supports, and all associated appurtenances. The core wall shall be vertically post-tensioned with thread bars, prestressed circumferentially with machine-wrapped seven-wire galvanized strand, and protected with several coats of shotcrete. The foundation shall be constructed with continuous shallow concrete spread footings below the perimeter wall.

The concrete floor shall be constructed with a concrete slab on grade.

2. In the event of a discrepancy between this section of the Specifications and any other section of the Specifications, this section shall govern.

3. The Tank Contractor shall furnish all labor, materials, tools, and equipment necessary to design, construct, and test the prestressed concrete tank.

B. Related sections:

1. Section 01757 - Disinfection.

2. Section 01759 - Water Leakage Test for Concrete Structures.

3. Section 03102 - Concrete Formwork.

4. Section 03150 - Concrete Accessories.

5. Section 03200 - Concrete Reinforcing.

6. Section 03300 - Cast-In-Place Concrete.

7. Section 03931 - Epoxy Injection System.

8. Section 09960 - High-Performance Coatings.

9. Section 09986 - Painting Prestressed Concrete Water Tanks.

1.02 REFERENCES
A. Abbreviations:

1. cfm - cubic feet per minute.

2. f’c - specified compressive strength of concrete.

3. g - gravitational constant, equal to 32.2 feet per second squared.

4. gpm - gallons per minute.

5. ksi - kips per square inch.

6. MG - million gallons.

7. mph - miles per hour.

8. pcf - pounds per cubic foot.

9. psf - pounds per square foot.

10. psi - pounds per square inch.

11. PVC - polyvinyl chloride.

12. sec - seconds.

B. Definitions:

1. Core Wall - That portion of the concrete tank wall that is circumferentially post-tensioned.

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2. Prestressed Concrete - Concrete in which internal compressive stresses of such magnitude and distribution have been introduced through post-tensioning to offset tensile stress development from service loads.

3. Prestressing Reinforcement - High-strength steel used to prestress the concrete tank wall.

4. Rebound - The shotcrete material that ricochets off of the receiving surface and falls.

5. Shotcrete - Pneumatically applied wet mortar or concrete used for embedment protection of the circumferential prestressed wall reinforcement.

6. Strand - A symmetrically arranged and helically twisted assembly of seven high-strength steel wires used for prestressing reinforcement or as non-prestressed seismic cables.

7. Stressing Machine - May refer to the automated wrapping machinery used to post-tension the strand around the tank circumference or vertical post-tensioning equipment used to post-tension vertical thread bars.

8. Tank Contractor - A qualified tank manufacturer and/or contractor that specializes in the design and construction of an AWWA D110 type of tank specified herein.

9. Tank Prestressor - A contractor or sub-contractor that specializes in the design of an AWWA D110 type of tank and specializes in the construction of the prestressed elements of the tank, such as the strand/wire wrapping and the vertical post-tensioning of the wall.

10. Tendon - High-strength thread bar, including end anchorages, used to impart vertical prestressed forces to the tank wall.

11. Wire - High-strength, cold-drawn steel wire used to assemble strands.

C. Reference Standards:

1. American Concrete Institute (ACI):
a. ACI 301-16 - Specifications for Structural Concrete, 2016. b. ACI 305.1-14 - Specification for Hot Weather Concreting, 2014. c. ACI 306.1-90 - Standard Specification for Cold Weather Concreting, 1990. d. ACI 350-06 - Code Requirements for Environmental Concrete Structures and Commentary, 2006.
e. ACI 350.1-10 - Specification for Tightness Testing for Environmental Engineering Concrete Containment Structures and Commentary, 2010. f. ACI 350.3-06 - Seismic Design of Liquid-Containing Concrete Structures and Commentary, 2006.
g. ACI 350.5-12 - Specifications for Environmental Concrete Structures, 2012.
h. ACI 372R-13 – Design and Construction of Circular Wire- and Strand-Wrapped Prestressed Concrete Structures, 2013.
i. ACI 506R-16 - Guide to Shotcrete, 2016.
j. ACI 506.2-13 - Specification for Shotcrete, 2013.

2. ASTM International (ASTM):
a. A 416 - Standard Specifications for Steel Strand, Uncoated Seven-Wire for Prestressed Concrete.
b. A 475 - Standard Specification for Zinc-Coated Steel Wire Strand. c. A 615 - Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement.
d. A 706 - Standard Specification for Low-Alloy Deformed and Plain Bars for Concrete Reinforcing.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) e. A 722 - Standard Specification for Uncoated High-Strength Steel Bars for Prestressed Concrete.
f. C 33 - Standard Specification for Concrete Aggregates. g. C 150 - Standard Specification for Portland Cement.
h. C 171 - Standard Specification for Sheet Materials for Curing Concrete. i. C 618 - Type F Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete.
j. D 570 - Standard Test Method for Water Absorption of Plastics. k. D 624 - Standard Test Method for Tear Strength of Conventional Vulcanized Rubber and Thermoplastic Elastomers.
l. D 638 - Standard Test Method for Tensile Properties of Plastics. m. D 746 - Standard Test Method for Brittleness Temperature of Plastics and Elastomers by Impact.
n. D 747 - Standard Test Method for Apparent Bending Modulus of Plastics by Means of a Cantilever Beam.
o. D 792 - Standard Test Methods for Density and Specific Gravity (Relative Density) of Plastics by Displacement.
p. D 1056 - Standard Specification for Flexible Cellular Materials- Sponge or Expanded Rubber.
q. D 2000 - Standard Classification System for Rubber Products in Automotive Applications.
r. D 2240 - Standard Test Method for Rubber Property-Durometer Hardness.

3. American Society of Civil Engineers (ASCE):
a. 7-16 - Minimum Design Loads for Buildings and Other Structures.

4. American Water Works Association (AWWA):
a. C652 - Standard for Disinfection of Water-Storage Facilities. b. D110-13 - Wire- and Strand-Wound, Circular, Prestressed Concrete Water Tanks, 2013.

5. NSF International (NSF):
a. 61 - Drinking Water System Components - Health Effects.

6. Code of Federal Regulations (CFR):
a. Part 1910 - Occupational Safety and Health Standards (OSHA).

7. U. S. Army Corps of Engineers (USACE):
a. CRD C 572 - Corps of Engineers Specifications for Polyvinylchloride Waterstop.

1.03 SUBMITTALS
A. Product data:

1. Admixtures:
a. Submit evidence of NSF 61 compliance for all concrete admixtures.

2. Waterstops:
a. Submit samples, prints, and complete physical property data covering waterstops.
b. Laboratory test reports: Submit reports indicating that average properties of polyvinyl chloride waterstops material and finish conform to requirements specified in this Section.

3. Epoxy grouting equipment: Submit product information.

4. Neoprene bearing pads: Submit product information.

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5. Stressing machine:
a. Submit a description of the proposed equipment.
b. Submit calibration reports for force recording equipment used installation of vertical thread bars and circumferential prestressing.

B. Shop drawings:

1. Drawings showing all plan views, sections, and details of the tank construction, including, but not limited to, all structural elements, all appurtenances, connections, joints, waterstop, roof hatches, vents, ladders, fall arrest and protection systems, guardrails, piping, pipe penetrations, pipe supports, sub-grade preparation, base liners, tank instrumentation, and materials for roof drainage and conductance.

2. Drawings of entire prestressing operation showing vertical thread bar and circumferential strand placement with associated schedules and intermediate lock-off elevations, prestressing bar and strand size, ducts for vertical thread bars, and anchorage details.

3. Drawings for placement and detailing of all reinforcing steel.

4. Drawings showing:
a. Neoprene bearing pads and methods of pad installation. b. Waterstop and methods of installation.
c. Sponge filler pads or sleeves and methods of installation. d. Exterior coating system.

5. All shop drawings shall be signed and sealed by a registered California structural or civil engineer.

C. Design Submittals:

1. Structural calculations for all aspects of the structural design of the tank, along with calculations for prestressing reinforcement, elongation estimates, soil capacity checks, and calculations for any other structural design aspect.

2. Concrete mix designs in accordance with Specification 03300 - Cast-in Place Concrete, and additional provisions specified herein.

3. Shotcrete mix designs in accordance with the provisions specified herein.

4. Admixtures to be used in the concrete and/or shotcrete and their purpose.

5. All design submittals shall be signed and sealed by a registered California structural or civil engineer.

D. Tank responsibility statement:

1. The Tank Contractor shall submit a statement attesting that they have assumed responsibility for the tank design and construction. No other submittal items will be reviewed until a satisfactory statement has been received.

E. Qualifications statement:

1. Failure to submit a qualifications statement package will be deemed an irregularity, which will cause bid to be rejected as nonresponsive.

2. Submit pertinent information that demonstrates conformance with Quality Assurance requirements specified herein.

3. To include:
a. Company history, contact person(s), address, and telephone number.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) b. Project references with City and engineer’s contact information. c. Name and work history of the on-site project manager to be assigned to the project.

F. Quality control submittals:

1. Certificates of Compliance:
a. Thread Bars: Submit certified test reports that verify bars and anchorage meet specified material standards.
b. Waterstop: Submit certificates certifying that waterstops provided on this project meet or exceed physical property requirements of current USACE CRD C 572.
c. Circumferential prestressing: Submit certified test reports for each size, heat, and reel that verify conformance to applicable ASTM standards for materials, strength, and yield properties.

G. Test reports:

1. Strand and vertical thread bar prestressing records.

H. Manufacturer's instructions:

1. Tank appurtenances: Submit manufacturer’s installation instructions.

1.04 NON-RESPONSIVE BID
A. Qualifications statement package:

1. Submit a qualifications statement package with the bid. The package shall contain information as required per Section 1.03.E.

2. Failure to submit a qualifications statement package will be deemed an irregularity that may cause bid to be rejected as non-responsive.

1.05 QUALITY ASSURANCE
A. Qualifications:

1. Singular Responsibility:
a. It is the intent of these Specifications to create singular responsibility for design, construction, and performance of the prestressed concrete tank.

The design and construction of all aspects of the foundation, floor slab, core wall, prestressing, shotcrete, and roof of the tank shall be performed by the Tank Contractor:
1) The Tank Contractor may subcontract with a Tank Prestressor as required for the design and construction of the tank.
2) The Tank Contractor shall have a working agreement with the Tank Prestressor in which the Tank Contractor is approved by the Tank Prestressor to perform all construction of the specified tank except the presstressing.
3) The Tank Contractor agrees to meet the minimum standard of care required by the Tank Prestressor and their design or as specified herein, whichever is more stringent.
4) The Tank Contractor has successfully teamed with the Tank Prestressor to successfully construct at least 5 tanks within the last 10 years.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) 5) The Tank Contractor may subcontract labor for reinforcing steel installation and for concrete slab finishing under the
Tank Contractor’s direct supervision.
b. The Tank Contractor’s on-site project manager shall supervise the work of any subcontractors and their personnel.
c. If the Tank Contractor believes that any requirement of this Section represents a departure from its normal recommendations that will affect the quality or performance of the tank, notify the Engineer in writing of such concerns. For each provision of concern, cite the relevant paragraphs of this Section and indicate the Tank Contractor’s recommended modifications or alternatives to those provisions:
1) Acceptance of Tank Contractor’s alternatives shall be at the discretion of the Engineer, and the decision of the Engineer shall be final.

2. The specified tank shall be constructed by the Tank Contractor. The Tank Contractor shall be experienced in the construction of circumferentially prestressed tanks with cast-in-place concrete core wall sections using freed neoprene bearing pad connections at the base of the wall, PVC waterstops, seismic cables placed between the wall and the foundation, and a flat concrete roof:
a. No Tank Contractor is considered qualified unless it has built the following projects:
1) At least ten circumferentially prestressed concrete tanks conforming to AWWA D110, Type I in the last twenty years.
2) At least five circumferentially prestressed concrete tanks conforming to AWWA D110, Type I used for water storage that have been in successful operation for at least five years.
3) At least five circumferentially prestressed concrete tanks conforming to AWWA D110, Type I that are 1.0 MG or larger in the last ten years.
b. The Tank Contractor shall have in its employ for this project a team, comprised of staff of both the Tank Contractor and Tank Prestressor, consisting of an on-site project manager, concrete foreman, shotcrete foreman, shotcrete nozzleman, and prestressing foreman, each of whom shall have constructed in the last ten years a minimum of five AWWA D110 Type I tanks with flat concrete roofs having a capacity of

1.0 MG or greater:
1) Experience gained on shotcrete pool and ditch construction will not be considered as qualifying experience for nozzleman.
2) Skill of nozzleman:
a) Capable of applying thin coats of even and uniform thickness. b) Certified shotcrete nozzleman in accordance with ACI 506R.

3. The specified tank shall be designed by the Tank Prestressor. The Tank Prestressor shall have in its employ a design engineer with a minimum of ten years of experience in the design of AWWA D110 Type I tanks with domed or flat-slab concrete roofs. The design engineer shall have been the engineer of record for a minimum of ten AWWA D110 Type I tanks designed by the

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) Tank Prestressor in its own name. The design engineer shall be licensed as a civil or structural engineer in the state of California:
a. No Tank Prestressor is considered qualified unless it has designed the following projects:
1) At least ten circumferentially prestressed concrete tanks with flat concrete roofs conforming to AWWA D110, Type I in the last twenty years.
2) At least five circumferentially prestressed concrete tanks with flat concrete roofs conforming to AWWA D110, Type I used for water storage that have been in successful operation for at least five years. 3) At least five circumferentially prestressed concrete tanks with flat concrete roofs conforming to AWWA D110, Type I that are 1.0 MG or larger in the last ten years.

4. Experience in the design and construction of AWWA D110 Type II, Type III, or Type IV tanks will not be accepted as demonstrating the qualifications required by the preceding paragraphs.

1.06 DESIGN CRITERIA
A. Except as modified herein, the prestressed concrete tank shall be designed and constructed in compliance with the provisions of AWWA D110 for strand-wound circular, prestressed concrete water tanks with Type I core wall:

1. The prestressed concrete tank core wall shall be of cast-in-place concrete construction. Shotcrete or precast core walls are not permitted under the provisions of this Section.

B. Standards/Codes:

1. The prestressed concrete tank shall be designed and constructed as specified herein, and in accordance with provisions of the following standards and codes:
a. AWWA D110-13.
b. California Building Code, 2022.
c. ACI 350-06 with modifications per ASCE 7-16 §15.7.7.3. d. ACI 350.3-06.
e. ASCE 7-16.

2. Where conflicts between the requirements of this Section and of these standards and codes occur, the more restrictive provisions shall apply:
a. Exception: Requirements for concrete cover and member thickness shall be as specified in this Section.

C. California Department of Public Health:

1. Contractor is advised that the prestressed concrete tank specified herein will be used in potable water service.

2. All admixtures used in the concrete mix design for the prestressed concrete tank shall be certified in compliance with NSF 61.

D. Load criteria and requirements to be used by the Tank Contractor in the design calculations:

1. Capacity: 6 MG usable storage below the maximum water elevation shown on the Drawings:
a. Inside Diameter: 172 feet.

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2. Dead Load: shall be the estimated weight of all permanent imposed loads:
a. Unit weight of concrete shall be taken as 150 pounds per cubic foot. b. Unit weight of steel shall be taken as 490 pounds per cubic foot.

3. Fluid Load: shall be the lateral pressure and weight of the water when the tank is filled to a level that is 6 inches above the elevation of the top of the overflow elevation as indicated on the Drawings (to allow for overflow conditions):
a. Unit weight of water shall be taken as 62.4 pounds per cubic foot.

4. Roof Live Load:
a. Uniform: 40 pounds per square foot, non-reducible.
b. Any concentrated reactions due to the use of fall protection equipment. c. Application of fall protection equipment reaction loads shall be applied concurrently with uniform roof live load. However, load factors for the load case where the combination of uniform and fall protection reactions are considered simultaneously may be taken as unity.

5. Construction Loads:
a. Loads applied to the tank during construction shall be accounted for in the design of the tank.

6. Geotechnical Report: See Section A - Special Provisions.

7. Foundation Loads: the tank foundation shall be proportioned so that the net foundation bearing pressure shall be less than the net allowable soil bearing pressure specified in the Geotechnical Report:
a. The allowable soil bearing pressure may be increased by 33 percent for load combinations that include wind or seismic loads.
b. Settlement Loads: the tank shall be designed to resist the effects of total and differential settlement indicated in the Geotechnical Report.

8. The final design for wind and seismic loads shall consider a reduced capacity to resist sliding due to membranes placed between the bottom of the concrete foundation and the soil.

9. Wind Load: determined in accordance with ASCE 7-16:
a. Exposure Category C.
b. Basic Wind Speed V = 99 mph (3-sec gust).
c. Importance Factor, IW = 1.00.

10. Seismic Design Criteria: seismic design shall be based on the applicable sections of AWWA D110-13, ASCE 7-16, and ACI 350.3-06. The seismic forces shall be calculated using each code separately. The total base shear used for design shall be the maximum value obtained from the three codes used:
a. When comparing force and base shear values, those obtained from ASCE and ACI shall be based on service level loads.
b. AWWA D110-13 Design Criteria:
1) Occupancy Category, IV.
2) Importance Factor, I = 1.50.
3) See Site Specific Ground Motion Hazard Analysis.
4) Site Class C.
5) Impulsive Structure Coefficient, RI = 3.5.
6) Convective Structure Coefficient, RC = 1.0.
7) Overstrength Factor,Ωo, 2.0.
c. ASCE 7-16 Design Criteria:
1) Risk Category IV.
2) See Site Specific Ground Motion Hazard Analysis.
3) Site Class C.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) 4) Response Modification Factor, R = 3.25.
5) Overstrength Factor,Ωo, 2.0.
6) Long-period Transition Period, TL = 12 sec.
7) Importance Factor, Ie = 1.50.
d. ACI 350.3-06 Design Criteria:
1) See Site Specific Ground Motion Hazard Analysis in section 0800.

Site Class C.
2) Impulsive Structure Coefficient, RI = 3.25.
3) Convective Structure Coefficient, RC = 1.0.
4) Long-period Transition Period, TL = 12 sec.
5) Importance Factor, I = 1.50.
e. The sloshing wave height shall be taken as the larger of the values calculated in accordance with AWWA D110-13, ASCE 7-16, and ACI 350.3-06:
1) In the event that the calculated height of the “sloshing wave” exceeds the freeboard of the tank (distance from the maximum operating water surface elevation to the bottom of the roof at the wall), the tank and the roof shall be designed to accommodate the dynamic effects as follows:
a) Any portion of the convective sloshing wave that extends above the top of the tank wall (bottom of the roof at the wall) shall be calculated and applied to the roof as an uplift pressure in accordance with section 15.7.6.1.2.e of ASCE 7-16.
b) Additionally, the mass of any confined portion of the convective sloshing wave shall be included with the impulsive mass used in the estimation of the hydrodynamic forces applied to the tank for design, also in accordance with section 15.7.6.1.2.e of ASCE 7-16.
c) Any revisions to the tank, including but not limited to, the roof elevation, and water overflow level, that are required to meet the specified provisions to resist sloshing loads and its effect on the hydrodynamic design shall not result in additional costs to the City.

11. Temperature and moisture gradients: effects due to changes in temperature and due to temperature and moisture gradients across structural members shall be considered in the design. Refer to Section 01601 - Product Requirements.

12. Prestressing application: forces applied to the wall shall be considered in the design of the wall, especially where wall penetrations result in locally increased prestressing force application to the wall.

13. Vent Capacity Requirements (after accounting for resistance to air flow based on screen mesh size and screen open area):
a. The vent shall be sized for a minimum rate of 1,400 cfm or the rate of volumetric withdrawal assuming the outlet pipe has ruptured, whichever is greater.

14. Overflow Weir Design Capacity: 10,000 gpm with maximum 6-inch water height over the top of the overflow weir.

E. Floor Slab and Wall Footing Requirements:

1. The floor slab shall be designed as a membrane floor slab as defined in ACI 372R, Section 3.2.2 that is not less than 6.5 inches thick; or the floor slab

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6.5 inches.

2. Construction joint locations shall be submitted to the Engineer for review. a. Where construction joint spacing exceeds 50 feet, provide means for reducing shrinkage below the limit specified in Section 03300 - Cast-in-Place Concrete in proportion to the extent the spacing limit of 50 feet is exceeded.
b. Use of construction joints in the floor slab shall be minimized.

3. Minimum ratio of floor slab reinforcement area to concrete area shall be

0.5 percent for each orthogonal direction, with bars spaced no greater than 12 inches on center or two times the slab thickness, whichever is less.

4. Minimum concrete cover over reinforcing steel shall be in accordance with Table 3.3.2.3 of ACI 350.5.

5. Wall footings shall bear below floor sub-grade and shall be placed monolithically with the floor slab:
a. The bottom of the wall footing shall be embedded a minimum of 18 inches below the lowest finish grade elevation over the outside edge of the footing or as indicated on the Drawings, whichever is greater.

6. Design of the floor and wall footing shall consider the differential base stiffness and at concrete encasements or hard points below the floor and wall footing.

F. Column Footing Design Requirements:

1. Column footings shall be designed in accordance with ACI 350.

2. Column footings shall be constructed on top of the floor slab (no projections below the floor slab).

3. Where column footings are to be located, recess the floor slab 2 inches and roughen the top surface of the slab in the recessed area to a 1/4-inch magnitude.

G. Wall Design Requirements:

1. The prestressed concrete tank wall shall be constructed with a cast-in-place core wall that is circumferentially wrapped with seven-wire strand prestressing reinforcement at the exterior and encapsulated within protective shotcrete layers. The core wall is to be vertically prestressed with post-tensioned thread bars.

2. The thickness of the core wall shall not be less than 10 inches thick.

3. The minimum average vertical compressive axial prestress in the core wall provided by the vertical prestressing reinforcement shall be 200 psi after deduction for all losses:
a. Vertical prestressing reinforcement shall be spaced on average no greater than 50 inches on center or seven times the thickness of the core wall, whichever is less.

4. The minimum average circumferential residual prestress compression in the wall shall not be less than 200 psi.

5. The connection between the base of the wall and the foundation shall be an anchored flexible connection in accordance with Section 4.2.1 and Figure 4B of AWWA D110-13:
a. The joint at the base of the wall shall permit unrestrained radial expansion and contraction of the wall relative to the foundation. b. The joint at the base of the wall shall provide restraint against lateral seismic loads acting tangentially to the wall.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) c. Restraint cables shall be provided between the core wall and the foundation to resist seismic loads. The cable installation shall be detailed in a manner that does not introduce radial restraint between the wall and the foundation.

6. The minimum concrete cover over non-prestressed reinforcing shall be in accordance with Table 3.3.2.3 of ACI 350.5 with the following exception:
a. Provide minimum 2-inch concrete cover on inside face of concrete wall exposed to liquid for non-prestressed reinforcing.

7. Vertical non-prestressed reinforcing:
a. Provide vertical non-prestressed reinforcing over the full height of the wall. b. The tensile stress shall be limited to a maximum of 18,000 psi. c. Reinforcing size shall not exceed 3/4-inch in diameter. d. Reinforcing spacing shall not exceed 12 inches on center.

8. Horizontal non-prestressed reinforcing:
a. Provide horizontal non-prestressed reinforcing around the entire perimeter of the wall. The reinforcing shall be continuous through vertical joints in wall.
b. Reinforcing size shall not exceed 3/4-inch in diameter. c. Reinforcing spacing shall not exceed 12 inches on center.

H. Flat Roof and Column Design Requirements:

1. The roof shall be a flat, cast-in-place concrete structure that spans in two directions.

2. The minimum thickness of the roof slab shall be 9 inches.

3. The roof slab shall be provided with drop panels at concrete column supports.

4. Columns shall be limited to a maximum spacing of 25 feet.

5. Columns shall be circular with a minimum diameter of 18 inches.

6. Columns shall be reinforced with spirals.

7. Minimum concrete cover over reinforcing steel shall be in accordance with Table 3.3.2.3 of ACI 350.5.

8. The reinforcing steel for the roof structure shall be sized in accordance with ACI 350 with the environmental durability factor, Sd, applied to limit flexural stress. Reinforcing steel shall be proportioned and distributed to control cracking for normal environmental exposure.

9. The effects of thermal expansion and contraction shall be accounted for in the design of the roof structure. Appurtenances and roof connections shall be detailed to limit restraint to thermal radial movement.

10. The Tank Contractor shall submit, for the Engineer's approval, a plan showing the roof configuration that includes construction joints. Construction joints shall incorporate a 6-inch PVC waterstop.

I. Painting and Coating:

1. All interior metals shall be coated per Section 09960 - High Performance Coatings. All coatings in contact with potable water shall comply with NSF 61 requirements.

2. Tank exterior shall be painted per Section 09986 - Painting Prestressed Concrete Water Tanks and coated per Section 09920 - Graffiti-Resistant Coating.

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1.07 PRODUCT DELIVERY, STORAGE, AND HANDLING
A. Prestressing steel shall be adequately packaged for protection against corrosion and physical damage during shipping and storage.

B. Prestressing steel that has rusted or has otherwise sustained damage will be rejected.

C. Prestressing material and appurtenances delivered to project site: Store off ground on planks, supported by 4-by-4 timber. Cover with polyethylene sheeting or treated paper to prevent exposure to moisture.

1.08 PROJECT CONDITIONS
A. Environmental requirements:

1. Cold weather epoxy grouting of tendons:
a. In cold weather, and especially during frosts, take special precautions to avoid freezing of epoxy.
b. In event that grouting procedure cannot be postponed, keep wall temperature above freezing point with hot blankets or by other means acceptable to Engineer.

B. Site safety precautions:

1. Take every precaution to keep personnel and visitors outside the area of danger from breaking prestressing strands or bars.

2. At no time shall anyone stand in the line of stressed circumferential strand.

3. No work shall be performed by anyone, other than the prestressing crew within 100 feet of circumferential wrapping operation or vertical bar stressing operation.

4. Where access to the site by unauthorized persons cannot be controlled while prestressing work is in progress, or where property lines are less than 100 feet from the wrapping operation, erect protective fencing to prevent breaking strands from endangering such persons.

C. Welding:

1. Perform no welding to anchor plates after prestressing tendons have been assembled.

2. Do not use prestressing steel as ground for welding operations.

1.09 SEQUENCING AND SCHEDULING
A. Polyvinyl chloride waterstops:

1. Welding of polyvinyl chloride waterstops: Prior to installing waterstops in forms, demonstrate ability to weld acceptable joints in waterstops.

2. Quality of welded joints: Are to be subject to acceptance of the Engineer.

B. Restrictions on shotcrete operations:

1. Abrasive Blasting:
a. Do not commence prior to the completion date of curing period of tank corewall.
b. Do not commence until all form tie holes have been drypacked.

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2. Wind conditions: Do not apply shotcrete under such strong wind conditions that considerable amount of cement and moisture is removed by wind from mortar spray between nozzle and surface on which shotcrete is applied.

3. Temperature requirements:
a. Peak temperature during day must be expected to rise to at least 55 degrees Fahrenheit.
b. Night temperature of first night after shotcrete application must not be expected to drop below 33 degrees Fahrenheit.

4. Cold weather conditions:
a. Application of shotcrete under cold weather conditions is solely at the Tank Contractor's risk.
b. Shotcrete may be applied in cold weather provided surfaces are not frozen.
c. Damage to shotcrete: Whenever rain or frost damages shotcrete which has not had chance to take set:
1) Remove and replace such shotcrete.
2) Remove damaged shotcrete before applying any new layers of shotcrete.
d. Type III Portland cement may be utilized for shotcrete for cold weather application.

C. Ultimate initial prestressing force for vertical thread bars: Do not apply until concrete compressive strength in walls reaches specified strength.

D. Wrapping of circumferential prestressing strands:

1. May start when core wall concrete has reached a compressive strength of 3,000 pounds per square inch and intermediate layers of shotcrete coats over prestressing strands has reached a compressive strength of 250 pounds per square inch or 12 hours after the shotcrete coat was applied, whichever is greater.

2. The compressive stress in the concrete due to wrapping shall not exceed 55 percent of f'c at any time.

1.10 GUARANTEE
A. The Tank Contractor shall guarantee the structure against defective materials or workmanship for a period of two years from the final date of completion. If any materials or workmanship prove to be defective within two years, those materials shall be replaced or repaired by the Tank Contractor at the expense of the Tank Contractor.

B. Access hatches and manways (through-roof and wall access) warranty:

1. Manufacturer is to warranty proper operation and against defects in material or workmanship for a period of 5 years.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) PART 2 PRODUCTS

2.01 MATERIALS
A. General:

1. Materials of construction for the strand-wound prestressed concrete tank shall be selected by the Tank Contractor, subject to the limitations of this Section.

B. Concrete:

1. Concrete shall conform to Section 03300 - Cast-in-Place Concrete and ACI 301, except as modified herein.

2. Unless otherwise specified, all concrete for tank construction shall have a minimum 28-day compressive strength of 4,000 psi.

3. The concrete for the tank floor, footings, and pipe encasement shall conform to the following requirements:
a. Concrete shall not be air-entrained.
b. The coarse and fine aggregate shall meet the requirements of ASTM C33 and sized to meet member thickness and clearance requirements of ACI 350.
c. Superplasticizer and water-reducing admixtures shall be incorporated into the concrete for the floor slab and wall footing.

4. Proportioning for concrete shall be in accordance with ACI 301.

5. All concrete shall have a maximum water-soluble chloride ion concentration of

0.06 percent by weight of cement.

6. Cement shall conform to ASTM C 150, Type I or Type II.

7. Accelerating and retarding admixtures shall not be incorporated into the any concrete mix without prior acceptance by the Engineer.

C. Reinforcing Steel:

1. Reinforcing steel shall be new billet steel Grade 60 meeting the requirements of ASTM A 615.

2. Reinforcing steel that is to be welded shall be ASTM A 706, Grade 60.

3. Reinforcing steel shall be accurately fabricated and shall be free from loose rust, scale, and contaminants.

4. Reinforcing steel shall be accurately positioned on supports, spacers, hangers, or other reinforcement and shall be secured in place with wire ties or suitable clips. Rebar chair supports shall be provided in accordance with Section 03200 - Concrete Reinforcing.

5. Minimum reinforcing steel lap splice length shall be as indicated on Drawings.

D. Prestressing Materials:

1. Seven-wire strand:
a. Prestressing strand shall be in accordance with ASTM A 416 prior to hot-dip galvanizing.
b. Individually hot-dip galvanize each wire of strand before forming the wires into a strand.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) c. Hot-dip galvanized 7-wire strand shall meet following minimum requirements:

Physical Characteristics Required Results
Nominal Strand Diameter Before Galvanizing 3/8 inch
Nominal Area After Galvanizing 0.089 square inch
Nominal Weight Per 1,000 Linear Feet 303 pounds
Pitch of Strand 12 to 16
Minimum Yield Strength At 1 Percent Extension 180,000 psi Minimum Ultimate Strength After Galvanizing 240,000 psi Elongation In 24 Inches At Fracture 4.5 percent
Weight Of Zinc Coating per ASTM A475 0.85 ounces per square foot

2. High strength thread bars:
a. Thread bars and deformations: Hot rolled:
1) Thread bars with cold rolled threads or with quenched or tempered steels will not be permitted.
b. Deformations of thread bars:
1) Provide deformations that form screw-thread suitable for mechanically coupling lengths of thread bar and provide positive attachment of anchor assemblies.
2) Provide deformations that are in accordance with ASTM A 722, Type II requirements and are uniform such that any length of bar may be cut at any point and internal threads of coupler designated for that size of bar can be freely screwed on bar.
c. Tensile and physical properties: Bars manufactured in accordance with ASTM A 722, Type II requirements are to comply with following minimum requirements:

Physical Characteristics Required Results
Nominal Diameter 1.25 inches or 1.375 inches
Nominal Cross-Sectional Area 1.245 square inches or

1.577 square inches
Nominal Bar Weight 4.39 pounds per foot or

5.56 pounds per foot
Minimum Tensile Stress 150 ksi
Minimum Yield Stress At 0.2 Percent Offset 120 ksi
Elongation At Rupture In Gauge Length of
20 Bar Diameters
4 percent minimum
Maximum Carbon Content of Bar 0.55 percent
d. Nuts: Minimum ultimate strength shall be 95 percent of minimum ultimate strength of thread bar.

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3. Anchorages for vertical post-tensioned thread bars:
a. All post-tensioned prestressing shall be secured at the ends by means of approved permanent anchoring devices, which shall hold the prestressing steel at a force not less than 95 percent of the guaranteed minimum tensile strength of the prestressing steel.
b. The load from the vertical prestressing anchoring device shall be distributed to the concrete through steel bearing plates and shall not exceed the values specified by the Post-Tensioning Institute (PTI), Guide Specifications, Paragraph 3.1.7.
c. Fully-threaded anchor connections shall be used at both ends of the vertical prestressing bar, which shall incorporate a spherical-shaped bearing surface to match the conical surface in the bearing plate. d. Wedge anchors shall not be used for permanent anchor hardware.

4. Testing of Prestressing Material:
a. Provide mill certificates.
b. Prior to preparation of shop drawings and installation of vertical thread bars, provide proof that the thread bar anchorage system meets the requirements specified herein.
c. Before any prestressing operations may be started, the Tank Contractor shall calibrate all recording equipment at an approved testing laboratory to the satisfaction of the Engineer.
d. All continuous force readings for either the vertical or the circumferential prestressing operations shall be developed with electronic (or the substantial equivalent) force (strain gauge method) sensing transducers, all having a maximum nonlinearity error of +/- 0.5 percent and a maximum hysteresis error of +/- 0.25 percent.

5. Anchor pockets for vertical thread bars:
a. Consist of steel cans fabricated from steel tubing, hot-dip galvanized after cutting and subsequently welded to the top bearing plate. b. Provide adequate means for flushing of vertical ducts during concrete placement.

6. Ducts for vertical thread bars:
a. Duct enclosures shall be standard 1.25-inch or 1.375-inch diameter PVC pipe class 160 or class 200, respectively, unless otherwise specified on the Drawings.
b. Threaded hose connections shall be provided at the top of each duct for water flushing.
c. All ducts shall be provided with expandable valves to facilitate the injection of epoxy grout after prestressing.

7. Epoxy grout for vertical thread bars:
a. The vertical thread bar system shall offer complete two-part epoxy protection of the prestressing steel inside ducting and anchors. b. Portland cement grout will not be accepted.

E. Seismic Cables and Sleeves:

1. Seismic cables:
a. Hot-dipped galvanized seven-wire strand:
b. Prestressing strand shall be in accordance with ASTM A 416 prior to galvanizing and ASTM A 475 after galvanizing.
c. Individually hot-dip galvanize each wire of strand before forming the wires into a strand.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) d. The galvanized strand shall have a minimum ultimate tensile strength of 240,000 psi.
e. The cables shall be installed to connect the wall and the foundation. f. The minimum weight of zinc galvanic coating shall be 0.85 ounces per square foot.
g. Only seven-wire strand will be allowed. Single wire will not be allowed.

2. Neoprene sleeves for seismic cables shall conform to SCE-43 of ASTM D 1056 and as further modified by the following:

Physical Characteristics Required Results
Compressive deflection 9 to 13 psi
Shore 00 durometer 60 to 80 pcf
Density 12 to 28 pcf
Water absorption by weight 5 percent
Temperature range: Low (flex without cracking)
High continuous
High intermittent
-40 degrees Fahrenheit
150 degrees Fahrenheit
250 degrees Fahrenheit
Compressive set (average): 1/2-inch sample
compressed at 50 percent for 22 hours at 70 degrees
Fahrenheit and 24 hour recovery
15 to 35 percent
Maximum linear shrinkage during heat aging (7 days at
158 degrees Fahrenheit)
5 percent
Minimum tensile strength 175 psi
Minimum elongation 180 percent
Resilience (bayshore – percent rebound average
1/2-inch thickness at 72 degrees Fahrenheit)
20 to 40 percent
F. Shotcrete:

1. General:
a. Shotcrete shall conform to ACI 506.2, except as modified herein. b. Minimum compressive strength of shotcrete shall be 4,500 psi at 28 days. c. Shotcrete used in the tank construction shall have a maximum water soluble chloride ion concentration of 0.06 percent by weight of cement. d. Rebound materials shall not be reused in any form for shotcrete.

2. Portland cement shall meet the general requirements in Section 03300 - Cast-in-Place Concrete.

3. Fine aggregates:
a. Fine aggregates shall meet the requirements as specified in Section 03300 – Cast-in-Place Concrete and the following paragraphs. b. Coarse sand:
1) Shotcrete applications: Use well graded coarse sand, unless otherwise noted.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) 2) Gradations:

Sieve Size Percent Passing by Weight
3/8 inch 100
Number 4 95-100
Number 8 80-100
Number 16 50-85
Number 30 25-60
Number 50 10-30
Number 100 2-10
c. Fineness modulus shall be between 2.7 and 3.0.

4. Water shall be in accordance with Section 03300 – Cast-in-Place Concrete.

5. Class F fly ash shall conform to ASTM C618 and shall not make up more than 20 percent of the cementitious material in the shotcrete mix.

G. Elastomeric Materials:

1. Bearing pads shall be natural rubber or neoprene:
a. Natural rubber bearing pads shall contain only virgin natural polyisoprene as the raw polymer and the physical properties shall comply with ASTM D 2000 Line Call-Out M4AA414A13.
b. Neoprene bearing pads shall have a hardness of 40 to 50 durometer, a minimum tensile strength of 1,500 psi, a minimum elongation of 500 percent, and a maximum compressive set of 50 percent. Pads shall meet the requirements of ASTM D 2000 Line Call-Out M2BC410 A14 B14 or 2 BC 415 A1 4 B14 for 40 durometer material.

2. Sponge filler shall be closed-cell neoprene or rubber conforming to ASTM D 1056, Type 2, Class A, and Grade 3. Compression deflection limited to 25 percent at two to five psi.

H. Waterstops:

1. Requirements:
a. Material: Polyvinyl chloride.
b. Size and type:
1) Centered at construction joints in cast-in-place concrete: 6-inch flat ribbed type.
2) At tank walls to tank wall-footing joints: 9-inch wide with 1-inch diameter hollow bulb ribbed type.
3) Type not allowed: Dumbbell type.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) c. Physical characteristics:

Physical Characteristics Test Method Required Results
Specific Gravity ASTM D 792 Not less than 1.3
Hardness ASTM D 2240 70 to 90 Type A Shore
durometer
Tensile Strength ASTM D 638 Not less than 2,000 pounds per square inch
Ultimate Elongation ASTM D 638 Not less than 300 percent Alkali Extraction CRD C 572 7 day weight change between minus 0.1 percent and plus

0.25 percent. Hardness change
within 5 points.

Low Temperature Brittle
Point
ASTM D 746 No sign of cracking or chipping
at minus 35 degrees Fahrenheit
Water Absorption ASTM D 570 24 hours, not more than

0.15 percent
Accelerated Extraction
Tensile
CRD C 527 Not less than 1,600 pounds per
square inch
Stiffness in Flexure ASTM D 747 Not less than 600 pounds per square inch
Tear Resistance ASTM D 624 225 pounds per square inch
Weight Requirements
Thickness 3/8 inch
Center Bulb Outside
Diameter
1 inch nominal
Allowable Tolerances
Width Plus or minus 3/16 inch
Thickness Plus or minus 1/32 inch
d. Manufacturers: One of the following or equal:
1) Burke Concrete Accessories, Inc.
2) Greenstreak PVC Waterstops, Sika Corporation.
3) Kirkhill Rubber Company.
4) Williams Products, Inc.
5) Vinylex Corporation.

I. Tank Appurtenances:

1. General:
a. Provide and install all appurtenances as shown on the Drawings and as specified herein.

2. Piping:
a. Inlet: As indicated on the Drawings.
b. Outlet: As indicated on the Drawings.
c. Overflow piping and overflow cone: As indicated on the Drawings.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) d. Drain piping: As indicated on the Drawings.

3. Pipe Supports:
a. Provide as required to adequately support piping under all load and operating conditions.
b. Refer to Section 15061 - Pipe Supports.

4. Conduits:
a. As indicated on Drawings.

5. Conduit Supports:
a. Proivde as required to adequately support conduits under all load and operating conditions.
b. Refer to Section 16070 - Hangers and Supports.

6. Ladders:
a. Conforming to all requirements of OSHA and as indicated on the Drawings:
1) Provide brackets and fasteners required for support and secure mounting to tank structure.
2) Rungs: solid bar stock.
3) Welds: fillet or full penetration as appropriate to the condition. 4) Fasteners Ladder bolts, concrete anchors, nuts, washers, and flush steel inserts: Type 316 stainless steel.
b. Interior:
1) Materials: Type 304/304L stainless steel.
2) Fall protection: Fall arrest device as specified in the following paragraphs. Material to match that of ladder. Provide removable center rail extension projecting at least 48 inches above top rung of ladder.
c. Exterior:
1) Materials: As indicated on the Drawings.
2) Fall protection: “Saf-T-Climb” as indicated on the Drawings. 3) Anti-climb door: Per ladder manufacturer. Material to match that of the exterior ladder.
d. Horizontal lifeline fall protection system: As indicated on the Drawings. e. Fall arrest device consisting of sliding/locking mechanism with safety belt and belt attachment to center climbing rail:
1) Device material: Type 304 stainless steel.
2) Devices: To include following items, all fabricated of device material unless otherwise accepted by the Engineer:
a) Rails: Lengths as required.
b) Brackets: Complete with brackets necessary for attaching rail to ladders.
c) Removable rail extension: 48-inch long.
3) Sleeve assemblies and safety belts: 2.
4) Manufacturers: The following or equal:
a) Norton Company, Air Space Device Division, Cerritos, CA, Saf-T-Climb with SAF-T-NOTCH RAIL and SAF-T-LOCK
SLEEVE.

7. Access hatches (through-roof access):
a. Sizes: Nominal size(s) as indicated on the Drawings. b. Material and construction:
1) Door leaf/leaves: Aluminum diamond pattern plate with reinforcement if required for spans provided.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) 2) Frame: Minimum 1/4-inch thick, aluminum channel with anchor flange around perimeter.
3) Door hardware: Equip doors with following:
a) Hinges: Minimum 2 heavy forged stainless steel hinges and pins for each leaf.
b) Operators, hold-open and handle: Spring operators and automatic hold-open arm with release handle for each leaf. c) Lock: A Type 316 stainless steel snap lock with fixed handle shall be mounted on the underside of one cover. In addition, the lock shall be a cylinder style with a threaded security cover plug. d) Seals: Leaf seals shall be dust and water tight.
e) Drainage coupling: 1-1/2-inch coupling located in front right corner of frame. Drain shall be installed to drain to the exterior side of the tank, adjust curb height as required.
4) Finish: Manufacturer's standard mill finish.
5) Manufacturers: One of the following or equal:
a) Bilco Co., Type JD-AL.
b) Babcock-Davis Associates, Inc., Type AM or GT.
c) Nystrom, Inc.

8. Hinged manway(s) (through-wall access):
a. Sizes: Nominal clear opening size(s) as indicated on the Drawings. b. Materials and construction:
1) All Type 304 stainless steel components, unless otherwise accepted by the ENGINEER.
2) Lock: Provide stainless steel padlocks on the hand wheel and yoke. c. Manufacturers: The following or equal:
1) Chase Associates, Edgecomb, Maine, CM-1.

9. Grating, Guardrail, and Miscellaneous Fabrications:
a. Refer to Section 05500 - Metal Fabrications.
b. Materials: As indicated on the Drawings.

10. Roof Ventilator:
a. Size: As required to meet the air flow design requirements, but not less than indicated on the Drawings.
b. Materials and construction:
1) Aluminum components.
2) Stainless steel anchors.
3) Flashing shall wrap over the edge of the concrete curb and extend down a minimum of 2 inches.
4) 2-inch aluminum filters.
5) Insect screens.
6) 12-inch tall base.
7) Fiberglass hood insulation.
c. Manufacturers: The following or equal:
1) Greenheck Fabra Hood.
d. Finish: Manufacturer’s standard mill finish.

11. Downspouts and conductor heads:
a. 3-inch Schedule 10 galvanized steel downspouts at locations indicated on the Drawings.
b. Galvanized in accordance with ASTM A 653 to G90 designation.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) c. Fastened to the tank wall with minimum 2-inch x 3/16-inch galvanized steel straps, bolted to exterior concrete with 3/8-inch stainless steel anchors.
d. Field painted. Match color as specified in Section 09986 - Painting Prestressed Concrete Water Tanks.

J. Form ties:

1. General: The requirements of this Section supplement the form ties requirements stated in Section 03102 - Concrete Formwork.

2. Requirements:
a. Form ties for forming system selected for concrete other than corewall:

Cone-snap tie or flat bar type with waterstops.
b. Form ties for forming system selected for tank corewall: Tapered ties.

K. Wall Forms: As specified in Section 03102 - Concrete Formwork SYMONS, ALUMA, and regular plywood forms may be used for forming of circular walls, as long as there are no straight sections longer than 36 inches at any place around the outside circumference of such walls:

1. Forms shall be designed to resist the construction loads for full height wall pours.

L. Polyethylene sheeting:

1. Minimum 6-mils thick and in accordance with ASTM C 171.

M. Granular leveling base:

1. Material shall meet the requirements for aggregate base course specified in Section 02050 - Soils and Aggregates for Earthwork.

N. Epoxy injection materials: As specified in Section 03931 - Epoxy Injection System and the following products:

1. Grout injection pipes: Provide with positive mechanical shutoff valves.

O. Materials for repair of chipped out concrete areas:

1. Epoxy bonding agent: As specified in Section 03071 - Epoxies.

P. Geomembrane Liner:

1. As specified in Section 02666 - High Density Polyethylene Geomembrane Liners.

2. Install as indicated on the Drawings.

2.02 SOURCE QUALITY CONTROL
A. Concrete testing:

1. As specified in Section 03300 - Cast-in-Place Concrete.

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3.01 SUPERVISION
A. The Tank Contractor shall provide a full-time on-site project manager during all aspects of tank construction.

3.02 INSTALLATION
A. Waterstops:

1. General: The requirements of this Section supersede the waterstop requirements stated in Section 03150 - Concrete Accessories.

2. Requirements:
a. Install in concrete joints where indicated on the Drawings. b. Connect the ends of the radial waterstop in the wall footing joints to the circumferential waterstop in the wall to wall footing joint and to the circumferential waterstops in the floor to wall-footing joints if they should exist.
c. Provide waterstop in each joint in water-bearing structures, whether indicated on the Drawings or not.
d. Provide waterstops that are continuous.
e. Set accurately to position and line indicated on the Drawings. f. Hold and securely fix edges in position at intervals of not more than 12 inches and secure in manner that they cannot move during placing of concrete.
g. A hog-ring or nail may be driven through both ends of the waterstop to facilitate placing and tying of waterstops to reinforcing steel forms or form-ties.
h. Tank Contractor's option: One of the following:
1) Use waterstop tie wires at not more than 12 inches on centers, near outer ribs, to tie waterstops into position.
2) Use special clips.
i. Waterstop terminations: Terminate 3 inches from top of finished surfaces of walls and slabs unless otherwise specified or indicated on the Drawings.
j. Installation of waterstops:
1) Install so that joints are watertight.
2) Provide field welded polyvinyl chloride waterstop joints such as unions, crosses, ells, and tees.
3) Make all splices to waterstop in accordance with manufacturer's recommendations.
4) Clean waterstops of all concrete, dirt, and foreign matter.

B. Form and accessories removal:

1. General: The requirements of this Section supercede the form and accessories removal requirements stated in Section 03102 - Concrete Formwork.

2. Requirements:
a. Other forms supporting concrete and shoring: Remain in place as follows:
1) Sides of footings, sides of slabs, and columns: 24 hours minimum. 2) Core walls: 12 hours minimum.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) C. Neoprene bearing pads:

1. General:
a. Secure bottom surface of pads by positive attachment to structure such that horizontal crawling is prevented.

D. Closed cell neoprene joint fillers and sleeves (“sponge filler”):

1. When joint filler pads or sponge filler sleeves are indicated on the Drawings or specified, place materials in correct position before concrete is placed against them.

2. Holes and joints in pads are to be filled with caulking to prevent passage of mortar or concrete from one side of the joint to the other.

3.03 FLOOR
A. Prior to placement of the floor reinforcing, a 6-mil polyethylene moisture barrier shall be placed over the leveling base material. Joints in the polyethylene shall be overlapped a minimum of six inches.

B. Prior to placement of the floor concrete, all piping that penetrates the floor shall be set and encased in concrete to the limits indicated on the Drawings. Provide waterstops at the joints between the encasement and the concrete floor slab where indicated on the Drawings.

C. The vertical waterstops between the wall and footing shall be placed and supported to locate the center bulb within the joint as indicated on the Drawings and as required by the Tank Contractor. The waterstop shall be spliced using a thermostatically controlled sealing iron and each splice shall be successfully spark tested prior to encasement in concrete.

D. The floor shall be poured without construction joints, except as otherwise allowed by the Engineer. There shall be no construction joints between the floor and wall footing.

3.04 CONCRETE
A. All concrete shall be conveyed, placed, finished, and cured as specified in Section 03300 – Cast-in-Place Concrete, except as modified herein.

B. Requirements:

1. Cold joints:
a. Cold joints in floors, roof, and wall footings are not allowed. b. Continuously cover joints with new concrete, and thoroughly integrate through vibration, even if it means that horizontal passes of only 6 inches in width can be made until additional concrete and equipment becomes available to permit wider passes in concrete placement.

2. Blockouts or other types of wall openings: Do not provide openings other than those indicated on the Drawings.

C. Weather Limitations:

1. Unless specifically authorized in writing by the Engineer, concrete shall not be placed without special protection during cold weather when the ambient

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) temperature is below 35 degrees Fahrenheit and when the concrete is likely to be subjected to freezing temperatures before initial set has occurred and the concrete strength has reached 500 psi. Concrete shall be protected in accordance with ACI 306.1. The temperature of the concrete shall be maintained in accordance with the requirements of ACI 301 and ACI 306.1. All methods and equipment for heating and for protecting concrete in place shall be subject to the approval of the Engineer.

2. During hot weather, concreting shall be in accordance with the requirements of ACI 305.1.

3. Placement of concrete during periods of low humidity (below 50 percent) shall be avoided when feasible and economically possible, particularly when large surface areas are to be finished. In any event, surfaces exposed to drying wind shall be covered with polyethylene sheets immediately after finishing, or flooded with water, or shall be water cured continuously from the time the concrete has taken initial set. Curing compounds may be used in conjunction with water curing, provided they are compatible with coatings that may be applied later and if they are degradable.

D. Finishes:

1. Provide manufacturer’s standard finish unless otherwise noted.

E. Curing:

1. Except where specified herein, concrete curing shall be as specified in Section 03300 - Cast-in-Place Concrete.

2. Requirements:
a. Any concrete surface that is designated to receive paint or upon which any material is to be bonded: No curing compound shall be used. b. Concrete designated to be painted: Water or plastic membrane cure. c. Tank core walls: Water curing.
d. Floor slab:
1) The floor shall be cured by flooding with water, and shall remain saturated for a minimum of seven days after placement.
2) Alternatively, the floor slab may be cured with a sprayed on curing compound and prepared as follows:
a) After the surface is dry to the touch, a 6-mil thick polyethylene sheet shall be carefully taped and sealed to the concrete surface and kept on such surface for as long as possible, but not less than 7 days, to minimize the loss of moisture trapped between the polyethylene sheet and the concrete.
b) Alternatively, heavy curing blankets may be used in lieu of the polyethylene sheet.
e. Roof: Water or plastic membrane cure.
f. Other concrete surfaces: Water curing.

F. Testing Cast-in-Place Concrete:

1. All concrete testing shall be in accordance with Section 03300 - Cast-in-Place Concrete, except as noted herein.

2. Testing shall be at the expense of the City as specified in Section 01455 - Regulatory Quality Assurance.

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3.05 SEISMIC CABLES
A. Requirements:

1. Provide seismic cables to connect wall and wall footing.

2. Quantity and spacing of seismic cables shall be as indicated on the Shop Drawings.

3. Where necessary, seismic cables shall be pre-bent before placing units in wall and wall footing.

4. Tie seismic cables to lower horizontal circumferential tie-bar for vertical prestress tendons as indicated on the Drawings.

5. In wall-footing, tie seismic cables to radial footing bars.

3.06 PRESTRESSING
A. Circumferential Prestressing Equipment:

1. The circumferential stressing system shall produce a continuously, electronically (or substantial equivalent) monitored permanent stress or force recording along its full length as it is being applied and the stress variation in any strand at any point around the circumference shall not be greater than +/- 1.5 percent of the ultimate strength of the steel. In addition to this recording, any system which deflects the tensioned prestressing material between the tensioning device and the wall after it has left the tensioning device, shall provide a similar continuously monitored stress or force record along its full length as it is being applied to the wall. These recordings shall show that either before or after deflection that the stress variation in the prestressing material at any point around the circumference shall not be greater than +/- 1.5 percent of the ultimate strength of the steel.

2. Due to prior instances of force measurement inaccuracies and the inherent problems associated with hand-held stressometers, no manually recorded force readings will be accepted. This requirement shall be strictly followed.

3. Any wrapping that does not meet the stress tolerances specified and/or cannot meet the requirements of above will not be accepted and will be removed at the expense of the Tank Contractor. The Tank Contractor is responsible for all costs associated with meeting the specified tolerances.

4. Since intermittent force applications can result in an unequal stress distribution around the wall (due to friction losses), the prestressing system shall be capable of applying a continuous wrapped force at any point around the circumference within the specified tolerances. Circumferential stressing systems based on jack-operated cable or rod-type tendons (such as those placed inside of ducts incorporated in the corewall or placed manually around the exterior of the corewall) will not be allowed.

5. Since wrapping systems which utilize single solid prestressing material will not provide the desired bond between the prestressing material and the shotcrete and since single solid prestressing material will not provide an adequate safety factor against failure, only machine wrapping systems which utilize seven-wire prestressing strandwrapping will be allowed.

B. Circumferential Prestressing Application:

1. All cracks in the core wall and floor slab shall be repaired as specified following the circumferential prestressing of the tank walls.

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2. Wrapped strand shall be anchored to the wall at least once for every coil or reel.

3. Permanently anchoring one strand to a previously wrapped strand will not be permitted. Wrapped strand ends shall be joined by suitable splicing methods that shall develop 90 percent of the full strength of the strand.

4. Use of different alloys in the splicing material shall not be permitted.

5. The clear vertical spacing between any two wrapped strands shall be

1.5 strand diameters or 3/8-inch, whichever is larger. A 1/4-inch construction tolerance shall apply to strand spacing, as well as to this minimum spacing requirement.

6. All wrapped strand not meeting the spacing requirements shall be spread by approved methods or shall otherwise be removed.

C. Vertical Prestressing Equipment:

1. The Tank Contractor shall provide a continuously, electronically (or substantial equivalent), monitored permanent force elongation record from zero to full force at the final lock-off for all of the vertical prestressing work.

2. The ordinate of the permanent recording shall show the elongation in inches and the abscissa shall show the force in pounds or kips.

3. Manually recorded force and elongation readings will not be accepted.

4. The vertical prestressing machinery shall have automatic electronic tensioning cut-off devices or equivalent means to ensure that the specified force and elongation is not exceeded at any time during any thread bar stressing operation.

5. The force readings at the stressed bar ends, immediately after lock-off, for any stressing operation, on any thread bar, shall not fluctuate more than +/- 1.5 percent (of the minimum ultimate strength of the steel) from the desired average force setting.

6. The applied force, immediately after lock-off for the final stressing operation on any thread bar, shall be no less than 72 percent of the ultimate strength of the steel and the applied force before lock-off shall be no greater than 75 percent of the ultimate strength of the steel.

D. Vertical Prestressing Application:

1. All permanent anchor hardware shall have a ball-shaped threaded nut that can be screwed down on to a matching cone-shaped bearing surface in the bearing plate after the desired tension on the anchor hardware and/or prestressing steel has been applied.

2. The number and spacing of the thread bars shall not be altered under any condition.

3. High-strength thread bars shall be used for vertical prestressing.

4. All ducts shall be clean and free of water and deleterious materials that would impair bonding of the grout or interfere with grouting procedures.

5. Grout injection pipes shall be fitted with positive mechanical shutoff valves, which shall not be removed within the first 24 hours.

6. Grouting of thread bars shall begin at the lowest grout connection.

7. Each vertical thread bar duct shall be pumped until the entire nut at the top anchor has been covered with epoxy.

8. In cold weather, and especially during frosts, special precautions must be taken to avoid the freezing of grout. In the event that the grouting procedure

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) cannot be postponed, the wall temperature must be kept above the freezing point with hot blankets or by other approved means.

9. Upon completion of the vertical stressing and grouting operation, all anchor pocket areas above the anchor nuts shall be dry packed with a 1 part cement to 2 parts sand mortar mix immediately after the epoxy coating on the inside can surface has become tacky, or alternatively, the metal can may be filled with concrete aggregates and epoxy.

10. The inside surfaces of any metal cans to be dry packed shall be coated with a 2 part epoxy. Dry packing shall not proceed until the epoxy coat has become tacky. The dry pack surface shall be finished flush with the adjoining concrete surface.

11. Damaged PVC tubing shall be replaced unless repairs are made and approved by the Engineer.

12. Vertical thread bar components shall be assembled off the ground and as detailed on the Shop Drawings. All vertical thread bars must be fully assembled before they are installed in the forms.

13. Vertical thread bars shall be accurately placed and fastened securely in place to reinforcing steel and form ties to prevent movement during placement of concrete.

14. All vertical thread bars must be flushed with water from the top immediately upon completion of the concrete vibrating operation. Water shall be introduced through a taped-off hole in the wooden lids on the anchor pockets and be permitted to drain through the bottom grout tube. Flushing shall not be accomplished by introducing water through the bottom connection. Should a thread bar duct not flush properly, the Engineer shall be notified immediately.

15. Cleaning of ducts with air only (not water), or removal of water with air from the bottom connection, will not be permitted.

16. Placing of vertical thread bars shall be done to proper locations, elevations, and alignments, with a maximum tolerance of plus or minus 1/4 inch.

17. All vertical thread bars shall be properly tied at the anchor plates and shall be tied with No. 4 bars at intervals of 24 inches or less between the anchor plates.

The maximum permissible misalignment of the anchor plate to the vertical thread bar is +/- 2.5 degrees.

18. Anchor plates must be installed at right angles to the thread bar alignment near the anchor. Anchor plates must be installed with long sides, aligned parallel with the wall forms and secured to prevent their rotation while concrete is placed.

19. Unless indicated otherwise on the Plans, the minimum concrete cover around steel anchor pockets and bearing plates shall be 1.5 inches.

20. The vertical clearance between bottom anchor plate and the waterstop at the base of the tank walls shall be no less than 2 inches nor more than 4 inches.

E. Circumferential and Vertical Prestressing Operations:

1. The maximum initial electronically recorded steel stress shall not exceed 75 percent of the guaranteed minimum ultimate strength of the steel at any time during or after stressing.

2. An automatic, continuously electronically (or substantial equivalent) monitored permanent recording of the applied force, at any point on the strand, at any point on and around the tank wall, must be made during the entire circumferential prestressing application. All such recordings must be based on a continuous sensing of the applied force on the strand between the tensioning

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) drum and the wall when, and as, the strand is being wrapped and laid on the wall.

3. The force setting on wrapping and vertical thread bar stressing machinery shall be such that the applied forces fall within the specified minimum or maximum stress or force limitations; the force setting shall be corrected immediately when the applied force falls outside the required force tolerance limitations.

4. In the event that the stressing machinery is incapable of holding the applied forces within the specified stress or force limitations, the Engineer will order, at the expense of the Tank Contractor, the removal and replacement of such machinery in favor of a different unit capable of maintaining such tolerance requirements.

5. The loss in stress in post-tensioned prestressing steel due to creep and shrinkage of concrete and sequence stressing is to be assumed as 25,000 psi.

The final stress is the average initial stress reduced by the stress loss of 25,000 psi.

6. The final force is the steel section multiplied by the final stress.

7. The final force for the vertical thread bars shall be no less than the required final force shown on the Shop Drawings.

8. The initial force for the circumferential wrapped strand shall be no less than the required initial force shown on the Shop Drawings.

9. The continuous, electronically-produced force application chart during the wrapping application becomes the property of the City.

10. An automatic, continuously electronically (or substantial equivalent) monitored and simultaneously recorded force-elongation reading must be made for each vertical stressing application.

11. The force-elongation reading must represent the true relationship between the elongation at any given point of the vertical stressing operation and the applied force on the prestressing steel at that same point.

12. The force-elongation relationship must be constantly maintained from the beginning, starting with the removal of the slack to the point of lock-off and complete release of the force on the vertical prestressing steel after retraction of the stressing piston or equivalent stressing device.

13. All electronically produced force-elongation readings during the vertical thread bar stressing operations become the property of the City.

14. After the concrete core wall has reached the specified 28-day compressive strength, the vertical thread bars shall be stressed.

15. Circumferential wrapping shall not start until the vertical thread bars have been stressed.

16. In the event gaps between concrete core wall and wrapped strand develop that exceed 3/8 inch, discontinue wrapping. Before resuming any wrapping, either:
a. Build-up walls with shotcrete to provide proper curvature before resuming any wrapping.
b. If acceptable to Engineer, drypack gaps after wrapping is completed and before shotcreting is started.

17. Wrapping over intermediate shotcrete coats or built-up shotcrete areas may commence 12 hours after shotcrete has been applied, or when the shotcrete has reached a strength of 250 psi, whichever duration is longest.

18. Prestressing strand exposed to excessive temperatures greatly increases the possibility of irrevocable damage to the strand such as steel embrittlement,

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) stress corrosion, and strand splitting. The temperature of the prestressed strand during wrapping shall not be allowed to increase by more than 50 degrees at any time during application due to stressing technique.

19. All vertical thread bar ducting and anchors (both vertical and circumferential prestressing) shall be pressure grouted with an approved 2 part water insensitive epoxy and approved epoxy grouting equipment.

3.07 ABRASIVE BLASTING
A. Exterior surfaces of concrete walls shall be prepared prior to the commencement of any shotcreting or strand wrapping, to remove all deteriorated concrete and bond-inhibiting contaminants. The surface preparation shall achieve a minimum profile of International Concrete Repair Institute (ICRI) CSP5 over a minimum of 90 percent of the surface area required to be prepared. The prestressing operator who is performing the abrasive blasting shall make available to the inspector an ICRI surface preparation sample to assist with evaluation of the surface preparation.

B. The concrete surface shall have no traces of laitance, form-oil, original surface smoothness, or surface color.

C. In order to mitigate environmental concerns, conform to environmental constraints, and achieve the desired profile, the Tank Contractor shall utilize either a self-contained mechanical etching or shot blast system, combined with a vacuum recovery system, or a high pressure water jetting system. Abrasive blasting systems which rely on sandblasting or steel shot without a vacuum recovery system, or systems that have not been used successfully in the past to prepare surfaces for shotcreting and standwrapping, will not be permitted.

3.08 SHOTCRETING
A. Shotcrete Equipment:

1. Shotcrete mixing shall be in conformance with the requirements of Section 03300 - Cast-in-Place Concrete.

2. The delivery equipment shall be of an approved design and size that has given satisfactory results in similar previous work.

3. The equipment must be capable of discharging mixed materials into the hose under close control and it must be able to deliver a continuous smooth stream of uniformly mixed material at the proper velocity to the discharge nozzle, free from slugs of any kind.

4. The nozzle shall be of a design and size that will insure a smooth and uninterrupted flow of materials.

5. Delivery equipment shall be thoroughly cleaned at the end of each shift.

6. Equipment parts shall be regularly inspected and replaced as required.

7. The capacity of the compressor shall be large enough that the minimum amount of air to be available at the nozzle shall be no less than 400 cfm, irrespective of whether or not air from the same air supply is used for other purposes.

B. Placement and Testing of Shotcrete:

1. Shotcrete shall be applied by an ACI 506 certified nozzleman.

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2. Manually applied shotcrete shall be applied with the nozzle held at a small upward angle not exceeding five degrees and constantly moving during application in a smooth motion with the nozzle pointing in a radial direction toward the center of the tank. The nozzle distance from the prestressing shall be such that shotcrete does not build up or cover the front face of the wire or strand until the spaces behind and between the prestressing elements are filled.

3. Unless applied by an automated shotcrete process, total cover coat thickness shall be controlled by shooting guide wires. Vertical wires shall be installed under tension and spaced no more than two feet apart to establish uniform and correct coating thickness. Monofilament line (100 lb. test) or 18 or 20 gauge high tensile strength steel wire shall be used. Guide wires shall be removed after placement of the cover coat.

4. Shotcrete applied by an automated shotcrete process shall be applied using the wet mix only. Nozzles shall be kept mounted on power driven machinery enabling the nozzle to travel parallel to the surface to be sprayed at a uniform linear or bi-directional speed. The nozzle shall be kept at a uniform constant distance from the surface, always maintaining a right angle spray of the material to the surface. The high velocity impact shall be developed pneumatically by injecting compressed air at the nozzle.

5. Testing:
a. Testing shall be by an independent testing laboratory, acceptable to Engineer, and engaged by and at the expense of the Tank Contractor. b. Test shotcrete in accordance with ACI 506, except as specified herein.

One test panel shall be made for each of the following operations: core wall, cove, wire cover, and cover coat. Test panels shall be made from the shotcrete as it is being placed, and shall, as nearly as possible, represent the material being applied. The method of making a test sample shall be as follows: A frame of wire fabric (one foot square, three inches in depth) shall be secured to a plywood panel and hung or placed in the location where shotcrete is being placed. This form shall be filled in layers simultaneously with the nearby application. After 24 hours, the fabric and plywood backup shall be removed and the sample slab placed in a safe location at the site.
c. The sample slab shall be moist cured in a manner identical to that used for the regular surface application. The sample slab shall be sent to the testing laboratory. Nine three-inch cubes shall be cut from the sample slab and subjected to compression tests in accordance with current ASTM Standards. Three cubes shall be tested at the age of 7 days, three shall be tested at the age of 28 days, and three shall be retained as spares.

C. Shotcrete Placing and Finishing:

1. Shotcrete shall be applied in a steady, uninterrupted flow. Should the flow become intermittent for any cause, the machine operator shall direct the nozzle away from the work until it again becomes constant, or shut off the flow of materials.

2. The nozzle shall be held at approximately right angles to the surface and shall be kept at the proper and the same distance from the surface dictated by good practice standards for the type of application, type of nozzle and air pressure employed.

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3. Sufficient time shall be allowed for each layer of shotcrete to set up so it may take the next layer without sagging.

4. The shotcrete shall be started at the bottom of the wall until all wrapped strand has been covered. Subsequent shotcrete layers may be applied from the top down or from the bottom up at the discretion of the Tank Contractor.

5. While the nozzle travels around the wall, the nozzle shall be raised or lowered at a uniform rate in such a manner that an adequate overlapping of coatings and a uniform finish will develop.

6. The nozzle shall be spiraled up or down around the tank to either the top or the bottom of the wall or to the termination of the intermediate strand layer.

7. To ensure proper penetration around the strand and proper conveyance of the material through the hose, a 5 to 7-inch slump of the mortar at the pump is recommended.

8. The application of the shotcrete in the number and thickness of layers specified herein is mandatory for proper penetration of shotcrete behind prestressing material and to reduce shrinkage due to more uniform in-depth drying of the shotcrete.

9. Each layer of wrapped prestressing steel shall be covered with shotcrete until a minimum clear cover of 3/8-inch or the diameter of the strand, whichever is greater, has been placed over the prestressing steel.

10. The final cover coat, to make up for the full thickness of shotcrete over the final strand layer, shall be applied in at least 3 layers of equal thickness.

11. Each layer of shotcrete shall be completed for the full circumference of the tank and substantially the full height of that layer before the next layer of shotcrete may be applied.

12. All shotcrete coatings shall be built up in layers of approximately 3/8-inch in thickness until the final required thickness has been obtained. The Tank Contractor shall demonstrate by a reliable means that the proper thickness of shotcrete has been obtained with each layer applied.

13. Unless otherwise specified on the Drawings, the minimum shotcrete cover over all wrapped steel shall not be less than the following:
a. For shotcrete in contact with soil: 2 inches.
b. For other shotcrete exposures: 2 inches.

14. The Tank Contractor shall make provisions to protect adjacent structures, equipment, vehicles, etc., from being damaged by overshooting shotcrete and rebound materials. Overshot shotcrete deposited onto the roof shall be removed before it adheres to the concrete surface.

15. After the minimum shotcrete cover specified over the wrapped prestressing strand has been completed by the automated shotcrete procedure, and if such finish requirements are shown on the Drawings, the exterior surface shall be given an acceptable float finish true to line and curvature and to details shown on the Drawings.

16. If a float finish is required on the Drawings, plaster or hand-applied shotcrete may be used to build up and level the surface and to obtain the desired surface finish and projections.

17. The finish coat mix (if a smooth float finish is required on the Drawings), shall consist of a minimum of one sack of cement for each 3-1/2 cubic feet of moist plaster sand.

18. The Tank Contractor shall be responsible for all damages caused by shotcreting operations and shall bare the cost for making repairs.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13207 (BidSet) D. Hand Placed Shotcrete for Repairs Only:

1. To ensure a high quality shotcrete, the Tank Contractor shall satisfy the Engineer that the nozzleman has had sufficient and acceptable experience in the application of structural shotcrete and is a certified nozzleman in accordance with ACI 506.

2. Experience gained on shotcrete pool and ditch construction will not be considered as experience for qualifying the nozzleman.

3. The nozzleman shall be capable of applying thin coats of even and uniform thickness.

4. The nozzleman's skill shall be tested and the results of such tests shall be acceptable to the Engineer before that nozzleman may start any work.

E. Restrictions on Shotcrete Operation:

1. Shotcrete shall not be applied under such strong wind conditions that a considerable amount of cement and moisture will be removed by the wind from the mortar spray between the nozzle and the surface on which the shotcrete is applied.

2. Shotcrete may be applied in cold weather provided the surfaces are not frozen.

3. The temperature during the day must be expected to rise to at least 40 degrees Fahrenheit and the night temperature of the first night after the shotcrete application must not be expected to drop below 27 degrees Fahrenheit.

4. The use of Type 3 Portland cement is required (when readily available) in the event shotcrete is applied at temperatures below 40 degrees Fahrenheit.

5. The Tank Contractor may apply shotcrete under the conditions specified herein solely at his own risk.

6. Whenever rain or frost has damaged shotcrete which has not had a chance to set up, such shotcrete must be removed and replaced.

7. The Tank Contractor shall consult with the Engineer to determine whether or not he will accept the shotcrete damaged by rain or frost before applying any new layers of shotcrete.

F. Shotcrete Curing:

1. Intermediate layers of shotcrete shall be kept damp by hand curing or other means no sooner than 12 hours after the shotcrete has been applied.

2. Watercuring is not required should additional shotcrete be applied on the entire wall surface within the following 12 hours.

3. Indiscriminate use of continuous watercure for intermediate layers should be avoided.

4. Complete shotcrete surfaces, which do not receive any additional shotcrete coatings, shall be membrane cured with plastic for a period of at least seven (7) days. Plastic membrane used shall contain and prevent loss of moisture from shotcrete as much as possible. Membrane curing methods utilizing curing compounds or wax-based residuals will not be permitted.

3.09 CLEANING
A. After construction is completed, the interior of the tank shall be completely cleaned of debris and flushed with clean water to remove all dirt and loose material.

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3.10 FILLING AND WATERTIGHTNESS TESTING
A. Filling:

1. The water used for the first filling of the tank will be furnished by the City. If the leakage test fails, the Tank Contractor shall refill the tank and retest it. The Tank Contractor shall be responsible for the cost of refilling the tank for subsequent tests.

2. The tank shall be filled in approximately 8-foot increments with 8 working hours between each increment for observation of possible leaks through ring drains, wall, and wall-footing.

B. Testing:

1. If only damp spots and small puddles of water are observed during filling, the filling of tank can continue. If leaks that are large enough to potentially fail the leakage test specified in Section 01759 - Water Leakage Test for Concrete Structures are observed, the filling process shall cease, and those leaks shall be thoroughly investigated prior to continuing to fill the tank.

2. Fill tank with water and hold water level at 3 inches below the overflow level for a period of 24 hours.

3. Test tank for leakage in accordance with the provisions of Section 01759 - Water Leakage Test for Concrete Structures.

4. Examine the tank and soil at the perimeter of the tank footings for evidence of leaks.
a. Acceptance criteria shall be as specified in Section 01759 - Water Leakage Test for Concrete Structures.

C. Repairing tank leaks:

1. Repair leaks to satisfaction of the Engineer.

2. Any areas that, in opinion of the Engineer, are exposed to contamination during repair work shall be sprayed with disinfection water mix.

3. Leakage through joints, which may have resulted from bent over waterstops or honeycomb under or around waterstops, may require removal of concrete around waterstops in suspected areas.

4. Repair of chipped out concrete areas:
a. Coat chipped out concrete surface with epoxy bonding agent. b. Properly drypack with drypack mix for repair of concrete tank areas.

5. Any cracks, voids, honeycomb, or cold joints showing or causing running leaks of water, shall be repaired by epoxy injection as specified in Section 03931 - Epoxy Injection System until such cracks and voids have been completely sealed.

END OF SECTION

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ELECTRIC ACTUATORS
PART 1 GENERAL

1.01 SUMMARY
A. Section includes:

1. Electric motor-driven actuators for valves.

1.02 REFERENCES
A. American Water Works Association (AWWA):

1. C504 - Standard for Rubber-Seated Butterfly Valves.

2. C542 - Standard for Electric Motor Actuators for Valves and Slide Gates.

B. International Organization for Standardization (ISO):

1. 12944 - Paints and Varnishes.

C. National Electrical Manufacturers Association (NEMA):

1. 250 - Enclosures for Electrical Equipment (1,000 V Maximum).

1.03 SUBMITTALS
A. Submit as specified in Section 01330 - Submittal Procedures and Section 01601 - Product Requirements.

B. Provide a complete list/schedule of actuators being provided with their associated tag names, as indicated on the Drawings and/or Specifications, service process area and the size of the valve they are actuating.

C. Product data:

1. Electrical ratings:
a. Voltage and number of phases.
b. Starting and running current.
c. Voltage levels and source for control and status.

2. Description of integral control interface.

3. Environmental ratings, including NEMA enclosure rating and submergence capabilities.

4. Gear ratios for both manual and motorized actuation.

5. Opening and closing directions.

6. Electric motor data.

7. Allowable starts per hour.

8. List of included options and accessories.

9. Full travel times.

10. Gearbox data, including gear ratio, and gearbox efficiency.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13447 (BidSet) D. Shop Drawings:

1. Wiring diagrams:
a. Include options and expansion cards furnished with each actuator.

2. Dimensioned drawings of each valve and actuator combination.

3. Dimensioned drawings of each valve gearbox.

E. Calculations:

1. Operating torque.

2. Maximum torque calculations for seating and unseating.

3. Maximum operating torque at starting and normal operation.

F. Installation instructions:

1. Detail the complete installation of the equipment, including rigging, moving, and setting into place.

2. Provide manufacturer’s installation instructions.

G. Quality Control Submittals:

1. Manufacturer’s representative qualifications.

2. Manufacturer’s Certificate of Source Testing as specified in Section 01756 - Commissioning.

3. Manufacturer’s Certificate of Installation as specified in Section 01756 - Commissioning.

4. Manufacturer’s Certificate of Functional Compliance as specified in Section 01756 - Commissioning.

H. Owner Training Submittals:

1. As specified in Section 01756 - Commissioning.

I. Operation and maintenance manuals:

1. As specified in Section 01782 - Operation and Maintenance Manuals.

2. Include a list of configurable parameters and the final values for each.

3. Include a troubleshooting chart covering the complete valve and controls/electrical power systems, showing description of trouble, probable cause, and suggested remedy.

1.04 DELIVERY, STORAGE, AND HANDLING
A. As specified in Section 01601 - Product Requirements, Section 15050 - Common Work Results for Mechanical, and the manufacturer’s instructions.

1.05 PROJECT OR SITE CONDITIONS
A. As specified in Section 01850 - Design Criteria.

1.06 WARRANTY
A. As specified in Section 01783 - Warranties and Bonds.

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2.01 MANUFACTURERS
A. Lines 4 inches and larger:

1. One of the following, or equal:
a. EIM Electric Actuators, Emerson US.

2.02 MATERIALS
A. Enclosures:

1. Constructed of materials suitable for the environment where the actuator will be installed.

2. Stainless steel external fasteners.

3. Provide O-ring seals for each of the following areas:
a. Between the terminal compartment and the internal electrical elements. b. Between the mechanical and electrical portions to protect from the ingress of oil, and to protect the mechanical components of oil from dust and moisture when the electrical terminal is open.

4. Ratings:
a. As scheduled and specified.
b. NEMA Type 6P: Double sealed and IP68 rated for prolonged submergence. c. XP: Factory Mutal (FM) approved for Class I, Division 1 and Division 2 locations.

B. Coatings:

1. Material requirements:
a. Factory prime and coat with an ISO 12944 classification coating of C5M (Marine, offshore estuaries with high salinity) coating with 15 year durability. b. Touch-up damaged coatings with manufacturer provided coating repair kit.

2. Application requirements:
a. Painting shall commence within 4 hours of blast cleaning. b. Each paint coat within the system is to be applied in accordance with the paint manufacturer’s instructions.
c. Paint thickness shall be checked for each coat on each actuator.

3. Qualification requirements:
a. Operators shall be experienced and proficient in surface preparation and coating application techniques.
b. Personnel shall have relevant knowledge of health and safety hazard, use of protective equipment, coating materials, mixing and thinning coatings, coating pot life, surface requirements, etc.
c. Personnel carrying out inspection or verification shall be certified as NACE coating inspector or equivalent such as ICorr.

2.03 CHARACTERISTICS FOR ACTUATORS ON LINES 4 INCHES AND LARGER A. Provide actuators complete and operable with all components and accessories required for operation.

B. Power supply:

1. Voltage and phases as indicated in the Actuator Schedule.

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2. Valve or gate motion independent of power supply phase rotation.

3. Provide an internal backup power source or mechanical indicator to maintain settings and track valve position when main power is off.

4. Actuators shall incorporate major components such as the motor, starter, local controls, terminals, etc., housed within a self-contained, sealed enclosure.

C. Size actuator to move gates or valves from full open to closed position within the time indicated in the Actuator Schedule:

1. If an operating time is not indicated on the Actuator Schedule, size the actuator to move gates or valves at minimum 12 inches per minute under maximum load. Measure rate of closure for valves at maximum diameter of disc, plug, or ball.

2. Size actuators so that gear boxes are not required where possible.

D. Control interface:

1. Configuration:
a. Provide a non-intrusive, non-contacting interface for configuring input and output settings, control values, ranges, torque switch settings, valve positions switch settings, and options.
1) Configurable from a handheld configuring tool or input devices on the actuator.

2. Local interface, integral to actuator:
a. Non-intrusive, non-contacting selector switches:
1) LOCAL-STOP-REMOTE:
a) Motor actuator operation is prevented with the switch in STOP. 2) OPEN-CLOSE:
a) Controls the valve when LOCAL-STOP-REMOTE is in LOCAL. b) Spring return to center.
c) Configurable between maintained (actuator runs until end of travel, high torque, or a LOCAL-STOP-REMOTE is switched to STOP) and momentary (actuator stops when lever is released). b. Local display:
1) Valve fully open and fully closed indicators.
2) Numerical display showing actual valve or gate position in percent of travel.

3. Control inputs:
a. Capable of using discrete 24 VDC or 120 VAC.
b. Controls the valve when LOCAL-STOP-REMOTE is in REMOTE. c. Isolated inputs capable of operating from external control voltage source or internal power supply.
d. Provide the following inputs:
1) OPEN.
2) CLOSE.
3) STOP.
e. OPEN and CLOSE inputs configurable between maintained (actuator runs until end of travel, high torque, or a STOP input) and momentary (actuator stops when command is removed).

4. Status outputs:
a. Monitor relay output: Dry contact, normally closed, opens when actuator is not in REMOTE or in the event of any internal fault or alarm condition.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13447 (BidSet) b. Dry contact outputs configured for the functions indicated on the Drawings. Provide the following outputs for all actuators:
1) Fully closed.
2) Fully open.
3) LOCAL-STOP-REMOTE in REMOTE position.
c. Contacts and communications:
1) As specified in the Contract Documents.
2) Dry contacts rated for both 120 VAC and 24 VDC.
d. Analog input:
1) 4-20 mA analog input for analog modulating valves when indicated on the Drawings.
e. Analog output:
1) Isolated 4-20 mA analog output when indicated on the Drawings. a) Loop power sourced from the actuator power supply.
b) Output proportional to process value(s) indicated on the Drawings.

E. Features:

1. Time delay on reversal: Incorporate time delay between stopping actuator and starting in opposite direction to limit excessive current, torque, and heating from instantaneous reversal.

2. Data logging:
a. Store diagnostic data and reference data.
b. Time-stamped historical operating data, including number of operations.

3. Provide display of logged data on the actuator, or provisions to download to a personal computer.

F. Components:

1. Motors:
a. Specifically designed for valve actuator service with high starting torque, totally enclosed non-ventilated construction.
b. Torque ratings equal to or greater than that required for valve seating and dynamic torques with a 25 percent factor of safety.
1) Design requirements for rubber-seated AWWA butterfly valves:
a) Design actuators for maximum gate or valve operating torque, in accordance with and using safety factors required in
AWWA C504 and AWWA C542.
(1) Valve actuator torque requirement for open-close service:

Not less than the required valve-seating and dynamic
torques under design operating conditions in accordance with AWWA C504.
(2) Valve actuator torque requirement for modulating service:

Not less than twice the required valve dynamic torque
under design operating conditions in accordance with
AWWA C504.
2) Design requirements for slide gates, gate valves, knife gate valves, globe valves, and diaphragm valves:
a) Design valves and actuators for maximum operating torque in accordance with and using safety factors required in
AWWA C542.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13447 (BidSet) b) Design for the maximum torque and thrust running load over the full cycle.
c) Maximum torque or thrust rating: Actuator stall torque or maximum thrust output shall not exceed the torque or thrust capability of the valve or gate, as determined by the valve or gate manufacturer.
c. Capable of being removed and replaced without draining the actuator gear case.
d. Motor bearings shall be amply proportioned of the anti-friction type and permanently lubricated.
e. Rated for operating under the following conditions without exceeding temperature limits with ambient temperature of 40 degrees Celsius. 1) Continuous operation for 15 minutes or twice the open-to-close operating time (whichever is greater) at normal operating torque or 33 percent of maximum torque (whichever is greater).
2) 60 starts per hour for open/close service or 1,200 starts per hour for modulating service.
f. Provide the following motor protection features:
1) Jammed valve (no valve motion detected through a time delay). 2) High motor temperature (sensed by an embedded thermostats). 3) High torque.
4) Single phasing protection.

G. Position sensing:

1. Electronic and adjustable using a solid-state encoder wheel. a. Mechanical limit switches and potentiometers are not acceptable.

2. Capable of retaining position and monitoring valve or gate motion when valve is manually actuated and when main power is not present.

3. Valve range and position switch outputs field adjustable.

H. Torque sensing:

1. Torque shutdown setting: 40 percent to 100 percent rated torque:
a. Adjustable in 1 percent increments.

2. Torque display: 0 to 100 percent-rated torque.

3. Capable of interrupting control circuits during both opening and closing and when valve torque overload occurs.

4. Electrical or electronic torque sensing.

5. Independent of variations in frequency, voltage, or temperature.

6. Actuator shall store actual operational torque curves for retrieval by plant maintenance staff.

7. Provide a temporary inhibit of the torque sensing system during unseating or during starting in mid-travel against high inertia loads.

8. Provide visible verification of torque switch status without any housing disassembly.

I. Manual actuators:

1. Hand wheel for manual operation.
a. Maximum 80-pound pull on rim when operating gate or valve under maximum load.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13447 (BidSet) b. Provide pull chain when motorized actuator is located more than 6 feet above floor surface.
1) Chain shall be of sufficient length to reach approximately 4 feet above the operating level.
2) Where the chain obstructs an aisle or walkway, provide holdback or other means to ensure chain does not create a nuisance or hazard to operating personnel.
3) Provide Type 316 stainless steel.

2. Declutch lever: Padlockable, capable of mechanically disengaging motor and related gearing and freeing hand wheel for manual operation.

J. Gearing: Hardened alloy steel spur or helical gears and self-locking, alloy bronze worm gear set.

1. Accurately cut to ensure minimum backlash.

K. Bearings:

1. Anti-friction bearing with caged balls or rollers throughout.

2. Sealed-for-life type thrust bearings housed in a separate thrust base.

L. Drive bushing:

1. Easily detachable for machining to suit the valve stem or gearbox input shaft.

2. Positioned in a detachable base of the actuator.

M. Lubrication:

1. Provide totally enclosed actuator gearing with oil or grease filled gear case suitable for operation at any angle.

2. Actuators requiring special or exotic lubricants are not acceptable.

2.04 ACCESSORIES
A. Termination module cover:

1. Provide sunshades for outdoor installations of remote control stations that use an LCD or similar screen. Regular pushbutton, sector switches, and pilot light control stations will not require a sunshade.

2.05 SOURCE QUALITY CONTROL
A. Source Testing:

1. Design and performance test reports in accordance with AWWA C542.

2. Test each actuator with a simulated load.
a. Simulate a typical valve load.

3. Furnish test reports and the Manufacturer’s Certificate of Source Testing.

PART 3 EXECUTION

3.01 INSTALLATION
A. As specified in Section 15050 - Common Work Results for Mechanical Equipment.

B. Install the equipment in accordance with the manufacturer’s instructions.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/13447 (BidSet) C. Position visual indicators so that they are most easily visible.

D. Installation Verification:

1. Furnish Manufacturer’s Certificate of Installation Verification.

3.02 FIELD QUALITY CONTROL
A. As specified in Section 01756 - Commissioning, Section 15958 - Mechanical Equipment Testing, and this Section.

B. Functional Testing:

1. Installed actuator:
a. Test witnessing: Witnessed.
b. Conduct Level 2 General Equipment Performance Tests. c. Conduct Level 2 Vibration Tests.
d. Conduct Level 2 Noise Tests.

2. Electrical Instrumentation and Controls:
a. Test witnessing: Witnessed.
b. Conduct testing as specified in Section 17950 - Commissioning for Instrumentation and Controls.

3. Furnish test reports and the Manufacturer’s Certificate of Functional Compliance.

3.03 ACTUATOR SCHEDULE
A. Provide actuators indicated on the Drawings:

1. Major process actuators are listed in the Actuator Schedule shown in Attachment A - Actuator Schedule.
a. Attachment A - Actuator Schedule does not include all number and types of actuators required for the Project.

END OF SECTION

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ATTACHMENT A - ACTUATOR SCHEDULE

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ACTUATOR SCHEDULE
Item
Reference
DWG Type Size Duty
NEMA
Rating
Voltage/
Phase/Hz Notes Service Controls
MOV-1 M01 BFV 24” STD 6P 120/1/60 Hz - O/C D
Abbreviations:

Type:

BFV = Butterfly Valve.

BV = Ball Valve.

PV = Plug Valve.

SG = Slide Gate.

Duty:

MD = Modulating duty (~1,200 starts/hr).

MOD = Modulating.

STD = Standard service (0-60 starts/hr) duty.

NEMA Rating:
4X for general locations.
6P for vaults and possible submergence.

XP for Class I, Division 1 and Division 2 locations.

Service:

CTRL = Control.

O/C = Open/Close.

Controls:

A = Analog.

D = Discrete.

DP = Profibus DP.

E-IP = Ethernet/IP.

E-TCP = Ethernet TCP or TCP/IP.

FF = Foundation Fieldbus H1.

MB = Modbus RTU (RS-485).

NET = Manufacturer’s proprietary network.

PA = Profibus PA.

Common Work Results for Mechanical Equipment
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COMMON WORK RESULTS FOR MECHANICAL EQUIPMENT
PART 1 GENERAL

1.01 SUMMARY
A. Section includes:

1. Mechanical equipment requirements for:
a. Basic design and performance criteria.
b. Prescriptive requirements for common components.
c. Installation requirements.

1.02 REFERENCES
A. American Bearing Manufactures Association (ABMA):

1. 9 - Load Ratings and Fatigue Life for Ball Bearings.

2. 11 - Load Ratings and Fatigue Life for Roller Bearings.

B. American Gear Manufacturer's Association (AGMA) Standards.

C. ASTM International (ASTM):

1. A193 - Standard Specification for Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications.

2. A194 - Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure or High Temperature Service, or Both.

3. A320 - Standard Specification for Alloy-Steel and Stainless Steel Bolting for Low-Temperature Service.

4. F593 - Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs.

5. F594 - Standard Specification for Stainless Steel Nuts.

D. Hydraulic Institute (HI):

1. 9.6.8 - Guideline for Dynamics of Pumping Machinery.

E. International Concrete Repair Institute (ICRI):

1. Guideline No. 310.2R, Selecting and Specifying Concrete Surface Preparation for Sealers, Coatings, Polymer Overlays, and Concrete Repair.

F. International Organization for Standardization (ISO):

1. 21940 - Mechanical Vibration - Rotor Balancing - Part 1: Introduction.

G. National Electrical Manufacturers Association (NEMA):

1. MG-1 - Motors and Generators.

H. Society for Protective Coatings (SSPC):

1. SP-1-Solvent Cleaning.

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1.03 TERMINOLOGY
A. The words and terms listed below are not defined terms that require initial capital letters, but, when used in this Section, have the indicated meaning.

1. Definitions used in this specification and equipment Submittals for terms related to rotor-dynamic pumps shall be in accordance with HI 9.6.8, Appendix A, as clarified below.

2. These definitions shall be applied to equipment other than pumps, unless otherwise specified in Technical Sections.

3. Rotordynamic Analysis Level:
a. The level of detail required for rotordynamic analysis is indicated in the Technical Sections schedules as None (no analysis required), Analysis Level 1, Analysis Level 2, or Analysis Level 3, which correlate to increasing levels of required detailed equipment design analysis. Analysis Levels 1, 2, and 3 are based on HI 9.6.8.
b. Where these specifications differ from HI the more stringent shall apply.

4. Resonant Frequency:
a. The frequency of a periodic excitation force that is close to the natural frequencies of an object. Also known as critical frequency, critical speed, or resonant speed.
b. An undamped resonant frequency within the separation margin is always considered harmful under Level 1 analysis.
c. A resonant frequency that occurs within a separation margin of 15 percent above or below the operating speed range and has a log decrement greater than +0.3 is considered harmful under Level 2 and Level 3 analysis.

5. Separation Margin:
a. The span of operating speeds within which interference between excitation orders and resonant frequencies indicate the possibility of harmful vibrations.
b. The separation margin for a specific application extends 15 percent above and 15 percent below the span of operating speed required for the specified performance conditions.

1.04 ADMINISTRATIVE REQUIREMENTS
A. Roof coordination.

1. Show roof penetrations for mechanical equipment on roof drawing Submittal and include mechanical equipment information:
a. Type.
b. Size.
c. Location.
d. Configuration of penetration and the surround.
e. Weight.
f. Anchoring and support details.

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1.05 SUBMITTALS
A. Items in this Section are components of equipment or systems specified in other sections.

1. Include data for this Section’s components with the equipment or system Submittal.

PART 2 PRODUCTS

2.01 DESIGN AND PERFORMANCE CRITERIA
A. General:

1. Equipment manufacturer's responsibility extends to selection and mounting of gear drive units, motors or other prime movers, accessories, and auxiliaries to provide a complete, operable unit.

2. Manufacturer shall analyze all rubber-bearing vertical-column pumps, and equipment identified as non-reversing in the Technical Sections for reverse rotation and provide non reversing motor ratchets.

3. Equipment that prevents reverse rotation shall be capable of both:
a. Handling 150 percent of the maximum torque at maximum operating speed. b. 150 percent of torque that will be generated in reverse direction due to equipment shutoff head as calculated by the manufacturer.

4. The motor shall be designed to run safely in the reverse direction at up to 140 percent times the reverse runaway speed under shutoff head conditions.

B. Rotordynamic analysis and vibration testing:

1. Submit information for the Rotordynamic Analysis Level specified for each piece of equipment as shown in the Technical Sections prior to manufacture of the equipment.

2. Rotordynamic analysis shall be performed on “like-new” and “as-worn” conditions, representing conditions when first installed and conditions when parts wear to the manufacturer's maximum allowable operating tolerances.

Conditions assumed for the “as-worn” condition shall be 2 times the “like-new” tolerances unless specified otherwise.

3. Rotordynamic analysis criteria:
a. Torsional excitation forcing function magnitudes shall be no less than 1 percent of the maximum transmitted torque at given speed. b. Motor mass elastic information in accordance with NEMA MG-1 shall be obtained from the original equipment manufacturer and included in the analysis. Motors shall be precision balanced to ISO 21940 grade G2.5. c. Bearings:
1) At maximum bearing loads an L-10 life of 100,000 hours in accordance with ABMA 9-11 to be proven.

4. Submit factory and field testing requirements as specified in the Technical Sections and specified in Section 15958 - Mechanical Equipment Testing after manufacture and installation respectively.

5. Repair, replace, and modify equipment exhibiting vibration performance that does not meet criteria specified in this Section at no additional cost to City. a. Acceptable remedies include adjustments to equipment component geometry, materials, energy absorbing couplings, etc.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/15050 (BidSet) b. Locking out speed interval(s) within equipment specified operating range is unacceptable.

6. Vibration analysis expert:
a. Provide vibration analysis expert when specified in the equipment Technical Sections.
1) The vibration analysis expert must be a 3rd party, unaffiliated with the equipment vendor or Contractor.
b. The vibration analysis expert, and analysis shall be provided by one of the following or equal:
1) Mechanical Solutions, Inc. (MSI, New Jersey).
2) Engineering Dynamics Inc. (EDI, Texas).
c. The analysis shall be:
1) Stamped by a registered professional mechanical Engineer. 2) Verified in-situ by the vibration analysis expert including certification that installation conforms to field conditions assumed in the reports. 3) Verified in-situ by the vibration analysis expert including witness of at least 1 field vibration test, and certification that vibration measurements corroborate the rotordynamic analysis.
4) Supplemented with additional field investigation and analysis should conditions during field vibration testing activity indicate non-compliance with these specifications; supplemental field investigation and analysis shall indicate remedies to comply with the specifications and shall be stamped by a registered professional mechanical Engineer.

7. Rotordynamic Analysis Level 1:
a. Before the equipment is released for manufacture it shall be determined that the equipment/motor structures do not have any harmful resonant frequencies in the lateral and torsional modes. Representative analysis results for identical equipment may be submitted.
b. Calculate rotor lateral and torsional and equipment structural components' lateral frequencies with a spreadsheet calculation or finite element analysis software.
1) Equipment structure lateral frequency shall include the motor. 2) Speed changing drive systems (belt, gear) effects on rotational inertia and stiffness shall be incorporated.
c. Determine the equipment system components (rotor and structure) resonant frequencies.
d. An intersection of an equipment component resonant frequency with the 1x run speed excitation order that occurs within separation margin is unacceptable.

8. Rotordynamic Analysis Level 2:
a. Before the equipment and motor are released for manufacture it shall be determined that the equipment/motor structures do not have any harmful critical speeds in the lateral and torsional modes.
b. Calculate rotor lateral and torsional and structure lateral frequencies with finite element analysis software.
1) Equipment structure lateral frequency shall include the motor. 2) Speed changing drive systems (belt, gear) effects on rotational inertia and stiffness shall be incorporated.
3) The rotational inertia of water within the impeller, in the wet well and inside the equipment structure, e.g., the column of a vertical pump,

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/15050 (BidSet) shall be included in the calculation at both the high level and low level conditions.
c. Potentially harmful critical speeds shall be investigated further with a forced, damped analysis to determine component stresses do not exceed material properties.
d. Forced damped analysis:
1) Forced lateral analysis shall include forcing function magnitudes at least 10 percent of rotor disc weight at each disc position and hydraulic imbalance at 5 operating conditions spaced equally over the equipment operating range. If synchronous motors are used ensure that the rotor analysis includes startup, shutdown, and motor control transients.
2) Forced torsional analysis shall include not less than 1 percent of the maximum permitted torque at any given speed. Damping shall be 1 percent of critical at all shaft elements.
3) The equipment rotor total stress (steady-state and alternating torque components plus lateral-bending stresses) shall not exceed:
a) Constant torque: Total stress limited to 30 percent of the material fatigue limit and to a maximum of 18 percent of ultimate tensile strength.
b) Variable torque (including variable speed equipment): Total stress limited to 50 percent of the material fatigue limit and to a maximum of 4 percent of the material ultimate tensile strength. c) Submit documentation of material fatigue limit.
e. Report Submittals:
1) Confirmation of compliance with this Section, or detailed exceptions taken.
2) Software used for analysis.
3) Results with interpretation.
4) Preparer's professional engineering stamp and seal.
5) Input data including component properties, materials and connectivity to other components.
6) Schematic diagram of model mode shapes, nodes and elements. 7) Bearing stiffness and damping properties, impeller/diffuser interaction coefficients, and seal dynamic properties.
8) Campbell diagrams showing the system natural frequencies, excitation orders, and operating speed range for both lateral and torsional analysis.
a) Campbell diagram shall include equipment operating range; excitation lines at 1x, 2x run speed, and vane pass (or equivalent); and critical speeds associated with equipment system components including the rotor, each major equipment structural component and the motor.
9) Forced, damped analysis indicating acceptable material stress limits are maintained at interference points shown on the Campbell diagram.

9. Rotordynamic Analysis Level 3:
a. Before the equipment and motor are released for manufacture it shall be determined that the equipment/motor structures do not have any harmful critical speeds in the lateral and torsional modes.

Common Work Results for Mechanical Equipment
15050-6 201631 September 2025
pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/15050 (BidSet) b. Calculate rotor lateral and torsional and structure lateral frequencies with finite element analysis software.
1) Equipment structure lateral frequency shall include the motor. 2) Speed changing drive systems (belt, gear) effects on rotational inertia and stiffness shall be incorporated.
3) The rotational inertia of water within the impeller, in the wet well and inside the equipment structure, e.g., the column of a vertical pump, shall be included in the calculation at both the high level and low level conditions.
c. Potentially harmful critical speeds shall be investigated further with a forced, damped analysis to determine component stresses do not exceed material properties.
d. Forced damped analysis:
1) Forced lateral analysis shall include forcing function magnitudes at least 10 percent of rotor disc weight at each disc position and hydraulic imbalance at 5 operating conditions spaced equally over the equipment operating range. If synchronous motors are used ensure that the rotor analysis includes startup, shutdown, and motor control transients.
2) Forced torsional analysis shall include 1 percent of the maximum permitted torque at any given speed. Damping shall be 1 percent of critical at all shaft elements.
3) The equipment rotor total stress (steady-state and alternating torque components plus lateral-bending stresses) shall not exceed:
a) Constant torque: Total stress limited to 30 percent of the material fatigue limit and to a maximum of 18 percent of ultimate tensile strength.
b) Variable Torque (including variable speed equipment): Total stress limited to 50 percent of the material fatigue limit and to a maximum of 4 percent of the material ultimate tensile strength. c) Submit documentation of material fatigue limit.
e. Report Submittals:
1) Report 1: Executive Summary including:
a) Confirmation of compliance with this specification section, or detailed exceptions taken.
b) Software used for analysis.
c) Results with interpretation.
d) Preparer's professional engineering stamp and seal.
e) Campbell diagrams showing the system natural frequencies, excitation orders, and operating speed range for both lateral and torsional analysis.
(1) Campbell diagram shall include equipment operating range; excitation lines at 1x, 2x run speed, vane pass (or
equivalent), line- and twice-line frequency, motor-pole frequency, torsional harmonics from reciprocating drivers (including up to 6 times operating speed), control pulse frequencies induced by VFDs (with certification from VFD manufacturer of frequencies up to 24 times motor running speed), any torque harmonic greater than 1 percent of
steady torque at primary excitation, and synchronous motor requirements; and critical speeds associated with

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/15050 (BidSet) equipment system components including the rotor and each major equipment structural component.
f) Report 1 shall not include detailed analysis elements listed for Submittal under Report 2 below, Submittal of full analysis details in Report 1 is unacceptable.
g) Following Submittal of Report 1, submit Report 2: Detailed Analysis including responses to comments made on Report 1:

Rotor-dynamic Executive Summary.
2) Report 2: Rotor-dynamic Detailed Analysis including:
a) Input data including component properties, materials and connectivity to other components.
b) Schematic diagram of model mode shapes, nodes and
elements.
c) Bearing stiffness and damping properties, impeller/diffuser interaction coefficients, and seal dynamic properties.
d) Forced, damped analysis indicating acceptable material stress limits are maintained at interference points shown on the Campbell diagram.
e) Synchronous motor information including time-integration study results showing transient peak stresses at startup, shutdown and motor control transient events. Provide tomographic diagrams including root and keyway stress concentration locations and the corresponding speeds that result in reported peak stresses.

2.02 POWER TRANSMISSION SYSTEMS
A. V-belts, sheaves, shaft couplings, chains, sprockets, mechanical variable-speed drives, variable frequency drives, gear reducers, open and enclosed gearing, clutches, brakes, intermediate shafting, intermediate bearings, and U-joints:

1. Rated for 24 hour-a-day continuous service, or for intermittent service with frequent stops-and-starts, whichever is most severe.

2. Sized with a service factor of 1.5 or greater:
a. Apply service factor to nameplate horsepower and torque of prime source of power and not to actual equipment loading.
b. Apply service factors in accordance with AGMA or as specified in the Technical Sections.

2.03 BEARINGS
A. Oil or grease lubricated, ball or roller antifriction type, of standard manufacture.

1. Design lubrication system based on the equipment location to operate in the temperatures as specified in Section 01850 - Design Criteria. a. Design lubrication system to safely start after being shut off for 24 hours and operate safely:
1) Suitable for the outdoor winter temperature as specified in Section 01850 - Design Criteria.

B. Oil-lubricated bearings:

1. Provide either pressure lubricating system or separate oil reservoir splash-type system as specified in the Technical Section.

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2. Design oil-lubrication system to safely absorb heat energy generated in bearings when equipment is operating in the following conditions:
a. With the highest load and the temperature 15 degrees Fahrenheit above the outdoor summer temperature as specified in Section 01850 - Design Criteria.

C. Grease lubricated bearings, except those specified to be factory sealed:

1. Fit with easily accessible grease supply, flush, drain, and relief fittings.

2. Lubrication lines and fittings:
a. Lines: Minimum 1/4-inch diameter stainless steel tubing. b. Multiple fitting assemblies: Mount fittings together in easily accessible location.
c. Use standard hydraulic-type grease supply fittings:
1) Manufacturers: One of the following or equal:
a) Alemite.
b) Zerk.

D. Ratings: Rated in accordance with ABMA 9 or ABMA 11 L10 life for bearings rating life of not less than 50,000 hours.

2.04 BELT DRIVES
A. Sheaves:

1. Separately mounted on bushings by means of at least 3 pull-up bolts or cap tightening screws.

2. When 2 sheave sizes are specified, provide separate belts sized for each set of sheaves.

3. Statically balanced for all; dynamically balanced for sheaves that operate at a peripheral speed of more than 5,500 feet per minute.

4. Key bushings to drive shaft.

B. Belts:

1. Anti-static type when explosion-proof equipment or environment is specified.

2. When spare belts are specified, furnish 1 spare belt for every different type and size of belt-driven unit:
a. Where 2 or more belts are involved, furnish matched sets. b. Identify as to equipment, design, horsepower, speed, length, sheave size, and use.
c. Package in boxes labeled with identification of contents.

C. Manufacturers: One of the following or equal:

1. Dodge, Dyna-V belts with matching Dyna-V sheaves and Taper-Lock bushings.

2. T. B. Woods, Ultra-V belts with matching Sure-Grip sheaves and Sure-Grip bushings.

2.05 FLANGED PIPING CONNECTIONS
A. Unless otherwise in the Technical Sections or indicated on the Drawings, provide flat face flanges.

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2.06 ASSEMBLY FASTENERS
A. General service: Stainless steel, Type 316:

1. Bolts: In accordance with ASTM F593, Alloy Group 2.

2. Nuts: In accordance with ASTM F594, Alloy Group 2.

3. Washers: Alloy group matching bolts and nuts.

B. High-temperature service or high-pressure service: Stainless steel, Type 316:

1. Bolts: In accordance with ASTM A193, Grade B8M, Class 1, heavy hex.

2. Nuts: In accordance with ASTM A194, Grade 8, heavy hex.

3. Washers: Alloy group matching bolts and nuts.

C. Low-temperature service: Stainless steel, Type 316:

1. Bolts: In accordance with ASTM A320, Grade B8M, Class 1, heavy hex.

2. Nuts: In accordance with ASTM A194, Grade B8M, heavy hex.

3. Washers: Alloy group matching bolts and nuts.

2.07 GUARDS AT HIGH-TEMPERATURE SURFACES
A. Exposed surfaces having an external surface temperature of 120 degrees Fahrenheit or higher and located within 7 feet measured vertically from floor or working level or within 15 inches measured horizontally from stairways, ramps or fixed ladders.

B. Cover with a thermal insulating material unless otherwise guarded against contact.

1. Insulation thickness such that the insulation exterior temperature is below 120 degrees Fahrenheit.

2. Insulation:
a. Material: Rigid cellular glass in accordance with ASTM C552, Type II. b. Temperature range: -450 degrees Fahrenheit to 900 degrees Fahrenheit. c. K-factor at 75 degrees Fahrenheit: Not more than 0.32 Btu-inch/hoursquare feet-degrees Fahrenheit. d. Minimum average density: 7.5 pounds per cubic foot.
e. Maximum moisture absorption, volume percent: 5.
f. Minimum compressive strength: 87 pounds per square inch. g. Moisture permeability: 0.00 perm-inch.
h. Manufacturers: The following or equal:
1) Owens Corning, Foamglas® One™.

2.08 GUARDS AT MOVING COMPONENTS
A. Provide guards on rotating components that are within 7.5 vertical feet of an operating floor or platform.

B. Allow visual inspection of moving parts without removal.

C. Allow access to lubrication fittings.

D. Easily removable for maintenance.

E. Prevent entrance of rain or dripping water for outdoor locations.

Common Work Results for Mechanical Equipment
15050-10 201631 September 2025
pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/15050 (BidSet) F. Size belt and sheave guards to allow for installation of sheaves 15 percent larger and addition of 1 belt.

G. Materials:

1. Sheet metal: Carbon steel, 12-gauge minimum thickness, hot-dip galvanized after fabrication.

2. Fasteners: Type 316 stainless steel.

2.09 SHOP FINISHES
A. Manufacturer’s standard primer and finish coatings.

1. Primer only if field coatings are to be applied.

2.10 GEAR MOTORS
A. Parallel shaft drives: Helical gearing.

B. Right-angle drives: Worm gearing.

C. Manufacturers: One of the following or equal:

1. Baldor Electric Company.

2. Bodine Electric Company.

2.11 GEAR REDUCTION UNITS
A. Design and performance criteria:

1. Gear type:
a. Helical or herringbone.

2. AGMA Class II service:
a. Use more severe service condition when such is recommended by unit’s manufacturer.

3. Cast-iron housing with gears running in oil.

4. Anti-friction bearings.

5. Thermal horsepower rating based on maximum horsepower rating of prime mover, not actual load.

2.12 MOUNTING AND LIFTING PROVISIONS FOR EQUIPMENT
A. Equipment bases and base plates:

1. Provide equipment bases with machined support pads, dowels for alignment for mating of adjacent items, openings for electrical conduits, and openings to facilitate grouting.

2. Provide jacking screws in bases and supports for equipment and for equipment weighing 500 pounds or more.

3. Materials:
a. Match equipment material or steel.
b. Coating: Match equipment.

Common Work Results for Mechanical Equipment
15050-11 201631 September 2025
pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/15050 (BidSet) B. Steel support frames:

1. Carbon steel:
a. At exterior locations, and at interior wet or moist locations, provide continuous welds on both sides to close seams and edges between steel members.
b. Grind closure welds smooth.

C. Lifting lugs or eyes:

1. Equipment units weighing 50 pounds or more:
a. Provide with lifting lugs or eyes to allow removal with lifting device.

2.13 NAMEPLATES
A. Fastened to equipment at factory in an accessible and visible location.

B. Metal engraved or stamped with text, holes drilled or punched for fasteners.

C. Material: Aluminum or stainless steel.

D. Fasteners: Number 4 or larger oval head stainless steel screws or drive pins.

E. Text:

1. Manufacturer’s name, equipment model number, equipment serial number, and identification tag number.

2. Additional items indicated in the Technical Sections.

3. Indicate the following additional information as applicable:
a. Maximum and normal rotating speed.
b. Service class in accordance with applicable standards.

4. Include for pumps:
a. Rated total dynamic head in feet of fluid.
b. Rated flow in gallons per minute.
c. Impeller, gear, screw, diaphragm, or piston size.

5. Include for motors:
a. Drive speed.
b. Motor horsepower with rated capacity.

6. Include for gear reduction units:
a. AGMA class of service.
b. Service factor.
c. Input and output speeds.

2.14 PUMP SHAFT COUPLINGS
A. General:

1. Type and ratings: Non-lubricated designed for not less than 50,000 hours of operating life.

2. Sizes: Provide as recommended by manufacturer for specific application, considering horsepower, speed of rotation, balance, and type of service.

3. Suitable for an ambient temperature range between -40 degrees to +200 degrees Fahrenheit.

Common Work Results for Mechanical Equipment
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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/15050 (BidSet) B. Close-couplings for electric-motor-driven equipment:

1. Manufacturers: One of the following or equal:
a. Lovejoy.
b. T.B. Woods.

2. Provide flexible couplings designed to accommodate angular misalignment, parallel misalignment, and end float.

3. Manufacture flexible component of coupling from synthetic rubber or urethane.

4. Provide service factor of 2.5 for electric motor drives and 3.5 for engine drives.

5. Do not allow metal-to-metal contact between driver and driven equipment.

C. Flexible couplings for direct connected electric-motor-driven equipment:

1. Manufacturers: One of the following or equal:
a. Rexnord.
b. T.B. Woods.

2. Provide flexible couplings designed to accommodate shock loading, vibration, and shaft misalignment or offset.

3. Provide flexible connecting element of rubber and reinforcement fibers.

4. Provide service factor of 2.0.

5. Connect stub shafts through collars or round flanges, firmly keyed to their shafts with neoprene cylinders held to individual flanges by through pins.

D. Spacer couplings:

1. Where cartridge-type mechanical seals or non-split seals are specified, provide a spacer-type coupling of sufficient length to remove the seal without disturbing the driver or driven equipment.

2.15 PUMP SEAL CHAMBER AND SEALS
A. Seal chamber (stuffing box):

1. Large enough to retrofit with double mechanical seal.

B. Seal Types: Based on the following and as specified in the Technical Section:

1. Type 1: Packing:
a. Provide when specified in the Technical Section for wastewater, non-potable water, and sludge applications:
1) Asbestos free.
2) PTFE (Teflon™) free.
3) Braided graphite.
4) Manufacturers: One of the following or equal:
a) Chesterton, 1400.
b) John Crane.
b. Provide when specified for drinking water service:
1) Asbestos free.
2) Material: Braided PTFE (Teflon™).
3) Manufacturers: One of the following or equal:
a) Chesterton, 1725.
b) John Crane.
c. Design:
1) Packing gland to allow adjustment and repacking without dismantling pump except to open up stuffing box.

Common Work Results for Mechanical Equipment
15050-13 201631 September 2025
pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/15050 (BidSet) 2) Seal chamber (stuffing box) large enough to retrofit with double mechanical seal.
3) Manufacturers: One of the following or equal:
a) Chesterton, 1725.
b) John Crane.

2. Type 2: Mechanical seal, flushing, cartridge, single O-ring. a. Manufacturers: One of the following or equal:
1) Chesterton, S10.
2) John Crane, 5610 Series.

3. Type 3: Mechanical seal, flushing, cartridge, double O-ring:
a. Manufacturers: One of the following or equal:
1) Chesterton, S20.
2) John Crane, 5620 Series.

4. Type 4: Mechanical seal, flushing, cartridge, double split-ring:
a. Manufacturers: One of the following or equal:
1) Chesterton, S20.
2) John Crane, 5620 Series.

5. Type 5: Mechanical seal, flushing, cartridge, single split-ring:
a. Manufacturers: One of the following or equal:
1) Chesterton, 442.
2) John Crane, 5860.

6. Type 6: Mechanical seal, flushless, cartridge, single split-ring:
a. Manufacturers: One of the following or equal:
1) Chesterton, 156.
2) John Crane, 3740 Series.

C. Mechanical seals, Types 2 to 6:

1. Balanced hydraulically.

2. Spring:
a. Stationary, out of pumping fluid.
b. Material as specified in the Technical Section. Hastelloy C; Type Elgiloy or 17-7 PH stainless steel for split seals.

3. O-ring: Viton™ 747.

4. Gland: Type 316L stainless steel.

5. Set screws: Type 316L stainless steel.

6. Faces: Reaction bonded, silicon carbide/carbon.

7. Minimum differential pressures in either direction: 300 pounds per square inch gauge.
a. Manufacturers: One of the following or equal:
1) Chesterton, 1400.
2) John Crane, equivalent product.

8. Drinking water service:
a. Asbestos free.
b. Material: Braided PTFE (Teflon™).
c. Manufacturers: One of the following or equal:
1) Chesterton, 1725.
2) John Crane, equivalent product.

D. Flushing system:

1. Provide flushing connections:
a. 3/4-inch size.

Common Work Results for Mechanical Equipment
15050-14 201631 September 2025
pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/15050 (BidSet) b. Provide API Standard 682 seal water plan arrangement as specified in the Technical Section:
1) Plan 11 - Product stream seal water from discharge thru seal. 2) Plan 13 - Product stream seal water thru seal to suction. 3) Plan 23 - Closed loop seal water with cooler and pumping ring. 4) Plan 32 - Production seal water discharged to product stream. 5) Plan 54 - Production Seal Water Excluded from Product Stream.

2.16 SHIPPING
A. Prior to shipment of equipment:

1. Bearings (and similar items):
a. Pack separately or provide other protection during transport. b. Greased and lubricated.

2. Gear boxes:
a. Oil filled or sprayed with rust preventive protective coating.

3. Fasteners:
a. Inspect for proper torques and tightness.

PART 3 EXECUTION

3.01 PRE-INSTALLATION
A. Field measurements:

1. Prior to Shop Drawings preparation, take measurements and verify dimensions indicated on the Drawings.

2. Ensure equipment and ancillary appurtenances fit within available space.

B. Sequencing and scheduling:

1. Coordinate details of equipment with other related parts of the Work, including verification that structures, piping, wiring, and equipment components are compatible.

2. Equipment anchoring: Obtain anchoring material and setting drawings from equipment manufacturers in adequate time for templates to be constructed and anchors to be cast-in-place.

3.02 LUBRICATION LINES AND FITTINGS
A. Support and protect lines from source to point of use.

B. Fittings:

1. Bring fittings to outside of equipment in manner such that they are readily accessible from outside without necessity of removing covers, plates, housings, or guards.

2. Mount fittings together wherever possible using factory-mounted multiple fitting assemblies securely mounted, parallel with equipment lines, and protected from damage.

3. Fittings for underwater bearings: Bring fittings above water surface and mount on edge of structure above.

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3.03 ALIGNMENT OF DRIVERS AND EQUIPMENT
A. Where drive motors or other drivers are connected to driven equipment by flexible coupling, disconnect coupling halves and align driver and equipment after driven equipment has been leveled on its foundation.

B. Comply with procedures of appropriate HI, AGMA Standards, alignment tolerances of equipment manufacturers and the following requirements to bring components into angular and parallel alignment:

1. Maximum total coupling offset (not the per-plane offset): Not to exceed

0.5 mils per inch of coupling length for spacer couplings based on coupling length (not dial separation).

2. Utilize jacking screws, wedges, or shims as recommended by the equipment manufacturer and as specified in the equipment sections.

C. Use reverse-indicator arrangement dial-type or laser-type alignment indicators:

Mount indicators on the driver/coupling flange and equipment/coupling flange.

Alignment instrumentation accuracy shall be sufficient to read angular and radial misalignment at 10 percent or less of the manufacturer’s recommended acceptable misalignment.

D. Alignment and calculations shall include measurement and allowance for thermal growth, spacer coupling length, indicator separation, and axial spacing tolerances of the coupling.

E. When alignment satisfies most stringent tolerance of system components, grout between base and foundation.

1. Allow minimum 48 hours for grout to harden.

2. After grout hardens, remove jacking screws, tighten anchor bolts and other connections, and recheck alignment.

3. Correct alignment as required.

3.04 EQUIPMENT SUPPORT AND ANCHORING TO STRUCTURES
A. Anchor equipment to structures as indicated on the Drawings and as specified.

B. Obtain final anchor bolt layouts for equipment prior to:

1. Detailing reinforcement for equipment pads.

2. Preparation of Shop Drawings for metal structures supporting equipment.

C. Anchor bolt templates:

1. Provide templates as specified in the Technical Sections.

2. Use final anchor bolt layout to construct templates for setting anchor bolts.

3. Make templates:
a. Rigid, and non-deformable during use.
b. With longitudinal axes of anchors parallel.
c. With longitudinal axes of anchors perpendicular to surface supporting the equipment.

4. Templates may be reused for multiple locations of the same equipment only if:
a. Templates are in “like-new” condition prior to each reuse.

Common Work Results for Mechanical Equipment
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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/15050 (BidSet) b. The anchor layout has not been deformed or damaged by previous installation, removal, or handling of templates.

5. Sequence:
a. Set and support templates prior construction of structures surrounding anchors.
b. Position anchors in templates to provide designated embedment in supporting structure, with required projection for installation of grout, base plates, and hardware for tightening.
c. Construct concrete or masonry around anchors using methods that preserve required anchor positions and alignment, and clearances to edges of supports or structures.

D. Anchor adjustment sleeves:

1. Use of adjustment sleeves around anchors:
a. Is at the option of the Contractor.
b. Does not relieve Contractor of obligation to construct and use templates for setting of anchors.
c. May required increased anchor embedment length to develop the strength of the anchor in the embedded length below the adjustment sleeve.

2. Submittal requirements for anchor adjustment sleeves:
a. Provide within sufficient time for Engineer approval and not less than 10 working days before setting those items.
b. Proposed locations of sleeves.
c. Details and dimensions of sleeves.
d. Sleeve materials of construction, and coatings.
e. Information on sleeve filler material and means of filler removal. f. Type, details, and dimensions of anchor bolts or anchor rods to be used with sleeves.
g. Calculations showing development of anchor load capacity below the bottom of the sleeve.
h. Plan for removal of sleeve fillers, if any.
i. Plan for placement and consolidation of flowable grout inside sleeves and to a level equal to top of concrete slab or equipment pad surrounding the sleeve.

3.05 GROUTING UNDER EQUIPMENT BASES, BASE PLATES, SOLE PLATES,

AND SKIDS
A. General:

1. Comply with equipment manufacturer’s installation instructions including:
a. Tolerances for level.
b. Tolerances for vertical and horizontal alignment.
c. Requirements or recommendations for grouting spaces and grout installation.
d. Recommendations for tightening of equipment anchors after grout has cured.

2. Install equipment over grout as indicated on the Drawings or specified only after:
a. Equipment is leveled and in proper alignment.
b. Piping connections are complete and in alignment with no strain transmitted to equipment.

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3. Install flowable grout, as specified in Section 03600 - Grouting, placed with forms and head boxes.
a. Use flowable, non-shrink grout.
b. Use flowable, non-shrink epoxy grout, only where indicated on the Drawings, where specified in Technical Sections, or when approved in advance by the Engineer.
c. Grouting with dry-pack materials is not permitted.

B. Prepare equipment bases, base plates, soleplates, and skids for grouting:

1. Concrete equipment bases:
a. Roughen surface in accordance with ICRI, Guideline No. 310.2R, Surface Preparation Profiles CSP-3 and CSP-4.
b. Clean roughened concrete surfaces.

2. Base plates, soleplates, and skids:
a. Clean surfaces in accordance with SSPC-SP-1-Solvent Cleaning, to remove dirt, dust, oil, grease, paint, and other material.

C. Level equipment for grouting:

1. Use removable jack screws, or removable steel wedges and shims to support and level equipment bases, base plates, sole plates, and skids. a. Do not use leveling nuts placed on equipment anchors to support or level equipment bases, base plates, sole plates, and skids.

2. Removable jack screws:
a. Provide number, size, and locations of jack screws required to support and level equipment in accordance with manufacturer's
recommendations.
b. Drill and tap equipment base plates, sole plates, and skids for jack screws.
c. Support jack screws on circular steel plates that have been epoxy bonded to the equipment foundation.
1) Provide plates fabricated from Type 316 stainless steel where edges of support plates will have grout side cover of 3 inches or less in the finished work.
d. Make provision for removal of jack screws after grouting:
1) Prevent grout from bonding to jack screws by wrapping jack screw threads that will be in contact with grout with multiple layers of tape or other material acceptable to the Engineer.
e. Place and cure grout.
f. After grout is placed and cured:
1) Remove jack screws and material used to prevent grout from bonding to jack screws.
2) Provide jack screws to City for future use.
3) Fill jack screw holes with grout.
4) Cure grout as specified.

3. Removable steel wedges and shims:
a. Use for equipment bases, base plates, sole plates, and skids where it is not practical to use jack screws.
b. Provide number, size, and locations of wedges and shims required to support and level equipment in accordance with manufacturer's recommendations.

Common Work Results for Mechanical Equipment
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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/15050 (BidSet) c. Make provision for removal of wedges and shims after grouting:
1) Prevent grout from bonding to wedges and shims by wrapping wedges and shims that contact grout with multiple layers of tape or other material acceptable to the Engineer.
2) Locate and orient wedges and shims to allow for removal after grouting, and to facilitate placement of grout in the remaining voids. d. Place and cure grout.
e. After grout is placed and cured:
1) Remove wedges and shims, and material used to prevent grout from bonding to them.
2) Fill jack screw holes with grout.
3) Cure grout as specified.

D. Construct grout forms:

1. Provide forms:
a. Rigid with adequate strength to withstand placement of grout. b. With surfaces that will produce a smooth, uniform finish for grout edges exposed in the finished work.
c. That allow grout to flow horizontally beyond the perimeter of the equipment base plate a distance not less than the thickness of the grout, and not less than 1 inch.

2. Install forms:
a. Seal form cracks and joints with elastomeric sealant to make form watertight.
b. Line form surfaces in contact with grout with polyethylene film, or coat with 2 coats of heavy-duty paste wax.

3. Construct grout “head box” over entire length of one side of form. a. Make head box height sufficient to force grout to flow under full dimensions of equipment base and to the surrounding form faces.

E. Pre-grouting procedures:

1. Concrete surfaces receiving flowable, non-shrink grout:
a. Saturate concrete surface in contact with grout and concrete surfaces extending not less than least 6 inches beyond limits of grout with clean water for a minimum of 24 hours prior to grouting.
b. Just prior to grout placement, remove standing water using clean rags or oil-free compressed air. Provide “saturated surface dry” (SSD) concrete for grout placement.

2. Concrete surfaces receiving flowable, non-shrink epoxy grout:
a. Do not saturate concrete prior to grout placement.

F. Grout placement and curing:

1. Place and cure grout as specified in Section 03600 - Grouting, and in this Section.

2. Grouting:
a. Keep level of grout in head box above bottom of equipment bases, base plates, sole plates, and skids always to drive flow under base. b. Maintain continuous grout flow from head box to opposite sides of forms without trapping air or forming voids.
c. Vibrate, rod, or chain grout to facilitate grout flow, to consolidate grout, and to remove entrapped air.

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3. After grout sets, remove forms and trim grout edges at 45-degree angle from bottom edge of equipment bases, base plates, sole plates, and skids.

4. Cure grout as specified in Section 03600 - Grouting.

G. After grout is cured:

1. Remove jack screws or wedges and shims, and material used to prevent grout from bonding to leveling devices.

2. Fill pockets from removed leveling devices with grout.

3. Cure filled voids as specified in Section 03600 - Grouting.

4. Tighten equipment anchors in accordance with equipment manufacturer requirements.

3.06 FIELD FINISHES
A. When touchup or repair is required, apply primer and coating systems as recommended by the equipment manufacturer.

END OF SECTION

Pipe Supports
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PIPE SUPPORTS
PART 1 GENERAL

1.01 SUMMARY
A. Section includes: Supports for pipe, fittings, valves, and appurtenances.

1.02 REFERENCES
A. ASTM International (ASTM):

1. A123 - Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products.

2. A380 - Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems.

3. A967 - Standard Specification for Chemical Passivation Treatments for Stainless Steel Parts.

B. Manufacturer's Standardization Society (MSS):

1. SP-58 - Pipe Hangers and Supports - Materials, Design, and Manufacture.

1.03 SUBMITTALS
A. Submit as specified in Section 01330 - Submittal Procedures.

B. Product data.

1. Design features.

2. Load capacities.

3. Material designations by UNS alloy number or ASTM Specification and Grade.

4. Data needed to verify compliance with the Specifications.

5. Catalog data.

6. Clearly mark submittal information to show specific items, materials, and accessories or options being furnished.

1.04 WARRANTY
A. Provide warranty as specified in Section 01783 - Warranties and Bonds.

PART 2 PRODUCTS

2.01 GENERAL
A. As specified in Section 01601 - Product Requirements.

Pipe Supports
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2.02 MATERIALS
A. General:

1. Hot dip galvanized:
a. Fabricate as specified in Section 05120 - Structural Steel Framing. b. Hot dip after fabrication of support in accordance with ASTM A123. c. Repair galvanized surface as specified in Section 05120 - Structural Steel Framing.

2. Stainless steel.
a. Fabricate as specified in Section 05120 - Structural Steel Framing. b. Finish requirements: Remove free iron, heat tint oxides, weld scale, and other impurities, and obtain a passive finished surface. c. At the shop, perform pickling and passivation on all surfaces inside and out in accordance with ASTM A380 or A967.
1) Passivation treatments using citric acid are not allowed. d. Field welding is prohibited unless specifically allowed by the Engineer and Construction Manager in writing. All field welds shall be passivated.

B. Outdoor areas: Areas exposed to the natural outdoor environment:

1. Type 316 Stainless Steel.

C. Indoor areas: Areas exposed to an indoor environment including galleries and tunnels:

1. Type 316 Stainless Steel.

D. Submerged, 3 feet or less above water level in a structure, or inside a water bearing structure:

1. Type 316 Stainless Steel.

E. Stainless steel piping system:

1. Type 316 Stainless Steel.

F. Fasteners:

1. As specified in Section 05120 - Structural Steel Framing.

2.03 PIPE SUPPORTS
A. Hanger rods: Sized to match suspended pipe hanger, or as indicated on the Drawings:

1. Manufacturers: One of following or equal:
a. For stainless steel piping:
1) Bergen-Power, Figure 133.
2) Nibco-Tolco, Figure 103.
b. For all other piping, unless indicated on the Drawings:
1) Anvil International, Figure 140.
2) Bergen-Power, Figure 133.
3) Cooper B-Line Systems, Inc., Figure B3205.

Pipe Supports
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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/15061 (BidSet) B. Hanger rods, continuously threaded: Sized to match suspended pipe hanger, or as indicated on the Drawings:

1. Manufacturers: One of the following or equal:
a. For stainless steel piping:
1) Bergen-Power, Figure 94.
2) FM Stainless Fasteners.
b. For steel and ductile iron piping:
1) Anvil International, Figure 146.
2) Bergen-Power, Figure 94.

C. Eye bolts:

1. For stainless steel piping:
a. Type 316 stainless steel, welded and rated equal to full load capacity of rod.

2. For all other piping, unless indicated on the Drawings:
a. Welded and rated equal to full load capacity of rod.

D. Welded eyebolt rod:

1. Manufacturers: One of the following or equal:
a. For stainless steel piping:
1) Nibco-Tolco, Figure 101.
2) FM Stainless Fasteners.
b. For all other piping, unless indicated on the Drawings:
1) Anvil International, Figure 278.
2) Bergen-Power, Figure 93.
3) Cooper B-Line Systems, Inc., Figure B3210.

E. Adjustable ring hangers: MSS SP-58, Type 7 or Type 9 (system dependent):

1. Manufacturers: One of the following or equal:
a. For stainless steel piping:
1) Nibco-Tolco, Figure 1C.I.
2) Bergen-Power, Figure 100SS.
b. For all other piping, unless indicated on the Drawings:
1) Anvil International, Figure 69.
2) Cooper B-Line Systems, Inc., Figure B3172.

F. Adjustable clevis hangers: MSS SP-58, Type 1:

1. Manufacturers: One of the following or equal:
a. For stainless steel piping:
1) Cooper B-Line Systems, Inc., Figure B3100 or B3102.
2) FM Stainless Fasteners, Figure 60.
b. For all other piping, unless indicated on the Drawings:
1) Anvil International, Figure 260 or Figure 590.
2) Bergen-Power, Figure 100.
3) Cooper B-Line Systems, Inc., Figure B3100 or B3102.

G. Adjustable clevis hangers for insulated pipe: Oversize:

1. Manufacturers: One of the following or equal:
a. For stainless steel piping:
1) Nibco-Tolco, Figure 1A.

Pipe Supports
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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/15061 (BidSet) b. For all other piping, unless indicated on the Drawings:
1) Anvil International, Figure 300.
2) Bergen-Power, Figure 100EL.
3) Cooper B-Line Systems, Inc. Figure B3108.

H. Single rod hangers for steam pipe: MSS SP-58, Type 43; malleable iron or steel yoke and roller hangers; swivel to allow rotation of yoke on rod:

1. Manufacturers: One of the following or equal:
a. For stainless steel piping:
1) Nibco-Tolco, Figure 324.
2) Cooper B-Line Systems, Inc., Figure B3110.
3) FM Fasteners, Figure 81.
b. For all other piping, unless indicated on the Drawings:
1) Anvil International, Figure 181.
2) Cooper B-Line Systems, Inc., Figure B3110.

I. Double rod hangers for steam pipe: MSS SP-58, Type 41:

1. Manufacturers: One of the following or equal:
a. For stainless steel piping:
1) FM Stainless Fasteners, Figure 71.
b. For all other piping, unless indicated on the Drawings:
1) Anvil International, Figure 171.
2) Cooper B-Line Systems, Inc., Figure B3114.

J. Brackets: MSS SP-58, Type 32 with back plate; rated for 1,500 pounds:

1. Manufacturers: One of the following or equal:
a. For stainless steel piping:
1) Nibco-Tolco, Figure 30M.
2) Cooper B-Line Systems, Inc., Figure B3066.
3) FM Stainless Fasteners, Figure 98.
b. For all other piping, unless indicated on the Drawings:
1) Anvil International, Figure 195.
2) Cooper B-Line Systems, Inc., Figure B3066.

K. Standard U-bolt: MSS SP-58, Type 24:

1. Manufacturers: One of the following or equal:
a. For stainless steel piping:
1) Nibco-Tolco, Figure 110.
2) Cooper B-Line Systems, Inc., Figure B3188.
3) FM Stainless Fasteners, Figure 37.
b. For all other piping, unless indicated on the Drawings:
1) Anvil International, Figure 137.
2) Bergen-Power, Figure 283.
3) Cooper B-Line Systems, Inc., Figure B3188.

L. Riser clamps: MSS SP-58, Type 8:

1. Manufacturers: One of the following or equal:
a. For stainless steel piping:
1) Cooper B-Line Systems, Inc., Figure B3373.
2) FM Stainless Fasteners, Figure 61.

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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/15061 (BidSet) b. For all other piping, unless indicated on the Drawings:
1) Anvil International, Figure 261.
2) Bergen-Power, Figure 126.
3) Cooper B-Line Systems, Inc., Figure B3373.

M. Pipe clamps: MSS SP-58, Type 4:

1. Manufacturers: One of the following or equal:
a. For stainless steel piping:
1) Nibco-Tolco, Figure 4.
2) Cooper B-Line Systems, Inc., Figure 3140.
b. For all other piping, unless indicated on the Drawings:
1) Anvil International, Figure 212.
2) Bergen-Power, Figure 175.
3) Cooper B-Line Systems, Inc., Figure B3140.

N. Adjustable offset pipe clamp:

1. Manufacturers: One of the following or equal:
a. For stainless steel piping:
1) Nibco-Tolco, Figure 4.
2) Cooper B-Line Systems, Inc., Figure B3149.
3) FM Stainless Fasteners, Figure 63.
b. For all other piping, unless indicated on the Drawings:
1) Anvil International, Figure 100.
2) Cooper B-Line Systems, Inc., Figure B3149.

O. Offset pipe clamp:

1. Manufacturers: One of the following or equal:
a. For stainless steel piping:
1) Nibco-Tolco, Figure 8.
2) Cooper B-Line Systems, Inc., Figure 3148.
b. For all other piping, unless indicated on the Drawings:
1) Anvil International, Figure 103.
2) Cooper B-Line Systems, Inc., Figure B3148.

P. Floor stand or stanchion saddles: MSS SP-58, Type 37. Provided with U-bolt hold down yokes:

1. Manufacturers: One of the following or equal:
a. For stainless steel piping:
1) Nibco-Tolco, Figure 318.
2) FM Stainless Fasteners, Figure 59.
b. For all other piping, unless indicated on the Drawings:
1) Anvil International, Figure 259.
2) Bergen-Power, Figure 125.
3) Cooper B-Line Systems, Inc., Figure B3090.
c. Threaded pipe stand support stanchion. Match pipe support material. 1) Anvil International, Figure 63T.
2) Bergen-Power, Figure 138.
3) Cooper B-Line Systems Inc., Figure B3088ST.

Pipe Supports
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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/15061 (BidSet) Q. Spring hangers:

1. Manufacturers: One of the following or equal:
a. For stainless steel piping:
1) Bergen-Power, Figure 920.
b. For all other piping, unless indicated on the Drawings:
1) Anvil International, Figure B-268, Type G.
2) Bergen-Power, Figure 920.

R. Welded beam attachment: MSS SP-58, Type 22:

1. Manufacturers: One of the following or equal:
a. For stainless steel piping:
1) Nibco-Tolco, Figure 304.
2) Cooper B-Line Systems, Inc., Figure 3083.
b. For all other piping, unless indicated on the Drawings:
1) Anvil International, Figure 66.
2) Bergen-Power, Figure 113A or 113B.
3) Cooper B-Line Systems, Inc., Figure B3083.

S. Heavy pipe clamp: MSS SP-58, Type 4:

1. Manufacturers: One of the following or equal:
a. For stainless steel piping:
1) Nibco-Tolco, Figure 4H.
b. For all other piping, unless called out otherwise on the drawings:
1) Anvil International, Figure 216.
2) Bergen-Power, Figure 298.

T. PTFE pipe slide assembly: MSS SP-58, Type 35 with lateral and vertical restraint:

1. Manufacturers: One of the following or equal:
a. For stainless steel piping:
1) Nibco-Tolco, Figure 426.
b. For all other piping, unless indicated on the Drawings:
1) Anvil International, Figure 257, Type 3.
2) Cooper B-Line Systems, Inc., Figure B3893.

U. Anchor bolts, concrete anchors, concrete inserts, powder-actuated fasteners, and sleeve anchors: As specified in Section 05120 - Structural Steel Framing.

PART 3 EXECUTION

3.01 INSTALLATION
A. Support, suspend, or anchor exposed pipe, fittings, valves, and appurtenances to prevent sagging, overstressing, or movement of piping; and to prevent thrusts or loads on or against connected pumps, blowers, and other equipment.

B. Field verify support location, orientation, and configuration to eliminate interferences prior to fabrication of supports.

C. Carefully determine locations of inserts. Anchor to formwork prior to placing concrete.

Pipe Supports
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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/15061 (BidSet) D. Use flush shells only where indicated on the Drawings.

E. Do not use anchors relying on deformation of lead alloy.

F. Do not use powder-actuated fasteners for securing metallic conduit or steel pipe larger than 1-inch to concrete, masonry, or wood.

G. Suspend pipe hangers from hanger rods and secure with double nuts.

H. Install continuously threaded hanger rods only where indicated on the Drawings.

I. Use adjustable ring hangers or adjustable clevis hangers for 4-inch and smaller diameter pipe.

J. Use adjustable clevis hangers for pipe larger than 4 inches in diameter.

K. Secure pipes with double nutted U-bolts or suspend pipes from hanger rods and hangers.

1. For stainless steel piping, use stainless steel U-bolts.

2. For all other piping, use galvanized U-bolts.

L. Support spacing:

1. Support 2-inch and smaller piping on horizontal and vertical runs at maximum 5 feet on center, unless otherwise specified.

2. Support larger than 2-inch piping on horizontal and vertical runs at maximum 10 feet on center, unless otherwise specified.

3. Support exposed polyvinyl chloride and other plastic pipes at maximum 5 feet on center, regardless of size.

4. Support tubing, PVC pipe 1-inch and smaller, copper pipe and tubing, fiber-reinforced plastic pipe or duct, and rubber hose and tubing at intervals close enough to prevent sagging greater than 1/4-inch between supports.

5. Do not suspend or support valves, pipe and fittings from another pipe or conduit.

M. Install supports at:

1. Any change in direction.

2. Both sides of flexible pipe connections.

3. Base of risers.

4. Floor penetrations.

5. Connections to pumps, blowers, and other equipment.

6. Valves and appurtenances.

N. Securely anchor plastic pipe, valves, and headers to prevent movement during operation of valves.

O. Anchor plastic pipe between expansion loops and direction changes to prevent axial movement through anchors.

P. Provide elbows or tees supported from floors with base fittings where indicated on the Drawings.

Pipe Supports
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pw://Carollo/Documents/CA/Vallejo/201631-100000/04 Design/04 Specs/Carollo/15061 (BidSet) Q. Support base fittings with metal supports or when indicated on the Drawings support on concrete piers.

R. Do not use chains, plumbers' straps, wire, or similar devices for permanently suspending, supporting, or restraining pipes.

S. Support plumbing drainage and vents in accordance with plumbing code as specified in Section 01410 - Regulatory Requirements.

T. Supports, clamps, brackets, and portions of support system bearing against copper pipe: Copper plated, copper throughout, or isolated with neoprene or polyvinyl chloride tape.

U. Where pipe is insulated, install over-sized supports and hangers.

V. Install thermal pipe shield in accordance with MSS SP-58, Type 40 on all pipe supports for insulated pipes.

W. Install riser clamps at floor penetrations and where indicated on the Drawings.

X. Coat support system components as specified in Section 09960 - High-Performance Coatings.

END OF SECTION

Preformed Channel Pipe Support System
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PREFORMED CHANNEL PIPE SUPPORT SYSTEM
PART 1 GENERAL

1.01 SUMMARY
A. Section includes: Preformed channel pipe support system consisting of preformed channels, fittings, straps, and fasteners engineered to support piping.

1.02 REFERENCES
A. American Institute of Steel Construction (AISC).

B. American Iron and Steel Institute (AISI).

C. Manufacturer's Standardization Society (MSS):

1. SP-58 - Pipe Hangers and Supports - Materials, Design, and Manufacture.

1.03 SUBMITTALS
A. Submit as specified in Section 01330 - Submittal Procedures.

B. Product data.

1.04 QUALITY ASSURANCE
A. Design preformed channel pipe support system for loads in accordance with applicable provisions of:

1. AISC Manual of Steel Construction.

2. AISI Cold-Formed Steel Design Manual.

B. Product standards:

1. Pipe support materials: In accordance with MSS SP-58.

PART 2 PRODUCTS

2.01 MANUFACTURERS
A. Fabricate preformed channel pipe support system using, as a minimum, parts specified below and meeting the requirements specified under Design Criteria.

1. Manufacturers: One of the following or equal:
a. Unistrut, Series P1000 or P1001; P5500 or P5501.
b. Allied Support Systems, Power Strut, Figure PS-200 or PS-200 2TS; PS-150 or PS-150 2TS.
c. Cooper Ind., B-Line, Channel Type B22 or B22A; B12 or B12A.

Preformed Channel Pipe Support System
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2.02 DESIGN AND PERFORMANCE CRITERIA
A. Design responsibility:

1. The manufacturer of the preformed channel pipe support system is responsible for the design of the support system.

2. Prepare design calculations utilizing the design criteria included in these Specifications.

3. Prepare detailed shop drawings illustrating the layout of the support system and identifying the components of the support system.

B. Design criteria:

1. Include live, dead, and seismic loads associated with piping, valves, and appurtenances. Consider the content of the pipes in load calculations.

2. Minimum gauge thickness: 12-gauge.

3. Allowable stress of channels:
a. Stainless steel channels: 0.66 times the yield stress of the stainless steel alloy.

4. Maximum deflection: 1/240 of span.

5. Allowable column loads: As recommended by manufacturer in published instruction for column's unsupported height and "K" value for calculating effective column length of not less than 1.0.

6. Future loads:
a. Support systems indicated on the Drawings may include spaces intended to accommodate future pipes.
b. Assume such spaces are occupied by 6-inch diameter ductile iron pipes.

Only the number of pipes that would physically fit into the space need be considered.
c. Include the weight of the pipe contents in determining future loads.

Assume pipe contents are water.

7. Seismic design criteria: As specified in Section 01850 - Design Criteria as specified for mechanical equipment.

8. Spacing of supports: As required to comply with design requirements but not more than 5 feet.

C. Use Type 316 stainless steel for support system components.

2.03 ACCESSORIES
A. Preformed channel concrete inserts: Minimum 12 inches long:

1. Manufacturers: One of the following or equal:
a. Unistrut, Series P-3200.
b. Allied Support Systems, Figure 282.
c. Cooper Ind., B-Line Series B32I.

B. 90-degree angle fittings:

1. Manufacturers: One of the following or equal:
a. Unistrut, P1026.
b. Allied Support Systems, Power Strut, P603.