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7061 Technical Specs City of Denton Hickory Creek Detention Facility and Pecan Creek Water Reclamation Plant West Peak Flow Pump Station Contract 5768 December 5, 2018 TBPE Firm Registration No. F-13618 City of Denton Hazen and Sawyer BID SET 00003-1 Table of Contents City of Denton Hickory Creek Detention Facility and Pecan Creek WRP West Peak Flow Pump Station Contract 5768 Division Section Title 1 GENERAL REQUIREMENTS 01010 Summary of Work 01070 Abbreviations 01090 Reference Standards 01200 Project Meetings 01300 Submittals 01400 Quality Control 01470 Watertightness Testing of Concrete Structures 01510 Temporary Utilities 01520 Maintenance of Utility Operations During Construction 01530 Protection of Existing Facilities 01550 Site Access and Storage 01560 Temporary Environmental Controls 01590 Field Office, Equipment and Services 01600 Materials and Equipment 01700 Project Closeout TECHNICAL SPECIFICATIONS 2 SITEWORK 02050 Demolition 02100 Clearing, Grubbing and Site Preparation 02200 Earthwork 02207 Aggregate Materials 02214 Flowable Fill 02274 Geotextiles 02276 Erosion and Sedimentation Control 02371 Drilled Piers 02500 Surface Restoration 02604 Utility Structures 02831 Steel Fencing 02910 Final Grading and Landscaping 3 CONCRETE 03100 Concrete Formwork 03200 Reinforcing Steel 03230 Stressing Tendons 03250 Concrete Accessories 03290 Joints in Concrete 03300 Cast-in-Place Concrete City of Denton Hazen and Sawyer BID SET 00003-2 Table of Contents Division Section Title 3 CONCRETE (CONTINUED) 03350 Concrete Finishes 03360 Shotcrete 03370 Concrete Curing 03400 Precast Concrete 03600 Grout 4 MASONRY (NOT USED) 5 METALS 05010 Metal Materials 05035 Galvanizing 05050 Metal Fastening 05061 Stainless Steel 05120 Structural Steel 05140 Structural Aluminum 05500 Metal Fabrications 05515 Ladders 05520 Handrails and Railings 05531 Gratings, Access Hatches, and Access Doors 05540 Castings 05830 Bearing Devices and Anchoring 6 WOOD AND PLASTICS (NOT USED) 7 THERMAL AND MOISTURE PROTECTION (NOT USED) 07900 Joint Fillers, Sealants and Caulking 8 DOORS AND WINDOWS (NOT USED) 9 FINISHES 09900 Painting 10 SPECIALTIES (NOT USED) 11 EQUIPMENT GENERAL PROVISION 11000 Equipment General Provisions 11100 Pumps General 11130 Submersible Non-Clog Pumps 11901 Booster Pump Skid 12 FURNISHINGS (NOT USED) City of Denton Hazen and Sawyer BID SET 00003-3 Table of Contents Division Section Title 13 SPECIAL CONSTRUCTION 13205 13217 13252 Prestressed Concrete Tank (Type III) Tank Cleaning System Activated Carbon Odor Control System 14 CONVEYING SYSTEMS 14600 Cranes and Hoists 15 MECHANICAL 15000 Basic Mechanical Requirements 15006 Ductile Iron Pipe 15008 PVC Pipe 15012 Steel Pipe for Water and Wastewater 15017 FRP Pipe 15020 Pipe Supports 15030 Piping and Equipment Identification Systems 15095 Valves, General 15100 Valve Operators and Electric Valve Actuators 15101 Butterfly Valves 15105 Check Valves 15107 Yard Hydrants 15108 Gate Valves (Including Knife Gate Valves) 15109 Plug Valves 15114 Miscellaneous Valves 15121 Piping Expansion Compensation 15170 Low Voltage Electric Motors 15390 Schedules 15892 FRP Duct Systems 16 ELECTRICAL 16000 Basic Electrical Requirements 16111 Conduit 16118 Underground Electrical 16123 Low Voltage Wire and Cable 16130 Boxes 16141 Wiring Devices 16170 Grounding and Bonding 16190 Supporting Devices 16195 Electrical-Identification 16426 16440 Low Voltage Switchboards Disconnect Switches 16470 Panelboards 16481 Individual Motor Controllers 16498 Manual Transfer Switch City of Denton Hazen and Sawyer BID SET 00003-4 Table of Contents Division Section Title 16 ELECTRICAL (CONTINUED) 16500 Lighting 16670 Lightning Protection Systems 16902 Electric Controls and Relays 17 CONTROL AND INFORMATION SYSTEMS 17000 Control and Information System Scope and General Requirements 17030 Control and Information System Submittals 17040 Control and Information System Training Requirements 17050 Tools, Supplies, and Spare Parts, General 17060 Signal Coordination Requirements 17070 Control and Information System Testing, General 17071 Factory Acceptance Test 17072 Field Testing 17073 Final Acceptance Test 17080 Quality Assurance 17100 Control and Information System Hardware, General 17120 Programmable Logic Controllers 17135 Radio Telemetry System (Licensed) 17180 Process Control System Networks 17190 Uninterruptible Power Systems 17200 Control and Information System Software Requirements 17500 Enclosures, General 17510 Cabinets and Panels 17520 Field Panels 17550 Panel Instruments and Accessories 17560 Surge Protection Devices 17600 Unpowered Instruments, General 17650 Pressure Gauges 17660 Vane Operated Flow Switches 17670 Level Switches (Suspended Float Type) 17675 Pressure Switches 17698 Instrumentation and Control System Accessories 17700 Powered Instruments, General 17740 Ultrasonic Level Measurement Systems 17749 Submersible Level (Pressure) Sensor 17760 Pressure Indicating Transmitters 17900 Schedules and Control Descriptions, General 17910 Instrument Schedule 17920 Control System Input/Output Schedule 17950 Functional Control Descriptions City of Denton Hazen and Sawyer BID SET Seal Sheets City of Denton Hickory Creek Detention Facility and Pecan Creek WRP West Peak Flow Pump Station Contract 5768 SEAL SHEET - STRUCTURAL Division Section Title TECHNICAL SPECIFICATIONS 3 CONCRETE 03100 Concrete Formwork 03200 Reinforcing Steel 03230 Stressing Tendons 03250 Concrete Accessories 03290 Joints in Concrete 03300 Cast-in-Place Concrete 03350 Concrete Finishes 03360 Shotcrete 03370 Concrete Curing 03400 Precast Concrete 03600 Grout 5 METALS 05010 Metal Materials 05035 Galvanizing 05050 Metal Fastening 05061 Stainless Steel 05120 Structural Steel 05140 Structural Aluminum 05500 Metal Fabrications 05515 Ladders 05520 Handrails and Railings 05531 Gratings, Access Hatches, and Access Doors 05540 Castings 05830 Bearing Devices and Anchoring 7 THERMAL AND MOISTURE PROTECTION (NOT USED) 07900 Joint Fillers, Sealants and Caulking 13 SPECIAL CONSTRUCTION 13205 Prestressed Concrete Tank (Type III) City of Denton Hazen and Sawyer BID SET This page intentionally left blank City of Denton Hazen and Sawyer BID SET Seal Sheet City of Denton Hickory Creek Detention Facility and Pecan Creek WRP West Peak Flow Pump Station Contract 5768 SEAL SHEET - MECHANICAL Division Section Title 1 GENERAL REQUIREMENTS 01010 Summary of Work 01070 Abbreviations 01090 Reference Standards 01200 Project Meetings 01300 Submittals 01400 Quality Control 01470 Watertightness Testing of Concrete Structures 01510 Temporary Utilities 01520 Maintenance of Utility Operations During Construction 01530 Protection of Existing Facilities 01550 Site Access and Storage 01560 Temporary Environmental Controls 01590 Field Office, Equipment and Services 01600 Materials and Equipment 01700 Project Closeout TECHNICAL SPECIFICATIONS 2 SITEWORK 02050 Demolition 02100 Clearing, Grubbing and Site Preparation 02200 Earthwork 02207 Aggregate Materials 02214 Flowable Fill 02274 Geotextiles 02276 Erosion and Sedimentation Control 02371 Drilled Piers 02500 Surface Restoration 02604 Utility Structures 02831 Steel Fencing 02910 Final Grading and Landscaping 9 FINISHES 09900 Painting City of Denton Hazen and Sawyer BID SET Seal Sheet Division Section Title 11 EQUIPMENT GENERAL PROVISION 11000 Equipment General Provisions 11100 Pumps General 11130 Submersible Non-Clog Pumps 11901 Booster Pump Skid 13 SPECIAL CONSTRUCTION 13217 13252 Tank Cleaning System Activated Carbon Odor Control System 14 CONVEYING SYSTEMS 14600 Cranes and Hoists 15 MECHANICAL 15000 Basic Mechanical Requirements 15006 Ductile Iron Pipe 15008 PVC Pipe 15012 Steel Pipe for Water and Wastewater 15017 FRP Pipe 15020 Pipe Supports 15030 Piping and Equipment Identification Systems 15095 Valves, General 15100 Valve Operators and Electric Valve Actuators 15101 Butterfly Valves 15105 Check Valves 15107 Yard Hydrants 15108 Gate Valves (Including Knife Gate Valves) 15109 Plug Valves 15114 Miscellaneous Valves 15121 Piping Expansion Compensation 15170 Low Voltage Electric Motors 15390 Schedules 15892 FRP Duct Systems LIC NES E D 113114 BRANDT N. MILLER City of Denton Hazen and Sawyer BID SET Seal Sheets City of Denton Hickory Creek Detention Facility and Pecan Creek WRP West Peak Flow Pump Station Contract 5768 SEAL SHEET - ELECTRICAL Division Section Title TECHNICAL SPECIFICATIONS 16 ELECTRICAL 16000 Basic Electrical Requirements 16111 Conduit 16118 Underground Electrical 16123 Low Voltage Wire and Cable 16130 Boxes 16141 Wiring Devices 16170 Grounding and Bonding 16190 Supporting Devices 16195 Electrical-Identification 16426 16440 Low Voltage Switchboards Disconnect Switches 16470 Panelboards 16481 Individual Motor Controllers 16498 Manual Transfer Switch 16500 Lighting 16670 Lightning Protection Systems 16902 Electric Controls and Relays 17100 Control and Information System Hardware, General 17120 Programmable Logic Controllers 17135 Radio Telemetry System (Licensed) 17180 Process Control System Networks 17190 Uninterruptible Power Systems 17200 Control and Information System Software Requirements 17500 Enclosures, General 17510 Cabinets and Panels 17520 Field Panels 17550 Panel Instruments and Accessories 17560 Surge Protection Devices 17600 Unpowered Instruments, General 17650 Pressure Gauges 17660 Vane Operated Flow Switches 17670 Level Switches (Suspended Float Type) 17675 Pressure Switches 17698 Instrumentation and Control System Accessories 17700 Powered Instruments, General 17740 Ultrasonic Level Measurement Systems 17749 Submersible Level (Pressure) Sensor 17760 Pressure Indicating Transmitters City of Denton Hazen and Sawyer BID SET Seal Sheets Division Section Title 17900 Schedules and Control Descriptions, General 17910 Instrument Schedule 17920 Control System Input/Output Schedule 17950 Functional Control Descriptions LIC NES E D 121398 BRETT D. BUELTEL City of Denton Hazen and Sawyer BID SET Seal Sheet City of Denton Hickory Creek Detention Facility and Pecan Creek WRP West Peak Flow Pump Station Contract 5768 SEAL SHEET - INSTRUMENTATION AND CONTROLS Division Section Title TECHNICAL SPECIFICATIONS 17 CONTROL AND INFORMATION SYSTEMS 17000 Control and Information System Scope and General Requirements 17030 Control and Information System Submittals 17040 Control and Information System Training Requirements 17050 Tools, Supplies, and Spare Parts, General 17060 Signal Coordination Requirements 17070 Control and Information System Testing, General 17071 Factory Acceptance Test 17072 Field Testing 17073 Final Acceptance Test 17080 Quality Assurance 17100 Control and Information System Hardware, General 17120 Programmable Logic Controllers 17135 Radio Telemetry System (Licensed) 17180 Process Control System Networks 17190 Uninterruptible Power Systems 17200 Control and Information System Software Requirements 17500 Enclosures, General 17510 Cabinets and Panels 17520 Field Panels 17550 Panel Instruments and Accessories 17560 Surge Protection Devices 17600 Unpowered Instruments, General 17650 Pressure Gauges 17660 Vane Operated Flow Switches 17670 Level Switches (Suspended Float Type) 17675 Pressure Switches 17698 Instrumentation and Control System Accessories 17700 Powered Instruments, General 17740 Ultrasonic Level Measurement Systems 17749 Submersible Level (Pressure) Sensor 17760 Pressure Indicating Transmitters 17900 Schedules and Control Descriptions, General 17910 Instrument Schedule 17920 Control System Input/Output Schedule 17950 Functional Control Descriptions City of Denton Hazen and Sawyer BID SET This page intentionally left blank City of Denton Hazen and Sawyer BID SET 01010-1 Summary of Work SECTION 01010 SUMMARY OF WORK PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Work to be done under these Contracts and in accordance with these Specifications consists of furnishing all equipment, superintendence, labor, skill, material and all other items necessary for the construction of the Hickory Creek Detention Facility (HCDF) and Pecan Creek Water Reclamation Plant (PCWRP) West Peak Flow Pump Station (WPFPS). The Contractor shall perform all work required for such construction in accordance with the Contract Documents and subject to the terms and conditions of the Contract, complete and ready for use. B. The principal features of the Work to be performed under these Contracts includes furnishing and installing two peak flow management facilities, referred to in these specifications as the “Hickory Creek Detention Facility” and the “Pecan Creek WRP West Peak Flow Pump Station” and described below. Hickory Creek Detention Facility: • One diversion structure at the Hickory Creek Interceptor with baffle wall to mitigate floatables, static overflow weir and a water surface level measurement device • One 48-inch gravity sewer pipeline conveying flow from the Hickory Creek Interceptor to the Hickory Creek Peak Flow Pump Station • One 24-million gallon per day firm capacity pump station with constant speed, non- clog submersible pumps, pump retrieval system, force main piping, valves and appurtenances • One 3.5-million gallon nominal storage volume, above ground, covered, pre-stressed concrete tank with pump in, gravity out configuration with all piping connections and appurtenances. Site layout will designate the location for a second 3.5-4.5 MG above ground tank to be designed and constructed at a later date • One 12-inch pressurized sewer pipeline conveying flow from the Hickory Creek Detention Facility Storage Tank to the Hickory Creek Interceptor • One tank flushing system which includes three tank cleaning machines, two vertical turbine water booster pumps, interconnecting piping, valves and appurtenances • One 8-inch potable water pipeline providing water service from the nearby Bent Creek Estates to the Hickory Creek Detention Facility. The water line includes connection to the existing water line in the Creekbend Drive Right of Way, concrete replacement, installation of all valves and appurtenances including but not limited to isolation valves, air release valves and a double check backflow preventer. The water line crosses the Kansas City Southern Railroad requiring a steel casing and installation using methods other than open cut • One 6-inch non-potable water pipeline from the back flow prevent described above to the Hickory Creek Detention Facility equipment pads as shown on the Drawings City of Denton Hazen and Sawyer BID SET 01010-2 Summary of Work • A new permanent vehicle access road at the project site including a concrete paved access driveway at Country Club Road (FM1830), asphalt road along the railroad to the existing fence line on the City’s, an asphalt access driveway at the Hickory Creek Detention Facility and a gravel access driveway around the storage tank as shown on the Drawings. Construction of the road from the City’s property gate to the site will be the responsibility of the City of Denton as designated on the Drawings • One ventilation and activated carbon odor control system that exhausts both the Hickory Creek Peak Flow Pump Station wet well and the storage tank including an exhaust fan, deal bed activated carbon vessel, interconnecting duct work, dampers and appurtenances • The scope of electrical improvements and responsibility of the Contractor is described in Section 16000 • Miscellaneous site civil improvements including but not limited to fencing around facility with an access gate, grading, drainage and erosion control Pecan Creek WRP West Peak Flow Pump Station: • One diversion structure at the Hickory Creek Interceptor with baffle wall to mitigate floatables, static overflow weir and a water surface level measurement device • One 42-inch gravity sewer pipeline conveying flow from the Pecan Creek Interceptor to the West Peak Flow Pump Station • A new gravel vehicle access drive from the existing road at PCWRP to the pump station • One 24-million gallon per day firm capacity pump station with constant speed, non-clog submersible pumps, pump retrieval system, piping, valves and appurtenances • One 36-inch force main from the West Peak Flow Pump Station to the existing 42-inch diversion pipeline and ultimately to the existing peak flow storage basin with all valves and appurtenances • Miscellaneous site civil improvements including but not limited to fencing around facility with an access gate, grading, drainage and erosion control • The scope of electrical improvements and responsibility of the Contractor is described in Section 16000 C. The foregoing description(s) shall not be construed as a complete description of all work required. 1.02 CONTRACT DOCUMENTS A. The Work to be done is shown on the set of Drawings entitled Hickory Creek Detention Facility and Pecan Creek Water Reclamation Plant West Peak Flow Pump Station and dated December 5, 2018. The numbers and titles of all Drawings appear on the index sheet of the Drawings, Sheet G-02. All drawings so enumerated shall be considered an integral part of the Contract Documents as defined herein. B. Certain Document Sections refer to Divisions of the Contract Specifications. Sections are each individually numbered portions of the Specifications (numerically) such as 08110, 13182, 15206, etc. The term Division is used as a convenience term meaning all Sections within a numerical grouping. Division 16 would thus include Sections 16000 through 16902. City of Denton Hazen and Sawyer BID SET 01010-3 Summary of Work C. Where references in the Contract Documents are made to Contractors for specific disciplines of work (i.e. Electrical Contractor, etc.), these references shall be interpreted to be the single prime Contractor when the project is bid or awarded as a single prime contract. 1.03 GENERAL ARRANGEMENT A. Drawings indicate the extent and general arrangement of the work. If any departures from the Drawings are deemed necessary by the Contractor to accommodate the materials and equipment he proposes to furnish, details of such departures and reasons therefore shall be submitted as soon as practicable to the Engineer for approval. No such departures shall be made without the prior written approval of the Engineer. Approved changes shall be made without additional cost to the Owner for this work or related work under other Contracts of the Project. B. The specific equipment proposed for use by the Contractor on the project may require changes, in structures, auxiliary equipment, piping, electrical, mechanical, controls or other work to provide a complete satisfactory operating installation. The Contractor shall submit to the Engineer, for approval, all necessary Drawings and details showing such changes to verify conformance with the overall project structural and architectural requirements and overall project operating performance. The Bid Price shall include all costs in connection with the preparation of new drawings and details and all changes to construction work to accommodate the proposed equipment, including increases in the costs of other Contracts. 1.04 CONSTRUCTION PERMITS, EASEMENTS AND ENCROACHMENTS A. The Owner shall obtain or cause to be obtained all permanent and temporary construction easements as shown on the Drawings. The Owner shall further obtain or cause to be obtained a right-of-way encroachment agreement from Texas Department of Transportation. The Contractor shall verify that these agreements have been obtained and shall comply with the conditions set forth in each agreement. B. The Contractor shall obtain, keep current and pay all fees for any necessary construction permits from those authorities, agencies, or municipalities having jurisdiction over land areas, utilities, or structures which are located within the Contract limits and which will be occupied, encountered, used, or temporarily interrupted by the Contractor's operations unless otherwise stated. Record copies of all permits shall be furnished to the Engineer. C. When construction permits are accompanied by regulations or requirements issued by a particular authority, agency or municipality, it shall be the Contractor's responsibility to familiarize himself and comply with such regulations or requirements as they apply to his operations on this Project. D. The Contractor shall provide any required Performance and Indemnity Bond(s) and any additional specific insurance coverage required of the Owner. City of Denton Hazen and Sawyer BID SET 01010-4 Summary of Work 1.05 ADDITIONAL ENGINEERING SERVICES A. In the event that the Engineer is required to provide additional engineering services as a result of substitution of materials or equipment which are not "or equal" by the Contractor, or changes by the Contractor in dimension, weight, power requirements, etc., of the equipment and accessories furnished, or if the Engineer is required to examine and evaluate any changes proposed by the Contractor for the convenience of the Contractor, then the Engineer's charges in connection with such additional services shall be charged to the Contractor by the Owner. B. Structural design shown on the Contract Drawings is based upon typical weights for major items of equipment as indicated on the Contract Drawings and specified. If the equipment furnished exceeds the weights of said equipment, the Contractor shall assume the responsibility for all costs of redesign and for any construction changes required to accommodate the equipment furnished, including the Engineer's expenses in connection therewith. C. In the event that the Engineer is required to provide additional engineering services as a result of Contractor's errors, omissions, or failure to conform to the requirements of the Contract Documents, or if the Engineer is required to examine and evaluate any changes proposed by the Contractor solely for the convenience of the Contractor, then the Engineer's charges in connection with such additional services shall be charged to the Contractor by the Owner. 1.06 ADDITIONAL OWNER'S EXPENSES A. In the event the Work of this Contract is not completed within the time set forth in the Contract or within the time to which such completion may have been extended in accordance with the Contract Documents, the additional engineering or inspection charges incurred by the Owner may be charged to the Contractor and deducted from the monies due him. Extra work or supplemental Contract work added to the original Contract, as well as extenuating circumstances beyond the control of the Contractor, will be given due consideration by the Owner before assessing engineering and inspection charges against the Contractor. B. Unless otherwise specifically permitted, the normal time of work under this Contract is limited to 8 hours per day, Monday through Friday. Work beyond these hours will result in additional expense to the Owner. Any expenses and/or damages, including the cost of the Engineer's on site personnel, arising from the Contractor's operations beyond the hours and days specified above shall be borne by the Contractor. C. Charges assessed to the Contractor for additional engineering and inspection costs will be determined based on actual hours charged to the job by the Engineer. Daily rates will depend on the number and classifications of employees involved, but in no case shall such charges exceed $400 per day for field personnel and $600 per day for engineering personnel, based on an eight hour workday. D. Charges for additional Owner's expenses shall be in addition to any liquidated damages assessed in accordance with the Contract. City of Denton Hazen and Sawyer BID SET 01010-5 Summary of Work 1.07 TIME OF WORK A. The normal time of work for this Contract is limited to 40 hours per week and shall generally be between the hours of 7:00 a.m. and 6:00 p.m., Monday through Friday. The Contractor may elect to work beyond these hours or on weekends provided that all costs incurred by the Owner for additional engineering shall be borne by the Contractor. 1. The Owner shall deduct the cost of additional engineering costs from monies due the Contractor. B. If it shall become imperative to perform work at night, the Owner and Engineer shall be informed a reasonable time in advance of the beginning of such work. Temporary lighting and all other necessary facilities for performing and inspecting the work shall be provided and maintained by the Contractor. C. Unless otherwise specifically permitted, all work that would be subject to damage shall be stopped during inclement, stormy or freezing weather. Only such work as will not suffer injury to workmanship or materials will be permitted. Contractor shall carefully protect his work against damage or injury from the weather, and when work is permitted during freezing weather, he shall provide and maintain approved facilities for heating the materials and for protecting the finished work. 1.08 SUBSURFACE DATA A. Subsurface data are offered in good faith solely for placing the Bidder in receipt of all information available to the Owner and Engineer and in no event is to be considered as part of the Contract Documents. B. The Bidder must interpret such subsurface data according to his own judgment and acknowledge that he is not relying upon the same as accurately describing the subsurface conditions, which may be found to exist. 1. The test boring logs present factual information of the subsurface conditions at the specific test boring location only. The Bidder should not consider, or conclude, that the subsurface conditions will be consistent between test boring locations. C. The Bidder further acknowledges that he assumes all risks contingent upon the nature of the sub-surface conditions to be actually encountered by him in performing the work covered by the Contract, even though such actual conditions may result in the Bidder performing more or less work than he originally anticipated. D. The Bidder is further advised that the Owner has made sub-surface investigations and a report has been prepared, in connection with this project for the Engineer, a copy of which is appended to the rear of these specifications. E. In making this data available, the Owner makes no guarantee, either expressed or implied, as to their accuracy or to the accuracy of any interpretation thereof. City of Denton Hazen and Sawyer BID SET 01010-6 Summary of Work 1.09 SURVEYS AND LAYOUT A. All work under this Contract shall be constructed in accordance with the lines and grades shown on the Drawings or as directed by the Engineer. Elevation of existing ground and appurtenances are believed to be reasonably correct but are not guaranteed to be absolute and therefore are presented only as an approximation. Any error or apparent discrepancy in the data shown or omissions of data required for accurately accomplishing the stake out survey shall be referred immediately to the Engineer for interpretation or correction. B. All survey work for construction control purposes shall be made by the Contractor at his expense. The Contractor shall provide a Licensed Surveyor as Chief of Party, competently qualified men, all necessary instruments, stakes, and other material to perform the work. C. Contractor shall establish all baselines for the location of the principal component parts of the work together with a suitable number of bench marks and batter boards adjacent to the work. Based upon the information provided by the Contract Drawings, the Contractor shall develop and make all detail surveys necessary for construction, including slope stakes, batter boards, stakes for all working points, lines and elevations. D. Contractor shall have the responsibility to carefully preserve the bench marks, reference points and stakes, and in the case of destruction thereof by the Contractor or resulting from his negligence, the Contractor shall be charged with the expense and damage resulting therefrom and shall be responsible for any mistakes that may be caused by the unnecessary loss or disturbance of such bench marks, reference points and stakes. E. Existing or new control points, property markers and monuments that will be or are destroyed during the normal causes of construction shall be reestablished by the Contractor and all reference ties recorded therefore shall be furnished to the Engineer. All computations necessary to establish the exact position of the work shall be made and preserved by the Contractor. F. The Engineer may check all or any portion of the work and the Contractor shall afford all necessary assistance to the Engineer in carrying out such checks. Any necessary corrections to the work shall be immediately made by the Contractor. Such checking by the Engineer shall not relieve the Contractor of any responsibilities for the accuracy or completeness of his work. G. At completion of the work, the Contractor shall furnish Record Drawings indicating the final layout of all structures, roads, all structures, existing bench marks, etc. The Record Drawings shall indicate all critical elevations of piping, structures, finish grades, etc. H. Contractor shall have all weirs surveyed by a licensed land surveyor and adjusted to match specified elevations as shown on the Contract Drawings. Weirs shall be surveyed at no more than ten (10) feet spacing, but no less than 2 points shall be surveyed on each section of weir plate. Final elevations shall be set to within a tolerance of +/- 0.05 inches of specified elevation. If a greater tolerance is allowed, it will be noted on the Contract Drawings. A final report showing all specified and surveyed elevations shall be certified by the surveyor and delivered to the Engineer. City of Denton Hazen and Sawyer BID SET 01010-7 Summary of Work 1.11 FIRE PROTECTION A. Contractor shall take all necessary precautions to prevent fires at or adjacent to the work, buildings, etc., and shall provide adequate facilities for extinguishing fires which do occur. Burning, if permitted in Division 2, shall be limited to areas approved by the Engineer and Owner and properly controlled by the Contractor. B. When fire or explosion hazards are created in the vicinity of the work as a result of the locations of fuel tanks, or similar hazardous utilities or devices, the Contractor shall immediately alert the local Fire Marshal, the Engineer, and the Owner of such tank or device. The Contractor shall exercise all safety precautions and shall comply with all instructions issued by the Fire Marshal and shall cooperate with the Owner of the tank or device to prevent the occurrence of fire or explosion. 1.12 CHEMICALS A. All chemicals used during project construction or furnished for project operation, whether herbicide, pesticide, disinfectant, polymer, or reactant of other classification, must show approval of either the EPA or USDA. Use of all such chemicals and disposal of residues shall be in strict conformance with all applicable rules and regulations. 1.13 FIRST AID FACILITIES AND ACCIDENTS A. First Aid Facilities 1. The Contractor shall provide at the site such equipment and facilities as are necessary to supply first aid to any of his personnel who may be injured in connection with the work. B. Accidents 1. The Contractor shall promptly report, in writing, to the Engineer and Owner all accidents whatsoever out of, or in connection with, the performance of the work, whether on or adjacent to the site, which cause death, personal injury or property damage, giving full details and statements of witnesses. 2. If death, serious injuries, or serious damages are caused, the accident shall be reported immediately by telephone or messenger to both the Owner and the Engineer. 3. If any claim is made by anyone against the Contractor or a Subcontractor on account of any accidents, the Contractor shall promptly report the facts, in writing, to the Engineer and Owner, giving full details of the claim. City of Denton Hazen and Sawyer BID SET 01010-8 Summary of Work 1.14 ULTIMATE DISPOSITION OF CLAIMS BY ONE CONTRACTOR ARISING FROM ALLEGED DAMAGE BY ANOTHER CONTRACTOR A. During the progress of the work, other Contractors may be engaged in performing other work or may be awarded other Contracts for additional work on this project. In that event, the Contractor shall coordinate the work to be done hereunder with the work of such other Contractors and the Contractor shall fully cooperate with such other Contractors and carefully fit its own work to that provided under other Contracts as may be directed by the Engineer. The Contractor shall not commit or permit any act which will interfere with the performance of work by any other Contractor. B. If the Engineer shall determine that the Contractor is failing to coordinate his work with the work of the other Contractors as the Engineer directed, then the Owner shall have the right to withhold any payments otherwise due hereunder until the Contractor completely complies with the Engineer's directions. C. If the Contractor notifies the Engineer in writing that another Contractor is failing to coordinate his work with the work of this Contract as directed, the Engineer will promptly investigate the charge. If the Engineer finds it to be true, he will promptly issue such directions to the other Contractor with respect thereto as the situation may require. The Owner, the Engineer, nor any of their agents shall not, however, be liable for any damages suffered by the Contractor by reason of the other Contractor's failure to promptly comply with the directions so issued by the Engineer, or by reason of another Contractor's default in performance, it being understood that the Owner does not guarantee the responsibility or continued efficiency of any Contractor. D. The Contractor shall indemnify and hold the Owner and the Engineer harmless from any and all claims of judgments for damages and from costs and expenses to which the Owner may be subjected or which it may suffer or incur by reason of the Contractor's failure to comply with the Engineer's directions promptly. E. Should the Contractor sustain any damage through any act or omission of any other Contractor having a Contract with the Owner for the performance of work upon the site or of work which may be necessary to be performed for the proper execution of the work to be performed hereunder, or through any act or omission of a Subcontractor of such Contract, the Contractor shall have no claim against the Owner or the Engineer for such damage, but shall have a right to recover such damage from the other Contractor under the provision similar to the following provisions which have been or will be inserted in the Contracts with such other Contractors. F. Should any other Contractor having or who shall hereafter have a Contract with the Owner for the performance of work upon the site sustain any damage through any act or omission of the Contractor hereunder or through any act or omission of any Subcontractor of the Contractor, the Contractor agrees to reimburse such other Contractor for all such damages and to defend at his own expense any suit based upon such claim and if any judgment or claims against the Owner shall be allowed, the Contractor shall pay or satisfy such judgment or claim and pay all costs and expenses in connection therewith and shall indemnify and hold the Owner harmless from all such claims. City of Denton Hazen and Sawyer BID SET 01010-9 Summary of Work G. The Owner's right to indemnification hereunder shall in no way be diminished, waived or discharged, by its recourse to assessment of liquidated damages as provided in the Contract, or by the exercise of any other remedy provided for by Contract Documents or by law. 1.15 BLASTING AND EXPLOSIVES A. THE USE OF BLASTING OR EXPLOSIVES SHALL NOT BE ALLOWED UNDER THIS PROJECT. 1.16 LIMITS OF WORK AREA A. The Contractor shall confine his construction operations within the Contract limits shown on the Drawings and/or property lines and/or fence lines. Storage of equipment and materials, or erection and use of sheds outside of the Contract limits, if such areas are the property of the Owner, shall be used only with the Owner's approval. Such storage or temporary structures, even within the Contract's limits, shall be confined to the Owner's property and shall not be placed on properties designated as easements or rights-of-way unless specifically permitted elsewhere in the Contract Documents. 1.17 WEATHER CONDITIONS A. No work shall be done when the weather is unsuitable. The Contractor shall take necessary precautions (in the event of impending storms) to protect all work, materials, or equipment from damage or deterioration due to floods, driving rain, or wind, and snow storms. The Owner reserves the right, through the opinion of the Engineer, to order that additional protection measures over and beyond those proposed by the Contractor, be taken to safeguard all components of the Project. The Contractor shall not claim any compensation for such precautionary measures so ordered, nor claim any compensation from the Owner for damage to the work from weather elements. B. The mixing and placing of concrete or pavement courses, the laying of masonry, and installation of sewers and water mains shall be stopped during rainstorms, if ordered by the Engineer; and all freshly placed work shall be protected by canvas or other suitable covering in such manner as to prevent running water from coming in contact with it. Sufficient coverings shall be provided and kept ready at hand for this purpose. The limitations and requirements for mixing and placing concrete, or laying of masonry, in cold weather shall be as described elsewhere in these Specifications. 1.18 PERIODIC CLEANUP: BASIC SITE RESTORATION A. During construction, the Contractor shall regularly remove from the site of the work all accumulated debris and surplus materials of any kind which result from his operations. Unused equipment and tools shall be stored at the Contractor's yard or base of operations for the Project. B. When the work involves installation of sewers, drains, water mains, manholes, underground structures, or other disturbance of existing features in or across streets, rights-of-way, easements, or private property, the Contractor shall (as the work progresses) promptly City of Denton Hazen and Sawyer BID SET 01010-10 Summary of Work backfill, compact, grade, and otherwise restore the disturbed area to the basic condition which will permit resumption of pedestrian or vehicular traffic and any other critical activity or functions consistent with the original use of the land. The requirements for temporary paving of streets, walks, and driveways are specified elsewhere. Unsightly mounds of earth, large stones, boulders, and debris shall be removed so that the site presents a neat appearance. C. The Contractor shall perform the cleanup work on a regular basis and as frequently as ordered by the Engineer. Basic site restoration in a particular area shall be accomplished immediately following the installation or completion of the required facilities in that area. Furthermore, such work shall also be accomplished, when ordered by the Engineer, if partially completed facilities must remain incomplete for some time period due to unforeseen circumstances. D. Upon failure of the Contractor to perform periodic cleanup and basic restoration of the site to the Engineer's satisfaction, the Owner may, upon five (5) days prior written notice to the Contractor, without prejudice to any other rights or remedies of the Owner, cause such work for which the Contractor is responsible to be accomplished to the extent deemed necessary by the Engineer, and all costs resulting therefrom shall be charged to the Contractor and deducted from the amounts of money that may be due him. 1.19 USE OF FACILITIES BEFORE COMPLETION A. The Owner reserves the right to enter and use any portion of the constructed facilities before final completion of the whole work to be done under this Contract. However, only those portions of the facilities which have been completed to the Engineer's satisfaction, as evidenced by his issuing a Certificate of Substantial Completion covering that part of the work, shall be placed in service. B. It shall be the Owner's responsibility to prevent premature connections to or use of any portion of the installed facilities by private or public parties, persons or groups of persons, before the Engineer issues his Certificate of Substantial Completion covering that portion of the work to be placed in service. C. Consistent with the approved progress schedule, the Contractor shall cooperate with the Owner, his agents, and the Engineer to accelerate completion of those facilities, or portions thereof, which have been designated for early use by the Owner. PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION - City of Denton Hazen and Sawyer BID SET 01070-1 Abbreviations SECTION 01070 ABBREVIATIONS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The following is a partial list of typical abbreviations which may be used in the Specifications, and the organizations to which they refer: AASHTO - American Association of State Highway and Transportation Officials ACI - American Concrete Institute ACIFS - American Cast Iron Flange Standards AFBMA - Anti-Friction Bearing Manufacturer's Association AGA - American Gas Association AGMA - American Gear Manufacturers Association AIA - American Institute of Architects AISC - American Institute of Steel Construction AISI - American Iron and Steel Institute ANSI - American National Standard Institute API - American Petroleum Institute ASCE - American Society of Civil Engineers ASHRAE - American Society of Heating, Refrigeration, and Air Conditioning Engineers ASME - American Society of Mechanical Engineers ASTM - American Society for Testing and Materials AWS - American Welding Society AWWA - American Water Works Association CEMA - Conveyor Equipment Manufacturer's Association CRSI - Concrete Reinforcing Steel Institute DIPRA - Ductile Iron Pipe Research Association Fed Spec - Federal Specifications IEEE - Institute of Electrical and Electronic Engineers IPCEA - Insulated Power Cable Engineers Association ISO - Insurance Services Offices NBS - National Bureau of Standards NCDOT - North Carolina Department of Transportation NEC - National Electric Code NEMA - National Electrical Manufacturers Association OSHA - Occupational Safety and Health Act PCI - Precast Concrete Institute UL - Underwriters Laboratories, Inc. USGS - United States Geological Survey City of Denton Hazen and Sawyer BID SET 01070-2 Abbreviations PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION - City of Denton Hazen and Sawyer BID SET 01090-1 Reference Standards SECTION 01090 REFERENCE STANDARDS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Wherever reference is made to any published standards, codes, or standard specifications, it shall mean the latest standard code, specification, or tentative specification of the technical society, organization, or body referred to, which is in effect at the date of invitation for Bids. B. All materials, products, and procedures used or incorporated in the work shall be in strict conformance with applicable codes, regulations, specifications, and standards. C. A partial listing of codes, regulations, specifications, and standards includes the following: Air Conditioning and Refrigeration Institute (ARI) Air Diffusion Council (ADC) Air Moving and Conditioning Association (AMCA) The Aluminum Association (AA) American Architectural Manufacturers Association (AAMA) American Concrete Institute (ACI) American Gear Manufacturers Association (AGMA) American Hot Dip Galvanizers Association (AHDGA) American Institute of Steel Construction, Inc. (AISC) American Iron and Steel Institute (AISI) American National Standards Institute (ANSI) American Society of Civil Engineers (ASCE) American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc. (ASHRAE) American Society of Mechanical Engineers (ASME) American Society for Testing and Materials (ASTM) American Standards Association (ASA) City of Denton Hazen and Sawyer BID SET 01090-2 Reference Standards American Water Works Association (AWWA) American Welding Society (AWS) American Wood-Preserver's Association (AWPA) Anti-Friction Bearing Manufacturers Association (AFBMA) Building Officials and Code Administrators (BOCA) Conveyor Equipment Manufacturers Association (CEMA) Consumer Product Safety Commission (CPSC) Factory Mutual (FM) Federal Specifications International Building Code (IBC) Instrument Society of America (ISA) Institute of Electrical and Electronics Engineers (IEEE) National and Local Fire Codes Lightning Protection Institute (LPI) National Electrical Code (NEC) National Electrical Manufacturer's Association (NEMA) National Electrical Safety Code (NESC) National Electrical Testing Association (NETA) National Fire Protection Association (NFiPA) Regulations and Standards of the Occupational Safety and Health Act (OSHA) Southern Building Code Congress International, Inc. (SBCCI) Sheet Metal & Air Conditioning Contractors National Association (SMACCNA) Standard Building Code Standard Mechanical Code Standard Plumbing Code City of Denton Hazen and Sawyer BID SET 01090-3 Reference Standards Uniform Building Code (UBC) Underwriters Laboratories Inc. (UL) D. Contractor shall, when required, furnish evidence satisfactory to the Engineer that materials and methods are in accordance with such standards where so specified. E. In the event any questions arise as to the application of these standards or codes, copies shall be supplied on-site by the Contractor. PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION – City of Denton Hazen and Sawyer BID SET 01090-4 Reference Standards This page left blank intentionally City of Denton Hazen and Sawyer BID SET 01200-1 Project Meetings SECTION 01200 PROJECT MEETINGS PART 1 -- GENERAL 1.01 PRE-BID MEETING A. A pre-bid meeting will be held at the time and place to be designated in the Instructions to Bidders. B. The Engineer will be available to discuss the project and answer pertinent questions. No oral interpretation will be made as to the meaning of the Documents. Interpretation, if deemed necessary by the Engineer, will be in the form of an Addendum to the Contract Documents. 1.02 PRECONSTRUCTION MEETING A. A preconstruction meeting will be held after Award of Contract, but prior to starting work at the site. B. Attendance: 1. Owner 2. Engineer 3. Contractor 4. Major subcontractors 5. Representatives of governmental or other regulatory agencies (if necessary) C. Minimum Agenda: 1. Tentative construction schedule 2. Critical work sequencing 3. Designation of responsible personnel 4. Processing of Field Decisions and Change Orders 5. Adequacy of distribution of Contract Documents 6. Submittal of Shop Drawings and samples 7. Procedures for maintaining record documents City of Denton Hazen and Sawyer BID SET 01200-2 Project Meetings 8. Use of site and Owner's requirements 9. Major equipment deliveries and priorities 10. Safety and first aid procedures 11. Security procedures 12. Housekeeping procedures 13. Processing of Partial Payment Requests 14. General regard for community relations 1.03 PROGRESS MEETING A. A minimum of 12 progress meetings will be held monthly at the Pecan Creek Water Reclamation Plant’s Conference Room during the performance of the work of this Contract. Additional meetings may be called as progress of work dictates. B. Engineer will preside at meetings and record minutes of proceedings and decisions. Engineer will distribute copies of minutes to participants. C. Attendance: 1. Engineer 2. Contractor 3. Subcontractors, only with Engineer's approval or request, as pertinent to the agenda D. Minimum Agenda: 1. Review and approve minutes of previous meetings. 2. Review progress of Work since last meeting. 3. Review proposed 30-60 day construction schedule. 4. Note and identify problems which impede planned progress. 5. Develop corrective measures and procedures to regain planned schedule. 6. Revise construction schedule as indicated and plan progress during next work period. 7. Maintaining of quality and work standards. 8. Complete other current business. City of Denton Hazen and Sawyer BID SET 01200-3 Project Meetings 9. Schedule next progress meeting. PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION – City of Denton Hazen and Sawyer BID SET 01200-4 Project Meetings This page left blank intentionally City of Denton Hazen and Sawyer BID SET 01300-1 Submittals SECTION 01300 SUBMITTALS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Progress Schedule 1. Within thirty (30) days after issuance of the Notice to Proceed, the Contractor shall prepare and submit one (1) electronic copy in PDF format and three (3) hard copies of his proposed progress schedule to the Engineer for review and approval. 2. Within sixty (60) days after issuance of Notice to Procced, the Contractor shall prepare and submit one (1) electronic copy in PDF format and three (3) hard copies of his proposed list of submittals and schedule for submittals to the Engineer for review. 3. If so required, the schedule shall be revised until it is approved by the Engineer. 4. Schedule shall be updated monthly, depicting progress to the last day of the month and one (1) electronic copy in PDF format and three (3) hard copies submitted to the Engineer not later than the fifth day of the month, and prior to the application for progress payment. Failure to provide monthly schedule updates will be grounds for the Engineer or Owner to withhold progress payment approval. 5. Schedule shall be prepared in the form of a horizontal bar chart showing in detail the proposed sequence of the work and identifying construction activities for each structure and for each portion of work. 6. Schedule shall be time scaled, identifying the first day of each week. The Schedule shall be provided with estimated dates for Early Start, Early Finish, Late Start and Late Finish. The work shall be scheduled to complete the Project within the Contract time. The Late Finish date shall equal the Contract Completion Date. 7. Schedule shall show duration (number of days) and float for each activity. Float shall be defined as the measure of leeway in starting or completing a scheduled activity without adversely affecting the project completion date established by the Contract Documents. 8. Updated schedule shall show all changes since the previous submittal. 9. All revisions to the schedule must have the prior approval of the Engineer. City of Denton Hazen and Sawyer BID SET 01300-2 Submittals B. Equipment and Material Orders Schedule 1. Contractor shall prepare and submit one (1) electronic copy in PDF format and three (3) hard copies of his schedule of principal items of equipment and materials to be purchased to the Engineer for review and approval. 2. If so required, the schedule shall be revised until it is approved by the Engineer. 3. Schedule shall be updated monthly and one (1) electronic copy in PDF format and three (3) hard copies submitted to the Engineer not later than the fifth day of every month with the application for progress payment. 4. The updated schedule shall be based on the Progress Schedule developed under the requirements of Paragraph 1.01(A) of this Section. 5. Schedule shall be in tabular form with appropriate spaces to insert the following information for principal items of equipment and materials: a. Dates on which Shop Drawings are requested and received from the manufacturer. b. Dates on which certification is received from the manufacturer and transmitted to the Engineer. c. Dates on which Shop Drawings are submitted to the Engineer and returned by the Engineer for revision. d. Dates on which Shop Drawings are revised by manufacturer and resubmitted to the Engineer. e. Date on which Shop Drawings are returned by Engineer annotated either "Furnish as Submitted" or "Furnish as Corrected". f. Date on which accepted Shop Drawings are transmitted to manufacturer. g. Date of manufacturer's scheduled delivery. h. Date on which delivery is actually made. C. Working Drawings 1. Within thirty (30) days after the Notice to Proceed, each prime Contractor shall prepare and submit one (1) electronic copy in PDF format and one (1) hard copies of his preliminary schedule of Working Drawing submittals to the Engineer for review and approval. If so required, the schedule shall be revised until it is approved by the Engineer. 2. Working Drawings include, but are not limited to, Shop Drawings, layout drawings in plan and elevation, installation drawings, elementary wiring diagrams, interconnecting wiring diagrams, manufacturer's data, etc. Contractor shall be City of Denton Hazen and Sawyer BID SET 01300-3 Submittals responsible for securing all of the information, details, dimensions, Drawings, etc., necessary to prepare the Working Drawings required and necessary under this Contract and to fulfill all other requirements of his Contract. Contractor shall secure such information, details, Drawings, etc., from all possible sources including the Drawings, Working Drawings prepared by subcontractors, Engineers, suppliers, etc. 3. Working Drawings shall accurately and clearly present the following: a. All working and installation dimensions. b. Arrangement and sectional views. c. Units of equipment in the proposed positions for installation, details of required attachments and connections, and dimensioned locations between units and in relation to the structures. d. Necessary details and information for making connections between the various trades including, but not limited to, power supplies and interconnecting wiring between units, accessories, appurtenances, etc. 4. In the event that the Engineer is required to provide additional engineering services as a result of a substitution of materials or equipment by the Contractor, the additional services will be provided in accordance with Section 01010 - Summary of Work, and will be covered in supplementary or revised Drawings which will be issued to the Contractor. All changes indicated that are necessary to accommodate the equipment and appurtenances shall be incorporated into the Working Drawings submitted to the Engineer. 5. Working Drawings specifically prepared for this Project shall be on mylar or other approved reproducible material sheets of the same size as the Drawings. Working Drawings shall conform to recognized drafting standards and be neat, legible and drawn to a large enough scale to show in detail the required information. 6. The Drawings are used for engineering and general arrangement purposes only and are not to be used for Working Drawings. 7. Shop Drawings a. Contractor shall submit for review by the Engineer Shop Drawings for all fabricated work and for all manufactured items required to be furnished by the Contract Documents. b. Structural and all other layout Drawings prepared specifically for the Project shall have a plan scale of not less than 1/4-inch = 1 foot. c. Where manufacturer's publications in the form of catalogs, brochures, illustrations or other data sheets are submitted in lieu of prepared Shop Drawings, such submittals shall specifically indicate the item for which approval is requested. Identification of items shall be made in ink, and submittals showing only general information are not acceptable. City of Denton Hazen and Sawyer BID SET 01300-4 Submittals 8. Layout and Installation Drawings a. Contractor shall prepare and submit for review by the Engineer layout and installation drawings for all pipes, valves, fittings, sewers, drains, heating and ventilation ducts, all electrical, heating, ventilating and other conduits, plumbing lines, electrical cable trays, lighting fixture layouts, and circuiting, instrumentation, interconnection wiring diagrams, communications, power supply, alarm circuits, etc., under this Contract. The final dimensions, elevation, location, etc., of pipe, valves, fittings, sewers, ducts, conduits, electrical cable trays, equipment, etc., may depend upon the dimensions of equipment and valves to be furnished by the Contractor. b. Layout and installation drawings are required for both interior and exterior piping, valves, fittings, sewers, drains, heating and ventilation ducts, conduits, plumbing lines, electrical cable trays, etc. c. Layout and installation Drawings shall show connections to structures, equipment, sleeves, valves, fittings, etc. d. Drawings shall show the location and type of all supports, hangers, foundations, etc., and the required clearances to operate valves, equipment, etc. e. The Drawings for pipes, ducts, conduits, etc., shall show all 3-inch and larger electrical conduits and pressure piping, electrical cable trays, heating and ventilation ducts or pipes, structure, manholes or any other feature within four (4) feet (measured as the clear dimension) from the pipe duct, conduit, etc., for which the profile is drawn. 9. Contractor Responsibilities a. All submittals from subcontractors, manufacturers or suppliers shall be sent directly to the Contractor for checking. Contractor shall thoroughly check all Drawings for accuracy and conformance to the intent of the Contract Documents. Drawings found to be inaccurate or otherwise in error shall be returned to the subcontractors, manufacturers, or suppliers by the Contractor for correction before submitting them to the Engineer. b. All submittals shall be bound, dated, properly labeled and consecutively numbered. Information on the label shall indicate Specification Section, Drawing number, subcontractor's, manufacturer's or supplier's name and the name or type of item the submittal covers. Each part of a submittal shall be marked and tabulated. c. Working Drawings shall be submitted as a single complete package including all associated drawings relating to a complete assembly of the various parts necessary for a complete unit or system. City of Denton Hazen and Sawyer BID SET 01300-5 Submittals d. Shop Drawings shall be submitted as a single complete package for any operating system and shall include all items of equipment and any mechanical units involved or necessary for the functioning of such system. Where applicable, the submittal shall include elementary wiring diagrams showing circuit functioning and necessary interconnection wiring diagrams for construction. e. ALL SUBMITTALS SHALL BE THOROUGHLY CHECKED BY THE CONTRACTOR FOR ACCURACY AND CONFORMANCE TO THE INTENT OF THE CONTRACT DOCUMENTS BEFORE BEING SUBMITTED TO THE ENGINEER AND SHALL BEAR THE CONTRACTOR'S STAMP OF APPROVAL CERTIFYING THAT THEY HAVE BEEN SO CHECKED. SUBMITTALS WITHOUT THE CONTRACTOR'S STAMP OF APPROVAL WILL NOT BE REVIEWED BY THE ENGINEER AND WILL BE RETURNED TO THE CONTRACTOR. f. If the submittals contain any departures from the Contract Documents, specific mention thereof shall be made in the Contractor's letter of transmittal. Otherwise, the review of such submittals shall not constitute approval of the departure. g. No materials or equipment shall be ordered, fabricated, shipped or any work performed until the Engineer returns to the Contractor the submittals, herein required, annotated "Furnish as Submitted", "Furnish as Corrected", or “Furnish as Corrected – Confirm.” If a submittal is returned “Furnish as Corrected – Confirm” the portions of work covered by the submittal that require confirmation by the Engineer shall not be ordered, fabricated, shipped, or any work performed until those portions are approved in a subsequent submittal either "Furnish as Submitted" or "Furnish as Corrected". h. Where errors, deviations, and/or omissions are discovered at a later date in any of the submittals, the Engineer's prior review of the submittals does not relieve the Contractor of the responsibility for correcting all errors, deviations, and/or omissions. 10. Procedure for Review a. Submittals shall be transmitted in sufficient time to allow the Engineer at least thirty (30) working days for review and processing. b. Contractor shall transmit one electronic copy in PDF format and three (3) hard copies of all technical data or drawing to be reviewed. c. Submittal shall be accompanied by a letter of transmittal containing date, project title, Contractor's name, number and titles of submittals, a list of relevant specification sections, notification of departures from any Contract requirement, and any other pertinent data to facilitate review. City of Denton Hazen and Sawyer BID SET 01300-6 Submittals d. Submittals will be annotated by the Engineer in one of the following ways: "Furnish as Submitted" (FAS) - no exceptions are taken "Furnish as Corrected" (FAC) - minor corrections are noted and shall be made. “Furnish as Corrected – Confirm” (FACC) - some corrections are noted and a partial resubmittal or additional information are required as specifically requested. "Revise and Resubmit" (R&R) - major corrections are noted and a full resubmittal is required. "For Information Only – Not Reviewed” (FIO) – submittal was received and was distributed for record purposes without review. e. If a submittal is satisfactory to the Engineer in full or in part, the Engineer will annotate the submittal "Furnish as Submitted", "Furnish as Corrected", or “Furnish as Corrected – Confirm”, retain two (2) copies and return remaining copies to the Contractor. If reproducible transparencies are submitted, the Engineer will retain the copies and return the reproducible transparencies to the Contractor. In the case of “Furnish as Corrected – Confirm” a partial resubmittal or additional information are required as specifically requested. f. If a full resubmittal is required, the Engineer will annotate the submittal "Revise and Resubmit" and transmit three (3) copies to the Contractor for appropriate action. If reproducible transparencies are submitted, the Engineer will retain the copies and return the reproducible transparencies to the Contractor. g. Contractor shall continue to resubmit submittals in part if they are returned “Furnish as Corrected – Confirm” or in full if they are returned “Revise and Resubmit” as required by the Engineer until submittals are acceptable to the Engineer. It is understood by the Contractor that Owner may charge the Contractor the Engineer's charges for review in the event a submittal is not approved (either "Furnish as Submitted" or "Furnish as Corrected") by the third submittal for a system or piece of equipment. These charges shall be for all costs associated with engineering review, meetings with the Contractor or manufacturer, etc., commencing with the fourth submittal of a system or type of equipment submitted for a particular Specification Section. h. Acceptance of a Working Drawing by the Engineer will constitute acceptance of the subject matter for which the Drawing was submitted and not for any other structure, material, equipment or appurtenances indicated or shown. 11. Engineer's Review a. Engineer's review of the Contractor's submittals shall in no way relieve the Contractor of any of his responsibilities under the Contract. An acceptance City of Denton Hazen and Sawyer BID SET 01300-7 Submittals of a submittal shall be interpreted to mean that the Engineer has no specific objections to the submitted material, subject to conformance with the Contract Drawings and Specifications. b. Engineer's review will be confined to general arrangement and compliance with the Contract Drawings and Specifications only, and will not be for the purpose of checking dimensions, weights, clearances, fittings, tolerances, interferences, coordination of trades, etc. 12. Record Working Drawings a. Contractor shall maintain current record drawings onsite for the Engineer’s review. Record drawings shall be updated monthly at a minimum. b. Prior to final payment, the Contractor shall furnish the Engineer one complete set of all accepted Working Drawings, including Shop Drawings, for equipment, piping, electrical work, heating system, ventilating system, air conditioning system, instrumentation system, plumbing system, structural, interconnection wiring diagrams, etc. c. Working Drawings furnished shall be corrected to include any departures from previously accepted Drawings. D. Operation and Maintenance Manuals 1. One electronic copy in PDF format preliminary copy of Operation and Maintenance Manuals, prepared specifically for this Project, shall be furnished for each item of equipment furnished under this Contract. The preliminary manuals shall be provided to the Engineer not less than 60 days prior to the start-up of the respective equipment. 2. The preliminary manuals shall be reviewed by the Engineer prior to the Contractor submitting final copies for distribution to the Owner. Following review of the preliminary copies of the Operation and Maintenance Manuals, one (1) electronic copy in PDF format will be returned to the Contractor with required revisions noted, or the acceptance of the Engineer noted. 3. Manuals shall contain complete information in connection with assembly, operation, lubrication, adjustment, wiring diagrams and schematics, maintenance, and repair, including detailed parts lists with drawings or photographs identifying the parts. 4. Manuals furnished shall be assembled and bound in separate volumes, by major equipment items or trades, and properly indexed to facilitate locating any required information. In addition, manuals should be labeled in the front cover with the project, name, equipment description, and manufacturer contact information. 5. Engineer and the Owner shall be the sole judge of the acceptability and completeness of the manuals and may reject any submittal for insufficient information included, incorrect references and/or the manner in which the material is assembled. City of Denton Hazen and Sawyer BID SET 01300-8 Submittals 6. Following the Engineer’s review of the preliminary manuals, the Contractor shall submit four (4) paper copies and two (2) electronic copies of the final Operation and Maintenance Manuals to the Engineer. The manuals shall reflect the required revisions noted during the Engineer’s review of the preliminary documents. Failure of the final manuals to reflect the required revisions noted by the Engineer during a review of the Preliminary documents will result in the manuals being returned to the Contractor. Acceptable final Operation and Maintenance Manuals shall be provided not less than two week prior to equipment start-up. E. Certified Shop Test Reports 1. Each piece of equipment for which pressure, head, capacity, rating, efficiency, performance, function or special requirements are specified or implied shall be tested in the shop of the manufacturer in a manner which shall conclusively prove that its characteristics comply fully with the requirements of the Contract Documents and applicable test codes and standards. Contractor shall keep the Engineer advised of the scheduling of shop tests so that the Engineer may arrange for the witnessing or inspection at the proper time and place. 2. The Contractor shall secure from the manufacturers four (4) copies of the actual test data, the interpreted results and a complete description of the testing facilities and testing setup, all accompanied by a certificate of authenticity sworn to by a responsible official of the manufacturing company and notarized. These reports shall be forwarded to the Engineer for review. 3. In the event any equipment fails to meet the test requirements, the manufacturer shall make all necessary changes, adjustments or replacements and the tests shall be repeated, at no additional cost to the Owner or Engineer, until the equipment test requirements are acceptable to the Engineer. 4. No equipment shall be shipped to the Project until the Engineer notifies the Contractor, in writing, that the shop test reports are acceptable. F. Samples 1. Contractor shall furnish for review all samples as required by the Contract Documents or requested by the Engineer. 2. Samples shall be of sufficient size or quantity to clearly illustrate the quality, type, range of color, finish or texture and shall be properly labeled to show the nature of the material, trade name of manufacturer and location of the work where the material represented by the sample will be used. 3. Samples shall be checked by the Contractor for conformance to the Contract Documents before being submitted to the Engineer and shall bear the Contractor's stamp of approval certifying that they have been so checked. Transportation charges on samples submitted to the Engineer shall be prepaid by the Contractor. City of Denton Hazen and Sawyer BID SET 01300-9 Submittals 4. Engineer's review will be for compliance with the Contract Documents and his comments will be transmitted to the Contractor with reasonable promptness. 5. Accepted samples will establish the standards by which the completed work will be judged. G. Construction Photographs 1. The Contractor shall engage a competent photographer to take digital photographs at the locations and at such stages of the construction as directed by the Engineer. 2. Provide the equivalent of 20 different photographs per month for the duration of the Contract time. When directed by the Engineer, frequency of photographs may be increased to weekly sessions provided that the equivalent number of exposures is not exceeded. Engineer may waive requirements for photographs during inactive construction periods in favor of increased photographs during active construction sequences. PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION – City of Denton Hazen and Sawyer BID SET 01300-10 Submittals This page left blank intentionally City of Denton Hazen and Sawyer BID SET 01400-1 Quality Control SECTION 01400 QUALITY CONTROL PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Testing Laboratory Services 1. Laboratory testing and checking required by the Specifications, including the cost of transporting all samples and test specimens, shall be provided and paid for by the Owner unless otherwise indicated in the Specifications. 2. Materials to be tested include, but are not necessarily limited to the following: cement, concrete aggregate, concrete, bituminous paving materials, structural and reinforcing steel, waterproofing, select backfill, crushed stone or gravel and sand. 3. Tests required by the Owner shall not relieve the Contractor from the responsibility of supplying test results and certificates from manufacturers or suppliers to demonstrate conformance with the Specifications. 4. Procedure a. The Contractor shall plan and conduct his operations to permit taking of field samples and test specimens, as required, and to allow adequate time for laboratory tests. b. The collection, field preparation and storage of field samples and test specimens shall be as directed by the Engineer with the cooperation of the Contractor. 5. Significance of Tests a. Test results shall be binding on both the Contractor and the Owner, and shall be considered irrefutable evidence of compliance or noncompliance with the Specification requirements, unless supplementary testing shall prove, to the satisfaction of the Owner, that the initial samples were not representative of actual conditions. 6. Supplementary and Other Testing a. Nothing shall restrict the Contractor from conducting tests he may require. Should the Contractor at any time request the Owner to consider such test results, the test reports shall be certified by an independent testing laboratory acceptable to the Owner. Testing of this nature shall be conducted at the Contractor's expense. City of Denton Hazen and Sawyer BID SET 01400-2 Quality Control 1.02 FIELD TESTING OF EQUIPMENT A. All equipment shall be set, aligned and assembled in conformance with the manufacturer's drawings and instructions. B. Preliminary Field Tests 1. As soon as conditions permit, after the equipment has been secured in its permanent position, the Contractor shall check the equipment for alignment, direction of rotation and that it is free from defects. 2. Contractor shall flush all bearings, gear housings, etc., in accordance with the manufacturer's recommendations, to remove any foreign matter accumulated during shipment, storage or erection. Lubricants shall be added as required by the manufacturer's instructions. 3. Preliminary field tests must be completed before equipment is subjected to final field tests. C. Final Field Tests 1. Upon completion of the installation, and at a time approved by the Engineer, equipment will be tested by operating it as a unit with all related piping, ducting, electrical controls and mechanical operations. 2. The equipment will be placed in continuous operation as prescribed or required and witnessed by the Engineer or his assigned representative and the Owner or his assigned representative. 3. The tests shall prove that the equipment and appurtenances are properly installed, meet their operating cycles and are free from defects such as overheating, overloading, and undue vibration and noise. Equipment shall be tested for the characteristics as specified for the item. 4. Each pump shall be tested at maximum rated speed for at least four points on the pump curve for capacity, head and electric power input. The rated motor nameplate current and power shall not be exceeded at any point within the specified range. Vibrometer readings shall be taken when directed by the Engineer and the results recorded. Additional tests shall be performed as prescribed in other sections of the Specifications. 5. Pumps with drive motors rated at less than five horsepower shall only be tested for excess current or power when overheating or other malfunction becomes evident in general testing. 6. Until final field tests are acceptable to the Engineer, the Contractor shall make all necessary changes, readjustments and replacements at no additional cost to the Owner. City of Denton Hazen and Sawyer BID SET 01400-3 Quality Control 7. Defects which cannot be corrected by installation adjustments will be sufficient grounds for rejection of any equipment. 8. All costs in connection with such tests including all materials, equipment, instruments, labor, etc., shall be borne by the Contractor. 1.03 IMPERFECT WORK, EQUIPMENT, OR MATERIALS A. Any defective or imperfect work, equipment, or materials furnished by the Contractor which is discovered before the final acceptance of the work, as established by the Certificate of Substantial Completion, or during the subsequent guarantee period, shall be removed immediately even though it may have been overlooked by the Engineer and estimated for payment. Any equipment or materials condemned or rejected by the Engineer shall be tagged as such and shall be immediately removed from the site. Satisfactory work or materials shall be substituted for that rejected. B. The Engineer may order tests of imperfect or damaged work, equipment, or materials to determine the required functional capability for possible acceptance, if there is no other reason for rejection. The cost of such tests shall be borne by the Contractor; and the nature, tester, extent and supervision of the tests will be as determined by the Engineer. If the results of the tests indicate that the required functional capability of the work, equipment, or material was not impaired, consistent with the final general appearance of same, the work, equipment, or materials may be deemed acceptable. If the results of such tests reveal that the required functional capability of the questionable work, equipment, or materials has been impaired, then such work, equipment, or materials shall be deemed imperfect and shall be replaced. The Contractor may elect to replace the imperfect work, equipment, or material in lieu of performing the tests. 1.04 INSPECTION AND TESTS A. The Contractor shall allow the Engineer ample time and opportunity for testing materials and equipment to be used in the work. He shall advise the Engineer promptly upon placing orders for material and equipment so that arrangements may be made, if desired, for inspection before shipment from the place of manufacture. The Contractor shall at all times furnish the Engineer and his representatives, facilities including labor, and allow proper time for inspecting and testing materials, equipment, and workmanship. The Contractor must anticipate possible delays that may be caused in the execution of his work due to the necessity of materials and equipment being inspected and accepted for use. The Contractor shall furnish, at his own expense, all samples of materials required by the Engineer for testing, and shall make his own arrangements for providing water, electric power, or fuel for the various inspections and tests of structures and equipment. B. The Contractor shall furnish the services of representatives of the manufacturers of certain equipment, as prescribed in other Sections of the Specifications. The Contractor shall also place his orders for such equipment on the basis that, after the equipment has been tested prior to final acceptance of the work, the manufacturer will furnish the Owner with certified statements that the equipment has been installed properly and is ready to be placed in functional operation. Tests and analyses required of equipment shall be paid for by the Contractor, unless specified otherwise in the Section which covers a particular piece of equipment. City of Denton Hazen and Sawyer BID SET 01400-4 Quality Control C. Where other tests or analyses are specifically required in other Sections of these Specifications, the cost thereof shall be borne by the party (Owner or Contractor) so designated in such Sections. The Owner will bear the cost of all tests, inspections, or investigations undertaken by the order of the Engineer for the purpose of determining conformance with the Contract Documents if such tests, inspection, or investigations are not specifically required by the Contract Documents, and if conformance is ascertained thereby. Whenever nonconformance is determined by the Engineer as a result of such tests, inspections, or investigations, the Contractor shall bear the full cost thereof or shall reimburse the Owner for said cost. In this connection, the cost of any additional tests and investigations, which are ordered by the Engineer to ascertain subsequent conformance with the Contract Documents, shall be borne by the Contractor. PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION - City of Denton Hazen and Sawyer BID SET 01470-1 Watertightness Testing of Concrete Structures SECTION 01470 WATERTIGHTNESS TESTING OF CONCRETE STRUCTURES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. It is the intent of these Specifications that all concrete work and sealing work around built-in items and penetrations be performed as required to insure that groundwater, surface water, and water or liquids in tanks, channels and containers will not intrude into any equipment rooms, pipe galleries, habitable areas or other generally dry areas. B. The required watertightness shall be achieved by quality concrete construction and proper sealing of all joints and penetrations. C. Each unit shall be tested separately and the leakage tests shall be made prior to backfilling and before equipment is installed. Testing water shall be from any potable, non-potable, or natural moving source such as a river or stream, but not from any still water source such as a lake or pond, and not from any wastewater source. D. All water holding structures shall be tested for leakage by the Contractor. The Contractor shall provide at his own expense all labor, material, temporary bulkheads, pumps, water measuring devices, etc., necessary to perform the required tests. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 01400 – Quality Control B. Section 03300 – Cast-in-Place Concrete 1.03 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. ACI 350.1-10 - Specification for Tightness Testing of Environmental Engineering Concrete Structures 1.04 SUBMITTALS A. Testing procedures shall be submitted for approval prior to the test. B. Testing Report: Prior to placing the structure in service, submit for review and approval a detailed bound report summarizing the watertightness test data, describing the testing procedure and showing the calculations on which the test data is based. City of Denton Hazen and Sawyer BID SET 01470-2 Watertightness Testing of Concrete Structures PART 2 – PRODUCTS (NOT USED) PART 3 – EXECUTION 3.01 TEST PREPARATION A. The design capability of the structure to withstand testing shall be verified for the pressures to be applied. Another type of test shall not be substituted for hydrostatic tightness testing without approval of the Engineer. B. The structure shall not be tested before all elements of the structure which resist any portion of the retained liquid pressure are in place and the concrete has attained its specified compressive strength. C. Unless otherwise specified, coatings shall not be applied until after the hydrostatic tightness testing is complete. Liners that are mechanically locked to the surface during the placement of the concrete shall be installed before the hydrostatic tightness testing. Interior liners shall be visually examined for deficiencies (pinholes, tears and partially fused splices) and must pass integrity testing. Deficiencies shall be prepared. D. Clean the exposed concrete surfaces of the structure, including the floor, of all foreign material and debris. Prior to testing, standing water in or outside of the structure that would interfere with the inspection of the exposed concrete surfaces of the structure shall be removed. E. The concrete surfaces and concrete joints shall be thoroughly inspected for potential leakage points. Areas of potential leakage shall be repaired before filling the containment structure with water. F. All openings, fittings, and pipe penetrations in the structure shell shall be inspected at both faces of the concrete, if practical. Defective or cracked concrete shall be repaired prior to testing. All structural penetrations and inlet/outlets shall be securely sealed to prevent the loss of water from the structure during the test. All structural penetrations shall be monitored before and during the test to determine the watertightness of these appurtenances. If the structure is to be filled using the inlet/outlet pipe, positive means shall be provided to check that water is not entering or leaving through this pipe once the structure is filled to the test level. Leakage at these inlet/outlets shall be repaired prior to testing. No allowance shall be made in test measurements for uncorrected known points of leakage G. The flow from any underdrain system, if a system is provided, shall be monitored during this same period, and any increase in flow shall be recorded and considered for information as a part of the hydrostatic tightness testing. H. The ground water level shall be brought to a level below the top of the base slab and kept at that elevation or at a lower elevation during the test. I. No backfill shall be placed against the walls or on the wall footings of the structure to be tested unless otherwise specified. City of Denton Hazen and Sawyer BID SET 01470-3 Watertightness Testing of Concrete Structures 3.02 PROCEDURE A. The initial filling of a new structure should not exceed a rate of 4 ft/h. Filling shall be continued until the water surface is at the design maximum liquid level, or either 1 in. below any fixed overflow level in covered containment structure or 4 in. in open structure, whichever is lower. B. The exterior surfaces of the structure shall be inspected during the period of filling the structure. If any flow of water is observed from the structure exterior surfaces, including joints or cracks, the defect causing the leakage shall be repaired prior to testing. C. Watertightness Test - Part 1: Qualitative Criteria 1. The water shall be kept at the test level for at least 3 days prior to Part 2 of the testing. 2. The exterior surfaces of the structure shall be observed in both the early mornings and later afternoons during the 3-day period before Part 2 of the test. If any water is observed on the structure exterior surfaces, including joints, repaired honeycombed areas and cracks, where moisture can be picked up on a dry hand, the containment structure shall be considered to have failed Part 1 of the test. 3. Wet areas on top of wall footing shall not be cause to fail Part 1 of the test unless the water can be observed to be flowing. 4. Part 2 of the test may begin prior to completion of repairs for Part 1. However, all defects causing the failure of Part 1 shall be repaired before the structure is accepted. D. Watertightness Test - Part 2: Quantitative Criteria 1. The test measurements shall not be scheduled for a period when the forecast is for a difference of more than 35°F between the ambient temperature readings at the times of the initial and final level measurements of the water surface. The test shall also not be scheduled when the weather forecast indicates the water surface would be frozen before the test is completed. 2. The vertical distance to the water surface shall be measured to within 1/16 in. from a fixed point on the structure above the water surface. Measurements shall be recorded at 24-hour intervals. Measurements taken at the same time of day will reduce the probability of temperature difference. 3. Measurements shall be taken at two locations, 180° apart, which will minimize the effect of differential settlement. Measurements shall be taken at the same locations to reduce the probability of measurement differences. 4. The test period shall be at least the theoretical time required to lower the water surface 3/8 in. assuming a loss of water at 0.050% of the water volume per 24-hour period. The test period shall not be longer than five days. City of Denton Hazen and Sawyer BID SET 01470-4 Watertightness Testing of Concrete Structures 5. The water temperature shall be recorded at a depth of 18 in. below the water surface at the start and end of the test. 6. A floating, restrained, partially filled, calibrated, open container for evaporation and precipitation measurement should be positioned in open structures and the water level in the container recorded at 24-hour intervals. Determination of evaporation by a shallow pan-type measuring device is not acceptable due to possible heating of the bottom of the shallow pan resulting in accelerated evaporation. 3.03 EVALUATION A. The containment structure shall continue to be observed in both the early mornings and late afternoons to verify compliance with Part 1 of the test during Part 2. B. At the end of the test period, the water surface shall be recorded to within 1/16-in at the location of original measurements. The water temperature and the evaporation and precipitation measurements shall be recorded. C. The allowable loss of water for tightness tests shall not exceed 0.050% of the test water volume in 24 hours. D. The change in water volume in the structure shall be calculated and corrected, if necessary, for evaporation, precipitation, and temperature based on the change recorded in the water level from the open container. If the loss exceeds the allowable loss, the structure shall be considered to have failed the test. E. During Part 2 of the test, observed flow or seepage of water from the exterior surface, including that from cracks and joints, should be considered as a failed test. The structure shall also be considered to have failed the test if moisture can be transferred from the exterior surface to a dry hand. Dampness or wetness on top of a footing shall not be considered as a failure test. 3.04 RETESTING A. A restart of the test shall be required when test measurements become unreliable due to unusual precipitation or other external factors. B. The Contractor shall be permitted to immediately retest when no visible leakage is exhibited. If the structure fails the second test or if the Contractor does not exercise the option of immediately retesting after the first test failure, the interior of the structure shall be inspected by a diver or by other means to determine probable areas of leakage. The structure shall only be retested after the most probable areas of leakage are repaired. C. If the leakage exceeds the allowable limit, the work shall be corrected by methods approved by the Engineer. D. Upon completion of the necessary remedial work, the leakage test shall be repeated until it is successfully passed. City of Denton Hazen and Sawyer BID SET 01470-5 Watertightness Testing of Concrete Structures 3.05 NOTIFICATION BY ENGINEER A. If any leaks, in excess of the specified amount, are not remedied by the Contractor within four (4) weeks of notification by the Engineer, regardless of whether the cause of these leaks is or is not determined, the Engineer shall have the authority to have these leaks repaired by others. The cost of repairs, by others, shall be deducted from monies due or to become due to the Contractor. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 01470-6 Watertightness Testing of Concrete Structures This page left blank intentionally City of Denton Hazen and Sawyer BID SET 01510-1 Temporary Utilities SECTION 01510 TEMPORARY UTILITIES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall provide temporary light and power, heating, water service and sanitary facilities for his operations. The temporary services shall be provided for use throughout the construction period. B. The Contractor shall coordinate and install all temporary services in accordance with the requirements of the utility companies having jurisdiction and as required by applicable codes and regulations. C. At the completion of the work, or when the temporary services are no longer required, the facilities shall be restored to their original conditions. D. All costs in connection with the temporary services including, but not limited to, installation, utility company service charges, maintenance, relocation and removal shall be borne by the Contractor at no additional cost to the Owner. E. Some temporary facilities that may be required may be indicated on the Drawings; however, the Drawings do not necessarily show any or all of the temporary facilities that the Contractor ultimately uses to complete the Work. F. Temporary Light and Power 1. The temporary general lighting and small power requirements shall be serviced by 120/240 V, 1 phase, 3 wire temporary systems furnished and installed by the Contractor. This service shall be furnished complete with main disconnect, overcurrent protection, meter outlet, branch circuit breakers, and wiring as required; including branch circuit breakers and wiring as required for furnishing temporary power to the Contractor's field office service connections, all in accordance with the requirements of the servicing power company and applicable standards and codes. The meter for the temporary 120/240 V service for construction purposes shall be registered in the name of the Contractor and all energy charges for furnishing this temporary electric power shall be borne by the Contractor. Contractor with a need for power other than the 120/240 V, 1 phase, 3 wire shall provide such power at his own expense. 2. The Contractor shall make all necessary arrangements, and pay for all permits, inspections, and power company charges for all temporary service installations. All temporary systems shall comply with and meet the approval of the local authorities having jurisdiction. All temporary electrical systems shall consist of wiring, switches, necessary insulated supports, poles, fixtures, sockets, receptacles, lamps, guards, cutouts, and fuses as required to complete such installations. The Contractor shall City of Denton Hazen and Sawyer BID SET 01510-2 Temporary Utilities furnish lamps and fuses for all temporary systems furnished by him and shall replace broken and burned out lamps, blown fuses, damaged wiring and as required to maintain these systems in adequate and safe operating condition. All such temporary light and power system shall be installed without interfering with the work of the other Contractors. 3. When it is necessary during the progress of construction that a temporary electrical facility installed under this Division interferes with construction operations, the Contractor shall relocate the temporary electrical facilities to maintain temporary power as required at no additional cost to the Owner. The Contractor shall be responsible at all times for any damage or injury to equipment, materials, or personnel caused by improperly protected or installed temporary installations and equipment. 4. The Contractor shall keep the temporary general lighting and power systems energized fifteen minutes before the time that the earliest trade starts in the morning and de-energized fifteen minutes after the time the latest trade stops. This applies to all weekdays, Monday through Friday, inclusive, which are established as regular working days. 5. Any work requiring temporary light and power before or after the hours set forth hereinbefore, or on a Saturday, Sunday, or holiday, shall pay for the additional cost of keeping the system energized and repaired. 6. The temporary general lighting system shall be installed progressively in structures as the various areas are enclosed or as lighting becomes necessary because of partial enclosure. Lighting intensities shall be not less than 10 foot candles. 7. The Contractor shall provide a separate temporary night lighting circuit for construction security. This system shall be energized at the end of each normal working day and de-energized at the start of each normal working day by the Contractor. The system is to be left energized over Saturdays, Sundays, and all holidays. Lighting intensities shall be not less than 2 foot candles. 8. Electrical welders provided by each trade used in the erection and fabrication of the buildings, structures and equipment shall be provided with an independent grounding cable connected directly to the structure on which the weld is being made rather than adjacent conduit piping, etc. Electricians and other tradesmen necessary for the required connections and operation of welding equipment and generator, standby generators and similar equipment shall be furnished by the Contractor. All costs for such labor and equipment shall be borne by the Contractor. 9. Upon completion of the work, but prior to acceptance by the Owner, the Contractor shall remove all temporary services, security lighting systems, temporary general lighting systems and all temporary electrical work from the premises. City of Denton Hazen and Sawyer BID SET 01510-3 Temporary Utilities G. Temporary Heating 1. The Contractor shall provide temporary heating, ventilation coverings and enclosures necessary to properly protect all work and materials against damage by dampness and cold, to dry out the work and to facilitate work in all structures. 2. The equipment, fuel, materials, operating personnel and methods used shall be at all times satisfactory and adequate to maintain critical installation temperatures and ventilation for all work in those areas where the same is required. 3. After any structure is enclosed, the minimum temperature to be maintained is 50°F, unless otherwise specified, where work is actually being performed. 4. Before and during the application of interior finishing, painting, etc., the Contractor shall provide sufficient heat to maintain a temperature of not less than 65°F. 5. Any work damaged by dampness or insufficient or abnormal heating shall be replaced by the Contractor at no additional cost to the Owner. H. Temporary Sanitary Service 1. Sanitary conveniences, in sufficient numbers, for the use of all persons employed on the work and properly screened from public observation, shall be provided and maintained at suitable locations by the Contractor, all as prescribed by State Labor Regulations and local ordinances. The contents of same shall be removed and disposed of in a manner consistent with local and state regulations, as the occasion requires. Contractor shall rigorously prohibit the committing of nuisances within, on, or about the work. Sanitary facilities shall be removed from the site when no longer required. I. Temporary Water 1. The Contractor shall provide temporary water service for construction purposes, sanitary facilities, fire protection, field offices and for cleaning. The Contractor shall make all arrangements for connections to the potable water at the plant site. The Contractor shall pay all charges associated with the connection and all charges for potable water used under this Contract. 2. Each Contractor shall supply potable water for his employees either by portable containers or drinking fountains. 3. An adequate number of hose bibbs, hoses, and watertight barrels shall be provided for the distribution of water. 4. Water service shall be protected from freezing and the service shall be extended and relocated as necessary to meet temporary water requirements. City of Denton Hazen and Sawyer BID SET 01510-4 Temporary Utilities PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION - City of Denton Hazen and Sawyer BID SET 01520-1 Maintenance of Utility Operations SECTION 01520 MAINTENANCE OF UTILITY OPERATIONS DURING CONSTRUCTION PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Pecan Creek Water Reclamation Plant and collection system will be maintained in continuous operation by the Owner during the entire construction period of all Contracts as hereinafter specified. The intent of this section is to outline the minimum requirements necessary to allow the Owner to continuously operate and maintain the treatment facility and collection system in order to remain in compliance with all permit requirements. B. Work under each Contract shall be scheduled and conducted by each Contractor so as not to impede any treatment process, reduce the quality of the plant effluent or cause odor or other nuisance except as explicitly permitted hereinafter. In performing the work shown and specified, the Contractor shall plan and schedule his work to meet the plant and collection system operating requirements, and the constraints and construction requirements as outlined in this Section. No discharge of raw or inadequately treated wastewater shall be allowed. The Contractor shall pay all civil penalties, costs, assessments, etc., associated with any discharge of raw or inadequately treated wastewater associated with the Contractor's work. C. The Contractor shall be responsible for coordinating the general construction and electrical, HVAC and plumbing construction schedules and for ensuring that permanent or temporary power is available for all existing, proposed, and temporary facilities that are required to be on line at any given time. D. The Contractor has the option of providing additional temporary facilities that can eliminate a constraint, provided it is done without cost to the Owner and provided that all requirements of these Specifications are fulfilled. The Contractor shall submit any such plan for providing additional temporary facilities to eliminate a constraint to the PM for review. Such plans must be approved by the Engineer and Owner prior to the Contractor proceeding. Work not specifically covered in the following paragraphs may, in general, be done at any time during the contract period, subject to the operating requirements and constraints and construction requirements outlined hereinafter. All references to days in this Section shall be consecutive calendar days. 1.02 GENERAL CONSTRAINTS A. The Contractor shall schedule the Work so that the plant is maintained in continuous operation. All treatment processes shall be maintained in continuous operation during the construction period except during approved process interruptions. All short-term system or partial systems shutdowns and diversions shall be approved by the Engineer. Long-term process shutdowns and diversions shall conform to the requirements hereinafter specified and shall be minimized by the Contractor as much as possible. If in the judgement of the Engineer a requested shutdown is not required for the Contractor to perform the Work, the City of Denton Hazen and Sawyer BID SET 01520-2 Maintenance of Utility Operations Contractor shall utilize approved alternative methods to accomplish the Work. All shutdowns shall be coordinated with and scheduled at times suitable to the Owner. Shutdowns shall not begin until all required materials are on hand and ready for installation. Each shutdown period shall commence at a time approved by the Owner, and the Contractor shall proceed with the Work continuously, start to finish, until the Work is completed and normal plant operation is restored. If the Contractor completes all required Work before the specified shutdown period has ended, the Owner may immediately place the existing system back into service. B. The Contractor shall schedule short-term and long-term shutdowns in advance and shall present all desired shutdowns in the 30 and 60-day schedules at the progress meetings (see Section 01200). Shutdowns shall be fully coordinated with the Plant Superintendent at least 96 hours before the scheduled shutdown. Owner personnel shall operate Owner's facilities involved in the short-term and long-term shutdowns and diversions. C. Short term shutdowns in plant flow will be allowed for tie-ins to existing facilities, installation of temporary bulkheads, etc. All such shutdowns shall be scheduled for week-end low-flow periods and shall be limited to less than two (2) hours depending on incoming flow rate and storage volume in the collection and treatment system. Any shutdown of two (2) hours or longer duration shall be defined as a long-term shutdown. The Contractor shall provide appropriate diversion facilities to be approved by the Owner, and at no additional cost to the Owner, when the plant cannot be shut down for a sufficient long time to accomplish the required work. The Contractor may be allowed additional time for short-term interruptions if he can demonstrate to the Owner and Engineer that the collection system will not surcharge or overflow during the requested shutdown period. Duration of short-term interruptions allowed will depend on incoming wastewater flow rate and prevention of any discharge of raw wastewater from the collection system. The schedule and duration of short-term shutdowns shall be at the discretion of the Owner. D. Any temporary work, facilities, roads, walks, protection of existing structures, piping, blind flanges, valves, equipment, etc. that may be required within the Contractor's work limits to maintain continuous and dependable plant operation shall be furnished by the Contractor at the direction of the Engineer at no extra cost to the Owner. E. The Owner shall have the authority to order Work stopped or prohibited that would, in his opinion, unreasonably result in interrupting the necessary functions of the plant operations. F. If the contractor impairs performance or operation of the plant as a result of not complying with specified provisions for maintaining plant operations, then the contractor shall immediately make all repairs or replacements and do all work necessary to restore the plant to operation to the satisfaction of the Engineer. Such work shall progress continuously to completion on a 24-hours per day, seven work days per week basis. G. The Contractor shall provide the services of emergency repair crews on call 24-hours per day to affect repairs to portions of the plant affected by the Contractor’s operations. City of Denton Hazen and Sawyer BID SET 01520-3 Maintenance of Utility Operations 1.03 GENERAL OPERATING REQUIREMENTS, CONSTRAINTS, AND CONSTRUCTION REQUIREMENTS A. Access to Plant Site, Roadways, and Parking Areas 1. An unobstructed traffic route through the Main Gate shall be maintained at all times for the Owner's operations personnel and maintenance equipment. Parking for personal vehicles of construction personnel shall not be allowed within the fence of the treatment plant. Construction personnel shall park on City property inside the Contractor’s designated lay down area; parking outside this area requires approval by the Owner. The Contractor shall be responsible for providing access to and for preparing and maintaining/approved parking areas. 2. An unobstructed traffic route around the plant site shall be maintained at all times for the Owner's operations personnel and maintenance equipment. Vehicular access to the treatment units and buildings for Owner personnel shall be maintained at all times by the Contractor. 3. The Contractor shall provide temporary measures to protect the existing pavement by filling over with earthen material or supplying other measures acceptable to the Engineer, and he shall repair any damage to existing paved surfaces that occurs during the construction period. Any areas disturbed along the shoulders of the access road and interior roads and elsewhere inside and outside of the plant shall be repaired, graded, seeded, etc. as necessary to match pre-existing conditions. 4. The Contractor shall not undertake the restoration/construction of new roadway (paved, gravel, or asphalt overlay) shown on the Contract Drawings, until all other work on the plant improvements has been completed. 5. It shall be the responsibility of the Contractor to obtain any permits required from the T.X. Department of Transportation and pay all associated fees. B. Personnel Access 1. Treatment plant personnel shall have access to all areas which remain in operation throughout the construction period. The Contractor shall locate stored material, dispose of construction debris and trash, provide temporary walkways, provide temporary lighting, and other such work as directed by the Engineer to maintain personnel access to areas in operation. Access and adequate parking areas for plant personnel must be maintained throughout construction. C. Plumbing Facilities 1. Unless otherwise allowed by the Engineer, sanitary facilities in the existing structures shall be operational at all times for plant operating personnel. All other building plumbing systems such as roof and floor drains, pumping, etc., shall be maintained for all structures. City of Denton Hazen and Sawyer BID SET 01520-4 Maintenance of Utility Operations D. Power, Light and Communications Systems (General) 1. Electric power, lighting service and communications systems shall be maintained in uninterrupted operation in all areas which remain in operation. Individual units may be disconnected as required for replacement, but service shall be available at all times including periods when plant elements are out of service. Shutdown of electrical facilities shall be limited to not more than five (5) hours. The Owner may allow longer outages under conditions determined by the Owner by making use of the existing and/or the proposed engine-generator at the plant. All costs associated with operation of the engine-generators shall be paid by the Contractor. The Electrical Contractor shall coordinate shutdowns required with the Contractor to minimize the total number of shutdowns required to complete construction. Owner's phone service to the plant shall be maintained in continuous operation during construction. E. Draining Process Pipes and Conduits (General) 1. The contents of all pipes and conduits to be removed, replaced or relocated (or dewatered for a specific purpose) shall be transferred to a suitable facility in a manner approved by the Owner through hoses or piping, or by using pumps if hydraulic conditions so require them. The Contractor shall provide the pumps, piping and hoses at no additional cost to the Owner. No uncontrolled spillage of a pipe or conduit shall be permitted. Any spillage, other than potable water, shall be immediately washed down and flushed into the appropriate process flow train. F. Potable Water System 1. Potable water service shall be maintained in continuous service at all times during construction except for short term interruptions required for tie-ins. Shutdown of the potable water system shall be fully planned and coordinated with the Plant Superintendent and shall be limited to not more than two (2) hours. Existing fire hydrants within the plant site shall be operational at all times, unless otherwise approved by the Owner. G. Sump Pumps and Sumps 1. All existing sumps shall be maintained in an operable condition with either existing pumps or temporary pumps. Interim piping, power and controls shall be provided as required by the staged construction sequence. 1.04 SPECIFIC OPERATIONAL CONSTRAINTS A. The Contractor shall schedule the work for the following based on the constraints given in such a manner as to maintain the wastewater treatment plant and collection system in continuous operation. 1. All existing collection system interceptors shall remain in service throughout the duration of the Work. City of Denton Hazen and Sawyer BID SET 01520-5 Maintenance of Utility Operations PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION – City of Denton Hazen and Sawyer BID SET 01520-6 Maintenance of Utility Operations This page left blank intentionally City of Denton Hazen and Sawyer BID SET 01530-1 Protection of Existing Facilities SECTION 01530 PROTECTION OF EXISTING FACILITIES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Contractor shall be responsible for the preservation and protection of property adjacent to the work site against damage or injury as a result of his operations under this Contract. Any damage or injury occurring on account of any act, omission or neglect on the part of the Contractor shall be restored in a proper and satisfactory manner or replaced by and at the expense of the Contractor to an equal or superior condition than previously existed. B. Contractor shall comply promptly with such safety regulations as may be prescribed by the Owner or the local authorities having jurisdiction and shall, when so directed, properly correct any unsafe conditions created by, or unsafe practices on the part of, his employees. In the event of the Contractor's failure to comply, the Owner may take the necessary measures to correct the conditions or practices complained of, and all costs thereof will be deducted from any monies due the Contractor. Failure of the Engineer to direct the correction of unsafe conditions or practices shall not relieve the Contractor of his responsibility hereunder. C. In the event of any claims for damage or alleged damage to property as a result of work under this Contract, the Contractor shall be responsible for all costs in connection with the settlement of or defense against such claims. Prior to commencement of work in the vicinity of property adjacent to the work site, the Contractor, at his own expense, shall take such surveys as may be necessary to establish the existing condition of the property. Before final payment can be made, the Contractor shall furnish satisfactory evidence that all claims for damage have been legally settled or sufficient funds to cover such claims have been placed in escrow, or that an adequate bond to cover such claims has been obtained. 1.02 PROTECTION OF WORK AND MATERIAL A. During the progress of the work and up to the date of final payment, the Contractor shall be solely responsible for the care and protection of all work and materials covered by the Contract. B. All work and materials shall be protected against damage, injury or loss from any cause whatsoever, and the Contractor shall make good any such damage or loss at his own expense. Protection measures shall be subject to the approval of the Engineer. 1.03 BARRICADES, WARNING SIGNS AND LIGHTS A. The Contractor shall provide, erect and maintain as necessary, strong and suitable barricades, danger signs and warning lights along all roads accessible to the public, as required by the authority having jurisdiction, to insure safety to the public. All barricades and City of Denton Hazen and Sawyer BID SET 01530-2 Protection of Existing Facilities obstructions along public roads shall be illuminated at night and all lights for this purpose shall be kept burning from sunset to sunrise. B. The Contractor shall provide and maintain such other warning signs and barricades in areas of and around their respective work as may be required for the safety of all those employed in the work, the Owner's operating personnel, or those visiting the site. 1.04 EXISTING UTILITIES AND STRUCTURES A. The term existing utilities shall be deemed to refer to both publicly-owned and privately-owned utilities such as electric power and lighting, telephone, water, gas, storm drains, process lines, sanitary sewers and all appurtenant structures. B. Where existing utilities and structures are indicated on the Drawings, it shall be understood that all of the existing utilities and structures affecting the work may not be shown and that the locations of those shown are approximate only. It shall be the responsibility of the Contractor to ascertain the actual extent and exact location of existing utilities and structures. In every instance, the Contractor shall notify the proper authority having jurisdiction and obtain all necessary directions and approvals before performing any work in the vicinity of existing utilities. C. Prior to beginning any excavation work, the Contractor shall, through field investigations, determine any conflicts or interferences between existing utilities and new utilities to be constructed under this project. This determination shall be based on the actual locations, elevations, slopes, etc., of existing utilities as determined in the field investigations, and locations, elevation, slope, etc. of new utilities as shown on the Drawings. If an interference exists, the Contractor shall bring it to the attention of the Engineer as soon as possible. If the Engineer agrees that an interference exists, he shall modify the design as required. Additional costs to the Contractor for this change shall be processed through a Change Order as detailed elsewhere in these Contract Documents. In the event the Contractor fails to bring a potential conflict or interference to the attention of the Engineer prior to beginning excavation work, any actual conflict or interference which does arise during the Project shall be corrected by the Contractor, as directed by the Engineer, at no additional expense to the Owner. D. The work shall be carried out in a manner to prevent disruption of existing services and to avoid damage to the existing utilities. Temporary connections shall be provided, as required, to insure uninterruption of existing services. Any damage resulting from the work of this Contract shall be promptly repaired by the Contractor at his own expense in a manner approved by the Engineer and further subject to the requirements of any authority having jurisdiction. Where it is required by the authority having jurisdiction that they perform their own repairs or have them done by others, the Contractor shall be responsible for all costs thereof. E. Where excavations by the Contractor require any utility lines or appurtenant structures to be temporarily supported and otherwise protected during the construction work, such support and protection shall be provided by the Contractor. All such work shall be performed in a manner satisfactory to the Engineer and the respective authority having jurisdiction over such work. In the event the Contractor fails to provide proper support or protection to any existing utility, the Engineer may, at his discretion, have the respective authority to provide City of Denton Hazen and Sawyer BID SET 01530-3 Protection of Existing Facilities such support or protection as may be necessary to insure the safety of such utility, and the costs of such measures shall be paid by the Contractor. PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION – City of Denton Hazen and Sawyer BID SET 01530-4 Protection of Existing Facilities This page left blank intentionally City of Denton Hazen and Sawyer BID SET 01550-1 Site Access and Storage SECTION 01550 SITE ACCESS AND STORAGE PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Access Roads 1. The Contractor shall construct and maintain such temporary access roads as required to perform the work of this Contract. 2. Access roads, where possible, shall be located over the areas of the future road system. 3. Access roads shall be located within the property lines of the Owner. 4. Existing access roads used by the Contractor shall be suitably maintained by the Contractor at his expense during construction. Contractor shall not be permitted to restrict Owner access to existing facilities. Engineer may direct Contractor to perform maintenance of existing access roads when Engineer determines that such work is required to insure all weather access by the Owner. 5. The Contractor shall obtain and pay all cost associated with any bonds required by the T.X. Department of Transportation for the use of State maintained roads. B. Parking Areas 1. Each Contractor shall construct and maintain suitable parking areas for his construction personnel on the project site where approved by the Engineer and the Owner. C. Restoration 1. At the completion of the work, the surfaces of land used for access roads and parking areas shall be restored by each Contractor to its original condition and to the satisfaction of the Engineer. At a minimum, such restoration shall include establishment of a permanent ground cover adequate to restrain erosion for all disturbed areas. City of Denton Hazen and Sawyer BID SET 01550-2 Site Access and Storage D. Traffic Regulations 1. Contractor shall obey all traffic laws and comply with all the requirements, rules and regulations of the Texas Department of Transportation and other local authorities having jurisdiction to maintain adequate warning signs, lights, barriers, etc., for the protection of traffic on public roadways. E. Storage of Equipment and Materials 1. Contractor shall store his equipment and materials at the job site in accordance with the requirements of the General Conditions, the Supplemental Conditions, and as hereinafter specified. All equipment and materials shall be stored in accordance with manufacturer's recommendations and as directed by the Owner or Engineer, and in conformity to applicable statutes, ordinances, regulations and rulings of the public authority having jurisdiction. Where space or strip heaters are provided within the enclosure for motors, valve operators, motor starters, panels, instruments, or other electrical equipment, the Contractor shall make connections to these heaters from an appropriate power source and operate the heaters with temperature control as necessary until the equipment is installed and being operated according to its intended use. 2. Contractor shall enforce the instructions of Owner and Engineer regarding the posting of regulatory signs for loadings on structures, fire safety, and smoking areas. 3. Contractor shall not store materials or encroach upon private property without the written consent of the owners of such private property. 4. Contractor shall not store unnecessary materials or equipment on the job site, and shall take care to prevent any structure from being loaded with a weight which will endanger its security or the safety of persons. 5. Materials shall not be placed within ten (10) feet of fire hydrants. Gutters, drainage channels and inlets shall be kept unobstructed at all times. 6. Contractor shall provide adequate temporary storage buildings/facilities, if required, to protect materials or equipment on the job site. PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION - City of Denton Hazen and Sawyer BID SET 01560-1 Temporary Environmental Controls SECTION 01560 TEMPORARY ENVIRONMENTAL CONTROLS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Dust Control 1. Contractor shall take all necessary measures to control dust from his operations, and to prevent spillage of excavated materials on public roads. 2. Contractor shall remove all spillage of excavated materials, debris or dust from public roads by methods approved by the Engineer. 3. Contractor shall sprinkle water at locations and in such quantities and at such frequencies as may be required by the Engineer to control dust and prevent it from becoming a nuisance to the surrounding area. 4. Dust control and cleaning measures shall be provided at no additional cost to the Owner. PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION – City of Denton Hazen and Sawyer BID SET 01560-2 Temporary Environmental Controls This page left blank intentionally City of Denton Hazen and Sawyer BID SET 01590-1 Field Office, Equipment and Storage SECTION 01590 FIELD OFFICE, EQUIPMENT AND SERVICES PART 1 -- GENERAL 1.01 THE REQUIREMENT D. Contractor's Field Office 1. The Contractor shall furnish, equip and maintain a field office at the site of a size required for his operations. The Contractor shall provide his own telephone service and shall have readily accessible at the field office, copies of the Contract Documents, latest approved Shop Drawings and all field Project related correspondence, Change Order, etc. The Contractor is responsible for all temporary utilities required for day to day operation. E. Project Sign and Sign Panel 1. The Contractor shall erect a sign at each Project site identifying the Project. The sign shall be erected within twenty-one (21) days after the Notice to Proceed, and shall be in accordance with the Specifications and details included in this Section. The project sign and sign panel shall be furnished, erected, and maintained by the Contractor at the location designated by the Engineer. Wording and colors shall be as shown on the detail after the end of this Section. The Hickory Creek Detention Facility construction sign shall be installed at the existing entrance gate to the City property. The West Peak Flow Pump Station construction sign shall be installed on the north side of the PCWRP access driveway near the construction entrance. 2. The project sign shall be fabricated, erected and maintained by the Contractor in accordance with the following specifications: a) Sign Panel: The sign panel shall be constructed of 3/4 inch minimum thickness marine plywood rabetted into a 2 inch x 4 inch wood frame. All fasteners used in the construction of the sign shall be of a rustproof nature. b) Painting: All supports, trim and back of the sign panel shall be painted with at least two (2) coats of the same paint used for the sign face. All paint used shall be exterior grade paint, suitable for use on wood signs. c) Sign Supports: The supports for the project sign shall be at least two 4" by 4" treated wood posts. The sign panel shall be securely fastened to the sign supports with at least six (6) 3/8  galvanized bolts, nuts and washers. The positioning and alignment of the sign shall be as determined by the Engineer. City of Denton Hazen and Sawyer BID SET 01590-2 Field Office, Equipment and Storage d) Maintenance: The project sign shall be maintained by the Contractor, in good condition, at all times, for the duration of construction. e) Removal of Sign from Project Site: The removal of the project sign from the construction site by the Contractor shall be at the completion of construction, when ordered by the Engineer. f) Payment: The cost of the fabrication, erection, maintenance, and removal of the project sign, including all labor and materials, shall be included in the General Contractor's Lump Sum Bid. No extra payment will be made for obliterating certain names and offices and replacement thereof of others because of administrative changes during the course of this Contract. PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION – City of Denton Hazen and Sawyer BID SET 01600-1 Materials and Equipment SECTION 01600 MATERIALS AND EQUIPMENT PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Furnish and Install 1. Where the words "furnish", "provide", "supply", "replace", or "install" are used, whether singularly or in combination, they shall mean to furnish and install, unless specifically stated otherwise. 2. In the interest of brevity, the explicit direction "to furnish and install" has sometimes been omitted in specifying materials and/or equipment herein. Unless specifically noted otherwise, it shall be understood that all equipment and/or materials specified or shown on the Drawings shall be furnished and installed under the Contract as designated on the Drawings. B. Concrete Foundations for Equipment 1. Each Contractor shall provide all concrete foundations shown, specified or required for all equipment furnished under their respective Contract. 2. Anchor bolts and templates for equipment foundations shall be furnished and installation by the Contractor. 3. All concrete foundations for equipment shall be treated, by the Contractor, with an approved sealer to prevent oil from seeping into the concrete. 1.02 EQUIPMENT AND MATERIALS A. All equipment, materials, instruments or devices incorporated in this project shall be new and unused, unless indicated otherwise in the Contract Documents. Equipment and materials to be incorporated into the work shall be delivered sufficiently in advance of their installation and use to prevent delay in the execution of the work, and they shall be delivered as nearly as feasible in the order required for executing the work. B. The Contractor shall protect all equipment and materials from deterioration and damage, including provisions for temporary storage buildings as needed and as specified in Section 01550, Site Access and Storage. Storage of equipment and materials shall be in locations completely protected from flooding, standing water, excessive dust, falling rock, brush fire, etc. Storage areas shall be located sufficiently distant from all construction activities and the movement of construction vehicles to minimize the potential for accidental damage. Any equipment or materials of whatever kind which may have become damaged or deteriorated from any cause shall be removed and replaced by good and satisfactory items at the Contractor's expense for both labor and materials. City of Denton Hazen and Sawyer BID SET 01600-2 Materials and Equipment 1.03 INSTALLATION OF EQUIPMENT A. Equipment and materials shall be installed in accordance with the requirements of the General Conditions, Supplemental Conditions and the respective Specification Sections. B. Concrete foundations for equipment shall be of approved design and shall be adequate in size, suitable for the equipment erected thereon, properly reinforced, and tied into floor slabs by means of reinforcing bars or dowels. Foundation bolts of ample size and strength shall be provided and properly positioned by means of suitable templates and secured during placement of concrete. Foundations shall be built and bolts installed in accordance with the manufacturer's certified drawings. C. Before mounting equipment on a foundation, the Contractor shall clean the top surface; if necessary, rough it with a star chisel and clean again; and clean out all foundation bolt sleeves. The Contractor shall provide a sufficient number of steel plate shims about 2-inches wide and 4-inches long, and of a varying thickness from 1/8 to 1/2-inch. A combination of these shims shall be placed next to each foundation bolt to bring the bottom of the bedplate or frame about 1/8-inch above the final setting. The equipment shall be lowered by changing the combination of shims. Using brass shim stock of various thicknesses, continue to level the equipment a little at a time and in rotation until it is at the correct elevation in both directions. When the equipment is level, tighten down on the foundation bolts a little at a time in rotation to make certain the equipment remains level and does not shift on the shims. A preliminary alignment check shall be made before grout is placed. D. Equipment shall be set, aligned and assembled in conformance with manufacturer's drawings or instructions. Run out tolerances by dial indicator method of alignment shall be plus or minus .002-inches, unless otherwise approved by the Engineer. E. All blocking and wedging required for the proper support and leveling of equipment during installation shall be furnished by the Contractor. All temporary supports shall be removed, except steel wedges and shims, which may be left in place with the approval of the Engineer. F. Each piece of equipment or supporting base, bearing on concrete foundations, shall be bedded in grout. The Contractor shall provide a minimum of 1-1/2-inch thick grouting under the entire baseplate supporting each pump, motor drive unit and other equipment. Grout shall be non-shrink grout, as specified under Section 03600, Grout. G. When motors are shipped separately from driven equipment, the motors shall be received, stored, meggered once a month, and the reports submitted to the Engineer. After driven equipment is set, the motors shall be set, mounted, shimmed, millrighted, coupled and connected complete. 1.04 CONNECTIONS TO EQUIPMENT A. Connections to equipment shall follow manufacturer's recommendations as to size and arrangement of connections and/or as shown in detail on the Drawings or approved Shop City of Denton Hazen and Sawyer BID SET 01600-3 Materials and Equipment Drawings. Piping connections shall be made to permit ready disconnection of equipment with minimum disturbance of adjoining piping and equipment. B. The Contractor shall be responsible for bringing proper electrical service to each item of equipment requiring electrical service as shown on the Drawings or approved Shop Drawings. Electrical connections to equipment requiring electrical service shall be made by the Contractor, unless otherwise indicated on the Drawings or in the Technical Specifications. C. The Contractor shall bring and connect HVAC service and condensate drains to all equipment items requiring same as shown on the Drawings. Electrical connections to equipment requiring electrical service shall be made by the Contractor, unless otherwise indicated on the Drawings or in the Technical Specifications. D. The Contractor shall bring and connect plumbing service to all equipment items requiring same as shown on the Drawings. 1.05 SUBSTITUTIONS A. Requests for substitutions of equipment or materials shall conform to the requirements of the General Conditions, Supplemental Conditions, and as hereinafter specified. 1. Contractor shall submit for each proposed substitution sufficient details, complete descriptive literature and performance data together with samples of the materials, where feasible, to enable the Owner and Engineer to determine if the proposed substitution is equal. 2. Contractor shall submit certified tests, where applicable, by an independent laboratory attesting that the proposed substitution is equal. 3. A list of installations where the proposed substitution is equal. 4. Requests for substitutions shall include full information concerning differences in cost, and any savings in cost resulting from such substitutions shall be passed on to the Owner. B. Where the approval of a substitution requires revision or redesign of any part of the work, including that of other Contracts, all such revision and redesign, and all new drawings and details therefore, shall be provided by the Contractor at his own cost and expense, and shall be subject to the approval of the Owner and Engineer. C. In the event that the Engineer is required to provide additional engineering services, then the Engineer's charges for such additional services shall be charged to the Contractor by the Owner in accordance with the requirements of the General Conditions, and the Supplemental Conditions. D. In all cases the Owner and Engineer shall be the judge as to whether a proposed substitution is to be approved. The Contractor shall abide by their decision when proposed substitute items are judged to be unacceptable and shall in such instances furnish the item City of Denton Hazen and Sawyer BID SET 01600-4 Materials and Equipment specified or indicated. No substitute items shall be used in the work without written approval of the Owner and Engineer. E. Contractor shall have and make no claim for an extension of time or for damages by reason of the time taken by the Engineer in considering a substitution proposed by the Contractor or by reason of the failure of the Engineer to approve a substitution proposed by the Contractor. F. Acceptance of any proposed substitution shall in no way release the Contractor from any of the provisions of the Contract Documents. PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION - City of Denton Hazen and Sawyer BID SET 01700-1 Project Closeout SECTION 01700 PROJECT CLOSEOUT PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Final Cleaning 1. At the completion of the work, the Contractor shall remove all rubbish from and about the site of the work, and all temporary structures, construction signs, tools, scaffolding, materials, supplies and equipment which he or any of his Subcontractors may have used in the performance of the work. Contractor shall broom clean paved surfaces and rake clean other surfaces of grounds. 2. Contractor shall thoroughly clean all materials, equipment and structures; all marred surfaces shall be touched up to match adjacent surfaces; dirty filters and burned out lights replaced as required; all glass surfaces cleaned and floors cleaned and polished so as to leave work in a clean and new appearing condition. 3. Contractor shall maintain cleaning until project, or portion thereof, is occupied by the Owner. C. Spare Parts and Special Tools 1. As soon as practicable after approval of the list of equipment, the Contractor shall furnish spare parts data for each different item of equipment listed. The data shall include a complete list of parts and supplies, with current unit prices and source or sources of supply. 2. Contractor shall also furnish a list of parts, and supplies that are either normally furnished at no extra cost with the purchase of the equipment or specified to be furnished as part of the Contract and a list of additional items recommended by the manufacturer to assure efficient operation for a period of one-hundred and twenty (120) days for the particular installation. 3. All parts shall be securely boxed and tagged, and clearly marked on the box and individually for identification as to the name of manufacturer or supplier, applicable equipment, part number, description and location in the equipment. All parts shall be protected and packaged for a shelf life of at least ten (10) years. 4. Contractor shall furnish at no additional cost to the Owner with each piece of equipment as a minimum, one (1) complete set, or the number of sets called for in the Technical Specifications, of suitably marked special tools and appliances which may be needed to adjust, operate, maintain, or repair the equipment. City of Denton Hazen and Sawyer BID SET 01700-2 Project Closeout 5. Contractor shall submit, for approval by the Engineer, a complete list of the special tools and appliances to be furnished. Such tools and appliances shall be furnished in approved painted steel cases properly labeled and equipped with good grade cylinder locks and duplicate keys. D. Equipment Start-Up Services 1. Equipment start-up period, for the training of plant personnel, shall begin after satisfactory completion and acceptance of the field tests and coincidentally with the certified date of substantial completion for the part of the work for which the equipment is included. If the equipment is not covered by a certificate of substantial completion for a part of the work, the period shall begin upon substantial completion of the project. 2. During the equipment start-up period the Contractor shall furnish, at no additional cost to the Owner the services of factory trained representatives of the equipment manufacturers for the equipment designated in the Specifications to: a. Assist in the start-up and operations of the equipment. b. Assist in the training of plant personnel, designated by the Owner in the proper operation and maintenance of the equipment. 3 The Owner shall: a. Provide the necessary plant personnel to be instructed in the operation and maintenance of the equipment. The Owner's personnel shall operate all equipment. b. Pay for all fuel, power and chemicals consumed beyond quantities specified in the Contract Documents. The Contractor shall pay for fuel, power, and chemicals consumed up to the date of "certified substantial completion" except as otherwise specified herein. 4. Contractor shall be available to promptly repair all work during the start-up period so as to cause minimum disruption to the total plant operation. 5. Upon completion of a minimum of ten (10) consecutive and continuous days of satisfactory operation, or the number of days called for in the Technical Specifications, the Owner will assume operation and operating cost of the equipment. If the equipment malfunctions during this start-up period, the start-up period will be repeated until satisfactory operation is achieved. 6. In the event a system, equipment or component proves defective or is unable to meet specified performance criteria, the Contractor shall replace the defective item and the minimum one (1) year guarantee period, or the guarantee period called for in the Technical Specifications for the item shall start after satisfactory replacement and testing of the item. City of Denton Hazen and Sawyer BID SET 01700-3 Project Closeout E. Final Cleanup; Site Rehabilitation 1. Before finally leaving the site, the Contractor shall wash and clean all exposed surfaces which have become soiled or marked, and shall remove from the site of work all accumulated debris and surplus materials of any kind which result from his operation, including construction equipment, tools, sheds, sanitary enclosures, etc. The Contractor shall leave all equipment, fixtures, and work, which he has installed, in a clean condition. The completed project shall be turned over to the Owner in a neat and orderly condition. 2. The site of the work shall be rehabilitated or developed in accordance with other sections of the Specifications and the Drawings. In the absence of any portion of these requirements, the Contractor shall completely rehabilitate the site to a condition and appearance equal or superior to that which existed just prior to construction, except for those items whose permanent removal or relocation was required in the Contract Documents or ordered by the Owner. F. Final Inspection 1. Final cleaning and repairing shall be so arranged as to be finished upon completion of the construction work. The Contractor will make his final cleaning and repairing, and any portion of the work finally inspected and accepted by the Engineer shall be kept clean by the Contractor, until the final acceptance of the entire work. 2. When the Contractor has finally cleaned and repaired the whole or any portion of the work, he shall notify the Engineer that he is ready for final inspection of the whole or a portion of the work, and the Engineer will thereupon inspect the work. If the work is not found satisfactory, the Engineer will order further cleaning, repairs, or replacement. 3. When such further cleaning or repairing is completed, the Engineer, upon further notice, will again inspect the work. The "Final Payment" will not be processed until the Contractor has complied with the requirements set forth, and the Engineer has made his final inspection of the entire work and is satisfied that the entire work is properly and satisfactorily constructed in accordance with the requirements of the Contract Documents. G. Project Close Out 1. As construction of the project enters the final stages of completion, the Contractor shall, in concert with accomplishing the requirements set forth in the Contract Documents, attend to or have already completed the following items as they apply to his contract: a. Scheduling equipment manufacturers' visits to site. b. Required testing of project components. c. Scheduling start-up and initial operation. City of Denton Hazen and Sawyer BID SET 01700-4 Project Closeout d. Scheduling and furnishing skilled personnel during initial operation. e. Correcting or replacing defective work, including completion of items previously overlooked or work which remains incomplete, all as evidenced by the Engineer's "Punch" Lists. f. Attend to any other items listed herein or brought to the Contractor's attention by the Engineer. 2. In addition, and before the Certificate of Substantial Completion is issued, the Contractor shall submit to the Engineer (or to the Owner if indicated) certain records, certifications, etc., which are specified elsewhere in the Contract Documents. A partial list of such items appears below, but it shall be the Contractor's responsibility to submit any other items which are required in the Contract Documents: a. Test results of project components. b. Performance Affidavits for equipment. c. Certification of equipment or materials in compliance with Contract Documents. d. Operation and maintenance instructions or manuals for equipment. e. One set of neatly marked-up record drawings showing as-built changes and additions to the work under his Contract. f. Any special guarantees or bonds (Submit to Owner). g. Licensed surveyor’s report showing elevations of weirs specified in the Contract Drawings and the final surveyed elevation. 3. The Contractor's attention is directed to the fact that required certifications and information under Item 3 above, must actually be submitted earlier in accordance with other Sections of the Specifications. PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION - City of Denton Hazen and Sawyer BID SET 02050-1 Demolition SECTION 02050 DEMOLITION PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish all labor, materials and equipment in accordance with the requirements of Section 01520 - Maintenance of Utility Operations During Construction. B. In addition, the Contractor shall demolish and remove all concrete and asphaltic paving, curbs, sidewalk, and miscellaneous yard structures as required and shown on the Contract Drawings during the construction work. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 01090 - Reference Standards B. Section 01520 - Maintenance of Utility Operations During Construction C. Section 01540 - Demolition and Removal of Existing Structures and Equipment 1.03 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. References shall be in accordance with reference standards, codes, and specifications as set forth herein and in Section 02100 - Clearing, Grubbing, and Site Preparation. PART 2 -- EXECUTION 2.01 DEMOLITION A. Existing concrete and asphaltic paving, curbs, sidewalk and miscellaneous yard structures within the areas designated for new construction work shall be completely demolished and all debris removed from the site. B. Excavation caused by demolition shall be backfilled with fill free from rubbish and debris. C. Work shall be performed in such manner as not to endanger the safety of the workmen or the public or cause damage to nearby structures. D. Provide all barriers and precautionary measures in accordance with Owner's requirements and other authorities having jurisdiction. E. Where parts of existing structures are to remain in service, demolish the portions to be removed, repair damage, and leave the structure in proper condition for the intended use. Remove concrete and masonry to the lines designated by drilling, chipping, or other suitable City of Denton Hazen and Sawyer BID SET 02050-2 Demolition methods. Leave the resulting surfaces reasonably true and even, with sharp straight corners that will result in neat joints with new construction and be satisfactory for the purpose intended. Where existing reinforcing rods are to extend into new construction, remove the concrete so that the reinforcing is clean and undamaged. Cut off other reinforcing 1/2-inch below the surface and fill with epoxy resin binder flush with the surface. F. Prior to the execution of the work, the Contractor, Owner and Engineer shall jointly survey the condition of the adjoining and/or nearby structures. Photographs and records shall be made of any prior settlement or cracking of structures, pavements, and the like, that may become the subject of possible damage claims. 2.02 DISPOSAL OF MATERIAL A. All debris resulting from the demolition and removal work shall be disposed of by the Contractor as part of the work of this Contract. Material designated by the Engineer to be salvaged shall be stored on the construction site as directed. All other material shall be disposed of off site by the Contractor at his expense. B. Burning of any debris resulting from the demolition will not be permitted at the site. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 02100-1 Cleaning, Grubbing and Site Prep. SECTION 02100 CLEARING, GRUBBING, AND SITE PREPARATION PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Includes all labor, material, equipment and appliances required for the complete execution of any additions, modifications, or alterations to existing building(s) and new construction work as shown on the Drawings and specified herein. B. Principal items of work include: 1. Notifying all authorities owning utility lines running to or on the property. Protecting and maintaining all utility lines to remain and capping those that are not required in accordance with instructions of the Utility Companies, and all other authorities having jurisdiction. 2. Clearing the site within the Contract Limit Lines, including removal of grass, brush, shrubs, trees, loose debris and other encumbrances except for trees marked to remain. 3. Boxing and protecting all trees, shrubs, lawns and the like within areas to be preserved. Relocating trees and shrubs, so indicated on the Drawings, to designated areas. 4. Repairing all injury to trees, shrubs, and other plants caused by site preparation operations shall be repaired immediately. Work shall be done by qualified personnel in accordance with standard horticultural practice and as approved by the Engineer. 5. Removing topsoil to its full depth from designated areas and stockpiling on site where directed by the Engineer for future use. 6. Disposing from the site all debris resulting from work under this Section. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 02200 - Earthwork 1.03 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Denton Development Code Chapters 17, 18 and 19. B. City of Denton Drainage Criteria Manual. C. City of Denton Site Design Criteria Manual. D. Texas Department of Transportation. E. Kansas City Southern Railroad Requirements. City of Denton Hazen and Sawyer BID SET 02100-2 Cleaning, Grubbing and Site Prep. 1.04 STREET AND ROAD BLOCKAGE A. Closing of streets and roads during progress of the work shall be in compliance with the requirements of the Owner and other authorities having jurisdiction. Access shall be provided to all facilities remaining in operation. Access to neighboring properties along the access road shell be maintained at all times. 1.05 PROTECTION OF PERSONS AND PROPERTY A. All work shall be performed in such a manner to protect all personnel, workmen, pedestrians and adjacent property and structures from possible injury and damage. B. All conduits, wires, cables and appurtenances above or below ground shall be protected from damage. C. Provide warning and barrier fence where shown on the Drawings and as specified herein. PART 2 -- EXECUTION 2.01 CLEARING OF SITE A. Before removal of topsoil, and start of excavation and grading operations, the areas within the clearing limits shall be cleared and grubbed. B. Clearing shall consist of cutting, removal, and satisfactory disposal of all trees, fallen timber, brush, bushes, rubbish, sanitary landfill material, fencing, and other perishable and objectionable material within the areas to be excavated or other designated areas. Prior to the start of construction, the Contractor shall survey the entire Contract site and shall prepare a plan which defines the areas to be cleared and grubbed, trees to be pruned, extent of tree pruning, and/or areas which are to be cleared but not grubbed. This plan shall be submitted to the Engineer for approval. Should it become necessary to remove a tree, bush, brush or other plants adjacent to the area to be excavated, the Contractor shall do so only after permission has been granted by the Engineer. C. Excavation resulting from the removal of trees, roots and the like shall be filled with suitable material, as approved by the Engineer, and thoroughly compacted per the requirements contained in Section 02200, Earthwork. D. Unless otherwise shown or specified, the Contractor shall clear and grub a strip at least 15 ft. wide along all permanent fence lines installed under this Contract. E. In temporary construction easement locations, only those trees and shrubs shall be removed which are in actual interference with excavation or grading work under this Contract, and removal shall be subject to approval by the Engineer. However, the Engineer reserves the right to order additional trees and shrubs removed at no additional cost to the Owner, if such, in his opinion, are too close to the work to be maintained or have become damaged due to the Contractor's operations. City of Denton Hazen and Sawyer BID SET 02100-3 Cleaning, Grubbing and Site Prep. 2.02 STRIPPING AND STOCKPILING EXISTING TOPSOIL A. Existing topsoil and sod on the site within areas designated on the Drawings shall be stripped to whatever depth it may occur, and stored in locations directed by the Engineer. B. The topsoil shall be free of stones, roots, brush, rubbish, or other unsuitable materials before stockpiling the topsoil. C. Care shall be taken not to contaminate the stockpiled topsoil with any unsuitable materials. 2.03 GRUBBING A. Grubbing shall consist of the removal and disposal of all stumps, roots, logs, sticks and other perishable materials to a depth of at least 6-inches below ground surfaces. B. Large stumps located in areas to be excavated may be removed during grading operations, subject to the approval of the Engineer. 2.04 DISPOSAL OF MATERIAL A. All debris resulting from the clearing and grubbing work shall be disposed of by the Contractor as part of the work of this Contract. Material designated by the Engineer to be salvaged shall be stored on the construction site as directed by the Engineer for reuse in this Project or removal by others. B. Burning of any debris resulting from the clearing and grubbing work will not be permitted at the site. 2.05 WARNING AND BARRIER FENCE A. The fence shall be made of a visible, lightweight, flexible, high strength polyethylene material. The fence shall be MIRASAFE as manufactured by Mirafi, Inc., or equal. B. Physical Properties Fence: Color: International Orange Roll Size: 4' x 164' Roll weight: 34 lbs. Mesh opening: 1-1/2" x 3" Posts: ASTM Designation: ASTM 702 Length: 5 feet long (T-Type) Weight: 1.25 #/Foot (min) Area of Anchor Plate: 14 Sq. In. City of Denton Hazen and Sawyer BID SET 02100-4 Cleaning, Grubbing and Site Prep. C. Drive posts 12 to 18 inches into ground every 10' to 12'. Wrap fence material around first terminal post allowing overlap of one material opening. Use metal tie wire or plastic tie wrap to fasten material to itself at top, middle and bottom. At final post, cut with utility knife or scissors at a point halfway across an opening. Wrap around and tie at final post in the same way as the first post. D. Use tie wire or tie wrap at intermediate posts and splices as well. Thread ties around a vertical member of the fence material and the post, and bind tightly against the post. For the most secure fastening, tie at top, middle and bottom. Overlap splices a minimum of four fence openings, tie as above, fastening both edges of the fence material splice overlap. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 02200-1 Earthwork SECTION 02200 EARTHWORK PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Furnish all labor, equipment and materials required to complete all work associated with excavation, including off-site borrow excavation, dewatering, backfill, drainage layers beneath and around structures, foundation and backfill stone, filter fabric, embankments, stockpiling topsoil and any excess suitable material in designated areas, in place compaction of embankments, backfill and subgrades beneath foundations and roadways, excavation support, disposing from the site all unsuitable materials, providing erosion and sedimentation control grading, site grading and preparation of pavement and structure subgrade, and other related and incidental work as required to complete the work shown on the Drawings and specified herein. B. All excavations shall be in conformity with the lines, grades, and cross sections shown on the Drawings or established by the Engineer. C. It is the intent of this Specification that the Contractor conduct the construction activities in such a manner that erosion of disturbed areas and off-site sedimentation be absolutely minimized. D. All work under this Contract shall be done in conformance with and subject to the limitations of the latest editions of the Texas Department of Transportation Standard Specifications for Construction and Maintenance of Highways, Streets, and Bridges and the City of Denton Drainage and Site Design Criteria Manual. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Requirements of related work are included in Division 1 and Division 2 of these Specifications. 1.03 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Without limiting the generality of the other requirements of the Specifications, all work herein shall conform to the applicable requirements of the following documents. All referenced Specifications, codes, and standards refer to the most current issue available at the time of Bid. 1. Texas Department of Transportation Standard Specifications for Construction and Maintenance of Highways, Streets, and Bridges, latest edition. 2. American Society for Testing and Materials (ASTM): ASTM C 127 Test for Specific Gravity and Absorption of Coarse Aggregate. City of Denton Hazen and Sawyer BID SET 02200-2 Earthwork ASTM C 136 Test for Sieve Analysis of Fine and Coarse Aggregates. ASTM D 422 Particle Size Analysis of Soils. ASTM D 423 Test for Liquid Limit of Soils. ASTM D 424 Test for Plastic Limit and Plasticity Index of Soils. ASTM C 535 Test for Resistance to Degradation of Large Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine. ASTM D 698 Standard Method of Test for the Moisture - Density Relations of Soils Using a 5.5 lb. (2.5 kg) Rammer and a 12-inch (305 mm) Drop. ASTM D1556 Test for Density of Soil in Place by the Sand-Cone Method. ASTM D1557 Test for Moisture-Density Relations of Soils and Soil Aggregate Mixtures Using 10-lbs. (4.5 kg) Rammer and 18-inch (457 mm) Drop. ASTM D2049 Test Method for Relative Density of Cohesionless Soils. ASTM D2167 Test for Density of Soil in Place by the Rubber-Balloon Method. ASTM D2216 Test for Laboratory Determination of Water (Moisture) Content of Soil, Rock, and Soil Aggregate Mixtures. ASTM D2487 Test for Classification of Soils for Engineering Purposes. ASTM D2922 Test for Density of Soil and Soil-Aggregate in Place by Nuclear Methods (Shallow Depth). 1.04 SUBSURFACE CONDITIONS A. Information on subsurface conditions is referenced under Division 1, General Requirements. B. Attention is directed to the fact that there may be water pipes, storm drains and other utilities located in the area of proposed excavation. Perform all repairs to same in the event that excavation activities disrupt service. 1.05 SUBMITTALS A. In accordance with the procedures and requirements set forth in Section 01300 - Submittals, the Contractor shall submit the following: 1. Name and location of all material suppliers. City of Denton Hazen and Sawyer BID SET 02200-3 Earthwork 2. Certificate of compliance with the standards specified above for each source of each material. 3. List of disposal sites for waste and unsuitable materials and all required permits for use of those sites. 4. Plans and cross sections of open cut excavations showing side slopes and limits of the excavation at grade. 5. Samples of synthetic filter fabric and reinforced plastic membrane with manufacturer's certificates or catalog cuts stating the mechanical and physical properties. Samples shall be at least one (1) foot wide and four (4) feet long taken across the roll with the warp direction appropriately marked. 6. Construction drawings and structural calculations for any types of excavation support required. Drawings and calculations shall be sealed by a currently registered Professional Engineer in the State of Texas. 7. Monitoring plan and pre-construction condition inspection and documentation of all adjacent structures, utilities, and roadways near proposed installation of excavation support systems and near areas where dewatering is required to facilitate construction. 8. Dewatering procedures. 1.06 PRODUCT HANDLING A. Soil and rock material shall be excavated, transported, placed, and stored in a manner so as to prevent contamination, segregation and excessive wetting. Materials which have become contaminated or segregated will not be permitted in the performance of the work and shall be removed from the site. 1.07 USE OF EXPLOSIVES A. Explosives shall not be utilized in the performance of the Work. PART 2 -- PRODUCTS 2.01 SELECT FILL A. Soils from the excavations meeting requirements stipulated herein with the exceptions of topsoil and organic material may be used as select fill for backfilling, constructing embankments, reconstructing existing embankments, and as structural subgrade support. B. Select fill used for embankment construction shall be a clayey sand or very sandy clay soil material with a Maximum Liquid Limit (LL) of 50 and a Plasticity Index (PI) between 8 and 16. C. Select fill used for backfilling shall either be material as described in Paragraph B above or a granular soil material with a Maximum Plasticity Index (PI) of 6. City of Denton Hazen and Sawyer BID SET 02200-4 Earthwork D. Regardless of material used as select fill, materials shall be compacted at a moisture content satisfactory to the Engineer, which shall be approximately that required to produce the maximum density except that the moisture content shall not be more than 2% below nor more than 2% above the optimum moisture content for the particular material tested in accordance with the ASTM D698. E. Select fill used as subgrade support shall be a coarse aggregate material meeting the gradation requirements of #57 or #78 aggregates in accordance with ASTM C-33, or Stone Flexible Base as defined in Section 02207 – Aggregate Materials. F. On-site moisture conditioned fill, where required in the drawings for subgrade reconstruction, shall be select fill which is moisture conditioned on-site. On-site moisture conditioned fill shall consist of clayey sand or sandy clay having a PI of 8 to 16. Compaction moisture requirements for on-site moisture conditioned fill shall be determined by the Engineer following testing of bulk samples. A minimum of two weeks prior to excavation, two 10 feet deep test pits shall be excavated by the contractor to obtain bulk samples for testing by the Engineer to determine actual compaction moisture contents. G. Where excavated material does not meet requirements for select fill and where indicated on the drawings, Contractor shall furnish off-site borrow material meeting the specified requirements herein. Determination of whether the borrow material will be paid for as an extra cost will be made based on Article 4 of the General Conditions, as amended by the Supplementary Conditions. When the excavated material from required excavations is suitable for use as backfill, bedding, or embankments, but is replaced with off-site borrow material for the Contractor’s convenience, the costs associated with such work and material shall be borne by the Contractor. Where drawings indicate that off-site borrow material is to be placed the cost of such work and material shall be included in the lump sum bid item. 2.02 TOPSOIL A. Topsoil shall be considered the surface layer of soil and sod, suitable for use in seeding and planting. It shall contain no mixture of refuse or any material toxic to plant growth. 2.03 FOUNDATION DRAINAGE SYSTEMS A. The Contractor shall provide foundation drainage systems as indicated on the Drawings and specified herein. The materials and placement shall be as indicated under Section 02712 - Foundation Drainage Systems. 2.04 GEOTEXTILES A. The Contractor shall provide geotextiles as indicated on the Drawings and specified herein. The materials and placement shall be as indicated under Section 02274 - Geotextiles. PART 3 -- EXECUTION 3.01 STRIPPING OF TOPSOIL City of Denton Hazen and Sawyer BID SET 02200-5 Earthwork A. In all areas to be excavated, filled, paved, or graveled the topsoil shall be stripped to its full depth and shall be deposited in storage piles on the site, at locations designated by the Engineer, for subsequent reuse. Topsoil shall be kept separated from other excavated materials and shall be piled free of roots and other undesirable materials. 3.02 EXCAVATION A. All material excavated, regardless of its nature or composition, shall be classified as UNCLASSIFIED EXCAVATION. Excavation shall include the removal of all soil, rock, weathered rock, rocks of all types, boulders, conduits, pipe, and all other obstacles encountered and shown to be removed within the limits of excavation shown on the Drawings or specified herein. The cost of excavation shall be included in the Lump Sum Bid Price and no additional payment will be made for the removal of obstacles encountered within the excavation limits shown on the Drawings and specified herein. B. Excavation by blasting is prohibited. C. All suitable material removed in the excavation shall be used as far as practicable in the formation of embankments, subgrades, and shoulders, and at such other places as may be indicated on the Drawings or indicated by the Engineer. No excavation shall be wasted except as may be permitted by the Engineer. Refer to the drawings for specific location and placement of suitable excavated materials in the formation of embankments, backfill, and structural and roadway foundations. THE ENGINEER AND/OR MATERIALS TESTING CONSULTANT WILL DESIGNATE MATERIALS THAT ARE UNSUITABLE. The Contractor shall furnish off site disposal areas for the unsuitable material. Where suitable materials containing excessive moisture are encountered above grade in cuts, the Contractor shall construct above grade ditch drains prior to the excavation of the cut material when in the opinion of the Engineer and/or materials testing consultant such measures are necessary to provide proper construction. D. All excavations shall be made in the dry and in such a manner and to such widths as will give ample room for properly constructing and inspecting the structures and/or piping they are to contain and for such excavation support, pumping and drainage as may be required. Excavation shall be made in accordance with the grades and details shown on the Drawings and as specified herein. E. Excavation slopes shall be flat enough to avoid slides that will cause disturbance of the subgrade or damage of adjacent areas. Excavation requirements and slopes shall be as indicated in the Drawings. The Contractor shall intercept and collect surface runoff both at the top and bottom of cut slopes. The intersection of slopes with natural ground surfaces, including the beginning and ending of cut slopes, shall be uniformly rounded as shown on the Drawings or as may be indicated by the Engineer. Concurrent with the excavation of cuts the Contractor shall construct intercepting berm ditches or earth berms along and on top of the cut slopes at locations shown on the Drawings or designated by the Engineer. All slopes shall be finished to reasonably uniform surfaces acceptable for seeding and mulching operations. No rock or boulders shall be left in place which protrude more than 1 foot within the typical section cut slope lines, and all rock cuts shall be cleaned of loose and overhanging material. All protruding roots and other objectionable vegetation shall be removed from slopes. The Contractor shall be required to submit plans of open-cut excavation for review by the Engineer before approval is given to proceed. City of Denton Hazen and Sawyer BID SET 02200-6 Earthwork F. It is the intent of these Specifications that all structures shall bear on an aggregate base, crushed stone or screened gravel bedding placed to the thickness shown on the Drawings, specified in these Specifications, or not less than 6-inches. Bedding for process piping shall be as specified in Section 15000 - Basic Mechanical Requirements, or as shown on the Drawings. G. The bottom of all excavations for structures and pipes shall be examined by the Engineer and/or materials testing consultant for bearing value and the presence of unsuitable material. If, in the opinion of the Engineer and/or materials testing consultant, additional excavation is required due to the low bearing value of the subgrade material, or if the in-place soils are soft, yielding, pumping and wet, the Contractor shall remove such material to the required width and depth and replace it with thoroughly compacted select fill, and/or crushed stone or screened gravel as indicated by the Engineer. Payment for such additional work ordered by the Engineer shall be made as an extra by a Change Order in accordance with the General Conditions and Division 1. No payment will be made for subgrade disturbance caused by inadequate dewatering or improper construction methods. H. All cuts shall be brought to the grade and cross section shown on the Drawings, or established by the Engineer, prior to final inspection and acceptance by the Engineer. I. Slides and overbreaks which occur due to negligence, carelessness or improper construction techniques on the part of the Contractor shall be removed and disposed of by the Contractor as indicated by the Engineer at no additional cost to the Owner. If grading operations are suspended for any reason whatsoever, partially completed cut and fill slopes shall be brought to the required slope and the work of seeding and mulching or other required erosion and sedimentation control operations shall be performed. J. Where the excavation exposes sludge, sludge contaminated soil or other odorous materials, the Contractor shall cover such material at the end of each workday with a minimum of 6-inches and a maximum of 24-inches of clean fill. The work shall be an odor abatement measure and the material shall be placed to the depth deemed satisfactory by the Engineer for this purpose. 3.03 EXCAVATION SUPPORT A. The Contractor shall furnish, place, and maintain such excavation support which may be required to support sides of excavation or to protect pipes and structures from possible damage and to provide safe working conditions. If the Engineer is of the opinion that at any point sufficient or proper supports have not been provided, he may order additional supports put in at the expense of the Contractor. The Contractor shall be responsible for the adequacy of all supports used and for all damage resulting from failure of support system or from placing, maintaining and removing it. B. Selection of and design of any proposed excavation support systems is exclusively the responsibility of the Contractor. Contractor shall submit drawings and calculations on proposed systems sealed by a Professional Engineer currently registered in the State of Texas. City of Denton Hazen and Sawyer BID SET 02200-7 Earthwork C. The Contractor shall exercise caution in the installation and removal of supports to insure that excessive or unusual loadings are not transmitted to any new or existing structure. The Contractor shall promptly repair at his expense any and all damage that can be reasonably attributed to installation or removal of excavation support system. D. Contractor shall monitor movement in the excavation support systems as well as movement at adjacent structures, utilities and roadways near excavation supports. Contractor shall submit a monitoring plan developed by the excavation support design engineer. All pre-construction condition assessment and documentation of adjacent structures on-site and off- site shall be performed by the Contractor. If any sign of distress such as cracking or movement occurs in any adjacent structure, utility or roadway during installation of supports, subsequent excavation, service period of supports, subsequent backfill and construction, or removal of supports, Engineer shall be notified immediately. Contractor shall be exclusively responsible for repair of any damage to any roadway, structure, utility, pipes, etc. both on-site and off-site, as a result of his operations. E. All excavation supports shall be removed upon completion of the work except as indicated herein. The Engineer may permit supports to be left in place at the request and expense of the Contractor. The Engineer may order certain supports left permanently in place in addition to that required by the Contract. The cost of the materials so ordered left in place, less a reasonable amount for the eliminated expense of the removal work omitted, will be paid as an extra by a Change Order in accordance with the General Conditions and Division 1. Any excavation supports left in place shall be cut off at least two (2) feet below the finished ground surface or as directed by the Engineer. 3.04 PROTECTION OF SUBGRADE A. To minimize the disturbance of bearing materials and provide a firm foundation, the Contractor shall comply with the following requirements: 1. Use of heavy rubber-tired construction equipment shall not be permitted on the final subgrade unless it can be demonstrated that drawdown of groundwater throughout the entire area of the structure is at least 3 feet below the bottom of the excavation (subgrade). Even then, the use of such equipment shall be prohibited should subgrade disturbance result from concentrated wheel loads. 2. Subgrade soils disturbed through the operations of the Contractor shall be excavated and replaced with compacted select fill or crushed stone at the Contractor's expense as indicated by the Engineer. 3. The Contractor shall provide positive protection against penetration of frost into materials below the bearing level during work in winter months. This protection can consist of a temporary blanket of straw or salt hay covered with a plastic membrane or other acceptable means. 3.05 PROOFROLLING A. The subgrade of all structures and all areas that will support pavements or select fill shall be proofrolled. After stripping of topsoil, excavation to subgrade and prior to placement of fills, the exposed subgrade shall be carefully inspected by probing and testing as needed. Any City of Denton Hazen and Sawyer BID SET 02200-8 Earthwork topsoil or other organic material still in place, frozen, wet, soft, or loose soil, and other undesirable materials shall be removed. The exposed subgrade shall be proofrolled with a heavily loaded tandem-wheeled dump truck to check for pockets of soft material hidden beneath a thin crust of better soil. Any unsuitable materials thus exposed shall be removed and replaced with an approved compacted material. 3.06 DEWATERING A. The Contractor shall do all dewatering as required for the completion of the work. Procedures for dewatering proposed by the Contractor shall be submitted to the Engineer for review prior to any earthwork operations. All water removed by dewatering operations shall be disposed of in accordance with the Texas Commission on Environmental Quality. B. The dewatering system shall be of sufficient size and capacity as required to control groundwater or seepage to permit proper excavation operations, embankment construction and reconstruction, subgrade preparation, and to allow concrete to be placed in a dry condition. The system shall include a sump system or other equipment, appurtenances and other related earthwork necessary for the required control of water. The Contractor shall drawdown groundwater to at least 3 feet below the bottom of excavations (subgrade) at all times in order to maintain a dry and undisturbed condition. C. The Contractor shall control, by acceptable means, all water regardless of source. Water shall be controlled and its disposal provided for at each berm, structure, etc. The entire periphery of the excavation areas shall be ditched and diked to prevent water from entering the excavation. The Contractor shall be fully responsible for disposal of the water and shall provide all necessary means at no additional expense to the Owner. The Contractor shall be solely responsible for proper design, installation, proper operation, maintenance, and any failure of any component of the system. D. The Contractor shall be responsible for and shall repair without cost to the Owner, any damage to work in place and the excavation, including damage to the bottom due to heave and including removal of material and pumping out of the excavated area. The Contractor shall be responsible for damages to any other area or structure caused by his failure to maintain and operate the dewatering system proposed and installed by the Contractor. E. The Contractor shall take all the steps that he considers necessary to familiarize himself with the surface and subsurface site conditions, and shall obtain the data that is required to analyze the water and soil environment at the site and to assure that the materials used for the dewatering systems will not erode, deteriorate, or clog to the extent that the dewatering systems will not perform properly during the period of dewatering. Copies of logs of borings and laboratory test results are available to the Contractor. This data is furnished for information only, and it is expressly understood that the Owner and Engineer will not be held responsible for any interpretations or conclusions drawn therefrom by the Contractor. F. Prior to the execution of the work, the Contractor, Owner and Engineer shall jointly survey the condition of adjoining structures. Photographs and records shall be made of any prior settlement or cracking of structures, pavements, and the like, that may become the subject of possible damage claims. 3.07 EMBANKMENTS City of Denton Hazen and Sawyer BID SET 02200-9 Earthwork A. The Contractor shall perform the construction of embankments in such a manner that cut and fill slopes will be completed to final slopes and grade in a continuous operation. The operation of removing excavation material from any cut and the placement of embankment in any fill shall be a continuous operation to completion unless otherwise permitted by the Engineer. B. Surfaces upon which embankments are to be constructed shall be stripped of topsoil, organic material, rubbish and other extraneous materials. After stripping and prior to placing embankment material, the Contractor shall compact the top 12-inches of in place soil as specified under Paragraph 3.09, COMPACTION. C. Any soft or unsuitable materials revealed before or during the in place compaction shall be removed as indicated by the Engineer and/or materials testing consultant and replaced with select fill. D. Ground surfaces on which embankment is to be placed, shall be scarified or stepped in a manner which will permit bonding of the embankment with the existing surface. The embankment soils shall be as specified under Part 2 - Products, and shall be deposited and spread in successive, uniform, approximately horizontal layers not exceeding 8-inches in compacted depth for the full width of the cross section, and shall be kept approximately level by the use of effective spreading equipment. Hauling shall be distributed over the full width of the embankment, and in no case will deep ruts be allowed to form during the construction of the embankment. The embankment shall be properly drained at all times. Each layer of the embankment shall be thoroughly compacted to the density specified under Paragraph 3.09, COMPACTION. E. The embankment or fill material in the layers shall be of the proper moisture content before rolling to obtain the prescribed compaction. Wetting or drying of the material and manipulation when necessary to secure a uniform moisture content throughout the layer shall be required. Should the material be too wet to permit proper compaction or rolling, all work on all portions of the embankment thus affected shall be delayed until the material has dried to the required moisture content. Samples of all embankment materials for testing, both before and after placement and compaction, will be taken at frequent intervals. From these tests, corrections, adjustments, and modifications of methods, materials, and moisture content will be made to construct the embankment. F. Where embankments are to be placed and compacted on hillsides, or when new embankment is to be compacted against embankments, or when embankment is built in part widths, the slopes that are steeper than 4:1 shall be loosened or plowed to a minimum depth of 6 inches or, if in the opinion of the Engineer, the nature of the ground is such that greater precautions should be taken to bind the fill to the original ground then benches shall be cut in the existing ground as indicated by Engineer. G. When rock and other embankment material are excavated at approximately the same time, the rock shall be incorporated into the outer portions of the embankments and the other material which meets the requirements for select fill shall be incorporated into the formation of the embankments. Stones or fragmentary rock larger than 4-inches in their greatest dimension will not be allowed within the top 6-inches of the final grade. Stones, fragmentary rock, or boulders larger than 12-inches in their greatest dimension will not be allowed in any City of Denton Hazen and Sawyer BID SET 02200-10 Earthwork portions of embankments and shall be disposed of by the Contractor as indicated by the Engineer. When rock fragments or stone are used in embankments, the material shall be brought up in layers as specified or directed and every effort shall be exerted to fill the voids with finer material to form a dense, compact mass which meets the densities specified for embankment compaction. City of Denton Hazen and Sawyer BID SET 02200-11 Earthwork 3.08 BACKFILLING A. All structures and pipes shall be backfilled with the type of materials shown on the Drawings and specified herein. Select fill shall be deposited in successive, uniform, approximately horizontal layers not exceeding 8-inches in compacted depth for the full width. Stones or fragmentary rock larger than 4-inches in their greatest dimension will not be allowed within the top 6-inches of the ground nor within 6 inches of pipes. No stone or fragmentary rock larger than 12-inches in their greatest dimension will be allowed for any portion of backfill. Compaction shall be in accordance with the requirements of Paragraph 3.09, COMPACTION. B. Where excavation support is used, the Contractor shall take all reasonable measures to prevent loss of support beneath and adjacent to pipes and existing structures when supports are removed. If significant volumes of soil cannot be prevented from clinging to the extracted supports, the voids shall be continuously backfilled as rapidly as possible. The Contractor shall thereafter limit the depth below subgrade that supports will be installed in similar soil conditions or employ other appropriate means to prevent loss of support. 3.09 COMPACTION A. The Contractor shall compact embankments, backfill, crushed stone, aggregate base, and in place subgrade in accordance with the requirements of this Section. The densities specified herein refer to percentages of maximum density as determined by the noted test methods. Compaction of materials on the project shall be in accordance with the following schedule: Density % Std. Proctor (D698) Density % Mod. Proctor (D1557) Max. Lift Thickness as Compacted Inches Embankments Beneath Structures* 98 95 8 Other Embankments 95 92 8 Backfill Around Structures 95 92 8 Backfill in Pipe Trenches 95 92 8 Crushed Stone Beneath Structures ** ** 12 Select Sand -- 98 8 Stone Flexible Base Beneath Pavements and Structures -- 98 8 Crushed Stone Backfill ** ** 12 Crushed Stone Pipe Bedding ** ** 12 In place Subgrade Beneath Structures 98 95 Top 12-inches * Embankments beneath structures shall be considered to include a zone 10 feet out from the foundation of the structure extending down to the natural ground on a 45 slope. City of Denton Hazen and Sawyer BID SET 02200-12 Earthwork ** The aggregate shall be compacted to a degree acceptable to the Engineer by use of a vibratory compactor and/or crawler tractor. B. Field density tests will be made by the materials testing consultant to determine if the specified densities have been achieved, and these tests shall be the basis for accepting or rejecting the compaction. In-place density tests will be performed in accordance with ASTM D 1556, ASTM D 2167, or ASTM D 2922. The Engineer in conjunction with the materials testing consultant will be the judge as to which test method will be the most appropriate. Failure to achieve the specified densities shall require the Contractor to re-compact the material or remove it as required. The Contractor shall, if necessary, increase his compactive effort by increasing the number of passes, using heavier or more suitable compaction equipment, or by reducing the thickness of the layers. The Contractor shall adjust the moisture contents of the soils to bring them within the optimum range by drying them or adding water as required. C. Testing will be performed as frequently as deemed necessary by the Engineer and/or materials testing consultant. As a minimum, one in-place density test shall be performed for each 1000 cubic yards of embankment placed and 500 cubic yards of backfill placed or one test performed each day for either. 3.10 REMOVAL OF EXCESS AND UNSUITABLE MATERIALS A. The Contractor shall remove and dispose of off-site all unsuitable materials. Within thirty (30) consecutive days after Notice to Proceed, the Contractor shall submit to the Engineer for review all required permits and a list of disposal sites for the unsuitable materials. If the disposal site is located on private property, the submittal shall also include written permission from the owner of record. B. All unsuitable materials shall be disposed of in locations and under conditions that comply with federal, state and local laws and regulations. C. The Contractor shall obtain an off-site disposal area prior to beginning demolition or excavation operations. D. All excess and unsuitable materials shall be hauled in trucks of sufficient capacity and tight construction to prevent spillage. Trucks shall be covered to prevent the propagation of dust. E. When all excess and unsuitable material disposal operations are completed, the Contractor shall leave the disposal sites in a condition acceptable to the Owner and Owner(s) of the disposal site(s). 3.11 BORROW EXCAVATION A. Description The work covered by this section consists of the excavation of approved material from borrow sources and the hauling and utilization of such material as required on the Drawings or directed by the Engineer. It shall also include the removing, stockpiling, and replacement of topsoil on the borrow source; the satisfactory disposition of material from the borrow source which is not suitable for use; and the satisfactory restoration of the borrow source City of Denton Hazen and Sawyer BID SET 02200-13 Earthwork and haul roads to an acceptable condition upon completion of the work. Borrow excavation shall not be used before all available suitable unclassified excavation has been used for backfill and incorporated into the embankments. B. Coordination with Seeding Operations The Contractor shall coordinate the work covered by this section with the construction of embankments so that the requirements of Section 02200 are met. C. Materials All material shall meet the requirements of Division 2 shown below: Borrow Material ..................................Section 02200, Subsection 2.01 - Select Fill D. Construction Methods 1. General The surface of the borrow area shall be thoroughly cleared and grubbed and cleaned of all unsuitable material including all organics, topsoil, etc., before beginning the excavation. Disposal of material resulting from clearing and grubbing shall be in accordance with Section 02100. Each borrow operation shall not be allowed to accumulate exposed, erodible slope area in excess of 1 acre at any one given time without the Contractor's beginning permanent seeding and mulching of the borrow source or other erosion control measures as may be approved by the Engineer. The topsoil shall be removed and stockpiled at locations that will not interfere with the borrow operations and that meet the approval of the Engineer. Temporary erosion control measures shall be installed as may be necessary to prevent the erosion of the stockpile material. Once all borrow has been removed from the source or portion thereof, the stockpiled topsoil shall be spread uniformly over the source. Where it is necessary to haul borrow material over existing roads, the Contractor shall use all necessary precautions to prevent damage to the existing roads. The Contractor shall also conduct his hauling operations in such a manner as to not interfere with the normal flow of traffic and shall keep the traffic lanes free from spillage at all times. 2. Owner Furnished Sources Where borrow sources are furnished by the Owner the location of such sources will be as designated on the Drawings or as directed by the Engineer. The Owner will furnish the necessary haul road right-of-way at locations designated by the Engineer. All haul roads required shall be built, maintained, and when City of Denton Hazen and Sawyer BID SET 02200-14 Earthwork directed by the Engineer, obliterated, at no cost to the Owner. Where the haul road is to be reclaimed for cultivation the Contractor shall plow or scarify the area to a minimum depth of 8 inches. The borrow sources shall be left in a neat and presentable condition after use. All slopes shall be smoothed, rounded, and constructed not steeper than 3:1. Where the source is to be reclaimed for cultivation the source shall be plowed or scarified to a minimum depth of 8 inches, disc harrowed, and terraces constructed. The source shall be graded to drain such that no water will collect or stand and a functioning drainage system shall be provided. All sources shall be seeded and mulched in accordance with Section 02910. 3. Contractor Furnished Sources Prior to the approval of any off-site borrow source(s) developed for use on this project, the Contractor shall obtain certification from the State Historic Preservation Officer of the State Department of Cultural Resources certifying that the removal of the borrow material from the borrow source(s) will have no effect on any known district, site building, structure, or object that is included or eligible for inclusion in the National Register of Historic Places. A copy of this certification shall be furnished to the Engineer prior to performing any work on the proposed borrow source. The approval of borrow sources furnished by the Contractor shall be subject to the following conditions: a. The Contractor shall be responsible for acquiring the right to take the material and any rights of access that may be necessary; for locating and developing the source; and any clearing and grubbing and drainage ditches necessary. Such right shall be in writing and shall include an agreement with the Owner that the borrow source may be dressed, shaped, seeded, mulched, and drained as required by these Specifications after all borrow has been removed. b. Except where borrow is to be obtained from a commercial source, the Contractor and the property owner shall jointly submit a borrow source development, use, and reclamation plan to the Engineer for his approval prior to engaging in any land disturbing activity on the proposed source other than material sampling that may be necessary. The Contractor's plan shall address the following: (1) Drainage The source shall be graded to drain such that no water will collect or stand and a functioning drainage system shall be provided. If drainage is not practical, and the source is to serve as a pond, the minimum average depth below the water table shall be 4 feet or the source graded so as to create wetlands as appropriate. City of Denton Hazen and Sawyer BID SET 02200-15 Earthwork (2) Slopes The source shall be dressed and shaped in a continuous manner to contours which are comparable to and blend in with the adjacent topography, but in no case will slopes steeper than 3:1 be permitted. (3) Erosion Control The plan shall address the temporary and permanent measures that the Contractor intends to employ during use of the source and as a part of the reclamation. The Contractor's plan shall provide for the use of staged permanent seeding and mulching on a continual basis while the source is in use and the immediate total reclamation of the source when no longer needed. 4. Maintenance During construction and until final acceptance the Contractor shall use any methods approved by the Engineer which are necessary to maintain the work covered by this section so that the work will not contribute to excessive soil erosion. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 02207-1 Aggregate Materials SECTION 02207 AGGREGATE MATERIALS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish all labor, equipment and materials required to complete all work associated with the installation of aggregate material beneath foundations, as backfill and as roadway subgrades and other related and incidental work as required to complete the work shown on the Drawings and specified herein. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 01090 - Reference Standards B. Section 02200 - Earthwork C. Section 02276 - Erosion and Sedimentation Control D. Section 02510 - Paving and Surfacing E. Section 02712 - Foundation Drainage Systems F. Section 02910 - Final Grading and Landscaping 1.03 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. Without limiting the generality of the other requirements of the Specifications, all work herein shall conform to the applicable requirements of the following documents. All referenced specifications, codes, and standards refer to the most current issue available at the time of Bid. 1. Texas Department of Transportation Standard Specifications for Construction and Maintenance of Highways, Streets, and Bridges (TXDOT Standard Specifications); 2. ASTM C 127 Test for Specific Gravity and Absorption of Coarse Aggregate. 3. ASTM C 136 Test for Sieve Analysis of Fine and Coarse Aggregates. 4. ASTM C 535 Test for Resistance to Degradation of Large Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine. 1.04 SUBMITTALS A. Submit the following in accordance with Section 01300, Submittals. City of Denton Hazen and Sawyer BID SET 02207-2 Aggregate Materials 1. Materials gradation and certification. 2. ASTM C127, ASTM C136, and ASTM C535 test results PART 2 -- PRODUCTS 2.01 CRUSHED STONE, SCREENED GRAVEL and STONE FLEXIBLE BASE A. Crushed stone or screened gravel shall meet the requirements of Aggregate Standard Size No. 57 or No. 67 as defined by TXDOT Standard Specifications. B. Stone Flexible Base shall meet the requirements of item 247, Type A, Grade1, as defined by TXDOT Standard Specifications. 2.02 SELECT SAND A. Select sand shall meet the requirements of Sections 2.12 of the TXDOT Standard Specifications for materials and gradation. PART 3 -- EXECUTION 3.01 CRUSHED STONE, SCREENED GRAVEL AND STONE FLEXIBLE BASE A. Contractor shall install crushed stone, screened gravel and Stone Flexible Base in accordance with the TXDOT Standard Specifications and as shown on the Drawings and indicated in the Contract Documents. 1. Unless otherwise stated herein or shown on the Drawings, all mat foundations (bottom slabs) for the proposed structures shall have a blanket of crushed stone or Stone Flexible Base 6-inches thick minimum placed directly beneath the proposed mat. The blanket shall extend a minimum of 12 inches beyond the extremities of the mat. 2. For subgrade preparation at structures and structural fill, the foundation material shall be Stone Flexible Base where specifically specified on Drawings, otherwise, crushed stone or screened gravel shall be used. 3. For ground under drains, pipe bedding, and drainage layers beneath structures the coarse aggregate shall meet the requirements of aggregate standard Size No. 57 or No. 67, as defined by TXDOT Standard Specifications. 3.02 SELECT SAND A. Contractor shall install select sand in accordance with the TXDOT Standard Specifications and as shown on the Drawings and indicated in the Contract Documents. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 02214-1 Flowable Fill SECTION 02214 FLOWABLE FILL PART 1 – GENERAL 1.01 WORK INCLUDED A. The Contractor shall furnish all labor, equipment, materials and services, including pumping equipment and application, necessary for the manufacture, transportation and placement of all cementitious flowable fill as shown on the Contract Drawings or as ordered by the Engineer, except for the work specifically included under other items. 1.02 RELATED WORK A. Division 3 - Concrete 1.03 SUBMISSIONS A. In accordance with the procedures and requirements set forth in the General Conditions and Division 1, the Contractor shall submit the following: 1. Shop Drawings 2. Certifications of specification compliance for all sources of each material 3. Manufacturer’s data on all admixtures 4. Mix design and trial mix test results 5. Aggregate gradation 1.04 QUALITY CONTROL A. The Contractor shall engage the services of a testing laboratory, with the qualifications required by Section 03300 - Cast-In-Place Concrete, and experienced in the design and testing of flowable fill materials and mixes, to perform material evaluation tests and to design mixes for flowable fill. A trial mix shall be performed to verify the flowable fill mix design. The trial mix shall also report slump, air content, yield, cement content, and dry unit weight per ASTM C143 and ASTM D6023. PART 2 – MATERIALS 2.01 CEMENTITIOUS FLOWABLE FILL A. Flowable fill (controlled low strength material) shall be a uniform mixture of sand, Type II Portland cement, fly ash, admixtures and water. The mix design shall produce a flowable material with little or no bleed water, which produces a minimum compressive strength of 50 psi and maximum compressive strength of 100 psi at 56 days. The cured City of Denton Hazen and Sawyer BID SET 02214-2 Flowable Fill material shall be excavatable and have a maximum dry weight of 100 pounds per cubic foot. Slump of mix at the point of application shall be 7-inches to 10-inches. B. Admixtures specifically designed for flowable fill shall be used to improve flowability, reduce unit weight, control strength development, reduce settlement and reduce bleed water. Admixtures shall be Rheocell-Rheofill by BASF Construction Chemicals; Darafill by Grace Construction Products; or approved equal. Cement and all other materials shall be as specified in Section 03300 - Cast-In-Place Concrete. C. Fine Aggregate (Sand) shall consist of natural or manufactured siliceous sand, clean and free from deleterious substances, and graded within the following limits: Sieve Size Percent Passing by Weight 3/8" 100 No. 4 95 to 100 No. 8 80 to 100 No. 16 50 to 85 No. 30 25 to 60 No. 50 10 to 30 No. 100* 2 to 10 *For manufactured sand, the percent passing the No. 100 Sieve may be increased up to 20%. PART 3 – EXECUTION 3.01 PLACEMENT OF FLOWABLE FILL A. Flowable fill shall be batched and premixed by an approved producer, dispensed from ready-mix trucks, and placed by approved methods and equipment. B. Flowable fill shall be placed so as to completely fill the space to receive it with no trapped air pockets or other voids. Positive means of allowing the air to escape shall be provided where necessary and after approval of the Engineer. Where placed against, around and inside existing structures, lift heights shall be limited so as not to overload the structure. The Engineer shall approve lift heights and procedures. Specific procedures and methods shall be included in the Contractor’s shop drawing submittals. C. Where flowable fill is placed around piping and other elements subject to floating within the fill space, positive means shall be taken to provide temporary balancing loads to prevent uplift, or fill lift heights shall be limited to prevent uplift. D. Application of loads or placement of other fill materials or concrete on top of flowable fill shall not occur until the flowable fill surface is determined to be suitable for loading per ASTM D6024 subject to the approval of the Engineer. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 02274-1 Geotextiles SECTION 02274 GEOTEXTILES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish and install all Geotextiles, including all necessary and incidental items, as detailed or required for the Contractor to complete the installation in accordance with the Drawings and these Specifications. B. For the location of each type of Geotextile see the Drawings. 1.02 REFERENCES A. AASHTO Standards 1. AASHTO M 288-06 (2011) Geotextile Specification for Highway Applications 1.03 SUBMITTALS A. Prior to shipping to the site, the Contractor shall submit to the Engineer two copies of a mill certificate or affidavit signed by a legally authorized official of the Manufacturer for each type of Geotextile. The Supplier shall also submit three Geotextile samples of each product, 1 yard square each, seamed and unseamed as appropriate, with the mill certificate for each Geotextile type supplied. The mill certificate or affidavit shall attest that the Geotextile meets the chemical, physical and manufacturing requirements stated in the specifications. The samples shall be labeled with the manufacturer's lot number, machine direction, date of sampling, project number, specifications, manufacturer and product name. B. The Engineer shall be furnished copies of the delivery tickets or other acceptable receipts as evidence for materials received that will be incorporated into construction. PART 2 -- MATERIALS 2.01 MATERIALS A. Filter Geotextile shall be a minimum 6-ounce per square yard (nominal) nonwoven needle punched synthetic fabric consisting of staple or continuous filament polyester or polypropylene manufactured in a manner accepted by the Engineer and the Owner. The Geotextiles shall be inert and unaffected by long-term exposure to chemicals or liquids with a pH range from 3 to 10. The Geotextiles shall have a minimum threshold water head of 0.25-inches in the "as received" condition. City of Denton Hazen and Sawyer BID SET 02274-2 Geotextiles 1. Filter Geotextile shall have a Survivability Class of Class 1, 2 or 3 in accordance with AASHTO M288, unless otherwise specified herein. B. Cushion Geotextile shall be a minimum 16-ounce per square yard nonwoven needle punched synthetic fabric consisting of continuous filament or staple polyester or polypropylene manufactured in a manner accepted by the Engineer and the Owner. The Geotextiles shall be inert and unaffected by long-term exposure to chemicals or liquids with a pH range from 3 to 10. 1. Cushion Geotextile shall have a Survivability Class of Class 1 in accordance with AASHTO M288. C. Type I Separator Geotextile shall be a minimum 8-ounce per square yard (nominal) nonwoven neddlepunched synthetic fabric consisting of staple or continuous filament polyester or polypropylene manufactured in a manner accepted by the Engineer and the Owner. The Geotextiles shall be inert and unaffected by long term exposure to chemicals or liquids with a pH range from 3 to 10. 1. Type I Separator Geotextile shall have a Survivability Class of Class 1 or 2 in accordance with AASHTO M288, unless otherwise specified herein. D. Type II Separator Geotextile shall be a woven slit film or monofilament synthetic fabric consisting of polyester or polypropylene in a manner approved by the Engineer. Geotextile shall be treated to resist degradation due to exposure to ultraviolet light. 1. Type II Separator Geotextile shall have a Survivability Class of Class 1 in accordance with AASHTO M288, unless otherwise specified herein. E. All Geotextiles shall conform to the properties listed using the test methods listed in Table 1. The Contractor shall be responsible for timely submittals of all confirmation test data for Geotextiles. PART 3 -- EXECUTION 3.01 SHIPPING, HANDLING AND STORAGE A. During all periods of shipment and storage, all Geotextiles shall be protected from direct sunlight, temperature greater than 140°F water, mud, dirt, dust, and debris. B. To the extent possible, the Geotextile shall be maintained wrapped in heavy-duty protective covering until use. Geotextile delivered to the project site without protective covering shall be rejected. After the protective covering has been removed, the Geotextile shall not be left uncovered for longer than fourteen (14) days, under any circumstances. C. The Owner shall approve the shipping and delivery schedule prior to shipment. The Owner shall designate the on-site storage area for the Geotextiles. Unloading and storage of Geotextiles shall be the responsibility of the Contractor. City of Denton Hazen and Sawyer BID SET 02274-3 Geotextiles D. Geotextiles that are damaged during shipping or storage shall be rejected and replaced at Contractor expense. 3.02 QUALITY ASSURANCE CONFORMANCE TESTING A. At the option of the Engineer representative samples of Geotextiles shall be obtained and tested by the Engineer to assure that the material properties conform to these Specifications. Conformance testing shall be conducted by the Engineer and paid for by the Owner. B. Conformance testing shall be completed at a minimum frequency of one sample per 100,000 square feet of Geotextile delivered to the project site. Sampling and testing shall be as directed by the Engineer. C. Conformance testing of the Geotextiles shall include but not be limited to the following properties: 1. Mass Per Unit Area (ASTM D5261) 2. Grab Tensile Strength (ASTM D4632) 3. Trapezoidal Tear (ASTM D4533) 4. Puncture Resistance (ASTM D6241) D. The Engineer may add to, remove or revise the test methods used for determination of conformance properties to allow for use of improved methods. E. All Geotextile conformance test data shall meet or exceed requirements outlined in Table 1 of these Specifications for the particular category of Geotextile prior to installation. Any materials that do not conform to these requirements shall be retested or rejected at the direction of the Engineer. F. Each roll of Geotextile will be visually inspected by the Engineer or his representative. The Engineer reserves the right to sample and test at any time and reject, if necessary, any material based on visual inspection or verification tests. G. A Geotextile that is rejected shall be removed from the project site and replaced at the Contractor's expense. Sampling and conformance testing of the Geotextile supplied as replacement for rejected material shall be performed by the Engineer at Contractor's expense. 3.03 INSTALLATION A. Geotextiles shall be placed to the lines and grades shown on the Drawings. At the time of installation, the Geotextile shall be rejected by the Engineer if it has defects, rips, holes, flaws, evidence of deterioration, or other damage. B. It is the intent of these Specifications that Geotextiles used to protect natural drainage media be placed the same day as the drainage media to prevent soil, sediment or windblown soils to make contact with the drainage media. City of Denton Hazen and Sawyer BID SET 02274-4 Geotextiles C. The Geotextiles shall be placed smooth and free of excessive wrinkles. Geotextiles shall conform to and be in contact with the approved subgrade. D. When the Geotextiles are placed on slopes, the upslope fabric portion shall be lapped such that it is the upper or exposed Geotextile. E. Geotextiles shall be temporarily secured in a manner accepted by the Engineer prior to placement of overlying materials. F. In the absence of specific requirements shown on the Drawings, the following shall be used for overlaps of adjacent rolls of Geotextile: GEOTEXTILE TYPE/ APPLICATION OVERLAP OF ADJACENT ROLLS(1) (INCHES) TRANSVERSE END OVERLAP (INCHES) Filter Geotextile 6 min 12 min Cushion Geotextile 12 min 12 min Separator-Roadway Applications 12 min 24 min Separator-Slope Protection 18 min 24 min Separator Geotextile 12 min 18 min (1) Overlaps may be reduced if adjacent panels are sewn or heat bonded where approved by the Engineer. G. Any Geotextile that is torn or punctured shall be repaired or replaced as directed by the Engineer by the Contractor at no additional cost to the Owner. The repair shall consist of a patch of the same type of Geotextile placed over the failed areas and shall overlap the existing Geotextile a minimum of 12-inches from any point of the rupture. H. Any Geotextile that is subjected to excessive sediment buildup on its surface during construction shall be replaced by the Contractor prior to placement of overlying material. City of Denton Hazen and Sawyer BID SET 02274-5 Geotextiles TABLE 1 - MINIMUM REQUIRED GEOTEXTILE PROPERTIES* GEOTEXTILE PROPERTY FILTER GEOTEXTILE CUSHION GEOTEXTILE TYPE I SEPARATOR GEOTEXTILE TYPE II SEPARATOR GEOTEXTILE Geotextile Construction Nonwoven Needlepunched Nonwoven Needlepunched Nonwoven Neddlepunched Woven Mass per Unit Area (Unit Weight), ASTM D5261 (oz/yd2) 5.6 15.7 7.8 N/A Ultraviolet Resistance, (500 hrs.) ASTM D4355, Average % Strength Retention 70 70 70 70 Grab Tensile Strength (lbs.), ASTM D4632 150 340 200 390(1)X250(2) Grab Tensile elongation (%) ASTM D4632 50 50 50 20 MAX Wide Width Tensile Strength, (lbs./in.) ASTM D4595 N/A N/A N/A N/A Trapezoid Tear Strength (lbs) ASTM D4533 65 155 90 100 Apparent Opening Size (AOS), (mm), ASTM D4751 0.25 N/A 0.25 0.4 Permittivity at 50 mm constant head (sec-1), ASTM D4491 1.6 N/A 1.2 0.1 Puncture Resistance, ASTM D6241 (lb) 430 1100 575 950 * MINIMUM AVERAGE ROLL VALUE (MARV) (1) Warp Direction (2) Fill Direction - END OF SECTION – City of Denton Hazen and Sawyer BID SET 02274-6 Geotextiles This page left blank intentionally City of Denton Hazen and Sawyer BID SET 02276-1 Erosion and Sedimentation Control SECTION 02276 EROSION AND SEDIMENTATION CONTROL PART 1 -- GENERAL 1.01 THE REQUIREMENTS A. The Contractor is responsible for implementing Best Management Practices (BMPs) to prevent and minimize erosion and resultant sedimentation in all cleared and grubbed areas during and after construction. This item covers the work necessary for the installation of structures and measures for the prevention of soil erosion and control of sedimentation. The Contractor shall furnish all material, labor and equipment necessary for the proper installation, maintenance, inspection, monitoring, reporting, and removal (where applicable) of erosion prevention and sediment control measures and, if applicable, to cause compliance with all local permits and the Texas Commission on Environmental Control (TCEQ) General Permit to Discharge Under the Texas Pollutant Discharge Elimination System, Permit No. TXR150000, for any land disturbance or construction activity of one (1) acre or more. B. Contractor must pay any required application fees and water quality fees outlines in the TPDES General Permit TXR150000. C. Any land disturbance as the result of modifications to a site’s drainage features or topography requires protection from erosion and sedimentation. D. All excavations shall be in conformity with the lines, grades, and cross sections shown on the Contract Drawings or established by the Engineer. E. It is the intent of this Specification that the Contractor conducts the construction activities in such a manner that erosion of disturbed areas and off site sedimentation be absolutely minimized. F. All work under this Contract shall be done in conformance with and subject to the limitations of the City of Denton Development Code, City of Denton Drainage and Site Criteria Manuals. G. Portions of the Work fall within City of Denton Develop Code Environmentally Sensitive Areas described in Section 35.17.7.A.3 (Undeveloped Floodplain) and 35.17.8.A.7 (Riparian Buffer). The Work is permitted within these areas to address state regulated sanitary sewer overflows. Disturbances in these areas shall be minimized and the site shall be restored to pre-existing conditions with native grasses planted for stabilization. H. Due to the nature of the work required by this Contract, it is anticipated that the location and nature of the erosion and sediment control devices will be adjusted on several occasions to reflect the current phase of construction. The construction schedule adopted by the Contractor will impact the placement and need for specific devices required for the control of erosion. The Contractor shall develop and implement such additional techniques as may be required to minimize erosion and off-site sedimentation. City of Denton Hazen and Sawyer BID SET 02276-2 Erosion and Sedimentation Control The location and extent of erosion and sedimentation control devices shall be revised at each phase of construction that results in a change in either the quantity or direction of surface runoff from constructed areas. All deviations from the erosion and sedimentation control provisions shown on the Contract Drawings shall have the prior acceptance of the Engineer and shall be completed at no additional cost to the Owner. I. Erosion and sedimentation controls applicable to this project shall be as shown on the Contract Drawings, as specified herein, as indicated by the Engineer and as detailed in the North Carolina Erosion and Sediment Control Planning and Design Manual. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 01300 – Submittals B. Section 02100 – Clearing, Grubbing, and Site Preparation D. Section 02200 – Earthwork E. Section 02274 – Geotextiles F. Section 02500 – Surface Restoration G. Section 02910 – Final Grading and Landscaping 1.03 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. Without limiting the generality of other requirements of these specifications, all work hereunder shall conform to the applicable requirements of the referenced portions of the following documents, to the extent that the requirements therein are not in conflict with the provisions of this Section. 1. City of Denton Development Code 2. City of Denton Drainage and Site Construction Design Manuals, latest edition 3. TCEQ TPDES General Permit No. TXR150000, for any land disturbance or construction activity of one (1) acre or more 4. Texas Department of Transportation Standard Specifications for Roads and Structures, latest edition 5. North Central Texas Council of Governments (NCTCOG) Public Works Construction Standards (PWCS) B. See Specification Section 01090 - Reference Standards. 1.04 REGULATORY COMPLIANCE A. Land disturbance activities are not authorized to begin until after all required erosion and sediment control permits are obtained from the United States, the State of Texas and City of Denton Hazen and Sawyer BID SET 02276-3 Erosion and Sedimentation Control local authorities, as necessary. Contractor is the Co-Primary Permittee and Operator under the provisions of the TPDES Permit. As such, the Contractor will be required to sign certain certifications as described in the TPDES Permit. Contractor shall comply with requirements specified in the Contract Documents, on the approved Erosion Control Plan, and by the Engineer. Contractor shall also comply with all other laws, rules, regulations, ordinances and requirements concerning soil erosion and sediment control established in the United States, the State of Texas and local authorities as applicable. The following documents and the documents referenced therein define the regulatory requirements for this Section 02276. 1. TPDES PERMIT: TCEQ TPDES General Permit No. TXR150000, for any land disturbance or construction activity of one (1) acre or more. On applicable sites, Contractor is responsible for complying with terms and conditions of this permit. 2. City of Denton Development Code. 2. Manual for Erosion and Sediment Control: Contractor shall follow Practices and Standards of the City of Denton Drainage and Site Design Manuals, latest edition. B. During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge stormwater associated with construction activity including clearing, grading and excavation activities resulting in the disturbance of land and related support activities. Such discharges shall be controlled, limited and monitored as specified below. 1. The Contractor shall prepare necessary forms, Storm Water Pollution Prevention Plan (SWPPP) and comply with the TPDES General Permit No. TXR150000. Land disturbing activity shall not commence until the plan is approved by the Engineer. 2. Implement the approved plan. Deviation from the plan is allowed only to correct emergency situations of sediment discharge offsite or when minor modifications are made to improve performance of the measures and the approval authority has been notified. Note allowed deviations on the plan maintained on the site. 3. Manage onsite activities such that no adverse impacts to water quality occur from site activities or allowed discharges. The following activities, and others on a site-specific basis, require oversight throughout the construction and development process to assure that all water quality standards are protected. a. Equipment Operation and Maintenance: Equipment utilized during the construction activity on a site must be operated and maintained in such a manner as to prevent the potential or actual pollution of the surface or ground waters of the State. Fuels, lubricants, coolants, and hydraulic fluids, or any other petroleum products, shall not be discharged onto the ground or into surface waters. Spent fluids shall be disposed of in a manner so as not to enter the waters, surface or ground, of the State and in accordance with applicable state and federal disposal regulations. Any spilled fluids shall be cleaned up to the extent practicable and disposed of City of Denton Hazen and Sawyer BID SET 02276-4 Erosion and Sedimentation Control in a manner so as not to allow their entry into the waters, surface or ground, of the State. b. Material Handling: Herbicide, pesticide, and fertilizer usage during the construction activity shall be consistent with the Federal Insecticide, Fungicide, and Rodenticide Act and shall be in accordance with label restrictions. c. Building Material Waste Handling: All wastes composed of building materials shall be disposed of in accordance with Texas Administrative Code, Part 1, Chapter 330. In particular, the following guidelines shall be followed: d. Litter and Sanitary Waste: The Permittee shall control the management and disposal of litter and sanitary waste from the site. C. Violations and Fines 1. Contractor shall be responsible for reimbursing the Owner for any fines incurred as a result of violations to the TPDES General Permit No TXR150000, and any applicable delegated local program’s sediment control regulations until construction activities are complete and the project is accepted by the Owner. 2. If violations result in the issuance of a Notice of Violation, the Contractor shall comply with the requirements of the Notice within the specified time period for compliance. Failure to comply could result in the assessment of a penalty for each day of the continuing violation, beginning with the date of the violation. 3. Violations may result in civil and/or criminal penalties which include fines and imprisonment. 1.05 SUBMITTALS A. Prior to the start of the work, the Contractor shall prepare and submit a plan for implementing the temporary and permanent erosion and sedimentation control measures approved by the appropriate regulatory authority. B. The Contractor shall perform inspections of erosion and sedimentation control measures and stormwater discharge outfalls and prepare inspection reports as described in Part 3 of this Section. Copies of the inspection reports shall be submitted to the Owner with the application for payment on a monthly basis. 1.06 GUARANTEE A. All restoration and re-vegetation work shall be subject to the one-year guarantee period of the Contract as specified in the General Conditions. City of Denton Hazen and Sawyer BID SET 02276-5 Erosion and Sedimentation Control PART 2 -- MATERIALS 2.01 MATERIALS A. Materials for use in erosion and sedimentation control devices shall be in accordance with the City of Denton Drainage and Site Design Criteria Manuals. B. All erosion and sediment control bid prices shall include all excavation, grading, maintenance, legal sediment disposal, permits and all other work and appurtenances necessary to design, install and maintain the sediment and erosion control measures as detailed herein and in accordance with the City of Denton requirements. 2.02 SILT FENCE A. Silt (or sediment) fence shall be constructed as shown on the Contract Drawings, at other locations indicated by the Engineer, as specified herein. Silt fences shall be installed below small disturbed areas that are less than ¼ acre disturbed per 100-feet of fence when slopes are less than 2%. Silt fence shall not be installed across streams, ditches, or waterways or other areas of concentrated flows. B. Silt fence shall be a woven geotextile filter fabric made specifically for sediment control. Filter fabric shall not rot when buried and shall resist attack from soil chemicals, alkalines and acids in the pH range from 2 to 13, and shall resist damage due to prolonged ultraviolet exposure. Filter fabric shall be C-50NW as manufactured by Contech Earth Stabilization Solutions, GT 142 as manufactured by SKAPS Industries, Soiltex ST 120N as manufactured by Geo-Synthetics, Inc., or approved equal. The cost of silt fence shall include the materials, excavation, backfill, aggregate, etc. and all maintenance and restoration activities required. C. Silt fence shall be stable for the 10-year peak storm runoff. Fabric shall meet the following specifications: City of Denton Hazen and Sawyer BID SET 02276-6 Erosion and Sedimentation Control Temporary Silt Fence Material Property Requirements Test Material Units Supported1 Silt Fence Un-Supported1 Silt Fence Type of Value Grab Strength ASTM D 4632 N (lbs) Machine Direction 400 550 MARV (90) (90) x-Machine Direction 400 450 MARV (90) (90) Permittivity2 ASTM D 4491 sec-1 0.05 0.05 MARV Apparent Opening Size2 ASTM D 4751 mm 0.60 0.60 Max. ARV3 (US Sieve #) (30) (30) Ultraviolet Stability ASTM D 4355 % Retained Strength 70% after 500 hours exposure 70% after 500 hours exposure Typical 1 Silt Fence support shall consist of 14 gage steel wire with a mesh spacing of 150 mm (6 inches), or prefabricated polymer mesh of equivalent strength. 2 These default values are based on empirical evidence with a variety of sediment. For environmentally sensitive areas, a review of previous experience and/or site or regionally specific geotextile tests in accordance with Test Method D 5141 should be performed by the agency to confirm suitability of these requirements. 3 As measured in accordance with Test Method D 4632. D. The synthetic filter fabric shall consist of at least 95% by weight of polyolefins or polyester, certified by the manufacturer. E. The posts for silt fences shall be 1.33 lb/linear feet steel with a minimum length of 5 feet; posts shall have projections to facilitate fastening of the fabric. F. For reinforcement of standard strength filter fabric use wire fence with a minimum 14 gauge and a maximum mesh spacing of 6 inches. 2.03 INTERCEPTOR SWALE A. The Contractor shall construct interceptor swales as shown on the Contract Drawings, at other locations indicated by the Engineer and as detailed in Section 201.6 of the NCTCOG PWCS. B. Interceptor swales shall be designed, installed and maintained in accordance with Section 201.6 of the NCTCOG PWCS. The cost for interceptor swale shall include the excavation, grading, materials, etc. and all maintenance and restoration activities required. City of Denton Hazen and Sawyer BID SET 02276-7 Erosion and Sedimentation Control 2.04 RIP RAP A. The Contractor shall place rip rap as shown on the Contract Drawings, as specified in Section 803.3 of the NCTCOG PWCS. The stone for rip rap shall consist of field stone or rough un-hewn quarry stone. The rip rap shall be sound, tough, dense, and resistant to the action of air and water. Neither the width nor thickness of individual stones shall be less than one third their length. The rip rap shall be Type A or B as specified in the NCTCOG PWCS, Section 803.3, unless otherwise shown on the Contract Drawings. B. Rip rap shall be designed, installed and maintained in accordance with Section 803.3 of the NCTCOG PWCS. The cost for rip rap shall include furnishing, weighing, stockpiling, rehandling, placing and maintaining rip rap; disposal of any rip rap not incorporated into the project if directed by the Engineer; and any other incidentals necessary to complete the work. 2.05 ROLLED EROSION CONTROL PRODUCTS (RECPs) A. RECPs, including Turf Reinforcement Mat (TRM) and Erosion Control Blankets (EBC), shall be installed as shown on the Contract Drawings, at other locations indicated by the Engineer, as specified herein, and as detailed in Section 2.01.15 of the NCTCOG PWCS. RECPs should be utilized to aid stabilization of slopes greater than 2:1 and with more than 10 feet of vertical relief. RECPs should also be used when mulch cannot be adequately tacked and where immediate ground cover is required to prevent erosion damage. Examples of RECPs are blankets, nets and matting. B. RECPs shall be designed, installed and maintained in accordance with Section 2.01.15 of the NCTCOG Standard Specifications. The cost for RECPs shall include all excavation, grading, and materials, and all maintenance activities. C. RECPs shall be used to aid in permanent stabilization of vegetated channels where runoff velocity will exceed 2 feet/second on bare earth during the 2-year rainfall event that produces peak runoff. D. Typically, nets shall be used in conjunction with mulching; the use of mulching is typically not required with excelsior, woven straw blankets and coir blankets. E. The recommended anchoring devices are 12-inch minimum length wooden stakes, 11-gauge staples that are at least 6 inches long by 1 inch wide, or rigid, biodegradable stakes of a minimum of 6 inches in length. If Manufacturer’s recommendations are more stringent, they shall supersede. F. The minimum bare soil shear stress values for specific RECPs are as follows: 1. Straw with net temporary RECP shall be North American Green S150, American Excelsior Co. Curlex I, Contech SFB1, or equal with a minimum bare soil shear stress value of 1.5 lb/ft2. 2 Curled wood or coconut fiber RECP shall be American Excelsior Curlex II, North American Green C125, Contech EFB4 or equal matting with a minimum bare soil shear stress value of 2.0 lb/ft2. City of Denton Hazen and Sawyer BID SET 02276-8 Erosion and Sedimentation Control 3. Synthetic Turf Reinforcement Mat (TRM) shall be Enkamat 7020 as manufactured by Colbond Geosynthetics, Synthetic Industries Landlock Erosion Mat TRM 1060, TH8 as manufactured by TC Mirafi, or equal matting with a minimum long-term vegetated shear stress value of 5.0 lb/ft2. 2.06 TEMPORARY DIVERSIONS A. Temporary diversions shall be constructed as shown on the Contract Drawings, at other locations indicated by the Engineer, as specified herein, and as detailed in Section 201.7 of the NCTCOG PWCS. Temporary diversions shall be constructed adjacent to disturbed areas to collect surface runoff from disturbed areas and direct the runoff to sediment basins or to divert non-sediment laden runoff away from undisturbed areas and/or sediment basins. All temporary diversions transporting sediment-laden runoff shall terminate in a sediment trapping device. All temporary diversions shall be stabilized with vegetation or other means within 7 days of installation. Dimensions shall be as shown on the Contract Drawings. B. Temporary diversions shall be designed, installed and maintained in accordance with Section 201.7 of the NCTCOG PWCS, to the satisfaction of the Engineer, until the site has been stabilized. The cost of temporary diversions shall include the excavation, grading, materials, etc. and all maintenance and restoration activities required. 2.07 TEMPORARY SLOPE DRAINS A. Temporary slope drains shall be constructed as shown on the Contract Drawings, at other locations indicated by the Engineer, as specified herein, and as detailed in Section 201.13 of the NCTCOG PWCS. Temporary slope drains are used to convey concentrated runoff down the face of a slope without causing erosion and are generally used in conjunction with temporary diversions. B. The pipe diameter for temporary slope drains shall be selected according to Table 201.13.1(a) of the NCTCOG PWCS. The pipe shall be heavy-duty flexible material such as non-perforated, corrugated plastic pipe or specially designed flexible tubing. C. Temporary slope drains shall be designed, installed and maintained in accordance with Section 201.13 of the NCTCOG PWCS, to the satisfaction of the Engineer, until the site has been stabilized. The cost of the temporary slope drains shall include the piping, earthwork, stone for erosion control, and all maintenance activities required. 2.08 TEMPORARY CONSTRUCTION ENTRANCES/EXITS A. Temporary construction entrances/exits shall be located at points where vehicles enter and leave a construction site, at other locations indicated by the Engineer, as detailed in Section 201.11 of the NCTCOG PWCS. B. Temporary construction entrances/exits shall be designed, installed and maintained in accordance with Section 201.11 of the NCTCOG PWCS, to the satisfaction of the Engineer, until the site has been stabilized. The cost of temporary gravel construction City of Denton Hazen and Sawyer BID SET 02276-9 Erosion and Sedimentation Control entrances/exits shall include the materials and all maintenance activities required, including additional tire washing as may be necessary. 2.09 TEMPORARY AND PERMANENT STABILIZATION OF DISTURBED AREAS A. Temporary and permanent stabilization of disturbed areas will be provided at the locations shown on the Contract Drawings, at other locations indicated by the Engineer. The Contractor shall provide ground cover adequate to restrain erosion on disturbed areas that will be left un-worked for periods exceeding 7 to 14 days, as noted in Section 1.01. F. of this specification. B. Soil amendments, including lime and fertilizer, shall be as detailed in Section 02500 Surface Restoration. C. Seed mixtures and sod shall be selected based on site location and seasonal recommendations outlined in Section 02500 Surface Restoration. D. Mulch shall be as detailed in Section 201.16 of the NCTCOG PWCS. RECPs shall be as detailed in 2.05 herein. E. Temporary soil stabilizer shall consist of an especially prepared highly concentrated powder which, when mixed with water, forms a thick liquid such as "Enviroseal 2001" by Enviroseal Corporation, "Terra Control" by Quattro Environmental, Inc., or "CHEM- CRETE ECO-110” by International CHEM-CRETE Corporation, and having no growth or germination inhibiting factors. The agent shall be used for hydroseeding grass seed in combination with other approved amendments resulting in a highly viscous slurry which, when sprayed directly on the soil, forms a gelatinous crust. F. The cost of temporary and permanent stabilization of disturbed areas shall include all grading, excavation and materials as well as all reseeding and other maintenance activities required until stabilization is achieved. 2.10 CHECK DAMS A. Check dams shall be constructed at the locations shown on the Contract Drawings, at other locations indicated by the Engineer as detailed in Section 201.9 of the NCTCOG PWCS. B. Check dams and check dams with weirs shall not be constructed in an intermittent or perennial stream. The drainage area for any one check dam or check dam with weir shall be limited to ½ acre. C. Dimensions shall be as shown on the Contract Drawings. Check dams shall be constructed of stone or riprap with filter fabric, fiber filtration tubes, or sediment logs, as indicated on the Contract Drawings. Check dams with weirs shall be constructed of stone or riprap with filter fabric. Material specifications for stone, riprap, fiber filtration tubes, and sediment logs appear herein. If Manufacturer’s recommendations are more stringent, they shall supersede. Filter fabric shall be Type II Separator Geotextile, as specified in Section 02274 – Geotextiles. City of Denton Hazen and Sawyer BID SET 02276-10 Erosion and Sedimentation Control D. Check dams shall be designed, installed and maintained in accordance with Section 201.9 of the NCTCOG PWCS. The cost of check dams and check dams with weirs shall include all excavation, grading and materials as well as all maintenance activities required. 2.11 INLET EROSION CONTROL MEASURES A. Yard, Curb and other Inlet Erosion Control Measures shall be constructed at the locations shown on the Contract Drawings, at other locations indicated by the Engineer, as specified herein, and as detailed in Section 201.14 of the NCTCOG PWCS. Inlet erosion control measures shall be used to prevent or limit the introduction of sediment to storm drain systems and allow early use of the of the storm drainage system. Maximum drainage areas for inlet erosion control measures vary from 1 acre for excavated drop inlet protection, hardware & cloth gravel inlet protection, and block and gravel inlet protection to more than 5 acres for rock pipe inlet protection. In addition to the inlet protection measures described in the NCTCOG PWCS, other measures may be specified by the Engineer. For measures not detailed in the NCTCOG PWCS, the materials will be as specified by the Engineer’s and Manufacturer’s instructions, with more stringent specifications superseding. B. Inlet Erosion Control Measures shall be designed, installed and maintained in accordance with Section 201.14 of the NCTCOG PWCS. Measures not described in the NCTCOG PWCS shall be designed, installed, and maintained in accordance with the Engineer’s and Manufacturer’s instructions, with more stringent instructions superseding. The cost of inlet erosion control measures shall include all excavation, grading and materials as well as all maintenance activities required. 2.12 FIBER FILTRATION TUBES (FFTs) AND SEDIMENT LOGS A. FFTs and sediment logs shall be installed at the locations shown on the Contract Drawings, at other locations indicated by the Engineer, and as specified herein. B. FFTs shall consist of composite wood fibers and man-made fibers, with or without performance-enhancing polymers, encased with cylindrical tubes composed of a heavy-duty, knitted, high density polyethylene mesh. The photodegradable mesh shall be oriented in a diamond or hexagonal pattern and shall move freely at all knitted yarn intersections. C. Sediment logs shall consist of natural fibers (wood, coconut, etc.) inside heavy duty knitted cylindrical tubing. D. FFTs and sediment logs shall be designed, installed and maintained as specified herein. If Manufacturer’s recommendations are more stringent, they shall supersede. The cost of FFTs shall include all excavation, grading and materials as well as all maintenance activities required. City of Denton Hazen and Sawyer BID SET 02276-11 Erosion and Sedimentation Control 2.13 OUTLET SEDIMENT TRAP A. Stone outlet sediment traps shall be constructed at the locations shown on the Contract Drawings, at other locations indicated by the Engineer as detailed in Section 201.12 of the NCTCOG PWCS. B. Outlet sediment traps shall be designed, installed and maintained in accordance with Section 201.12 of the NCTCOG PWCS. The cost of outlet sediment trap shall include all excavation, grading and materials as well as all maintenance activities required. 2.14 FLEXIBLE GROWTH MEDIUM A. Flexible growth medium shall be applied at the locations shown on the Contract Drawings, at other locations indicated by the Engineer, and as specified herein. B. Flexible growth medium is a spray-on flexible blanket that controls soil erosion and accelerates seed germination for establishment of vegetation. It is made of wood fibers, man-made fibers, and additives that are applied wet to the prepared surface. The flexible growth medium may be mixed with seed and fertilizer prior to application. Seed and fertilizer rates shall comply with applicable stabilization of disturbed area requirements of this Section. C. Flexible growth medium shall not be used in areas of concentrated flow unless installed in conjunction with a RECM or TRM. D. Flexible growth medium shall be installed and maintained in accordance with Part 3 of this Section. If Manufacturer’s recommendations are more stringent, they shall supersede. The cost of flexible growth medium shall include all materials as well as all maintenance activities required. 2.15 TREE PROTECTION FENCE A. Tree protection fence shall be installed at the locations shown on the Contract Drawings, at other locations indicated by the Engineer. B. Tree protection fence shall used to protect trees and their root zones during construction. Tree protection fence shall be brightly-colored, UV-resistant poly barricade fabric. Signs designating the area as protected shall be installed on all sides of the fence. Wording and spacing of the signage shall be as indicated on the Contract Drawings. C. The cost of tree protection fence shall include all materials as well as all maintenance activities required. City of Denton Hazen and Sawyer BID SET 02276-12 Erosion and Sedimentation Control PART 3 -- EXECUTION 3.01 INSTALLATION AND MAINTENANCE A. All installation and maintenance shall be conducted in accordance with this specification, NCTCOG PWCS, the City of Denton Criteria Manuals. In the event of a discrepancy between this specification, Manufacturer’s recommendations, the NCTCOG PWCS and the City’s Criteria Manuals, the more stringent requirements shall take precedence. B. If applicable, all requirements of the NPDES Permit shall be followed. In the event of a discrepancy between this specification and the NPDES Permit requirements, the more stringent requirements shall take precedence. C. If possible, erosion and sedimentation control devices shall be established prior to clearing operations in a given area. Where such practice is not feasible, the erosion and sedimentation control device(s) shall be established concurrent with the clearing operations or immediately following completion of the clearing operations. D. The Contractor shall furnish the labor, materials and equipment required for routine maintenance of all erosion and sedimentation control devices. At a minimum, maintenance shall be scheduled as required for a particular device to maintain the removal efficiency and intent of the device. Maintenance shall include but not be limited to 1) the removal and satisfactory, legal disposal of accumulated sediment from traps or silt barriers and 2) replacement of filter fabrics used for silt fences and stone impaired by sediment in stone filters, gravel construction entrances, etc. Maintenance as noted in items 1) and 2) above shall be performed as required, and at least once every 3 months for the duration of construction activities. Sediment removed from erosion and sedimentation control devices shall be disposed of in locations that will not result in off-site sedimentation as acceptable to the Engineer, at no additional cost to the Owner. If no suitable on site locations are available, all such sediment will be legally disposed of off site, at no additional cost to the Owner. 3.02 SILT FENCE A. Silt Fence shall be designed, installed and maintained in accordance with the requirements of Section 201.5 of the NCTCOG PWCS. Silt fence shall be erected at the locations shown on the Contract Drawings and at all other locations as may be directed by the Engineer. Silt fence shall be erected and maintained to the satisfaction of the Engineer until a vegetative ground cover has been established. Replacement of the filter fabric and its associated appurtenances, if required by the Engineer, will be at the Contractor's expense. B. Silt fence shall not be installed across streams, ditches, waterways or other areas of concentrated flow. C. Dig a trench approximately 8 inches deep and 4 inches wide and place the fabric in the bottom of the excavated ditch or use the slicing method to insert the fabric into a cut sliced in the ground with a disc. Ensure that the height of the sediment fence does not exceed 24 inches above the ground surface. City of Denton Hazen and Sawyer BID SET 02276-13 Erosion and Sedimentation Control D. Install posts 4 feet apart in critical areas and 6 feet apart on standard applications when extra strength filter fabric is used. When wire mesh support is used, posts shall be installed a maximum of 8 feet apart. Install posts 2 feet deep on the downstream side of the silt fence, as close as possible to the fabric. E. Joints should be avoided along the fencing. When joints are necessary, securely fasten the filter cloth only at a support post with 4 feet minimum overlap to the next post. F. Compaction is vitally important for effective results. Compact the soil immediately next to the silt fence fabric with the front wheel of the tractor, skid steer or roller exerting at least 60 pounds per square inch. Compact the upstream side first and then each side twice for a total of 4 trips. G. Stabilized outlets for silt fence shall be provided at locations shown on the Contract Drawings. The outlet section shall have a maximum width of 4 feet. The height of silt fence at the outlet shall be a maximum of 1 foot. A 5 foot x 5 foot (minimum) apron of #57 washed stone shall be provided on the downstream side of the silt fence outlet. H. Silt fence shall be erected around all catch basins which are located downstream from any construction work unless other inlet protection is specified. Should any catch basins be indicated to be relocated or modified, silt fence shall be utilized until work is completed on the catch basins. Upon completion of the modification, the area shall be rough graded, as shown on the Contract Drawings, until the end of the project, at which time final grading shall occur. I. Inspect silt fence at least once a week and after each rainfall event. Make any required repairs immediately. J. Should the fabric of any silt fence collapse, tear, decompose or become ineffective, replace it promptly. All fabric shall be replaced after the first 3 months of construction activity and every 3 months thereafter until construction activities are complete. K. Remove sediment deposits as necessary to provide adequate storage volume for the next rain and to reduce pressure on the fence. Take care to avoid undermining the fence during cleanout. L. Remove all fencing materials and unstable sediment deposits and bring the area to grade and stabilize it after the contributing drainage area has been properly stabilized. Removal of any silt fence shall be permitted only with the prior approval of the Engineer or the local governing agency. 3.03 RIPRAP A. Riprap shall be designed, installed and maintained in accordance with the requirements of Section 803.3 of the NCTCOG PWCS. Riprap shall be graded so that the smaller stones are uniformly distributed through the mass. The Contractor may place the stone by mechanical methods, augmented by hand placing where necessary or ordered by the Engineer. The placed riprap shall form a properly graded, dense, neat layer of stone. The placed riprap shall have a minimum depth of 24 inches unless otherwise specified City of Denton Hazen and Sawyer BID SET 02276-14 Erosion and Sedimentation Control by the Engineer. Type II Separator Geotextile, as specified in Section 02274 – Geotextiles, shall be used under all riprap unless otherwise noted. B. Inspect periodically for scour or dislodged stones. Control of weed and brush growth may be needed. 3.04 ROLLED EROSION CONTROL PRODUCTS A. RECPs shall be designed, installed and maintained in accordance with the requirements of Section 201.15 of the NCTCOG PWCS. The Engineer may direct the Contractor to place RECPs in permanent channels or on slopes at other locations in addition to those shown on the Contract Drawings. If Manufacturer’s instructions are more stringent, they shall supersede. B. The Contractor shall place the RECPs where directed immediately after the channel or slope has been properly graded and, if applicable, prepared, fertilized, and seeded. C. Grade the surface of the installation area so that the ground is smooth and loose. Remove all large rocks, debris, etc. so as to ensure that good contact between the RECP and the ground is maintained so that no erosion occurs beneath the RECP. Terminal anchor trenches are required at RECP ends and intermittent trenches must be constructed across channels at 25-foot intervals. Terminal anchor trenches should be a minimum of 12 inches in depth and 6 inches in width, while intermittent trenches should be a minimum of 6 inches deep and 6 inches wide. Take care to maintain direct contact between the soil and the RECP. D. For slope installation, place RECP 2-3 feet over top of slope and into an approximately 12 inch deep by 6 inch wide excavated end trench. Using staples, stakes, or pins, anchor the RECP at 1 foot intervals along the bottom of the trench, backfill, and compact. Along the slope, pin the RECP in a 3 foot center-to-center pattern; provide a minimum 3 inch overlap for adjacent rolls. E. For channel installations, excavate 12 inch deep by 6 inch wide terminal trenches across the upper and lower end of the lined channel. Anchor the RECP at a minimum of 25 foot intervals utilizing either two rows of anchors or 6 inch by 6 inch cross trenches. Bury outside RECP edges in longitudinal trenches 6 inches deep and wide along the channel edges. Pin the RECP in at 1 foot intervals along the bottom of terminal trenches, backfill, and compact. Overlap adjacent rolls a minimum of 3 inches and pin at 1 foot intervals. Place the first RECP at the downstream end of the channel and unroll upstream. When starting installation of a new roll, begin in a trench or shingle-lap ends of rolls a minimum of 1 foot with upstream RECP on top to prevent uplifting. F. Staples, stakes, and pins shall be driven so that the top is flush with the ground. G. During the establishment period, check RECPs at least weekly and within 24 hours after any storm event of greater than ½ inch of rain per 24-hour period. Immediately make repairs. Good contact with the ground must be maintained. Monitor and repair the RECP as necessary until ground cover is established. City of Denton Hazen and Sawyer BID SET 02276-15 Erosion and Sedimentation Control 3.05 TEMPORARY DIVERSIONS A. Temporary diversions shall be designed, installed and maintained in accordance with the requirements of Section 201.7 of the NCTCOG PWCS. The Contractor shall provide temporary and permanent diversions at all locations noted on the Contract Drawings and at all other locations as may be directed by the Engineer. B. Remove and properly dispose of all trees, debris, etc. Fill and compact all ditches, swales, etc. that will be crossed to natural ground level or above. C. Excavate, shape and stabilize diversions as shown on the Contract Drawings and described herein. Unless otherwise noted, provide vegetative stabilization immediately after installation of permanent diversions. Temporary diversions that are to serve longer than 7 working days shall be seeded and mulched as soon as they are constructed to preserve dike height and reduce maintenance. Seed and mulch disturbed areas draining into the diversions within 14 calendar days of completing any phase of grading. D. For temporary diversions, ensure that the top of the dike is not lower at any point than the design elevation plus the specified settlement. Provide sufficient room around temporary diversions to permit machine re-grading and cleanout. Vegetate the ridge of temporary diversions immediately after construction unless they will remain in place less than 7 working days. E. Provide outlet protection adequate to accept flow from diversion plus any other contributing runoff. Sediment-laden runoff shall be routed through a sediment-trapping device. F. Inspect temporary diversions once a week and after every rainfall event. Immediately remove sediment from the flow area and repair the diversion ridge. Carefully check outlets and make timely repairs as needed. When the area protected is permanently stabilized, remove the ridge and the channel to blend with the natural ground level and appropriately stabilize it. Inspect permanent diversions weekly and after every rainfall event during construction operations until permanent vegetation is established. After vegetation is established, inspect after major storms. Immediately remove any debris and make repairs as needed in a timely manner. Maintain healthy vegetation at all times. 3.07 TEMPORARY SLOPE DRAINS A. Temporary slope drains shall be designed, installed and maintained in accordance with the requirements of Section 201.13 of the NCTCOG PWCS. The Contractor shall provide temporary slope drains with inlet and outlet protection and associated diversion channels at all locations noted on the Contract Drawings, and at other locations as may be directed by the Engineer. B. Place slope drains on undisturbed soil or well compacted fill. Slightly slope the section of pipe under the dike toward its outlet. Hand-tamp the soil under and around the entrance section in lifts not to exceed 6 inches. City of Denton Hazen and Sawyer BID SET 02276-16 Erosion and Sedimentation Control C. Ensure that all slope drain connections are watertight. Ensure that all fill material is well- compacted. Securely fasten the exposed section of the drain with grommets or stakes spaced no more than 10 feet apart. Extend the drain beyond the toe of the slope and provide outlet protection. D. Immediately stabilize all disturbed areas following construction. E. Inspect the temporary slope drain, inlet and outlet protection, and supporting diversions weekly and after every rainfall event and promptly make any necessary repairs. When the protected area has been permanently stabilized, temporary measures may be removed, materials disposed of properly, and all disturbed areas stabilized appropriately. 3.08 TEMPORARY GRAVEL CONSTRUCTION ENTRANCES/EXITS A. Temporary gravel construction entrances/exits shall be designed, installed and maintained in accordance with the requirements of Section 201.11 of the NCTCOG PWCS. The Contractor shall provide temporary gravel construction entrances/exits at all locations noted on the Contract Drawings and at all other locations as may be directed by the Engineer. B. Maintain the gravel pad in a condition to prevent mud or sediment from leaving the construction site. This may require periodic topdressing with 2 – 3 inch stone. Inspect each construction entrance at least weekly and after each rainfall event and replace stone impaired by sediment as necessary. Immediately remove all objectionable materials spilled, washed, or tracked onto public roadways. C. If, despite the use of a gravel construction entrance/exit, most of the mud and sediment are not removed from vehicle tires, tire washing may be necessary. If necessary this shall be done at no additional cost to the Owner. 3.09 TEMPORARY AND PERMANENT STABILIZATION OF DISTURBED AREAS A. The Contractor shall temporarily stabilize disturbed areas that will not be brought to final grade within 14 calendar days unless as noted in 1.01 F. of this Section. Temporary seeding shall be applied on areas that include diversions, dams, temporary sediment basins, temporary road banks and topsoil stockpiles. Areas to be stabilized with permanent vegetation must be seeded or planted within 14 working days after final grade is reached, unless temporary stabilization is applied. Temporary seeding provides protection for no more than 1 year, after which permanent stabilization should be initiated. B. Complete grading before preparing seedbeds, and install all necessary erosion control measures. Minimize steep slopes. If soils become compacted during grading, loosen to a depth of 6-8 inches. C. Reseed and mulch temporary seeding areas where seedling emergence is poor, or where erosion occurs, as soon as possible. Do not mow. Protect from traffic as much as possible. City of Denton Hazen and Sawyer BID SET 02276-17 Erosion and Sedimentation Control D. Refer to Section 02500 for additional information and specifications regarding seedbed requirements, plant selection, seeding and mulching for temporary seeding applications. E. The operation of equipment is restricted on slopes steeper than 3:1. Provisions for vegetation establishment can be made during final grading. Vegetation chosen for these sites must not require mowing or other intensive maintenance. Good mulching practices are critical for protecting against erosion on steep slopes. F. Generally, a stand of vegetation cannot be determined to be fully established until soil cover has been maintained for one full year from planting. Inspect seeded areas for failure and make necessary repairs and reseedings within the same season, if possible. G. Reseeding – If a stand has inadequate cover, re-evaluate choice of plant materials and quantities of lime and fertilizer. Re-establish the stand after seedbed preparation or over-seed the stand. Consider seeding temporary, annual species if the time of year is not appropriate for permanent seeding. H. If vegetation fails to grow, soil must be tested to determine if acidity or nutrient imbalance is responsible. I. Fertilization - On the typical disturbed site, full establishment usually requires re- fertilization in the second growing season. Fine turf requires annual maintenance fertilization. Use soil tests if possible or follow the guidelines given for the specific seeding mixture. J. Inspect all seeded areas weekly and after heavy rains until permanent cover is established. Inspect within 6 weeks of planting to see if stands are adequate. Fertilize, reseed and mulch damaged and sparse areas immediately. 3.10 CHECK DAMS A. Check dams shall be designed, installed and maintained in accordance with the requirements of Section 201.9 of the NCTCOG PWCS. The Contractor shall provide check dams or check dams with weirs at all locations noted on the Contract Drawings and at all other locations as may be directed by the Engineer. B. Stone shall be placed on a filter fabric foundation. Center stone shall be at least 9 inches below natural ground level and stone shall extend 1.5 feet beyond ditch bank. C. For check dams with weirs, provide an apron with a length 3 times the height of the dam and a width a minimum of 4 feet. A 12-inch layer (minimum) of sediment control stone shall be placed on the upstream side of the dam. Excavate sediment storage area to the dimensions shown on the Contract Drawings. D. Fiber filtration tubes and sediment logs may be specified for use as check dams. These measures shall be installed according to instructions included herein. If Manufacturer’s recommendations are more stringent, they shall supersede. E. Spacing shall be such that the elevation of the top of the lower dam is the same as the toe elevation of the upper dam. City of Denton Hazen and Sawyer BID SET 02276-18 Erosion and Sedimentation Control F. Check dams and check dams with weirs shall be inspected at least weekly and within 24 hours after any storm event of greater than ½ inch of rain per 24-hour period. Sediment, limbs and other debris shall be cleared from the channel. Repairs shall be made immediately. 3.11 INLET EROSION CONTROL MEASURES A. Inlet erosion control measures shall be designed, installed and maintained in accordance with the applicable requirements of Section 201.14 of the NCTCOG PWCS. The Contractor shall provide inlet erosion control measures at all locations noted on the Contract Drawings, and at all other locations as may be directed by the Engineer. B. Block and gravel inlet protection shall be installed and maintained in accordance with 201.14 of the NCTCOG PWCS. Drainage area shall be limited to 1 acre unless site conditions allow for frequent removal of accumulated sediment. The height of the block barrier shall be no more than 12 inches and no less than 24 inches. On the bottom row, place some of the blocks on their side to allow for dewatering. Place wire mesh over all block openings to hold gravel in place. Lateral support may be provided by placement of 2 x 4 wood studs through block openings. Place gravel 2 inches below the top of the block barrier. The top elevation of the structure must be at least 6 inches below the ground elevation downslope from the inlet to ensure that all stormwater flows over the structure and enters the storm drain instead of bypassing the structure. Block and gravel inlet protection shall not be used near the edge of fill material and shall not divert water away from the storm drain. Inspect at least weekly and after every storm event until the contributing drainage area has been permanently stabilized. Remove sediment as necessary to provide adequate storage volume for subsequent rains. Replace stone as needed. 3.12 FIBER FILTRATION TUBES (FFTs) AND SEDIMENT LOGS A. FFTs and sediment logs shall be placed along slopes to function as slope breaks and to minimize sediment transport and in diversions/channels to serve as check dams. The Contractor shall provide FFTs and sediment logs at all locations noted on the Contract Drawings, and at all other locations as may be directed by the Engineer. B. FFTs and sediment logs shall be installed to maintain contact with the soil surface. Install prior to seeding. May be installed before or after installation of RECPs. C. Anchor the upstream/upslope side of the FFTs using wire staples or approved devices at 1-foot intervals. Drive wooden stakes through downstream/downslope side of the FFTs at 2-foot intervals. Take care not to compress the FFTs. Backfill and compact loose soil against the upstream/upslope side. Overlap adjacent FFT ends by a minimum of 1 foot. D. For channel installation, construct anchor trench 3 inches deep by FFT diameter and place loose soil against upstream side of FFT. For channel gradients of 2%, install trenches on 25-foot intervals. Decrease interval distance with steeper channel gradients or more highly erosive soils. City of Denton Hazen and Sawyer BID SET 02276-19 Erosion and Sedimentation Control E. Any sediment accumulation at the base of the FFT must be removed when it reaches one-third of the height of the tube. FFT may need to be removed if fully loaded with captured sediment for maximum product performance. FFTs are to be left in place or removed from the site as directed by the Engineer. F. Sediment logs do not require installation trenches. Wood stakes shall be placed at least every 2 feet along the length of the sediment log. Stakes shall only penetrate the netting around the log. They shall not be driven through the center of the log. Sediment logs are to be left in place or removed from the site as directed by the Engineer. G. The FFTs and sediment logs shall be shall be inspected at least weekly and within 24 hours after any storm event of greater than ½ inch of rain per 24-hour period. Look for signs of flow undercutting the logs. Re-anchor and replace as necessary. 3.15 OUTLET SEDIMENT TRAP A. Outlet stabilization structures shall be designed, installed and maintained in accordance with the requirements of Section 201.12 of the NCTCOG PWCS. B. The Contractor shall ensure the subgrade, riprap and gravel filter conforms to the grading limits shown on the plans. C. Riprap shall be installed in accordance with the specifications contained herein, with filter fabric placed under the riprap. F. Outlet sediment traps shall be inspected at least weekly and within 24 hours after any storm event of greater than ½ inch of rain per 24-hour period to see if any erosion around or below the riprap has taken place or if stones have been dislodged. Repairs shall be made immediately. 3.16 FLEXIBLE GROWTH MEDIUM A. Flexible growth medium shall be applied and maintained in accordance with the requirements detailed herein. If Manufacturer’s recommendations are more stringent, they shall supersede. B. Grade area according to the Contract Drawings and prepare seedbed in accordance with this Section and Section 2910 – Final Grading and Landscaping. C. Apply flexible growth medium at rate noted on the Contract Drawings. Application may be made either in conjunction with application of seed and fertilizer or following application of seed and fertilizer. Slope interruption devices are recommended when slope lengths exceed 100 feet. Traffic shall be kept off treated areas. D. Areas treated with flexible growth medium shall be inspected at least weekly and within 24 hours after any storm event of greater than ½ inch of rain per 24-hour period until vegetation is established. Reapply in areas where seedling emergence is poor. City of Denton Hazen and Sawyer BID SET 02276-20 Erosion and Sedimentation Control 3.17 TREE PROTECTION FENCE A. Tree protection fence shall be installed and maintained in accordance with the manufacturer’s recommendations. B. Install tree protection fence around all designated tree protection areas prior to clearing, deliveries, and other construction activities onsite. Post signs designating area as protected on all sides of the fencing. C. Inspect tree protection fence weekly. Repair and replace as needed. 3.18 ADDITIONAL REQUIREMENTS A. All storm sewer piping shall be blocked at the end of every working day until the inlet is constructed above grade. B. All streets around the construction area shall be scraped as necessary to prevent accumulation of dirt and debris. C. The Contractor shall provide adequate means to prevent any sediment from entering any storm drains, curb inlets (curb inlet filter box), ditches, streams, or bodies of water downstream of any area disturbed by construction. Excavation materials shall be placed upstream of any trench or other excavation to prevent sedimentation of offsite areas. Silt fence will be provided, at no additional cost to the Owner, around excavation materials if deemed necessary by the Engineer. In areas where a natural buffer area exists between the work area and the closest stream or water course, this area shall not be disturbed. D. The Engineer may direct the Contractor to place any additional sediment and erosion control devices at other locations not shown on the Drawings. 3.19 INSPECTIONS AND MAINTENANCE A. The Contractor shall designate an Authorized Representative to perform inspections and maintenance as described herein. Contractor shall perform regular inspections and maintain records as follows: 1. Inspections shall be performed, at a minimum, once every seven calendar days and within 24 hours after any storm event of greater than ½ inch of rain per 24 hour period. 2. A rain gauge shall be maintained in good working order on the site and all rainfall amounts recorded throughout the duration of construction activities. 3. Inspection reports must be available on-site during business hours unless a site-specific exemption is approved. 4. Inspection records must be kept for 3 years following completion of construction and be available upon request. City of Denton Hazen and Sawyer BID SET 02276-21 Erosion and Sedimentation Control 5. Electronically-available records may be substituted under certain conditions as approved by Land Quality and DWQ. B. During inspections the following will be observed and appropriate maintenance activities shall be performed: 1. The conformance to specifications and current condition of all erosion and sediment control structures. 2. The effectiveness and operational success of all erosion and sediment control measures. 3. The presence of sediments or other pollutants in storm water runoff at all runoff discharge points. 4. The presence of sediments or other pollutants in receiving waters. 5. Evidence of off-site tracking at all locations where vehicles enter or exit the site. 6. Evidence of impacts to water quality due to site activities pertaining to equipment operation and maintenance, material handling, and material storage and construction laydown areas exposed to precipitation. C. Immediate action shall be taken to repair/maintain erosion and sediment control measures that are not performing as designed. The State reserves the right to stop all construction activities not related to these measures until such deficiencies are repaired. D. In areas that have undergone final stabilization, inspections and, if necessary, maintenance by Contractor will occur at least once per month for the duration of the contract or project, whichever is longer. 3.20 MONITORING AND REPORTING A. The Contractor shall be responsible for the implementation of the approved Storm Water Prevention Plan. The implementation must comply with guidelines as set forth in the TPDES General Permit TXR150000, as well as those of any local regulatory authorities. 3.21 REMOVAL OF TEMPORARY SEDIMENT CONTROL STRUCTURES A. At such time that temporary erosion and sediment control structures are no longer required under this item, the Contractor shall notify the Engineer of its intent and schedule for the removal of the temporary structures. The Contractor shall obtain the Engineer’s approval in writing prior to removal. Once the Contractor has received such written approval from the Engineer, the Contractor shall remove, as approved, the temporary structures and all sediments accumulated at the removed structure shall be returned upgrade and stabilized so they do not re-erode. In areas where temporary control structures are removed, the site shall be left in a condition that will restore original drainage. Such areas shall be evenly graded and seeded as specified in Section 02910 - Final Grading and Landscaping. City of Denton Hazen and Sawyer BID SET 02276-22 Erosion and Sedimentation Control -END OF SECTION- City of Denton Hazen and Sawyer BID SET 02371-1 Drilled Piers SECTION 02371 DRILLED PIERS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The work covered by this Section consists of the construction of "drilled piers" consisting of "Drilled Shafts" and "Caissons" as detailed on the Drawings and described in these Specifications. Drilled piers shall be of reinforced concrete section, cast-in-place against in situ soil. Drilled piers shall be straight shaft type, and shall be vertical. B. The Contractor shall furnish all labor, material, equipment, and incidental items necessary to excavate the shafts and complete the work as shown on the Drawings and as specified herein. C. The Contractor shall perform any general excavation and drilling required prior to placing drilled piers. Material resulting from drilling shafts shall be disposed of by the Contractor. D. The Contractor shall provide all necessary access including access ramps, barges, haul roads, etc., prior to the commencement of the drilled pier operations. E. The Contractor shall furnish the names of all subcontractors which he proposes to use for this work including necessary evidence and/or experience records. The Contractor or subcontractor performing the drilled pier construction shall have a minimum of three (3) years experience in dried pier construction on similar projects. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Division 2 - Sitework B. Division 3 - Concrete 1.03 SUBMITTALS A. In accordance with the procedures and requirements set forth in the General Requirements and Division 1, the Contractor shall submit the following: 1. Concrete mix design with material certifications for cement, aggregates, and admixtures. 2. Reinforcing bar details. 3. Construction sequence plan including drilling, casing, reinforcing, and concrete placement procedures. City of Denton Hazen and Sawyer BID SET 02371-2 Drilled Piers 4. Details of proposed drilling equipment and casing. 5. Experience qualifications of contractor or subcontractor. PART 2 -- MATERIALS 2.01 CONCRETE A. The concrete used for drilled pier construction shall meet the requirements of Division 3 except as modified herein. B. Workability shall be such that vibrating or prodding will not be required to consolidate the concrete. At time of placing, slump shall be within the range of five to seven inches. Sufficient mix water shall be used to produce an initial slump of two to three inches, and an approved high range water reducer or high range water reducing retarder shall be added at the job site to attain the additional slump required. These admixtures shall meet the requirements of ASTM C494, Type F or G, respectively. In the event Type F is used, a compatible approved retarder shall also be used in the quantity recommended by the manufacturer. 2.02 REINFORCING STEEL A. The reinforcing steel used for drilled pier construction shall meet the requirements of Section 03200. PART 3 -- EXECUTION 3.01 EXCAVATION A. Drilled shafts shall be advanced with flight, bucket and coring augers, capable of drilling soils, cobbles, boulders, and rock, or other approved drilling tools capable of drilling through whatever materials encountered to the dimensions and elevations shown on the Drawings. The drilled shafts shall have a minimum penetration of ten (10) feet into the hard rock which cannot be drilled with conventional earth augers and/or underreaming tools, and requires the use of special rock augers, core barrels, air tools, blasting and/or other methods of hand excavation. Depth of rock socket shall be based on penetration into dark gray unweathered marl. Penetration into unweathered marl shall not be included in rock socket depth. The Contractor will be required to drill a one and a half inch diameter test hole in each drilled shaft to a depth at least six (6) feet below the final bearing elevation of the pier for probing to verify the conditions and continuity of the bearing material. B. Drilled pier construction shall be stabilized with temporary steel casing. The steel casing utilized to stabilize the drilled shaft, protect personnel, and prevent caving or sloughing, shall be smooth metal, and of ample strength to withstand handling stresses, the pressure of concrete, surrounding earth or backfill material, and shall be watertight. Casing shall be seated and sealed within unweathered dark gray marl to prevent seepage of water into drilled shaft excavations. The outside diameter of the casing shall not be less than the specified size of the piers, except for casing to protect inspecting personnel. City of Denton Hazen and Sawyer BID SET 02371-3 Drilled Piers C. Installation of individual shafts shall be completed within an eight hour period. Concrete shall be placed as soon as practical after completion of drilling. No shaft shall be left open for more than eight hours. D. Regardless of construction methods used, the bottom of the excavation shall be cleaned of loose material, using a bucket auger or any other technique approved by the Engineer. Drilled shaft bottoms shall be excavated to a level plane or stepped with a maximum step height of 12 inches. After cleaning, a suitable weight steel probe shall be lowered to the base of the drilled shaft to insure that cleaning has been satisfactorily completed. E. Utilization or wasting of excavated material shall be as directed by the Engineer. F. After completion of shaft excavation and prior to placement of reinforcing steel and concrete, the proper condition of the drilled shaft will be demonstrated by the Contractor and verified by the Engineer. The Contractor shall measure the shaft dimensions, determine the plumb deviation of the caisson and provide such information for the Engineer's review. G. Any sloughage or other loose material shall be machine or hand cleaned from the shaft prior to placing reinforcing steel and concrete. If caving or sloughing is experienced, no compensation will be provided to the Contractor for additional concrete to fill the voids. An accumulation of loose soils, muck, etc., at the bottom of the excavation shall not be allowed. Prior to inspection of drilled pier, water in excavation shall be removed to a maximum depth of six inches above the bottom of the excavation. 3.02 DRILLED PIER LOCATIONS, ALIGNMENT, AND TOLERANCES A. Drilled piers shall be excavated as accurately as possible at locations shown on the plans and within the tolerances specified herein. Should these tolerances be exceeded, the Contractor shall provide additional construction to bring the piers within the tolerances specified. The drilled piers shall be constructed such that the axis of the piers, at the top of the piers, is no more than three (3) inches from its plan horizontal location. Drilled piers shall be within one percent (1%) of the plumb deviation for the total length of the piers. The plumbness of the drilled shafts shall be measured by an accurate procedure, inclinometer on the Kelly bar or other techniques as may be approved by the Engineer. B. The diameter of the stem of the drilled piers shall not be less than that shown on the plans. The finished top of pier shall be between one (1) inch high and three (3) inches low of the plan elevation. 3.03 DRILLED SHAFT INSPECTION A. All drilled shafts shall be inspected by the Engineer. The Contractor shall give ample notice to the Engineer prior to commencing drilled shaft work to permit scheduling of field personnel. B. The Contractor shall provide bosun chairs, safety equipment, lights, mirrors, weighted tape measures, steel probe, personnel, and all assistance that may be required for the Engineer to inspect the drilled shafts. Steel probe shall be as required to probe test hole at bottom of shaft excavation. City of Denton Hazen and Sawyer BID SET 02371-4 Drilled Piers C. Field review of the work by the Engineer shall in no way relieve the Contractor of his responsibility to furnish materials and construction in full compliance with the Drawings, Specifications and requirements of the work. 3.04 PLACEMENT OF REINFORCING STEEL A. The cage of reinforcing steel, consisting of longitudinal and spiral or tie bars, shall be completely assembled and placed in the drilled shaft as a unit upon completion of drilling and immediately prior to concrete placement. If concrete placement does not follow immediately after cage placement, the steel must be removed from the shaft unless determined otherwise by the Engineer, and the integrity of the excavation shall be recertified prior to reinstallation of the cage. Cage pickup shall be done in a manner such that racking and cage distortion will not occur. B. If it is determined in the field that the shaft must be drilled deeper, adequate reinforcement will be required in the extended zone, as directed by the Engineer. C. Every effort should be made to keep the cage plumb during concrete placement operations and casing extraction. Setting the cage on the bottom of the drilled shaft will NOT be allowed. Six (6) inch minimum high concrete blocks or cylinders shall be provided to limit the extent of any potential rebar cage settlement. The blocks shall be four (4) inches in diameter and placed under each vertical reinforcing bar. The block shall have a depression to receive the steel bar. D. The concrete cover around the rebar cage shall be as specified on the Drawings. Reasonable tolerances for construction practices are understood. However, an absolute minimum of four (4) inches should be provided at any location along the caisson. Cover less than four (4) inches may be cause for rejection. E. To ensure adequate (four (4) inch minimum) concrete cover, and achieve concentric spacing of the entire length of the cage within the shaft, concrete or steel spacer blocks shall be securely tied at five (5) points around the cage perimeter. Spacer blocks shall be thick enough to provide a minimum four (4) inch "blocking" from the outside face of the spiral bars to the outermost surface of the caisson. The blocks shall span two (2) adjacent vertical bars. Block locations shall start at the bottom of the cage and continue up along its length at spacing no greater than ten (10) feet. F. Additional peripheral blocks and closer intervals may be required as determined by conditions in the field. The vertical reinforcement and spiral or tied reinforcement shall be securely tied at each intersection. The cage shall be supported or held down by some positive method to minimize vertical displacement during concrete placement or extraction of the casing. Generally, any upward movement of the steel not exceeding two inches, or downward movement not exceeding four inches per 20 feet of shaft length will be acceptable. City of Denton Hazen and Sawyer BID SET 02371-5 Drilled Piers 3.05 PLACEMENT OF CONCRETE A. Concrete shall be placed as soon as possible after all excavation is complete and immediately after the reinforcing steel is placed. Prior to placing concrete, the bottom of the excavation shall be cleaned and free of all loose material, as specified above. B. Water in-flow rate after pumping will determine the concrete placement procedure. If the in- flow rate is less than one (1) foot per hour, the concrete placement will be considered dry. If the in-flow rate is more than one (1) foot per hour, the concrete placement will be considered wet. C. Dry Placement of Concrete 1. Prior to placing the concrete, the shaft shall be dry, such that the flow of concrete completely around the reinforcing steel can be certified by visual inspection. Maximum water level in shaft at commencement of concrete placement shall be six inches above bottom of excavation. 2. The tremie for depositing concrete in a dry drilled shaft shall consist of: a 10 inch minimum diameter tube of solid construction; a tube constructed of sections which can be added and removed; or a tube of other approved design. Concrete may be passed through a hopper at the tube end or through side openings as the tremie is retrieved during concrete placement. The tremie shall be supported so that the free fall of the concrete is less than five feet at all times. D. Wet Placement of Concrete 1. The water level shall be static in the excavation prior to placing concrete under water. The placing of concrete through a tremie shall be according to the applicable parts of Division 3 of the Specifications. 2. After the concrete in the shaft reaches the same elevation as the static water level before concrete placement was started, and after the water above the concrete has been removed, the dry method of concrete placement shall be used. Prior to resuming concrete placement, the concrete surface shall be cleaned of all scum, laitance and sediment to expose good sound concrete. E. Casing removal shall not be started until the level of concrete within the casing is in excess of ten (10) feet above the bottom of the casing being removed. Concrete level must be maintained at least ten (10) feet above the bottom of casing throughout the entire casing extraction operation, except when concrete is at or above top of drilled pier elevation. A sufficient head of concrete shall be maintained above the bottom of casing to overcome outside soil and water pressure. F. Upward movement of the casing shall be short pulls of a few inches only, while exerting downward pressure on the cage. Hammering and vibrating the casing will be permitted to facilitate extraction. City of Denton Hazen and Sawyer BID SET 02371-6 Drilled Piers G. Concrete placement into the shaft shall be within the time frames specified in Division 3 and herein. In NO case will the placement be so fast as to trap air, slurry, water, fluids, soil or any other deleterious materials in the vicinity of the reinforcing steel and the annular zone between the rebar cage and the excavation walls. H. The Contractor shall clean any contaminated concrete from the top of the drilled pier. Such wasted or contaminated concrete shall be removed from the area of the pier. Should a delay occur because of concrete delivery or other factors, the rate of placement of concrete shall be reduced so as to maintain some movement of the concrete. A maximum of forty- five (45) minutes shall be allowed between placements. In addition to the above, the procedures employed shall be such that the concrete within the caisson consists of a monolithic homogeneous structure. Vibration shall only be employed, if needed, in the upper ten (10) feet of shaft or as directed by the Engineer. 3.06 SCHEDULING AND RESTRICTIONS A. After the first drilled pier has been successfully constructed, no significant change shall be made in construction methods, equipment, or materials to be used in the construction of such drilled piers, unless approved by the Engineer. The first caisson must be approved prior to proceeding with additional caissons. Drilling may commence on a subsequent pier at an approved location provided that the concrete operation on the first drilled pier is in progress and the manpower is adequate to cover all required operations. B. Prior to the elapse of at least sixteen (16) hours after a caisson has achieved its initial concrete set (as determined by the Engineer), no adjacent shaft shall be drilled, no equipment wheel loads, and no "excessive" vibrations shall be allowed to occur at any point within a twenty (20) foot radius of the caisson. C. In the event that the Contractor fails to satisfactorily perform the procedures described within, the Engineer may shut down the construction operations and/or reject the caisson. If the integrity of the caisson is in question, core drilling, sonic, or other approved methods, shall be employed by the Contractor at his expense, under the direction of the Engineer. Core drilled holes will be backfilled with grout or mortar. Any remedial measures will be directed and approved by the Engineer. No compensation will be given to the Contractor for losses or damage due to remedial work or any testing required on caissons found defective or not in accordance with the details within these Specifications or Drawings. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 02500-1 Surface Restoration SECTION 02500 SURFACE RESTORATION PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Provide all labor, equipment, and materials necessary for final grading, topsoil placement, and miscellaneous site work not included under other Sections but required to complete the work as shown on the Drawings and specified herein. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 02200 - Earthwork B. Section 02276 - Erosion and Sedimentation Control C. Section 02910 - Final Grading and Landscaping PART 2 -- MATERIALS 2.01 TOPSOIL A. Topsoil shall meet the requirements of Section 02200 – Earthwork. PART 3 -- EXECUTION 3.01 FINAL GRADING A. Following approval of rough grading the subgrade shall be prepared as follows: 1. For riprap, bare soil 24 inches below finish grade or as directed by Engineer. 2. For topsoil, scarify 2-inches deep at 4 inches below finish grade. 3.02 TOPSOIL PLACEMENT A. Topsoil shall be placed over all areas disturbed during construction under any contract except those areas which will be paved, graveled or rip rapped. B. Topsoil shall be spread in place for lawn and road shoulder seed areas at a 6-inch consolidated depth and at a sufficient quantity for plant beds and backfill for shrubs and trees. C. Topsoil shall not be placed in a frozen or muddy condition. City of Denton Hazen and Sawyer BID SET 02500-2 Surface Restoration D. Final surface shall be hand or mechanically raked to an even finished surface to finish grade as shown on Drawings. E. All stones and roots over 4-inches and rubbish and other deleterious materials shall be removed and disposed of. - END OF SECTION - BID SET 02604-1 Utility Structures SECTION 02604 UTILITY STRUCTURES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Furnish all materials, labor, equipment, and tools required for the design, fabrication, delivery and installment of utility structures and appurtenances in accordance with the Drawings and as specified herein. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 02200 – Earthwork B. Section 03200 – Reinforcing Steel C. Section 03250 – Concrete Accessories D. Section 03300 – Cast-in-Place Concrete E. Section 03400 – Precast Concrete F. Section 05540 – Castings 1.03 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. Without limiting the generality of the other requirements of the specifications, all work herein shall conform to the applicable requirements of the following documents. All referenced specifications, codes, and standards refer to the most current issue available at the time of Bid. 1. ASTM C478 – Specification for Precast Reinforced Concrete Manhole Sections 2. ASTM C857 – Minimum Structural Design Loading for Underground Precast Concrete Utility Structures 3. ASTM C990 - Specifications for Joints in Concrete Pipe, Manholes, and Precast Box Sections Using Preformed Flexible Joint Sealants 1.04 SUBMITTALS A. Submit samples and/or Shop Drawings in accordance with Section 01300, Submittals. B. In addition to items listed in Section 03400, Precast Concrete, Shop Drawings shall include, but not be limited to: 1. Complete layout and installation Drawings and schedules with clearly marked dimensions. BID SET 02604-2 Utility Structures 2. Material certificates on all piping materials. 3. Structural design calculations sealed by a P.E. registered in the State of Texas. Design calculations for precast manholes and vaults shall include confirmation structures adequately resist flotation when they are totally empty and subjected to groundwater full height of structure. 4. Results of leakage test PART 2 -- PRODUCTS 2.01 PRECAST VAULTS, AND METER BOXES A. Precast utility structures shall be furnished with waterstops, sleeves and openings as noted on the Drawings. Box out for wall pipes shall conform accurately to the sizes and elevations of the adjoining pipes. Precast utility structures shall be watertight and conform to the requirements of ASTM C 478 and ASTM C857 with the following modifications there to: 1. Materials shall conform to Section 03400, Precast Concrete. 2. The date and name of manufacturer shall be marked inside each precast section. 3. No more than two lift holes may be cast or drilled in each section. 4. Dimensions shall be as shown on the Drawings. 5. Covers and frames shall be as specified in Section 2.13. 6. Mechanical Details such as piping, electrical, and other details shall be as shown on the Drawings. B. Joints between manhole and utility structures riser sections and at base slabs shall be groove type. 2.02 BRICK A. Brick shall be sound, hard-burned common brick conforming to ASTM C32, Grade MS. 2.03 MORTAR A. Mortar shall conform to Section 04100 Mortar and Masonry Grout. 2.04 CONCRETE A. Concrete shall conform to Section 03300, Cast-in-Place Concrete. 2.05 REINFORCING A. Reinforcing shall conform to Section 03200, Reinforcing Steel. BID SET 02604-3 Utility Structures 2.06 PRECAST CONCRETE A. Precast concrete shall conform to Section 03400, Precast Concrete. 2.07 CONCRETE BLOCK A. Concrete block shall be solid, rectangular concrete masonry units conforming to ASTM C139. 2.08 CASTINGS A. Castings shall conform to Section 05540, Castings. Casting shall be of the type and size indicated on the Drawings. 2.09 STEPS A. Steps shall be constructed of Grade 60 steel reinforcing rod (min. 1/2-inch) and completely encapsulated with a wear resistant and chemical resistant rubber. B. Each step shall have a minimum vertical load resistance of 800 pounds and a minimum pull-out resistance of 400 pounds. C. The steps shall have 11-inch minimum tread width and shall be placed at 16-inches on center, as shown on the Drawings. D. Steps shall be cast in place with the concrete. E. Steps shall only be installed as shown on the Drawings or required in the Specifications. 2.10 JOINT SEALANT A. Joint sealant shall be a preformed flexible sealant conforming to the requirements of ASTM C990, paragraph 6.2, Butyl Rubber Sealant. Joint sealant shall be Pro-Stik Butyl Sealant by Press-Seal, Butyl-Nek Join Sealant by Henry ,CS-102 Butyl Rubber Sealant for all Precast Structures by ConSeal, or equal. 2.11 FLEXIBLE RUBBER SLEEVE A. The spring set type shall have a stainless steel interior power sleeve or expander and shall be the PSX assembly by Press-Seal Gasket Corporation, the Kor-N-Seal assembly by National Pollution Control Systems, or Lock Joint Flexible Manhole Sleeve by Interpace Corp. B. The cast-in-place type shall conform to ASTM C923 and shall include stainless steel take up clamps. C. Flexible seal assemblies shall permit at least an eight (8) degree deflection from the center line of the opening in any direction while maintaining a watertight connection. BID SET 02604-4 Utility Structures 2.12 RUBBER BLADDER A The rubber bladder seal shall conform to ASTM C923 suitable for pressure testing at 10 psi minimum, with a 3/8 inch minimum wall thickness. B. The rubber bladder seal shall contain an environmentally safe, anti-bacterial compound which turns into a high viscosity gel when in contact with pressurized water. C. The rubber bladder seal shall be NPC Contour Seal by Kor-N-Seal, or equal. 2.13 COVERS AND FRAMES A. Covers and frames shall comply with Section 05540, Castings and shall be provided by the utility structure manufacturer. B. Manhole covers and frames shall meet the following requirements: 1. Locate so that there is ready access to the manhole steps 2. Clear opening shall be a minimum of 22 inches, unless otherwise indicated on the Drawings. 3. Watertight manhole frames and covers shall be suitable for 20 psi internal pressure and shall be Neenah Model R-1915, Type P or L or equal cast in place. 4. Non-watertight manhole covers shall be perforated and shall be Neenah Model R-1668, or equal. 5. Storm drain grated inlet frames and grates shall be Neenah R-1878-B7G, East Jordan Iron Works V5660, or equal. 6. Curb inlet frames and grates shall be Neenah R-3067, East Jordan Iron Works EJ 7030, or equal, and shall include frame, grate, and hood. C. Vault covers shall have lifting handles and shall be bolted with stainless steel bolts complying with Section 05050, Metal Fastening. D. All frames and covers shall be given one shop coat of asphalt or coal tar varnish, unless otherwise specified. E. Frames and covers shall be identical throughout the Contract. 2.14 GRATES A. Grates shall comply with Section 05540, Castings. 2.15 CONCRETE BALLAST A. Concrete ballast shall be Class B concrete in conformance with Section 03300, Cast-in-Place Concrete. Ballast shall be provided as necessary to insure manhole resists flotation when empty and subjected to full height groundwater conditions. BID SET 02604-5 Utility Structures 2.16 FLEXIBLE JOINT SEALER A. Flexible joint sealer shall be a rubber ring waterstop as manufactured by Fernco Joint Sealer Co., or equal. 2.17 EPOXY BONDING AGENT A. Epoxy bonding agent shall conform to Section 03250, Concrete Accessories. PART 3 -- EXECUTION 3.01 DESIGN CRITERIA A. Minimum structural design loading for underground precast concrete vaults shall be as indicated in ASTM C857, unless otherwise noted herein. Precast items subjected to vehicular traffic shall be designed for H-20 traffic loading. Other precast items shall be designed for a vertical live load of 300 psf. B. Walls of precast items shall be designed for a vertical surcharge of 100 psf. C. Precast manholes and vaults shall be designed to resist flotation when totally empty and subjected to groundwater full height of the manhole/vault. 3.02 FABRICATION AND CASTING A. Fabrication and casting shall conform to Section 03400, Precast Concrete, and to Section 03300, Cast-in-Place Concrete. B. All base sections designated to receive concrete ballast and all electrical manholes shall extend monolithically a minimum of 6 inches beyond the outside face of the wall for the entire periphery. All other utility structures shall have a standard base. C. Utility structures built around existing pipe shall have a cast-in-place base slab. 3.03 HANDLING, TRANSPORTING, AND STORING A. Handling, transporting and storing of precast items shall comply with Section 03400, Precast Concrete. 3.04 INSTALLATION A. Installation shall conform with Section 03400, Precast Concrete and with the manufacturer's recommendations or to Section 03300, Cast-in-Place Concrete. B. Frames and covers or grates shall be set so that tops are at elevations indicated on the Drawings or flush with finished grade where no elevation is indicated. C. Joints between riser sections shall be sealed with joint sealant. BID SET 02604-6 Utility Structures D. All openings in utility structures shall have flexible rubber sleeves sized to fit the connecting pipe and installed to provide watertight joints in accordance with the manufacturer's recommendations. The interior of the sleeve shall be filled with Class B concrete. E. Openings that are too large for flexible rubber sleeves shall utilize rubber bladder seals which are expanded by water injected using a pressure pump. F. All units shall be installed plumb and level. G. All lift holes and joints shall be filled with non-shrink grout conforming to Section 03600, grout inside and out. H. The manhole frames shall be set to their required elevations either with grade rings or with two or three courses of brick masonry laid around the top of the upper wall section. Such brick work shall be given a 1-inch mortar coat on the inside and out. I. Concrete ballast shall be placed so that it bears directly on the utility structure base against the outer wall monolithically encircling the structure for the full height indicated on the Drawings. Additional ballast may be required where the depth or elevation of the structure varies from the Drawings. J. Brick or Concrete Block Brick or concrete block shall be laid with broken joints and all horizontal and vertical joints filled with cement-sand mortar. Outside of walls shall be plastered with a minimum 1-inch thick coat of cement-sand mortar troweled smooth. K. Connection to Existing Pipe 1. Verify the diameter and invert elevation of existing pipe to be connected to new utility structures prior to beginning work on the structures. 2. Provide adequate protection to prevent damage to the existing pipe. 3. Provide adequate means for plugging and/or transferring the existing flow in the pipe to allow for the construction of inverts and grouting. 4. Cut off the existing pipe sufficiently for connection to the new structure and remove. 5. Thoroughly clean all foreign matter and coat the pipe surface with epoxy adhesive where the pipe joins the new structure. 6. Install a flexible joint sealer around the pipe. 7. Grout inside and outside of wall penetration with nonshrink grout. L. Backfill structures in accordance with Section 02200, Earthwork. M. Clean all structures of any accumulation of silt, debris, or foreign matter and keep clean until final acceptance of the work. N. Excavation shall conform to Section 02200, Earthwork. BID SET 02604-7 Utility Structures O. Structure bases shall bear on a minimum of 8 inches of compacted stone unless otherwise indicated on the Drawings. P. Channel Inverts 1. Inverts shall be placed using Class B concrete with forms sufficient to provide a smooth half-round shape as shown on the Drawings. Manhole bases employing full depth precast inverts are acceptable. 2. Where the slope of the line does not change through a manhole, a constant slope shall be maintained in the invert. Where slope changes occur within a given manhole, the transition shall be smooth and shall occur at the approximate center of the manhole. 3. Inverts shown on the Drawings are taken at the center of the manhole unless otherwise noted. 3.05 ADJUSTMENTS TO EXISTING UTILITY STRUCTURES A. Adjust structures as indicated on the Drawings using concrete or cast iron adjustment rings by approved methods. B. Clean covers and inlet castings of all foreign material and paint with one coat of coal tar epoxy. 3.06 ADJUSTING COLLARS AND FINAL ADJUSTMENTS A. Adjusting collars shall be as shown on the Drawings. Final adjustments shall be made so that the manhole ring and cover will be smooth and flush with the finished grade of the adjacent surface, or as otherwise indicated on the Drawings for manholes shown above grade. 3.07 FLUSHING AND TESTING A. Obstruction - After backfilling, all sewers shall be inspected for obstructions and shall be flushed with water. Flushing shall be a minimum velocity of 2.5 feet per second for a duration acceptable to the Engineer. Flushing shall remove all dirt, stones, pieces of wood and other debris which accumulated in the sewer during construction. The Contractor shall provide a means acceptable to the Engineer for removal of debris flushed from each section of sewer. If after flushing, any obstructions remain, they shall be removed at the Contractor's expense. B. Visual Inspection - Sewer lines shall be visually inspected from every manhole by use of mirrors, television cameras, or other devices for visual inspection, and the lines shall all exhibit a fully circular pattern when viewed from one manhole to the next. Lines which do not exhibit a true line and grade or have structural defects shall be corrected to meet these qualifications. C. Leakage - Sewers shall be tested for leakage. The program of testing shall fit the conditions as mutually determined by the Engineer and the Contractor. The Contractor shall take all necessary precautions to prevent any joints from drawing while the sewers or their appurtenances are being tested. The Contractor shall, at his own expense, correct any BID SET 02604-8 Utility Structures excess leakage and repair any damage to the pipe and their appurtenances, or to any structures resulting from or caused by these tests. D. Leakage Test Procedure - Each section of sewer shall be tested by closing the lower end of the sewer to be tested and the inlet sewer of the upper manhole with stoppers and filling the pipe and manhole with water to a point 6 feet above the crown of the open sewer in the upper manhole, or, if ground water is present, 6 feet above the sections average adjacent ground water level as indicated by a monitor well installed adjacent to each manhole. The line shall be filled with water prior to testing and allowed to stand until the pipe has reached its maximum absorption, but not less than two (2) hours. After maximum absorption has been reached, the head shall be re-established and tested for at least six (6) hours maintaining the head specified above by measured additions of water. The sum of these additions shall be the leakage for the test period. If ground water is present to a height of at least 6 feet above the crown of the sewer at the upper end of the pipe section to be tested, the leakage test may be made by measuring the rate of infiltration using a suitable weir or other measuring device approved by the Engineer. Whether the test is made by infiltration or exfiltration, the allowable leakage shall not exceed 100 gallons per day per inch of diameter per mile of sewer being tested. Where the actual leakage exceeds the allowable, the Contractor shall discover the cause and correct it before the sewer will be accepted. For the purpose of this subsection, a section of sewer is defined as that length of sewer between successive manholes or special structures or stubouts for future connections. E. Low Pressure Compressed Air Test - If the leakage cannot be located by infiltration or exfiltration testing, this type test may be used. The pipeline shall be considered acceptable, when tested at an average pressure of 3.0 psi greater than the average back pressure of any groundwater that may submerge the pipe, if the section under test does not lose air at a rate greater than 0.0030 cfm per sq. ft. of internal pipe surface. F. Deflection Test - No sooner than thirty (30) days after final backfill installation, each section of PVC pipe shall be checked for vertical deflection using an electronic deflecto-meter or a rigid "Go-No-Go" device. Vertical deflection shall not exceed five (5) percent of the inside pipe diameter for PVC pipe. Where the actual deflection exceeds the allowable, the Contractor shall discover the cause and correct it before the pipe will be acceptable. For the purpose of this subsection, a section of sewer is defined as that length of sewer between successive manholes or special structures or stubouts for future connections. G. Cost of Testing and Repairs - Any and all work necessary to bring the line into conformance with the infiltration and deflection specifications shall be performed by the Contractor at no extra cost to the Owner. All apparent sources of infiltration and excessive deflection shall be repaired by the Contractor. The Contractor shall provide all water, plugs, hoses, pumps, equipment, etc. necessary for the proper flushing and testing of the sewers. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 02831-1 Steel Fencing SECTION 02831 STEEL FENCING PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish and install steel fencing, posts, gates, etc., where shown on the Drawings and in compliance with these Specifications. B. Fencing shall be of the chain link type topped with barbed wire. The 10-foot high fabric shall clear the final grade by 3 inches, and shall be topped with three strands of barbed wire. The barbed wire shall be angled outward at the top. All components which are to be galvanized shall be hot dipped galvanized, coating to be 1.8 ounces per square foot of surface. Alternate coatings which employ a zinc coating of less than 1.8 ounces per square foot are not acceptable. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 03300 - Cast-in-Place Concrete. 1.03 SUBMITTALS A. Shop Drawings shall be furnished in accordance with Section 01300, Submittals. PART 2 -- PRODUCTS 2.01 CHAIN LINK FABRIC A. Fabric shall be 9 gauge aluminum coated wire woven in a 2-inch diamond mesh conforming to ASTM A491. Top and bottom selvage to have a barbed finish. Minimum weight of coating shall be 0.40 ounce per square foot of wire surface. The coated wire shall have a minimum tensile strength of 80,000 lbs. per square inch. B. Install fabric 3 inches above ground level. Fence shall be stretched tight and securely fastened to posts at points spaced 12 inches apart maximum. 2.02 POSTS A. Posts and rails shall be galvanized standard weight pipe conforming to the requirements of ASTM F1083. 1. Line Posts: Line posts shall be Schedule 40, 2-3/8 inch O.D. galvanized pipe with minimum bending strength of 201 pounds under a 6-foot cantilever load. Line posts shall be spaced at a maximum 10-foot O.C. City of Denton Hazen and Sawyer BID SET 02831-2 Steel Fencing 2. Terminal Posts: All end, corner, intermediate, and pull posts and gate leaves 6'0" wide and less shall be 2-7/8 inch O.D. galvanized Schedule 40 pipe with minimum bending strength of 381 pounds on 6-foot cantilever load. Gate posts for gate leaves shall be Schedule 40 pipe complying with ASTM F1083 of diameters as follows: Gate Leaf Width Pipe O.D. Weight per Ft. 0' to 6' 2-7/8" 5.79 lbs. Over 6' to 13' 4" 9.1 lbs. Over 13' to 18' 6-5/8" 18.97 lbs. Over 18' 8-5/8" 24.7lbs. 2.03 TENSION WIRE A. Top and bottom tension wire shall be No. 7 gauge aluminum coated steel wire. Fabric shall be securely tied to tension wire at intervals not to exceed 24-inches. 2.04 POST TOPS AND BARBED WIRE SUPPORTS A. Gate, end, corner and line post tops shall be malleable iron or pressed steel and shall be hot dipped galvanized conforming to ASTM A153. B. Extension arms for supporting the three (3) strands of barbed wire for line posts shall be of pressed steel with malleable iron base, or solid aluminum alloy castings. C. Angles for line post extension arms shall be approximately 45 degrees from the vertical and the top slot for barbed wire shall be a minimum of 12 inches above the fabric and a minimum of 10 inches from the fence line. 2.05 BARBED WIRE A. Barbed wire shall consist of three strands of 12-1/2 gauge aluminum coated steel wire with 4-point barbs of 14 gauge aluminum wire spaced 5 inches apart, conforming to ASTM A585. B. Additional strands of barbed wire shall be added beneath the chain link fabric at all ditch crossings to maintain the security of the fence installation. 2.06 BRACES AND TOP RAILS A. Braces and top rails (where shown on the Drawings) shall be 1.66-inch O.D., Schedule 40 galvanized pipe with minimum vertical bending strength of 202 pounds on 10-foot span. B. Top rails shall be continuous and shall pass through the post tops. The coupling used to join the top rail lengths shall allow for expansion. Brace rails shall be provided at all terminal posts, located between the top and grade lines and extend from the terminal post to the first adjacent post. Braces shall be securely fastened at both ends. Brace ends for receiving brace rails shall be malleable iron or castings of 356.0 (formerly SG70A) alloy, or equivalent of ASTM B26 or B108. City of Denton Hazen and Sawyer BID SET 02831-3 Steel Fencing C. Truss and stretcher bands shall be 1/8-inch x 7/8-inch pressed steel, supplied with carriage bolts and nuts. Bolts shall be 5/16-inch by 1 1/4-inch. Truss rods shall be 3/8-inch nominal diameter. 2.07 FABRIC TIES A. Wire ties shall be preformed 0.148-inch diameter (9 gauge) aluminum. Flat band type ties shall be 1100-H18 or 3003-H14, .064-inch thick by 1/2-inch wide. B. Hog rings for attaching tension wire to fabric shall be 0.105-inch diameter, Alloy 1100-H14. 2.08 GATES A. Gate frames shall be made of 2-inch O.D. ASTM F1083 pipe, 2.72 lbs. per foot hot dipped galvanized. Fabric shall match fence. Gate frames shall be welded or assembled with riveted corner castings. Gate frames shall be equipped with 3/8-inch diameter adjustable truss bars. Hinges shall be ball and socket. B. Gate shall be equipped with positive latching device with provision for padlocking. Personnel gates shall be minimum 36-inch clear opening. 2.09 SLIDING GATE A. Sliding gates shall be manual, cantilever type of the same height as adjacent fence. Gate shall be constructed of 2-1/2-inch O.D. Schedule 40 pipe 2-inch O.D. braces. Unit shall be similar in construction to swing gates. Gates shall be adequately braced for the size shown with all corners electrically welded. Sliding gates shall slide fully open one way with stops at both ends to prevent derailment. PART 3 -- EXECUTION 3.01 INSTALLATION A. All line posts shall be spaced equidistant in the fence line on a maximum of 10-foot centers. Posts shall be set plumb in concrete bases as detailed on Drawings. The top of the posts shall be brought to a smooth grade line. The wire fence shall be set accurately to line and grade and shall be plumb. B. End, corner, pull or intermediate posts shall be placed in the following locations: corners; changes in direction; abrupt changes in grade; intervals no greater than 500 feet in the fence line. Each end or gate post shall have one brace assembly and each corner or intermediate post shall have two brace assemblies. C. Horizontal braces shall be provided at all terminal posts, corner posts, and intermediate posts between top rail and ground and shall extend from the above-mentioned posts to the first adjacent line posts. Braces shall be securely fastened to the line posts by brace ends and brace bands and to the terminal posts by approved rail end connectors. Diagonal brace rods shall be trussed from the brace end on the line post back to the terminal post, corner post or intermediate post and fastened to it by an approved connector. City of Denton Hazen and Sawyer BID SET 02831-4 Steel Fencing 3.02 POST FOUNDATIONS A. Post holes shall be in true alignment and of sufficient size to provide a permanent foundation of concrete. Holes shall be well centered on the posts. A minimum diameter of 12 inches shall be required for all posts. B. Post foundations shall be carefully rodded or tamped into place. The top of concrete shall extend 2 inches above ground line and shall be neatly troweled and leveled up from edges to the posts so as to have a pitch outward in all directions. C. No materials shall be installed on the posts, nor shall any load be applied to the posts within 3 days after the individual post foundation is completed. D. All concrete shall be Class "B" in conformance with Section 03300, Cast-in-Place Concrete. 3.03 RESETTING OF EXISTING FENCE A. Where shown on the Drawings that resetting of existing fence is required, the fence, after resetting, shall be in a condition that is equal to or better than before the fence was removed. B. The Contractor shall replace any of the fence components which have been unnecessarily damaged by him. 3.04 PADLOCK AND KEYS A. One solid brass padlock shall be furnished with each gate. Padlocks shall be master keyed to the system specified under Section 08710, Finish Hardware. 3.05 TEMPORARY FENCING A. The Contractor shall furnish and install all temporary fencing and appurtenances as shown on the Drawings or as required during construction to adequately secure the site prior to installation of the permanent fence. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 02910-1 Final Grading and Landscaping SECTION 02910 FINAL GRADING AND LANDSCAPING PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Furnish all labor, equipment, and materials necessary for final grading, topsoiling, seeding, and miscellaneous site work not included under other Sections, but required to complete the work as shown on the Drawings and specified herein. Under this Section, all areas of the project site disturbed by excavation, materials storage, temporary roads, etc., shall be reseeded as specified herein. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 02276 - Erosion and Sedimentation Control. B. Section 02500 - Surface Restoration. 1.03 SUBMITTALS A. Submit the following in accordance with Section 01300, Submittals. 1. Product Data 2. Certification of all materials 3. Three (3) copies of composition and germination certification and of test results for grass seed. PART 2 -- PRODUCTS 2.01 CONTRACTOR'S RESPONSIBILITIES A. Furnish and submit certification for the materials used as specified in the General Conditions, Division 1 and Division 2. 2.02 TOPSOIL A. Upon completion and approval of the rough grading, the Contractor shall place the topsoil over all areas disturbed during construction under any contract except those areas which will be paved, graveled or rip rapped. Topsoil shall not be placed in a frozen or muddy condition and shall contain no toxic materials harmful to grass growth. Topsoil shall be as defined under Section 02200, Earthwork. City of Denton Hazen and Sawyer BID SET 02910-2 Final Grading and Landscaping 2.03 WATER A. Water shall be furnished to the Contractor by the Owner from existing facilities as directed by the Engineer. B. The Contractor shall furnish all hoses and connections necessary to complete the landscaping work. 2.04 FERTILIZER A. Fertilizer shall be a complete commercial fertilizer with components derived from commercial sources. Fertilizer analysis shall be determined from field soil sampling in appropriate number taken by the Contractor and analyzed by the Texas Department of Agriculture or other independent laboratory. Contractor shall furnish fertilizer in accordance with the recommendations of the Texas Department of Agriculture. B. One-quarter of the Nitrogen shall be in the form of nitrates, one-quarter in the form of ammonia salts, and one-half in the form of natural organic Nitrogen. Available Phosphoric Acid shall be free from superphosphate, bone, or tankage. Potash shall be Sulphate of Potash. Elements shall conform to the standards of Association of Official Agricultural Chemists. C. Fertilizer shall be delivered in standard size bags marked with the weight, analysis of contents, and the name of the manufacturer. Fertilizer shall be stored in weatherproof storage areas and in such a manner that its effectiveness will not be impaired. 2.05 LIME A. At least 50% shall pass a No. 200 U.S.S. mesh sieve. At least 90% shall pass a No. 100 U.S.S. mesh sieve and 100% shall pass a No. 10 U.S.S. mesh sieve. Total carbonates shall not be less than 80% or 44.8% Calcium Oxide equivalent. For the purpose of calculation, total carbonates shall be considered as Calcium Carbonate. 2.06 GRASS SEED A. The Contractor shall furnish the kinds and amounts of seed to be seeded in all areas disturbed by the construction work. All seed must have been tested within six (6) months immediately preceding the planting of such material on the job. B. The inoculant for treating legume seed shall be a pure culture of nitrogen-fixing bacteria prepared specifically for the species. Inoculants shall not be used later than the date indicated on the container. The quality of the seed shall conform to the following: City of Denton Hazen and Sawyer BID SET 02910-3 Final Grading and Landscaping Type Minimum Seed Purity (%) Minimum Germination (%) Maximum Weed Seed (%) Fescue (fungus free) 98 90 1.00 Lolium multiform - Italian or Annual Rye 98 90 0.50 Sudan grass 98 85 0.25 Millet 98 85 0.50 Sericea Lespedeza Scarified Unscarified 98 98 85 85 0.50 0.50 Cynodon Dactylon – Common Bermuda 98 85 0.50 Bouteloua gracilis - Blue grama 98 85 0.50 Buchloe dactyloides - Buffalo 98 85 0.50 Hilaria belangeri – Curly Mesquite 98 85 0.50 C. Scarified Lespedeza may contain 20% hard seed and unscarified 50% hard seed. Seed containing prohibited noxious weed seed shall not be accepted. D. Seed mixtures to be used on the project shall be as follows: P - 150#/acre Buffalo (Add 25#/acre Curly Mesquite or Blue Grama grass in May) T - 100#/acre Italian or Annual Rye and 20#/acre unhulled Common Bermuda Note: P - Permanent Seeding T - Temporary Seeding E. On cut and fill slopes 2:1 or steeper add 30#/acre of Common Bermuda to the P seed mixture. 2.07 WOOD CELLULOSE FIBER MULCH A. For use in hydroseeding grass seed in combination with fertilizers and other approved additions, shall consist of especially prepared wood cellulose fibers such as "Conwed", "Mat-Fiber", or equal, and have no growth or germination inhibiting factors, and be dyed green. B. The wood cellulose fiber shall have the additional characteristic of dispersing rapidly in water to form a homogeneous slurry and remain in such state when agitated in the hydraulic mulching unit, or adequate equal, with the specified materials. City of Denton Hazen and Sawyer BID SET 02910-4 Final Grading and Landscaping C. When applied, the wood cellulose fiber with additives will form an absorptive mat but not a plant inhibiting membrane, which will allow moisture, natural or mechanical, to percolate into underlying soil. D. The mulch shall be supplied, compressed in packages containing 50 pounds of material having an equilibrium air dry moisture content at time of manufacture of 12% plus or minus 3%. Wood cellulose fiber mulch shall be stored in a weatherproof storage area and in such a manner that effectiveness will not be impaired. 2.08 STRAW MULCH A. Straw used for mulch shall be small grain hay. Hay shall be undamaged, air dry, threshed straw, free of undesirable weed seed. Straw mulch is not required for seeded areas treated with a temporary soil stabilizer. 2.09 TEMPORARY SOIL STABILIZER A. The temporary agent for soil erosion control shall consist of an especially prepared highly concentrated powder which, when mixed with water, forms a thick liquid such as "Enviroseal 2001" by Enviroseal Corporation, "Terra Control" by Quattro Environmental, Inc., or "CHEM-CRETE ECO-110” by International CHEM-CRETE Corporation, and having no growth or germination inhibiting factors. The agent shall be used for hydroseeding grass seed in combination with other approved amendments resulting in a highly viscous slurry which, when sprayed directly on the soil, forms a gelatinous crust. 2.10 ROLLED EROSION CONTROL PRODUCTS A. The rolled erosion control products (RECPs) shall be as specified in Section 02276 - Erosion and Sedimentation Control. 2.11 RIPRAP AND HERBICIDES A. Furnish and install sufficient quantity of landscape gravel or riprap to cover over the ground to a minimum 4-inch depth for gravel and 24-inch depth for riprap, unless otherwise noted, or indicated on the Drawings. Also furnish and apply an approved herbicide to the subgrade surface just prior to installing the landscape gravel or riprap. B. During placing, the stone shall be graded so that the smaller stones are uniformly distributed through the mass. The Contractor may place the stone by mechanical methods, augmented by hand placing where necessary or ordered by the Engineer. The placed riprap shall form a properly graded, dense, neat layer of stone. C. All topsoil and vegetative matter shall be removed from the subgrade surfaces prior to the application of the weed killer (herbicide) and to the placement of landscape gravel or riprap. Apply commercial-type herbicide as preemergence control of miscellaneous grasses and broadleaf weeds in granular or liquid form such as "Treflan", "Dymid", or equal. Methods and rates of application shall be in strict compliance to manufacturer's directions and acceptable to the Engineer. City of Denton Hazen and Sawyer BID SET 02910-5 Final Grading and Landscaping D. The herbicide selected shall be safe for use around ornamental plantings, have long-lasting weed control, and shall be resistant to leaching away under excessive rainfall. E. A second application of the herbicide shall be made on the surface of the landscape gravel or riprap sometime after the first six (6) months, but not later than 12-months. Same methods and rates apply as specified previously. PART 3 -- EXECUTION 3.01 GRADING A. After approval of the rough grading, the Contractor shall commence his preparations of the subgrade for the various major conditions of the work as follows: 1. Bare soil for riprap area at subgrade (24-inches below final grade, or as directed by the Engineer). 2. Topsoil for lawn and road shoulder seed area - scarify 2-inch depth of subgrade (4-inches below final grade) prior to placing topsoil. B. Final surface grading of the topsoiled, landscape graveled, and riprapped areas shall be mechanically raked or hand raked to an even finished surface alignment. 3.02 TOPSOIL A. Topsoil shall be spread in place for quantity required for lawn and road shoulder seed areas at 6-inch consolidated depth, and sufficient quantity for certain plant beds and backfill for shrubs and trees as specified. 3.03 SEEDBED PREPARATION A. Contractor shall prepare all areas to receive temporary or permanent seeding measures prior to planting. B. Topsoil shall be placed in areas to be seeded and roughened with tracked equipment or other suitable measures. Slopes steeper than 3:1 may be roughened by grooving, furrowing, tracking, or stairstep grading. Slopes flatter than 3:1 should be grooved by disking, harrowing, raking, operating planting equipment on the contour. C. Soil amendments including, but not limited to, lime and fertilizer shall be spread as necessary, and at the rates specified in this Section. Seeding shall be as per the type and rates specified in this Section. Seed shall be broadcast as soon as possible following roughening, before surface has been sealed by rainfall. 3.04 HYDROSEEDING AND GRASS A. The Contractor shall grow a stand of grass by hydroseeding method on all disturbed areas. The Contractor shall be responsible for the satisfactory growth of grass throughout the period of the one-year guarantee. City of Denton Hazen and Sawyer BID SET 02910-6 Final Grading and Landscaping B. The Contractor's work shall include the preparation of the topsoil and bare soil seed bed, application of fertilizer, limestone, mulching, inoculant, temporary soil stabilizer, watering, and all other operations necessary to provide a satisfactory growth of sod at the end of the one-year maintenance period. Areas without satisfactory sod at the end of one (1) year shall be replanted until satisfactory growth is obtained and acceptable to the Engineer. C. All areas to be seeded shall be done by the hydraulic seeding method including all additives and amendments required. A "Reinco", "Finn", or "Bowie" type hydromulcher with adjustable nozzles and extension hoses, or equal, shall be utilized. General capacity of tank should range from 500 to 2,500 gallons, or as approved by the Engineer. D. Hydraulic seeding shall be carried out in three steps. Step one shall consist of the application of lime. In step two the seed mixture shall be mixed with the fertilizer, wood cellulose fiber mulch, and any required inoculants and applied to the seed bed. Step three shall consist of application of top dressing during the first spring or fall, whichever comes first, after step two. E. Top dressing shall consist of a commercial grade fertilizer plus Nitrogen or other analysis as may be recommended by soil testing. Types and application rates of seed mixtures, lime, fertilizer, and wood cellulose fiber mulch, shall be as shown in the Seeding Schedule. F. Ingredients for the mixture and steps should be dumped into a tank of water and thoroughly mixed to a homogeneous slurry and sprayed out under a minimum of 300-350 pounds pressure, in suitable proportions to accommodate the type and capacity of the hydraulic machine to be used. Applications shall be evenly sprayed over the ground surface. The Contractor shall free the topsoil of stones, roots, rubbish, and other deleterious materials and dispose of same off the site. The bare soil, except existing steep embankment area, shall be rough raked to remove stones, roots, and rubbish over 4-inches in size, and other deleterious materials and dispose of same off the site. G. No seeding should be undertaken in windy or unfavorable weather, when the ground is too wet to rake easily, when it is in a frozen condition, or too dry. Any bare spots shown in two to three weeks shall be recultivated, fertilized at half the rate, raked, seeded, and mulched again by mechanical or hand broadcast method acceptable to the Engineer. H. Areas that have been seeded with a temporary seed mixture shall be mowed to a height of less than 2-inches and scarified prior to seeding with the permanent seed mixture. I. The Contractor shall provide, at his own expense, protection for all seeded areas against trespassing and damage at all times until acceptance of the work. Slopes shall be protected from damage due to erosion, settlement, and other causes and shall be repaired promptly at the Contractor's expense. J. The Contractor shall water newly seeded areas of the lawn and road shoulder mix once a week until the grasses have germinated sufficiently to produce a healthy turf, or unless otherwise directed by the Engineer. Each watering shall provide three (3) gallons per square yard. The Contractor shall furnish all necessary hoses, sprinklers, and connections. City of Denton Hazen and Sawyer BID SET 02910-7 Final Grading and Landscaping K. The first and second cutting of the lawn grasses only shall be done by the Contractor. All subsequent cuttings will be done by the Owner's forces in a manner specified by the Contractor. 3.05 DITCH AND SWALE EROSION PROTECTION A. All ditches and swales indicated on the Drawings shall be lined with a rolled erosion control product (RECP). The area to be covered shall be properly graded and hydroseeded before the RECP is installed. Installation shall be in accordance with Section 02276, Erosion and Sedimentation Control. 3.06 MAINTENANCE A. The Contractor shall be responsible for maintaining all seeded areas through the end of his warranty period including installing temporary irrigation piping and sprinklers as needed. Maintenance shall include but not be limited to, annual fertilization, mowing, repair of seeded areas, irrigation, and weed control. The Contractor shall provide, at his own expense, protection for all seeded areas against trespassing and damage at all times until acceptance of the work. Slopes shall be protected from damage due to erosion, settlement, and other causes and shall be repaired promptly at the Contractor's expense. B. Annual fertilization shall consist of an application of 500#/acre of 10-10-10 commercial grade fertilizer, or its equivalent and 60#/acre of nitrogen in early fall, or other analysis as may be determined by soil test. Annual fertilization shall be in addition to top dressing and shall be performed by the Contractor each fall season after planting until the work is substantially complete. C. Mowing shall be scheduled so as to maintain a minimum stand height of 4-inches or as directed by the Engineer. Stand height shall be allowed to reach 8 to 10-inches prior to mowing. D. All seeded areas shall be inspected on a regular basis and any necessary repairs or reseedings made within the planting season, if possible. If the stand should be over 60% damaged, it shall be re-established following the original seeding recommendations. E. Weed growth shall be maintained mechanically and/or with herbicides. When chemicals are used, the Contractor shall adhere strictly to the instructions on the label of the herbicide. No herbicide shall be used without prior approval of the Engineer. 3.07 CLEANUP A. The Contractor shall remove from the site all subsoil excavated from his work and all other debris including, but not limited to, branches, paper, and rubbish in all landscape areas, and remove temporary barricades as the work proceeds. B. All areas shall be kept in a neat, orderly condition at all times. Prior to final acceptance, the Contractor shall clean up the entire landscaped area to the satisfaction of the Engineer. City of Denton Hazen and Sawyer BID SET 02910-8 Final Grading and Landscaping 3.08 SEEDING SCHEDULE A. All seeding and mulching to be completed by the Contractor shall conform to the following schedule. No permanent seeding shall be performed from May 1 - August 31 and November 1 - February 14. Temporary seed mixtures will be used during these times if seeding is necessary. Areas seeded with temporary seed mixtures shall be reseeded by the Contractor at no additional cost to the Owner with permanent seed as directed by the Engineer. B. Application rates of seed mixtures, lime, fertilizer, mulch and top dressing are shown in the schedule. City of Denton Hazen and Sawyer BID SET 02910-9 Final Grading and Landscaping SEEDING SCHEDULE Application Rates (Pounds/Acre) Seed Mixture Planting Season Limea Seeda Fertilizera Strawb Mulch Topdressinga Annual Fertilizer Comments P Feb. 15-May 31 1000 150 1000 4000 500 of 10-10-10 60 of Nitrogen - Contractor shall provide temporary watering as required to maintain grass T Oct. 1-Feb 1 1000 100 750 4000 - - Temporary seeding shall be established prior the following summer season (June). Contractor shall provide temporary watering to maintain grass for erosion control during the summer. Over seed with Type P seed mixture during next planting season. Footnotes: a. Application rates and/or chemical analysis shall be confirmed or established by soil testing and site specific conditions. b. On cut and fill slopes 2:1 or steeper, add 30#/acre Common Bermuda to Type P seed mixture. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 02910-10 Final Grading and Landscaping This page left blank intentionally City of Denton Hazen and Sawyer BID SET 03100-1 Concrete Formwork SECTION 03100 CONCRETE FORMWORK PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Provide materials, labor, and equipment required for the design and construction of all concrete formwork, bracing, shoring and supports in accordance with the provisions of the Contract Documents. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 03200 - Reinforcing Steel B. Section 03250 - Concrete Accessories C. Section 03290 - Joints in Concrete D. Section 03300 - Cast-in-Place Concrete 1.03 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. Without limiting the generality of the other requirements of the specifications, all work herein shall conform to the applicable requirements of the following documents. All referenced specifications, codes, and standards refer to the most current issue available at the time of Bid. 1. State of Texas Building Code 2. ACI 318 - Building Code Requirements for Structural Concrete 3. ACI 301 - Specifications for Structural Concrete for Buildings 4. ACI 347 - Recommended Practice for Concrete Formwork 5. U.S. Product Standard for Concrete Forms, Class I, PS 1 6. ACI 117 - Standard Specifications for Tolerances for Concrete Construction and Materials 1.04 SUBMITTALS A. Submit the following in accordance with Section 01300, Submittals. 1. Manufacturer's data on proposed form release agent City of Denton Hazen and Sawyer BID SET 03100-2 Concrete Formwork 2. Manufacturer's data on proposed formwork system including form ties 1.05 QUALITY ASSURANCE A. Concrete formwork shall be in accordance with ACI 301, ACI 318, and ACI 347. PART 2 -- PRODUCTS 2.01 FORMS AND FALSEWORK A. All forms shall be smooth surface forms unless otherwise specified. B. Wood materials for concrete forms and falsework shall conform to the following requirements: 1. Lumber for bracing, shoring, or supporting forms shall be Douglas Fir or Southern Pine, construction grade or better, in conformance with U.S. Product Standard PS20. All lumber used for forms, shoring or bracing shall be new material. 2. Plywood for concrete formwork shall be new, waterproof, synthetic resin bonded, exterior type Douglas Fir or Southern Pine high density overlaid (HDO) plywood manufactured especially for concrete formwork and shall conform to the requirements of PS1 for Concrete Forms, Class I, and shall be edge sealed. Thickness shall be as required to support concrete at the rate it is placed, but not less than 5/8-inch thick. C. Other form materials such as metal, fiberglass, or other acceptable material that will not adversely affect the concrete and will facilitate placement of concrete to the shape, form, line and grade indicated may be submitted to the Engineer for approval, but only materials that will produce a smooth form finish equal or better than the wood materials specified will be considered. 2.02 FORMWORK ACCESSORIES A. Form ties shall be provided with a plastic cone or other suitable means for forming a conical hole to insure that the form tie may be broken off back of the face of the concrete. The maximum diameter of removable cones for rod ties, or of other removable form-tie fasteners having a circular cross-section, shall not exceed 7/8-inch, and all such fasteners shall be such as to leave holes of regular shape for reaming. B. Form ties for water-retaining structures shall have integral waterstops. Removable taper ties may be used when acceptable to the Engineer. A preformed mechanical EPDM rubber plug shall be used to seal the hole left after the removal of the taper tie. Plug shall be X-Plug by the Greenstreak Group, Inc., or approved equal. Friction fit plugs shall not be used. C. Form release agent shall be a blend of natural and synthetic chemicals that employs a chemical reaction to provide quick, easy and clean release of concrete from forms. It shall City of Denton Hazen and Sawyer BID SET 03100-3 Concrete Formwork not stain the concrete and shall leave the concrete with a paintable surface. Formulation of the form release agent shall be such that it would minimize formation of "bug holes" in cast- in-place concrete. PART 3 -- EXECUTION 3.01 FORM DESIGN A. Forms and falsework shall be designed for total dead load, plus all construction live load as outlined in ACI 347. Design and engineering of formwork and safety considerations during construction shall be the responsibility of the Contractor. B. Forms shall be of sufficient strength and rigidity to maintain their position and shape under the loads and operations incident to placing and vibrating the concrete. The maximum deflection of facing materials reflected in concrete surfaces exposed to view shall be 1/240 of the span between structural members. C. All forms shall be designed for predetermined placing rates per hour, considering expected air temperatures and setting rates. 3.02 CONSTRUCTION A. The type, size, quality, and strength of all materials from which forms are made shall be subject to the approval of the Engineer. No falsework or forms shall be used which are not clean and suitable. Deformed, broken or defective falsework and forms shall be removed from the work. B. Forms shall be smooth and free from surface irregularities. Suitable and effective means shall be provided on all forms for holding adjacent edges and ends of panels and sections tightly together and in accurate alignment so as to prevent the formation of ridges, fins, offsets, or similar surface defects in the finished concrete. Joints between the forms shall be sealed to eliminate any irregularities. The arrangement of the facing material shall be orderly and symmetrical, with the number of seams kept to a practical minimum. C. Forms shall be true to line and grade, and shall be sufficiently rigid to prevent displacement and sagging between supports. Curved forms shall be used for curved and circular structures. Straight panels joined at angles will not be acceptable for forming curved structures. Forms shall be properly braced or tied together to maintain their position and shape under a load of freshly-placed concrete. Facing material shall be supported with studs or other backing which shall prevent both visible deflection marks in the concrete and deflections beyond the tolerances specified. D. Forms shall be mortar tight so as to prevent the loss of water, cement and fines during placing and vibrating of the concrete. Specifically, the bottom of wall forms that rest on concrete footings or slabs shall be provided with a gasket to prevent loss of fines and paste during placement and vibration of concrete. Such gasket may be a 1 to 1-1/2 inch diameter polyethylene rod held in position to the underside of the wall form. City of Denton Hazen and Sawyer BID SET 03100-4 Concrete Formwork E. All vertical surfaces of concrete members shall be formed, and side forms shall be provided for all footings, slab edges and grade beams, except where placement of the concrete against the ground is called for on the Drawings. Not less than 1-inch of concrete shall be added to the thickness of the concrete member as shown where concrete is permitted to be placed against trimmed ground in lieu of forms. Such permission will be granted only for members of comparatively limited height and where the character of the ground is such that it can be trimmed to the required lines and will stand securely without caving or sloughing until the concrete has been placed. F. All forms shall be constructed in such a manner that they can be removed without hammering or prying against the concrete. Wood forms shall be constructed for wall openings to facilitate loosening and to counteract swelling of the forms. G. Adequate clean-out holes shall be provided at the bottom of each lift of forms. Temporary openings shall be provided at the base of column forms and wall forms and at other points to facilitate cleaning and observation immediately before the concrete is deposited. The size, number and location of such clean-outs shall be as acceptable to the Engineer. H. Construction joints shall not be permitted at locations other than those shown or specified, except as may be acceptable to the Engineer. When a second lift is placed on hardened concrete, special precautions shall be taken in the way of the number, location and tightening of ties at the top of the old lift and bottom of the new to prevent any unsatisfactory effect whatsoever on the concrete. For flush surfaces at construction joints exposed to view, the contact surface of the form sheathing over the hardened concrete in the previous placement shall be lapped by not more than 1 inch. Forms shall be held against hardened concrete to prevent offset or loss of mortar at construction joints and to maintain a true surface. I. The formwork shall be cambered to compensate for anticipated deflections in the formwork due to the weight and pressure of the fresh concrete and due to construction loads. Set forms and intermediate screed strips for slabs accurately to produce the designated elevations and contours of the finished surface. Ensure that edge forms and screed strips are sufficiently strong to support vibrating screeds or roller pipe screeds if the nature of the finish specified requires the use of such equipment. When formwork is cambered, set screeds to a like camber to maintain the proper concrete thickness. J. Positive means of adjustment (wedges or jacks) for shores and struts shall be provided and all settlement shall be taken up during concrete placing operation. Shores and struts shall be securely braced against lateral deflections. Wedges shall be fastened firmly in place after final adjustment of forms prior to concrete placement. Formwork shall be anchored to shores or other supporting surfaces or members to prevent upward or lateral movement of any part of the formwork system during concrete placement. If adequate foundation for shores cannot be secured, trussed supports shall be provided. K. Runways shall be provided for moving equipment with struts or legs. Runways shall be supported directly on the formwork or structural member without resting on the reinforcing steel. City of Denton Hazen and Sawyer BID SET 03100-5 Concrete Formwork 3.03 TOLERANCES A. Unless otherwise indicated in the Contract Documents, formwork shall be constructed so that the concrete surfaces will conform to the tolerance limits listed in ACI 117. B. Structural framing of reinforced concrete around elevators and stairways shall be accurately plumbed and located within 1/4 in. tolerance from established dimensions. C. The Contractor shall establish and maintain in an undisturbed condition and until final completion and acceptance of the project, sufficient control points and bench marks to be used for reference purposes to check tolerances. Plumb and string lines shall be installed before concrete placement and shall be maintained during placement. Such lines shall be used by Contractor's personnel and by the Engineer and shall be in sufficient number and properly installed. During concrete placement, the Contractor shall continually monitor plumb and string line form positions and immediately correct deficiencies. D. Regardless of the tolerances specified, no portion of the building shall extend beyond the legal boundary of the building. 3.04 FORM ACCESSORIES A. Suitable moldings shall be placed to bevel or round all exposed corners and edges of beams, columns, walls, slabs, and equipment pads. Chamfers shall be 3/4 inch unless otherwise noted. B. Form ties shall be so constructed that the ends, or end fasteners, can be removed without causing appreciable spalling at the faces of the concrete. After ends, or end fasteners of form ties have been removed, the embedded portion of the ties shall terminate not less than 2 inches from the formed face of the concrete that is exposed to wastewater or enclosed surfaces above the wastewater, and not less than 1 inch from the formed face of all other concrete. Holes left by the removal of form tie cones shall be reamed with suitable toothed reamers so as to leave the surface of the holes clean and rough before being filled with mortar as specified in Section 03350 - Concrete Finishing. No form-tying device or part thereof, other than metal, shall be left embedded in the concrete. Ties shall not be removed in such manner as to leave a hole extending through the interior of the concrete member. The use of snap-ties which cause spalling of the concrete upon form stripping or tie removal will not be permitted. No snap ties shall be broken off until the concrete is at least three days old. If steel panel forms are used, rubber grommets shall be provided where the ties pass through the form in order to prevent loss of cement paste. 3.05 APPLICATION - FORM RELEASE AGENT A. Forms for concrete surfaces that will not be subsequently waterproofed shall be coated with a form release agent. Form release agent shall be applied on formwork in accordance with manufacturer's recommendations. City of Denton Hazen and Sawyer BID SET 03100-6 Concrete Formwork 3.06 INSERTS AND EMBEDDED ITEMS A. Sleeves, pipe stubs, inserts, anchors, expansion joint material, waterstops, and other embedded items shall be positioned accurately and supported against displacement prior to concreting. Voids in sleeves, inserts, and anchor slots shall be filled temporarily with readily removable material to prevent the entry of concrete into the voids. 3.07 FORM CLEANING AND REUSE A. The inner faces of all forms shall be thoroughly cleaned prior to concreting. Forms may be reused only if in good condition and only if acceptable to the Engineer. Light sanding between uses will be required wherever necessary to obtain uniform surface texture. Unused tie rod holes in forms shall be covered with metal caps or shall be filled by other methods acceptable to the Engineer. 3.08 FORM REMOVAL AND SHORING A. Forms shall not be disturbed until the concrete has attained sufficient strength. Sufficient strength shall be demonstrated by structural analysis considering proposed loads, strength of forming and shoring system, and concrete strength data. Shoring shall not be removed until the supported member has acquired sufficient strength to support its weight and the load upon it. Members subject to additional loads during construction shall be adequately shored to sustain all resulting stresses. Forms shall be removed in such manner as not to impair safety and serviceability of the structure. All concrete to be exposed by form removal shall have sufficient strength not to be damaged thereby. B. Provided the strength requirements specified above have been met and subject to the Engineer's approval, forms may be removed at the following minimum times. The Contractor shall assume full responsibility for the strength of all such components from which forms are removed prior to the concrete attaining its full design compressive strength. Shoring may be required at the option of the Engineer beyond these periods. Ambient Temperature (°F.) During Concrete Placement Over 95° 70°-95° 60°-70° 50°-60° Below 50° Walls 5 days 2 days 2 days 3 days Do not remove until directed by Engineer (7 days minimum) Columns 7 days 2 days 3 days 4 days Beam Soffits 10 days 7 days 7 days 7 days Elevated Slabs 12 days 7 days 7 days 7 days C. When, in the opinion of the Engineer, conditions of the work or weather justify, forms may be required to remain in place for longer periods of time. D. An accurate record shall be maintained by the Contractor of the dates of concrete placings and the exact location thereof and the dates of removal of forms. These records shall be available for inspection at all times at the site, and two copies shall be furnished the Engineer upon completion of the concrete work. City of Denton Hazen and Sawyer BID SET 03100-7 Concrete Formwork 3.09 RESHORING A. When reshoring is permitted or required the operations shall be planned in advance and subjected to approval by the Engineer. B. Reshores shall be placed after stripping operations are complete but in no case later than the end of the working day on which stripping occurs. C. Reshoring for the purpose of early form removal shall be performed so that at no time will large areas of new construction be required to support their own weight. While reshoring is under way, no construction or live loads shall be permitted on the new construction. Reshores shall be tightened to carry their required loads but they shall not be overtightened so that the new construction is overstressed. Reshores shall remain in place until the concrete has reached its specified 28-day strength, unless otherwise specified. D. For floors supporting shores under newly placed concrete, the original supporting shores shall remain in place or reshores shall be placed. The shoring or reshoring system shall have a capacity sufficient to resist the anticipated loads and in all cases shall have a capacity equal to at least one-half of the capacity of the shoring system above. Reshores shall be located directly under a reshore position above unless other locations are permitted. E. In multi-story buildings, reshoring shall extend over a sufficient number of stories to distribute the weight of newly placed concrete, forms, and construction live loads so the design superimposed loads of the floors supporting shores are not exceeded. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 03100-8 Concrete Formwork This page left blank intentionally City of Denton Hazen and Sawyer BID SET 03200-1 Reinforcing Steel SECTION 03200 REINFORCING STEEL PART 1 -- GENERAL 1.01 THE REQUIREMENTS A. Provide all concrete reinforcing including all cutting, bending, fastening and any special work necessary to hold the reinforcing steel in place and protect it from injury and corrosion in accordance with the requirements of this section. B. Provide deformed reinforcing bars to be grouted into reinforced concrete masonry walls. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 03100 - Concrete Formwork B. Section 03230 - Stressing Tendons C. Section 03250 - Concrete Accessories D. Section 03300 - Cast-in-Place Concrete E. Section 03400 - Precast Concrete 1.03 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Without limiting the generality of the other requirements of the specifications, all work herein shall conform to the applicable requirements of the following documents. All referenced specifications, codes, and standards refer to the most current issue available at the time of Bid. 1. State of Texas Building Code 2. CRSI - Concrete Reinforcing Institute Manual of Standard Practice 3. ACI SP66 - ACI Detailing Manual 4. ACI 315 - Details and Detailing of Concrete Reinforcing 5. ACI 318 - Building Code Requirements for Structural Concrete 6. WRI - Manual of Standard Practice for Welded Wire Fabric 7. ASTM A 615 - Standard Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcing City of Denton Hazen and Sawyer BID SET 03200-2 Reinforcing Steel 8. ASTM A 1064 - Standard Specification for Steel Wire and Welded Wire Reinforcement, Plain and Deformed, for Concrete 1.04 SUBMITTALS A. Submit the following in accordance with Section 01300, Submittals. 1. Detailed placing and shop fabricating drawings, prepared in accordance with ACI 315 and ACI Detailing Manual - (SP66), shall be furnished for all concrete reinforcing. These drawings shall be made to such a scale as to clearly show joint locations, openings, and the arrangement, spacing and splicing of the bars. 2. Mill test certificates - 3 copies of each. 3. Description of the reinforcing steel manufacturer's marking pattern. 4. Requests to relocate any bars that cause interferences or that cause placing tolerances to be violated. 5. Proposed supports for each type of reinforcing. 6. Request to use splices not shown on the Drawings. 7. Request to use mechanical couplers along with manufacturer's literature on mechanical couplers with instructions for installation, and certified test reports on the couplers' capacity. 8. Request for placement of column dowels without the use of templates. 9. Request and procedure to field bend or straighten partially embedded reinforcing. 10. International Code Council–Evaluation Services Evaluation Services Report (ICC-ES ESR) for dowel adhesives. 11. Certification that all installers of dowel adhesive are certified as Adhesive Anchor Installers in accordance with the ACI-CRSI Anchor Installer Certification Program. 12 Adhesive dowel testing plan. 1.05 QUALITY ASSURANCE A. If requested by the Engineer, the Contractor shall provide samples from each load of reinforcing steel delivered in a quantity adequate for testing. Costs of initial tests will be paid by the Owner. Costs of additional tests due to material failing initial tests shall be paid by the Contractor. B. Installer Qualifications for Drilled-In Rebar: Drilled-in rebar shall be installed by an Installer with at least three years of experience performing similar installations. Installer shall be City of Denton Hazen and Sawyer BID SET 03200-3 Reinforcing Steel certified as an Adhesive Anchor Installer in accordance with ACI-CRSI Adhesive Anchor Installation Certification Program. C. Installer Training: Conduct a thorough training with the manufacturer or the manufacturer’s representative for the Installer on the project. Training shall consist of a review of the complete installation process for drilled-in anchors, to include but not be limited to the following: 1. Hole drilling procedure. 2. Hole preparation and cleaning technique. 3. Adhesive injection technique and dispenser training/maintenance. 4. Rebar doweling preparation and installation. 5. Proof loading/torquing. D. Special inspections for adhesive dowels shall be conducted in accordance with the manufacturer’s instructions and Specification Section 01450. Downward installations require periodic inspection and horizontal and overhead installations require continuous inspection. PART 2 -- PRODUCTS 2.01 REINFORCING STEEL A. Bar reinforcing shall conform to the requirements of ASTM A 615 for Grade 60 Billet Steel reinforcing. All reinforcing steel shall be from domestic mills and shall have the manufacturer's mill marking rolled into the bar which shall indicate the producer, size, type and grade. All reinforcing bars shall be deformed bars. Smooth reinforcing bars shall not be used unless specifically called for on Drawings. B. Welded wire fabric reinforcing shall conform to the requirements of ASTM A 1064 and the details shown on the Drawings. C. A certified copy of the mill test on each load of reinforcing steel delivered showing physical and chemical analysis shall be provided, prior to shipment. The Engineer reserves the right to require the Contractor to obtain separate test results from an independent testing laboratory in the event of any questionable steel. When such tests are necessary because of failure to comply with this Specification, such as improper identification, the cost of such tests shall be borne by the Contractor. D. Field welding of reinforcing steel will not be allowed. E. Use of coiled reinforcing steel will not be allowed. City of Denton Hazen and Sawyer BID SET 03200-4 Reinforcing Steel 2.02 ACCESSORIES A. Accessories shall include all necessary chairs, slab bolsters, concrete blocks, tie wires, dips, supports, spacers and other devices to position reinforcing during concrete placement. Slab bolsters shall have gray plastic-coated legs. B. Concrete blocks (dobies), used to support and position bottom reinforcing steel, shall have the same or higher compressive strength as specified for the concrete in which it is located. 2.03 MECHANICAL COUPLERS A. Mechanical couplers shall develop a tensile strength which exceeds 100 percent of the ultimate tensile strength and 125 percent of the yield strength of the reinforcing bars being spliced. The reinforcing steel and coupler used shall be compatible for obtaining the required strength of the connection. B. Where the type of coupler used is composed of more than one component, all components required for a complete splice shall be supplied. C. Hot forged sleeve type couplers shall not be used. Acceptable mechanical couplers are Dayton Superior Dowel Bar Splicer System by Dayton Superior, Dayton, Ohio, or approved equal. Mechanical couplers shall only be used where shown on the Drawings or where specifically approved by the Engineer. D. Where the threaded rebar to be inserted into the coupler reduces the diameter of the bar, the threaded rebar piece shall be provided by the coupler manufacturer. 2.04 DOWEL ADHESIVE SYSTEM A. Where shown on the Drawings, reinforcing bars anchored into hardened concrete with a dowel adhesive system shall use a two-component adhesive mix which shall be injected with a static mixing nozzle following manufacturer's instructions. B. All holes shall be drilled in accordance with the manufacturer’s instructions except that core drilled holes shall not be permitted unless specifically allowed by the Engineer. Cored holes, if allowed by the manufacturer and approved by the Engineer, shall be roughened in accordance with manufacturer’s requirements. C. Thoroughly clean drill holes of all debris, drill dust, and water in accordance with manufacturer’s instructions with compressed air and a wire brush prior to installation of adhesive and reinforcing bar. D. Degree of hole dampness shall be in strict accordance with manufacturer recommendations. Installation conditions shall be either dry or water-saturated. Water filled or submerged holes shall not be permitted unless specifically approved by the Engineer. E. Injection of adhesive into the hole shall be performed in a manner to minimize the formation of air pockets in accordance with the manufacturer’s instructions. City of Denton Hazen and Sawyer BID SET 03200-5 Reinforcing Steel F. Embedment Depth: 1. The embedment depth of the bar shall be as shown on the Drawings. Although all manufacturers listed below are permitted, the embedment depth shown on the Drawings is based on “PE 1000+” by Powers Fasteners. If the Contractor submits one of the other named dowel adhesives from the list below, the Engineer shall evaluate the required embedment and the Contractor shall provide the required embedment depth stipulated by the Engineer specific to the approved dowel adhesive. 2. Where the embedment depth is not shown on the Drawings, the embedment depth shall be determined to provide the minimum allowable bond strength equal to the tensile strength of the rebar according to the manufacturer’s ICC-ES ESR. 3. The embedment depth shall be determined using the actual concrete compressive strength, a cracked concrete state, maximum long term temperature of 110 degrees F, and maximum short term temperature of 140 degrees F. In no case shall the embedment depth be less than the minimum, or more than the maximum, embedment depths stated in the manufacturer’s ICC-ES ESR. G. Engineer's approval is required for use of this system in locations other than those shown on the Drawings. H. The adhesive system shall be IBC compliant for use in both cracked and uncracked concrete in all Seismic Design Categories and shall be "Epcon C6+ Adhesive Anchoring System" as manufactured by ITW Redhead, " HIT-HY 200 Adhesive Anchoring System" as manufactured by Hilti, Inc. “SET-XP Epoxy Adhesive Anchors” as manufactured by Simpson Strong-Tie Co. or “PE-1000+ Epoxy Adhesive Anchor System” by Powers Fasteners. Fast-set epoxy formulations shall not be acceptable. No or equal products will be considered, unless pre-qualified and approved. I. All individuals installing dowel adhesive system shall be certified as an Adhesive Anchor Installer in accordance with the ACI-CRSI Anchor Installation Certification Program. PART 3 – EXECUTION 3.01 TEMPERATURE REINFORCING A. Unless otherwise shown on the Drawings or in the absence of the concrete reinforcing being shown, the minimum cross sectional area of horizontal and vertical concrete reinforcing in walls shall be 0.0033 times the gross concrete area and the minimum cross sectional area of reinforcing perpendicular to the principal reinforcing in slabs shall be 0.0020 times the gross concrete area. Temperature reinforcing shall not be spaced further apart than five times the slab or wall thickness, nor more than 18 inches. City of Denton Hazen and Sawyer BID SET 03200-6 Reinforcing Steel 3.02 FABRICATION A. Reinforcing steel shall be accurately formed to the dimensions and shapes shown on the Drawings and the fabricating details shall be prepared in accordance with ACI 315 and ACI 318, except as modified by the Drawings. B. The Contractor shall fabricate reinforcing bars for structures in accordance with the bending diagrams, placing lists and placing Drawings. C. No fabrication shall commence until approval of Shop Drawings has been obtained. All reinforcing bars shall be shop fabricated unless approved to be bent in the field. Reinforcing bars shall not be straightened or rebent in a manner that will injure the material. Heating of bars will not be permitted. D. Welded wire fabric with longitudinal wire of W9.5 size or smaller shall be either furnished in flat sheets or in rolls with a core diameter of not less than 10 inches. Welded wire fabric with longitudinal wires larger than W9.5 size shall be furnished in flat sheets only. 3.03 DELIVERY, STORAGE AND HANDLING A. All reinforcing shall be neatly bundled and tagged for placement when delivered to the job site. Bundles shall be properly identified for coordination with mill test reports. B. Reinforcing steel shall be stored above ground on platforms or other supports and shall be protected from the weather at all times by suitable covering. It shall be stored in an orderly manner and plainly marked to facilitate identification. C. Reinforcing steel shall at all times be protected from conditions conducive to corrosion until concrete is placed around it. D. The surfaces of all reinforcing steel and other metalwork to be in contact with concrete shall be thoroughly cleaned of all dirt, grease, loose scale and rust, grout, mortar and other foreign substances immediately before the concrete is placed. Where there is delay in depositing concrete, reinforcing shall be reinspected and if necessary recleaned. 3.04 PLACING A. Reinforcing steel shall be accurately positioned as shown on the Drawings and shall be supported and wired together to prevent displacement, using annealed iron wire ties or suitable clips at intersections. All reinforcing steel shall be supported by concrete, plastic or metal supports, spacers or metal hangers which are strong and rigid enough to prevent any displacement of the reinforcing steel. Where concrete is to be placed on the ground, supporting concrete blocks (or dobies) shall be used in sufficient numbers to support the reinforcing bars without settlement. In no case shall concrete block supports be continuous. B. The portions of all accessories in contact with the formwork shall be made of plastic or steel coated with a 1/8 inch minimum thickness of plastic which extends at least 1/2 inch from the concrete surface. Plastic shall be gray in color. City of Denton Hazen and Sawyer BID SET 03200-7 Reinforcing Steel C. Tie wires shall be bent away from the forms in order to provide the specified concrete coverage. D. Reinforcing bars additional to those shown on the Drawings, which may be found necessary or desirable by the Contractor for the purpose of securing reinforcing in position, shall be provided by the Contractor at no additional cost to the Owner. E. Reinforcing placing, spacing, and protection tolerances shall be within the limits specified in ACI 318 except where in conflict with the Building Code, unless otherwise specified. F. Reinforcing bars may be moved within one bar diameter as necessary to avoid interference with other concrete reinforcing, conduits, or embedded items. If bars are moved more than one bar diameter, or enough to exceed placing tolerances, the resulting arrangement of bars shall be as acceptable to the Engineer. G. Welded wire fabric shall be supported on slab bolsters spaced not less than 30 inches on centers, extending continuously across the entire width of the reinforcing mat and supporting the reinforcing mat in the plane shown on the Drawings. H. Reinforcing shall not be straightened or rebent unless specifically shown on the drawings. Bars with kinks or bends not shown on the Drawings shall not be used. Coiled reinforcement shall not be used. I. Dowel Adhesive System shall be installed in strict conformance with the manufacturer’s recommendations and as required in Article 2.04 above. A representative of the manufacturer must be on site prior to adhesive dowel installation to provide instruction on proper installation procedures for all adhesive dowel installers. Testing of adhesive dowels shall be as indicated below. If the dowels have a hook at the end to be embedded in subsequent work, an approved mechanical coupler shall be provided at a convenient distance from the face of existing concrete to facilitate adhesive dowel testing while maintaining required hook embedment in subsequent work. J. Adhesive Dowel Testing 1. At all locations where adhesive dowels are shown on the Drawings, at least 25 percent of all adhesive dowels installed shall be tested to the value indicated on the Drawings, with a minimum of one tested dowel per group. If no test value is indicated on the Drawings but the installed dowel is under direct tension, the Contractor shall notify the Engineer to verify the required test value. 2. Contractor shall submit a plan and schedule indicating locations of dowels to be tested, load test values and proposed dowel testing procedure (including a diagram of the testing equipment proposed for use) prior to conducting any testing. The testing equipment shall have a minimum of three support points and shall be of sufficient size to locate the edge of supports no closer than two times the anchor embedment depth from the center of the anchor. 3. Where Contract Documents indicate adhesive dowel design is the Contractor’s responsibility, the Contractor shall submit a plan and schedule indicating locations of City of Denton Hazen and Sawyer BID SET 03200-8 Reinforcing Steel dowels to be tested and load test values, sealed by a Professional Engineer currently registered in the State of Texas. The Contractor shall also submit documentation indicating the Contractor’s testing procedures have been reviewed and the proposed procedures are acceptable. 4. Adhesive Dowel shall have no visible indications of displacement or damage during or after the proof test. Concrete cracking in the vicinity of the dowel after loading shall be considered a failure. Dowels exhibiting damage shall be removed and replaced. If more than 5 percent of tested dowels fail, then 100 percent of dowels shall be proof tested. 5. Proof testing of adhesive dowels shall be performed by an independent testing laboratory hired directly by the Contractor. The Contractor shall be responsible for costs of all testing, including additional testing required due to previously failed tests. 3.05 SPLICING A. Reinforcing bar splices shall only be used at locations shown on the Drawings. When it is necessary to splice reinforcing at points other than where shown, the splice shall be as acceptable to the Engineer. B. The length of lap for reinforcing bars, unless otherwise shown on the Drawings shall be in accordance with ACI 318 for a class B splice. C. Laps of welded wire fabric shall be in accordance with ACI 318. Adjoining sheets shall be securely tied together with No. 14 tie wire, one tie for each 2 running feet. Wires shall be staggered and tied in such a manner that they cannot slip. D. Mechanical splices shall be used only where shown on the drawings or when approved by the Engineer. E. Couplers which are located at a joint face shall be a type which can be set either flush or recessed from the face as shown on the Drawings. The couplers shall be sealed during concrete placement to completely eliminate concrete or cement paste from entering. After the concrete is placed, couplers intended for future connections shall be plugged and sealed to prevent any contact with water or other corrosive materials. Threaded couplers shall be plugged with plastic plugs which have an O-ring seal. 3.06 INSPECTION A. The Contractor shall advise the Engineer of his intentions to place concrete and shall allow him adequate time to inspect all reinforcing steel before concrete is placed. B. The Contractor shall advise the Engineer of his intentions to place grout in masonry walls and shall allow him adequate time to inspect all reinforcing steel before grout is placed. City of Denton Hazen and Sawyer BID SET 03200-9 Reinforcing Steel 3.07 CUTTING OF EMBEDDED REBAR A. The Contractor shall not cut embedded rebar cast into structural concrete without prior approval. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 03200-10 Reinforcing Steel This page left blank intentionally City of Denton Hazen and Sawyer BID SET 03230-1 Stressing Tendons SECTION 03230 STRESSING TENDONS PART 1 -- GENERAL 1.01 THE REQUIREMENTS A. The Contractor shall furnish and place all stressing tendons for pretensioned and post-tensioned prestressed concrete, including all burning, measuring, draping, preventing bond, jacking and any special work necessary to hold the tendons in place and protect them from injury and corrosion in accordance with the requirements of this Section. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 03200 - Reinforcing Steel 1.03 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Without limiting the generality of the Specifications, all work specified herein shall conform to the applicable requirements of the following documents. All referenced specifications, codes, and standards refer to the most current issue available at the time of Bid. 1. ASTM A416 Uncoated 7-Wire Stress-Relieved Strand for Prestressed Concrete 2. ASTM A421 Uncoated Stress-Relieved Wire for Prestressed Concrete 3. ASTM A910 Uncoated, Weldless, 2 and 3 Wire Steel Strand for Prestressed Concrete 4. AASHTO M203 American Association of State Highway and Transportation Officials 5. ACI 222R Protection of Metals in Concrete Against Corrosion 6. ACI 222.2R Report on Corrosion of Prestressing Steels 7. ACI 318 Building Code Requirements for Structural Concrete 8. ACI 350 Code Requirements for Environmental Engineering Concrete Structures 1.04 SUBMITTALS A. The Contractor shall submit the following in accordance with the requirements of Section 01300, "Submittals". City of Denton Hazen and Sawyer BID SET 03230-2 Stressing Tendons 1. Records of standard, certified mill tests run by the tendon manufacturer shall be kept on file, and current copies shall be submitted to the Engineer. 2. The manufacturer's certification and load-elongation curve, in accordance with the prestressed concrete fabricator for each lot of tendon. The Contractor shall obtain and submit the data to the Engineer for approval, in permanent record form. 3. Tubular conduit for preventing bond, when breaking bond at specific locations as required by the design. 4. Bed layout showing method of draping and tensioning, including calculations. 5. Records of initial jacking load, final jacking load and respective elongation. PART 2 -- PRODUCTS 2.01 PRESTRESSING TENDONS A. Prestressing tendons for use in pretensioned and post-tensioned, prestressed concrete shall consist of multi-wire (2, 3 or 7) stress-relieved strands, stress-relieved single wire, or low- relaxation strands conforming to the requirements of ASTM A910, ASTM A416, and ASTM A421, respectively. B. Wires shall be uncoated and shall be of a size and of a stress relieved or low relaxation type such as to insure sufficient prestress transfer bond. Only cold-drawn wire shall be utilized, no quenched and tempered steel shall be allowed. C. Oil tempered wires shall not be used. D. The tendons shall be clean and free of excessive rust, scale and pitting. E. Strands or wires used in units of any one bed layout shall be manufactured by the same plant. PART 3 -- EXECUTION 3.01 TENSIONING DEVICES A. Devices for tensioning shall be adequate to produce and maintain the required tension in all tendons until the concrete has reached the required transfer strength. All jacks shall be equipped with accurate and calibrated gages for registering jacking loads. Gages shall be calibrated for the jacks with which they are used. All jacks and gages shall be calibrated by an approved testing company at no cost to the Owner at intervals not to exceed 12 months. During progress of the work, if gage readings and elongations indicate materially differing loads, recalibration may be required. Gages shall have a full load capacity of 1-1/2 to 2 times their normal working load. The loads to be gaged shall be not less then one-fourth or more than three-fourths of the total graduated capacity unless calibration data clearly City of Denton Hazen and Sawyer BID SET 03230-3 Stressing Tendons establishes consistent accuracy over a wider range. Gages shall have indicating dials at least 6 inches in diameter and the gage pointers shall not fluctuate, preventing an accurate reading, but shall remain steady until the jacking load is released. All gages shall have an accuracy of reading within 2 percent. Means shall be provided for measuring the elongation of tendons within 1/4-inch. 3.02 PLACING STRANDS A. Tendons shall be positioned in accordance with the detailed dimensions shown on the Drawings or as detailed by the supplier and effectively secured against displacement from their correct positions. The steel reinforcing shall be placed in final position after tensioning of the tendons. All tie wires shall be bent to the inside of the member so that the ends are farther from the edge than the material being tied. Bottom tendons shall be supported at spacings not to exceed 20 feet by supports meeting the requirements of Section 03200 or by other means approved by the Engineer. B. Tendons with kinks, bends, nicks, scale, excessive rust or other defects will not be permitted. No more than one broken wire per casting bed will be permitted. Slight rusting will not be cause for rejection, provided it is not sufficient to cause visible pits. Precautions shall be taken to prevent contamination of tendons and reinforcing steel. The tendons and reinforcing steel shall be cleaned to an acceptable condition before concrete is poured. Concrete shall not be placed in the forms until the tendon and reinforcement condition and arrangement have been inspected by the plant inspector. C. Tendon splices will only be permitted at the end of a reel and when using a single strand jack. The tendon lengths to be spliced together shall have the same lay of wire to avoid unraveling and the splice shall be positioned so that it does not fall within a member. The ends of the tendon lengths to be spliced shall not be torch cut. They shall be cut by shears, abrasive grinders, or other means approved by the Engineer. No more than one strand splice will be permitted on an individual strand and the reuse of strands will not be permitted. D. Where bonding of tendons is to be prevented, it shall be accomplished by encasing the tendons in a tubular conduit capable of resisting the pressure exerted by the concrete. Slit conduit shall not be used. The conduit used shall be of high density polyethylene or polypropylene with a minimum wall thickness of 0.025 inch. The inside diameter of the conduit shall be of sufficient size to allow free movement of the encased tendon but it shall not be greater than the diameter of the tendon plus 1/8-inch. The conduit shall be secured so that longitudinal movement along the tendon will be prevented, and bonding of the tendon will be prevented at the location shown on the Drawings plus or minus 1 inch. Concrete shall be prevented from entering the conduit by taping. The tape shall be manufactured from a non-corrosive material compatible with the concrete, conduit, and steel. 3.03 CORROSION PROTECTION A. All tendons, including all trimmed strand ends, shall be protected by multi-level corrosion protection appropriate for an aggressive environment. Examples of multi-level protection include adequate concrete or grout cover, use of low permeability concrete and grout, use of corrosion inhibiting admixtures, water resistant grease, sheathing, encapsulated strands, etc. City of Denton Hazen and Sawyer BID SET 03230-4 Stressing Tendons B. Time between tendon stressing and grouting shall be not exceed 7 days to limit corrosion risk of unprotected tendons. Temporary corrosion protection is required when time between tendon stressing and grouting will exceed 7 days. 3.04 TENSIONING PROCEDURE A. Each tendon shall be tensioned to the required load prior to placing the concrete. B. The load induced in the tendon shall be measured both by jacking gages and strand elongations on at least the first 5 tendons and every third tendon thereafter on each pour. Loads on all other tendons shall be measured by either jacking gages or tendon elongations. When both methods of measurement are used, if a discrepancy between gage and elongation of more than 5 percent is apparent, the entire operation shall be carefully checked and the source of error determined before proceeding further. The computed elongation and jacking loads shall make appropriate allowances for load losses due to friction and all possible slippage or relaxation of the anchorage. References shall be established periodically at each tendon anchorage to indicate any yielding or slippage that may occur between the time of initial tensioning and final release of the tendons. C. In determining the applied load by measuring the elongation of the tendon, a modulus of elasticity taken from the typical stress-strain curve for the brand, size, and type of tendon being tensioned shall be used. The Contractor shall submit stress-strain curve data for the actual heats of material used in the tendons to the plant inspector before the tendons are used. Each reel or tendon shall be identified by tagging in accordance with AASHTO M203. A standard color marking every 100 ft. on the tendons will be required. The standard color markings shall be white for stress relieved tendons, green for low relaxation tendons and a double marking of green and red for special low relaxation tendons. D. Tendons may be tensioned in a group or individually. Prior to being given its full tensioning, each tendon shall be brought to an initial tension of 2,000 lbs, for all beds under 150 ft in length, 3,000 lbs, for all beds 150 to 300 ft in length, and 4,000 lbs for all beds longer than 300 ft. in length. This initial tension shall be measured by a calibrated gauge or other approved means, and the elongation due to initial tensioning shall then be computed. The difference between the required final tension and the initial tension shall be used to compute the expected additional elongation. E. After initial tensioning, the tendons shall be tensioned until the required elongation and jacking load are attained and reconciled with the limits specified above. A permanent record shall be kept of the initial jacking load, the final jacking load and the elongation produced thereby. In single tendon tensioning, rotation of the jacking ram will not be allowed. F. When draped tendons are to be used, the Contractor shall submit to the Engineer for his approval a bed layout showing the method of draping and tensioning the draped tendons and also calculations determining the loads required for tensioning the draped tendons. The tendons for all members to be cast in any one tensioning operation shall be draped before any beam is cast. End templates or bulkheads at ends of beams shall remain vertical or as otherwise shown on the Drawings. Unless otherwise approved by the Engineer, draping for City of Denton Hazen and Sawyer BID SET 03230-5 Stressing Tendons all members shall be done either simultaneously or in increments not to exceed one-fourth of the total draping. G. The device used for deflecting the draped tendons shall be of a type and dimensions approved by the Engineer. The part in contact with the tendon shall be rounded to a diameter of not less than 3/4-inch. Support and hold-down devices shall be of sufficient rigidity and have adequate support so that the final position of the tendons will be as shown on the Drawings. H. With tendons tensioned in accordance with the above requirements and with other reinforcement in place, the concrete members shall be cast so as to achieve the required lengths. Tendon load shall be maintained between anchorages until the concrete has reached the required compressive strength for transfer of load from the anchorages to the members. 3.05 TRANSFER OF LOAD A. Transfer of load procedures shall be such as to not cause cracks in members. Transfer of load shall be by gradual release of the tendons as a group, by gradual release of part of the group, or by burning of the fully tensioning tendons at the ends of the members. If tendons are to be released by a method other than gradual release of the entire group, the proposed method and pattern of release, if not so shown on the Drawings, shall be submitted by the Contractor to the Engineer for his approval. The approved method and pattern of release shall be rigidly followed. When the fully tensioned tendons are being burned each tendon or group of tendons shall be burned simultaneously at each end of the bed in its indicated order in the pattern and at each end of each member before proceeding to the tendons in the next group in the pattern at any point. B. When detensioning all beams, girders, cored slabs, and piles, tendons shall not be burned quickly but shall be heated with a low oxygen flame played along the tendon for a minimum of 5 inches until the metal gradually loses its strength. Heat shall be applied at such a rate that failure of the first wire in each tendon shall not occur until at least 5 seconds after heat is first applied. When detensioning other members, the above procedure shall be followed unless an alternate procedure has been approved by the Engineer. Detensioning by arc welder will not be allowed. C. All tendon releases shall be in a manner as to cause a minimum shock and lateral eccentricity of loading and shall meet the Engineer's approval. Failure to follow the above procedures for transfer of load will be grounds for rejection of the members involved. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 03230-6 Stressing Tendons This page left blank intentionally City of Denton Hazen and Sawyer BID SET 03250-1 Concrete Accessories SECTION 03250 CONCRETE ACCESSORIES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Furnish all materials, labor and equipment required to provide all concrete accessories including waterstops, expansion joint material, joint sealants, expansion joint seals, contraction joint inserts, and epoxy bonding agent. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 03100 - Concrete Formwork B. Section 03290 - Joints in Concrete C. Section 03300 - Cast-in-Place Concrete D. Section 07900 - Joint Fillers, Sealants, and Caulking 1.03 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. Without limiting the generality of the other requirements of the specifications, all work herein shall conform to the applicable requirements of the following documents. All referenced specifications, codes, and standards refer to the most current issue available at the time of Bid. 1. ASTM C881 Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete 2. ASTM D412 Standard Tests for Rubber Properties in Tension 3. ASTM D 624 Standard Test method for Rubber Property - Tear Resistance 4. ASTM D 638 Standard Test Method for Tensile Properties of Plastics 5. ASTM D1751 Standard Specifications for Preformed Expansion Joint fillers for Concrete Paving and Structural Construction (nonextruding and resilient bituminous types) 6. ASTM D 1752 Standard Specification for Preformed Sponge Rubber and Cork Expansion Joint Fillers for Concrete Paving and Structural Construction 7. ASTM D 1171 Standard Test Method for Ozone Resistance at 500 pphm City of Denton Hazen and Sawyer BID SET 03250-2 Concrete Accessories 8. ASTM D 471 Standard Test Method for Rubber Properties 1.04 SUBMITTALS A. Submit the following in accordance with Section 01300, Submittals. 1. Manufacturer's literature on all products specified herein including material certifications. 2. Proposed system for supporting PVC waterstops in position during concrete placement 3. Samples of products if requested by the Engineer. PART 2 -- PRODUCTS 2.01 POLYVINYL CHLORIDE (PVC) WATERSTOPS A. PVC waterstops for construction joints shall be flat ribbed type, 6 inches wide with a minimum thickness at any point of 3/8 inches. B. Waterstops for expansion joints shall be ribbed with a center bulb. They shall be 9 inches wide with a minimum thickness at any point of 3/8 inch unless shown or specified otherwise. The center bulb shall have a minimum outside diameter of 1 inch and a minimum inside diameter of 1/2 inch. C. The waterstops shall be manufactured from virgin polyvinyl chloride plastic compound and shall not contain any scrap or reclaimed material or pigment whatsoever. The properties of the polyvinyl chloride compound used, as well as the physical properties of the waterstops, shall exceed the requirements of the U.S. Army Corps. of Engineers' Specification CRD-C572. The waterstop material shall have an off-white, milky color. D. The required minimum physical characteristics for this material are: 1. Tensile strength - 1,750 psi (ASTM D-638). 2. Ultimate elongation - not less than 280% (ASTM D-638). E. No reclaimed PVC shall be used for the manufacturing of the waterstops. The Contractor shall furnish certification that the proposed waterstops meet the above requirements. F. PVC waterstops shall be as manufactured by BoMetals, Inc., DuraJoint Concrete Accessories, or Sika Greenstreak. G. All waterstop intersections, both vertical and horizontal, shall be made from factory fabricated corners and transitions. Only straight butt joint splices shall be made in field. City of Denton Hazen and Sawyer BID SET 03250-3 Concrete Accessories 2.02 RETROFIT WATERSTOPS A. Retrofit waterstops shall be used where specifically shown on Drawings for sealing joints between existing concrete construction and new construction. B. Retrofit waterstops shall be PVC waterstops fabricated from material as described in Section 2.01 of this Specification. C. Retrofit waterstop shall be attached to existing concrete surface as shown on Drawings. D. Use of split waterstop in lieu of specially fabricated retrofit waterstop will not be acceptable. E. Retrofit Waterstop manufacturer must provide a complete system including all Waterstop, stainless steel anchoring hardware, and epoxy for installation. F. For construction joints, retrofit waterstop shall be style number 609 by Sika Greenstreak, RF-638 by BoMetals, Inc., Type 18 kit by DuraJoint Concrete Accessories, or approved equal. For expansion joints, retrofit waterstop shall be style number 667 by Sika Greenstreak, Type 18-9 kit by DuraJoint Concrete Accessories, or approved equal. 2.03 CHEMICAL RESISTANT WATERSTOPS A. Where specifically noted on Contract Drawings, chemical resistant waterstops shall be used instead of PVC waterstops. B. Chemical resistant waterstops for construction joints shall be ribbed with a center bulb. They shall be 6 inches wide with a minimum thickness at any point of 3/16 inches. C. Chemical resistant waterstops for expansion joints shall be ribbed tear web. They shall be 9 inches wide with a tear web designed to accommodate 1 inch of free movement minimum. D. Chemical resistant retrofit waterstop shall be a minimum of 2½” wide along the ribbed side and a minimum 5” wide along the side attached to the existing concrete surface. Retrofit waterstop shall include a centerbulb and shall have a minimum thickness of 3/16”. Retrofit waterstop manufacturer shall provide a complete system including waterstop, stainless steel anchoring hardware and epoxy for installation. E. Chemical resistant waterstops shall be manufactured from a fully crosslinked thermoplastic vulcanizate rubber. F. Waterstops shall be TPE-R by BoMetals, Inc., Earth Shield TPV/TPE-R by JP Specialties, Inc., Westec TPE-R by Westec Barrier Technologies, or TPE-R by DuraJoint Concrete Accessories. 2.04 HYPALON RUBBER WATERSTOPS A. Hypalon rubber waterstops shall be Sikadur Combiflex by Sika Corporation or approved equal. Minimum width of waterstop material shall be twelve (12) inches unless shown otherwise on Contract Drawings. City of Denton Hazen and Sawyer BID SET 03250-4 Concrete Accessories 2.05 EXPANDING RUBBER WATERSTOP A. Expanding rubber shall be designed to expand under hydrostatic conditions. Waterstops shall be Adeka Ultra Seal MC-2010M by Adeka Ultra Seal/OCM, Inc., or Hydrotite CJ-1020- 2K by Sika Greenstreak, for concrete thickness greater than nine inches. For thicknesses less than nine inches, Adeka Ultra Seal KBA-1510FF or Hydrotite CJ-1020-2K shall be used. B. Waterstop shall be a chemically modified natural rubber product with a hydrophilic agent. C. Waterstop has a stainless steel mesh or coextrusion of non-hydrophilic rubber to direct expansion in the thickness direction and restrict the expansion in the longitudinal direction. 2.06 WATERSTOP ADHESIVE A. Adhesive between waterstops and existing concrete shall be 20+F Contact Cement by Miracle Adhesives Corporation, Neoprene Adhesive 77-198 by JGF Adhesives, Sikadur 31 Hi-Mod Gel by Sika Corporation, DP-605 NS Urethane Adhesive by 3M Adhesive Systems. B. Hydrophilic, non-bentonite water swelling elastic sealant shall be used to bond expanding rubber waterstops to rough surfaces. Hydrophilic elastic sealant shall be P-201 by Adeka Ultra Seal/OCM, Inc., Leakmaster LV-1 by Sika Greenstreak, or approved equal. 2.07 JOINT SEALANTS A. Joint sealants shall comply with Section 07900, Joint Fillers, Sealants, and Caulking. 2.08 EXPANSION JOINT MATERIAL A. Preformed expansion joint material shall be non-extruding, and shall be of the following types: 1. Type I - Sponge rubber, conforming to ASTM D1752, Type I. 2. Type II - Cork, conforming to ASTM D1752, Type II. 3. Type III - Self-expanding cork, conforming to ASTM D1752, Type III. 4. Type IV - Bituminous fiber, conforming to ASTM Designation D1751. 2.09 EXPANSION JOINT SEAL A. Expansion Joint Seal System shall consist of a preformed neoprene profile, installed using the same dimensions as the joint gap, bonded with a two-component epoxy adhesive and pressurized during the adhesive cure time. B. The expansion joint system shall be Hydrozo/Jeene Structural Sealing joint system by Hydrozo/Jeene, Inc. City of Denton Hazen and Sawyer BID SET 03250-5 Concrete Accessories 2.10 CONTRACTION JOINT INSERTS A. Contraction joint inserts shall be ZipCap Control Joint former by Greenstreak Plastic Products. 2.11 EPOXY BONDING AGENT A. Epoxy bonding agent shall conform to ASTM C881 and shall be Sikadur 32 Hi-Mod, Sika Corporation, Lyndhurst, N.J.; Euco #452 Epoxy System, Euclid Chemical Company, Cleveland, OH, MasterInject 1500 by BASF Master Builder Solutions (BASF). 2.12 EPOXY RESIN BINDER A. Epoxy resin binder shall conform to the requirements of ASTM C-881, Type III, Grade 3, Class B and C for epoxy resin binder and shall be Sikadur 23, Low-Mod-Gel, manufactured by the Sika Corporation, Lyndhurst, N.J., Flexocrete Gel manufactured by DuraJoint Concrete Accessories or Euco #352 Gel, Euclid Chemical Company, MasterEmaco ADH 327 or 327 RS by BASF Master Builder Solutions. PART 3 -- EXECUTION 3.01 PVC AND CHEMICAL RESISTANT WATERSTOPS A. PVC and chemical resistant waterstops shall be provided in all construction and expansion joints in water bearing structures and at other such locations as required by the Drawings. B. Waterstops shall be carefully positioned so that they are embedded to an equal depth in concrete on both sides of the joint. They shall be kept free from oil, grease, mortar or other foreign matter. To ensure proper placement, all waterstops shall be secured in correct position at 12" on center along the length of the waterstop on each side, prior to placing concrete. Such method of support shall be submitted to the Engineer for review and approval. Grommets or small pre-punched holes as close to the edges as possible will be acceptable for securing waterstops. C. Splices in PVC waterstops and chemical resistant waterstops shall be made with a thermostatically controlled heating element. Only straight butt joint splices will be allowed in the field. Factory fabricated corners and transitions shall be used at all intersections. Splices shall be made in strict accordance with the manufacturer's recommended instructions and procedures. At least three satisfactory sample splices shall be made on the site. The Engineer may require tests on these splices by an approved laboratory. The splices shall exhibit not less than 80 percent of the strength of the unspliced material. D. All splices in waterstops will be subject to rigid review for misalignment, bubbles, inadequate bond, porosity, cracks, offsets, discoloration, charring, and other defects which would reduce the potential resistance of the material to water pressure at any point. All defective joints shall be replaced with material which will pass said review and all faulty material shall be removed from the site and disposed of by the Contractor at no additional cost to the Owner. City of Denton Hazen and Sawyer BID SET 03250-6 Concrete Accessories E. Retrofit waterstops shall be installed as shown on Contract Drawings using approved waterstop adhesive and Type 316 stainless steel batten bars and expansion anchors. F. Waterstop installation and splicing defects which are unacceptable include, but are not limited to the following: 1. Tensile strength not less than 80 percent of parent material. 2. Overlapped (not spliced) Waterstop. 3. Misalignment of Waterstop geometry at any point greater than 1/16 inch. 4. Visible porosity or charred or burnt material in weld area. 5. Visible signs of splice separation when splice (24 hours or greater) is bent by hand at sharp angle. 3.02 HYPALON RUBBER AND EXPANDING RUBBER WATERSTOPS A. Waterstops shall be installed only where shown on the Drawings. B. Waterstops shall be installed in strict accordance with manufacturer's recommendations. 3.03 WATERSTOP ADHESIVE A. Adhesive shall be applied to both contact surfaces in strict accordance with manufacturer's recommendations. B. Adhesive shall be used where waterstops are attached to existing concrete surfaces. 3.04 INSTALLATION OF EXPANSION JOINT MATERIAL AND SEALANTS A. Type I, II, or III shall be used in all expansion joints in structures and concrete pavements unless specifically shown otherwise on the Drawings. Type IV shall be used in sidewalk and curbing and other locations specifically shown on the Drawings. B. All expansion joints exposed in the finish work, exterior and interior, shall be sealed with the specified joint sealant. Expansion joint material and sealants shall be installed in accordance with manufacturer's recommended procedures and as shown on the Drawings. C. Expansion joint material that will be exposed after removal of forms shall be cut and trimmed to ensure a neat appearance and shall completely fill the joint except for the space required for the sealant. The material shall be held securely in place and no concrete shall be allowed to enter the joint or the space for the sealant and destroy the proper functions of the joint. D. A bond breaker shall be used between expansion joint material and sealant. The joint shall be thoroughly clean and free from dirt and debris before the primer and the sealant are applied. Where the finished joint will be visible, masking of the adjoining surfaces shall be City of Denton Hazen and Sawyer BID SET 03250-7 Concrete Accessories carried out to avoid their discoloration. The sealant shall be neatly tooled into place and its finished surfaces shall present a clean and even appearance. E. Type 1 joint sealant shall be used in all expansion and contraction joints in concrete, except where Type 7 or Type 8 is required as stated below, and wherever else specified or shown on the Drawings. It shall be furnished in pour grade or gun grade depending on installation requirements. Primers shall be used as required by the manufacturer. The sealant shall be furnished in colors as directed by the Engineer. F. Type 8 joint sealant shall be used in all concrete pavements and floors subject to heavy traffic and wherever else specified or shown on the Drawings. G. Type 7 joint sealant shall be used for all joints in chlorine contact tanks and wherever specified or shown on the Drawings. 3.05 EXPANSION JOINT SEAL A. The expansion joint seal system shall be installed as shown on the Drawings in strict accordance with the manufacturer's recommendations. 3.06 CONTRACTION JOINT INSERTS A. For contraction joints in slabs, inserts shall be floated in fresh concrete during finishing. B. For contraction joints in walls, inserts shall be secured in place prior to casting wall. C. Inserts shall be installed true to line at the locations of all contraction joints as shown on the Drawings. D. Inserts shall extend into concrete sufficient depth as indicated on the Drawings or specified in Section 03290, Joints in Concrete. E. Inserts shall not be removed from concrete until concrete has cured sufficiently to prevent chipping or spalling of joint edges due to inadequate concrete strength. 3.07 EPOXY BONDING AGENT A. The Contractor shall use an epoxy bonding agent for bonding fresh concrete to existing concrete as shown on the Drawings. B. Bonding surface shall be clean, sound and free of all dust, laitance, grease, form release agents, curing compounds, and any other foreign particles. C. Application of bonding agent shall be in strict accordance with manufacturer's recommendations. D. Fresh concrete shall not be placed against existing concrete if epoxy bonding agent has lost its tackiness. City of Denton Hazen and Sawyer BID SET 03250-8 Concrete Accessories 3.08 EPOXY RESIN BINDER A. Epoxy resin binder shall be used to seal all existing rebar cut and burned off during demolition operations. Exposed rebar shall be burned back 1/2-inch minimum into existing concrete and the resulting void filled with epoxy resin binder. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 03290-1 Joints In Concrete SECTION 03290 JOINTS IN CONCRETE PART 1 -- GENERAL 1.01 THE REQUIREMENTS A. Provide all materials, labor and equipment required for the construction of all joints in concrete specified herein and shown on the Drawings. B. Types of joints in concrete shall be as follows: 1. Construction Joints - Joints between adjacent concrete placements continuously connected with reinforcement. 2. Expansion Joints - Joints in concrete which allow thermal expansion and contraction of concrete. Reinforcement terminates within concrete on each side of joint. 3. Contraction Joints - Joints formed in concrete to provide a weakened plane in concrete section to control formation of shrinkage cracks. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 03100 - Concrete Formwork B. Section 03250 - Concrete Accessories C. Section 03300 - Cast-in-Place Concrete D. Section 07900 - Joint Fillers, Sealants and Caulking 1.03 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. Without limiting the generality of the other requirements of the specifications, all work herein shall conform to the applicable requirements of the following documents. All referenced specifications, codes, and standards refer to the most current issue available at the time of Bid. 1. ACI 301 - Specifications for Structural Concrete for Buildings 2. ACI 318 - Building Code Requirements for Structural Concrete 3. ACI 350 – Code Requirements for Environmental Engineering Concrete Structures City of Denton Hazen and Sawyer BID SET 03290-2 Joints In Concrete 1.04 SUBMITTALS A. Submit the following in accordance with Section 01300, Submittals. 1. Layout drawings showing location and type of all joints to be placed in each structure. 2. Details of proposed joints in each structure. PART 2 -- MATERIALS 2.01 MATERIALS A. All materials required for joint construction shall comply with Section 03250 - Concrete Accessories, and Section 07900 - Joint Fillers, Sealants and Caulking. PART 3 -- EXECUTION 3.01 CONSTRUCTION JOINTS A. Construction joints shall be as shown on the Drawings. Otherwise, Contractor shall submit description of the joint and its location to Engineer for approval. B. Unless noted otherwise on the Drawings, construction joints shall be located near the middle of the spans of slabs, beams, and girders unless a beam intersects a girder at this point. In this case, the joints in the girders shall be offset a distance equal to twice the width of the beam. Joints in walls and columns shall be at the underside of floors, slabs, beams, or girders and the top of footings or floor slabs unless noted otherwise on Drawings. Beams, girders, brackets, column capitals, haunches, and drop panels shall be placed at the same time as slabs. Joints shall be perpendicular to the main reinforcement. C. Maximum distance between horizontal joints in slabs and vertical joints in walls shall be 45'-0". For exposed walls with fluid or earth on the opposite side, the spacing between vertical and horizontal joints shall be a maximum of 25’-0”. D. All corners shall be part of a continuous placement, and should a construction joint be required, the joint shall not be located closer than five feet from a corner. E. All reinforcing steel and welded wire fabric shall be continued across construction joints. Keys and inclined dowels shall be provided as shown on the Drawings or as directed by the Engineer. Longitudinal keys shall be provided in all joints in walls and between walls and slabs or footings, except as specifically noted otherwise on the Drawings. Size of keys shall be as shown on the Drawings. F. All joints in water bearing structures shall have a waterstop. All joints below grade in walls or slabs which enclose an accessible area shall have a waterstop. City of Denton Hazen and Sawyer BID SET 03290-3 Joints In Concrete 3.02 EXPANSION JOINTS A. Size and location of expansion joints shall be as shown on the Drawings. B. All expansion joints in water-bearing structures shall have a center-bulb type waterstop. All expansion joints below grade in walls or slabs which enclose an accessible area shall have a center-bulb type waterstop. Waterstop shall be as shown on Drawings and specified in Section 03250, Concrete Accessories. 3.03 CONTRACTION JOINTS A. Location of contraction joints shall be as shown on the Drawings. B. Contraction joints shall be formed with contraction joint inserts as specified in Section 03250, Concrete Accessories. C. Sawcutting of contraction joints in lieu of forming will not be allowed unless otherwise noted on the Drawings. Where sawcutting is allowed, joints shall be sawed as soon as the concrete can support foot traffic without leaving any impression, normally the same day as concrete is placed and in no case longer than 24 hours after concrete is placed. D. Unless noted otherwise on Drawings, depth of contraction joints shall be 1-1/2 inches in reinforced concrete and 1/3 of concrete thickness in unreinforced concrete. 3.04 JOINT PREPARATION A. No concrete shall be allowed to enter the joint or the space for the sealant and destroy the proper functions of the joint. B. The surface of the concrete at all joints shall be thoroughly cleaned and all laitance removed by wire brushing, air or light sand blasting. C. The joint shall be thoroughly clean and free from dirt and debris before the primer and the sealant are applied. Where the finished joint will be visible, masking of the adjoining surfaces shall be carried out to avoid their discoloration. The sealant shall be neatly tooled into place and its finished surface shall present a clean and even appearance. D. All joints shall be sealed as shown on the Drawings and specified in Section 03250, Concrete Accessories. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 03290-4 Joints In Concrete This page left blank intentionally City of Denton Hazen and Sawyer BID SET 03300-1 Cast-in-Place Concrete SECTION 03300 CAST-IN-PLACE CONCRETE PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Provide all labor, equipment, materials and services necessary for the manufacture, transportation and placement of all plain and reinforced concrete work, as shown on the Drawings or as ordered by the Engineer. B. The requirements in this section shall apply to the following types of concrete: 1. Class A1 Concrete: Normal weight structural concrete to be used in all structures qualifying as environmental concrete structures that are designed in accordance with ACI 350 including pump stations, tanks, basins, process structures, and any structures containing fluid or process chemicals or other materials used in treatment process. 2. Class A2 Concrete: Normal weight structural concrete in all structures other than structures qualifying as environmental concrete structures as described above, and for all sidewalks and pavement. 3. Class B Concrete: Normal weight structural concrete used for duct bank encasements, catch basins, fence and guard post embedment, concrete fill, and other areas where specifically noted on Contract Drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 03100 - Concrete Formwork B. Section 03200 - Reinforcing Steel C. Section 03250 - Concrete Accessories D. Section 03290 - Joints in Concrete E. Section 03350 - Concrete Finishes F. Section 03370 - Concrete Curing G. Section 03600 - Grout City of Denton Hazen and Sawyer BID SET 03300-2 Cast-in-Place Concrete 1.03 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. Without limiting the generality of the Specifications, all work herein shall conform to or exceed the applicable requirements of the following documents. All referenced specifications, codes, and standards refer to the most current issue available at the time of Bid. 1. State of Texas Building Code 2. ACI 214 Recommended Practice for Evaluation of Strength Test Results of Concrete 3. ACI 301 Specifications for Structural Concrete for Buildings 4. ACI 304 Guide for Measuring, Mixing, Transporting, and Placing Concrete 5. ACI 305 Hot Weather Concreting 6. ACI 306 Cold Weather Concreting 7. ACI 309 Recommended Practice for Consolidation of Concrete 8. ACI 318 Building Code Requirements for Structural Concrete 9. ACI 350 Code Requirements for Environmental Engineering Concrete Structures 10. ASTM C 31 Standard Methods of Making and Curing Concrete Test Specimens in the Field 11. ASTM C 33 Standard Specification for Concrete Aggregates 12. ASTM C 39 Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens 13. ASTM C42 Obtaining and Testing Drilled Cores and Sawed Beams of Concrete 14. ASTM C 88 Standard Test Method for Soundness of Aggregates by use of Sodium Sulfate or Magnesium Sulfate 15. ASTM C 94 Standard Specification for Ready-Mixed Concrete 16. ASTM C 114 Standard Test Method for Chemical Analysis of Hydraulic Cement 17. ASTM C 136 Standard Method for Sieve Analysis of Fine and Coarse Aggregate City of Denton Hazen and Sawyer BID SET 03300-3 Cast-in-Place Concrete 18. ASTM C 138 Standard Test Method for Unit Weight, Yield, and Air Content (Gravimetric) of Concrete 19. ASTM C 143 Standard Test Method for Slump of Portland Cement Concrete 20. ASTM C 150 Standard Specification for Portland Cement 21. ASTM C 172 Standard Method of Sampling Fresh Concrete 22. ASTM C 192 Standard Method of Making and Curing Concrete Test Specimens in the Laboratory 23. ASTM C 231 Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method 24. ASTM C 260 Standard Specification for Air-Entraining Admixtures for Concrete 25. ASTM C 295 Standard Guide for Petrographic Examination of Aggregates for Concrete 26. ASTM C 457 Standard Recommended Practice for Microscopical Determination of Air-Void Content and Parameters of the Air-Void System in Hardened Concrete 27. ASTM C 494 Standard Specification for Chemical Admixtures for Concrete 28. ASTM C 595 Standard Specification for Blended Hydraulic Cements 29. ASTM C 618 Standard Specification for Fly Ash and Raw or Calcined Natural Pozzolan for use as a Mineral Admixture in Portland Cement Concrete 30. ASTM C 989 Standard Specification for Slag Cement for Use in Concrete and Mortars 31. ASTM C 1077 Recommended Practice for Labs Testing Concrete 32. ASTM C 1260 Test Method for Potential Alkali Reactivity of Aggregates (Mortar Bar Method) 33. ASTM C 1567 Standard Test Method for Potential Alkali-Silica Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated Mortar-Bar Method) 34. ASTM C 1602 Standard Specification for Mixing Water Used in the Production of Hydraulic Cement Concrete 35. ASTM C 1778 Reducing the Risk of Deleterious Alkali – Aggregate Reaction in Concrete City of Denton Hazen and Sawyer BID SET 03300-4 Cast-in-Place Concrete 1.04 SUBMITTALS A. Submit the following in accordance with Section 01300, Submittals. 1. Sources of all materials and certifications of compliance with specifications for all materials. 2. Certified current (less than 1 year old) chemical analysis of the Portland Cement or Blended Cement to be used. 3. Certified current (less than 1 year old) chemical analysis of fly ash or slag cement to be used. 4. Aggregate test results showing compliance with required standards, i.e., sieve analysis, aggregate soundness tests, petrographic analysis, mortar bar expansion testing, etc. 5. Manufacturer's data on all admixtures stating compliance with required standards. 6. Concrete mix design for each class of concrete specified herein. 7. Field experience records and/or trial mix data for the proposed concrete mixes for each class of concrete specified herein. 1.05 QUALITY ASSURANCE A. Tests on materials used in the production of concrete shall be required as specified in PART 2 -- PRODUCTS. These tests shall be performed by an independent testing laboratory approved by the Engineer at no additional cost to the Owner. B. Trial concrete mixes shall be tested when required in accordance with Article 3.01 at no additional cost to the Owner. C. Field quality control tests, as specified in Article 3.10, unless otherwise stated, will be performed by a materials testing consultant employed by the Owner. However, the Contractor shall be charged for the cost of any additional tests and investigation on work performed which does not meet the Specifications. Any individual who samples and tests concrete to determine if the concrete is being produced in accordance with this Specification shall be certified as a Concrete Field Testing Technician, Grade I, in accordance with ACI CP-2. Testing laboratory shall conform to requirements of ASTM C-1077. 1.06 CONCRETE COORDINATION CONFERENCE A. Unless waived by the Engineer, prior to any concrete submittals and at least 35 days prior to the start of the concrete construction schedule, the Contractor shall conduct a meeting at the site. The purpose of the meeting is to review the proposed concrete mix designs, to discuss the proposed approaches and procedures for mixing, transporting, placing, testing, finishing, and curing of all aspects of concrete work to ensure the concrete construction is performed in accordance with the Specifications, and to clarify roles of the parties involved. The City of Denton Hazen and Sawyer BID SET 03300-5 Cast-in-Place Concrete Contractor shall send a concrete coordination conference agenda to all attendees 20 days prior to a mutually agreed upon date for the conference. B. As a minimum the agenda shall include: 1. Concrete Materials and Mix Designs 2. Inspection Responsibilities 3. Concrete Sampling and Testing Specification Requirements 4. Cylinder Storage and Transportation 5. Acceptance/Rejection Responsibility and Authority for Fresh Concrete 6. Concrete finishing 7. Concrete Curing 8. Test Report Distribution 9. Miscellaneous Items C. The Contractor shall require responsible representatives of every party who is concerned with the concrete work to attend the conference, including but not limited to the following: 1. Contractor’s superintendent 2. Engineer 3. Owner’s representative (if he chooses to attend) 4. Laboratory retained for trial batching and construction quality control testing for the concrete. 5. Any subcontractors involved in placing, finishing, and curing of concrete 6. Concrete supplier 7. Concrete pumping subcontractor (if pumping is being proposed) D. Minutes of the meeting shall be recorded, typed, and printed by the Contractor and distributed to all attendees and any other concerned parties within five days of the meeting. City of Denton Hazen and Sawyer BID SET 03300-6 Cast-in-Place Concrete PART 2 -- PRODUCTS 2.01 HYDRAULIC CEMENT A. Portland Cement 1. Portland Cement shall be Type II conforming to ASTM C 150. Type I cement may be used provided either fly ash or slag cement is also included in the mix in accordance with Articles 2.02 or 2.03 respectively. 2. When potentially reactive aggregates as defined in Article 2.05 are to be used in concrete mix, cement shall meet the following requirements: a. For concrete mixed with only Portland Cement, the total alkalies in the cement (calculated as the percentage of NA2O plus 0.658 times the percentage of K2O) shall not exceed 0.40%. b. For concrete mixed with Portland Cement and an appropriate amount of fly ash (Article 2.02) or slag cement (Article 2.03) the total alkalies in the Portland Cement (calculated as the percentage of NA2O plus 0.658 times the percentage of K2O) shall not exceed 0.85%. 3. When non-reactive aggregates as defined in Article 2.05 are used in concrete mix, total alkalies in the cement shall not exceed 1.0%. 4. The proposed Portland Cement shall not contain more than 8% tricalcium aluminate and more than 12% tetracalcium aluminoferrite. B. Blended Cement 1. Blended cements shall be Type IP (Portland Fly Ash Cement) or Type IS (Portland Slag Cement) conforming to ASTM C 595. 2. Type IP cement shall be an interground blend of Portland Cement and fly ash in which the fly ash constituent is between 15% and 25% of the weight of the total blend. 3. Type IS cement shall be an interground blend of Portland Cement and slag cement in which the slag constituent is between 35% and 50% of the weight of the total blend. 4. Fly ash and slag cement used in the production of blended cements shall meet the requirements of Articles 2.02 and 2.03, respectively. 5. When reactive aggregates as defined in Article 2.05 are used in concrete mix, the total alkalies in the Portland Cement (calculated as the percentage of Na2O plus 0.658 times the percentage of K2O) shall not exceed 0.85%. The percentage of fly ash or slag cement shall be set to meet provisions of Article 2.05.G.3. City of Denton Hazen and Sawyer BID SET 03300-7 Cast-in-Place Concrete C. Different types of cement shall not be mixed nor shall they be used alternately except when authorized in writing by the Engineer. Different brands of cement or the same brand from different mills may be used alternately. A resubmittal will be required if different cements are proposed during the Project. D. Cement shall be stored in a suitable weather-tight building so as to prevent deterioration or contamination. Cement which has become caked, partially hydrated, or otherwise damaged will be rejected. 2.02 FLY ASH A. Fly ash shall meet the requirements of ASTM C 618 for Class F, except that the loss on ignition shall not exceed 4%. Fly ash shall also meet the optional physical requirements for uniformity as shown in Table 3 of ASTM C 618. B. For fly ash to be used in the production of type IP cement, the Pozzolan Activity Index shall be greater than 75% as specified in Table 3 of ASTM C 595. C. Where reactive aggregates as defined in Article 2.05 are used in concrete mix, the fly ash constituent shall be between 15% and 25% of the total weight of the combined Portland Cement and fly ash. The percentage of fly ash shall be set to meet the provisions of Article 2.05.G.3. D. For Type A1 concrete as required for use in environmental concrete structures, i.e. process structures or fluid containing structures, inclusion of fly ash or slag cement in the concrete mix, is mandatory. E. Additional fly ash shall not be included in concrete mixed with Type IS or IP cement. 2.03 SLAG CEMENT A. Slag cement shall meet the requirements of ASTM C 989 including tests for effectiveness of slag in preventing excessive expansion due to alkali-aggregate reactivity as described in Appendix X-3 of ASTM C 989. B. Where reactive aggregates as defined in Article 2.05 are used in concrete mix, the slag cement constituent shall be between 35% and 40% of the total weight of the combined Portland Cement and slag. The percentage of slag cement shall be set to meet the provisions of Article 2.05.G.3. C. For Type A1 concrete as required for use in environmental concrete structures, i.e. process structures or fluid containing structures, inclusion of fly ash or slag cement in the concrete mix, is mandatory. D. Additional slag cement shall not be included in concrete mixed with type IS or IP cement. City of Denton Hazen and Sawyer BID SET 03300-8 Cast-in-Place Concrete 2.04 WATER A. Water used for mixing concrete shall be clear, potable and free from deleterious substances such as objectionable quantities of silty organic matter, alkali, salts and other impurities. B. Water shall not contain more than 100 PPM chloride. C. Water shall not contain more than 500 PPM dissolved solids. D. Water shall have a pH in the range of 4.5 to 8.5. E. Water shall meet requirements of ASTM C 1602. 2.05 AGGREGATES A. All aggregates used in normal weight concrete shall conform to ASTM C 33. B. Fine Aggregate (Sand) in the various concrete mixes shall consist of natural or manufactured siliceous sand, clean and free from deleterious substances, and graded within the limits of ASTM C 33. C. Coarse aggregates shall consist of hard, clean, durable gravel, crushed gravel or crushed rock. Coarse aggregate shall be size #57 or #67 as graded within the limits given in ASTM C 33 unless otherwise specified. D. For Class A4 concrete, coarse aggregate shall be Size #8 in accordance with ASTM C33. E. Aggregates shall be tested for gradation by sieve analysis tests in conformance with ASTM C 136. F. Aggregates shall be tested for soundness in accordance with ASTM C 88. The loss resulting after five cycles shall not exceed 10 percent for fine or coarse aggregate when using either magnesium sulfate or sodium sulfate. G. Non-reactive aggregates shall meet the following requirements: 1. All aggregates shall be evaluated in accordance with ASTM C 1778 to determine potential reactivity. 2. A petrographic analysis in accordance with ASTM C295 shall be performed to identify the constituents of the fine and coarse aggregate. Non-reactive aggregates shall meet the following limitations: (1) Optically strained, microfractured, or microcrystalline quartz, 5.0%, maximum. (2) Chert or chalcedony, 3.0%, maximum. (3) Tridymite or cristobalite, 1.0%, maximum. City of Denton Hazen and Sawyer BID SET 03300-9 Cast-in-Place Concrete (4) Opal, 0.5%, maximum. (5) Natural volcanic glass in volcanic rocks, 3.0%, maximum. 3. If aggregates are deemed potentially reactive as per ASTM C-1778 and fly ash or slag cement is included in proposed concrete mix design, proposed concrete mix including proposed aggregates shall be evaluated by ASTM C-1567. Mean mortar bar expansions at 16 days shall be less than 0.08%. Tests shall be made using exact proportion of all materials proposed for use on the job in design mix submitted. 4. If aggregates are deemed potentially reactive as per ASTM C-1778 and a straight cement mix without fly ash or slag cement is proposed for concrete mix design, aggregates shall be evaluated by ASTM C-1260. Mean mortar bar expansions at 16 days shall be less than 0.08%. H. All aggregates shall be considered reactive unless they meet the requirements above for non-reactive aggregates. Aggregates with a lithology essentially similar to sources in the same region found to be reactive in service shall be considered reactive regardless of the results of the tests above. I. Contractor shall submit a new trial mix to the Engineer for approval whenever a different aggregate or gradation is proposed. 2.07 ADMIXTURES A. Air entraining agent shall be added to all concrete unless noted otherwise. The agent shall consist of a neutralized vinsol resin solution or a purified hydrocarbon with a cement catalyst which will provide entrained air in the concrete in accordance with ASTM C 260. The admixture proposed shall be selected in advance so that adequate samples may be obtained and the required tests made. Air content of concrete, when placed, shall be within the ranges given in the concrete mix design. B. The following admixtures are required or used for water reduction, slump increase, and/or adjustment of initial set. Admixtures permitted shall confirm to the requirements of ASTM C 494. Admixtures shall be non-toxic after 30 days and shall be compatible with and made by the same manufacturer as the air-entraining admixtures. 1. Water reducing admixture shall conform to ASTM C 494, Type A and shall contain no more than 0.05% chloride ions. Acceptable products are “Eucon Series” by the Euclid Chemical Company, “Master Pozzolith Series” by BASF, and “Plastocrete Series” by Sika Corporation. 2. High range water reducer shall be sulfonated polymer conforming to ASTM C 494, Type F or G. The high range water reducer shall be added to the concrete at either the batch plant or at the job site and may be used in conjunction with a water reducing admixture. The high range water reducer shall be accurately measured and pressure injected into the mixer as a single dose by an experienced technician. City of Denton Hazen and Sawyer BID SET 03300-10 Cast-in-Place Concrete A standby system shall be provided and tested prior to each day’s operation of the job site system. Concrete shall be mixed at mixing speed for a minimum of 100 mixer revolutions after the addition of the high range water reducer. Acceptable products are “Eucon 37” or Plastol 5000 by the Euclid Chemical Company, “Master Rheobuild 1000 or Master Glenium Series” by BASF, and “Daracem 100 or Advaflow Series” by W.R. Grace. 3. A non-chloride, non-corrosive accelerating admixture may be used where specifically approved by the Engineer. The admixture shall conform to ASTM C 494, Type C or E, and shall not contain more chloride ions than are present in municipal drinking water. The admixture manufacturer must have long-term non-corrosive test data from an independent testing laboratory (of at least a year’s duration) using an acceptable accelerated corrosion test method such as that using electrical potential measures. Acceptable products are “Accelguard 80/90 or NCA” by the Euclid Chemical Company and “Daraset” by W.R. Grace. 4. A water reducing retarding admixture may be used where specifically approved by the Engineer. The admixture shall conform to ASTM C494, Type D and shall not contain more than 0.05% chloride ions. Acceptable products are “Eucon NR or Eucon Retarder 100” by the Euclid Chemical Company, “Pozzolith Retarder” by BASF, and “Plastiment” by Sika Corporation. C. Admixtures containing calcium chloride, thiocyanate or more than 0.05 percent chloride ions are not permitted. The addition of admixtures to prevent freezing is not permitted. D. The Contractor shall submit manufacturer's data including the chloride ion content of each admixture and certification from the admixture manufacturer that all admixtures utilized in the design mix are compatible with one another and properly proportioned prior to mix design review. 2.08 CONCRETE MIX DESIGN A. The proportions of cement, aggregates, admixtures and water used in the concrete mixes shall be based on the results of field experience or preferably laboratory trial mixes in conformance with Section 5.3. "Proportioning on the Basis of Field Experience and/or Trial Mixtures" of ACI 318 and ACI 350. When trial mixes are used they shall also conform to Article 3.01 of this Section of the Specifications. If field experience records are used, concrete strength results shall be from concrete mixed with all of the ingredients proposed for use on job used in similar proportions to mix proposed for use on job. Contractor shall submit verification confirming this stipulation has been followed. Field experience records and/or trial mix data used as the basis for the proposed concrete mix design shall be submitted to the Engineer along with the proposed mix. B. Structural concrete shall conform to the following requirements. Cementitious materials refer to the total combined weight of all cement, fly ash, and slag cement contained in the mix. City of Denton Hazen and Sawyer BID SET 03300-11 Cast-in-Place Concrete 1. Compressive Strength (28-Day) a. Concrete Class A1 4,500 psi (minimum) b. Concrete Class A2 4,000 psi (minimum) c. Concrete Class B 3,000 psi (minimum) 2. Water/cementitious materials ratio, by weight Maximum Minimum a. Concrete Class A1 0.42 0.39 b. Concrete Class A2 0.45 0.39 c. Concrete Class B 0.50 0.39 3. Slump range 4" nominal unless high range water reducing admixture is used. 8” max if high range water reducing admixture is used. 4. Air Content a. Class A1, A2 6% ±1.5% b. Class B 3% Max (non air- entrained) PART 3 -- EXECUTION 3.01 TRIAL MIXES A. When trial mixes are used to confirm the quality of a proposed concrete mix in accordance with Section 5.3, "Proportioning on the Basis of Field Experience and/or Trial Mixtures" of ACI 318 and ACI 350, an independent qualified testing laboratory designated and retained by the Contractor shall test a trial batch of each of the preliminary concrete mixes submitted by the Contractor. The trial batches shall be prepared using the aggregates, cement and admixtures proposed for the project. The trial batch materials shall be of a quantity such that the testing laboratory can obtain enough samples to satisfy requirements stated below. Tests on individual materials stated in PART 2 -- PRODUCTS should already be performed before any trial mix is done. The cost of laboratory trial batch tests for each specified concrete mix will be borne by the Contractor and the Contractor shall furnish and deliver the materials to the testing laboratory at no cost to the Owner. B. The independent testing laboratory shall prepare a minimum of fifteen (15) standard test cylinders in accordance with ASTM C 31 in addition to conducting slump (ASTM C 143), air content (C 231) and unit weight (C 138) tests. Compressive strength test on the cylinders shall subsequently be performed by the same laboratory in accordance with ASTM C 39 as follows: Test 3 cylinders at age 7 days; test 3 cylinders at age 21 days; test 3 cylinders at City of Denton Hazen and Sawyer BID SET 03300-12 Cast-in-Place Concrete age 28 days and test 3 cylinders at 56 days. The cylinders shall be carefully identified as "Trial Mix, Contract No. , Product ." If the average 28-day compressive strength of the trial mix is less than that specified, or if any single cylinder falls below the required strength by more than 500 psi, the mix shall be corrected, another trial batch prepared, test cylinders taken, and new tests performed as before. Any such additional trial batch testing required shall be performed at no additional cost to the Owner. Adjustments to the mix shall be considered refinements to the mix design and shall not be the basis for extra compensation to the Contractor. 3.02 PRODUCTION OF CONCRETE A. All concrete shall be machine mixed. Hand mixing of concrete will not be permitted. The Contractor may supply concrete from a ready mix plant or from a site mixed plant. In selecting the source for concrete production the Contractor shall carefully consider its capability for providing quality concrete at a rate commensurate with the requirements of the placements so that well bonded, homogenous concrete, free of cold joints, is assured. B. Ready-Mixed Concrete 1. At the Contractor's option, ready-mixed concrete may be used meeting the requirements for materials, batching, mixing, transporting, and placing as specified herein and in accordance with ASTM C 94. 2. Truck mixers shall be equipped with electrically-actuated counters by which the number of revolutions of the drum or blades may be readily verified. The counter shall be of the resettable, recording type, and shall be mounted in the driver's cab. The counters shall be actuated at the time of starting mixers at mixing speeds. 3. Each batch of concrete shall be mixed in a truck mixer for not less than 100 revolutions of the drum or blades at the rate of rotation designated by the manufacturer of equipment. Additional mixing, if any, shall be at the speed designated by the manufacturer of the equipment as agitating speed. All materials including mixing water shall be in the mixer drum before actuating the revolution counter for determining the number of revolutions of mixing. 4. Truck mixers and their operation shall be such that the concrete throughout the mixed batch, as discharged, is within acceptable limits of uniformity with respect to consistency, mix and grading. If slump tests taken at approximately the 1/4 and 3/4 points of the load during discharge give slumps differing by more than one inch when the specified slump is 3 inches or less, or if they differ by more than 2 inches when the specified slump is more than 3 inches, the mixer shall not be used on the work unless the causing condition is corrected and satisfactory performance is verified by additional slump tests. All mechanical details of the mixer, such as water measuring and discharge apparatus, condition of the blades, speed of rotation, general mechanical condition of the unit and clearance of the drum, shall be checked before a further attempt to use the unit will be permitted. City of Denton Hazen and Sawyer BID SET 03300-13 Cast-in-Place Concrete 5. Ready-mixed concrete shall be delivered to the site for the work and discharge shall be completed before the drum has been revolved 300 revolutions and within the time requirements stated in Article 3.03 of this Section. 6. Each and every concrete delivery shall be accompanied by a delivery ticket containing at least the following information: a. Date and truck number b. Ticket number c. Mix designation of concrete d. Cubic yards of concrete e. Cement brand, type and weight in pounds f. Weight in pounds of fine aggregate (sand) g. Weight in pounds of coarse aggregate (stone) h. Air entraining agent, brand, and weight in pounds and ounces i. Other admixtures, brand, and weight in pounds and ounces j. Water, in gallons, stored in attached tank k. Water, in gallons, maximum that can be added without exceeding design water/cementitious materials ratio l. Water, in gallons, actually used (by truck driver) m. Time of loading n. Time of delivery to job (by truck driver) 7. Any truck delivering concrete to the job site, which is not accompanied by a delivery ticket showing the above information will be rejected and such truck shall immediately depart from the job site. 8. The use of non-agitating equipment for transporting ready-mixed concrete will not be permitted. Combination truck and trailer equipment for transporting ready-mixed concrete will not be permitted. The quality and quantity of materials used in ready-mixed concrete and in batch aggregates shall be subject to continuous inspection at the batching plant by the Engineer. C. Site Mixed Concrete 1. Scales for weighing concrete ingredients shall be accurate when in use within ±0.4 percent of their total capacities. Standard test weights shall be available to permit checking scale accuracy. 2. Operation of batching equipment shall be such that the concrete ingredients are consistently measured within the following tolerances: a. Cement, fly ash, or slag cement ± 1 percent b. Water ± 1 percent c. Aggregates ± 2 percent d. Admixtures ± 3 percent 3. Each batch shall be so charged into the mixer that some water will enter in advance of the cement and aggregates. Water shall continue for a period which may extend City of Denton Hazen and Sawyer BID SET 03300-14 Cast-in-Place Concrete to the end of the first 25 percent of the specified mixing time. Controls shall be provided to prevent batched ingredients from entering the mixer before the previous batch has been completely discharged. 4. The concrete shall be mixed in a batch mixer capable of thoroughly combining the aggregates, cement, and water into a uniform mass within the specified mixing time, and of discharging the concrete without harmful segregation. The mixer shall bear a manufacturer's rating plate indicating the rate capacity and the recommended revolutions per minute and shall be operated in accordance therewith. 5. Mixers with a rate capacity of 1 cu.yd. or larger shall conform to the requirements of the Plant Mixer Manufacturers' Division of the Concrete Plant Manufacturers' Bureau. 6. Except as provided below, batches of 1 cu. yd. or less shall be mixed for not less than 1 minute. The mixing time shall be increased 15 seconds for each cubic yard or fraction thereof of additional capacity. 7. Shorter mixing time may be permitted provided performance tests made in accordance with of ASTM C 94 indicate that the time is sufficient to produce uniform concrete. 8. Controls shall be provided to insure that the batch cannot be discharged until the required mixing time has elapsed. At least three-quarters of the required mixing time shall take place after the last of the mixing water has been added. 9. The interior of the mixer shall be free of accumulations that will interfere with mixing action. Mixer blades shall be replaced when they have lost 10 percent of their original height. 10. Air-entraining admixtures and other chemical admixtures shall be charged into the mixer as solutions and shall be measured by means of an approved mechanical dispensing device. The liquid shall be considered a part of the mixing water. Admixtures that cannot be added in solution may be weighed or may be measured by volume if so recommended by the manufacturer. 11. If two or more admixtures are used in the concrete, they shall be added separately to avoid possible interaction that might interfere with the efficiency of either admixture or adversely affect the concrete. 12. Addition of retarding admixtures shall be completed within 1 minute after addition of water to the cement has been completed, or prior to the beginning of the last three- quarters of the required mixing, whichever occurs first. Retarding admixtures shall not be used unless approved by the Engineer. 13. Concrete shall be mixed only in quantities for immediate use and within the time and mixing requirements of ASTM C 94. City of Denton Hazen and Sawyer BID SET 03300-15 Cast-in-Place Concrete 3.03 CONCRETE PLACEMENT A. No concrete shall be placed prior to approval of the concrete mix design. Concrete placement shall conform to the recommendations of ACI 304. B. Prior to concrete placement, all reinforcement shall be securely and properly fastened in its correct position. Formwork shall be clean, oiled and form ties at construction joints shall be retightened. All bucks, sleeves, castings, hangers, pipe, conduits, bolts, anchors, wire, and any other fixtures required to be embedded therein shall be in place. Forms for openings to be left in the concrete shall be in place and anchored by the Contractor. All loose debris in bottoms of forms or in keyways shall be removed and all debris, water, snow, ice and foreign matter shall be removed from the space to be occupied by the concrete. The Contractor shall notify the Engineer in advance of placement, allowing sufficient time for a concurrent inspection and for any corrective measures which are subsequently required. C. On horizontal joints where concrete is to be placed on hardened concrete, flowing concrete containing a high range water reducing admixture or cement grout shall be placed with a slump not less than 8 inches for the initial placement at the base of the wall. Concrete or cement grout shall meet all strength and service requirements specified herein for applicable class of concrete. This concrete shall be worked well into the irregularities of the hard surface. D. All concrete shall be placed during the daylight hours except with the consent of the Engineer. If special permission is obtained to carry on work during the night, adequate lighting must be provided. E. When concrete arrives at the project with slump below that suitable for placing, as indicated by the Specifications, water may be added to bring the concrete within the specified slump range provided that the design water-cementitious materials ratio is not exceeded. The water shall be incorporated by additional mixing equal to at least half of the total mixing required. Water may be added only to full trucks. On-site tempering shall not relieve the Contractor from furnishing a concrete mix that meets all specified requirements. F. Concrete shall be conveyed as rapidly as practicable to the point of deposit by methods which prevent the separation or loss of the ingredients. It shall be so deposited that rehandling will be unnecessary. Discharge of the concrete to its point of deposit shall be completed within 90 minutes after the addition of the cement to the aggregates. In hot weather, or under conditions contributing to quick stiffening of the concrete, the time between the introduction of the cement to the aggregates and discharge shall not exceed the requirements stated in Article 3.07 of this Section. G. Where concrete is conveyed to position by chutes, a practically continuous flow in the chute shall be maintained. The angle and discharge arrangement of the chute shall be such as to prevent segregation of the concrete ingredients. The delivery end of the chute shall be as close as possible to the point of deposit and in no case shall the free pour from the delivery end of the chute exceed five feet, unless approved otherwise. H. Special care must be exercised to prevent splashing of forms or reinforcement with concrete, and any such splashes or accumulations of hardened or partially hardened City of Denton Hazen and Sawyer BID SET 03300-16 Cast-in-Place Concrete concrete on the forms or reinforcement above the general level of the concrete already in place must be removed before the work proceeds. Concrete shall be placed in all forms in such way as to prevent any segregation. I. Placing of concrete shall be so regulated that the pressure caused by the wet concrete shall not exceed that used in the design of the forms. J. All concrete for walls shall be placed through openings in the form spaced at frequent intervals or through tremies (heavy duct canvas, rubber, etc.), equipped with suitable hopper heads. Tremies shall be of variable lengths so the free fall shall not exceed five (5) feet and a sufficient number shall be placed in the form to ensure the concrete is kept level at all times. K. When placing concrete which is to be exposed, sufficient illumination shall be provided in the interior of the forms so the concrete, at places of deposit, is visible from deck and runways. L. Concrete shall be placed so as to thoroughly embed all reinforcement, inserts, and fixtures. M. When forms are removed, surfaces shall be even and dense, free from aggregate pockets or honeycomb. To achieve this, concrete shall be consolidated using mechanical vibration, supplemented by forking and spading by hand in the corners and angle of forms and along form surfaces while the concrete is plastic under the vibratory action. Consolidation shall conform to ACI 309. N. Mechanical vibration shall be applied directly to the concrete, unless otherwise approved by the Engineer. The bottom of vibrators used on floor slabs must not be permitted to ride the form supporting the slab. Vibration shall be applied at the point of deposit and in the area of freshly placed concrete by a vertical penetration of the vibrator. Vibrators shall not be used to move concrete laterally within the forms. O. The intensity of vibration shall be sufficient to cause settlement of the concrete into place and to produce monolithic joining with the preceding layer. It shall be of sufficient duration to accomplish thorough compaction and complete embedment of reinforcement and fixtures with a vibrator transmitting not less than 7,500 impulses per minute. Since the duration of vibration per square foot of surface is dependent on the frequency (impulses per minute), size of vibrator, and slump of concrete, the length of time must therefore be determined in the field. Vibration, however, shall not be continued in any one location to the extent that pools of grout are formed. P. Care shall be taken to prevent cold joints when placing concrete in any portion of the work. The concrete placing rate shall be such as to ensure that each layer is placed while the previous layer is soft or plastic, so that the two layers can be made monolithic by penetration of the vibrators. Maximum thickness of concrete layers shall be 18 inches. The surface of the concrete shall be level whenever a run of concrete is stopped. Q. To prevent featheredges, construction joints located at the tops of horizontal lifts near sloping exposed concrete surfaces shall be inclined near the exposed surface, so the angle between such inclined surface and the exposed concrete surface will be not less than 50°. City of Denton Hazen and Sawyer BID SET 03300-17 Cast-in-Place Concrete R. In placing unformed concrete on slopes, the concrete shall be placed ahead of a non-vibrated slip-form screed extending approximately 2-1/2 feet back from its leading edge. The method of placement shall provide a uniform finished surface with the deviation from the straight line less than 1/8 inch in any concrete placement. Concrete ahead of the slip-form screed shall be consolidated by internal vibrators so as to ensure complete filling under the slip-form. Prior to placement of concrete on sloped walls or slabs, the Contractor shall submit a plan specifically detailing methods and sequence of placements, proposed concrete screed equipment, location of construction joints and waterstops, and/or any proposed deviations from the aforementioned to the Engineer for review and approval. S. Concrete shall not be placed during rains sufficiently heavy or prolonged to wash mortar from coarse aggregate on the forward slopes of the placement. Once placement of concrete has commenced in a block, placement shall not be interrupted by diverting the placing equipment to other uses. 3.04 PLACING FLOOR SLABS ON GRADE A. The subgrade for slabs on ground shall be well drained and of adequate and uniform loadbearing nature. The in-place density of the subgrade soils shall be at least the minimum required by the specifications. No foundation, slab, or pavement concrete shall be placed until the depth and character of the foundation soils have been inspected and approved by the materials testing consultant. B. The subgrade shall be free of frost before concrete placing begins. If the temperature inside a building where concrete is to be placed is below freezing it shall be raised and maintained above 50° long enough to remove all frost from the subgrade. C. The subgrade shall be moist at the time of concreting. If necessary, it shall be dampened with water in advance of concreting, but there shall be no free water standing on the subgrade nor any muddy or soft spots when the concrete is placed. D. Thirty-pound felt paper shall be provided between edges of slab-on-grade and vertical and horizontal concrete surfaces, unless otherwise indicated on the Drawings. E. Contraction joints shall be provided in slabs-on-grade at locations indicated on the Drawings. Contraction joints shall be installed as per Section 03290 - Joints in Concrete. F. Floor slabs shall be screeded level or pitched to drain as indicated on the Drawings. Finishes shall conform with requirements of Section 03350 - Concrete Finishes. Interior floor slabs shall be placed with non-air-entrained concrete (Class A3) if a steel troweled or hardened finish is required. 3.05 ORDER OF PLACING CONCRETE A. In order to minimize the effects of shrinkage, the concrete shall be placed in units as bounded by construction joints shown on the Drawings and maximum lengths as indicated on Drawings. Where required on the Drawings and wherever else practical, the placing of such units shall be done in a strip pattern in accordance with ACI 302.1. A minimum of 72 hours shall pass prior to placing concrete directly adjacent to previously placed concrete. City of Denton Hazen and Sawyer BID SET 03300-18 Cast-in-Place Concrete 3.06 CONCRETE WORK IN COLD WEATHER A. Cold weather concreting procedures shall conform to the requirements of ACI 306. B. The Engineer may prohibit the placing of concrete at any time when air temperature is 40°F. or lower. If concrete work is permitted, the concrete shall have a minimum temperature, as placed, of 55°F. for placements less than 12" thick, 50°F. for placements 12" to 36" thick, and 45°F. for placements greater than 36" thick. The temperature of the concrete as placed shall not exceed the aforementioned minimum values by more than 20°F, unless otherwise approved by the Engineer. C. All aggregate and water shall be preheated. Precautions shall be taken to avoid the possibility of flash set when aggregate or water are heated to a temperature in excess of 100°F. in order to meet concrete temperature requirements. The addition of admixtures to the concrete to prevent freezing is not permitted. All reinforcement, forms, and concrete accessories with which the concrete is to come in contact shall be defrosted by an approved method. No concrete shall be placed on frozen ground. 3.07 CONCRETE WORK IN HOT WEATHER A. Hot weather concreting procedures shall conform to the requirements of ACI 305. B. When air temperatures exceed 85°F., or when extremely dry conditions exist even at lower temperatures, particularly if accompanied by high winds, the Contractor and his concrete supplier shall exercise special and precautionary measures in preparing, delivering, placing, finishing, curing and protecting the concrete mix. The Contractor shall consult with the Engineer regarding such measures prior to each day's placing operation and the Engineer reserves the right to modify the proposed measures consistent with the requirements of this Section of the Specifications. All necessary materials and equipment shall be on hand an in position prior to each placing operation. C. Preparatory work at the job site shall include thorough wetting of all forms, reinforcing steel and, in the case of slab pours on ground or subgrade, spraying the ground surface on the preceding evening and again just prior to placing. No standing puddles of water shall be permitted in those areas which are to receive the concrete. D. The temperature of the concrete mix when placed shall not exceed 90°F. E. Temperature of mixing water and aggregates shall be carefully controlled and monitored at the supplier's plant, with haul distance to the job site being taken into account. Stockpiled aggregates shall, if necessary, be shaded from the sun and sprinkled intermittently with water. If ice is used in the mixing water for cooling purposes, it must be entirely melted prior to addition of the water to the dry mix. F. Delivery schedules shall be carefully planned in advance so that concrete is placed as soon as practical after it is properly mixed. For hot weather concrete work (air temperature greater than 85°F), discharge of the concrete to its point of deposit shall be completed within 60 minutes from the time the concrete is batched. City of Denton Hazen and Sawyer BID SET 03300-19 Cast-in-Place Concrete G. The Contractor shall arrange for an ample work force to be on hand to accomplish transporting, vibrating, finishing, and covering of the fresh concrete as rapidly as possible. 3.08 QUALITY CONTROL A. Field Testing of Concrete 1. The Contractor shall coordinate with the Engineer's project representative the on-site scheduling of the materials testing consultant personnel as required for concrete testing. 2. Concrete for testing shall be supplied by the Contractor at no additional cost to the Owner, and the Contractor shall provide assistance to the materials testing consultant in obtaining samples. The Contractor shall dispose of and clean up all excess material. B. Consistency 1. The consistency of the concrete will be checked by the materials testing consultant by standard slump cone tests. The Contractor shall make any necessary adjustments in the mix as the Engineer and/or the materials testing consultant may direct and shall upon written order suspend all placing operations in the event the consistency does not meet the intent of the specifications. No payment shall be made for any delays, material or labor costs due to such eventualities. 2. Slump tests shall be made in accordance with ASTM C 143. Slump tests will be performed as deemed necessary by the materials testing consultant and each time compressive strength samples are taken. 3. Concrete with a specified nominal slump shall be placed having a slump within 1” (higher or lower) of the specified slump. Concrete with a specified maximum slump shall be placed having a slump less than the specified slump. C. Unit Weight 1. Samples of freshly mixed concrete shall be tested for unit weight by the materials testing consultant in accordance with ASTM C 138. 2. Unit weight tests will be performed as deemed necessary by the Engineer and each time compressive strength samples are taken. D. Air Content 1. Samples of freshly mixed concrete will be tested for entrained air content by the materials testing consultant in accordance with ASTM C 231. 2. Air content tests will be performed as deemed necessary by the materials testing consultant and each time compressive strength samples are taken. City of Denton Hazen and Sawyer BID SET 03300-20 Cast-in-Place Concrete 3. In the event test results are outside the limits specified, additional testing shall occur. Admixture quantity adjustments shall be made immediately upon discovery of incorrect air entrainment. E. Compressive Strength 1. Samples of freshly mixed concrete will be taken by the materials testing consultant and tested for compressive strength in accordance with ASTM C 172, C 31 and C 39, except as modified herein. 2. In general, one sampling shall be taken for each placement in excess of five (5) cubic yards, with a minimum of one (1) sampling for each day of concrete placement operations, or for each one hundred (100) cubic yards of concrete, or for each 5,000 square feet of surface area for slabs or walls, whichever is greater. 3. Each sampling shall consist of at least five (5) 6x12 cylinders or (8) 4x8 cylinders. Each cylinder shall be identified by a tag, which shall be hooked or wired to the side of the container. The materials testing consultant will fill out the required information on the tag, and the Contractor shall satisfy himself that such information shown is correct. 4. The Contractor shall be required to furnish labor to the Owner for assisting in preparing test cylinders for testing. The Contractor shall provide approved curing boxes for storage of cylinders on site. The insulated curing box shall be of sufficient size and strength to contain all the specimens made in any four consecutive working days and to protect the specimens from falling over, being jarred or otherwise disturbed during the period of initial curing. The box shall be erected, furnished and maintained by the Contractor. Such box shall be equipped to provide the moisture and to regulate the temperature necessary to maintain the proper curing conditions required by ASTM C 31. Such box shall be located in an area free from vibration such as pile driving and traffic of all kinds and such that all specimen are shielded from direct sunlight and/or radiant heating sources. No concrete requiring inspection shall be delivered to the site until such storage curing box has been provided. Specimens shall remain undisturbed in the curing box until ready for delivery to the testing laboratory but not less than sixteen hours. 5. The Contractor shall be responsible for maintaining the temperatures of the curing box during the initial curing of test specimens with the temperature preserved between 60°F and 80°F as measured by a maximum-minimum thermometer. The Contractor shall maintain a written record of curing box temperatures for each day curing box contains test specimens. Temperature shall be recorded a minimum of three times a day with one recording at the start of the work day and one recording at the end of the work day. 6. When transported, the cylinders shall not be thrown, dropped, allowed to roll, or be damaged in any way. City of Denton Hazen and Sawyer BID SET 03300-21 Cast-in-Place Concrete 7. Compression tests shall be performed in accordance with ASTM C 39. For 6x12 cylinders, two test cylinders will be tested at seven days and two at 28 days. For 4x8 cylinders, three test cylinders will be tested at seven days, three at 28 days. The remaining cylinders will be held to verify test results, if needed. F. Evaluation and Acceptance of Concrete 1. Evaluation and acceptance of the compressive strength of concrete shall be according to the requirements of ACI 214, ACI 318, and ACI 350. 2. The strength level of concrete will be considered satisfactory if all of the following conditions are satisfied. a. Every arithmetic average of any three consecutive strength tests equals or exceeds the minimum specified 28-day compressive strength for the mix (see Article 2.08). b. No individual compressive strength test results falls below the minimum specified strength by more than 500 psi. c. No more than 10% of the compressive tests have strengths greater than the maximum strength specified. 3. In the event any of the conditions listed above are not met, the mix proportions shall be corrected for the next concrete placing operation. 4. In the event that condition 2B is not met, additional tests in accordance with Article 3.08, paragraph H shall be performed. 5. When a ratio between 7-day and 28-day strengths has been established by these tests, the 7-day strengths shall subsequently be taken as a preliminary indication of the 28-day strengths. Should the 7-day test strength from any sampling be more than 10% below the established minimum strength, the Contractor shall: a. Immediately provide additional periods of curing in the affected area from which the deficient test cylinders were taken. b. Maintain or add temporary structural support as required. c. Correct the mix for the next concrete placement operation, if required to remedy the situation. 6. All concrete which fails to meet the ACI requirements and these specifications is subject to removal and replacement at no additional cost to the Owner. G. When non-compliant concrete is identified, test reports shall be sent immediately to the Engineer for review. City of Denton Hazen and Sawyer BID SET 03300-22 Cast-in-Place Concrete H. Additional Tests 1. When ordered by the Engineer, additional tests on in-place concrete shall be provided and paid for by the Contractor. 2. In the event the 28-day test cylinders fail to meet the minimum strength requirements as outlined in Article 3.08, paragraph F, the Contractor shall have concrete core specimens obtained and tested from the affected area immediately. a. Three cores shall be taken for each sample in which the strength requirements were not met. b. The drilled cores shall be obtained and tested in conformance with ASTM C 42. The tests shall be conducted by a materials testing consultant approved by the Engineer. c. The location from which each core is taken shall be approved by the Engineer. Each core specimen shall be located, when possible, so its axis is perpendicular to the concrete surface and not near formed joints or obvious edges of a unit of deposit. d. The core specimens shall be taken, if possible, so no reinforcing steel is within the confines of the core. e. The diameter of core specimens should be at least 3 times the maximum nominal size of the course aggregate used in the concrete, but must be at least 2-inches in diameter. f. The length of specimen, when capped, shall be at least twice the diameter of the specimen. g. The core specimens shall be taken to the laboratory and when transported, shall not be thrown, dropped, allowed to roll, or damaged in any way. h. Two (2) copies of test results shall be mailed directly to the Engineer. The concrete in question will be considered acceptable if the average compressive strength of a minimum of three test core specimens taken from a given area equal or exceed 85% of the specified 28-day strength and if the lowest core strength is greater than 75% of the specified 28-day strength. 3. In the event that concrete placed by the Contractor is suspected of not having proper air content, the Contractor shall engage a materials testing consultant approved by the Engineer, to obtain and test samples for air content in accordance with ASTM Specification C 457. 4. Concrete placed with compressive strengths greater than the maximum strength specified shall be removed and replaced or repaired as deemed necessary by the Engineer. City of Denton Hazen and Sawyer BID SET 03300-23 Cast-in-Place Concrete 3.09 CARE AND REPAIR OF CONCRETE A. The Contractor shall protect all concrete against injury or damage from excessive heat, lack of moisture, overstress, or any other cause until final acceptance by the Owner. Particular care shall be taken to prevent the drying of concrete and to avoid roughening or otherwise damaging the surface. Care shall be exercised to avoid jarring forms or placing any strain on the ends of projecting reinforcing bars. Any concrete found to be damaged, or which may have been originally defective, or which becomes defective at any time prior to the final acceptance of the completed work, or which departs from the established line or grade, or which, for any other reason, does not conform to the requirements of the Contract Documents, shall be satisfactorily repaired or removed and replaced with acceptable concrete at no additional cost to the Owner. B. Areas of honeycomb shall be chipped back to sound concrete and repaired as directed. C. Concrete formwork blowouts or unacceptable deviations in tolerances for formed surfaces due to improperly constructed or misaligned formwork shall be repaired as directed. Bulging or protruding areas, which result from slipping or deflecting forms shall be ground flush or chipped out and redressed as directed. D. Areas of concrete in which cracking, spalling, or other signs of deterioration develop prior to final acceptance shall be removed and replaced, or repaired as directed. This stipulation includes concrete that has experienced cracking due to drying or thermal shrinkage of the concrete. Structural cracks shall be repaired using an approved epoxy injection system. Non-structural cracks shall be repaired using an approved hydrophilic resin pressure injected grout system, unless other means of repair are deemed necessary and approved. All repair work shall be performed at no additional cost to the Owner. E. Concrete which fails to meet the strength requirements as outlined in Article 3.08, paragraph F, will be analyzed as to its adequacy based upon loading conditions, resultant stresses and exposure conditions for the particular area of concrete in question. If the concrete in question is found unacceptable based upon this analysis, that portion of the structure shall be strengthened or replaced by the Contractor at no additional cost to the Owner. The method of strengthening or extent of replacement shall be as directed by the Engineer. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 03300-24 Cast-in-Place Concrete This page left blank intentionally City of Denton Hazen and Sawyer BID SET 03350-1 Concrete Finishes SECTION 03350 CONCRETE FINISHES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Furnish all materials, labor, and equipment required to provide finishes of all concrete surfaces specified herein and shown on the Drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 03100 – Concrete Formwork B. Section 03300 – Cast-in-Place Concrete C. Section 03600 – Grout 1.03 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. Without limiting the generality of the other requirements of the specifications, all work herein shall conform to the applicable requirements of the following documents. All referenced specifications, codes, and standards refer to the most current issue available at the time of Bid. 1. ACI 301 – Specifications for Structural Concrete for Buildings 2. ACI 318 – Building Code Requirements for Structural Concrete 1.04 SUBMITTALS A. Submit the following in accordance with Section 01300 – Submittals. 1. Manufacturer's literature on all products specified herein. PART 2 -- PRODUCTS 2.01 CONCRETE FLOOR SEALER A. Floor sealer shall be Diamond Clear VOX or Super Diamond Clear VOX by the Euclid Chemical Company, MasterKure CC 300 SB by BASF Master Builder Solutions. City of Denton Hazen and Sawyer BID SET 03350-2 Concrete Finishes 2.02 CONCRETE LIQUID DENSIFIER AND SEALANT A. Concrete liquid densifier and sealant shall be a high performance, deeply penetrating concrete densifier and sealant. Product shall be odorless, colorless, VOC-compliant, non-yellowing siliconate based solution designed to harden, dustproof and protect concrete floors subjected to heavy vehicular traffic and to resist black rubber tire marks on concrete surfaces. The product must contain a minimum solids content of 20% of which 50% is siliconate. Acceptable products are Diamond Hard by the Euclid Chemical Company, Seal Hard by L&M Construction Chemicals and MasterKure HD 210 WB by BASF Master Builder Solutions. 2.03 NON-METALLIC FLOOR HARDENER A. The specified non-metallic mineral aggregate hardener shall be formulated, processed, and packaged under stringent quality control at the manufacturer’s owned and controlled factory. The hardener shall be a factory-blended mixture of specifically processed graded mineral aggregate, selected Portland cement, and necessary plasticizing agents. Acceptable products shall be “Surflex” by the Euclid Chemical Company, “Harcol” by Sonneborn, “Maximent” by BASF, and “Mastercon” by BASF. 2.04 NON-OXIDIZING HEAVY DUTY METALLIC FLOOR HARDENER A. Non-oxidizing heavy duty metallic floor hardener shall be formulated, processed, and packaged under stringent quality control at the manufacturer’s owned and controlled factory. The hardener shall be a mixture of specifically processed non-rusting aggregate, selected Portland cement, and necessary plasticizing agents. Product shall be “Diamond-Plate” by the Euclid Chemical Company, or Masterplate by BASF Construction Chemicals. 2.05 NON-SLIP FLOORING ADDITIVE A. Non-slip flooring additives for slip resistant floors shall be non-metallic. Non-slip flooring additives shall be Frictex NS by BASF Construction Chemicals, A-H Alox by Anti-Hydro, or Euco Grip by the Euclid Chemical Company. PART 3 -- EXECUTION 3.01 FINISHES ON FORMED CONCRETE SURFACES A. After removal of forms, the finishes described below shall be applied in accordance with Article 3.05 - Concrete Finish Schedule. Unless the finish schedule specifies otherwise, all surfaces shall receive at least a Type I finish. The Engineer shall be the sole judge of acceptability of all concrete finish work. 1. Type I - Rough: All fins, burrs, offsets, marks and all other projections left by the forms shall be removed. Projections, depressions, etc. below finished grade required to be removed will only be those greater than ¼-inch. All holes left by removal of ends of ties, and all other holes, depressions, bugholes, air/blow holes or voids shall be filled solid with cement grout after first being thoroughly wetted and City of Denton Hazen and Sawyer BID SET 03350-3 Concrete Finishes then struck off flush. The only holes below grade to be filled will be tie holes and any other holes larger than ¼-inch in any dimension. Honeycombs shall be chipped back to solid concrete and repaired as directed by the Engineer. All holes shall be filled with tools, such as sponge floats and trowels, that will permit packing the hole solidly with cement grout. Cement grout shall consist of one part cement to three parts sand, epoxy bonding agent (for tie holes only) and the amount of mixing water shall be as little as consistent with the requirements of handling and placing. Color of cement grout shall match the adjacent wall surface. 2. Type II - Grout Cleaned: Where this finish is required, it shall be applied after completion of Type I finish. After the concrete has been predampened, a slurry consisting of one part cement (including an appropriate quantity of white cement in order to produce a color matching the surrounding concrete) and 1-1/2 parts sand passing the No. 16 sieve, by damp loose volume, shall be spread over the surface with clean burlap pads or sponge rubber floats. Mix proportions shall be submitted to the Engineer after a sample of the work is established and accepted. Any surplus shall be removed by scraping and then rubbing with clean burlap. 3. Type III - Smooth Rubbed: Where this finish is required, it shall be applied after the completion of the Type II finish. No rubbing shall be done before the concrete is thoroughly hardened and the mortar used for patching is firmly set. A smooth, uniform surface shall be obtained by wetting the surface and rubbing it with a carborundum stone to eliminate irregularities. Unless the nature of the irregularities requires it, the general surface of the concrete shall not be cut into. Corners and edges shall be slightly rounded by the use of the carborundum stone. Brush finishing or painting with grout or neat cement will not be permitted. A 100 square foot example shall be established at the beginning of the project to establish acceptability. 3.02 SLAB AND FLOOR FINISHES A. The finishes described below shall be applied to floors, slabs, flow channels and top of walls in accordance with Article 3.05 - Concrete Finish Schedule. The Engineer shall be the sole judge of acceptability of all such finish work. 1. Type "A" - Screeded: This finish shall be obtained by placing screeds at frequent intervals and striking off to the surface elevation required. When a Type "F" finish is subsequently to be applied, the surface of the screeded concrete shall be roughened with a concrete rake to 1/2” minimum deep grooves prior to final set. 2. Type "B" - Wood or Magnesium Floated: This finish shall be obtained after completion of a Type "A" finish by working a previously screeded surface with a wood or magnesium float or until the desired texture is reached. Floating shall begin when the water sheen has disappeared and when the concrete has sufficiently hardened so that a person's foot leaves only a slight imprint. If wet spots occur, water shall be removed with a squeegee. Care shall be taken to prevent the formation of laitance and excess water on the finished surface. All edges shall be edged with an 1/8-inch tool as directed by the Engineer. The finished surface shall be true, even, and free from blemishes and any other irregularities. City of Denton Hazen and Sawyer BID SET 03350-4 Concrete Finishes 3. Type "C" - Cork Floated: This finish shall be similar to Type "B" but slightly smoother than that obtained with a wood float. It shall be obtained by power or band floating with cork floats. 4. Type "D" - Steel Troweled: This finish shall be obtained after completion of a Type "B" finish. When the concrete has hardened sufficiently to prevent excess fine material from working to the surface, the surface shall be compacted and smoothed with not less than two thorough and complete steel troweling operations. In areas which are to receive a floor covering such as tile, resilient flooring, or carpeting, the applicable Specification Sections and Contract Drawings shall be reviewed for the required finishes and degree of flatness. In areas that are intermittently wet such as pump rooms, only one troweling operation is required to provide some trowel marks for slip resistance. All edges shall be edged with an 1/8-inch tool as directed by the Engineer. The finish shall be brought to a smooth, dense surface, free from defects and blemishes. 5. Type "E" - Broom or Belt: This finish shall provide the surface with a transverse scored texture by drawing a broom or burlap belt across the surface immediately after completion of a Type "B" finish. All edges shall be edged with an 1/8-inch tool as directed by the Engineer. 6. Type "F" - Swept in Grout Topping: This finish shall be applied after a completion of a Type "A" finish. The concrete surface shall be properly cleaned, washed, and coated with a mixture of water and Portland Cement. Cement grout in accordance with Section 03600 shall then be plowed and swept into neat conformance with the blades or arms of the apparatus by turning or rotating the previously positioned mechanical equipment. Special attention shall be paid to true grades, shapes and tolerances as specified by the manufacturer of the equipment. Before beginning this finish, the Contractor shall notify the Engineer and the equipment manufacturer of the details of the operation and obtain approval and recommendations. 7. Type “G” Hardened Finish: This finish shall be applied after completion of a Type “B” or Type “C” finish and prior to application of a Type “D” finish. Hardeners shall be applied in strict accordance with the manufacturer’s requirements. Hardeners shall be applied using a mechanical spreader. The hardener shall be applied in two shakes with the first shake comprising 2/3 of the total amount. Type “D” finish shall be applied following completion of application of the hardener. a. Non-metallic floor hardener shall be applied where specifically required on the Contract Drawings at the rate of 1.0 pounds/ft.2. b. Non-oxidizing heavy duty metallic floor hardener shall be applied at the loading docks and where specifically required on the Contract Drawings or specified herein at the rate of 1.5 pounds/ft.2. 8. Type "H" - Non-Slip Finish: This finish shall be provided by applying a non-slip flooring additive concurrently with the application of a Type "D" finish and/or installation of floor sealants. Application procedure shall be in accordance with City of Denton Hazen and Sawyer BID SET 03350-5 Concrete Finishes manufacturer's instructions. Finish shall be applied where specifically required on the Contract Drawings or specified herein. 9. Type "J" - Raked Finish: This finish shall be provided by raking the surface as soon as the condition of the concrete permits by making depressions of ±1/4 inch. 3.03 CONCRETE SEALERS A. Concrete sealers shall be applied where specifically required on the Contract Drawings or specified herein. B. Sealers shall be applied after installation of all equipment, piping, etc. and after completion of any other related construction activities. Application of sealers shall be in strict accordance with manufacturer’s requirements. C. Sealers shall be applied to all floor slabs not painted and not intended to be immersed. D. Floor slabs subjected to vehicular traffic shall be sealed with the concrete liquid densifier and sealer. E. All other floor slabs to receive sealer shall be sealed with concrete floor sealer. 3.04 FINISHES ON EQUIPMENT PADS A. Formed surfaces of equipment pads shall receive a Type III finish. B. Top surfaces of equipment pads, except those surfaces subsequently required to receive grout and support equipment bases, shall receive a Type "D" finish, unless otherwise noted. Surfaces which will later receive grout shall, before the concrete takes its final set, be made rough by removing the sand and cement that accumulates on the top to the extent that the aggregate will be exposed with irregular indentations in the surface up to 1/2 inch deep. City of Denton Hazen and Sawyer BID SET 03350-6 Concrete Finishes 3.05 CONCRETE FINISH SCHEDULE Item Type of Finish Concrete surfaces indicated to receive textured coating (as noted on Drawings and in Section 09800, Special Coatings) I Inner face of walls of tanks, flow channels, wet wells, perimeter walls, and miscellaneous concrete structures: From 1 feet below water surface to bottom of wall II From top of wall to 1 feet below water surface II Exterior concrete walls below grade I Exterior exposed concrete walls, ceilings, beams, manholes, hand holes, miscellaneous structures and columns (including top of wall) to one foot below grade. All other exposed concrete surfaces not specified elsewhere II All interior exposed concrete walls and vertical surfaces III Interior exposed ceiling, including beams III Floors of process equipment tanks or basins, wetwells, flow channels and slabs to receive roofing material or waterproof membranes B Exterior concrete sidewalks, steps, ramps, decks, slabs on grade and landings exposed to weather E Floors of process equipment tanks indicated on Drawings to receive grout topping F - END OF SECTION - City of Denton Hazen and Sawyer BID SET 03360-1 Shotcrete SECTION 03360 SHOTCRETE PART 1 -- GENERAL 1.01 THE REQUIREMENTS A. The Contractor shall furnish all labor, material, and equipment necessary to place the shotcrete as shown on the Drawings and specified herein. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 03300 – Cast-In-Place Concrete B. Section 13206 – Prestressed Concrete Tanks 1.03 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Without limiting the generality of other requirements of these Specifications, all work hereunder shall conform to the applicable requirements of the reference portions of the following documents, to the extent that the requirements therein are not in conflict with the provisions of this Section. 1. ACI 506 — Recommended Practice for Shotcreting 2. ACI 506.2 — Specification for Materials, Proportioning, and Application of Shotcrete 3. ACI CP-60 — ACI Shotcrete Nozzleman Certification 1.04 SUBMITTALS A. The Contractor shall submit the following in accordance with the requirements of Section 01300, Submittals: 1. Proposed mix proportions and test data on the mix. The test data may be from prior experience, if available, or from preconstruction testing in accordance with paragraph 1.05 below. 2. Certification that the source and quality of materials used in the proposed mix meets the requirements stated herein. 3. Copies of ACI Shotcrete Nozzleman Certificates. City of Denton Hazen and Sawyer BID SET 03360-2 Shotcrete 1.05 QUALITY ASSURANCE A. Preconstruction testing in accordance with ACI 506.2 shall be performed by the Contractor at Contractor's expense when the proposed mix including all materials has not previously been used and tested in similar previous work. Results of preconstruction testing shall be submitted with the proposed mix design submittal. In lieu of preconstruction testing, test data from previous jobs on the same mix design may be submitted for acceptance by the Engineer. B. Construction testing shall be performed on test panels in accordance with ACI 506.2. Contractor shall make and field cure the test panels in accordance with ACI 506.2 at his expense. The test panels will be tested by a testing agency employed by the Owner. Should the strengths of shotcrete shown by the test specimens fall below acceptable values as stated in ACI 506.2, the Engineer shall have the right to require changes in the shotcrete mix for the remainder of the work. Furthermore, the Engineer shall have the right to require additional curing on those portions of the structure represented by the failing test specimens and to order additional strength tests be performed on cores cut from the structure. The additional curing, coring, and testing shall be at the expense of the Contractor. In the event that such additional curing does not give the strength required, as evidenced by core tests, the Engineer shall have the right to require strengthening or replacement of those portions of the structure which fail to develop the required strength. The Contractor shall have no claim for reimbursement for the required corrective measures. PART 2 -- PRODUCTS 2.01 SHOTCRETE A. Shotcrete shall be composed of cement, pozzolan (fly ash or ground granulated blast furnace slag) aggregate, water, and an air-entraining admixture, all in conformance with ACI 506.2. Additional admixtures conforming to ACI 506.2 may be submitted for Engineer's approval. B. All components of shotcrete including cement, aggregates, pozzolan, and admixtures shall meet requirements specified in Section 03300 – Cast-In-Place Concrete. C. Shotcrete shall have a minimum design compressive strength, f'c, of 4,000 psi at 28 days, unless noted otherwise in the Contract Documents. PART 3 -- EXECUTION 3.01 BATCHING AND MIXING A. Mix proportions shall be controlled by weight batching in conformance with ACI 506.2. City of Denton Hazen and Sawyer BID SET 03360-3 Shotcrete 3.02 SURFACE PREPARATION A. Preparation of surfaces to receive shotcrete shall be performed in accordance with ACI 506.2. 3.03 PLACING SHOTCRETE A. Shotcrete nozzlemen shall be certified in accordance with ACI CP-60. B. Placement of shotcrete shall conform to ACI 506.2 and to the following requirements: 1. For shotcrete directly exposed to water or wastewater, cover of reinforcement as stated in ACI 506.2 shall be increased 1/2 inch. 2. No shotcrete shall be placed when the air temperature is below 40 degrees Fahrenheit or when other weather conditions are unfavorable. 3. At the end of each day's work, or similar stoppage period, the shotcrete shall be cut off as square as possible. Before resuming shooting, these exposed portions shall be thoroughly cleaned and wetted by means of air and water blast. 3.04 FINISHING A. Shotcrete shall have a sliced, troweled and rubbed finish unless noted otherwise on the Drawings. 3.05 CURING A. Shotcrete shall be cured in accordance with ACI 506.2. Natural curing shall not be allowed. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 03360-4 Shotcrete This page left blank intentionally City of Denton Hazen and Sawyer BID SET 03370-1 Concrete Curing SECTION 03370 CONCRETE CURING PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Protect all freshly deposited concrete from premature drying and from the weather elements. The concrete shall be maintained with minimal moisture loss at a relatively constant temperature for a period of time necessary for the hydration of the cement and proper hardening of the concrete in accordance with the requirements specified herein. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 03100 – Concrete Formwork B. Section 03300 – Cast-In-Place Concrete C. Section 03350 – Concrete Finishes 1.03 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. Without limiting the generality of the other requirements of the specifications, all work herein shall conform to the applicable requirements of the following documents. All referenced specifications, codes, and standards refer to the most current issue available at the time of Bid. 1. ACI 301 – Specifications for Structural Concrete for Buildings 2. ACI 304 – Guide for Measuring, Mixing, Transporting, and Placing Concrete 3. ACI 305 – Hot Weather Concreting 4. ACI 306 – Cold Weather Concreting 5. ACI 308 – Standard Practice for Curing Concrete 6. ASTM C171 – Standard Specifications for Sheet Materials for Curing Concrete 7. ASTM C309 – Standard Specification for Liquid Membrane-Forming Compounds for Curing Concrete 8. ASTM C1315 – Standard Specification for Liquid Membrane-Forming Compounds Having Special Properties for Curing and Sealing Concrete City of Denton Hazen and Sawyer BID SET 03370-2 Concrete Curing 1.04 SUBMITTALS A. Submit the following in accordance with Section 01300, Submittals. 1. Proposed procedures for protection of concrete under wet weather placement conditions. 2. Proposed normal procedures for protection and curing of concrete. 3. Proposed special procedures for protection and curing of concrete under hot and cold weather conditions. 4. Proposed method of measuring concrete surface temperature changes. 5. Manufacturer's literature and material certification for proposed curing compounds. PART 2 -- PRODUCTS 2.01 LIQUID MEMBRANE-FORMING CURING COMPOUND A. Clear curing and sealing compound shall be a clear styrene acrylate type complying with ASTM C 1315, Type 1, Class A with a minimum solids content of 30%. Moisture loss shall not be greater than 0.40 kg/m2 when applied at 300 sq.ft./gal. Manufacturer’s certification is required. Acceptable products are Super Diamond Clear VOX by the Euclid Chemical Company, MasteKure CC 300 SB by BASF Master Builder Solutions, and Cure & Seal 30 Plus by Symons Corporation. B. Where specifically approved by Engineer, on slabs to receive subsequent applied finishes, compound shall conform to ASTM C 309. Acceptable products are “Kurez DR VOX” or “Kurez W VOX” by the Euclid Chemical Company. Install in strict accordance with manufacturer’s requirements. 2.02 EVAPORATION REDUCER A. Evaporation reducer shall be BASF, "MasterKure ER 50”, or Euclid Chemical "Euco-Bar". PART 3 -- EXECUTION 3.01 PROTECTION AND CURING A. All freshly placed concrete shall be protected from the elements, flowing water and from defacement of any nature during construction operations. B. As soon as the concrete has been placed and horizontal top surfaces have received their required finish, provision shall be made for maintaining the concrete in a moist condition for at least a 5-day period thereafter except for high early strength concrete, for which the period City of Denton Hazen and Sawyer BID SET 03370-3 Concrete Curing shall be at least the first three days after placement. Horizontal surfaces shall be kept covered, and intermittent, localized drying will not be permitted. C. Walls that will be exposed on one side with either fluid or earth backfill on the opposite side shall be continuously wet cured for a minimum of five days. Use of a curing compound will not be acceptable for applications of this type. D. The Contractor shall use one of the following methods to insure that the concrete remains in a moist condition for the minimum period stated above. 1. Ponding or continuous fogging or sprinkling. 2. Application of mats or fabric kept continuously wet. 3. Continuous application of steam (under 150°F). 4. Application of sheet materials conforming to ASTM C171. 5. If approved by the Engineer, application of a curing compound in accordance with Article 3.04. E. The Contractor shall keep absorbent wood forms wet until they are removed. After form removal, the concrete shall be cured by one of the methods in paragraph D. F. Any of the curing procedures used in Paragraph 3.01-D may be replaced by one of the other curing procedures listed in Paragraph 3.01-D after the concrete is one-day old. However, the concrete surface shall not be permitted to become dry at any time. 3.02 CURING CONCRETE UNDER COLD WEATHER CONDITIONS A. Suitable means shall be provided for a minimum of 72 hours after placing concrete to maintain it at or above the minimum as placed temperatures specified in Section 03300, Cast-In-Place Concrete, for concrete work in cold weather. During the 72-hour period, the concrete surface shall not be exposed to air more than 20°F above the minimum as placed temperatures. B. Stripping time for forms and supports shall be increased as necessary to allow for retardation in concrete strength caused by colder temperatures. This retardation is magnified when using concrete made with blended cements or containing fly ash or ground granulated blast furnace slag. Therefore, curing times and stripping times shall be further increased as necessary when using these types of concrete. C. The methods of protecting the concrete shall be approved by the Engineer and shall be such as will prevent local drying. Equipment and materials approved for this purpose shall be on the site in sufficient quantity before the work begins. The Contractor shall assist the Engineer by providing holes in the forms and the concrete in which thermometers can be placed to determine the adequacy of heating and protection. All such thermometers shall be furnished by the Contractor in quantity and type which the Engineer directs. City of Denton Hazen and Sawyer BID SET 03370-4 Concrete Curing D. Curing procedures during cold weather conditions shall conform to the requirements of ACI 306. 3.03 CURING CONCRETE UNDER HOT WEATHER CONDITIONS A. When air temperatures exceed 85°F, the Contractor shall take extra care in placing and finishing techniques to avoid formation of cold joints and plastic shrinkage cracking. If ordered by the Engineer, temporary sun shades and/or windbreakers shall be erected to guard against such developments, including generous use of wet burlap coverings and fog sprays to prevent drying out of the exposed concrete surfaces. B. Immediately after screeding, horizontal surfaces shall receive an application of evaporation reducer. Apply in accordance with manufacturer's instructions. Final finish work shall begin as soon as the mix has stiffened sufficiently to support the workmen. C. Curing and protection of the concrete shall begin immediately after completion of the finishing operation. Continuous moist-curing consisting of method 1 or 2 listed in paragraph 3.01D is mandatory for at least the first 24 hours. Method 2 may be used only if the finished surface is not marred or blemished during contact with the coverings. D. At the end of the initial 24-hour period, curing and protection of the concrete shall continue for at least six (6) additional days using one of the methods listed in paragraph 3.01D. E. Curing procedures during hot weather conditions shall conform to the requirements of ACI 305. 3.04 USE OF CURING COMPOUND A. Curing compound shall be used only where specifically approved by the Engineer. Curing compound shall never be used for curing exposed walls with fluid or earth backfill on the opposite side. A continuous wet cure for a minimum of five days is required for these applications. Curing compound shall not be used on surfaces exposed to water in potable water storage tanks and treatment plants unless curing compound is certified in accordance with ANSI/NSF Standard 61. B. When permitted, the curing compound shall maintain the concrete in a moist condition for the required time period, and the subsequent appearance of the concrete surface shall not be affected. C. The compound shall be applied in accordance with the manufacturer's recommendations after water sheen has disappeared from the concrete surface and after finishing operations. Maximum coverage for the curing and sealing compound shall be 300 square feet per gallon for trowel finishes and 200 square feet per gallon for floated or broom surfaces. Maximum coverage for compounds placed where subsequent finishes will be applied shall be 200 square feet per gallon. For rough surfaces, apply in two directions at right angles to each other. City of Denton Hazen and Sawyer BID SET 03370-5 Concrete Curing 3.05 EARLY TERMINATION OF CURING A. Moisture retention measures may be terminated earlier than the specified times only when at least one of the following conditions is met: 1. The strength of the concrete reaches 85 percent of the specified 28-day compressive strength in laboratory-cured cylinders representative of the concrete in place, and the temperature of the in-place concrete has been constantly maintained at 50 degrees Fahrenheit or higher. 2. The strength of concrete reaches the specified 28-day compressive strength as determined by accepted nondestructive methods or laboratory-cured cylinder test results. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 03370-6 Concrete Curing This page left blank intentionally City of Denton Hazen and Sawyer BID SET 03400-1 Precast Concrete SECTION 03400 PRECAST CONCRETE PART 1 -- GENERAL 1.01 REQUIREMENTS A. The Contractor shall construct all precast concrete items as required in the Contract Documents, including all appurtenances necessary to make a complete installation. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 02604 - Utility Structures B. Section 03200 - Reinforcing Steel C. Section 03230 - Stressing Tendons D. Section 03300 - Cast-in-Place Concrete E. Section 03350 - Concrete Finishes F. Section 03370 - Concrete Curing G. Section 03600 - Grout H. Section 05010 - Metal Materials I. Section 05050 - Metal Fastening J. Section 05830 - Bearing Devices 1.03 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. Without limiting the generality of other requirements of these Specifications, all work specified herein shall conform to the applicable requirements of the following documents. All referenced specifications, codes, and standards refer to the most current issue available at the end of the Bid. 1. State of Texas Building Code 2. ACI 318-Building Code Requirements for Structural Concrete 3. PCI Standard MNL-116 - Manual for Quality Control for Plants and Production of Precast and Prestressed Concrete Products City of Denton Hazen and Sawyer BID SET 03400-2 Precast Concrete 4. PCI Design Handbook 1.04 SUBMITTALS A. The Contractor shall submit the following for review in accordance with Section 01300, Submittals. 1. Shop drawings for all precast concrete items showing all dimensions, locations, and type of lifting inserts, and details of reinforcement and joints. 2. A list of the design criteria used by the manufacturer for all manufactured, precast items. 3. Design calculations, showing at least the design loads and stresses on the item, shall be submitted. Calculations shall be signed and sealed by a Professional Engineer registered in the State of Texas. 4. Certified reports for all lifting inserts, indicating allowable design loads. 5. Information on lifting and erection procedures. 1.05 QUALITY ASSURANCE A. All manufactured precast concrete units shall be produced by an experienced manufacturer regularly engaged in the production of such items. All manufactured precast concrete and site-cast units shall be free of defects, spalls, and cracks. Care shall be taken in the mixing of materials, casting, curing and shipping to avoid any of the above. The Engineer may elect to examine the units at the casting yard or upon arrival of the same at the site. The Engineer shall have the option of rejecting any or all of the precast work if it does not meet with the requirements specified herein or on the Drawings. All rejected work shall be replaced at no additional cost to the Owner. B. Manufacturer Qualifications The precast concrete manufacturing plant shall be certified by the Prestressed Concrete Institute, Plant Certification Program, prior to the start of production. Certification is only required for plants providing prestressed structural members such as hollow core planks, double-T members, etc. C. Plant production and engineering must be under direct supervision and control of an Engineer who possesses a minimum of five years experience in precast concrete work. PART 2 -- PRODUCTS 2.01 CONCRETE A. Concrete materials including portland cement, aggregates, water, and admixtures shall conform to Section 03300, Cast-in-Place Concrete. City of Denton Hazen and Sawyer BID SET 03400-3 Precast Concrete B. For prestressed concrete items, minimum compressive strength of concrete at 28 days shall be 5,000 psi unless otherwise specified. Minimum compressive strength of concrete at transfer of prestressing force shall be 3,500 psi unless otherwise specified. C. For non-prestressed concrete items, minimum compressive strength of concrete at 28 days shall be 4000 psi unless otherwise specified. 2.02 GROUT A. Grout for joints between panels shall be a cement grout in conformance with Section 03600, Grout. B. Minimum compressive strength of grout at 7 days shall be 3,000 psi. 2.03 REINFORCING STEEL A. Reinforcing steel used for precast concrete construction shall conform to Section 03200, Reinforcing Steel. 2.04 PRESTRESSING STRANDS A. Prestressing strands shall be 7-wire, stress-relieved, high-strength strands Grade 250K or 270K in conformance with Section 03230, Stressing Tendons. 2.05 STEEL INSERTS A. Steel inserts shall be in accordance with Section 05010, Metal Materials. B. All steel inserts protruding from or occurring at the surface of precast units shall be galvanized in accordance with Section 05035, Galvanizing. 2.06 WELDING A. Welding shall conform to Section 05050, Metal Fastening. 2.07 BEARING PADS A. Neoprene bearing pads shall conform to Section 05830, Bearing Devices and Anchors. B. Plastic bearing pads shall be multi-monomer plastic strips which are non-leaching and support construction loads with no visible overall expansion, manufactured specifically for the purpose of bearing precast concrete. City of Denton Hazen and Sawyer BID SET 03400-4 Precast Concrete PART 3 -- EXECUTION 3.01 FABRICATION AND CASTING A. All precast members shall be fabricated and cast to the shapes, dimensions and lengths shown on the Drawings and in compliance with PCI MNL-116. Precast members shall be straight, true and free from dimensional distortions, except for camber and tolerances permitted later in this clause. All integral appurtenances, reinforcing, openings, etc., shall be accurately located and secured in position with the form work system. Form materials shall be steel and the systems free from leakage during the casting operation. B. All cover of reinforcing shall be the same as detailed on the Drawings. C. Because of the critical nature of the bond development length in prestressed concrete panel construction, if the transfer of stress is by burning of the fully tensioned strands at the ends of the member, each strand shall first be burned at the ends of the bed and then at each end of each member before proceeding to the next strand in the burning pattern. D. The Contractor shall coordinate the communication of all necessary information concerning openings, sleeves, or inserts to the manufacturer of the precast members. E. Concrete shall be finished in accordance with Section 03350, Concrete Finishes. Grout all recesses due to cut tendons which will not otherwise be grouted during erection. F. Curing of precast members shall be in accordance with Section 03370, Concrete Curing. Use of a membrane curing compound will not be allowed. G. The manufacturer shall provide lifting inserts or other approved means of lifting members. 3.02 HANDLING, TRANSPORTING AND STORING A. Precast members shall not be transported away from the casting yard until the concrete has reached the minimum required 28 day compressive strength and a period of at least 5 days has elapsed since casting, unless otherwise permitted by the Engineer. B. No precast member shall be transported from the plant to the job site prior to approval of that member by the plant inspector. This approval will be stamped on the member by the plant inspector. C. During handling, transporting, and storing, precast concrete members shall be lifted and supported only at the lifting or supporting points as indicated on the shop drawings. D. All precast members shall be stored on solid, unyielding, storage blocks in a manner to prevent torsion, objectionable bending, and contact with the ground. E. Precast concrete members shall not be used as storage areas for other materials or equipment. City of Denton Hazen and Sawyer BID SET 03400-5 Precast Concrete F. Precast members damaged while being handled or transported will be rejected or shall be repaired in a manner approved by the Engineer. 3.03 ERECTION A. Erection shall be carried out by the manufacturer or under his supervision using labor, equipment, tools and materials required for proper execution of the work. B. Contractor shall prepare all bearing surfaces to a true and level line prior to erection. All supports of the precast members shall be accurately located and of required size and bearing materials. C. Installation of the precast members shall be made by leveling the top surface of the assembled units keeping the units tight and at right angles to the bearing surface. D. Connections which require welding shall be properly made in accordance with Section 05050, Metal Fastening. E. Grouting between adjacent precast members and along the edges of the assembled precast members shall be accomplished as indicated on the drawings, care being taken to solidly pack such spaces and to prevent leakage or droppings of grout through the assembled precast members. Any grout which seeps through the precast members shall be removed before it hardens. F. In no case shall concentrated construction loads, or construction loads exceeding the design loads, be placed on the precast members. In no case shall loads be placed on the precast members prior to the welding operations associated with erection, and prior to placing of topping (if required). G. No Contractor, Subcontractor or any of his employees shall arbitrarily cut, drill, punch or otherwise tamper with the precast members. H. Precast members damaged while being erected will be rejected or shall be repaired in a manner approved by the Engineer. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 03400-6 Precast Concrete This page left blank intentionally City of Denton Hazen and Sawyer BID SET 03600-1 Grout SECTION 03600 GROUT PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Furnish all materials, labor, and equipment required to provide all grout used in concrete work and as bearing surfaces for base plates, in accordance with the Contract Documents. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Requirements of related work are included in Division 1 and Division 2 of these Specifications. 1.03 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. Without limiting the generality of the other requirements of the specifications, all work herein shall conform to the applicable requirements of the following documents. All referenced specifications, codes, and standards refer to the most current issue available at the time of Bid. 1. CRD-C 621 Corps of Engineers Specification for Non-shrink Grout 2. ASTM C 109 Standard Test Method for Compressive Strength of Hydraulic Cement Mortars (Using 2 inch or 50 mm cube Specimens) 3. ASTM C 531 Standard Test Method for Linear Shrinkage and Coefficient of Thermal Expansion of Chemical-Resistant Mortars, Grouts and Monolithic Surfacings 4. ASTM C 579 Test Method for Compressive Strength of Chemical-Resistant Mortars and Monolithic Surfacings 5. ASTM C 827 Standard Test Method for Early Volume Change of Cementitious Mixtures 6. ASTM C 144 Standard Specification for Aggregate for Masonry Mortar 7. ASTM C 1107 Standard Specification for Packaged Dry, Hydraulic Cement Grout (Nonshrink) City of Denton Hazen and Sawyer BID SET 03600-2 Grout 1.04 SUBMITTALS A. Submit the following in accordance with Section 01300 - Submittals. 1. Certified test results verifying the compressive strength and shrinkage and expansion requirements specified herein. 2. Manufacturer's literature containing instructions and recommendations on the mixing, handling, placement and appropriate uses for each type of grout used in the work. 1.05 QUALITY ASSURANCE A. Field Tests 1. Compression test specimens will be taken during construction from the first placement of each type of grout and at intervals thereafter as selected by the Engineer to insure continued compliance with these Specifications. The specimens will be made by the Engineer or its representative. a. Compression tests and fabrication of specimens for cement grout and non-shrink grout will be performed as specified in ASTM C 109 at intervals during construction as selected by the Engineer. A set of three specimens will be made for testing at seven days, 28 days and any additional time period as appropriate. b. Compression tests and fabrication of specimens for epoxy grout will be performed as specified in ASTM C 579, Method B, at intervals during construction as selected by the Engineer. A set of three specimens will be made for testing at seven days and any other time period as appropriate. 2. The cost of all laboratory tests on grout will be borne by the Owner, but the Contractor shall assist the Engineer in obtaining specimens for testing. The Contractor shall be charged for the cost of any additional tests and investigation on work performed which does not meet the specifications. The Contractor shall supply all materials necessary for fabricating the test specimens, at no additional cost to the Owner. 3. All grout, already placed, which fails to meet the requirements of these Specifications, is subject to removal and replacement at no additional cost to the Owner. City of Denton Hazen and Sawyer BID SET 03600-3 Grout PART 2 -- PRODUCTS 2.01 MATERIALS A. Cement Grout 1. Cement grout shall be composed of Portland Cement and sand in the proportion specified in the Contract Documents and the minimum amount of water necessary to obtain the desired consistency. If no proportion is indicated, cement grout shall consist of one part Portland Cement to three parts sand. Water amount shall be as required to achieve desired consistency without compromising strength requirements. White Portland Cement shall be mixed with the Portland Cement as required to match color of adjacent concrete. 2. The minimum compressive strength at 28 days shall be 4000 psi. 3. For beds thicker than 1-1/2 inch and/or where free passage of grout will not be obstructed by coarse aggregate, 1-1/2 parts of coarse aggregate having a top size of 3/8 inch should be added. This stipulation does not apply for grout being swept in by a mechanism. These applications shall use a plain cement grout without coarse aggregate regardless of bed thickness. 4. Sand shall conform to the requirements of ASTM C144. B. Non-Shrink Grout 1. Non-shrink grout shall conform to CRD-C 621 and ASTM C 1107, Grade B or C when tested at a max. fluid consistency of 30 seconds per CDC 611/ASTM C939 at temperature extremes of 45°F and 90°F and an extended working time of 15 minutes. Grout shall have a min. 28-day strength of 7,000 psi. Non-shrink grout shall be, "Euco N-S" by the Euclid Chemical Company, "Sikagrout 212" by Sika Corporation, “Conspec 100 Non-Shrink Non-Metallic Grout” by Conspec, “Masterflow 555 Grout” by BASF Master Builder Solutions. C. Epoxy Grout 1. Epoxy grout shall be "Sikadur 32 Hi-Mod" by Sika Corporation, "Duralcrete LV" by Tamms Industries, or "Euco #452 Series" by Euclid Chemical, “MasterEmaco ADH 1090 RS” by BASF Master Builder Solutions. 2. Epoxy grout shall be modified as required for each particular application with aggregate per manufacturer's instructions. D. Epoxy Base Plate Grout 1. Epoxy base plate grout shall be “Sikadur 42, Grout-Pak” by Sika Corporation, or “Masterflow 648” by BASF Master Builder Solutions. City of Denton Hazen and Sawyer BID SET 03600-4 Grout 2.02 CURING MATERIALS A. Curing materials shall be as specified in Section 03370, Concrete Curing for cement grout and as recommended by the manufacturer for prepackaged grouts. PART 3 -- EXECUTION 3.01 GENERAL A. The different types of grout shall be used for the applications stated below unless noted otherwise in the Contract Documents. Where grout is called for in the Contract Documents which does not fall under any of the applications stated below, non-shrink grout shall be used unless another type is specifically referenced. 1. Cement grout shall be used for grout toppings and for patching of fresh concrete. 2. Non-shrink grout shall be used for grouting beneath base plates of structural metal framing. 3. Epoxy grout shall be used for bonding new concrete to hardened concrete. 4. Epoxy base plate grout shall be used for precision seating of base plates including base plates for all equipment such as engines, mixers, pumps, vibratory and heavy impact machinery, etc. B. New concrete surfaces to receive cement grout shall be as specified in Section 03350, Concrete Finishes, and shall be cleaned of all dirt, grease and oil-like films. Existing concrete surfaces shall likewise be cleaned of all similar contamination and debris, including chipping or roughening the surface if a laitance or poor concrete is evident. The finish of the grout surface shall match that of the adjacent concrete. Curing and protection of cement grout shall be as specified in Section 03370, Concrete Curing. C. All mixing, surface preparation, handling, placing, consolidation, and other means of execution for prepackaged grouts shall be done according to the instructions and recommendations of the manufacturer. D. The Contractor, through the manufacturer of a non-shrink grout and epoxy grout, shall provide on-site technical assistance upon request, at no additional cost to the Owner. 3.02 CONSISTENCY A. The consistency of grouts shall be that necessary to completely fill the space to be grouted for the particular application. Dry pack consistency is such that the grout is plastic and moldable but will not flow. City of Denton Hazen and Sawyer BID SET 03600-5 Grout 3.03 MEASUREMENT OF INGREDIENTS A. Measurements for cement grout shall be made accurately by volume using containers. Shovel measurement shall not be allowed. B. Prepackaged grouts shall have ingredients measured by means recommended by the manufacturer. 3.04 GROUT INSTALLATION A. Grout shall be placed quickly and continuously, shall completely fill the space to be grouted and be thoroughly compacted and free of air pockets. The grout may be poured in place, pressure grouted by gravity, or pumped. The use of pneumatic pressure or dry-packed grouting requires approval of the Engineer. For grouting beneath base plates, grout shall be poured from one side only and thence flow across to the open side to avoid air-entrapment. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 03600-6 Grout This page left blank intentionally City of Denton Hazen and Sawyer BID SET 05010-1 Metal Materials SECTION 05010 METAL MATERIALS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Metal materials not otherwise specified shall conform to the requirements of this Section. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Materials for fasteners are included in Section 05050, Metal Fastening. B. Requirements for specific products made from the materials specified herein are included in other sections of the Specifications. See the section for the specific item in question. 1.03 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. ASTM A36 Standard Specification for Structural Steel B. ASTM A47 Standard Specification for Malleable Iron Castings C. ASTM A48 Standard Specification for Gray Iron Castings D. ASTM A53 Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc- Coated Welded and Seamless E. ASTM A167 Standard Specification for Stainless and Heat-Resisting Chromium- Nickel Steel Plate, Sheet, and Strip F. ASTM A276 Standard Specification for Stainless and Heat-Resisting Steel Bars and Shapes G. ASTM A307 Standard Specification for Carbon Steel Externally Threaded Standard Fasteners H. ASTM A446 Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) by the Hot-Dip Process, Structural (Physical) quality I. ASTM A500 Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes J. ASTM A501 Standard Specification for Hot-Formed Welded and Seamless Carbon Steel Structural Tubing City of Denton Hazen and Sawyer BID SET 05010-2 Metal Materials K. ASTM A529 Standard Specification for Structural Steel with 42 000 psi (290 Mpa) Minimum Yield Point (1/2 in. (12.7 mm) Maximum Thickness) L. ASTM A536 Standard Specification for Ductile Iron Castings M. ASTM A570 Standard Specification for Hot-Rolled Carbon Steel Sheet and Strip, Structural Quality N. ASTM A572 Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel O. ASTM A992 Standard Specification for Structural Steel Shapes P. ASTM A666 Standard Specification for Austenitic Stainless Steel, Sheet, Strip, Plate, and Flat Bar for Structural Applications Q. ASTM A1085 Standard Specification for Cold-Formed Welded Carbon Steel Hollow Structural Sections (HSS) R. ASTM B26 Standard Specification for Aluminum-Alloy Sand Castings S. ASTM B85 Standard Specification for Aluminum-Alloy Die Castings T. ASTM B108 Standard Specification for Aluminum-Alloy Permanent Mold Castings U. ASTM B138 Standard Specification for Manganese Bronze Rod, Bar, and Shapes V. ASTM B209 Standard Specification for Aluminum-Alloy Sheet and Plate W. ASTM B221 Standard Specification for Aluminum-Alloy Extruded Bars, Rods, Wire, Shapes, and Tubes X. ASTM B308 Standard Specification for Aluminum-Alloy Standard Structural Shapes, Rolled or Extruded Y. ASTM B574 Standard Specification for Nickel-Molybdenum-Chromium Alloy Rod Z. ASTM F468 Standard Specification for Nonferrous Bolts, Hex Cap Screws, and Studs for General Use a. ASTM F593 Standard Specification for Stainless Steel Fasteners 1.04 SUBMITTALS A. Material certifications shall be submitted along with any shop drawings for metal products and fabrications required by other sections of the Specifications. City of Denton Hazen and Sawyer BID SET 05010-3 Metal Materials 1.05 QUALITY ASSURANCE A. Owner may engage the services of a testing agency to test any metal materials for conformance with the material requirements herein. If the material is found to be in conformance with Specifications the cost of testing will be borne by the Owner. If the material does not conform to the Specifications, the cost of testing shall be paid by the Contractor and all materials not in conformance as determined by the Engineer shall be replaced by the Contractor at no additional cost to the Owner. In lieu of replacing materials the Contractor may request further testing to determine conformance, but any such testing shall be paid for by the Contractor regardless of outcome of such testing. PART 2 -- PRODUCTS 2.01 CARBON AND LOW ALLOY STEEL A. Material types and ASTM designations shall be as listed below: 1. Steel W Shapes A992 2. Steel HP Shapes A572 Grade 50 3. Steel M, S, C,and MC shapes and Angles, Bars, and Plates A36 4. Rods F 1554 Grade 36 5. Pipe - Structural Use A53 Grade B 6. Hollow Structural Sections A500 Grade C or A1085 7. Cold-Formed Steel Framing A 653 2.02 STAINLESS STEEL A. All stainless steel fabrications exposed to underwater service shall be Type 316. All other stainless steel fabrications shall be Type 304, unless noted otherwise. B. Material types and ASTM designations are listed below: 1. Plates and Sheets ASTM A167 or A666 Grade A 2. Structural Shapes ASTM A276 3. Fasteners (Bolts, etc.) ASTM F593 2.03 ALUMINUM A. All aluminum shall be alloy 6061-T6, unless otherwise noted or specified herein. City of Denton Hazen and Sawyer BID SET 05010-4 Metal Materials B. Material types and ASTM designations are listed below: 1. Structural Shapes ASTM B308 2. Castings ASTM B26, B85, or B108 3. Extruded Bars ASTM B221 - Alloy 6061 4. Extruded Rods, Shapes and Tubes ASTM B221 - Alloy 6063 5. Plates ASTM B209 - Alloy 6061 6. Sheets ASTM B221 - Alloy 3003 C. All aluminum structural members shall conform to the requirements of Section 05140, Structural Aluminum. D. All aluminum shall be provided with mill finish unless otherwise noted. E. Where bolted connections are indicated, aluminum shall be fastened with stainless steel bolts. F. Aluminum in contact with dissimilar materials shall be insulated with an approved dielectric. 2.04 CAST IRON A. Material types and ASTM designations are listed below: 1. Gray ASTM A48 Class 30B 2. Malleable ASTM A47 3. Ductile ASTM A536 Grade 60-40-18 2.05 BRONZE A. Material types and ASTM designations are listed below: 1. Rods, Bars and Sheets ASTM B138 - Alloy B Soft 2.06 HASTELLOY A. All Hastelloy shall be Alloy C-276. PART 3 -- EXECUTION (NOT USED) - END OF SECTION - City of Denton Hazen and Sawyer BID SET 05035-1 Galvanizing SECTION 05035 GALVANIZING PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Where galvanizing is called for in the Contract Documents, the galvanizing shall be performed in accordance with the provisions of this Section unless otherwise noted. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Further requirements for galvanizing specific items may be included in other Sections of the Specifications. See section for the specific item in question. 1.03 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Without limiting the generality of the other requirements of the specifications, all work herein shall conform to the applicable requirements of the following documents. All referenced specifications, codes, and standards refer to the most current issue available at the time of Bid. 1. Texas State Building Code 2. ASTM A123 - Standard Specification for Zinc (Hot-Galvanized) Coatings on Products Fabricated from Rolled, Pressed, and Forged Steel Shapes, Plates, Bars, and Strip 3. ASTM A153 - Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware 4. ASTM A924 - Standard Specification for General Requirements for Steel Sheet, Metallic-Coated by the Hot-Dip Process 5. ASTM A780 - Standard Practice of Repair of Damaged Hot-Dip Galvanized Coatings 6. ASTM F2329 - Standard Specification for Zinc Coating, Hot-Dip, Requirements for Application to Carbon and Alloy Steel Bolts, Screws, Washers, Nuts, and Special Threaded Fasteners City of Denton Hazen and Sawyer BID SET 05035-2 Galvanizing 1.04 SUBMITTALS A. Submit the following in accordance with Section 01300, Submittals. 1. Certification that the item(s) are galvanized in accordance with the applicable ASTM standards specified herein. This certification may be included as part of any material certification that may be required by other Sections of the Specifications. PART 2 -- PRODUCTS 2.01 GALVANIC COATING A. Material composition of the galvanic coating shall be in accordance with the applicable ASTM standards specified herein. PART 3 -- EXECUTION 3.01 FABRICATED PRODUCTS A. Products fabricated from rolled, pressed, and forged steel shapes, plates, bars, and strips, 1/8 inch thick and heavier which are to be galvanized shall be galvanized in accordance with ASTM A123. Products shall be fabricated into the largest unit which is practicable to galvanize before the galvanizing is done. Fabrication shall include all operations necessary to complete the unit such as shearing, cutting, punching, forming, drilling, milling, bending, and welding. Components of bolted or riveted assemblies shall be galvanized separately before assembly. When it is necessary to straighten any sections after galvanizing, such work shall be performed without damage to the zinc coating. The galvanizer shall be a member of American Galvanizers Association. B. Components with partial surface finishes shall be commercial blast cleaned prior to pickling. C. Sampling and testing of each lot shall be performed prior to shipment from the galvanizer’s facility per ASTM A123. 3.02 HARDWARE A. Iron and steel hardware which is to be galvanized shall be galvanized in accordance with ASTM A153 and ASTM F2329. 3.03 ASSEMBLED PRODUCTS A. Assembled steel products which are to be galvanized shall be galvanized in accordance with ASTM A123. All edges of tightly contacting surfaces shall be completely sealed by welding before galvanizing. City of Denton Hazen and Sawyer BID SET 05035-3 Galvanizing 3.04 SHEETS A. Iron or steel sheets which are to be galvanized shall be galvanized in accordance with ASTM A924. 3.05 REPAIR OF GALVANIZING A. Galvanized surfaces that are abraded or damaged at any time after the application of zinc coating shall be repaired by thoroughly wire brushing the damaged areas and removing all loose and cracked coating, after which the cleaned areas shall be painted with 2 coats of zinc rich paint meeting the requirements of Federal Specification DOD-P-21035A and shall be thoroughly mixed prior to application. Zinc rich paint shall not be tinted. The total thickness of the 2 coats shall not be less than 6 mils. In lieu of repairing by painting with zinc rich paint, other methods of repairing galvanized surfaces in accordance with ASTM A780 may be used provided the proposed method is acceptable to the Engineer. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 05035-4 Galvanizing This page left blank intentionally City of Denton Hazen and Sawyer BID SET 05050-1 Metal Fastening SECTION 05050 METAL FASTENING PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Furnish all materials, labor, and equipment required to provide all metal welds and fasteners not otherwise specified, in accordance with the Contract Documents. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 05010 - Metal Materials B. Section 05035 - Galvanizing C. Section 05061 – Stainless Steel D. Section 05120 - Structural Steel E. Section 05140 - Structural Aluminum 1.03 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Without limiting the generality of the other requirements of the specifications, all work herein shall conform to the applicable requirements of the following documents. All referenced specifications, codes, and standards refer to the most current issue available at the time of Bid. 1. State of Texas Building Code 2. AC 193 Acceptance Criteria for Mechanical Anchors in Concrete Elements 3. AC 308 Acceptance Criteria for Post-Installed Adhesive Anchors in Concrete Elements 4. ACI 318 Building Code Requirements for Structural Concrete 5. ACI 355.2 Qualifications of Post-Installed Mechanical Anchors in Concrete 6. ACI 355.4 Qualifications of Post-Installed Adhesive Anchors in Concrete City of Denton Hazen and Sawyer BID SET 05050-2 Metal Fastening 7. AISC 348 The 2009 RCSC Specification for Structural Joints 8. AISC Code of Standard Practice 9. AWS D1.1 Structural Welding Code - Steel 10. AWS D1.2 Structural Welding Code - Aluminum 11. AWS D1.6 Structural Welding Code – Stainless Steel 12. Aluminum Association Specifications for Aluminum Structures 13. ASTM A572/A572M-94C Standard Specification for High Strength Low-Alloy Columbium-Vanadium Structural Steel Grade 50 14. ASTM A36 Standard Specification for Carbon Structural Steel 15. ASTM A325 Standard Specification for High-Strength Bolts for Structural Steel Joints 16. ASTM A489 Standard Specification for Eyebolts 17. ASTM A490 Standard Specification for Quenched and Tempered Alloy Steel Bolts for Structural Steel Joints 18. ASTM A563 Standard Specifications for Carbon and Alloy Steel Nuts 19. ASTM D1785 Standard Specification for Polyvinyl Chloride (PVC) Plastic Pipe 20. ASTM E488 Standard Test Methods for Strength of Anchors in Concrete and Masonry Elements 21. ASTM F436 Standard Specification for Hardened Steel Washers 22. ASTM F467 Standard Specification for Nonferrous Nuts for General Use 23. ASTM F593 Standard Specification for Stainless Steel Bolts; Hex Cap Screws, and Studs 24. ASTM F594 Standard Specification for Stainless Steel Nuts 25. ASTM F1554 Standard Specification for Anchor Bolts, Steel, 36, 55, and 105-ksi Yield Strength City of Denton Hazen and Sawyer BID SET 05050-3 Metal Fastening 1.04 SUBMITTALS A. Submit the following in accordance with Section 01300, Submittals. 1. Shop Drawings providing the fastener's manufacturer and type and certification of the fastener's material and capacity. 2. Anchor design calculations sealed by a Professional Engineer currently registered in the State of Texas. Only required if design not shown on Contract Drawings. 3. Manufacturer’s installation instructions. 4. Copy of valid certification for each person who is to perform field welding. 5. Certified weld inspection reports, when required. 6. Welding procedures. 7. Installer qualifications. 8. Certification of Installer Training. 9. Inspection Reports. 10. Results of Anchor Proof Testing. 1.05 QUALITY ASSURANCE A. Fasteners not manufactured in the United States shall be tested and certification provided with respect to specified quality and strength standards. Certifications of origin shall be submitted for all U.S. fasteners supplied on the project. B. Installer Qualifications: All concrete anchors shall be installed by an Installer with at least three years of experience performing similar installations. Concrete adhesive anchor installer shall be certified as an Adhesive Anchor Installer in accordance with ACI-CRSI Adhesive Anchor Installation Certification Program. C. Installer Training: For concrete adhesive anchors, conduct a thorough training with the manufacturer or the manufacturer’s representative for the Installer on the project. Training shall consist of a review of the complete installation process to include but not be limited to the following: 1. Hole drilling procedure. 2. Hole preparation and cleaning technique. 3. Adhesive injection technique and dispenser training/maintenance. City of Denton Hazen and Sawyer BID SET 05050-4 Metal Fastening 4. Concrete adhesive anchor preparation and installation. 5. Proof loading/torquing. D. All steel welding shall be performed by welders certified in accordance with AWS D1.1. All aluminum welding shall be performed by welders certified in accordance with AWS D1.2. All stainless steel welding shall be performed by welders certified in accordance with AWS D1.6. Certifications of field welders shall be submitted prior to performing any field welds. E. Welds and high strength bolts used in connections of structural steel will be visually inspected in accordance with Article 3.04. F. The Owner may engage an independent testing agency to perform testing of welded connections and to prepare test reports in accordance with AWS. Inadequate welds shall be corrected or redone and retested to the satisfaction of the Engineer and/or an acceptable independent testing laboratory, at no additional cost to the Owner. G. Provide a welding procedure for each type and thickness of weld. For welds that are not prequalified, include a Performance Qualification Report. The welding procedure shall be given to each welder performing the weld. The welding procedure shall follow the format in Annex E of AWS D1.1 with relevant information presented. H. Special inspections for concrete adhesive anchors shall be conducted in accordance with the manufacturer’s instructions and Specifications Section 01450. Downward installations require periodic inspection and horizontal and overhead installations require continuous inspection. PART 2 -- PRODUCTS 2.01 ANCHOR RODS (ANCHOR BOLTS) A. Anchor rods shall conform to ASTM F1554 Grade 36 except where stainless steel or other approved anchor rods are shown on the Drawings. Anchor rods shall have hexagonal heads and shall be supplied with hexagonal nuts meeting the requirements of ASTM A563 Grade A. B. Where anchor rods are used to anchor galvanized steel or are otherwise specified to be galvanized, anchor rods and nuts shall be hot-dip galvanized in accordance with ASTM F1554. C. Where pipe sleeves around anchor rods are shown on the Drawings, pipe sleeves shall be cut from Schedule 40 PVC plastic piping meeting the requirements of ASTM D1785. 2.02 HIGH STRENGTH BOLTS A. High strength bolts and associated nuts and washers shall be in accordance with ASTM A325 or ASTM A490. Bolts, nuts and washers shall meet the requirements of AISC 348 "The 2009 RCSC Specification for Structural Joints”. City of Denton Hazen and Sawyer BID SET 05050-5 Metal Fastening B. Where high strength bolts are used to connect galvanized steel or are otherwise specified to be galvanized, bolts, nuts, and washers shall be hot-dip galvanized in accordance with ASTM A325. 2.03 STAINLESS STEEL BOLTS A. Stainless steel bolts shall conform to ASTM F-593. All underwater fasteners, fasteners in confined areas containing fluid, and fasteners in corrosive environments shall be Type 316 stainless steel unless noted otherwise. Fasteners for aluminum and stainless steel members not subject to the above conditions shall be Type 304 stainless steel unless otherwise noted. B. Stainless steel bolts shall have hexagonal heads with a raised letter or symbol on the bolts indicating the manufacturer, and shall be supplied with hexagonal nuts meeting the requirements of ASTM F594. Nuts shall be of the same alloy as the bolts. 2.04 CONCRETE ANCHORS A. General 1. Where concrete anchors are called for on the Drawings, one of the types listed below shall be used; except, where one of the types listed below is specifically called for on the Drawings, only that type shall be used. The determination of anchors equivalent to those listed below shall be on the basis of test data performed by an approved independent testing laboratory. There are two types used: a. Expansion anchors shall be mechanical anchors of the wedge, sleeve, drop-in or undercut type. b. Adhesive anchors shall consist of threaded rods or bolts anchored with an adhesive system into hardened concrete. Adhesive anchors shall be two part injection type using the manufacturer’s static mixing nozzle and shall be supplied as an entire system. 2. Expansion anchors shall not be used to hang items from above or in any other situations where direct tension forces are induced in anchor. 3. Unless otherwise noted, all concrete anchors which are submerged or are used in hanging items or have direct tension induced upon them, or which are subject to vibration from equipment such as pumps and generators, shall be adhesive anchors. 4. Adhesive anchors shall conform to the requirements of ACI 355.4 or alternately to AC 308. Expansion or mechanical anchors shall conform to the requirements of ACI 355.2 or alternately to AC 193. City of Denton Hazen and Sawyer BID SET 05050-6 Metal Fastening 5. Fire Resistance: All anchors installed within fire resistant construction shall either be enclosed in a fire resistant envelope, be protected by approved fire-resistive materials, be used to resist wind and earthquake loads only, or anchor non- structural elements. 6. Engineer’s approval is required for use of concrete anchors in locations other than those shown on the Drawings. B. Concrete Anchor Design: An anchor design consists of specifying anchor size, quantity, spacing, edge distance and embedment to resist all applicable loads. Where an anchor design is indicated on the Drawings, it shall be considered an engineered design and anchors shall be installed to the prescribed size, spacing, embedment depth and edge distance. If all parts of an anchor design are provided on the Drawings except embedment depth, the anchors will be considered an engineered design and the Contractor shall provide the embedment depth as indicated in Paragraph B.3 unless otherwise directed by the Engineer. Where an anchor design is not indicated by the Engineer on the Drawings, the Contractor shall provide the anchor design per the requirements listed below. 1. Structural Anchors: All concrete anchors shall be considered structural anchors if they transmit load between structural elements; transmit load between non- structural components that make up a portion of the structure and structural elements; or transmit load between life-safety related attachments and structural elements. Examples of structural concrete anchors include but are not limited to column anchor bolts, anchors supporting non-structural walls, sprinkler piping support anchors, anchors supporting heavy, suspended piping or equipment, anchors supporting barrier rails, etc. For structural anchors, the Contractor shall submit an engineered design with signed and sealed calculations performed by an Engineer currently registered in the State of Texas. Structural anchors shall be of a type recommended by the anchor manufacturer for use in cracked concrete and shall be designed by the Contractor in accordance with ACI 318 Appendix D. 2. Non-Structural Anchors: All other concrete anchors may be considered non-structural concrete anchors. The Contractor shall perform an engineered design for non-structural anchors. The Engineer may request the Contractor provide anchor design details for review, but submission of a signed, sealed design is not required. Non-structural anchors shall be designed by the contractor for use in uncracked concrete. 3. Embedment Depth a. Minimum anchor embedment shall be as indicated on the Drawings or determined by the Contractor’s engineered design. Although all manufacturers listed are permitted, the embedment depth indicated on the Drawings is based on “PE 1000+ by Powers Fasteners”. If the contractor submits one of the other concrete adhesive anchors listed, the Engineer shall evaluate the required embedment and the Contractor shall City of Denton Hazen and Sawyer BID SET 05050-7 Metal Fastening provide the required embedment depth stipulated by the Engineer specific to the approved dowel adhesive. b. Where the embedment depth is not shown on the Drawings, concrete anchors shall be embedded no less than the manufacturer’s standard embedment (expansion or mechanical anchors) or to provide a minimum allowable bond strength equal to the allowable yield capacity of the rod according to the manufacturer (adhesive anchors). c. The embedment depth shall be determined using the actual concrete compressive strength, a cracked concrete state, maximum long term temperature of 110 degrees F, and maximum short term temperature of 140 degrees F. In no case shall the embedment depth be less than the minimum or more than the maximum stated in the manufacturer’s literature. C. Structural Anchors: 1. Mechanical Anchors: a. Wedge Anchors: Wedge anchors shall be “Kwik Bolt TZ” by Hilti, Inc., “TruBolt +” by ITW Redhead, “Strong-Bolt 2” by Simpson Strong-Tie Co. or “Powerstud SD-1” or “Powerstud SD-2” by Powers Fasteners. b. Screw Anchors: Screw anchors shall be “Kwik HUS-EZ” and “KWIK HUS-EZ-I” by Hilti, Inc., “Titen HD” by Simpson Strong-Tie Co., or “Wedge-Bolt +” by Powers Fasteners. Bits specifically provided by manufacturer of chosen system shall be used for installation of anchors. c. Sleeve Anchors: Sleeve anchors shall be “HSL-3 Heavy Duty Sleeve Anchor” by Hilti, Inc. or “Power-Bolt +” by Powers Fasteners. d. Undercut Anchors: Undercut anchors shall be “HDA Undercut Anchor” by Hilti, Inc., “Torq-Cut Undercut Anchor” by Simpson Strong-Tie Co., “Atomic + Undercut Anchor” by Powers Fasteners 2. Adhesive Anchors: a. Adhesive anchors shall be “Epcon C6+ Adhesive Anchoring System” by ITW Redhead, “HIT HY-200 Adhesive Anchoring System” by Hilti, Inc., “AT-XP” or “SET-XP Epoxy Adhesive Anchors” by Simpson Strong-Tie Co., or “PE-1000+ Epoxy Adhesive Anchor System” by Powers Fasteners. b. Structural adhesive anchor systems shall be IBC compliant and capable of resisting short term wind and seismic loads (Seismic Design Categories A through F) as well as long term and short term sustained static loads in both cracked and uncracked concrete in all Seismic Design Categories. Structural adhesive anchor systems shall comply with the City of Denton Hazen and Sawyer BID SET 05050-8 Metal Fastening latest revision of ICC-ES Acceptance Criteria AC308, and shall have a valid ICC-ES report in accordance with the applicable building code. No or equal products will be considered unless prequalified and approved by the Engineer and Owner. D. Non-Structural Anchors: In addition to the acceptable non-structural anchors listed below, all structural anchors listed above may also be used as non-structural anchors. 1. Mechanical Anchors: a. Wedge Anchors: Wedge anchors shall be “Kwik Bolt 3” by Hilti, Inc., “Wedge-All” by Simpson Strong-Tie Co. or “TruBolt” by ITW Redhead. b. Screw Anchors: Screw anchors shall be “Kwik HUS” by Hilti, Inc., “Wedge-Bolt” by Powers Fasteners “Large Diameter Tapcon (LDT) Anchor” by ITW Redhead, or “Titen HD” by Simpson Strong-Tie Co. Bits specifically provided by manufacturer of chosen system shall be used for installation of anchors. c. Sleeve Anchors: Sleeve anchors shall be “HSL Heavy Duty Sleeve Anchors” by Hilti, Inc. “Power-Bolt” by Powers Fasteners “Dynabolt Sleeve Anchor” by ITW Redhead, or “Sleeve-All” by Simpson Strong-Tie Co. d. Drop-In Anchors: Drop-in anchors shall be “Drop-In” by Simpson Strong-Tie Co., “HDI Drop-In Anchor” by Hilti, Inc. or “Multi-Set II Drop-In Anchor” by ITW Redhead. e. Undercut Anchors: Undercut anchors shall be “HDA Undercut Anchor” by Hilti, Inc., or “Torq-Cut” by Simpson Strong-Tie Co. 2. Adhesive Anchors: a. Adhesive anchors shall be “Epcon A7” or “Epcon C6+ Adhesive Anchoring System” by ITW Redhead, “HIT HY-200 Adhesive Anchoring System” by Hilti, Inc., “SET Epoxy Tie High Strength Anchoring Adhesive” or “AT High Strength Anchoring Adhesive” by Simpson Strong-Tie Co., or “Powers AC 100+ Gold Vinylester Injection Adhesive Anchoring System” or “T308+ Epoxy Adhesive Injection System” by Powers Fasteners. b. Non-structural adhesive anchors systems shall be IBC compliant and capable of resisting short term wind and seismic (Seismic Design Categories A and B) as well as long term and short term sustained static loads in uncracked concrete. c. Non-structural adhesive anchor embedment depth of the rod shall provide a minimum allowable bond strength that is equal to the allowable yield capacity of the rod unless noted otherwise on the Drawings. City of Denton Hazen and Sawyer BID SET 05050-9 Metal Fastening d. No or equal products will be considered unless prequalified and approved by the Engineer and Owner. E. Concrete Anchor Rod Materials: 1. Concrete anchors used to anchor structural steel shall be a threaded steel rod per manufacturer’s recommendations for proposed adhesive system, but shall not have a yield strength (fy) less than 58 ksi nor an ultimate strength (fu) less than 72.5 ksi, unless noted otherwise. Where steel to be anchored is galvanized, concrete anchors shall also be galvanized unless otherwise indicated on the Drawings. 2. Concrete anchors used to anchor aluminum, FRP, or stainless steel shall be Type 304 stainless steel unless noted otherwise. All underwater concrete anchors shall be Type 316 stainless steel. 3. Nuts, washers, and other hardware shall be of a material to match the anchors. 2.05 MASONRY ANCHORS A. Anchors for fastening to solid or grout-filled masonry shall be adhesive anchors as specified above for concrete anchors. B. Anchors for fastening to hollow masonry or brick shall be adhesive anchors consisting of threaded rods or bolts anchored with an adhesive system dispensed into a screen tube inserted into the masonry. The adhesive system shall use a two-component adhesive mix and shall inject into the screen tube with a static mixing nozzle. Thoroughly clean drill holes of all debris and drill dust with nylon (not wire) brush prior to installation of adhesive and anchor. Contractor shall follow manufacturer’s installation instructions. The adhesive system shall be “HIT HY-70 System” as manufactured by Hilti, Inc., or “SET-XP Epoxy-Tie or “AT-XP Acrylic-Tie” as manufactured by Simpson Strong-Tie Co. C. Masonry anchors used to anchor steel shall be a threaded steel rod per manufacturer’s recommendations for proposed adhesive system, but shall not have a yield strength (fy) less than 58 ksi nor an ultimate strength (fu) less than 72.5 ksi, unless noted otherwise. Where steel to be anchored is galvanized, masonry anchors shall also be galvanized. D. Masonry anchors used to anchor aluminum, FRP, or stainless steel shall be Type 304 stainless steel unless noted otherwise. All underwater anchors shall be Type 316 stainless steel. 2.06 WELDS A. Electrodes for welding structural steel and all ferrous steel shall comply with AWS Code, using E70 series electrodes for shielded metal arc welding (SMAW), or F7 series electrodes for submerged arc welding (SAW). B. Electrodes for welding aluminum shall comply with the Aluminum Association Specifications and AWS D1.2. City of Denton Hazen and Sawyer BID SET 05050-10 Metal Fastening C. Electrodes for welding stainless steel and other metals shall comply with AWS D1.6. 2.07 WELDED STUD CONNECTORS A. Welded stud connectors shall conform to the requirements of AWS D1.1 Type C. 2.08 EYEBOLTS A. Eyebolts shall conform to ASTM A489 unless noted otherwise. 2.09 HASTELLOY FASTENERS A. Hastelloy fasteners and nuts shall be constructed of Hastelloy C-276. 2.10 ANTISEIZE LUBRICANT A. Antiseize lubricant shall be C5-A Anti-Seize by Loctite Corporation, Molykote P-37 Anti-Seize Paste by Dow Corning, 3M Anti-Seize by 3M, or equal. PART 3 -- EXECUTION 3.01 MEASUREMENTS A. The Contractor shall verify all dimensions and review the Drawings and shall report any discrepancies to the Engineer for clarification prior to starting fabrication. 3.02 ANCHOR INSTALLATION A. Anchor Rods, Concrete Anchors, and Masonry Anchors 1. Anchor rods shall be installed in accordance with AISC "Code of Standard Practice" by setting in concrete while it is being placed and positioned by means of a rigidly held template. Overhead adhesive anchors, and base plates or elements they are anchoring, shall be shored as required and securely held in place during anchor setting to prevent movement during anchor installation. Movement of anchors during curing is prohibited. 2. The Contractor shall verify that all concrete and masonry anchors have been installed in accordance with the manufacturer's recommendations and that the capacity of the installed anchor meets or exceeds the specified safe holding capacity. 3. Concrete anchors shall not be used in place of anchor rods without Engineer's approval. 4. All stainless steel threads shall be coated with antiseize lubricant. City of Denton Hazen and Sawyer BID SET 05050-11 Metal Fastening B. High Strength Bolts 1. All bolted connections for structural steel shall use high strength bolts. High strength bolts shall be installed in accordance with AISC 348 "The 2009 RCSC Specification for Structural Joints”. All bolted joints shall be Type N, snug-tight, bearing connections in accordance with AISC Specifications unless noted otherwise on the Drawings. C. Concrete Anchors 1. Concrete at time of anchor installation shall be a minimum age of 21 days, have a minimum compressive strength of 2500 psi, and shall be at least 50 degrees F. 2. Concrete anchors designed by the Contractor shall be classified as structural or non-structural based on the requirements indicated above. 3. Concrete Anchor Testing: a. At all locations where concrete anchors meet the requirements for structural anchors at least 25 percent of all concrete anchors installed shall be proof tested to the value indicated on the Drawings, with a minimum of one tested anchor per anchor group. If no test value is indicated on the Drawings but the installed anchor meets the requirements for structural anchors, the Contractor shall notify the Engineer to allow verification of whether anchor load proof testing is required. b. Contractor shall submit a plan and schedule indicating locations of anchors to be proof tested, load test values and proposed anchor testing procedure (including a diagram of the testing equipment proposed for use) to the Engineer for review prior to conducting any testing. Proof testing of anchors shall be in accordance with ASTM E488 for the static tension test. If additional tests are required, inclusion of these tests shall be as stipulated on Contract Drawings. c. Where Contract Documents indicate anchorage design to be the Contractor’s responsibility and the anchors are considered structural per the above criteria, the Contractor shall submit a plan and schedule indicating locations of anchors to be proof tested and load test values, sealed by a Professional Engineer currently registered in the State of Texas. The Contractor’s Engineer shall also submit documentation indicating the Contractor’s proof testing procedures have been reviewed and the proposed procedures are acceptable. Proof testing procedures shall be in accordance with ASTM E488. d. Concrete Anchors shall have no visible indications of displacement or damage during or after the proof test. Concrete cracking in the vicinity of the anchor after loading shall be considered a failure. Anchors exhibiting City of Denton Hazen and Sawyer BID SET 05050-12 Metal Fastening damage shall be removed and replaced. If more than 5 percent of tested anchors fail, then 100 percent of anchors shall be proof tested. e. Proof testing of concrete anchors shall be performed by an independent testing laboratory hired directly by the Contractor and approved by the Engineer. The Contractor shall be responsible for costs of all proof testing, including additional testing required due to previously failed tests. 4. All concrete anchors shall be installed in strict conformance with the manufacturer’s printed installation instructions. A representative of the manufacturer shall be on site when required by the Engineer. 5. All holes shall be drilled in accordance with the manufacturer’s instructions except that cored holes shall not be allowed unless specifically approved by the Engineer. If cored holes are allowed by the manufacturer and approved by the Engineer, cored holes shall be roughened in accordance with manufacturer requirements. Thoroughly clean drill holes of all debris, drill dust, and water in accordance with the manufacturer’s instructions prior to installation of adhesive and threaded rod unless otherwise recommended by the manufacturer. Degree of hole dampness shall be in strict accordance with manufacturer recommendations. Installation conditions shall be either dry or water-saturated. Water filled or submerged holes shall not be permitted unless specifically approved by the Engineer. . Injection of adhesive into the hole shall be performed to minimize the formation of air pockets in accordance with the manufacturer’s instructions. Wipe rod free from oil that may be present from shipping or handling. D. Other Bolts 1. All dissimilar metal shall be connected with appropriate fasteners and shall be insulated with a dielectric or approved equal. 2. All stainless steel bolts shall be coated with antiseize lubricant. 3.03 WELDING A. All welding shall comply with AWS Code for procedures, appearance, quality of welds, qualifications of welders and methods used in correcting welded work. B. Welded stud connectors shall be installed in accordance with AWS D1.1. 3.04 INSPECTION A. High strength bolting will be visually inspected in accordance with AISC 348 "The 2009 RCSC Specification for Structural Joints”. Rejected bolts shall be either replaced or retightened as required. B. Field welds will be visually inspected in accordance with AWS Codes. Inadequate welds shall be corrected or redone as required in accordance with AWS Codes. City of Denton Hazen and Sawyer BID SET 05050-13 Metal Fastening C. Post-installed concrete anchors shall be inspected as required by ACI 318. 3.05 CUTTING OF EMBEDDED REBAR A. The Contractor shall not cut embedded rebar cast into structural concrete during installation of post-installed fasteners without prior approval of the Engineer. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 05050-14 Metal Fastening This page left blank intentionally City of Denton Hazen and Sawyer BID SET 05061-1 Stainless Steel SECTION 05061 STAINLESS STEEL PART 1 -- GENERAL 1.01 SECTION INCLUDES A. The Contractor shall furnish, install and erect the stainless steel work as shown on the Contract Drawings and specified herein. B. Stainless steel work shall be furnished complete with all accessories, mountings and appurtenances of the type of stainless steel and finish as specified or required for a satisfactory installation. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 01300 - Submittals B. Section 05010 - Metal Materials C. Section 05050 - Metal Fastening D. Section 05500 - Metal Fabrications 1.03 REFERENCES A. ASTM A193 - Alloy-Steel and Stainless Steel Bolting Materials for High- Temperature Service. B. ASTM A194 - Carbon and Alloy Steel Nuts for Bolts for High-Pressure and High-Temperature Service. C. ASTM A262 - Practice for Detecting Susceptibility to Intergranular Attack in Austenitic Stainless Steel. D. ASTM A276 - Stainless and Heat-Resisting Steel Bars and Shapes. E. ASTM A314 - Stainless and Heat-Resisting Steel Billets and Bars for Forging. F. ASTM A380 - Practice for Cleaning and Descaling Stainless Steel Parts, Equipment and Systems. G. ASTM A473 - Stainless and Heat-Resisting Steel Forgings. City of Denton Hazen and Sawyer BID SET 05061-2 Stainless Steel H. ASTM A666 - Austenitic Stainless Steel, Sheet, Strip, Plate and Flat Bar. I. ASTM A774 - Stainless Steel Pipe Fittings J. ASTM A778 - Stainless Steel Pipe K. ASTM F593 - Stainless Steel Bolts, Hex Cap Screws and Studs. L. ASTM F594 - Stainless Steel Nuts. M. ANSI/ASME B1.1 - Unified Inch Screw Thread (UN and UNR Thread Form). 1.04 TESTS A. All stainless steel materials including stainless test welds, shall be checked for compliance with tests for susceptibility to intergranular attack. Such tests shall be Practices A, B and E of ASTM A262. Detailed procedures for the tests shall be submitted to the Engineer for approval prior to start of work. Practice A shall be used only for acceptance of materials but not for rejection of materials, and shall be used for screening material intended for testing in Practice B and Practice E. The maximum acceptable corrosion rate under Practice B shall be 0.004 inch per month, rounded off to the third decimal place. If the certified mill report indicates that such test has been satisfactory performed, the fabricator may not be required to repeat the test. Material passing Practice E shall be acceptable. B. Sample selection for the susceptibility to intergranular attack tests shall be as follows: 1. One (1) sample per heat per heat treatment lot for plates and forgings; 2. One (1) sample per each Welding Procedure Qualification regardless of the joint design; 3. If tests indicate a reduction in corrosion resistance, welding procedure shall be adjusted or heat treatment determined as needed to restore required corrosion resistance. 4. The samples so chosen shall have received all the post-weld heat treatments identical to the finished part. 1.05 SUBMITTALS A. The Contractor shall prepare and submit for approval shop drawings for all stainless steel fabrication in accordance with Section 01300, Submittals. B. Submittals shall include, but not be limited to, the following: 1. Certified test reports for susceptibility to intergranular attack. City of Denton Hazen and Sawyer BID SET 05061-3 Stainless Steel 2. Affidavit of compliance with type of stainless steel shown on the Contract Drawings or specified herein. 3. Certified weld inspection reports. 4. Cleaning and handling of stainless steel in accordance with Paragraph 3.04, Cleaning and Handling. C. Samples of finish, on each type of stainless steel to be furnished, shall be submitted to the Engineer upon request. 1.06 QUALITY ASSURANCE A. Shop inspections may be made by the Engineer. The Contractor shall give ample notice to the Engineer prior to the beginning of any stainless steel fabrication work so that inspection may be provided. The Contractor shall furnish all facilities for the inspection of materials and workmanship in the shop, and the inspectors shall be allowed free access to the necessary parts of the works. B. Inspectors shall have the authority to reject any materials or work which does not meet the requirements of the Contract Drawings or the Specifications. C. Inspection at the shop is intended as a means of facilitating the work and avoiding errors, but is expressly understood that it will in no way relieve the Contractor from his responsibility for furnishing proper materials or workmanship. 1.07 HANDLING, STORAGE AND DELIVERY A. Mechanical damage (e.g., scratches and gouges) to the stainless steel material shall not be permitted and is cause for rejection. Care shall be taken in the material handling since such mechanical damage will result in the passive oxide film being "punctured" leading to a possible lower resistance to the initiation of corrosion than the surrounding chemically-passivated surface. B. Stainless steel plates and sheets shall be stored vertically in racks and not be dragged out of the racks or over one another. Racks shall be protected to prevent iron contamination. C. Heavy stainless steel plates shall be carefully separated and chocked with wooden blocks so that the forks of a fork-lift could be inserted between plates without mechanically damaging the surface. D. Stainless steel plates and sheets laid out for use shall be off the floor and be divided by wooden planks to prevent surface damage and to facilitate subsequent handling. E. Plate clamps, if used, shall be used with care as the serrated faces can dig in, indent and gouge the surface. City of Denton Hazen and Sawyer BID SET 05061-4 Stainless Steel F. Stainless steel fabrications shall be loaded in such a manner that they may be transported and unloaded without being overstressed, deformed or otherwise damaged. G. Stainless steel fabrications and packaged materials shall be protected from corrosion and deterioration and shall be stored in a dry area. Materials stored outdoors shall be supported above ground surfaces on wood runners and protected with approved effective and durable covers. H. Stainless steel fabrications shall not be placed in or on a structure in a manner that might cause distortion or damage to the fabrication. The Contractor shall repair or replace damaged stainless steel fabrications or materials as directed by the Engineer. 1.08 FIELD MEASUREMENTS A. The Contractor shall verify all dimensions and shall make any field measurements necessary and shall be fully responsible for accuracy and layout of the work. B. The Contractor shall review the Contract Drawings and any discrepancies shall be reported to the Engineer for clarification prior to starting fabrication. PART 2 -- PRODUCTS 2.01 MATERIALS AND FINISHES A. Stainless steel shall be Type 304 unless it is used for underwater service. Stainless steel for underwater service shall be Type 316. Minimum mechanical finish shall be No. 4 as stated in Table 2 unless otherwise noted on the Contract Drawings. B. The basic mill forms (sheet, strip, plate and bar) are classified by size as shown on Table 1. Tables 2, 3 and 4 identify finishes and conditions in which sheet, bar and plate are available. C. Tables 2, 3 and 4 show numbered finishes and conditions for sheet, bar and plate. While there are no specific designations for polished finishes on bar or plate, the sheet finish designations are used to describe the desired effect. This also applies to finishes on ornamental tubing. D. There are three standard finishes for strip, which are broadly described by the finishing operations employed: 1. No. 1 Strip Finish No. 1 strip finish is approximately the same as No. 2D Sheet Finish. It varies in appearance from dull gray matte to a fairly reflective surface, depending largely on alloy composition and amount of cold reduction. City of Denton Hazen and Sawyer BID SET 05061-5 Stainless Steel 2. No. 2 Strip Finish is approximately the same as a No. 2B sheet finish. It is smoother, more reflective than No. 1, and likewise varies with alloy composition. 3. Bright annealed finish is a highly reflective finish that is retained by final annealing in a controlled atmosphere furnace. City of Denton Hazen and Sawyer BID SET 05061-6 Stainless Steel Table 1 Classification of Stainless Steel Product Form Item Description Dimensions Thickness Width Diameter or Size Sheet Coils and cut length: Mill finishes Nos. 1, 2D and 2B Polished finishes Nos. 3, 4, 6, 7 & 8 under 3/16" under 3/16" 24" and over all widths -- -- Strip Cold finished, coils or cut lengths Polished finishes Nos. 3, 4, 6,7 & 8 under 3/16" under 3/16" under 24" all widths -- -- Plate Flat rolled or forged 3/16" and over over 10" -- Bar Hot finished rounds, squares, octagons and hexagons Hot finished flats Cold finished rounds, squares, octagons and hexagons Cold finished flats -- 1/8" to 8" incl. -- 1/8" to 4-1/2" -- 1/4" to 10" incl. -- 3/8" to 4-1/2" 1/4" and over -- over 1/8" -- Wire Cold finishes only: (in coil) Round, square, octagon, hexagon and flat wire under 3/16" under 3/8" -- Pipe & Tubing Several different classifications, with differing specifications, are available. Extrusion Not considered “standard” shapes. Currently limited in size to approximately 6-1/2" diameter or structurals. City of Denton Hazen and Sawyer BID SET 05061-7 Stainless Steel Table 2 Standard Mechanical Sheet Finishes Unpolished or Rolled Finishes: No. 1 A rough dull surface which results from hot rolling to the specified thickness followed by annealing and descaling. No. 4 A polished surface obtained by finishing with a 120-150 mesh abrasive, following initial grinding with coarser abrasives. This is a general purpose bright finish with a visible "grain" which prevents mirror reflection. No. 2D A dull finish which results from cold rolling followed by annealing and descaling, and may perhaps get a final light roll pass through unpolished rolls. A 2D finish is used where appearance is of no concern. No. 6 A dull satin finish having lower reflectivity than No. 4 finish. It is produced by Tampico brushing the No. 4 finish in a medium of abrasive and oil. It is used for architectural applications and ornamentation where a high luster is undesirable, and to contrast with brighter finishes. No. 2B A bright cold-rolled finish resulting in the same manner as No. 2D finish, except that the annealed and descaled sheet receives a final light roll pass through polished rolls. This is the general purpose cold-rolled finish that can be used as is, or as a preliminary step to polishing. No. 7 A high reflective finish that is obtained by buffing finely ground surfaces but not to the extent of completely removing the "grit" lines. It is used chiefly for architectural and ornamental purposes. Polished Finishes: No. 3 An intermediate polish surface obtained by finishing with a 100 grit abrasive. Generally used where a semi-finished polished surface is required. A No. 3 finish usually receives additional polishing during fabrication. No. 8 The most reflective surface, which is obtained by polishing with successively finer abrasives and buffing extensively until all grit lines from preliminary grinding operations are removed. It is used for applications such as mirrors and reflectors. City of Denton Hazen and Sawyer BID SET 05061-8 Stainless Steel Table 3 Conditions and Finishes for Bar Conditions Surface Finishes1 Hot worked only (a) Scale not removed (excluding spot conditioning) (b) Rough turned2 (c) Pickled or blast cleaned and pickled. Annealed or otherwise heat treated. (a) Scale not removed (excluding spot conditioning) (b) Rough turned (c) Pickled or blast cleaned and pickled (d) Cold drawn or cold rolled (e) Centerless ground (f) Polished Annealed and cold worked to high tensile strength3 (d) Cold drawn or cold rolled (e) Centerless ground (f) Polished 1 Surface finishes (b), (e) and (f) are applicable to round bars only. 2 Bars of the 4xx series stainless steels which are highly hardenable, such as Types 414, 420, 420F, 431, 440A, 440B and 440C, are annealed before rough turning. Other hardenable grades, such as Types 403, 410, 416 and 416Se, may also require annealing depending on their composition and size. 3 Produced in Types 302, 303Se, 304 and 316. City of Denton Hazen and Sawyer BID SET 05061-9 Stainless Steel Table 4 Conditions and Finishes for Plate Condition and Finish Description and Remarks Hot rolled Scale not removed. Not heat treated. Plates not recommended for final use in this condition.4 Hot rolled, annealed or heat treated Scale not removed. Use of plates in this condition is generally confined to heat resisting applications. Scale impairs corrosion resistance.1 Hot rolled, annealed or heat treated, blast cleaned or pickled Condition and finish commonly preferred for corrosion resisting and most heat resisting applications. Hot rolled, annealed, descaled and temper passed Smoother finish for specialized applications. Hot rolled, annealed, descaled cold rolled, annealed, descaled, optionally temper passed Smooth finish with greater freedom from surface imperfection than the above. Hot rolled, annealed or heat treated, surface cleaned and polished Polished finishes refer to Table 2. 4 Surface inspection is not practicable on plates which have not been pickled or otherwise descaled. PART 3 -- EXECUTION 3.01 FABRICATION A. Holes for bolts and screws shall be drilled. Fastenings shall be concealed where practicable. Joints exposed to the weather shall be formed to exclude water. B. As far as practicable, all fabricated units shall be fitted and assembled in the shop, with all cuts and bends made to precision measurements in accordance with details shown on approved shop drawings. C. Work shall be fabricated so that it is installed in a manner that will provide for expansion and contraction, prevent the shearing of bolts, screws and other fastenings, ensure rigidity, and provide close fitting of sections. D. All finished and/or machined faces shall be true to line and level. Stainless steel sections shall be well formed to shape and size with sharp lines and angles; curved work shall be sprung evenly to curves. E. All work shall be fitted together at the shop as far as possible, and delivered complete City of Denton Hazen and Sawyer BID SET 05061-10 Stainless Steel and ready for erection. Proper care shall be exercised in handling all work so as not to injure the finished surfaces. 3.02 WELDING A. Welding shall be done in a manner that will prevent buckling and in accordance with Specification 05050 – Metal Fastening, and as modified hereinafter. B. All welds exposed in the work shall be ground smooth and finished to match the finish of the adjacent stainless steel surfaces. C. Select weld rods that provide weld filler metal having corrosion resistant properties as nearly identical or better than the base metal to insure preservation of the corrosion- resistant properties. Provide heat treatment at welds where testing of weld procedure indicates it is required to restore the corrosion resistance. D. Thermal conductivity of stainless steel is about half that of other steels; and the following methods may be used to accommodate this situation: 1. Use lower weld current setting. 2. Use skip-weld techniques to minimize heat concentration. 3. Use back-up chill bars or other cooling techniques to dissipate heat. E. Edges of the stainless steel to be welded shall be cleaned of contaminants. 3.03 FASTENERS A. Stainless steel fasteners shall be used for joining stainless steel work. B. Stainless steel fasteners shall be made of alloys that are equal to or more corrosion resistant than the materials they join. 3.04 CLEANING AND HANDLING A. All stainless steel surfaces shall be precleaned, descaled, passivated and inspected before, during and after fabrication in accordance with the applicable sections of ASTM A380 and as detailed in the procedures to be submitted to the Engineer for approval prior to start of work. Degreasing and passivation of stainless steel articles shall be conducted as the last step after fabrication. B. Measures to protect cleaned surfaces shall be taken as soon as final cleaning is completed and shall be maintained during all subsequent handling, storage and shipping. 1. The Contractor shall submit for approval specific procedures listing all the steps to be followed in detecting contamination and in descaling, cleaning, passivation and protecting of all stainless steel. City of Denton Hazen and Sawyer BID SET 05061-11 Stainless Steel 2. Area showing clear indications of contamination shall be recleaned, repassivated and reinspected. C. At approved stages in the shop operations, contaminants such as scale, embedded iron, rust, dirts, oil, grease and any other foreign matter shall be removed from the metal, as directed or approved by the Engineer. The adequacy of these operations shall be checked by the Engineer. Operations in the shop shall be conducted so as to avoid contamination of the stainless steel and to keep the metal surfaces free from dirt and foreign matter. D. In order to prevent incipient corrosion during fabrication, special efforts shall be made at all times to keep all stainless steel surfaces from coming in contact with other metals. 1. Stainless steel and stainless steel welds shall be cleaned with clean sand free of iron, stainless steel wool, stainless steel brushes, or other approved means and shall be protected at all times from contamination by any materials, including carbon steel, that shall impair its resistance to corrosion. 2. Approved methods of cutting, grinding and handling shall be used to prevent contamination. If air-arc, or carbon-arc cutting is used, additional metal shall be removed by approved mechanical means so as to provide clean, weldable edges. All grinding of stainless steel shall be performed with aluminum oxide or silicon carbide grinding wheels bonded with resin or rubber. Grinding wheels used on carbon steel shall not be used on stainless steel. 3. Sand, grinding wheels, brushes and other materials used for cleaning stainless steel shall be checked periodically by the Engineer for contaminants. Cleaning aids found to contain contaminants shall not be used on the work. 3.05 INSTALLATION A. All stainless steel fabrications shall be erected square, plumb and true, accurately fitted, adequately anchored in place, set at proper elevations and positions. B. All inserts, anchor rods and all other miscellaneous work specified in the Detailed Specifications or shown on the Contract Drawings or required for the proper completion of the work, which are embedded in concrete, shall be properly set and securely held in position in the forms before the concrete is placed. C. All stainless steel fabrications shall be installed in conformance with details shown on the Contract Drawings or on the approved shop drawings. -END OF SECTION – City of Denton Hazen and Sawyer BID SET 05061-12 Stainless Steel This page left blank intentionally City of Denton Hazen and Sawyer BID SET 05120-1 Structural Steel SECTION 05120 STRUCTURAL STEEL PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Furnish all equipment, labor, materials, and services required to provide all structural steel work in accordance with the Contract Documents. The term "structural steel" shall include items as defined in the AISC "Code of Standard Practice". 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 05010 - Metal Materials B. Section 05050 - Metal Fastening 1.03 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Without limiting the generality of the Specifications, all work specified herein shall conform to the applicable requirements of the following documents. 1. State of Texas Building Code 2. AISC - "Code of Standard Practice." 3. AISC - "Specification for Structural Steel Buildings". 4. AISC 348 - "The 2009 RCSC Specification for Structural Joints”. 5. AWS - "Structural Welding Code". 1.04 SUBMITTALS A. Submit the following in accordance with Section 01300, Submittals. 1. Certified Mill Test Reports 2. Affidavit of Compliance with grade specified 3. Shop Drawings which include the following: a. Layout drawings indicating all structural shapes, sizes, and dimensions. b. Beam and column schedules. City of Denton Hazen and Sawyer BID SET 05120-2 Structural Steel c. Detailed drawings indicating jointing, anchoring and connection details. 1.05 QUALITY ASSURANCE A. Shop inspection may be required by the Owner at his own expense. The Contractor shall give ample notice to the Engineer prior to the beginning of any fabrication work so that inspection may be provided. The Contractor shall furnish all facilities for the inspection of materials and workmanship in the shop, and the inspectors shall be allowed free access to the necessary parts of the work. Inspectors shall have the authority to reject any materials or work which do not meet the requirements of these Specifications. Inspection at the shop is intended as a means of facilitating the work and avoiding errors, but is expressly understood that it will in no way relieve the Contractor from his responsibility for furnishing proper materials or workmanship under this Specification. B. The erector shall be a qualified installer who participates in the AISC Certification program and is designated an AISC Certified Erector, Category ACSE. C. The fabricator shall be a qualified fabricator who participates in the AISC Certification program and is designated an AISC Certified Plant, Category STD. PART 2 -- PRODUCTS 2.01 MATERIALS A. Structural Steel 1. Structural steel for W shapes shall conform to ASTM A992 unless otherwise indicated. 2. Structural steel for HP shapes shall conform to ASTM A572 Grade 50 unless otherwise indicated. 3. Structural steel for S, M, C, and MC shapes and angles and plates shall conform to ASTM A36 unless otherwise indicated. 4. Steel pipe shall be ASTM A53, Grade B. 5. HSS shall be ASTM A500, Grade C or ASTM A1085. All members shall be furnished full length without splices unless otherwise noted or accepted by the Engineer. 6. All unidentified steel will be rejected and shall be removed from the site and replaced by the Contractor, all at the expense of the Contractor. 7. Fasteners for structural steel shall be in accordance with Section 05050, Metal Fastening. City of Denton Hazen and Sawyer BID SET 05120-3 Structural Steel B. Welds 1. Electrodes for welding shall be in accordance with Section 05050, Metal Fastening. PART 3 -- EXECUTION 3.01 MEASUREMENT A. The Contractor shall verify all dimensions and shall make any field measurements necessary and shall be fully responsible for accuracy and layout of work. The Contractor shall review the Drawings and any discrepancies shall be reported to the Engineer for clarification prior to starting fabrication. 3.02 FABRICATION A. Fabrication shall be in accordance with the AISC "Specification for Structural Steel Buildings and AISC "Code of Standard Practice". Fabrication shall begin only after Shop Drawing approval. B. Except where otherwise noted on the Drawings or in this Specification, all shop connections shall be welded. C. All holes in structural steel members required for anchors, anchor rods, bolts, sag rods or other members or for attachment of other work shall be provided by the fabricator and detailed on the Shop Drawings. D. All materials shall be properly worked and match-marked for field assembly. E. Where galvanizing of structural steel is required, it shall be done in accordance with Section 05035, Galvanizing. 3.03 DELIVERY, STORAGE AND HANDLING A. Structural members shall be loaded in such a manner that they may be transported and unloaded without being over-stressed, deformed or otherwise damaged. B. Structural steel members and packaged materials shall be protected from corrosion and deterioration. Material shall be stored in a dry area and shall not be placed in direct contact with the ground. Materials shall not be placed on the structure in a manner that might cause distortion or damage to the members or the supporting structures. The Contractor shall repair or replace damaged materials or structures as directed. 3.04 ERECTION A. The erection of all structural steel shall conform to the applicable requirements of the AISC "Specification for Structural Steel Buildings" and AISC "Code of Standard Practice". All temporary bracing, guys and bolts as may be necessary to ensure the safety of the structure until the permanent connections have been made shall be provided by the Contractor. City of Denton Hazen and Sawyer BID SET 05120-4 Structural Steel B. Structural members shall be set accurately to the lines and elevations indicated. The various members shall be aligned and adjusted to form a part of a complete frame or structure before permanently fastened. C. No cutting of structural steel members in the field will be allowed except by the written approval of the Engineer. D. Bearing surfaces and other surfaces which will be in permanent contact shall be cleaned before assembly. E. Field welding shall not be permitted unless specifically indicated in the Drawings or approved in writing by the Engineer. All field welding shall comply with Section 05050, Metal Fastening. F. All bolted connections shall use high strength bolts in accordance with Section 05050, Metal Fastening. High strength bolts shall be installed in accordance with AISC 348 “The 2009 RCSC Specification for Structural Joints”. Bolts specified or noted on the Drawings to be a tension or slip critical “SC” type connection shall be fully pretensioned with proper preparation of the faying surfaces. All other bolts shall be snug tightened unless otherwise noted on the Drawings. G. All field connections shall be accurately fitted up before being bolted. Drifting shall be only such as will bring the parts into position and shall not be sufficient to enlarge the holes or to distort the metal. All unfair holes shall be drilled or reamed. H. Misfits at Bolted Connections 1. Where misfits in erection bolting are encountered, the Engineer shall be immediately notified. The Contractor shall submit a method to remedy the misfit for review by the Engineer. The Engineer will determine whether the remedy is acceptable or if the member must be refabricated. 2. Incorrectly sized or misaligned holes in members shall not be enlarged by burning or by the use of drift pins. The Contractor shall notify the Engineer immediately and shall submit a proposed method of remedy for review by the Engineer. 3. Where misalignment between anchor rods and rod holes in steel members are encountered, the Engineer shall be immediately notified. The Contractor shall submit a method to remedy the misalignment for review by the Engineer. I. Grouting of Base Plates and Bearing Plates 1. The bottom surface of the plates shall be cleaned of all foreign materials, and concrete or masonry bearing surface shall be cleaned of all foreign materials and roughened to improve bonding. 2. Accurately set all base and bearing plates to designated levels with steel wedges or leveling plates. City of Denton Hazen and Sawyer BID SET 05120-5 Structural Steel 3. Baseplates shall be grouted with non-shrink grout to assure full uniform bearing. Grouting shall be done prior to placing loads on the structure. Non-shrink grout shall conform to Section 03600, Grout. 4. Anchor rods shall be tightened after the supported members have been positioned and plumbed and the non-shrink grout has attained its specified strength. J. Where finishing is required, assembly shall be completed including bolting and welding of units before start of finishing operations. 3.05 PAINTING A. Painting shall be performed according to Section 09900, Painting and the following additional requirements. 1. Concrete Encased Steel: Steel members which will be encased in concrete shall be cleaned but not painted prior to encasement. 2. Contact Surfaces: Contact surfaces such as at field connections, shall be cleaned and primed but not painted. 3. Finished Surfaces: Machine finished surfaces shall be protected against corrosion by a rust-inhibiting coating which is easily removed prior to erection or which has characteristics that make removal unnecessary prior to erection. 4. Surfaces Adjacent to Field Welds: Surfaces within 2 inches of any field weld location shall be free of materials that would prevent proper welding or produce objectionable fumes while welding is being done. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 05120-6 Structural Steel This page left blank intentionally City of Denton Hazen and Sawyer BID SET 05140-1 Structural Aluminum SECTION 05140 STRUCTURAL ALUMINUM PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Furnish all equipment, labor, materials, and services required to provide all structural aluminum work in accordance with the Contract Documents. The term "structural aluminum" shall include items as defined in the Aluminum Association "Specifications for Aluminum Structures". 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 05010 - Metal Materials B. Section 05050 - Metal Fastening C. Section 09900 - Painting 1.03 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Without limiting the generality of other requirements of the Specifications, all work specified herein shall conform to the applicable requirements of the following documents. All referenced specifications, codes, and standards refer to the most current issue available at the time of the Bid. 1. State of Texas Building Code 2. Aluminum Association "Specifications for Aluminum Structures" 3. AWS D1.2 - "Structural Welding Code". 1.04 SUBMITTALS A. Submit the following in accordance with Section 01300, Submittals. 1. Certified Mill Test Reports 2. Affidavit of Compliance with grade specified 3. Shop Drawings which include the following: a. Layout drawings indicating all structural shapes, sizes, and dimensions. b. Beam and column schedules. City of Denton Hazen and Sawyer BID SET 05140-2 Structural Aluminum c. Detailed drawings indicating jointing, anchoring and connection details. 1.05 QUALITY ASSURANCE A. Shop inspection may be required by the Owner at his own expense. The Contractor shall give ample notice to the Engineer prior to the beginning of any fabrication work so that inspection may be provided. The Contractor shall furnish all facilities for the inspection of materials and workmanship in the shop, and the inspectors shall be allowed free access to the necessary parts of the work. Inspectors shall have the authority to reject any materials or work which do not meet the requirements of these Specifications. Inspection at the shop is intended as a means of facilitating the work and avoiding errors, but is expressly understood that it will in no way relieve the Contractor from his responsibility for furnishing proper materials or workmanship under this Specification. PART 2 -- PRODUCTS 2.01 MATERIALS A. Structural aluminum shall comply with Section 05010, Metal Materials. B. Fasteners for structural aluminum shall be in accordance with Section 05050, Metal Fastening. C. Electrodes for welding shall be in accordance with Section 05050, Metal Fastening. PART 3 -- EXECUTION 3.01 MEASUREMENT A. The Contractor shall verify all dimensions and shall make any field measurements necessary and shall be fully responsible for accuracy and layout of work. The Contractor shall review the Drawings and any discrepancies shall be reported to the Engineer for clarification prior to starting fabrication. 3.02 FABRICATION A. Fabrication shall be in accordance with the Aluminum Association "Specifications for Aluminum Structures". Fabrication shall begin only after Shop Drawing approval. B. Except where otherwise noted on the Drawings or in this Specification, all shop connections shall be welded. C. All holes in structural aluminum members required for anchors, anchor rods, bolts, or other members or for attachment of other work shall be provided by the fabricator and detailed on the Shop Drawings. City of Denton Hazen and Sawyer BID SET 05140-3 Structural Aluminum D. All materials shall be properly worked and match-marked for field assembly. 3.03 DELIVERY, STORAGE AND HANDLING A. Structural members shall be loaded in such a manner that they may be transported and unloaded without being over-stressed, deformed or otherwise damaged. B. Structural aluminum members and packaged materials shall be protected from corrosion and deterioration. Material shall be stored in a dry area and shall not be placed in direct contact with the ground. Materials shall not be placed on the structure in a manner that might cause distortion or damage to the members or the supporting structures. The Contractor shall repair or replace damaged materials or structures as directed. 3.04 ERECTION A. All temporary bracing, guys and bolts as may be necessary to ensure the safety of the structure until the permanent connections have been made shall be provided by the Contractor. B. Structural members shall be set accurately to the lines and elevations indicated. The various members shall be aligned and adjusted to form a part of a complete frame or structure before being permanently fastened. C. No cutting of structural aluminum members in the field will be allowed except by the written approval of the Engineer. D. Bearing surfaces and other surfaces which will be in permanent contact shall be cleaned before assembly. E. Field welding shall not be permitted unless specifically indicated in the Drawings or approved in writing by the Engineer. All field welding shall comply with Section 05050, Metal Fastening. F. All bolted connections shall comply with Section 05050, Metal Fastening. G. All field connections shall be accurately fitted up before being bolted. Drifting shall be only such as will bring the parts into position and shall not be sufficient to enlarge the holes or to distort the metal. All unfair holes shall be drilled or reamed. H. Misfits at Bolted Connections 1. Where misfits in erection bolting are encountered, the Engineer shall be immediately notified. The Contractor shall submit a method to remedy the misfit for review by the Engineer. The Engineer will determine whether the remedy is acceptable or if the member must be refabricated. 2. Incorrectly sized or misaligned holes in members shall not be enlarged by burning or by the use of drift pins. The Contractor shall notify the Engineer immediately and shall submit a proposed method of remedy for review by the Engineer. City of Denton Hazen and Sawyer BID SET 05140-4 Structural Aluminum 3. Where misalignment between anchor bolts and bolt holes in aluminum members are encountered, the Engineer shall be immediately notified. The Contractor shall submit a method to remedy the misalignment for review by the Engineer. I. Grouting of Base Plates and Bearing Plates 1. The bottom surface of the plates shall be cleaned of all foreign materials, and concrete or masonry bearing surface shall be cleaned of all foreign materials and roughened to improve bonding. 2. Accurately set all base and bearing plates to designated levels with steel wedges or leveling plates. 3. Baseplates shall be grouted with non-shrink grout to assure full uniform bearing. Grouting shall be done prior to placing loads on the structure. Non-shrink grout shall conform to Section 03600, Grout. 4. Anchor bolts shall be tightened after the supported members have been positioned and plumbed and the non-shrink grout has attained its specified strength. J. Where finishing is required, assembly shall be completed including bolting and welding of units before start of finishing operations. 3.05 PAINTING A. Painting shall be performed according to Section 09900, Painting. B. Aluminum surfaces in contact with concrete or dissimilar metals shall be thoroughly protected with two coats of epoxy paint with a minimum total thickness of 16 mils or other approved isolating material in accordance with the requirements of Section 09900 - Painting. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 05500-1 Metal Fabrications SECTION 05500 METAL FABRICATIONS PART 1 -- GENERAL 1.01 REQUIREMENT A. Furnish all materials, labor, and equipment required to provide all metal fabrications not specifically included in other Sections, complete and in accordance with the requirements of the Contract Documents. B. Work shall include but may not be limited to guard posts, hoppers, and chutes. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 05010 - Metal Materials B. Section 05050 - Metal Fastening C. Section 05035 - Galvanizing D. Certain specific items are included in other Sections of the Specifications. See the section for the specific item in question. 1.03 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. Without limiting the generality of other requirements of the Specifications, all work specified herein shall conform to the applicable requirements of the following documents. All referenced specifications, codes, and standards refer to the most current issue available at the time of Bid. 1. State of Texas Building Code 2. AISC - Specification for Structural Steel Buildings 3. AISI - Specifications for the Design of Cold-Formed Steel Structural Members 4. Aluminum Association Specifications for Aluminum Structures 1.04 SUBMITTALS A. Submit the following in accordance with Section 01300, Submittals. 1. Complete fabrication and erection drawings of all metalwork specified herein. City of Denton Hazen and Sawyer BID SET 05500-2 Metal Fabrications 2. Other submittals as required in accordance with Section 05010, Metal Materials, and Section 05050, Metal Fastening. PART 2 -- PRODUCTS 2.01 METAL MATERIALS A. Metal materials used in metal fabrications shall conform to Section 05010, Metal Materials, unless noted otherwise. 2.02 METAL FASTENING A. All welds and fasteners used in metal fabrication shall conform to Section 05050, Metal Fastening, unless noted otherwise. 2.03 LINTELS A. Provide lintels as shown on the Drawings and specified herein with 8 inches minimum bearing each side unless noted otherwise. B. All lintels shall be steel in accordance with Section 05120, Structural Steel, and shall be galvanized in accordance with Section 05035, Galvanizing, unless noted otherwise. 2.04 GUARD POSTS (BOLLARDS) A. Guard posts shall be 6-inch diameter Schedule 40 galvanized steel pipe in accordance with ASTM A53. B. Guard posts shall be concrete filled and crowned, as detailed in the Drawings. PART 3 -- EXECUTION 3.01 FABRICATION A. All measurements and dimensions shall be based on field conditions and shall be verified by the Contractor prior to fabrication. Such verification shall include coordination with adjoining work. B. All fabricated work shall be shop fitted together as much as practicable, and delivered to the field, complete and ready for erection. All miscellaneous items such as stiffeners, fillets, connections, brackets, and other details necessary for a complete installation shall be provided. C. All work shall be fabricated and installed in a manner that will provide for expansion and contraction, prevent shearing of bolts, screws, and other fastenings, ensure rigidity, and provide a close fit of sections. City of Denton Hazen and Sawyer BID SET 05500-3 Metal Fabrications D. Finished members shall conform to the lines, angles, and curves shown on the Drawings and shall be free from distortions of any kind. E. All shearings shall be neat and accurate, with parts exposed to view neatly finished. Flame cutting is allowed only when performed utilizing a machine. F. All shop connections shall be welded unless otherwise indicated on the Drawings or specified herein. Bolts and welds shall conform to Section 05050, Metal Fastening. All fastenings shall be concealed where practicable. G. Fabricated items shall be shop painted when specified in Section 09900, Painting. 3.02 INSTALLATION A. Assembly and installation of fabricated system components shall be performed in strict accordance with manufacturer's recommendations. B. All miscellaneous metalwork shall be erected square, plumb and true, accurately fitted, adequately anchored in place, and set at proper elevations and positions C. Metal work shall be field painted when as specified in accordance with Section 09900, Painting. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 05500-4 Metal Fabrications This page left blank intentionally City of Denton Hazen and Sawyer BID SET 05515-1 Ladders SECTION 05515 LADDERS PART 1 -- GENERAL 1.01 REQUIREMENT A. Furnish all materials, labor, and equipment required to provide all ladders in accordance with the requirements of the Contract Documents. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 05010 - Metal Materials B. Section 05050 - Metal Fastening 1.03 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. Without limiting the generality of the Specifications, all work specified herein shall conform to the applicable requirements of the following documents. 1. State of Texas Building Code 2. Aluminum Association Specifications for Aluminum Structures 3. Occupational Safety and Health Administration (OSHA) Regulations 1.04 SUBMITTALS A. Submit the following in accordance with Section 01300, Submittals. 1. Complete fabrication and erection drawings of all metalwork specified herein. 2. Other submittals as required in accordance with Section 05010, Metal Materials, and Section 05050, Metal Fastening. PART 2 -- PRODUCTS 2.01 METAL MATERIALS A. Metal materials used for ladders shall conform to Section 05010, Metal Materials, unless noted otherwise. City of Denton Hazen and Sawyer BID SET 05515-2 Ladders 2.02 METAL FASTENING A. All welds and fasteners used for ladders shall conform to Section 05050, Metal Fastening, unless noted otherwise. 2.03 LADDERS A. Ladders shall be furnished with all mounting brackets, baseplates, fasteners, and necessary appurtenances for a complete and rigid installation. B. All ladders shall be aluminum alloy 6061-T6 or 6063-T5, with a clear, anodized finish, Aluminum Association M12C22A41. C. All ladders shall conform to dimensions indicated on the Drawings and shall comply with OSHA requirements. D. Side rails shall be 1-1/2 inch diameter Schedule 80 pipe, minimum. E. Rungs shall be serrated 3/4 inch diameter, minimum. F. All exposed connections shall be welded and ground smooth. G. Ladders shall be as manufactured by Thompson Fabricating Company, or equal. 2.04 FALL PREVENTION SYSTEM A. Ladders shall be installed with a fall prevention system, unless indicated otherwise on the drawings. For all ladders with an uninterrupted length exceeding 20 ft. between landings or floors, fall prevention system is mandatory. B. Fall prevention system shall comply with OSHA requirements. C. Fall prevention system shall include all necessary components to provide a fully operational system, including one full body safety harness with a 310 lb. weight capacity for each fall prevention system. System shall have a fall locking device, impact attenuator, and rail system. Rail extension with dismounting system, which allows detachment from the system while not standing on the ladder, shall be provided for ladders accessed thru hatch openings. All components shall be stainless steel with a non-metallic cable guide. D. Fall Prevention Systems shall be RTC 2000 Climb-Rite System, Research and Trading Corporation, or Saf-T-Climb Fall Prevention System, Norton by Honeywell. City of Denton Hazen and Sawyer BID SET 05515-3 Ladders PART 3 -- EXECUTION 3.01 FABRICATION A. All measurements and dimensions shall be based on field conditions and shall be verified by the Contractor prior to fabrication. Such verification shall include coordination with adjoining work. B. All fabricated work shall be shop fitted together as much as practicable, and delivered to the field, complete and ready for erection. C. All work shall be fabricated and installed in a manner that will provide for expansion and contraction, prevent shearing of bolts, screws, and other fastenings, ensure rigidity, and provide a close fit of sections. D. Finished members shall conform to the lines, angles, and curves shown on the Drawings and shall be free from distortions of any kind. E. All shearings shall be neat and accurate, with parts exposed to view neatly finished. Flame cutting is allowed only when performed utilizing a machine. F. All shop connections shall be welded unless otherwise indicated on the Drawings or specified herein. Bolts and welds shall conform to Section 05050, Metal Fastening. All fastenings shall be concealed where practicable. G. Fabricated items shall be shop painted when specified in accordance with Section 09900, Painting. 3.02 INSTALLATION A. Assembly and installation of fabricated system components shall be performed in strict accordance with manufacturer's recommendations. B. All miscellaneous metalwork shall be erected square, plumb and true, accurately fitted, adequately anchored in place, and set at proper elevations and positions. C. Metalwork shall be field painted when specified in accordance with Section 09900, Painting. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 05515-4 Ladders This page left blank intentionally City of Denton Hazen and Sawyer BID SETS 05520-1 Handrails and Railings SECTION 05520 HANDRAILS AND RAILINGS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Furnish all materials, labor, and equipment required to provide all handrails and railings in accordance with the Contract Documents. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 05010 - Metal Materials B. Section 05050 - Metal Fastening 1.03 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Without limiting the generality of the other requirements of the specifications, all work herein shall conform to the applicable requirements of the following documents. All referenced specifications, codes, and standards refer to the most current issue available at the time of Bid. 1. State of Texas Building Code 2. Aluminum Association Specifications for Aluminum Structures 3. Occupational Safety and Health Administration (OSHA) Regulations 1.04 SUBMITTALS A. Submit the following in accordance with Section 01300, Submittals. 1. Complete fabrication and erection drawings of all metal work specified herein. 2. Other submittals as required in accordance with Section 05010, Metal Materials and Section 05050, Metal Fastening. PART 2 -- PRODUCTS 2.01 METAL MATERIALS A. Metal materials used for handrails and railings shall conform to Section 05010, Metal Materials, unless noted otherwise. City of Denton Hazen and Sawyer BID SETS 05520-2 Handrails and Railings 2.02 METAL FASTENING A. All welds and fasteners used in handrails and railings shall conform to Section 05050, Metal Fastening, unless noted otherwise. 2.03 HANDRAILS AND RAILINGS A. General - Handrail systems shall consist of all railings, posts, toeboards, baseplates, anchors, and accessories required for a complete and rigid installation. 1. All handrail systems shall be fabricated from extruded aluminum alloy 6061-T6 or 6105-T5, with Aluminum Association M12C22A41 finish, unless otherwise noted. 2. Metal railings shall be fabricated from 1-1/2 inch Schedule 40 pipe. Metal railing support posts shall be fabricated from 1-1/2 inch Schedule 80 pipe. 3. The centerline of the top guard rail shall be 42 inches above the walking surface for level rail. For stair rail, the centerline of the top guard rail shall be 42 inches above the leading edge of the tread nosing. Stair handrail shall be 34 inches above the leading edge of the tread nosing. See Standard Detail 0552000. 4. Posts a. Maximum horizontal spacing between posts for level rail shall be six feet. b. Maximum horizontal spacing between posts for stair rail shall be five feet. 5. All rail joints shall be finished flush and shall occur only at supports. Posts shall not interrupt the continuation of the top rail at any point along the railing, including corners and end terminations. The top surface of the top railing shall be smooth and shall not be interrupted by projecting fittings. 6. Toeboards a. Toeboards shall project 4-inches above the walking surface and shall not infringe on the minimum required walkway width. b. Aluminum toeboards shall be extruded from aluminum alloy 6063-T6 unless otherwise noted. c. Toeboards shall have a minimum thickness of 1/8" at any point. Geometry of toeboard shall closely resemble geometry shown on Drawings. 7. Expansion joint splices shall be provided at 30 foot maximum spacing and at all expansion joints in the structure supporting the handrail. 8. The handrail system shall be designed to resist the design loads specified by both OSHA and the International Building Code - 2000. City of Denton Hazen and Sawyer BID SETS 05520-3 Handrails and Railings 9. Provide handrail extensions at top and bottom of stairs and ramps in accordance with the International Building Code - 2000. B. For metal handrail, the Contractor shall have the option of providing a handrail system of either an all welded type construction or a component type construction. 1. With both the all welded or component type construction, the baseplates and toeboards shall be furnished as shown on the Drawings. 2. Component Type System a. All fittings and brackets shall be designed for stainless steel concealed set screws with internal tyne type connectors. b. Exposed fittings shall be cast or extruded aluminum, or stainless steel to match ladder material, except where corrosion-resistant steel is employed as a standard fabricator's item for use. c. Component type handrail shall be as manufactured by Thompson Fabricating Company, Inc., or Hollaender Manufacturing Company, Inc. 3. Welded handrail may be field assembled using component type fittings as described herein. C. Handrail shall be either Type I or Type II handrail as shown on the Drawings. If no type is indicated on Drawings, handrail shall be Type I. 1. Type I handrail shall be a two-rail system. The centerline of the intermediate rail shall be 21 inches above the walking surface. 2. Type II handrail shall be a three-rail system with vertical posts spanning between the two intermediate rails. a. The centerline of the lower intermediate rail shall be 7 inches above the walking surface. b. The centerline of the upper intermediate rail shall be 5-3/4" below the centerline of the top rail. c. Vertical posts spanning between the intermediate rails shall be 1/2" diameter schedule 40 pipe or fiberglass rod. d. Spacing of vertical posts shall be as required to prevent passage of a 4-inch sphere at any point. D. Where gates are required in handrails as shown on the Drawings, they shall be self-closing and shall be provided by the same manufacturer as the handrail. Gates shall swing away from the opening being protected by the handrail. City of Denton Hazen and Sawyer BID SETS 05520-4 Handrails and Railings E. Where safety chains are required in handrails as shown on the Drawings, chains shall be constructed of Type 304 stainless steel. Chains shall be straight link style, 3/16-inch diameter, with at least twelve links per foot, and with snap hooks on each end. Snap hooks shall be boat type and eye bolts for attachment of chains shall be 3/8-inch bolts with 3/4-inch eye diameter welded to the railing posts. Two (2) chains, four inches longer than the anchorage spacing shall be supplied for each guarded area. 2.04 FREE STANDING RAILING SYSTEM A. Free standing railing system shall be installed on roof ledges where accessible equipment is provided on roof and roof does not have a perimeter parapet wall of a minimum height of 42 inches. Free standing railing system shall be Safety Rail 2000 Guardrail System by BlueWater Mfg., Inc. or approved equal. B. Toe Board brackets shall be used when the parapet wall is less than 3-1/2” in height. C. Performance Characteristics: Shall meet and exceed OSHA (Standards - 29 CFR) 1926.502 (b). 1. Railing System shall be designed to withstand a minimum 200 pounds of test load in any direction. 2. Railing System shall consist of a top rail and rail at mid height between top rail and walking surface. 3. Railing system shall extend to a height of at least 42" from the finished roof deck. 4. Railing system shall be free of sharp edges and snag points. D. Railing and Base 1. Rail shall be 1 5/8” O.D. Hot Rolled Pickled Electric Weld Tubing 2. Each support post shall have a free standing base cast from Class 30 Gray Iron material. 3. Each base shall have four (4) receiver posts for accepting the rails. 4. The receiver posts shall have a positive locking system. A friction locking system will not be acceptable. 5. The receiver posts shall have a slot to enable the rails to be mounted in any direction. E. Hardware 1. The securing pins shall be made from 1010 carbon steel. The pins shall be zinc plated and yellow chromate dipped. The pins shall consist of a collared pin and a lanyard that connects to a lynch pin. City of Denton Hazen and Sawyer BID SETS 05520-5 Handrails and Railings 2. For Gate Assemblies Only. Bolts and washers shall be 3/8" x 3 ½" and 3/8" x 3" grade 5, zinc plated. 3. Finish: Rails: Specify factory finish Safety Yellow Powder Coat Paint, Hot Dipped Galvanized or a color to match the building. Bases: Specify factory finish Safety Yellow Powder Coat Paint, Hot Dipped Galvanized or a color to match the building. PART 3 -- EXECUTION 3.01 FABRICATION A. All measurements and dimensions shall be based on field conditions and shall be verified by the Contractor prior to fabrication. Such verification shall include coordination with all adjoining work. B. All fabricated work shall be shop fitted together as much as practicable, and delivered to the field, complete and ready for erection. C. All work shall be fabricated and installed in a manner that will provide for expansion and contraction, prevent shearing of bolts, screws, and other fastenings, ensure rigidity, and provide a close fit of sections. D. Finished members shall conform to the lines, angles, and curves shown on the drawings and shall be free from distortions of any kind. E. All shearings shall be neat and accurate, with parts exposed to view neatly finished. Flame cutting is allowed only when performed utilizing a machine. F. Concrete anchors and bolts for attachment of handrail baseplates to supporting members shall conform to Section 05050, Metal Fastening. G. All fabricated items shall be shop painted in accordance with Section 09900, Painting. 3.02 INSTALLATION A. Assembly and installation of handrails and railings shall be performed in strict accordance with manufacturer's recommendations. B. All handrails and railings shall be erected square, plumb and true, accurately fitted, adequately anchored in place, and set at proper elevations and positions. - END OF SECTION – City of Denton Hazen and Sawyer BID SETS 05520-6 Handrails and Railings This page left blank intentionally City of Denton Hazen and Sawyer BID SET 05531-1 Gratings, Access Hatches, and Access Doors SECTION 05531 GRATINGS, ACCESS HATCHES, AND ACCESS DOORS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Furnish all materials, labor, and equipment required to provide all gratings, floor plates, and hatches in accordance with the Contract Documents. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 05010 - Metal Materials B. Section 05035 - Galvanizing C. Section 05050 - Metal Fastening 1.03 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. Without limiting the generality of the other requirements of the specifications, all work herein shall conform to the applicable requirements of the following documents. All referenced specifications, codes, and standards refer to the most current issue available at the time of Bid. 1. State of Texas Building Code 2. Aluminum Association Specifications for Aluminum Structures 3. Occupational Safety and Health Administration (OSHA) Regulations 1.04 SUBMITTALS A. Submit the following in accordance with Section 01300, Submittals. 1. Complete fabrication and erection Drawings of all gratings, access hatches, and access doors specified herein. 2. Other submittals as required in accordance with Section 05010, Metal Materials, and Section 05050, Metal Fastening. City of Denton Hazen and Sawyer BID SET 05531-2 Gratings, Access Hatches, and Access Doors PART 2 -- PRODUCTS 2.01 METAL MATERIALS A. Metal materials used for gratings, floor plates, and hatches shall conform to Section 05010, Metal Materials, unless noted otherwise. 2.02 METAL FASTENING A. All welds and fasteners used for gratings, floor plates, and hatches shall conform to Section 05050, Metal Fastening, unless noted otherwise. 2.03 GRATING A. General - Grating, including support frames, fastenings, and all necessary appurtenances for a complete installation, shall be furnished as indicated on the Drawings. 1. All exposed bearing ends of grating shall be enclosed in a perimeter band of the same dimensions and material as the main bars, including ends at all cutouts. 2. Grating shall be fabricated into easily removable sections and shall be fastened at each corner and as required with fasteners provided by the grating manufacturer. No fasteners shall be permitted to project above the walking surface. 3. Grating shall be designed for a loading of 150 psf unless otherwise required by the Drawings. Grating deflection shall not exceed 1/4 inch under a uniform load of 100 psf. Minimum grating depth shall be 1-1/2 inches, unless structural requirements based on clear span require more depth. 4. Grating installed in cast-in-place concrete shall be provided with embedded support frames on all perimeter and bearing edges. Support frames shall include anchor straps or headed studs at a maximum of 18” on-center, a minimum of two each side. Support frames shall be fabricated from the same material as the grating. B. Aluminum Grating 1. Aluminum grating shall be of I-bar type and shall consist of extruded bearing bars positioned and locked by crossbars. All supports, cross members, etc. shall be aluminum. Plank clips for grating holddowns or other required attachments, shall be aluminum or stainless steel. Bolts shall be stainless steel. Provide embedded aluminum support frames for cast-in-place concrete installations. 2. Grating shall be “19-SI-4 I-Bar Swage Locked” by Alabama Metal Industries Corporation (AMICO), “IB” by Harsco Industrial IKG, “I-Bar 19SGI4", by Ohio Grating Inc., or “I-Bar” by Thompson Fabricating LLC. City of Denton Hazen and Sawyer BID SET 05531-3 Gratings, Access Hatches, and Access Doors C. Aluminum Plank Grating 1. Aluminum plank grating shall be unpunched planks of extruded aluminum welded together to form panels. Panel ends shall have an extruded aluminum end bar welded in place. All support members shall be aluminum. Plank clips for grating holddowns or other required attachments, shall be aluminum or stainless steel. Bolts shall be stainless steel. Provide embedded aluminum support frames for cast-in- place concrete installations. 2. Aluminum plank grating shall be HD-P manufactured by Harsco Industrial IKG., Heavy Duty Series manufactured by Ohio Gratings, Inc., or Unpunched Duo-Grip Extruded Series manufactured by Alabama Metal Industries Corporation (AMICO). D. Heavy Duty Steel Grating 1. Heavy duty steel grating shall be galvanized according to Section 05035, Galvanizing. 2. Main bearing bars shall conform to ASTM A36. Cross bars shall be flush with the top of the grating. Provide embedded galvanized steel support frames for cast-in-place concrete installations. 3. Grating span shall be 36 inches maximum and shall satisfy AASHTO loading for H- 20 truck. 4. Grating shall be manufactured by Harsco Industrial IKG, Alabama Metal Industries Corporation (AMICO), and Ohio Gratings, Inc. 2.04 ACCESS HATCHES A. Access hatches shall be aluminum unless noted otherwise. B. All access hatches shall be checker plate with an approved raised pattern, non-skid surface. C. Access hatches shall be designed to carry a minimum live load of 150 psf, or a concentrated load of 300 pounds at the center, whichever produces the greatest stress. D. Access hatches shall not exceed an allowable fiber stress of 16,000 psi. Live load deflection shall be limited to L/240 of the span, but not more than 1/4-inch. E. All access hatches shall be fabricated from 1/4" plate, minimum and shall be stiffened as required to maintain allowable stress and deflection requirements specified herein. Stiffeners shall consist of angles or bars welded to the bottom of the plate. F. Hinges, where indicated on the Drawings, shall be insulated, heavy-duty, cadmium plated bronze with stainless steel pins and fasteners. City of Denton Hazen and Sawyer BID SET 05531-4 Gratings, Access Hatches, and Access Doors G. All access hatches as indicated on the Drawings shall be provided with recessed handles. Handle material shall be as shown on the Contract Drawings. H. Air-tight and water-tight access hatches shall be provided with a 1/8 inch thick neoprene gasket between the checkered plate and the support frame. Gasket material shall be bonded to the support frame and access hatches shall be bolted to the structural support frame with countersunk stainless steel flathead screws. 2.05 ACCESS DOORS A. General 1. Door opening sizes, number and direction of swing of door leaves, and locations shall be as shown on the Drawings. The Drawings shall indicate the clear opening dimensions. 2. All doors shall be aluminum unless otherwise noted. 3. Openings larger than 42 inches in either direction shall have double leaf doors. 4. Doors shall be designed for flush mounting and for easy opening from both inside and outside. 5. All doors shall be provided with an automatic hold-open arm with release handle. 6. Double leaf doors shall be provided with safety bars to go across the open sides of the door, when in the open position. Brackets shall be provided on the underside of the doors to hold the safety bars when not in use. 7. All hardware, including but not limited to, all parts of the latch and lifting mechanism assemblies, hold open arms and guides, brackets, hinges, springs, pins, and fasteners shall be stainless steel. 8. All doors shall be watertight with a continuous gasket. All single door applications shall include a continuous EPDM odor reduction gasket. 9. Door frames shall be extruded and equipped with a 1-1/2 inch minimum drain pipe located by the manufacturer. The drain pipe shall be provided by the Contractor and shall extend to the nearest point of discharge acceptable to the Engineer. B. Floor, Wet Well and Dry Pit Access Doors 1. Door leaves shall be 1/4 inch, minimum, diamond pattern plate with an approved raised pattern, non-skid surface. Plate shall be stiffened as required to maintain allowable stress and deflection requirements. Stiffeners shall consist of angles or bars welded to the bottom of plate. 2. Doors shall be designed for a 300 psf live load minimum, unless noted otherwise. City of Denton Hazen and Sawyer BID SET 05531-5 Gratings, Access Hatches, and Access Doors 3. Doors shall be designed for flush mounting and for easy opening from both inside and outside. 4. All doors shall have an enclosed compression spring assist and open to 90 degrees. 5. Exterior doors shall be Type "J-AL" or "JD-AL", by Bilco Company, Type ”W1S” or “W2S” by Halliday Products Inc., Type "TPS" or "TPD", by U.S.F. Fabrication Inc., Type "THG" or "THG-D", by Thompson Fabricating LLC. 6. Curb style exterior doors shall be Type “F1R” by Halliday Products Inc. and designed for a 625 psf live load minimum. 7. Doors rated for H-20 traffic loading shall be “JAL-HD” or “JDAL-HD” by the Bilco Company, Type “H1C” or “H2C” by Halliday Products, Inc., or Type “THS” or “THD” by U.S.F. Fabrication Inc. C. Roof Access Doors 1. Doors shall be designed for 50 psf live load unless noted otherwise. 2. Doors for service stairs shall be Bilco Type L roof Scuttles. 3. Doors for ladder access shall be Bilco Type S or SS Roof Scuttles. D. Fixed Ladders 1. Where the Contract Documents indicate fixed ladders are required under access doors, they shall be provided with “LadderUp, Model LU-4” by Bilco Company, “L1E Ladder Extension” by Halliday Products Inc., or “Ladder Climb-out Device” by Thompson Fabricating. 2. The safety posts shall be manufactured of the same material as the access door with telescoping tubular sections that lock automatically when fully extended. 3. Upward and downward movement shall be controlled by a stainless steel balancing mechanism. 4. Safety posts shall be assembled in strict accordance with manufacturer's recommendations. 2.06 FALL THROUGH PREVENTION SYSTEM A. All access hatches and access doors covering openings measuring 12 inches or more in its least dimension through which persons may fall shall be equipped with a fall through prevention system, except where noted on the Contract Drawings. Access hatches and access doors shall be provided with a permanent installed fall through prevention grate system that provides continuous safety assurance in both its closed and open positions. City of Denton Hazen and Sawyer BID SET 05531-6 Gratings, Access Hatches, and Access Doors The grate system shall be made with 6061-T6 aluminum or FRP and be designed for a 300 psf minimum liveload, unless noted otherwise. PART 3 -- EXECUTION 3.01 FABRICATION A. All measurements and dimensions shall be based on field conditions and shall be verified by the Contractor prior to fabrication. Such verification shall include coordination with adjoining work. B. All fabricated work shall be shop fitted together as much as practicable, and delivered to the field, complete and ready for erection. All miscellaneous items such as stiffeners, fillets, connections, brackets, and other details necessary for a complete installation shall be provided. C. All work shall be fabricated and installed in a manner that will provide for expansion and contraction, prevent shearing of bolts, screws, and other fastenings, ensure rigidity, and provide a close fit of sections. D. Finished members shall conform to the lines, angles, and curves shown on the Drawings and shall be free from distortions of any kind. E. All shearings shall be neat and accurate, with parts exposed to view neatly finished. Flame cutting is allowed only when performed utilizing a machine. F. All shop connections shall be welded unless otherwise indicated on the Drawings or specified herein. Bolts and welds shall conform to Section 05050, Metal Fastening. All fastenings shall be concealed where practicable. 3.02 INSTALLATION A. Assembly and installation of fabricated system components shall be performed in strict accordance with manufacturer's recommendations. B. All gratings, access hatches, and access doors shall be erected square, plumb and true, accurately fitted, adequately anchored in place, and set at proper elevations and positions. Embedded support frames shall be set level and square. C. Grating shall not be field cut or modified unless approved by Engineer. D. Grating shall not be used for equipment support or anchorage. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 05540-1 Castings SECTION 05540 CASTINGS PART 1 -- GENERAL 1.01 REQUIREMENT A. Furnish all materials, labor, and equipment required to provide all castings in accordance with the requirements of the Contract Documents. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 02604 – Utility Structures B. Section 05010 - Metal Materials 1.03 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. Without limiting the generality of the other requirements of the specifications, all work herein shall conform to the applicable requirements of the following documents. All referenced specifications, codes, and standards refer to the most current issue available at the time of Bid. 1. State of Texas Building Code 1.04 SUBMITTALS A. Submit the following in accordance with Section 01300, Submittals. 1. Complete fabrication and erection drawings of all castings specified herein. 2. Other submittals as required in accordance with Section 05010, Metal Materials, and Section 05050, Metal Fastening. PART 2 -- PRODUCTS 2.01 METAL MATERIALS A. Metal materials used for castings shall conform to Section 05010, Metal Materials, unless noted otherwise. 2.02 METAL FASTENING A. All welds and fasteners used for castings shall conform to Section 05050, Metal Fastening, unless noted otherwise. City of Denton Hazen and Sawyer BID SET 05540-2 Castings 2.03 IRON CASTINGS A. General - Iron Castings shall include, but not be limited to frames, covers, and grates for trench drains, catch basins, and inlets/. 1. Castings shall be of gray iron of uniform quality, free from defects, smooth and well cleaned by shotblasting. 2. Catalog numbers on the Drawings are provided only to show required types and configuration. All covers shall be cast with raised letters as designated on the Drawings. 3. Castings shall be as manufactured by Dewey Brothers, or Neenah Foundry Company. B. Covers and Grates 1. Covers and grates shall be provided with matching frames. Cover shall fit flush with the surrounding finished surface. The cover shall not rock or rattle when loading is applied. 2. Round covers and frames shall have machined bearing surfaces. 3. Design loadings: a. Where located within a structure, a minimum design loading of 300 psf shall be used, unless noted otherwise. b. At all locations not within a structure, the design loading shall be a standard AASHTO H-20 truck loading, unless otherwise noted. C. Watertight gasketing, bolting, locking devices, patterns, lettering, pickholes, vents, or self- sealing features shall be as detailed on the Drawings. PART 3 -- EXECUTION 3.01 FABRICATION A. All measurements and dimensions shall be based on field conditions and shall be verified by the Contractor prior to fabrication. Such verification shall include coordination with adjoining work. B. All fabricated work shall be shop fitted together as much as practicable, and delivered to the field, complete and ready for erection. All miscellaneous items such as stiffeners, fillets, connections, brackets, and other details necessary for a complete installation shall be provided. City of Denton Hazen and Sawyer BID SET 05540-3 Castings C. Finished members shall conform to the lines, angles, and curves shown on the Drawings and shall be free from distortions of any kind. 3.02 INSTALLATION A. Assembly and installation of fabricated system components shall be performed in strict accordance with manufacturer's recommendations. B. All castings shall be erected square, plumb and true, accurately fitted, adequately anchored in place, and set at proper elevations and positions. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 05540-4 Castings This page left blank intentionally City of Denton Hazen and Sawyer BID SET 05830-1 Bearing Devices and Anchoring SECTION 05830 BEARING DEVICES AND ANCHORING PART 1 -- GENERAL 1.01 THE REQUIREMENTS A. The Contractor shall furnish and install bearing plates, pads, expansion devices, anchor rods and bolts and/or other devices used in conjunction with bearings and anchoring of bearing devices and assemblies at supports in accordance with this item and in conformity with the Drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 05010 - Metal Materials B. Section 05035 - Galvanizing C. Section 05050 - Metal Fastening D. Section 05120 - Structural Steel E. Section 05140 - Structural Aluminum F. Section 09900 - Painting 1.03 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Without limiting the generality of other requirements of these Specifications, all work specified hereunder shall conform to the applicable requirements of the following documents to the extent that the provisions of such documents are not in conflict with the requirements of this Section. 1. RMA Rubber A4-F3-T.063-B2, Grade 2, Method B Handbook 2. ASTM A240, Standard Specification for Heat Resisting Chromium and Chromium - Nickel Stainless Steel Plate and Sheet 3. ASTM A480 Standard Specification for General Requirements for Flat-Rolled Stainless and Heat-Resisting Steel Plate, Sheet and Strip 4. ASTM D395, Standard Test for Rubber Property – Compression Set Method B City of Denton Hazen and Sawyer BID SET 05830-2 Bearing Devices and Anchoring 5. ASTM D412 Standard Test for Rubber Properties In Tension 6. ASTM D471 Standard Test for Rubber Property - Effect of Liquids 7. ASTM D573 Standard Test for Rubber-Deterioration In Air Oven 8. ASTM D575, Standard Test for Rubber Properties In Compression Method A 9. ASTM D624, Die C Standard Test for Rubber Property - Tear Resistance 10. ASTM D746 Standard Test for Brittleness Temperature of Plastics and Elastomers by Impact 11. ASTM D792 Standard Test for Specific Gravity and Density of Plastics by Displacement 12. ASTM D1149 Standard Test for Rubber Deterioration - Surface Ozone Cracking In a Chamber (Flat Specimens) 13. ASTM D1785 Standard Specification for Poly (Vinyl Chloride) (PVC) Plastic Pipe, Schedule 40 14. ASTM D2240 Standard Test for Rubber Property - Durometer Hardness 15. ASTM D2256 Standard Test for Breaking Load (Strength) and Elongation of Yarn by the Single-Strand Method 16. ASTM D4894 Standard Specification for PTFE Granular Molding and RPM Extension Materials 17. ASTM D4895 Standard Specification for PTFE Resin Produced From Dispersion 1.04 SUBMITTALS A. Submit the following in accordance with the requirements of Section 01300, Submittals: 1. Certification of compliance that the materials furnished under this section meet and conform to the property and physical requirements, including all testing, as stated herein and as referenced. Specifically, the certification shall state compliance with the applicable standards (ASTM, ANSI, etc.) for fabrication and testing. 2. Shop Drawings for all materials, including installation and adjustment instructions. Included with the Shop Drawings shall be all material certifications, mill test results, working drawings, etc., which are required by this and other applicable sections of the Specifications. City of Denton Hazen and Sawyer BID SET 05830-3 Bearing Devices and Anchoring PART 2 -- PRODUCTS 2.01 ELASTOMERIC BEARING PADS A. The elastomer portion of pads shall be new neoprene compound. Pads shall be cast under heat and pressure and may be individually molded or cut from pressure-cast stock. Variations from the dimensions shown on the Drawings shall not be more than the following: thickness, ±1/16 inch; width, -1/8 to +1/4 inch; length, -1/8 to +1/4 inch. Tolerances, dimensions, finish and appearance, flash, and rubber-to-metal bonding shall conform to the requirements of A 4-F3-T.063-B2, Grade 2, Method B, in accordance with the RMA Rubber Handbook. Pads shall be furnished in one piece and shall not be laminated unless otherwise specified. Pads shall be furnished in identifiable packages. B. Adhesive for use with elastomer pads shall be an epoxy-resin compound compatible with the elastomer having a sufficient shear strength to prevent slippage between pads and adjacent bearing surfaces. Adhesive shall be 20+F Contact Cement by Miracle Adhesives Corporation, Neoprene Adhesive 77-198 by IGI Adhesives, Sikodur 31, Hi-Mod Gel by Sika Corporation, or DP-605 NS Urethane Adhesive by 3M Adhesive Systems. C. Laminated pads shall consist of alternate laminations of elastomer and hot-rolled steel sheets molded together as a unit. Outer metal laminations shall be 3/16 inch, and inner laminations shall be 14 gage. Outer laminations of elastomer shall be 1/4 inch, and inner laminations shall be of equal thickness (at least 3/8 but not more than 1/2 inch), depending on the number of laminations and thickness of the pad. Edges of metal laminations shall have a cover of approximately 1/8 inch of elastomer. The top and bottom bearing surfaces shall each have an integral sealing rib approximately 1/8 inch in depth, in addition to the specified total thickness, and 3/16 inch in width around their peripheries. The bond between the elastomer and metal shall be such that failure shall occur in the elastomer and not between the elastomer and steel when tested for separation. Variations from specified dimensions for individual laminations shall not be more than those specified herein. The total thickness of the complete pad shall not vary more than ±1/8 inch. D. Material having a nominal durometer hardness of 70 and 50 shall be used for nonlaminated pads and laminated pads, respectively. Test samples will be prepared from finished pads. Samples of each thickness will be taken from 2 full-size pads from each shipment of 300 pads or less, with 1 additional pad for each additional increment of 300 pads or fraction thereof. When tested using the ASTM methods designated, samples shall comply with the following physical requirements. 1. Original Physical Properties: Test results for tear resistance, tensile strength, and ultimate elongation shall not be more than 10 percent below the following specified value: City of Denton Hazen and Sawyer BID SET 05830-4 Bearing Devices and Anchoring Nominal 50 Hardness 70 Min. tear resistance, ASTM D624, Die C (lb/in of thickness) 180 200 Hardness, ASTM D2240 (points) 50±5 70±5 Min. tensile strength, ASTM D412 (average psi of longitudinal and transverse) 2,500 2,500 Min. ultimate elongation (%) 400 300 The compressive deflection tested in accordance with ASTM D575, Method A, shall be as follows: a. Laminated Pads: The maximum compression deflection shall be 5 and 7 percent of the total rubber thickness at loads of 500 and 800 pounds per square inch, respectively. The maximum shear resistance shall be 50 pounds per square inch of the plan area at 25 percent shear deformation at – 20°F. Test pads shall be subjected to a compressive load of 1.5 times the maximum design load without visible damage to the bearing. b. Nonlaminated Pads: When loaded within 300 to 800 pounds per square inch, material shall show a compressive deflection within 20 percent of that given in the charts of Method A, interpolating for actual measured hardness. 2. Changes in Original Physical Properties: When pads are oven aged 70 hours at 212°F in accordance with ASTM D573, changes shall not be more than the following: Property Value Hardness (points change) 0 to +15 Tensile strength (% change) ±15 Ultimate elongation (% change) -40 3. Extreme Temperature Characteristics: Compression set under constant deflection, ASTM D395, Method B, 22 hours at 212°F, shall not be more than 35 percent. With the low-temperature brittleness test, ASTM D746, breaks shall not occur above –20°F. 4. Ozone Cracking Resistance: Upon exposure to 100 parts per million of ozone in air by volume at a strain of 20 percent and a temperature of 100±2°F in a test otherwise in accordance with ASTM D1149, cracks shall not develop within 100 hours. Samples shall be wiped with solvent before the test to remove traces of surface impurities. 5. Oil Swell: The volume change shall not be more than +120 percent when tested in accordance with ASTM D471 with ASTM Oil No. 3, 70 hours at 212°F. City of Denton Hazen and Sawyer BID SET 05830-5 Bearing Devices and Anchoring 2.02 TFE BEARING SURFACES A. TFE resin shall be virgin material conforming to the requirements of ASTM D4894 or D4895. The specific gravity shall be 2.13 to 2.19. The melting point shall be 623±2°F. B. Filler material shall be milled glass fibers, carbon, or other approved inert filler materials. C. Adhesive material shall be an epoxy resin conforming to FS MMM-A-134, FEB film or equal, as approved by the Engineer. D. When tested in accordance with ASTM D4894 or D4895, finished unfilled TFE sheets shall have a tensile strength of at least 2,800 pounds per square inch and an elongation of at least 200 percent. E. Filled TFE sheets shall contain inert filler material uniformly blended with TFE resin. Finished filled TFE sheets containing glass fiber or carbon shall conform to the following: ASTM Method 15% Glass Fibers 25% Carbon Min. tensile strength D4894/D4895 2,000 psi 1,300 psi Min. elongation D4894/D4895 150% 75% Min. specific gravity D792 2.20 2.10 Melting point D4894/D4895 327±10°C 317 ±10°C F. Fabric containing TFE fibers shall be manufactured from oriented multifilament TFE fluorocarbon fibers and other fibers as required by specific designs. When tested in accordance with ASTM D2256, the tensile strength of TFE fibers shall be at least 24,000 pounds per square inch and the elongation shall be at least 75 percent. G. Where TFE sheets are to be epoxy bonded, one surface of the sheet shall be factory treated by an approved manufacturer using the sodium naphthalene or sodium ammonia process. H. Stainless steel mating surfaces shall be at least 16 gage in thickness and shall conform to the requirements of ASTM A240, Type 304. The mating surface shall be a true plane surface with a Brinnell hardness of at least 125 and a surface finish of an at least No. 8 mirror finish in accordance with ASTM A480. Stainless steel mating surfaces shall be polished or rolled as necessary to conform to the friction requirements specified herein. The stainless steel shall be attached to the sole plate by means of a seal weld around the entire perimeter of the facing material. I. The coefficient of friction for the completed bearing assembly shall not be more than the following: City of Denton Hazen and Sawyer BID SET 05830-6 Bearing Devices and Anchoring Material Bearing Pressure 500 psi (3.447 MPa) 2,000 psi (13.790 Mpa) 3,500 psi (24.132 MPa) Unfilled TFE, fabric Containing TFE fibers, TFE perforated metal composite .08 .06 .04 Filled TFE .12 .10 .08 Interlocked bronze and filled TFE structures .10 .07 .05 2.03 ANCHOR RODS A. Anchor bolts shall be as specified in Section 05050, Metal Fastening. 2.04 PIPE SLEEVES AND COLLARS A. Pipe sleeves and collars shall be cut from schedule 40 PVC plastic pipe meeting the requirements of ASTM D1785 unless otherwise noted on the Drawings. PART 3 -- EXECUTION 3.01 STEEL PLATES, SHAPES, AND BARS A. Unless galvanizing is indicated on the Drawings, items shall be painted in accordance with the Drawings and Section 09900, Painting. B. If galvanizing is indicated on the Drawings, steel bearing assemblies for both structural steel beams and girders and prestressed concrete members shall be galvanized as specified in Section 05035, Galvanizing. Except for attachments of bearing plates to beams, all fabrication and welding of bearing plate assemblies shall be performed before the steel is galvanized. All joints of welded parts shall be sealed with weld material. Welds made for attaching bearing plates to beams or girders shall be cleaned and given 2 coats of zinc rich paint having a minimum total coating thickness of 3 mils. 3.02 ELASTOMERIC PADS A. Care shall be taken in fabricating pads and related metal parts so that effects detrimental to their proper performance, such as uneven bearing and excessive bulging, will not occur. 3.03 PLACEMENT OF BEARING PLATES AND PADS A. Bearing areas shall be finished to a true level plane which shall not vary perceptibly from a straightedge placed in any direction across the area. B. Bearing plates or pads shall be set level in exact position and shall have a uniform bearing over the entire area. Provision shall be made to keep plates or pads in the correct position during erection of beams or placement of concrete. City of Denton Hazen and Sawyer BID SET 05830-7 Bearing Devices and Anchoring C. Elastomeric pads and other flexible bearing materials shall be placed directly on masonry surfaces finished to a roughness equivalent to that of a No. 36 to No. 46 grit. Pads, bearing areas, or bridge seats and metal bearing plates shall be thoroughly cleaned and free from oil, grease, and other foreign materials. Metal bearing plates or bottoms of prefabricated beams that are to bear on elastomeric pads shall be coated with epoxy and then surfaced with a No. 36 to No. 46 silicon carbide or aluminum oxide grit. Bearing areas shall be finished to equivalent roughness. D. Metal bearing plates shall be bedded on seats as follows: 1. The seat bearing areas shall be thoroughly swabbed with approved paint, and three layers of duck, 12 to 15 ounce per square yard, shall be placed on it, each layer being thoroughly swabbed with paint on its top surface. 2. Superstructure shoes or pedestals shall be placed in position while paint is plastic. As an alternate to duct and paint, preformed fabric bedding material at least 1/8 inch in thickness may be used when called for on the Drawings or approved in writing by the Engineer. 3.04 PLACEMENT OF ANCHOR RODS A. All necessary anchor rods and bolts (anchors) shall be accurately set either in the concrete as they are being placed, in formed holes, or in holes cored after the concrete has set. If set in the concrete, the rods and bolts shall be accurately positioned by means of templates and rigidly held in position while the concrete is being placed. Holes may be formed by inserting or casting in the fresh concrete oiled wooden plugs, metal pipe or plastic sleeves, or other approved devices, and withdrawing them after the concrete has partially set or left in place as indicated on the Drawing’s or approved by the Engineer. Holes so formed shall be at least 3 inches in diameter or at least 2.5 times the diameter of the rod or bolt. If cored, holes shall be at least 2.5 times the diameter of the anchor used or as indicated on the Drawings. Equipment used for coring concrete shall have been approved by the Engineer. Impact tools will not be permitted. Reinforcing steel shall be placed to provide adequate space to core rod/bolt holes without cutting the reinforcing steel. For cored holes, anchor rods and bolts shall be adequately held in place at the centroid of the hole or as specified on the Drawings by using approved pre-fabricated equalizers designed to allow grout to penetrate and fill the hole completely and spaced as approved by the Engineer. B. During freezing conditions, anchor holes shall be protected from water accumulations at all times. C. Anchors which are to be placed in holes of sufficient and specified diameter after the concrete has set shall be bonded to the concrete with a non-shrink high-strength Portland cement grout in accordance with Section 03600 – Grout or shall be adhesive anchors in accordance with Section 05050 - Metal Fastening. The type anchoring system and grout shall be as indicated on the Drawings. The grout or adhesive shall completely fill the holes. Anchors shall be tested for sufficient pull-out capacity as indicated in applicable sections of the Specifications or as indicated on the Drawings. D. Anchors that are not designed to project through bearing plates shall be checked for proper projection above the masonry bearing area immediately prior to placement of bearing plates City of Denton Hazen and Sawyer BID SET 05830-8 Bearing Devices and Anchoring and beams. Nuts on anchor rods at expansion ends shall be adjusted to permit free movement of the span. E. Angles for anchor assemblies to be attached to sides of concrete beams shall not be installed until beams have received their full dead load and supporting falsework has been removed. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 07900-1 Joint Fillers, Sealants and Caulking SECTION 07900 JOINT FILLERS, SEALANTS AND CAULKING PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Furnish labor, materials, equipment and appliances required for the complete execution of Work shown on the Drawings and specified herein. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 03250 - Concrete Accessories B. Section 03290 - Joints in Concrete C. Section 08800 - Glass and Glazing 1.03 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. Without limiting the generality of the other requirements of the specifications, all work herein shall conform to the applicable requirements of the following documents. All referenced specifications, codes, and standards refer to the most current issue available at the time of Bid. 1. ASTM C-920 Elastomeric Joint Sealants 2. ASTM D-1056 Flexible Cellular Materials - Sponge or Expanded Rubber 3. SWRI Sealant and Caulking Guide Specification 1.04 SUBMITTALS A. In accordance with the procedures and requirements set forth in Section 01300 – Submittals, submit the following: 1. Manufacturers literature and installation instructions. 2. Color samples of each type of sealant. 1.05 QUALITY ASSURANCE A. Applicator shall be a company specializing in the installation of sealants with a minimum of five years experience. City of Denton Hazen and Sawyer BID SET 07900-2 Joint Fillers, Sealants and Caulking 1.06 DELIVERY, STORAGE AND HANDLING A. Deliver materials in unopened labeled packages. B. Store materials in location protected from freezing or damages. C. Reject and remove from the site materials within broken or damaged packaging. PART 2 -- PRODUCTS 2.01 MATERIALS A. Sealants 1. Type 1: Multi-component, non-sag, low-modulus polyurethane rubber sealant meeting ASTM C-920, Type M, Grade NS, Class 25, use NT, M, A, and O. Capable of withstanding 50% in extension or compression such as Sikaflex-2C NS/SL, Sika Corporation, or Sonolastic NP-2, Sonneborn, or DynaTrol II by Pecora Corporation. 2. Type 2: Not Used 3. Type 3: Not Used 4. Type 4: Not Used. 5. Type 5: Not Used 6. Type 6: Not Used. 7. Type 7: Not Used. 8. Type 8: Nonsag, Multi Component, traffic grade polyurethane sealant meeting ASTM C920, Type 19, Grade NS, Class 25, use T, M, A, and O. DynaTread by Pecora Corporation, Sonolastic Ultra by BASF Construction Chemicals. B. Primer: Non-staining primer recommended by sealant manufacturer for the substrates on this project. C. Backer Rod: Closed cell foam, nonreactive with caulking materials, non-oily, and approved by the sealant manufacturer. Minimum density shall be 2.00 pounds per cubic foot. Use no asphalt or bitumen-impregnated fiber with sealants. D. Joint Cleaner: Recommended by sealant or caulking compound manufacturer. E. Bond breaker: Either polyethylene film or plastic tape as recommended by the sealant manufacturer. City of Denton Hazen and Sawyer BID SET 07900-3 Joint Fillers, Sealants and Caulking F. Color: Where manufacturer’s standard colors do not closely match materials being sealed, provide a custom color. PART 3 -- EXECUTION 3.01 QUALITY CONTROL A. Coordinate work with details shown on approved shop drawings prepared by other trades. B. Verify conditions in the field. C. Schedule work to follow closely the installation of other trades. D. Apply sealants and related items in temperatures and dry conditions recommended by the manufacturers. E. Do not paint sealant, unless recommended by sealant and paint manufacturer. 3.02 PREPARATION A. Protect finished surfaces adjoining by using masking tape or other suitable materials. B. Clean and prime joints before starting any caulking or sealing work. C. Thoroughly clean joints and spaces of mortar and other foreign materials. Cleaning agent shall be Xylol or similar non-contaminating solvent to remove any film from metal surfaces. Masonry or concrete surfaces shall be brushed or air jet cleaned. D. Joint Requirements 1. All joints and spaces to be sealed in exterior work shall be less than 1/2 inch deep and not less than 1/4 inch wide. If joints in masonry are less than that specified herein, the mortar shall be cut out to the required width and depth. All joints and spaces to receive sealant shall be completely prepared and thoroughly dry before installation of sealant. 2. Unless otherwise specified, joints and spaces which are open to a depth of 1/2 inch or greater shall be solidly filled with back-up material to within 1/4 inch of the surface. Back-up material shall be packed tightly and made continuous throughout the length of the joints. Bond breaker shall be applied as required. If joints are less than 1/4 inch deep, the back-up material may be omitted, a bond breaker substituted and the joint completely filled with sealant. The back-up material shall not project beyond the 1/4 inch depth of the open space in any joint. The following width-to-depth ratio table shall be adhered to, unless otherwise recommended by manufacturer. City of Denton Hazen and Sawyer BID SET 07900-4 Joint Fillers, Sealants and Caulking Joint Width Sealant Depth Minimum Maximum ¼ inch 1/4 inch 1/4 inch Over 1/4 inch to 1/2 inch 1/4 inch Equal to width Over 1/2 inch to 1 inch 1/2 inch Equal to width Over 1 inch to 2 inch 1/2 inch 1/2 of width 3.03 APPLICATION A. Exercise care before, during, and after installation so as not to damage any material by tearing or puncturing. All finished work shall be approved before covering with any other material or construction. B. Apply sealant by an approved type of gun except where the use of a gun is not practicable, suitable hand tools shall be used. Avoid applying the compound to any surface outside of the joints or spaces to be sealed. Mask areas where required to prevent overlapping of sealant. C. All joints shall be waterproof and weathertight. D. Point sealed joints to make a slightly concave joint, the edges of which are flush with the surrounding surfaces. Exposed joints in the interior side of the door and other frames shall be neatly pointed flush or to match adjacent jointing work. E. Adjacent materials which have been soiled shall be cleaned immediately and the work left in neat and clean condition. F. Comply with sealant manufacturer's written instructions except where more stringent requirements are shown or specified and except where manufacturer's technical representative directs otherwise. 3.04 ADJUSTMENT AND CLEANING A. Remove misplaced sealant compounds promptly using methods and materials recommended by the manufacturer, as the work progresses. B. Allow sealants to cure and remove protective edging, of doors, louvers, saddles windows etc. as directed by the Engineer. City of Denton Hazen and Sawyer BID SET 07900-5 Joint Fillers, Sealants and Caulking 3.05 SCHEDULE Schedule of Sealants Application Sealant Color Vertical and horizontal expansion and construction joints in concrete structures unless noted otherwise herein or on Drawings. Type 1 To closely match adjacent surfaces or mortar and as selected by the Owner. Submerged in liquids. See Note 4. Type 1 Manufacturer's standard Horizontal Joints exposed to vehicular or pedestrian traffic. Type 8 To closely match adjacent surfaces. Other joints indicated on the drawings or customarily sealed but not listed. Type recommended by manufacturer To closely match adjacent surfaces and as selected by the Owner. Note 1. Sealant for Laboratory Countertop shall be as recommended by countertop manufacturer. Note 2. Provide UL approved sealants for penetrations thru fire-rated walls and as specified in Section 07270. Note 3. Sealants which will come in contact with potable water shall meet the requirements of NSF 61. Note 4. Where sealant will be immersed in liquid chemicals verify compatibility prior to installation of sealant. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 07900-6 Joint Fillers, Sealants and Caulking This page left blank intentionally City of Denton Hazen and Sawyer BID SET 09900-1 Painting SECTION 09900 PAINTING PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Furnish labor, materials, equipment and appliances required for complete execution of Work shown on Drawings and Specified herein. B. Section Includes: 1. Paint Materials 2. Shop Painting 3. Field Painting a. Surface Preparation b. Piping and Equipment Identification c. Schedule of Colors d. Work in Confined Spaces e. OSHA Safety Colors 1.02 RELATED SECTIONS A. Section 15030 - Piping and Equipment Identification Systems 1.03 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. Without limiting the generality of these specifications the Work shall conform to the applicable requirements of the following documents: 1. SSPC – The Society for Protective Coatings Standards a. SSPC-Vis 1 Pictorial Surface Preparation Standards for Painting Steel Structures b. SSPC-SP2 Hand Tool Cleaning c. SSPC-SP3 Power Tool Cleaning d. SSPC-SP5 White Metal Blast Cleaning City of Denton Hazen and Sawyer BID SET 09900-2 Painting e. SSPC-SP6 Commercial Blast Cleaning f. SSPC-SP10 Near-White Metal Blast g. SSPC-SP13/NACE6 Surface Preparation of Concrete 2. NACE - National Association of Corrosion Engineers 3. ASTM D1737 - Test Method for Elongation of Attached Organic Coatings with Cylindrical Mandrel Apparatus 4. ASTM B117 - Method of Salt Spray (Fog) Testing 5. ASTM D4060 - Test Method for Abrasion Resistance of Organic Coating by the Taber Abraser 6. ASTM D3359 - Method for Measuring Adhesion by Tape Test 1.04 SUBMITTALS A. In accordance with the procedures and requirements set forth in Section 01300 - Submittals, submit the following: 1. Manufacturer's literature and Material Safety Data Sheets for each product. 2. Painting schedule identifying surface preparation and paint systems proposed. Cross-reference with Tables 9-1 and 9-2. Provide the name of the paint manufacturer, and name, address, and telephone number of manufacturer's representative who will inspect the work. Submit schedule for approval as soon as possible following the Award of Contract, so approved schedule may be used to identify colors and specify shop paint systems for fabricated items. 1.05 SYSTEM DESCRIPTION A. Work shall include surface preparation, paint application, inspection of painted surfaces and corrective action required, protection of adjacent surfaces, cleanup and appurtenant work required for the proper painting of all surfaces to be painted. Surfaces to be painted are designated within the Painting Schedule and may include new and existing piping, miscellaneous metals, equipment, buildings, exterior fiberglass, exposed electrical conduit and appurtenance. B. Perform Work in strict accordance with manufacturer's published recommendations and instructions, unless the Engineer stipulates that deviations will be for the benefit of the project. C. Paint surfaces which are customarily painted, whether indicated to be painted or not, with painting system applied to similar surfaces, areas and environments, and as approved by Engineer. City of Denton Hazen and Sawyer BID SET 09900-3 Painting D. Piping and equipment shall receive color coding and identification. Equipment shall be the same color as the piping system. 1.06 QUALITY ASSURANCE A. Painting operations shall be accomplished by skilled craftsman and licensed by the state to perform painting work. B. Provide a letter indicating that the painting applicator has five years of experience, and 5 references which show previously successful application of the specified or comparable painting systems. Include the name, address, and the telephone number for the Owner of each installation for which the painting applicator provided services. 1.07 STORAGE AND DELIVERY A. Bring materials to the job site in the original sealed and labeled containers. B. Container label to include manufacturer's name, type of paint, brand name, lot number, brand code, coverage, surface preparation, drying time, cleanup requirements, color designation, and instructions for mixing and reducing. C. Store paint materials at minimum ambient temperature of 45 degrees F (7 degrees C) and a maximum of 90 degrees F (32 degrees C), in ventilated area, and as required by manufacturer's instructions. PART 2 -- MATERIALS 2.01 GENERAL INFORMATION A. The term "paint" is defined as both paints and coatings including emulsions, enamels, stains, varnishes, sealers, and other coatings whether organic or inorganic and whether used as prime, intermediate, or finish coats. B. Purchase paint from an approved manufacturer. Manufacturer shall assign a representative to inspect application of their product both in the shop and field. The manufacturer's representative shall submit a report to the Engineer at the completion the Work identifying products used and verifying that surfaces were properly prepared, products were properly applied, and the paint systems were proper for the exposure and service. C. Provide primers and intermediate coats produced by same manufacturer as finish coat. Use only thinners approved by paint manufacturer, and only within manufacturer's recommended limits. D. Ensure compatibility of total paint system for each substrate. Test shop primed equipment delivered to the site for compatibility with final paint system. Provide an acceptable barrier coat or totally remove shop applied paint system when incompatible with system specified, and repaint with specified paint system. E. Use painting materials suitable for the intended use and recommended by paint manufacturer for the intended use. City of Denton Hazen and Sawyer BID SET 09900-4 Painting F. Require that personnel perform work in strict accordance with the latest requirements of OSHA Safety and Health Standards for construction. Meet or exceed requirements of regulatory agencies having jurisdiction and the manufacturer's published instructions and recommendations. Maintain a copy of all Material Safety Data Sheets at the job site of each product being used prior to commencement of work. Provide and require that personnel use protective and safety equipment in or about the project site. Provide respiratory devices, eye and face protection, ventilation, ear protection, illumination and other safety devices required to provide a safe work environment. 2.02 ACCEPTABLE MANUFACTURERS A. Subject to compliance with the Specifications, provide products from one of the following manufacturers: 1. Tnemec Company Inc. 2. Ameron 3. CARBOLINE 4. Sherwin-Williams PART 3 -- EXECUTION 3.01 SHOP PAINTING A. Shop prime fabricated steel and equipment with at least one shop coat of prime paint compatible with finish paint system specified. Prepare surface to be shop painted in strict accordance with paint manufacturer's recommendations and as specified. Finish coats may be shop applied, if approved by the Engineer. Package, store and protect shop painted items until they are incorporated into Work. Repair painted surfaces damaged during handling, transporting, storage, or installation to provide a painting system equal to the original painting received at the shop. B. Identify surface preparation and shop paints on Shop Drawings. Verify compatibility with field applied paints. 3.02 SURFACE PREPARATION A. General 1. Surfaces to be painted shall be clean and dry, and free of dust, rust, scale, and foreign matter. No solvent cleaning, power or hand tool cleaning shall be permitted unless approved by the Engineer. 2. Protect or remove, during painting operations, hardware, accessories, machined surfaces, nameplates, lighting fixtures, and similar items not intended to be painted prior to cleaning and painting. Reposition items removed upon completion of painting operations. City of Denton Hazen and Sawyer BID SET 09900-5 Painting 3. Examine surfaces to be coated to determine that surfaces are suitable for specified surface preparation and painting. Report to Engineer surfaces found to be unsuitable in writing. Do not start surface preparation until unsuitable surfaces have been corrected. Starting surface preparation precludes subsequent claim that such surfaces were unsuitable for the specified surface preparation or painting. 4. Surface preparation shall be in accordance with specifications and manufacturer's recommendations. Provide additional surface preparation, and fill coats where manufacturer recommends additional surface preparation, in addition to requirements of specification. 5. Touch-up shop or field applied coatings damaged by surface preparation or any other activity, with the same shop or field applied coating; even to the extent of applying an entire coat when required to correct damage prior to application of the next coating. Touch-up coats are in addition to the specified applied systems, and not considered a field coat. 6. Protect motors and other equipment during blasting operation to ensure blasting material is not blown into motors or other equipment. Inspect motors and other equipment after blasting operations and certify that no damage occurred, or where damage occurred, the proper remedial action was taken. 7. Field paint shop painted equipment in compliance with Color Coding and as approved by Engineer. B. Metal Surface Preparation 1. Conform to current The Society for Protective Coatings Standards (SSPC) Specifications for metal surface preparation. Use SSPC-Vis-1 pictorial standards or NACE visual standards TM-01-70 or TM-01-75 to determine cleanliness of abrasive blast cleaned steel. 2. Perform blast cleaning operations for metal when following conditions exist: a. Moisture is not present on the surface. b. Relative humidity is below 80%. c. Ambient and surface temperatures are 5°F or greater than the dew point temperature. d. Painting or drying of paint is not being performed in the area. e. Equipment is in good operating condition. f. Proper ventilation, illumination, and other safety procedures and equipment are being provided and followed. City of Denton Hazen and Sawyer BID SET 09900-6 Painting 3. Sandblast ferrous metals to be shop primed, or component mechanical equipment in accordance with SSPC-SP5, White Metal Blast. 4. Sandblast field prepared ferrous metals in accordance with SSPC-SP10, Near White Metal Blast, where metal is to be submerged, in a corrosive environment, or in severe service. 5. Sandblast field prepared ferrous metals in accordance with SSPC-SP6 Commercial Blast, where metal is to be used in mild or moderate service, or non-corrosive environment. 6. Clean nonferrous metals, copper, or galvanized metal surfaces in accordance to SSPC-SP1, Solvent Cleaning, or give one coat of metal passivator or metal conditioner compatible with the complete paint system. 7. Prime cleaned metals immediately after cleaning to prevent rusting. 8. Clean rusted metals down to bright metal by sandblasting and immediately field primed. C. Concrete Surface Preparation 1. Cure concrete a minimum of 30 days before surface preparation, and painting begins. 2. Test concrete for moisture content, pH and salts using test method recommended by the paint manufacturer. Do not begin surface preparation, or painting until moisture content is acceptable to manufacturer. 3. Prepare concrete surfaces to receive coatings in accordance with SSPC-13 – Concrete Surface Preparation. Remove contaminants, open bugholes, surface voids, air pockets, and other subsurface irregularities using blasting or grinding. Do not expose underlying aggregate. Use dry, oil-free air for blasting operations. Surface texture after blasting shall achieve profile as required by manufacturer or where not defined by manufacturer similar to that of medium grit sandpaper. Remove residual abrasives, dust, and loose particles by vacuuming or other approved method. 4. Surface defects, such as hollow areas, bugholes, honeycombs, and voids shall be filled with polymeric filler compatible with painting system. Complete fill coats may be used in addition to specified painting system and as approved by the Engineer. Fins, form marks, and all protrusions or rough edges shall be removed. 5. Repair existing concrete surfaces which are deteriorated to the point that surface preparation exposes aggregate with fill coats or patching mortar as recommended by paint manufacturer and as directed by the Engineer. 6. Clean concrete of all dust, form oils, curing compounds, oil, tar, laitance, efflorescence, loose mortar, and other foreign materials before paints are applied. City of Denton Hazen and Sawyer BID SET 09900-7 Painting D. Wood 1. Clean wood surfaces free of all foreign matter, with cracks and nail holes and other defects properly filled and smoothed. Remove sap and resin by scraping and wipe clean with rags dampened with mineral spirits. 2. Saturate end grain, cut wood, knots, and pitch pockets with an appropriate sealer before priming. 3. Prime and backprime wood trim before setting in place. 4. After prime coat has dried, fill nailholes, cracks, open joints, and other small holes with approved spackling putty. Lightly sand wood trim prior to applying second coat of paint. E. Castings 1. Prepare castings for painting by applying a brush or a knife-applied filler. Fillers are not to be used to conceal cracks, gasholes, or excessive porosity. 2. Apply one coat of primer with a minimum thickness of 1.2 mils in addition to coats specified. Allow sufficient drying time before further handling. F. Masonry 1. Cure for a minimum of 30 days prior to paint application. 2. Clean masonry surfaces free from all dust, dirt, oil, grease, loose mortar, chalky deposits, efflorescence, and other foreign materials. 3. Test masonry for moisture content. Use test method recommended by paint manufacturer. Do not begin painting until moisture content is acceptable to manufacturer. G. Gypsum Drywall 1. Sand joint compound with sandpaper to provide a smooth flat surface. Avoid sanding of adjacent drywall paper. 2. Remove dust, dirt, and other contaminants. H. Previously-Painted Surfaces 1. Totally remove existing paint when: surface is to be submerged in a severe environment, paint is less than 75% intact, brittle, eroded or has underfilm rusting. 2. Surfaces which are greater than 75% intact require removal of failed paints and then spot primed. Spot priming is in addition to coats specified. City of Denton Hazen and Sawyer BID SET 09900-8 Painting 3. Remove surface contamination such as oil, grease, loose paint, mill scale, dirt, foreign matter, rust, mold, mildew, mortar, efflorescence, and sealers. 4. Clean and dull glossy surfaces prior to painting in accordance with the manufacturer's recommendations. 5. Check existing paints for compatibility with new paint system. If incompatible, totally remove existing paint system or apply a barrier coat recommended by the paint manufacturer. Remove existing paints of undetermined origin. Prepare a test patch of approximately 3 square feet over existing paint. Allow test patch to dry thoroughly and test for adhesion. If proper adhesion is not achieved remove existing paint and repaint. 3.03 APPLICATION OF PAINT A. Apply paint by experienced painters with brushes or other applicators approved by the Engineer, and paint manufacturer. B. Apply paint without runs, sags, thin spots, or unacceptable marks. C. Apply at rate specified by the manufacturer to achieve at least the minimum dry mil thickness specified. Apply additional coats, if necessary, to obtain thickness. D. Special attention shall be given to nuts, bolts, edges, angles, flanges, etc., where insufficient film thicknesses are likely. Stripe paint prior to applying prime coat. Stripe painting shall be in addition to coats specified. E. Perform thinning in strict accordance with the manufacturer's instructions, and with the full knowledge and approval of the Engineer and paint manufacturer. F. Allow paint to dry a minimum of twenty-four hours between application of any two coats of paint on a particular surface, unless shorter time periods are a requirement by the manufacturer. Longer drying times may be required for abnormal conditions as defined by the Engineer and paint manufacturer. Do not exceed manufacturer's recommended drying time between coats. G. Suspend painting when any of the following conditions exist: 1. Rainy or excessively damp weather. 2. Relative humidity exceeds 85%. 3. General air temperature cannot be maintained at 50F or above through the drying period, except on approval by the Engineer and paint manufacturer. 4. Relative humidity will exceed 85% or air temperature will drop below 40F within 18 hours after application of paint. 5. Surface temperature of item is within 5 degrees of dewpoint. City of Denton Hazen and Sawyer BID SET 09900-9 Painting 6. Dew or moisture condensation are anticipated. 7. Surface temperature exceeds the manufacturer's recommendations. 3.04 INSPECTION A. Each field coat of paint will be inspected and approved by the Engineer or his authorized representative before succeeding coat is applied. Tint successive coats so that no two coats for a given surface are exactly the same color. Tick-mark surfaces to receive black paint in white between coats. B. Use magnetic dry film thickness gauges and wet fiber thickness gauges for quality control. Furnish magnetic dry film thickness gauge for use by the Engineer. C. Coatings shall pass a holiday detector test. D. Determination of Film Thickness: Randomly selected areas, each of at least 107.5 contiguous square feet, totaling at least 5% of the entire control area shall be tested. Within this area, at least 5 squares, each of 7.75 square inches, shall be randomly selected. Three readings shall be taken in each square, from which the mean film thickness shall be calculated. No more than 20 percent of the mean film thickness measurements shall be below the specified thickness. No single measurement shall be below 80 percent of the specified film thickness. Total dry film thickness greater than twice the specified film thickness shall not be acceptable. Areas where the measured dry film thickness exceeds twice that specified shall be completely redone unless otherwise approved by the Engineer. When measured dry film thickness is less than that specified additional coats shall be applied as required. E. Holiday Testing: Holiday test painted ferrous metal surfaces which will be submerged in water or other liquids, or surfaces which are enclosed in a vapor space in such structures. Mark areas which contain holidays. Repair or repaint in accordance with paint manufacturer's printed instructions and retest. 1. Dry Film Thickness Exceeding 20 Mils: For surfaces having a total dry film thickness exceeding 20 mils: Pulse-type holiday detector such as Tinker & Rasor Model AP-W, D.E. Stearns Co. Model 14/20, shall be used. The unit shall be adjusted to operate at the voltage required to cause a spark jump across an air gap equal to twice the specified coating thickness. 2. Dry Film Thickness of 20 Mils or Less: For surfaces having a total dry film thickness of 20 mils or less: Tinker & Rasor Model M1 non-destructive type holiday detector, K-D Bird Dog, shall be used. The unit shall operate at less than 75-volts. For thicknesses between 10 and 20 mils, a non-sudsing type wetting agent, such as Kodak Photo-Flow, shall be added to the water prior to wetting the detector sponge. F. Paint manufacturer or his representative shall provide their services as required by the Engineer. Services shall include, but not be limited to, inspecting existing paint, determination of best means of surface preparation, inspection of completed work, and final inspection of painted work 11 months after the job is completed. City of Denton Hazen and Sawyer BID SET 09900-10 Painting 3.05 PROTECTION OF ADJACENT PAINT AND FINISHED SURFACES A. Use covers, masking tape, other method when protection is necessary, or requested by Owner or Engineer. Remove unwanted paint carefully without damage to finished paint or surface. If damage does occur, repair the entire surface adjacent to and including the damaged area without visible lapmarks and without additional cost to the Owner. B. Take all necessary precautions to contain dispersion of sandblasting debris and paint to the limits of the work. Take into account the effect of wind and other factors which may cause dispersion of the sandblasting debris and paint. Suspend painting operations when sanding debris or paint cannot be properly confined. Assume all responsibilities and cost associated with damage to adjacent structures, vehicles, or surfaces caused by the surface preparation and painting operations. 3.06 PIPING AND EQUIPMENT IDENTIFICATION A. Piping and equipment identification shall be in accordance with Section 15030, Piping and Equipment Identification Systems. 3.07 SCHEDULE OF COLORS A. Match colors indicated. Piping and equipment colors are indicated in Section 15030. Colors which are not indicated shall be selected from the manufacturer's full range of colors by the Engineer. No variation shall be made in colors without the Engineer's approval. Color names and numbers shall be identified according to the appropriate color chart issued by the manufacturer of the particular product in question. 3.08 WORK IN CONFINED SPACES A. Provide and maintain safe working conditions for all employees. Supply fresh air continuously to confined spaces through the combined use of existing openings, forced-draft fans and temporary ducts to the outside, or direct air supply to individual workers. Exhaust paint fumes to the outside from the lowest level in the contained space. Provide explosion-proof electrical fans, if in contact with fumes. No smoking or open fires will be permitted in, or near, confined spaces where painting is being done. Follow OSHA, state and local regulations at all times. 3.09 OSHA SAFETY COLORS A. Paint wall around wall-mounted breathing or fire apparatus with the appropriate safety red color; area not exceed 2-feet wide by 3-feet high, unless apparatus covers the area. Fire apparatus include fire hoses, extinguisher, and hydrants. B. Paint hazardous areas and objects in accordance with OSHA regulations. City of Denton Hazen and Sawyer BID SET 09900-11 Painting TABLE 9-1 PAINTING SCHEDULE SURFACE APPLICATION PAINTING SYSTEM & NO. OF COATS PRODUCT REFERENCE (TABLE 9.2) TOTAL MIN. DRY FILM THICKNESS (MILS) Concrete and Masonry Interior masonry and concrete walls and ceilings All new structures 1 coat sealer 2 coats acrylic epoxy 101 116 75-85 sq.ft./gal. 4-6/coat Interior masonry and concrete walls in chemical rooms 1 coat sealer 2 coats epoxy polyamide 117 102 60-80 sq.ft./gal. 4-6/coat Exterior masonry cavity walls on cavity face of inner wythe All new structures Dampproofing See Section 07150 Exterior below grade if interior is dry Accessible areas (e.g. pipe galleries, pump rooms, basements, etc.) Waterproofing See Section 07100 Submerged water Water retaining side of new wall surfaces where opposite side of wall is interior and dry and where indicated "epoxy waterproofing" on drawing 2 coats NSF approved epoxy polyamide Provide filler as required and recommended by manufacturer 105 4-6/coat Submerged wastewater 2 coats high solids epoxy Provide filler as required and recommended by manufacturer 119 6-10/coat Containment Liner1 Interior and exterior secondary containment floors, tank supports and walls 2 coats high solids epoxy coating 119 6-10/coat Metals Interior and exterior nonsubmerged (gloss) All new blowers, pumps, motors and mechanical equipment, piping, etc. 1 coat epoxy polyamide primer 1 coat epoxy polyamide 1 coat aliphatic polyurethane 104 102 115 4-6 4-6 3-5 Interior insulated 1 coat acrylic latex 103 4 Submerged water All metal piping, and mechanical equipment, etc. 2 coats NSF approved epoxy polyamide 105 4-6/coat Submerged Wastewater 2 coats high solids epoxy 119 8-10/coat Steel doors, windows and door frames, steel stairs, monorails, structural steel, misc. metals (steel) 1 coat epoxy polyamide 1 coat aliphatic polyurethane 102 115 5-8 3-4 Aluminum surfaces in contact with concrete 2 coats coal tar 107 26 Shop Primed Structural Steel Pre-Engineered Buildings 1 barrier coat 1 coat epoxy 1 coat epoxy 113 114 120 2-3 3-4 3-4 City of Denton Hazen and Sawyer BID SET 09900-12 Painting TABLE 9-1 PAINTING SCHEDULE (CONTINUED) SURFACE APPLICATION PAINTING SYSTEM & NO. OF COATS PRODUCT REFERENCE (TABLE 9.2) TOTAL MIN. DRY FILM THICKNESS (MILS) Other Interior: Gypsum Wallboard All new structures 2 coats acrylic latex matte or satin 103 2-3/coat Interior: Tar-dipped piping where color is required 2 coats epoxy resin sealer 2 coats epoxy polyamide 112 102 5-8/coat 5-8/coat PVC Piping 1 coat epoxy polyamide 1 coat aliphatic polyurethane 102 115 5-8 3-4 1. Painting manufacturer shall verify compatibility of containment liner and chemical to be contained. Where incompatible substitute a compatible coating system. City of Denton Hazen and Sawyer BID SET 09900-13 Painting TABLE 9-2 PRODUCT LISTING PRODUCT REF. SYSTEM PURPOSE Tnemec Series PPG1 AMERON CARBOLINE Sherwin-Williams 101 Acrylic filler Primer-sealer 130-6601 BLOXFIL 4000 Sanitile 100 Cement-Plex 875 102 Epoxy polyamide Finish coat semi-gloss or gloss 66 AMERLOCK 2/400 Carboguard 890 Macropoxy 646 103 Acrylic latex Sealer 6 PITT TECH PLUS Carbocrylic 3359DTM DTM Acrylic Primer/Finish 104 Epoxy Polyamide – metal Primer 66 AMERCOAT 385 Carboguard 893SG Macropoxy 646 105 Epoxy Primer/Finish 20 AMERLOCK 2 Carboguard 561/56LT Macropoxy 646 PW 106 Coal tar epoxy Finish high-coat build 46H-413 AMERCOAT 78HB Bitumastic 300M Hi-Mil Sher Tar Epoxy 107 Coal tar Sealer 46-465 AMERCOAT 78HB Bitumastic 300M Hi-Mil Sher Tar Epoxy 108 Alkyd-medium oil Finish coat 2H DEVGUARD 4308 Carbocoat 8215 Industrial Enamel 109 Alkyd-long oil Finish coat 1029 DEVGUARD 4308 Carbocoat 8215 Industrial Enamel 110 Epoxy polyamide Primer 66-1211 AMERCOAT 385 Carboguard 893SG Macropoxy 646 112 Epoxy polyamide Sealer 66-1211 AMERCOAT 385 Carboguard 893SG Macropoxy 920 Pre-Prime 113 Urethane Barrier coat 530 AMERLOCK SEALER Rustbond -- 114 Polyamine Epoxy Intermediate coat 27 AMERLOCK 385 Carboguard 893SG -- 115 Aliphatic Polyurethane Finish coat 1074 or 1075 AMERCOAT 450 HS Carbothane 134HG Acrolon 218HS 116 Acrylic epoxy Finish coat 113 or 114 AQUAPON WB Sanitile 255 Water-Based Catalyzed Epoxy 117 Epoxy block filler Sealer 54-562 AMERLOCK 400 BF Sanitile 600 Cement Plex 875 118 Catalyzed epoxy Finish coat 84 AMERLOCK 2/400 Carboguard 890 Macropoxy 646 119 High solids epoxy Finish coat 104 AMERLOCK 400 Carboguard 890 Dura-Plate 235 120 Epoxy Top coat N69 AMERLOCK 2/400 Carboguard 890 -- - END OF SECTION – City of Denton Hazen and Sawyer BID SET 09900-14 Painting This page left blank intentionally City of Denton Hazen and Sawyer BID SET 11000-1 Equipment General Provisions SECTION 11000 EQUIPMENT GENERAL PROVISIONS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, install, test, and place in acceptable operation all mechanical equipment and all necessary accessories as specified herein, as shown on the Drawings, and as required for a complete and operable system. B. The mechanical equipment shall be provided complete with all accessories, special tools, spare parts, mountings, and other appurtenances as specified, and as may be required for a complete and operating installation. C. It is the intent of these Specifications that the Contractor shall provide the Owner complete and operational equipment/systems. To this end, it is the responsibility of the Contractor to coordinate all interfaces with related mechanical, structural, electrical, instrumentation and control work and to provide necessary ancillary items such as controls, wiring, etc., to make each piece of equipment operational as intended by the Specifications. D. The complete installation shall be free from excessive vibration, cavitation, noise, and oil or water leaks. E. The requirements of this section shall apply to equipment furnished under Divisions 11, 13, 14, and 15. 1.02 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. All equipment, materials, and installations shall conform to the requirements of the most recent editions with latest revisions, supplements, and amendments of the specifications, codes, and standards listed in Section 01090, Reference Standards. 1.03 SHOP DRAWINGS A. Shop Drawings shall be submitted to the Engineer for all equipment in accordance with Section 01300, Submittals and shall include the following information in addition to the requirements of Section 01300, Submittals: 1. Performance characteristics and descriptive data. 2. Detailed equipment dimensional drawings and setting plans. 3. General lifting, erection, installation, and adjustment instructions, and recommendations. City of Denton Hazen and Sawyer BID SET 11000-2 Equipment General Provisions 4. Complete information regarding location, type, size, and length of all field welds in accordance with "Standard Welding Symbols" AWS A2.0 of the American Welding Society. Special conditions shall be fully explained by notes and details. 5. The total uncrated weight of the equipment plus the approximate weight of shipped materials. Support locations and loads that will be transmitted to bases and foundations. Exact size, placement, and embedment requirements of all anchor bolts. 6. Details on materials of construction of all components including applicable ASTM designations. 7. Information on bearing types and bearing life. 8. Gear box design and performance criteria and AGMA service factor. 9. Piping schematics. 10. Motor data sheet indicating motor horsepower; enclosure type; voltage; insulation class; temperature rise and results of dielectric tests; service-rating; rotative speed; motor speed-torque relationship; efficiency and power factor at ½, ¾, and full load; slip at full load; running, full load, and locked rotor current values; and safe running time-current curves. 11. Equipment and motor protective device details. Connection diagrams for motor and all protective devices. 12. Equipment shop coating systems, interior and exterior. 13. Panel layout drawings, schematic wiring diagrams, and component product data sheets for control panels. 14. A list of spare parts and special tools to be provided. 15. Any additional information required to show conformance with the equipment specifications. 16. Warranty documentation including statement of duration of warranty period and contact phone numbers and addresses for warranty issues. 1.04 OPERATION AND MAINTENANCE INSTRUCTION/MANUALS A. Operation and Maintenance (O&M) manuals shall be submitted in accordance with Section 01300, Submittals. B. O&M manuals shall include instructions, equipment ratings, technical bulletins, and any other printed matter such as wiring diagrams and schematics, prints or drawings, containing full information required for the proper operation, maintenance, and repair of the equipment. Included in this submission shall be a spare parts diagram, complete spare parts list, bill of City of Denton Hazen and Sawyer BID SET 11000-3 Equipment General Provisions materials, OEM part numbers and manufacturer’s catalog information of all equipment components. C. Each set of instructions shall be bound together in appropriate three-ring binders with a detailed Table of Contents. D. Written operation and maintenance instructions shall be required for all equipment items supplied for this project. The amount of detail shall be commensurate with the complexity of the equipment item. E. Information not applicable to the specific piece of equipment installed on this project shall be struck from the submission. F. Information provided shall include a source of replacement parts and names of service representatives, including address and telephone number. G. Extensive pictorial cuts of equipment are required for operator reference in servicing. H. When written instructions include Shop Drawings and other information previously reviewed by the Engineer, only those editions thereof which were approved by the Engineer, and which accurately depict the equipment installed, shall be incorporated in the instructions. 1.05 GENERAL INFORMATION AND DESCRIPTION A. All parts of the equipment furnished shall, be designed and constructed for the maximum stresses occurring during fabrication, transportation, installation, testing, and all conditions of operation. All materials shall be new, and both workmanship and materials shall be entirely suitable for the service to which the units are to be subjected and shall conform to all applicable sections of these Specifications. B. All parts of duplicate equipment shall be interchangeable without modification. Manufacturer's design shall accommodate all the requirements of these Specifications. C. Equipment and appurtenances shall be designed in conformity with ASTM, ASME, AIEE, NEMA, and other generally accepted applicable standards. D. All bearings and moving parts shall be adequately protected by bushings or other approved means against wear, and provision shall be made for accessible lubrication by extending lubrication lines and fittings to approximately 30 inches above finished floor elevation. E. Details shall be designed for appearance as well as utility. Protruding members, joints, corners, gear covers, etc., shall be finished in appearance. All exposed welds on machinery shall be ground smooth and the corners of structural shapes shall be rounded or chamfered. F. Machinery parts shall conform within allowable tolerances to the dimensions shown on the working drawings. G. All machinery and equipment shall be safeguarded in accordance with the safety codes of the USA and the State in which the project is located. City of Denton Hazen and Sawyer BID SET 11000-4 Equipment General Provisions H. All rotating shafts, couplings, or other moving pieces of equipment shall be provided with suitable protective guards of sheet metal or wire mesh, neatly and rigidly supported. Guards shall be removable as required to provide access for repairs. I. All equipment greater than 100 pounds shall have lifting lugs, eyebolts, etc., for ease of lifting, without damage or undue stress exerted on its components. J. All manufactured items provided under this Section shall be new, of current manufacture, and shall be the products of reputable manufacturers specializing in the manufacture of such products. . 1.06 EQUIPMENT WARRANTIES A. Warranty requirements may be added to or modified in the individual equipment specifications. B. The equipment furnished under this Contract shall be guaranteed to be free from defects in workmanship, design and/or materials for a period of one (1) year unless otherwise specified in the individual equipment specifications. The period of such warranties shall start on the date the particular equipment is placed in use by the Owner with corresponding start-up certification provided by the manufacturer’s technical representative as specified herein, provided that the equipment demonstrates satisfactory performance during the thirty day operational period after the equipment startup. If the equipment does not perform satisfactorily during the thirty day operational period, the start of the warranty period will be delayed until the equipment demonstrates proper operation. The Equipment Supplier shall repair or replace without charge to the Owner any part of equipment which is defective or showing undue wear within the guarantee period, or replace the equipment with new equipment if the mechanical performance is unsatisfactory; furnishing all parts, materials, labor, etc., necessary to return the equipment to its specified performance level. C. The Contractor shall provide an equipment warranty log book prepared specifically for this project and submit two (2) copies of the document to the Engineer prior to final payment. The equipment warranty log book shall include a summary listing of all equipment warranties provided, date received, and start date and end date of warranty period. A copy of each equipment warranty and equipment start-up certification shall also be provided in the document. D. The Equipment Supplier shall guarantee to the Owner that all equipment offered under these specifications, or that any process resulting from the use of such equipment in the manner stated is not the subject of patent litigation, and that he has not knowingly offered equipment, the installation or use of which is likely to result in a patent controversy, in which the Owner as user is likely to be made the defendant. Where patent infringements are likely to occur, each Equipment Supplier shall submit, as a part of his bid, license arrangements between himself, or the manufacturer of the equipment offered, and the patent owner or the controller of the patent, which will permit the use in the specified manner of such mechanical equipment as he may be bidding. Each Equipment Supplier, by submitting his bid, agrees to hold and save the Owner and Engineer or its officers, agents, servants, and employees harmless from liability of any City of Denton Hazen and Sawyer BID SET 11000-5 Equipment General Provisions nature or kind, including cost and expenses for, or on account of, any patented or unpatented invention, process, article, or appliance manufactured or used in the performance of the work under this contract, including the use of the same by the Owner. PART 2 -- PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS A. The materials covered by these Specifications are intended to be equipment of proven reliability, and as manufactured by reputable manufacturers having experience in the production of such equipment. The Contractor shall, upon request of the Engineer, furnish the names of not less than 5 successful installations of the manufacturer's equipment of the same size and model of that offered under this contract. The equipment furnished shall be designed, constructed, and installed in accordance with the industry accepted practices and shall operate satisfactorily when installed as shown on the Drawings and operated per manufacturer's recommendations. 2.02 ANCHORS AND SUPPORTS A. The Contractor shall furnish, install, and protect all necessary guides, bearing plates, anchor and attachment bolts, and all other appurtenances required for the installation of the devices included in the equipment specified. Working Drawings for installation shall be furnished by the equipment manufacturer, and suitable templates shall be used by the Contractor when required in the detailed equipment Specifications. B. Anchor bolts and fasteners shall be furnished in accordance with Section 05050, Metal Fastening, and with the individual equipment Specifications. All anchor bolts shall be a minimum of 1/2-inch diameter. All anchor bolts, handrail bolts, washers, clips, clamps, and fasteners of any type shall be constructed of 316 stainless steel, unless otherwise specified the individual equipment Specifications. C. The Contractor shall provide all concrete pads or pedestals required for equipment furnished. All concrete equipment pads shall be a minimum of 6” high, unless otherwise shown on the Drawings and shall be doweled. D. Pipe sleeves or other means of adjusting anchor bolts shall be provided where indicated or required. Equipment shall be leveled by first using sitting nuts on the anchor bolts, and then filling the space between the equipment base and concrete pedestal with non-shrink grout, unless alternate methods are recommended by the manufacturer and are acceptable to the Engineer (such as shim leveling pumps, or chemical grout). Non-shrink grout shall be as specified in Section 03600, Grout. 2.03 STRUCTURAL STEEL A. Structural steel used for fabricating equipment shall conform to the requirements of Section 05120, Structural Steel. B. All materials shall conform to applicable provisions of the AISC Specifications for the design and fabrication of structural steel, and to pertinent ASTM Standard Specifications. City of Denton Hazen and Sawyer BID SET 11000-6 Equipment General Provisions 2.04 DISSIMILAR METALS A. All dissimilar metals shall be properly isolated to the satisfaction of the Engineer. 2.05 GALVANIZING A. Where required by the equipment specifications, galvanizing shall be performed in accordance with Section 05035, Galvanizing. 2.06 STANDARDIZATION OF GREASE FITTINGS A. The grease fittings on all mechanical equipment shall be such that they can be serviced with a single type of grease gun. Fittings shall be “Zerk” type. 2.07 ELECTRICAL REQUIREMENTS A. All electrical equipment and appurtenances, including but not limited to motors, panels, conduit and wiring, etc., specified in the equipment specifications shall comply with the applicable requirements of the Division 16 specifications and the latest National Electric Code. B. Motors shall conform to the applicable requirements of Section 15170, Electric Motors. Medium voltage motors shall conform to the applicable requirements of Section 15171, Medium Voltage Electric Motors. C. In the individual equipment specifications, specified motor horsepower is intended to be the minimum size motor to be provided. If a larger motor is required to meet the specified operating conditions and performance requirements, the Contractor shall furnish the larger sized motor and shall upgrade the electrical service (conduit, wires, starters, etc.) at no additional cost to the Owner. D. Where variable frequency drives (VFDs) are specified, the Contractor shall be responsible for coordinating between equipment supplier and VFD supplier to ensure a complete and operational system. VFDs shall be furnished under Division 16. E. Motor starters and controls shall be furnished and installed under Division 16 and Division 17 unless otherwise specified in the individual pump specifications. 2.08 ACCESSORIES, SPARE PARTS, AND SPECIAL TOOLS A. Spare parts for equipment shall be furnished where indicated in the equipment Specifications or where recommended by the equipment manufacturer. B. Spare parts shall be identical and interchangeable with original parts. C. The spare parts shall be packed in containers suitable for long term storage, bearing labels clearly designating the contents and the pieces of equipment for which they are intended. City of Denton Hazen and Sawyer BID SET 11000-7 Equipment General Provisions D. Painting requirements for spare parts shall be identical to those for original, installed parts. Where no painting or protective coating is specified, suitable provisions shall be made to protect against corrosion. E. Spare parts shall be delivered at the same time as the equipment to which they pertain. Spare parts shall be stored separately in a locked area, maintained by the Contractor, and shall be turned over to the Owner in a group prior to substantial completion. All of these materials shall be properly packed, labeled, and stored where directed by the Owner and Engineer. F. The Contractor shall furnish all special tools necessary to operate, disassemble, service, repair, and adjust the equipment in accordance with the manufacturers operation and maintenance manual. G. The Contractor shall furnish a one year supply of all recommended lubricating oils and greases. The manufacturer shall submit a list of at least four manufacturer's standard lubricants which may be used interchangeably for each type of lubricant required. All of these materials shall be properly packed, labeled and stored where directed by the Engineer. 2.09 EQUIPMENT IDENTIFICATION A. All mechanical equipment shall be provided with a substantial stainless steel nameplate, mechanically fastened with stainless steel hardware in a conspicuous place, and clearly inscribed with the manufacturer's name, year of manufacture, serial number, and principal rating data. B. Each pump and other piece of mechanical equipment shall also be identified as to name and number by a suitable laminated plastic or stainless steel nameplate mechanically fastened with stainless steel hardware; for example, "Raw Water Pump #1". Coordinate name and number with same on remotely located controls, control panel, and other related equipment. C. Nameplates shall not be painted over. PART 3 -- EXECUTION 3.01 SHOP TESTING A. All equipment shall be tested in the shop of the manufacturer in a manner which shall conclusively prove that its characteristics comply fully with the requirements of the Contract Documents and that it will operate in the manner specified or implied. B. No equipment shall be shipped to the project until the Engineer has been furnished a certified copy of test results and has notified the Contractor, in writing, that the results of such tests are acceptable. C. Five (5) certified copies of the manufacturer's actual test data and interpreted results thereof shall be forwarded to the Engineer for review. City of Denton Hazen and Sawyer BID SET 11000-8 Equipment General Provisions D. If required by the individual equipment Specifications, arrangements shall be made for the Owner/Engineer to witness performance tests in the manufacturer's shop. The Engineer shall be notified ten working days before shop testing commences. Expenses are to be paid by Contractor. E. Shop testing of electric motors shall be in accordance with applicable requirements of Section 15170, Electric Motors; Section 15171, Medium Voltage Electric Motors, and Section 16000, Basic Electrical Requirements. 3.02 STORAGE OF EQUIPMENT AND MATERIALS A. Contractor shall store his equipment and materials at the job site in strict accordance with the manufacturer's recommendations and as directed by the Owner or Engineer, and in conformity to applicable statutes, ordinances, regulations, and rulings of the public authority having jurisdiction. Equipment and materials shall not be delivered to the site prior to 90 days in advance of the scheduled installation. Partial payment requests will not be processed for materials delivered prior to 90 days before installation or for materials that are not properly stored. B. Material or equipment stored on the job site is stored at the Contractor's risk. Any damage sustained of whatever nature shall be repaired to the Engineer's satisfaction at no expense to the Owner. Stored electrical equipment is to be protected from the elements and shall have space heaters energized. C. Contractor shall not store unnecessary materials or equipment on the job site and shall take care to prevent any structure from being loaded with a weight which will endanger its security or the safety of persons. D. Contractor shall observe all regulatory signs for loadings on structures, fire safety, and smoking areas. E. Contractor shall not store materials or encroach upon private property without the written consent of the owners of such private property. 3.03 MANUFACTURER’S FIELD SERVICES A. The Contractor shall arrange for a qualified Technical Representative from each manufacturer or supplier of equipment who is regularly involved in the inspection, installation, start-up, troubleshooting, testing, maintenance, and operation of the specified equipment. Qualification of the Technical Representative shall be appropriate to the type of equipment furnished and subject to the approval of the Engineer and the Owner. Where equipment furnished has significant process complexity, furnish the services of engineering personnel knowledgeable in the process involved and the function of the equipment. When necessary, the Contractor shall schedule multiple Technical Representatives to be present at the same time for the purpose of coordinating the operation of multiple pieces of related equipment. B. For each site visit, the Technical Representative shall submit jointly to the Owner, the Engineer, and the Contractor a complete signed report of the results of his inspection, operation, adjustments, and testing. The report shall include detailed descriptions of the City of Denton Hazen and Sawyer BID SET 11000-9 Equipment General Provisions points inspected, tests and adjustments made, quantitative results obtained if such are specified. C. The manufacturer's Technical Representative shall provide the following services. 1. Installation: The Technical Representative shall inspect the installed equipment to verify that installation is in accordance with the manufacturer’s requirements. Where required by individual equipment specifications, the Technical Representative shall also supervise the installation of the equipment. 2. Testing: After installation of the equipment has been completed and the equipment is presumably ready for operation, but before it is operated by others, the Technical Representative shall inspect, operate, test, and adjust the equipment as required to prove that the equipment is in proper condition for satisfactory operation under the conditions specified. Unless otherwise noted in the signed site visit report, the report shall constitute a certification that the equipment conforms to the requirements of the Contract and is ready for startup and that nothing in the installation will render the manufacturer's warranty null and void. The report shall include date of final acceptance field test, as well as a listing of all persons present during tests. 3. Startup: The Technical Representative shall start up the equipment for actual service with the help of the Contractor. In the event that equipment or installation problems are experienced, the Contractor and the representative shall provide the necessary services until the equipment is operating satisfactorily and performing according to the specifications at no additional cost to the Owner. Unless otherwise noted in the signed site visit report, the report shall constitute a certification that the equipment conforms to the requirements of the Contract and is ready for permanent operation and that nothing in the installation will render the manufacturer's warranty null and void. 4. Training: The Technical Representative shall instruct the Owner's operating personnel in correct operation and maintenance procedures. The instruction shall demonstrate start-up, operation, control, adjustment, trouble-shooting, servicing, maintenance, and shutdown of each item of equipment. Such instruction shall be scheduled at a time arranged with the Owner at least 2 weeks in advance of the training and shall be provided while the respective Technical Representative's equipment is fully operational. The Contractor shall have submitted, and had accepted, the O&M Manuals prior to commencement of training. Training shall be provided to two separate shifts of the Owner's personnel between the hours of 8:00 A.M. and 3:00 P.M. as necessary. 5. Services after Startup: Where required by the individual equipment specifications, the Technical Representative shall return to the project site thirty (30) days after the start up date to review the equipment performance, correct any equipment problems, and conduct operation and maintenance classes as required by the Owner. This follow-up trip is required in addition to the specified services of Technical Representative prior to and during equipment startup. At this time, if there are no equipment problems, each manufacturer shall certify to the Owner in writing that his equipment is fully operational and capable of meeting operating requirements. If the equipment is operating incorrectly, the Technical Representative will make no City of Denton Hazen and Sawyer BID SET 11000-10 Equipment General Provisions certification to the Owner until the problems are corrected and the equipment demonstrates a successful thirty (30) days operating period. D. Services of the Technical Representative will require a minimum of two (2) site visits, one for installation and testing and one for startup and training, and will be for the minimum number of days recommended by the manufacturer and approved by the Engineer but will not be less than the number of days specified in individual equipment sections. E. The Contract amount shall include the cost of furnishing the Technical Representative for the minimum number of days specified, and any additional time required to achieve successful installation and operation. The times specified for services by the Technical Representative in the equipment Specifications are exclusive of travel time to and from the facility and shall not be construed as to relieve the manufacturer of any additional visits to provide sufficient service to place the equipment in satisfactory operation. F. The Contractor shall notify the Engineer at least 14 days in advance of each equipment test or Owner training session. G. The Technical Representative shall sign in and out at the office of the Engineer's Resident Project Representative on each day he is at the project. 3.04 INSTALLATION A. The Contractor shall obtain written installation manuals from the equipment manufacturer prior to installation. Equipment shall be installed strictly in accordance with recommendations of the manufacturer. A copy of all installation instructions shall be furnished the Engineer's field representative one week prior to installation. B. The Contractor shall have on hand sufficient personnel, proper construction equipment, and machinery of ample capacity to facilitate the work and to handle all emergencies normally encountered in work of this character. To minimize field erection problems, mechanical units shall be factory-assembled insofar as practical. C. Equipment shall be erected in a neat and workmanlike manner on the foundations at the locations and elevations shown on the Drawings. D. All equipment sections and loose items shall be match-marked prior to shipping. E. For equipment such as pumping units, which require field alignment and connections, the Contractor shall provide the services of the manufacturer's qualified mechanic, millwright, or machinist, to align the pump and motor prior to making piping connections or anchoring the pump base. Alignment shall be as specified herein. F. The Contractor shall furnish oil and grease for initial operation and testing. The manufacturer and grades of oil and grease shall be in accordance with the recommendations of the equipment manufacturer. City of Denton Hazen and Sawyer BID SET 11000-11 Equipment General Provisions 3.05 ALIGNMENT A. Set equipment to dimensions shown on drawings. Dimensions shall be accurate to +/- 1/16 inch unless otherwise noted on the drawings. Wedges shall not be used for leveling, aligning, or supporting equipment. B. General Equipment Leveling: Non-rotating equipment shall be set level to +/- 1/16 inch per 10 foot length (.005 inch per foot) unless otherwise noted on the drawings. Shims shall be used unless equipment is furnished with leveling feet. Set shims flush with equipment baseplate edges. When grouting is required, equipment shall be shimmed to allow a minimum of one inch grout thickness. Grout shall cover shims at least 3 inches. Final level check shall be held for inspection and approval by Engineer before proceeding. C. Grouting 1. Fill anchor bolt holes or sleeves with grout, after bolt alignment is proven, and prior to placing grout under equipment bases. 2. Surface Preparation. Roughen surface by chipping, removing laitance, and unsound concrete. Clean area of all foreign material such as oil, grease, and scale. Saturate area with water at least 4 hours prior to grouting, removing excess water ponds. 3. Application. Place grout after the equipment base has been set and its alignment and level have been approved. Form around the base, mix grout, and place in accordance with the grout manufacturers published instructions. Eliminate all air or water pockets beneath the base using a drag chain or rope. 4. Finishing. Point the edges of the grout to form a smooth 45 degree slope. 5. After grout has cured (not before 3 days after placement) paint exposed surfaces of grout with shellac. 6. Level Verification. After grout has cured, and immediately prior to drive alignment, recheck equipment for level and plumb. Re-level and square as necessary. Hold final checks for inspection and approval by Engineer. D. Inspect for and remove all machining burrs or thread pulls in female holes on mating surfaces of mounting frame and machine feet. E. Inspect and clean equipment mounting base pads, feet, and frames to remove all grease, rust, paint and dirt. F. Assembled equipment shafts shall be set level to .0015 inches per foot of shaft length (+/- .0005 inches) up to a maximum of 0.015 inches for any length shaft unless the manufacturers requirements are more stringent or unless otherwise noted in the equipment specifications. Use the machined surfaces on which the equipment sets for the base/mounting frame leveling plane. Use the machined shaft surface for equipment leveling plane. City of Denton Hazen and Sawyer BID SET 11000-12 Equipment General Provisions G. Sprocket and Sheave Alignment. Check shaft mounted components for face runout and eccentricity (outside diameter) runout by magnetically mounting a dial indicator on a stationary base and indicating over 360 degrees on a continuous machined surface at the outside diameter of the component. Maximum allowable total indicated face runout and eccentricity for sprockets and sheaves will be per ANSI Standard B29.1-1975. H. Belt tensioning. Set drive belt tension to manufacturer's specification for the belt type. Recheck alignment after drive tensioning. I. Thermal/Mechanical Growth. Thermal/mechanical growth corrections for driver and driven machines will be used in vertical and horizontal alignment where applicable. The equipment manufacturer will determine thermal/mechanical growth applicability for any machine and provide the correction offsets to be used. J. Rotating Shaft Alignment 1. Fixtures will be set up on the driver and driven machine, machines shaft surfaces. Machined coupling hubs may be used only if there is no clearance to mount fixtures directly on the shafts. 2. Primary alignment method for direct drive machines is when coupled. Uncoupled alignment will be used only when approved by the Engineer. 3. Account for possible coupling flex by always rotating coupled machines in the same direction during alignment. 4. Uncoupled machines must be connected so that both shafts turn together without relative motion during alignment. 5. Indicator bar sag will be measured and included for each reverse indicator alignment setup. 6. Reverse Dial Indicator. The final maximum allowable misalignment: vertical and horizontal from the desired targets of .000 inches (for a non-thermal growth machine) or from the given target readings (for a thermal growth machine) must meet BOTH of the following conditions simultaneously: 1/2 the final total indicator reading at each indicator will be no more than shown in the table below AND the final remaining correction at each machine foot be no more than .001 inches of required movement. Machine Speed (RPM) Total Misalignment* (inches) Up to 1800 .002 1800 and greater .001 * 1/2 indicator reading 3.06 FIELD TESTING A. All equipment shall be set, aligned and assembled in conformance with the manufacturer's drawings and instructions. Provide all necessary calibrated instruments to execute performance tests. Submit report certified by the pump manufacturer’s representative. City of Denton Hazen and Sawyer BID SET 11000-13 Equipment General Provisions B. Preliminary Field Tests 1. As soon as conditions permit, after the equipment has been secured in its permanent position, the Contractor shall: a. Verify that the equipment is free from defects. b. Check for alignment as specified herein. c. Check for direction of rotation. d. Check motor for no load current draw. 2. Contractor shall flush all bearings, gear housings, etc., in accordance with the manufacturer's recommendations, to remove any foreign matter accumulated during shipment, storage or erection. Lubricants shall be added as required by the manufacturer's instructions. 3. Preliminary field tests, yellow tag, must be completed before equipment is subjected to final field tests, blue tag. C. Final Field Tests 1. Upon completion of the above, and at a time approved by the Engineer, the equipment will be tested by operating it as a unit with all related piping, ducting, electrical and controls, and other ancillary facilities. 2. The equipment will be placed in continuous operation as prescribed or required and witnessed by the Engineer or his assigned representative and the Owner or his assigned representative. 3. The tests shall prove that the equipment and appurtenances are properly installed, meet their operating cycles and are free from defects such as overheating, overloading, and undue vibration and noise. Operating field tests shall consist of the following: a. Check equipment for excessive vibration and noise as specified herein. b. Check motor current draw under load conditions. The rated motor nameplate current shall not be exceeded. c. Recheck alignment with dial indicators where applicable, after unit has run under load for a minimum of 24 hours. D. In addition to the above described field tests, any other tests specifically required by Section 11100, Pumps-General, the individual equipment Specifications, or by the manufacturer shall be performed. City of Denton Hazen and Sawyer BID SET 11000-14 Equipment General Provisions E. Until final field tests are acceptable to the Engineer, the Contractor shall make all necessary changes, readjustments and replacements at no additional cost to the Owner. F. Defects which cannot be corrected by installation adjustments will be sufficient grounds for rejection of any equipment. G. All costs in connection with field testing of equipment such as lubricants, temporary instruments, labor, equipment, etc., shall be borne by the Contractor. Power, fuel, chemicals, water, etc. normally consumed by specific equipment shall be supplied by the Owner unless otherwise specified in the individual equipment specifications. H. The Contractor shall be fully responsible for the proper operation of equipment during tests and instruction periods and shall neither have nor make any claim for damage which may occur to equipment prior to the time when the Owner formally takes over the operation thereof. I. Field testing of electric motors shall be in accordance with Section 15170, Electric Motors; Section 15171, Medium Voltage Electric Motors, and Section 16000, Basic Electrical Requirements. 3.07 VIBRATION TESTING A. Unless specified otherwise in the detailed equipment specifications, each pump, blower, compressor, motor or similar item of stationary rotating equipment having a rated power in excess of 40HP shall be tested after installation for acceptable vibration levels. B. Vibration testing shall be performed by an experienced factory-trained and authorized third- party analysis expert (not a sales representative) retained by the Contractor and approved by the Engineer. Each unit or pump system shall be tested separately without duplicate equipment running. All field testing shall be done in the presence of the Engineer. The Engineer shall be furnished with four (4) certified copies of vibration test data for each test performed. C. For systems with variable speed drives, tests shall be conducted at various speeds between maximum and minimum. For systems with two-speed drives, tests shall be conducted at both speeds. For systems with constant-speed drive, tests shall be conducted under various loading conditions as determined by the Engineer. D. All field vibration tests shall be performed with the equipment operating on the product for which it is intended, or a substitute acceptable to the Engineer. E. The term displacement, as used herein, shall mean total peak-to-peak movement of vibrating equipment, in mils; velocity or speed of the vibration cycle, measured in G's. Displacement and velocity shall be measured by suitable equipment equal to IRD Mechanalysis, Bentley, Nevada. E. Frequency of vibration, in cycles per minute (cpm), shall be determined when vibration exceeds specified levels or as otherwise necessary. Vibration shall be measured on the bearing housing, unless other locations are deemed necessary by the vibration analysis expert and Engineer. City of Denton Hazen and Sawyer BID SET 11000-15 Equipment General Provisions F. For all equipment tested, vibration shall be checked in the radial and axial directions. Unless otherwise specified elsewhere, axial vibration shall not exceed 0.1 in/sec; and radial vibration shall not exceed 0.2 in/sec. For pumps radial vibration shall not exceed that permitted by the Hydraulic Institute Standards except that, at vibration frequencies in excess of 8,000 cpm, the velocity shall not exceed 0.2 in/sec. G. Copies of test results shall be submitted to the Engineer for review. Should the vibration field test results exceed shop test results, the manufacturer’s recommendations, or the limits specified herein, the Contractor shall correct the deficiencies within thirty (30) days. After corrections have been completed, the vibration testing shall be re-run and the results re- submitted to the Engineer for review. H. Noise or vibration in any rotating equipment which the Engineer judges to be excessive or damaging, shall be cause for rejection. 3.08 FAILURE OF EQUIPMENT TO PERFORM A. Any defects in the equipment, or failure to meet the guarantees or performance requirements of the Specifications shall be promptly corrected by the Contractor by replacements or otherwise. B. If the Contractor fails to make these corrections, or if the improved equipment shall fail again to meet the guarantees or specified requirements, the Owner, notwithstanding his having made partial payment for work and materials which have entered into the manufacture of said equipment, may reject said equipment and order the Contractor to remove it from the premises at the Contractor's expense. C. The Contractor shall then obtain specified equipment to meet the contract requirements or upon mutual agreement with the Owner, adjust the contract price to reflect not supplying the specific equipment item. D. In case the Owner rejects said equipment, then the Contractor hereby agrees to repay to the Owner all sums of money paid to him for said rejected equipment on progress certificates or otherwise on account of the lump sum prices herein specified. E. Upon receipt of said sums of money, the Owner will execute and deliver to the Contractor a bill of sale of all his rights, title, and interest in and to said rejected equipment; provided, however, that said equipment shall not be removed from the premises until the Owner obtains from other sources other equipment to take the place of that rejected. F. Said bill of sale shall not abrogate Owner's right to recover damages for delays, losses, or other conditions arising out of the basic contract. 3.09 PAINTING A. All surface preparation, shop painting, field repairs, finish painting, and other pertinent detailed painting specifications shall conform to applicable sections of Section 09900, Painting. City of Denton Hazen and Sawyer BID SET 11000-16 Equipment General Provisions B. All shop coatings shall be compatible with proposed field coatings. C. All inaccessible surfaces of the equipment, which normally require painting, shall be finished painted by the manufacturer. The equipment and motor shall be painted with a high quality epoxy polyamide semi-gloss coating specifically resistant to chemical, solvent, moisture, and acid environmental conditions, unless otherwise specified. D. Gears, bearing surfaces, and other unpainted surfaces shall be protected prior to shipment by a heavy covering of rust-preventive compound sprayed or hand applied which shall be maintained until the equipment is placed in operation. This coating shall be easily removable by a solvent. 3.10 WELDING A. The Equipment Manufacturer's shop welding procedures, welders, and welding operators shall be qualified and certified in accordance with the requirement of AWS D1.1 "Structural Welding Code - Steel" or AWS D1.2 "Structural Welding Code - Aluminum" of the American Welding Society, as applicable. B. The Contractor's welding procedures, welders, and welding operators shall be qualified and certified in accordance with the requirements of AWS D1.1 "Structural Welding Code - Steel" or AWS D1.2 "Structural Welding Code - Aluminum" of the American Welding Society, as applicable. C. The Contractor shall perform all field welding in conformance with the information shown on the Equipment Manufacturer's drawings regarding location, type, size, and length of all welds in accordance with "Standard Welding Symbols" AWS A2.0 of the American Welding Society, and special conditions, as shown by notes and details. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 11100-1 Pumps General SECTION 11100 PUMPS - GENERAL PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, install, test, and make fully operational all pumping equipment, complete with all necessary accessories, in compliance with the Contract Documents. B. All pumping equipment shall be provided in accordance with the requirements of Section 11000, Equipment General Provisions. C. The provisions of this section shall apply to all pumps and pumping equipment specified except where specifically noted otherwise in the Contract Documents. D. The pumps shall be provided complete with all accessories, shims, sheaves, couplings, and other appurtenances as specified, and as may be required for a complete and operating installation. 1.02 SHOP DRAWINGS A. Shop Drawings shall include the following information in addition to the requirements of Section 01300, Submittals and Section 11000, Equipment General Provisions. 1. Details of shaft sealing system 2. Pump performance curves at rated speed and reduced speed (if reduced speeds are specified). Curves shall indicate flow, head, efficiency, brake horsepower, NPSH required, and minimum submergence. Curves shall include limits (minimum and maximum flows) for stable operation without cavitation, overheating, recirculation, or excessive vibration. 3. General cutaway sections, materials, dimension of shaft projections, shaft and keyway dimensions, shaft diameter, dimension between bearings, general dimensions of pump, suction head bolt orientation, and anchor bolt locations and forces. 4. Foundry certificates and results of Brinnell hardness testing showing compliance to ASTM A 532 (where required in the individual pump specifications). 5. Submersible pump submittals shall also include: a. Product data sheets for power and control cables and length of cables. b. Details on pump guide rail system and mounting requirements. City of Denton Hazen and Sawyer BID SET 11100-2 Pumps General PART 2 -- PRODUCTS 2.01 MATERIALS A. All materials employed in the pumping equipment shall be suitable for the intended application. Material not specifically called for shall be high-grade, standard commercial quality, free from all defects and imperfection that might affect the serviceability of the product for the purpose for which it is intended, and shall conform to the following requirements unless otherwise specified in individual pumping equipment Specifications: 1. Cast iron pump casings and bowls shall be of close-grained gray cast iron, conforming to ASTM A 48, or equal. 2. Bronze pump impellers shall conform to ASTM B 584, “G” bronze. 3. Stainless steel pump shafts shall be of Type 400, Series. Miscellaneous stainless steel parts shall be of Type 316. B. Suction and discharge flanges shall conform to ANSI standard B16.1 or B16.5 dimensions. C. Handholes on pump casings shall be shaped to follow the contours of the casing to avoid any obstructions in the water passage. 2.02 APPURTENANCES A. Pressure Gauges 1. The Contractor shall furnish and install pressure indicator gauges on the suction and discharge of each pump, except wet-pit submersible pumps and vertical turbine pumps. 2. The Contractor shall furnish and install pressure gauges on the discharge piping of each wet-pit submersible pump and vertical turbine pump in the locations shown on the Drawings or as directed by the Engineer. 3. Suction gauges shall be of the single scale compound type to indicate both pressure and vacuum. Each suction gauge shall be graduated in feet of water over the span of 34 feet below and above zero. 4. Discharge gauges shall be graduated in feet from zero to a minimum of five (5) feet of water above the respective pump shutoff head or to a minimum of 30% above the maximum operation pressure, whichever is greater. Graduation shall be in feet of water. 5. All gauges shall be supplied by one manufacturer and shall be as specified in Section 17650, Pressure Gauges. 6. All gauges shall be provided with diaphragm seals or isolating ring seals as specified in Section 17698, Instrumentation and Control Accessories. City of Denton Hazen and Sawyer BID SET 11100-3 Pumps General B. Flexible couplings for direct driven pumps shall be as manufactured by Falk, Dodge, Woods Corp., or equal and shall be furnished with guards in accordance with OSHA Rules and Regulations. Spacer couplings shall be provided where necessary to allow removal of the pump rotating element without disturbing the driver. 2.02 ELECTRICAL REQUIREMENTS A. All pumps shall be furnished with motors such that the motor shall not be overloaded throughout the full range of the pump operation, unless otherwise specifically approved by the Engineer. B. Where variable frequency drives (VFDs) are specified, the Contractor shall be responsible for coordinating between pump supplier and VFD supplier to ensure a complete and operational system. VFDs shall be furnished under Division 16 and shall be as specified in Section 16495, Low Voltage Variable Frequency Drive Systems. C. Motor starters and controls shall be furnished and installed under Division 16 and Division 17 unless otherwise specified in the individual pump specifications. 2.03 EQUIPMENT IDENTIFICATION A. In addition to the requirements of Section 11000, Equipment General Provisions, nameplate data for each pump shall include the rating in gallons per minute, rated head, speed, and efficiency at the primary design point. PART 3 -- EXECUTION 3.01 INSTALLATION A. Drains: All gland seals, air valves, and drains shall be piped to the nearest floor drain or trench drain with galvanized steel pipe or copper tube, properly supported with brackets. B. Solenoid Valves: Where required, the pump manufacturer shall furnish and install solenoid valves on the water or oil lubrication lines. Solenoid valve electrical rating shall be compatible with the motor control voltage and shall be furnished complete with all necessary conduit and wiring installation from control panel to solenoid. 3.02 SHOP TESTING A. Shop tests shall be performed in accordance with Section 11000, Equipment General Provisions, and except where stated otherwise herein, shall be conducted in accordance with the latest version of Hydraulic Institute Standard 14.6, Hydraulic Performance Acceptance Tests. B. Pump testing shall be witnessed by the Owner/Engineer where specified in the individual pump specifications. The testing procedure shall be submitted to the Engineer for review before scheduling the testing. The Engineer shall be given at least 2 weeks advanced notice of the scheduled testing date. City of Denton Hazen and Sawyer BID SET 11100-4 Pumps General C. Certified test curves for shall be provided for all centrifugal pumps unless otherwise specified in the individual pump specifications. Certified tests will not be required for submersible sump pumps (as specified in Sections 11133 and 11136) with motors less than 5 hp. D. Pumps shall be within the tolerances specified for Acceptance Grade 1U, in accordance with the latest version of Hydraulic Institute Standards 14.6. E. For wet pit submersible pumps and vertical turbine pumps, all tests shall be run at minimum pump submergence specified in the individual pump specifications. F. Where required in the individual pump specifications, each individual casting shall be Brinnell tested in a minimum of two places, in an area of representative casting thickness to ASTM Method E-10. Results shall be certified by a registered professional ENGINEER. Test results shall verify the satisfaction of the required Brinnell hardness of the finished product as specified in respective subsections. 3.03 FIELD TESTING A. Field tests shall be performed in accordance with in Section 11000, Equipment General Provisions and additionally as specified below and in the individual pump specifications. B. Final acceptance tests shall demonstrate the following: 1. The pumps have been properly installed and are in proper alignment. 2. The pumps operate without overheating or overloading of any parts and without objectionable vibration. Vibration shall be within the Hydraulic Institute limits, or manufacturer's limits if more stringent. 3. The pumps can meet the specified operating conditions. All pumps shall be checked at maximum speed for a minimum of four points on the pump curve for capacity, head, and amperage. The rated motor nameplate current shall not be exceeded at any point. Pumps with drive motors rated at less than five horsepower shall only be tested for overcurrent when overheating or other malfunction becomes evident in general testing. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 11130-1 Submersible Non-Clog Pumps SECTION 11130 SUBMERSIBLE NON-CLOG PUMPS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish and install submersible non-clog pumps at the locations shown on the Drawings and as specified herein. All pumps shall be supplied by the same manufacturer. B. Equipment shall be provided in accordance with the requirements of Section 11000, Equipment General Provisions and Section 11100, Pump – General and Section 15170, Low Voltage Electric Motors. 1.02 OPERATING CONDITIONS AND PERFORMANCE REQUIREMENTS No. Item 1 Location HCDF PCWRP WPFPS 2 Quantity required (duty + standby) 4 (3+1) 3 (2+1) 3 Pump type Single stage, non-clog, vertical centrifugal, submersible 4 Shutoff design point characteristics Flow, gpm Minimum total head, feet 0 152 0 106 5 Static head range, feet 65-70 33-37 6 Design Point Characteristics P S2 P S2 Speed, Hertz Flow, gpm Total head, feet Min. overall efficiency, percent3 Max. NPSH required, feet 60 6,500 80 75 23 60 5,600 87 77 19 60 11,500 45 72 31 60 10,500 52 74 26 7 Runout flow rate, gpm 10,000 13,000 8 Min. discharge diameter, inches4 12 16 9 Min. size of solids passing (spherical diameter), inches 3.0 10 Fluid pumped Raw, unscreened, sewage 11 Fluid temperature, degrees F 60-85 12 Drive type Constant Speed 1 Primary (P), Secondary (S) 2 Represents high flow condition with all duty pumps operating. 3 Overall wire-to-water efficiency, excluding VFD efficiency. 4 Indicates a dimension to be verified with manufacturer’s drawings. City of Denton Hazen and Sawyer BID SET 11130-2 Submersible Non-Clog Pumps 1.03 SUBMITTALS A. Submittals shall be provided in accordance with, or in addition to the submittal requirements specified in Section 01300, Submittals; Section 11000, Equipment General Provisions, Section 11100 Pumps General, and 15170, Low Voltage Electric Motors. 1.04 WARRANTY AND GUARANTEE A. All equipment supplied under this section shall be warranted for a period of five years by the pump manufacturer. Warranty shall cover 100% parts and labor for the first two years and 50% parts and labor the remaining 3 years. Warranty period shall commence on the date of Owner acceptance. B. The equipment shall be warranted to be free from defects in workmanship, design and materials. If any part of the equipment should fail during the warranty period, it shall be replaced at no additional cost to the Owner. PART 2 -- PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS A. Each pump shall be a submersible, non-clog, centrifugal pump, as manufactured by Xylem- Flygt, ABS-Sulzer, or equal. 2.02 MATERIALS A. The pump and all related equipment shall be designed for the wastewater applications specified herein and shall be suitable for continuous or intermittent operation. The pump shall be bottom suction, side discharge construction and shall be supplied with a foot mounted discharge connection elbow and integral sliding rail removal system of the pump manufacturer's design matched to the pumps being supplied. B. The lifting cover, stator housing, and volute casing shall be close grained cast iron conforming to ASTM A48-Class 30, 35, or 40. Ductile iron pump volute shall be furnished if recommended by pump manufacturer for specified pressure rating. All exposed nuts, bolts, washers, and other fastening devices shall be AISI type 316 stainless steel. C. Casing shall be a smooth surface devoid of blowholes, pits, burrs, or other irregularities. The casing shall have a suction cover, which can be easily removed for easy access to the impeller. All non-stainless steel metal surfaces coming in contact with the pumped media shall be protected by a factory applied spray coating of Supplier’s modified acrylic primer and finish. The volute shall be single piece, non-concentric design and shall have smooth fluid passages large enough at all points to pass any size solids which can pass through the impeller. Pump volute shall be provided with a cleanout port to allow for removal of any foreign material blocking or impeding performance of the pump. D. All mating surfaces where watertight sealing is required shall be machined and fitted with nitrile or Viton rubber O-rings. Fitting shall be such that sealing is accomplished by metal-to-metal contact between machined surfaces. This will result in controlled compression of the O-rings without the requirement of a specific torque limit. Secondary City of Denton Hazen and Sawyer BID SET 11130-3 Submersible Non-Clog Pumps sealing compounds, rectangular gaskets, elliptical O-rings, grease or other devices shall not be acceptable. E. The impeller shall be hard alloy gray cast iron conforming to ASTM A-48 Class 30, 35, or 40. Impellers shall be dynamically balanced, closed non-clogging design with multiple vanes. The impeller shall be capable of handling solids of specified sphere size, fibrous materials, heavy sludge, and other matter found in normal wastewater applications. The impeller shall be mechanically secured to the motor shaft per manufacturer’s recommendations utilizing machined stainless steel components. Adhesive or friction-type fits are not acceptable. Impeller shall be coated with the same system applied to the interior of the casing. F. A wear ring system shall provide efficient sealing between the volute and impeller. Casing and impeller wear ring shall be of stainless steel construction. Supplier shall submit AISI grades of stainless steel proposed for the wear rings. Rings shall be drive fitted to the volute inlet and heat-shrink fitted to the impeller. G. Shafting shall be constructed of AISI 329 stainless steel or 400 Series stainless steel for the pump and motor, sufficiently large in diameter to transmit safely the maximum torque developed by the drive unit and of such a design as to provide a rigid support for the impeller and to prevent excessive vibration. The shaft shall be suitably heat-treated, turned, ground, and polished over its entire length. H. Shaft Seals 1. Each pump shall be provided with a tandem mechanical shaft seal system consisting of two totally independent seal assemblies of high-pressure design. The seals shall operate in a lubricant reservoir that hydrodynamically lubricates the lapped seal faces at a constant rate. The lubricant chamber shall be designed to prevent overfilling and to provide lubricant expansion capacity. The drain and inspection plug, with positive anti-leak seal shall be easily accessible from the outside. The seal system shall not rely upon the pumped media for lubrication. Seal lubricant shall be FDA Approved, nontoxic. 2. The lower, primary seal unit, located between the pump and the lubricant chamber shall contain one stationary and one positively driven rotating, industrial duty, corrosion resistant, seal rings (Tungsten carbide/Tungsten carbide or Tungsten carbide/silicon carbide). The lower seal shall be independent of the impeller hub. 3. The upper, secondary seal unit, located between the lubricant chamber and the motor housing, chamber shall contain one stationary and one positively driven rotating, industrial duty, corrosion resistant, seal rings (ceramic/carbon or carbo/Ni-resist). 4. Each seal interface shall be held in contact by its own spring system. The seals shall require neither maintenance nor adjustment and shall be capable of operating in either clockwise or counter clockwise direction of rotation without damage or loss of seal. The seal system shall not be damaged when run dry. No external source of seal cooling or lubrication water shall be required. City of Denton Hazen and Sawyer BID SET 11130-4 Submersible Non-Clog Pumps 5. The following seal types shall not be considered acceptable nor equal to the dual independent seal specified: shaft seals without positively driven rotating members, or conventional double mechanical seals containing either a common single or double spring acting between the upper and lower seal faces. Cartridge type systems will not be acceptable. No system requiring a pressure differential to offset pressure and to effect sealing shall be used. I. The pump shaft shall rotate on at least two (2) heavy duty permanently lubricated bearings. Bearings shall be designed to carry all radial and axial thrust loads and shall have a minimum AFBMA B-10 life of 100,000 hours at all points along the usable portion of the pump curve at maximum pump speed. J. Each pump unit motor shall be provided with an integral cooling system that is adequately designed to cool the motor without an external cooling source. A motor cooling jacket shall encircle the stator housing, providing for dissipation of motor heat. An impeller integral to the cooling system and driven by the pump shaft, shall provide the necessary circulation of the cooling liquid through the jacket. Motor cooling shall be accomplished by circulating a non-toxic mixture of water and mono-propylene glycol, separate from the pumped media around the motor housing and dissipating heat by means of an internal heat exchanger (closed loop). The cooling liquid shall pass about the stator housing in the closed loop system in turbulent flow providing for superior heat transfer. The cooling system shall have on fill port and one drain port integral to the cooling jacket. Using the pumped media for cooling will not be accepted. 1. The cooling system shall be adequately designed to allow the motor to run continuously in a vertical position under full load while in a completely non-submerged (i.e. dry pit) condition in air having a temperature of up to 40°C (104°F) without the need for de-rating or reduced duty cycle, in accordance with NEMA standards. Restrictions limiting the ambient air or liquid temperatures at levels less than 40°C shall not be accepted. 2. The motor cooling jacket shall be of 304 stainless steel and shall be sealed to the motor housing with O-rings. 3. The motor cooling jacket shall be designed to adequately cool the pump with the pump operating at the minimum pumping rate specified in the pump schedule herein. K. Gauge taps shall be provided on the discharge piping of the vertical submersible pumps in a location as directed by the Engineer. Gauge taps shall be threaded corporation stops, conforming to the requirements of Section 15000, Basic Mechanical Requirements. Gauges shall be as specified in Section 17650, Pressure Gauges. L. The Slide Rail Mounting System shall be as shown on the Contract Drawings and as specified herein. 1. A rail system shall be provided and installed for each pump. The pump shall be easily removed from the wetpit for inspection or service without entering the pit or disconnecting piping. City of Denton Hazen and Sawyer BID SET 11130-5 Submersible Non-Clog Pumps 2. The pump shall be provided with a foot mounted discharge connection elbow constructed of cast iron conforming to ASTM A48-Class 30 or 35, permanently installed in the wet well along with the discharge piping. The discharge connection elbow shall be constructed with a 125 lb. ANSI standard flat faced flange. The pump shall be automatically connected to the discharge connection elbow when lowered into place, and shall be easily removed for inspection or service. Sealing of the pumping unit to the discharge connection elbow shall be accomplished by a simple downward motion of the pump. 3. A sliding guide bracket shall be an integral part of the pump unit. The entire weight of the pump unit shall be guided by the guide bar(s) and pressed tightly against the discharge connection elbow to provide positive sealing under all conditions. 4. The entire sliding rail system shall be designed to safely withstand all stresses imposed thereon by vibration, torque, shock and all possible direct and eccentric loads. No portion of the pump shall bear directly on the floor of the sump. 5. Lower guide bar holders shall be integral with the discharge connection. Guide bars shall be of at least standard weight 316 stainless steel pipe of a conservative size adequate for its intended use. The guide bars shall not support any portion of the weight of the pump. 6. All anchor bolts, lifting bolts, eye lugs and lifting cable, etc. necessary for a complete installation and maintenance of the pump shall be constructed of Type 316 stainless steel and shall be adequately designed for its intended use. 7. All metal to metal interfaces where movement might occur shall be non-sparking. The slide mounting system for the influent pumps shall meet or exceed Underwriters Laboratory requirements for operation in a Class I, Division 1, Group D hazardous location. M. All anchor bolts, lifting bolts, eye lugs, etc. necessary for complete installation and maintenance of the pump shall be furnished by Supplier and constructed of Type 316 stainless steel and shall be adequately designed for its intended use. 2.03 ELECTRICAL AND CONTROL REQUIREMENTS A. The pump manufacturer shall provide the power and control cables between the pump and the local disconnect switch, junction box, or control panel (see Drawings) and shall be responsible for reviewing the Drawings to determine the required cable length. All pumps for the same pumping application shall be provided with the same length of cable. No splices shall be allowed unless specifically indicated on the Drawings. Cables shall be PVC or oil resistant cloroprene rubber jacketed type SPC cable suitable for submersible pump applications, shall be sized according to NEC and ICEA standards, and shall meet with MSHA approval. Stainless steel strain relief connectors shall be furnished for all cables. B. Cable Entry Water Seal 1. The cable entry water seal design shall insure a watertight and submersible seal without specific torque requirements. The cable entry shall be comprised of a single City of Denton Hazen and Sawyer BID SET 11130-6 Submersible Non-Clog Pumps cylindrical elastomer grommet, flanked by stainless steel washers all having a close tolerance fit against the cable outside diameter and the entry inside diameter and compressed by the entry body containing a strain relief function, separate from the function of sealing the cable. The assembly shall bear against a shoulder in the pump top. The cable entry junction chamber and motor shall be separated by a stator lead sealing gland or terminal board, which shall isolate gaining access through the pump top. The junction chamber containing the terminal board shall be sealed from the motor by an elastomer compression seal O-ring. Connection between the cable conductors and stator leads shall be made with threaded compressed type binding post permanently affixed to the terminal board and thus perfectly leak proof. Each pump shall be equipped with separate terminal board that totally isolates the incoming power supply from the pump motor. 2. An acceptable alternate cable entry seal shall include cable leads shall enter at the top of the motor and shall allow the cable-to-motor connection to be accomplished in the field without soldering. All power and control lead wires shall be double sealed as they enter the motor in such a manner that cable-wicking will not occur. This sealing system shall consist of a rubber grommet followed by epoxy that is high in adhesive qualities and has a low coefficient of expansion. Each conductor shall have a small section of insulation removed to establish a window area of bare wire and each wire shall be untwisted and surrounded by epoxy potting material. A cable strain relief mechanism shall be an integral part of the sealing system. The cable sealing system shall be capable of withstanding an external pressure test of 1,200 psi as well as a cable assembly pull test as required by Underwriters Laboratories. Power and control leads shall be terminated on a sealed terminal board. The terminal board and its bronze lugs shall be O-ring sealed. C. Electrical Requirements HCDF PCWRP WPFPS Pumps Motors Rating 480V, 3 ph, 60 Hz 480V, 3 ph, 60 Hz Horsepower (Max) 185 185 Speed, rpm (Minimum) 850 700 Insulation Class F Class F Explosion Proof Yes Yes Inverter Duty No No Service Factor 1.15 1.15 Motor Winding Temperature Switches Yes Yes Moisture Detection Probes Yes Yes Cooling Jacket Yes Yes D. The pump motor shall be a squirrel-cage induction type, housed in a watertight chamber. The stator winding and stator leads shall be moisture resistant. The use of bolts, pins, or other fastening devices requiring penetration of the stator housing shall not be allowed. E. The motor shall be guaranteed for continuous unsubmerged duty, capable of sustaining a minimum of ten (10) starts per hour without overheating. City of Denton Hazen and Sawyer BID SET 11130-7 Submersible Non-Clog Pumps F. The motor shall be provided with pre-lubricated radial and thrust bearings which are designed to carry the entire load which may be imposed upon it under all operating conditions. G. All motors shall be of nationally known manufacture, shall be housed in enclosures specifically designed for submersible pump application. H. Moisture detector probes shall be provided in the oil-seal chamber. The pump manufacturer shall provide a moisture detection relay compatible with the probes for each submersible pump. The relay shall also be capable of monitoring the motor winding temperature switches. The relay shall be shipped loose to the motor starter manufacturer to be installed by the motor starter manufacturer within the motor starter enclosure for each individual pump. 2.04 SPARE PARTS A. Spare parts shall be provided in accordance with Section 11000, Equipment General Provisions and shall include the following for each series of pumps One (1) - set of lower and upper wearing rings One (1) - set of motor and pump bearings One (1) - complete mechanical seal assembly (upper and lower) Two (2) - complete set of gaskets and O-ring seals PART 3 -- EXECUTION 3.01 MANUFACTURER’S FIELD SERVICES A. The services of a qualified manufacturer's technical representative shall be provided in accordance with Section 11000, Equipment General Provisions. For each series of pumps, field services shall include the following site visits: Service Number of Trips Number of Days/Trip Installation and Testing 1 1 Startup and Training 1 1 Services after Startup 1 1 3.02 SHOP TESTING A. Shop testing shall be in accordance with Section 11000, Equipment General Provisions and with the following additional requirements: 1. Impeller, motor rating and electrical connections shall be checked. 2. A motor and cable insulation test for moisture content or defective insulation shall be made. 3. Prior to submergence, the pump shall be run dry to establish correct rotation and mechanical integrity. City of Denton Hazen and Sawyer BID SET 11130-8 Submersible Non-Clog Pumps 4. The pump shall be run for 30 minutes submerged, a minimum of six (6) ft. under water. 5. After the run-dry test, the insulation test shall be performed again. 6. After the run-dry test, the pump shall be run continuously unsubmerged for 2 hours under full load with no damage to the motor. During this test, the pump shall demonstrate compliance with the specified performance for flow, head, and horsepower and shall experience a heat rise of not greater than 45C (80F) above ambient temperature. 7. Provide a 7-point pump curve for each pump. The testing shall be in accordance with the Hydraulic Institute Standards. 8. Provide standard hydrostatic test of volute for each pump. The testing shall be in accordance with the Hydraulic Institute Standards. 9. Pump manufacturer shall provide a certified written report stating that the foregoing tests have been completed and including results of each test with each pump at the time of shipment. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 11901-1 Washdown Booster Pump Station SECTION 11901 WASHDOWN BOOSTER PUMP STATION PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Furnish, deliver, install, test, and place in satisfactory operation a washdown booster pump station, complete with all necessary accessories and as specified herein. B. The washdown booster pump station shall consist of a hydropneumatic tank, two water pumps, control panel, and interconnecting piping, valves and appurtenances, assembled and mounted on a single painted hot-dip galvanized structural steel base. C. The components of the washdown booster pump station form an integrated system and are to be furnished by a single manufacturer, who is to provide all of the equipment and appurtenances regardless of manufacturer and is responsible for the satisfactory operation of the entire system. D. The Contractor shall provide washdown nozzles and interconnecting piping and valves as noted in the specifications and the drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Division 1 - General Requirements B. Division 5 - Metals C. Section 09900 - Painting D. Section 11000 - Equipment General Provisions E. Section 11100 – Pumps, General F. Division 15 - Mechanical G. Division 16 - Electrical H. Division 17 - Instrumentation 1.03 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Shall be as specified in Section 01090, Reference Standards. City of Denton Hazen and Sawyer BID SET 11901-2 Washdown Booster Pump Station 1.04 CONTRACTOR'S RESPONSIBILITY A. The services of a qualified manufacturer's technical representative shall be provided for a period of not less than two days as follows: 1. At least one trip of one day to check and supervise the equipment installation and field tests, supervise initial start-up and operation and to instruct the City personnel in proper operation and maintenance of the equipment. PART 2 -- PRODUCTS 2.01 MANUFACTURER A. Subject to compliance with this Specification, the following manufacturers have the capability of manufacturing the specified equipment: 1. Aurora 2. Grundfos 3. Or approved equal 2.02 MATERIALS AND/OR EQUIPMENT A. General: 1. The washdown booster pump station shall be factory prefabricated on a common structural steel skid with all components mounted and all interconnecting wiring and piping completed and factory tested prior to shipment. The only field connections are to be the connection of the system to the water supply, connection of the discharge piping, three phase power connection and discrete control connections to PLC-HCDF. 2. The suction and discharge manifolds, as well as the pressure sensing lines with shut-off cocks for gauges and pressure switches shall be furnished assembled. 3. Any connections to process piping shall be made with stainless steel tubing with compression fittings. Plastic tubing is not acceptable. 4. All electrical wiring shall be completed between the components and the control panel except the main power feed to the panel. 5. Washdown booster pump station shall include two (2) pressure switches, two (2) pressure gauges, one (1) pressure transmitter and one (1) flow switch. The lead pump shall be activated by the lead start pressure switch and deactivated by the high-pressure switch. A lead stop flow switch shall be provided as a fail-safe. A lag start/stop pressure switch and a low-pressure alarm shall also be provided. City of Denton Hazen and Sawyer BID SET 11901-3 Washdown Booster Pump Station B. Service Conditions: 1. Number of pumps: 2 2. Type of drive (variable or constant): constant 3. Flow Rate: 250 gpm 4. Minimum pressure required at pump discharge: 100 psi 5. Minimum suction pressure: 20 psi 6. Maximum suction pressure: 90 psi 7. Pump cycle time: 10 minutes (a maximum of a 6 start/stop/start per hour per pump under actual load conditions). 8. Maximum skid dimensions: 7 feet wide by 10 feet long. 9. Skid anchors: Provided by manufacturer. Anchor system shall be capable of retraining skid within concrete pad shown on the drawings. Anchors shall be 304 Stainless Steel. C. Pumps: 1. Type: vertical in-line, multi-stage centrifugal type 2. Impeller: AISI 316 Stainless Steel for all wetted components, AISI 316 Stainless Steel for non-wetted components. Flanged connections shall conform to ANSI B16.1 specifications with a minimum 250 lbf rating with Cast iron slip rings for easy piping assembly. 3. Case: Cast iron, ASTM A48 Class 30. 4. Shaft Seal: Mechanical seals with tungsten carbide vs. tungsten carbide seal faces, EPDM elastomers and 316 Stainless Steel metal parts. 5. Pump/Motor Shaft: 18-8 stainless steel shaft or S.A.E. 1045 carbon steel with bronze shaft sleeve. 6. Fittings: All wetted parts to be bronze or 304 stainless steel. 7. Locate discharge connections to allow removal of the rotating element without disturbing the system piping connections. City of Denton Hazen and Sawyer BID SET 11901-4 Washdown Booster Pump Station D. Motors: 1. Horsepower: 40 hp (maximum); 2. RPM: As required by driven equipment; 3. Voltage: 480V, 3 phase, 60 hertz; 4. Enclosure: TEFC; E. Hydropneumatic Tank: 1. Type: pre-charged, bladder type hydropneumatic tank, with a tank volume of 100 gallons at 0 psig 2. Material: ASME Code construction for 250 psi with replaceable high quality butyl rubber bladder 3. Minimum Working Volume: As recommended by the manufacturer. 4. Inlet: The inlet fitting shall be 2-in with NPT threads. 5. An air charge valve shall enable the pre-charge pressure to be increased or decreased 6. Furnish with mounting pads and brackets if pumps are tank shell mounted. F. Piping and Valves: 1. Piping: a. Material: Ductile Iron Pipe. b. End Connections: Flanges. c. Furnish unions or Dresser style connections to facilitate removal of equipment. d. Flexible Connectors: shall be of the flanged, single arch type, designed for pressure and vacuum service e. Provide an air gap bronze fitting, Zurn No. Z-1025 or equivalent by Josam. f. All piping, fittings, valves and gaskets in the plant service water station shall be rated for 250 psi minimum. City of Denton Hazen and Sawyer BID SET 11901-5 Washdown Booster Pump Station 2. Valves: a. Butterfly Valves shall be in accordance with Section 15101. b. Check Valves shall be in accordance with Section 15105. c. Butterfly Valves shall be in accordance with Section 15110. d. Pressure Reducing Valves shall be in accordance with Section 15114. G. Electrical Equipment 1. Controls: All control panels must be UL 508A listed as a complete assembly by the system supplier. All wiring and construction shall be in accordance with the latest N.E.C. codes and applicable Division 16 specifications. a. There shall be permanently affixed to the interior side of the exterior enclosure door a data plate, a laminated wiring diagram, and a bill of materials. The nameplate information shall include: horsepower, voltage, phase, full-load amps and short circuit current rating. The wiring diagram shall include: the control panel manufacturer’s name, address and telephone number along with the date of manufacture. The wiring diagram must be updated to reflect the actual construction and shall be labeled ‘As-Built’. b. Terminal points of all wires and terminal strips shall be permanently identified. All terminal numbers and identifying nomenclature shall correspond to and be shown on electrical diagrams. All circuit breakers, control switches, indicator pilot lights and other control devices shall be identified with permanently affixed legend plates and lamicoid-type engraved nameplates where applicable. 2. Enclosure: The control and power equipment shall be mounted in a NEMA 4X, 316 SS floor-standing enclosure with leg kit and three-point latch that is lockable. The enclosure shall include a removable backplate. All indicating lights, reset buttons, H-O-A switches, etc., shall be in accordance with Section 16902, and shall be mounted on a panel. 3. Transient Voltage Surge Suppression: An internally-mounted transient voltage surge suppressor shall be provided on the incoming power source to protect all electrical devices. Protection shall be rated for a minimum surge current of 50,000 amps per phase with a response time less than five nanoseconds. The device shall be installed per the manufacturer’s recommendations keeping the lead lengths as short as possible from the main circuit breaker. The unit shall be designed in accordance with ANSI/IEEE 62.41 and shall meet the requirement of UL 1449 latest edition. Transient voltage surge suppressor shall be manufactured by Square D or approved equal. In addition, all low-voltage analog signal cable connected to external equipment shall be protected with a UL 479B listed, plug-in style TVSS device. The low-voltage TVSS shall be Phoenix. City of Denton Hazen and Sawyer BID SET 11901-6 Washdown Booster Pump Station 4. Full Voltage Motor Starters shall be in accordance with Section 16481. 5. Circuit Breakers: Thermal-magnetic, molded-case circuit breakers shall be used to supply short circuit protection for each motor and shall be rated for a minimum 18,000 amp interrupting current. Fuses shall not be acceptable for motor power circuit protection. Circuit breakers shall be sized according to U.L. guidelines and be provided for the main disconnect, for each individual pump or motor circuit, and for the control power circuit. Circuit breakers shall be manufactured by Square D, Allen-Bradley or equal. 6. Control Power: The control power shall be single phase, 120 V and shall be derived by an integral control power transformer. Transformer shall be protected by primary and secondary fuses of a rating to conform to U.L. 508A standards. Reference Section 16481. 7. GFCI Receptacle: A 15 amp, duplex, GFI convenience receptacle shall be provided integral to the control panel, and powered through a dedicated circuit breaker. Receptacle shall be in accordance with Section 16141. 8. Phase Monitor: A plug-in type phase monitor shall be provided to sense phase loss and phase sequence. Automatic reset of the phase protection circuit shall occur after the fault condition has been corrected. Individual phase monitors on each motor are not required; single point monitoring of incoming phase is acceptable. Phase monitor shall be manufactured by Diversified or equal. 9. Standard panel features shall include: a. HAND/OFF/AUTO switch shall be provided for each pump. b. Start/Stop pushbutton shall be provided for each pump. c. Individual run and fault lights shall be provided for each pump. 10. In the HAND position, the pump shall operate using the full-voltage/across-the- line starter. In the OFF position, pump operation is not allowed. In the AUTO position, operation of the pumps shall be controlled by the PLC through SCADA. 11. Standard program features shall include: If the lead main pump is not capable of meeting the system demand, additional lag main pump(s) shall be started. The lead main pump shall alternate after each cycle. 12. The pumps shall automatically shut down upon the following conditions: a. High discharge pressure b. Low discharge flow City of Denton Hazen and Sawyer BID SET 11901-7 Washdown Booster Pump Station 13. Standard alarm and warning conditions shall include: a. High discharge pressure for each pump (to VCP-2000) b. Low common discharge flow (to VCP-2000) c. Phase failure, Low voltage, Phase Imbalance, Phase Reversal for each pump (to VCP-2000) d. Motor start failure for each pump (to VCP-2000) e. All alarms shall automatically reset unless noted otherwise. All alarms shall be indicated by a general alarm light and horn mounted on the exterior of the enclosure. An ‘ALARM SILENCE’ pushbutton, also located on the exterior of the enclosure, shall be provided. 14. Conduit and Wiring: All external wiring between the control panel and remotely mounted devices shall be enclosed in conduit. Conduit shall be in accordance with Section 16111. Wiring shall be in accordance with Section 16123. H. Instruments: 1. Pressure Gauges shall be in accordance with Section 17650. 2. Flow Switches shall be in accordance with Section 17660. 3. Pressure Switches shall be in accordance with Section 17675. 4. Pressure Indicating Transmitters shall be in accordance with Section 17760. I. System Base: 1. Main support members shall be of a standard structural shape like channel, wide flange or I-beam. 2. Lifting lugs shall be provided in the system base for attachment of chains and spreader bar for off-loading and handling at the installation site. 3. The structural base shall be covered with tread plate (minimum thickness shall be 3/16”) to provide a safe surface for maintenance personnel. 4. Welding: Skip welding of the top surface of the tread plate to the frame is not acceptable. All welding shall be performed by AWS D1.1 certified welders – certificates must be submitted. City of Denton Hazen and Sawyer BID SET 11901-8 Washdown Booster Pump Station PART 3 -- EXECUTION 3.01 INSTALLATION A. Install the washdown booster pump station in accordance with the Drawings, shop drawings, and manufacturer’s installation manual. The service waster station shall be installed on an equipment pad. The underside of the skid shall be coated with coal tar epoxy, a minimum thickness of 10 mils, DFT. 3.02 PROTECTIVE COATINGS A. All surface preparation, shop painting, field painting and field repairs shall conform to Section 09900. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 13205-1 Prestressed Concrete Tank SECTION 13205 PRESTRESSED CONCRETE TANK (TYPE III) PART 1 -- GENERAL 1.01 THE REQUIREMENTS A. Provide all labor, material, and equipment required to design, construct, disinfect and test the AWWA D110 Type III prestressed concrete tank with all accessories required for a complete installation, as indicated in the Contract Documents and specified herein. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 03100 - Concrete Formwork B. Section 03200 - Reinforcing Steel C. Section 03250 - Concrete Accessories D. Section 03290 - Joints in Concrete E. Section 03300 - Cast-In-Place Concrete F. Section 03350 - Concrete Finishes G. Section 03360 - Shotcrete H. Section 03370 - Concrete Curing I. Section 03400 - Precast Concrete 1.03 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Without limiting the generality of other requirements of the Specifications, all work hereunder shall conform to the applicable requirements of the following documents to the extent that the requirements therein are not in conflict with the provisions of this Section. 1. ACI 301 — Specifications for Structural Concrete for Buildings 2. ACI 304 — Recommended Practice for Measuring, Mixing, Transporting, and Placing Concrete 3. ACI 305R — Hot Weather Concreting 4. ACI 306 — Cold Weather Concreting 5. ACI 318 — Building Code Requirements for Reinforced Concrete 6. ACI 347 — Recommended Practice for Concrete Formwork City of Denton Hazen and Sawyer BID SET 13205-2 Prestressed Concrete Tank 7. ACI 350 R — Code Requirements for Environmental Concrete Structures and Commentary 8. ACI 423 — Prestressed Concrete 9. AWWA D110 — Wire-Wound Circular Prestressed Concrete Water Tanks 1.04 INFORMATION FURNISHED BY OWNER A. Applicable information to be furnished by Purchaser for one prestressed concrete tank keyed to the respective paragraphs as outlined in the Foreword of AWWA Specification D110 is included in the following Tank Schedule A. Tank Schedule A Summary of Information to be Furnished by Purchaser for a Type III Core Wall Tank per AWWA Specification D110 AWWA ITEM 1. Tank shall be of Type III construction with composite shotcrete- mechanically bonded steel diaphragm walls and wire-wound construction designed in accordance with AWWA D110, ACI 350 and the International Building Code. Tank shall be designed by the manufacturer for loadings from all sources, including dead, live, internal fluid, soil, groundwater, wind and seismic in accordance with all applicable state and local codes. These loads shall be stated in the design calculations to be submitted in accordance with Article 1.05 of this Section. 2. One (1) tank with a nominal storage capacity of three million, five hundred thousand (3.5 million) gallons. Nominal inside diameter = 136’-6” Nominal side water depth = 32’-0” Design High Water Level = EL 614.00 Bottom Elevation at Perimeter = EL 582.00 3. Subdrainage and overflow collection systems shall be as indicated in the Contract Documents and as further detailed in Items 12, 13, and 19 of this Schedule. 4. All design loads and calculations shall be included in the design calculation report required by Section 1.05.d Dead load shall be the estimated weight of all permanent construction and fittings. The unit weight of concrete shall be 150 lbs. per cubic foot. The unit weight of steel shall be 490 lbs. per cubic foot. Live loads shall be the estimated weight of all the liquid when the tank is filled to the maximum water surface elevation designated herein. The unit weight of water shall be 62.4 lbs. per cubic foot. Snow loads shall be included in accordance with the International Building City of Denton Hazen and Sawyer BID SET 13205-3 Prestressed Concrete Tank Tank Schedule A Summary of Information to be Furnished by Purchaser for a Type III Core Wall Tank per AWWA Specification D110 Code, Section 1608 – Snow Loads, using a ground snow load of 5 psf, an importance factor of 1.10, a thermal factor of 1.2, and a snow exposure factor of 0.9, and AWWA D110. Wind loads shall be computed in accordance with Section 6 of ASCE 7 and the International Building Code, Section 1609 – Wind Loads, using a 120 mph basic wind velocity, exposure category C, and AWWA. The Contractor shall compute the seismic design loads per AWWA Standard D110. The Contractor shall also compute the seismic design loads in accordance with Section 1613 of the International Building Code, using a seismic importance factor of 1.25. The most stringent design loads from the two codes shall be used to design the tank and foundations. Seismic information required: a) Seismic Design Category A b) Seismic Importance factor = 1.25 c) Structural response coefficients for type of tank shall be as determined by the tank manufacturer. d) Seismic Site Class C 5. The tank is to be located on the property of the Owner at the location indicated on the Drawings. 6. Contractor is responsible for providing permanent 480 volt electric power for the facility and shall provide his own temporary power. Compressed air is not available at the site. The Contractor shall be responsible for providing compressed air as required for construction. 7. a) Concrete Dome Roof: Where a concrete dome roof is shown, it shall be cast-in-place concrete of spherical shape with a rise between 1:8 and 1:14 per the manufacturer's design, subject to this Specification. Dome shall be clear span, supported by the tank wall with no interior columns or supports with a circumferentially prestressed concrete ring beam designed to withstand all induced loads. Dome thickness shall be governed by buckling resistance, by minimum thickness for practical construction or by corrosion protection for reinforcement provided that the thickness of the dome shall not be less than three inches for monolithic concrete. The top of the dome shall not exceed the maximum elevation indicated on the drawings. b) Aluminum Dome Roof: (Not Used) 8. The tank shall be constructed as a composite precast concrete-steel core wall using a mechanically bonded and continuous steel diaphragm wall with wire wound prestressing, and shall be designed in accordance with AWWA D110, ACI 350 and the International Building Code. Where these specifications are in conflict, the more stringent requirements shall apply except where stated City of Denton Hazen and Sawyer BID SET 13205-4 Prestressed Concrete Tank Tank Schedule A Summary of Information to be Furnished by Purchaser for a Type III Core Wall Tank per AWWA Specification D110 otherwise herein. 9. A subsurface investigation report provided by the Owner is included as an Appendix to these Specifications. 10. Accessory equipment as detailed in Section 2.11 of this specification shall be provided in accordance with AWWA D110 and the Contract Documents. Locations shall be as indicated in the Contract Documents. 11. Piping shall conform to Division 15 - Mechanical. Piping includes, but is not limited to, inlet, outlet, and overflow piping. Earth cover over pipes shall be as indicated in the Contract Documents. Pipe material shall be as detailed in Contract Documents. Pipe supports and concrete pipe encasements attached to the tank shall be designed, furnished, and installed by the tank manufacturer. Pipe supports and fasteners shall be Type 316 stainless steel. Pipe Connections: The tank manufacturer shall furnish and install with the following pipe connections: a) 30" inlet connection through the floor b) 18” foul air roof outlet connection c) 24" overflow floor connection – alterations to the overflow diameter shall be based on the design of the tank manufacturer, based upon the maximum fill flow rate provided herein, and shall not be at the expense of the Owner. d) 12” floor drain connection and trash screen e) Three (3) 6" tank washdown nozzle roof connections f) Two 36” vacuum vent connections All pipe connections shall be made in a manner that will provide absolutely watertight connections and shall be in accordance with standard practices of the industry and applicable AWWA and NSF specifications. 12. Design fill rate and maximum fill, overflow and withdrawal rates shall be as follows: Design Fill Rate: 24 mgd Max Fill Rate: 24 mgd Max Overflow Rate: 24 mgd Max Withdrawal Rate: 5 mgd 13. The overflow pipe arrangement, elevation and freeboard shall be as shown on the Contract Drawings. 14. Exterior wall coatings and architectural treatment shall be as detailed in the Contract Documents. City of Denton Hazen and Sawyer BID SET 13205-5 Prestressed Concrete Tank Tank Schedule A Summary of Information to be Furnished by Purchaser for a Type III Core Wall Tank per AWWA Specification D110 15. Seismic joints shall be Type C – Unanchored and Uncontained Flexible Base per AWWA D110. However, it shall be the responsibility of the Contractor to determine whether Type B – Anchored Flexible Base joints are required to meet seismic requirements. If required, seismic cables, shall be designed in accordance with Section 5.8 of AWWA D110. 16. The maximum allowable stresses and reinforcement requirements shall be in accordance with Section 4.6 of AWWA D-110. 17. The maximum allowable coefficient of friction requirements shall be in accordance with Section 4.7 of AWWA D-110. 18. Foundations: A subsurface investigation report provided by the Owner is included as an Appendix to these Specifications. Foundations shall be designed and furnished by the Contractor as follows: a) The drilled pier supported floor slab for the Prestressed Concrete Tank shall be designed by the Prestressed Concrete Tank manufacturer in accordance with Article 3.02. Contractor shall submit details and calculations on the floor slab design. b) The design of the concrete floor slab, the specifications for the cement and aggregate, and the mixing of the aggregate shall be in accordance with the latest revision of Standard 318 of the American Concrete Institute and Section 03300 of these Specifications. Concrete for the tank floor slab and pipe encasement shall have a minimum compressive strength of 4,500 pounds per square inch at 28 days and meet requirements of Section 03300 for Class A1 concrete. Reinforcement shall comply with the latest revision of ASTM A615, Grade 60, and Section 03200 of these Specifications. 19. The required elevation of the overflow pipe shall be as shown on the Contract Drawings. 20. The Contractor shall be responsible for designing for any dynamic seismic forces caused by the backfill surrounding the tank. 21. Finished grade shall vary from approximately elevation 580.0’ to elevation 581.5’. 22. It shall be the responsibility of the Contractor to determine whether seismic cables are required between the base of the wall and the footing. If required, seismic cables, shall be designed in accordance with Section 5.8 of AWWA D110. City of Denton Hazen and Sawyer BID SET 13205-6 Prestressed Concrete Tank 1.05 SUBMITTALS A. Shop Drawings: 1. The following items shall be submitted with the Shop Drawings in accordance with, or in addition to the submittal requirements specified in Section 01300, Submittals: a. Complete record of experience of proposed prestressed concrete AWWA D110 Type III tank manufacturer, including names of Owners and dates of construction for no less than five installations designed and constructed in the name of the manufacturer, of comparable size or larger now in service. b. Shop Drawings of the tank and foundation including erection, installation, and adjustment instructions. Included with the Shop Drawings shall be all material certifications, mill test reports, etc., which are required by this and other applicable sections of the Specifications. c. Certification signed and sealed by a Professional Engineer currently registered in the State of Texas that the tank design conforms to the requirements of the Specifications, Codes, and Standards referenced herein. d. Design drawings and calculations for the tank shall be signed and sealed by a Professional Engineer currently registered in the State of Texas, with design loads listed at the beginning of the calculations. Submittal of calculations and subsequent review by the Engineer shall not relieve the Contractor from full responsibility for the accuracy and completeness of his design. e. Copies of Shotcrete Nozzlemen certificates. f. Operation and Maintenance Manuals. 1.06 QUALITY ASSURANCE A. Contractor shall be solely responsible for the adequacy of design and safety of the completed structure, and shall provide the services of the prestressed concrete tank manufacturer for the design and construction of the structure to meet the requirements stated herein. The entire tank, including all portions of the bottom slab, walls and roof shall be constructed by the prestressed concrete tank manufacturer. This stipulation applies even when design of bottom slab is included on Contract Drawings. B. The prestresed concrete tank manufacturer shall be a specialist in the design and construction of prestressed concrete tanks with at least ten years experience which shall include no less than five installations of comparable size or larger now in service. C. The prestressed concrete tank manufacturer shall have on its staff a full-time Professional Engineer registered in the State of Texas who will be in responsible engineering charge of the work and who has been the Engineer of Record for a minimum of five (5) Type III City of Denton Hazen and Sawyer BID SET 13205-7 Prestressed Concrete Tank AWWA D110 tanks of equal or greater capacity within the last 10 years, in successful service for at least five (5) years. All design calculations shall be sealed and signed by such Professional Engineer. 1.07 WARRANTY A. Contractor shall guarantee the design, workmanship, and materials for a period of five years from date of acceptance of the work. In case leakage or other defects appear within the five-year period, he shall promptly make required repairs at his own expense upon written notice by the Owner that such defects have been found. Leakage through the side walls shall be defined as the appearance of free liquid showing stream flow on the exterior surface, the source of which is from inside the tank. PART 2 -- PRODUCTS 2.01 GENERAL A. Prestressed concrete tank(s) shall be of precast concrete corewall with mechanically bonded steel diaphragm and wire wound construction. B. The AWWA D110 Type III tank(s) shall be as manufactured by DN Tanks., El Cajon, CA; Preload Inc., Hauppauge, NY. C. Experience in the design and construction of AWWA D110 Type I, Type II, or Type IV tanks is not an acceptable substitute for the specified Type III tank. 2.02 CONCRETE A. Concrete materials including cement, aggregate, water, admixtures, and mix design shall conform to Section 03300 - Cast-In-Place Concrete. Concrete for the tank wall and dome construction shall have a minimum compressive strength of 4,500 psi at 28 days. Concrete for the tank floor, footings, pipe encasement, and other work associated with construction of the tank shall have a minimum compressive strength of 4,500 psi at 28 days. All cast-in- place concrete used for construction of the Prestressed Concrete Tank shall meet the requirements of Class A1 concrete in accordance with Specification Section 03300. B. Concrete for tank wall and dome construction shall be air-entrained. C. Concrete or shotcrete in contact with prestressing steel shall have a maximum water soluble chloride ion concentration of 0.06 percent by weight of cement. D. Curing materials shall conform to Section 03370, "Concrete Curing". 2.03 GROUT A. Mortar fill and non-shrink grout shall have a minimum compressive strength of 4,500 psi at 28 days. City of Denton Hazen and Sawyer BID SET 13205-8 Prestressed Concrete Tank 2.04 FORMWORK A. Formwork for concrete work shall conform to Section 03100 - Concrete Formwork. 2.05 REINFORCING STEEL (OTHER THAN PRESTRESSING WIRE) A. Reinforcing bars, welded wire fabric, bar supports, bolsters, chairs, spacers, and tie wire shall conform to Section 03200 - Reinforcing Steel. 2.06 STEEL DIAPHRAGM A. Steel diaphragm shall be a minimum of 0.017 inch thick steel complying with ASTM A1008 for commercial quality cold rolled steel. B. Steel sheet shall be vertically ribbed with adjacent and opposing channels that provide a mechanical bond to the concrete. The base of the channels shall be wider than the throat. 2.07 PRESTRESSING WIRE A. Circumferential prestressing wire shall be cold drawn, high carbon wire conforming to the requirements of ASTM A821, having a minimum ultimate tensile strength of 210,000 psi. B. Splices and anchor clamps for prestressing wire shall be ferrous material compatible with the wire and shall develop the full strength of the wire. Wire splice and anchorage accessories shall not nick or otherwise damage the prestressing. C. Contractor shall furnish certified statement from approved independent testing laboratory for wire used. 2.08 SHOTCRETE A. Shotcrete shall conform to Section 03360 - Shotcrete, and shall have a compressive strength as required by the design, but shall in no case be less than that stated in Section 5.6 of AWWA D110. 2.09 WATERSTOP, BEARING PADS AND JOINTS A. Waterstop between foundation and core wall shall be PVC, conforming to Sections 03250 – Concrete Accessories and 03290 - Joints in Concrete. Splices shall be made in accordance with the manufacturer’s recommendations subject to the approval of the Engineer. B. Bearing pads shall be neoprene or natural rubber or other material which does not degrade in the presence of chloramines. Pads shall have a minimum tensile strength of 1500 psi, and a minimum elongation of 500 percent. 1. Natural rubber bearing pads shall contain only virgin natural polyisoprene as the raw polymer and the physical properties shall comply with ASTM D2000 Line Call-Out M 4 AA 414 A13. City of Denton Hazen and Sawyer BID SET 13205-9 Prestressed Concrete Tank 2. 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 D2000 Line Call-Out M 2 BC 410 A1 4 B14 for 40 durometer material. C. Sponge filler shall be closed-cell neoprene or rubber conforming to ASTM D1056, Type 2, Class A, and Grade 1. Compression deflection limited to 25 percent at two to five psi. D. Polysulfide or polyurethane sealant will be a two or three component elastomeric compound meeting the requirements of ASTM C920. Sealants must have permanent characteristics of bond to metal surfaces, flexibility, and resistance to extrusion due to hydrostatic pressure. Air cured sealants shall not be used. 2.10 COATINGS (NOT USED) 2.11 MISCELLANEOUS TANK ACCESSORIES A. The following accessories shall be furnished by the Contractor as indicated in the Contract Documents: 1. Aluminum exterior ladder, complete with a fall prevention system and anti-climb guard. Anti-climb guard shall not interfere with the fall prevention system, and it shall be hinged and lockable with a hasp. Aluminum ladder fall prevention system shall be as specified in Section 05515 - Ladders. 2. Aluminum handrail shall be as specified in Section 05520 - Handrails and Railings. 3. Roof hatch, service hatch and covers shall be as specified in Section 05531 - Gratings, Access Hatches, and Access Doors. Roof hatch shall be 48” x 48” with cover as indicated in the Contract Documents. Service hatch shall be 10’ x 10’ with cover as indicated in the Contract Documents. 4. Two (2) 36” aluminum vacuum ventilator with corrosion protection coating shall be provided. The ventilators shall be sized per the Tank Manufacturer and as indicated in the Contract Documents. 5. One circular 30 inch diameter Type 316 stainless steel wall manway with a hinged cover. A Type 316 stainless steel grab bar and an aluminum ladder shall be installed at the manway location. Manway cover to include a hand wheel and yoke with two padlock hasps. Locate access manway as shown on the drawings. 6. Piping shall conform to Division 15 - Mechanical. Piping includes, but is not limited to, inlet, outlet, drain and overflow piping. 7. Overflow piping shall be as indicated in the Contract Documents. Tank design shall consider support required for overflow piping. 8. Dome safety lifeline system shall be the Xenon Horizontal Lifeline System by Miller. The lifeline cable and system components shall be Type 304 stainless steel. City of Denton Hazen and Sawyer BID SET 13205-10 Prestressed Concrete Tank Intermediate supports shall be provided to insure the lifeline does not rest on the dome. These interior supports shall be either 6061-T6 Aluminum or Type 304 stainless steel. Anchors shall be used to connect the lifeline system to the tank dome shall be Type 304 stainless steel. 9. Fiberglass interior ladder, complete with a stainless steel fall prevention system and extendable safety post. Fall prevention system shall be as specified in Section 05515 - Ladders 2.11 VOID BOXES A. Void boxes shall be capable of supporting the weight of the foundation slab during placement and to accommodate soil expansion. Void boxes shall be fabricated with moisture resistant cardboard and have carton void forms. PART 3 -- EXECUTION 3.01 GENERAL A. Dimensions and structural details indicated in the Contract Documents are minimum requirements. The Contractor shall provide whatever additional thicknesses, reinforcing, etc is necessary to meet code and structural requirements. 3.02 TANK FLOOR AND FOUNDATION A. The concrete tank floor shall be constructed of Class A1 reinforced cast-in-place concrete containing not less than 0.5 percent reinforcing steel in each orthogonal direction distributed between two mats for slabs 24 inches, for slabs greater than 24 inches the minimum reinforcement may be as required for 24 inches, and conforming to all applicable sections of the Contract Documents for concrete and reinforcement, as listed herein. B. The floor slab shall be designed as a drilled pier concrete slab not less than 24” thick. The floor slab shall be thickened as required beneath baffle walls, at sumps and in other locations specified by the tank manufacturer. C. The minimum concrete cover over steel reinforcement shall be 2 inches. Where cast directly against grade, the cover shall be increased to 3 inches, unless otherwise indicated. D. The tank manufacturer shall be responsible for providing and protecting void boxes during construction. Void boxes shall be stored in a dry storage trailer or watertight containers until time of placement. Wet voids boxes are rejected and shall be replaced prior to concrete placement. E. The Contractor shall repair all cracks in the tank floor slab at his own expense using a method approved by the Engineer. 3.03 CORE WALL City of Denton Hazen and Sawyer BID SET 13205-11 Prestressed Concrete Tank A. The core wall shall be constructed of precast panels with mechanically bonded steel diaphragm. Vertical joints shall be filled with shotcrete, mortar or cast-in-place concrete. B. The diaphragm shall be continuous throughout the core wall providing a positive waterstop without horizontal joints. 1. Vertical diaphragm joints within a wall panel shall be roll seamed or otherwise fastened in a fashion that results in a firm mechanical lock. Only vertical diaphragm joints shall be used. Joints between wall panels that are not roll seamed shall be edge sealed with polysulfide or polyurethane sealant. The diaphragm, crimper, and sealant must have demonstrated suitability through successful use in at least five comparable installations. The final determination of suitability shall be determined solely by the Engineer. 2. The steel diaphragm shall extend to within one inch of the full height of the wall panel with no horizontal joints. 3. No holes, including nailholes, shall be made in the diaphragm for any purpose, including the purpose of erection, before, during, or subsequent to erection, except for those required for inserting pipe sleeves, temporary openings, or other special appurtenances. 4. Precast panels shall be fabricated to the curvature of the tank radius. The tolerance in panel wall thickness shall be – 0 to + ¼ inch. Concrete for each panel shall be placed in one continuous operation. 5. After each precast panel has firmed sufficiently, it shall be covered with polyethylene sheet for curing. C. Vertical reinforcing to compensate for shrinkage, temperature, and vertical bending moments in the core wall shall be as follows: 1. A continuous steel diaphragm with reinforcing steel bars as required by design computations. D. Core wall thickness at the top of the tank shall be not less than 8-inches. Base-of-wall thickness shall be determined by design calculations to resist the initial compressive stresses of the prestressing wire, backfill, and other applicable loads. The wall may taper uniformly on the outside face from top to bottom as required by design thicknesses. The wall taper shall be as determined by the tank manufacturer. Thickness + 1/4 inch to +1/2 inch Height 1/4 inch in 100 ft. not to exceed a total of 1/2 inch Out-of-plumb 1/4 inch in 10 ft. of height Out-of round ± 1 inch per 100 ft. diameter City of Denton Hazen and Sawyer BID SET 13205-12 Prestressed Concrete Tank E. Bearing pads shall be located and held in their proper position prior to erection of wall panels. Nailing of pads shall not be permitted. The edges of adjoining panels shall not vary inwardly or outwardly by more than 3/8 inch and shall be placed to the tank radius within +/- 3/8 inch. F. Unless specifically authorized in writing by the Engineer, concrete shall not be placed without special protection during cold weather when the ambient temperature is below 35 degrees Fahrenheit or when the concrete is likely to be subjected to freezing temperatures before initial set has occurred and the concrete strength has reached 500 psi. G. The Contractor shall furnish, install and coordinate all work including, but not limited to, tank construction, telemetry work, electrical work, and mechanical work. H. Prior to the placement of the drilled pier supported foundation concrete, all piping that penetrates the floor shall be set. 3.04 HORIZONTAL PRESTRESSING: A. Circumferential prestressing of the tank walls shall be accomplished by applying continuously and uniformly a prestressing steel wire to the core wall in a helix of such pitch as to provide an initial predetermined force and unit compressive stress in the core wall per lineal foot of height equivalent to that derivable from the Contract Documents. Splicing of the wire shall be permitted only when terminating an application of one complete coil of wire or in the event a defective section of wire must be removed during application. A machine shall be used for applying the wire, capable of continuously inducing a uniform initial force in the wire as it is laid on the tank wall. The wire winding machine shall be capable of consistently producing a stress in the wire within a range of -7 percent to +7 percent of the stress required by the design. Force in the wire shall be induced by methods in accordance with AWWA D110 Sections 2.5.2.1 and 5.6. Only the aggregate force of all stressed wires per foot shall be considered rather than the force per individual wire, and such aggregate force shall not be less than required by the Contract Documents. No circumferential movement of the wire along the tank wall will be permitted during or after stressing of the wire. Each coil of prestressing wire shall be temporarily anchored at sufficient intervals to minimize the loss of prestress in case a wire breaks during wrapping. The steel wire bands on the core wall and dome ring shall be so placed that the prestress "working force" per foot of wall height shall exceed the hydraulic ring tension forces by not less than 5 percent. The "work force" shall be defined as the force determined by multiplying the area of steel wire by the unit wire stress after a substantial allowance for prestress losses due to shrinkage and plastic flow in the shotcrete, relaxation in the steel, creep, etc has been made from the initial unit wire stresses. Such initial unit wire stress readings shall be made the same day the wire is placed, or if made later and after some stress losses have already occurred due to creep of wire, plastic flow, and shrinkage of core wall, allowances shall be made for such losses. B. Minimum clear space between prestressing wires is 5/16 inch or 1.5 wire diameters, whichever is greater. Any wires not meeting the spacing requirements shall be re-spaced. Prestressing shall be placed no closer than two inches from the top of the wall, edges of opening, or inserts, nor closer than three inches from the base of walls or floors where radial movement may occur. City of Denton Hazen and Sawyer BID SET 13205-13 Prestressed Concrete Tank C. At all openings through the sidewalls, the wires shall be placed equally above and below the opening. The displaced wires will be added to those for a foot or two above and below the opening, leaving an entire strip around the tank which is unbanded. Such unbanded strip shall be no more than 24-inches high. Bundling of wires shall be prohibited. A stress plate shall be required at all above grade locations where prestress wires are displaced 24 inches or greater. The stress plate shall be designed to transfer stress across the opening. D. No prestressing wire shall be installed until the corewall shotcrete has been shown by test to have attained at least 1.8 times the compressive stress being applied. No prestressing wire shall be applied when weather conditions are unfavorable. E. Each prestress wire shall be individually encased in shotcrete. Where more than one layer of wire is required, under layers shall be covered with shotcrete of sufficient thickness to provide approximately 1/4-inch cover over the wire. F. Finish covercoat shotcrete shall be applied as soon as practical after the last application of wire coat, see Article 3.07. G. Attention is directed to the fact that prestressing wire is susceptible to failure through corrosion. Extreme care shall be used to protect the wire against leakage of water from inside and outside the tank. 3.05 STRESS MEASUREMENT: A. The Contractor shall supply, at his own expense, special equipment at the job site capable of measuring the stress in the wire after it is in place on the wall. This stress-measuring equipment shall consist of an electronic direct-reading stressometer accurate to within 1 percent, calibrated by an independent laboratory immediately prior to construction. B. At least one stress reading per vertical foot or one stress reading for every roll of wire, whichever is greater, shall be taken immediately after the wire has been applied on the wall. All readings shall be recorded and shall refer to the applicable height and layer of wire for which the stress is being taken. If applied stresses fall below the design stress in the steel, additional wire will be provided to bring the force on the corewall up to the required design force. If the stress in the steel is more than 7% over the required design stress, the wrapping operation should be discontinued, and satisfactory adjustment made to the stressing equipment before proceeding. 3.06 TESTING A. Leakage Testing 1. The prestressed concrete tank shall be tested for leakage. For tanks containing potable water, leak testing may be concurrent with tank disinfection and shall be as defined herein. For tanks containing non-potable water, leakage testing shall be performed in accordance with Section 01470 Watertightness Testing of Concrete Structures. 2. Water for the initial leakage testing, cleaning and, rinsing shall be paid for and provided by the Owner. Water for all subsequent leakage testing should it be City of Denton Hazen and Sawyer BID SET 13205-14 Prestressed Concrete Tank required, shall be paid for by the Contractor and provided by the Owner. The Contractor shall reimburse the Owner for all water used at the current rates for water usage. The costs for all chemicals and equipment (pumps, testing kits, etc.) associated with leakage testing, cleaning, or rinsing, of the tank shall be the responsibility of the Contractor. Disposal of water for leak testing, cleaning and, rinsing, shall be the responsibility of the Contractor, performed under the City’s General Permit, and shall be performed in accordance with all federal, state and local requirements in such a manner as to cause no adverse environmental effects such as fish kills or erosion. A water disposal plan shall be submitted to the Engineer prior to tank cleaning and filling. 3. The wire-wound prestressed concrete tank shall be tested for water tightness in accordance with AWWA D110 Section 5.13 upon completion of the tank. 4. The following test shall be applied to determine water tightness: a. Fill the tank with potable water (at the Owner’s option) to the maximum liquid level indicated. b. At least 95 percent of the maximum wetted surface area shall be wetted for at least 72 hours to allow for moisture absorption by the concrete. c. The drop in liquid level shall be measured over the next 24 hours. The liquid-volume loss shall not exceed one twentieth of one percent of the tank capacity. Evaporative effects shall be taken into consideration in determining leakage. If leakage exceeds the maximum allowable, the tightness test shall be extended to a total of five days. If at the end of five days, average daily leakage does not exceed the maximum allowable, the test shall be considered satisfactory. If the average daily leakage exceeds the maximum allowable, the Contractor shall repair the tank and retest it at no additional cost to the Owner. The method of repair shall be submitted to the Engineer for approval. d. Damp spots on the exterior wall surface shall not be permitted. Damp spots are defined as spots where moisture can be picked up on a dry hand. The source of water movement through the wall shall be located and permanently sealed in an acceptable manner. No leakage that includes visible flow through the wall-floor joint shall be permitted. 3.07 EXTERIOR COVERCOAT A. After circumferential prestressing wires have been placed by a wire winding machine the wires shall be covered with shotcrete conforming to Section 03360 – Shotcrete, or equivalent, that will provide a minimum thickness over the wire of 1 inch. B. The exterior covercoat shall have a gun finish. Shotcrete shall be applied with the nozzle held at a small upward angle not exceeding five (5) 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 City of Denton Hazen and Sawyer BID SET 13205-15 Prestressed Concrete Tank build up or cover the front face of the wire until the spaces behind and between the prestressing elements are filled. C. Total covercoat thickness shall be controlled by shooting guide wires. Vertical wires shall be installed under tension and spaced no more than 2 feet apart to establish uniform and correct coating thickness. Guide wires shall be removed after placement of the covercoat. 3.08 PAINTING A. After erection and testing is complete, the tank exterior shall be painted if applicable in conformance with Section 09800 - Special Coatings, or Section 09900 - Painting. 3.09 START-UP SERVICES A. The Contractor shall furnish the services of the manufacturer's technical representative to inspect and correct or supervise correction of any defects or malfunctions and furnish start-up services. The Contractor shall provided qualified technical representative(s) to inspect the completed installation. Costs to check the installation shall be included in the purchase price of the equipment. The manufacturer's technical representative shall be available for system start-up, performance tests, and operating instructions for not less than a 2-day period. 3.10 FINAL INSPECTION A. On or near the one-year anniversary date of initial tank use the manufacturer's representative shall make a visual inspection of the tank exterior and appurtenances and the immediate area surrounding the tank. A written summary of this inspection shall be filed with the tank owner and the tank manufacturer. END OF SECTION City of Denton Hazen and Sawyer BID SET 13205-16 Prestressed Concrete Tank This page left blank intentionally City of Denton Hazen and Sawyer BID SET 13217-1 Tank Cleaning System SECTION 13217 TANK CLEANING SYSTEM PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The manufacturer shall furnish and test three (3) tank cleaning systems. Each cleaning system includes a turbine driven nozzle and all three nozzles shall operate concurrently. The Contractor shall install provide and install the cleaning machines and piping shown on the drawings for a complete and operable system. 1.02 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. International Organization for Standardization (ISO) 9001 Quality Standards B. American National Standards Institute (ANSI) Standards C. American Iron and Steel Institute (AISI) Standards D. American Society of Mechanical Engineers (ASME) Standards 1.03 SUBMITTALS A. In addition to the submittal requirements specified in Section 01300, Submittals, submit the following for each odor control system: 1. Operation and Maintenance Instructions 2. Manufacturer’s literature, illustrations, specifications and engineering data including dimensions, materials, size and weight of all components and complete assembly 3. Complete erection, installation, and adjustment instructions and recommendations 4. Drawings showing plans and sections of the equipment to demonstrate proper coordination between components, fabrication methods, assembly and accessories 5. Performance test procedures for the systems. 1.04 MANUFACTURER’S RESPONSIBILITY A. The Manufacturer shall be responsible for coordination of the design and fabrication of the tank cleaning system shown on the Drawings and specified herein. B. The Manufacturer shall coordinate and review installation procedures under other Sections and coordinate the installation of items that must be installed to comply with the requirements of the Work specified under this Section. City of Denton Hazen and Sawyer BID SET 13217-2 Tank Cleaning System C. The services of the manufacturer's representative shall be provided in accordance with Section 01650 – Field Testing, Section 01660 – Equipment Testing and Startup, and Section 11000 – Equipment General Provisions. D. Any additional time required to achieve successful installation and operation shall be at the expense of the Contractor. E. A written report covering the representative's findings and installation approval shall be submitted to the Engineer covering all inspection and outlining in detail any deficiencies noted. F. The times specified are exclusive of travel time to and from the facility and shall not be construed as to relieve the manufacturer of any additional visits to provide sufficient service to place the equipment in satisfactory operation. 1.05 QUALITY ASSURANCE A. All components of the tank cleaning system shall be supplied by a single manufacturer fully experienced, reputable, and qualified in the manufacture of the equipment to be furnished. B. Manufacturer shall have at least five (5) years experience in the design and fabrication of the specified tank cleaning system and shall, at the Engineer’s request, provide a list of at least five (5) successful installations operating for a minimum of three (3) years of comparable size and application, with references including valid current contact names and phone numbers. PART 2 -– MATERIALS 2.01 ACCEPTABLE MANUFACTURERS A. The manufacturer shall be responsible for the coordination of all equipment specified herein. The tank cleaning system shall be a turbine driven nozzle as manufactured by ScanJet or equal. B. The materials covered by these Specifications are intended to be standard equipment of proven reliability and as manufactured by reputable manufacturers having experience in the production of such equipment. The equipment furnished shall be designed, constructed, and installed in accordance with the best practices and methods and shall operate satisfactorily when installed as shown on the Contract Drawings and operated per manufacturer’s recommendations. 2.05 TANK CLEANING SYSTEM A. Each cleaning system shall be turbine driven with a set turning angle to be determined by the manufacturer and provided on the installation drawings. The spray pattern shall be programmable by use of external mechanical screws. The cleaning unit shall be programmed and tested specifically for the tank on this project, to cover the floor and walls up to the high City of Denton Hazen and Sawyer BID SET 13217-3 Tank Cleaning System water elevation shown on the Drawings. The unit shall operate without pneumatic or electrical drives or controls. B. Tank cleaning system nozzle shall be ScanJet model SC30T or equal with the following operating and design parameters. 1. Minimum nozzles size = 12mm 2. Maximum flow rate = 80 gpm per nozzle 3. Minimum pressure = 150 psig at the nozzle 4. Minimum inlet connection size = 2-inch 5. Maximum mounting flange size = 6-inch C. Tank cleaning system nozzle characteristics: 1. Mechanically operated with no electrical motors or controls 2. Mechanical drive external to the tank 3. Programmable turning and lifting motions with capability for manual override 4. Self-draining 5. Inlet shutoff valve and strainer 6. Grease lubricated mechanism D. Unit construction: 1. 316 stainless steel body 2. ANSI 150 pound flanges 3. 316 stainless steel and teflon mechanism and accessories PART 3 -- INSTALLATION 3.01 INSTALLATION A. All equipment shall be assembled and shipped so that field assembly will be minimized and installation can be completed with little or no field fabrication. B. The tank cleaning system will be received, unloaded, stored and installed by a Contractor. The Contractor shall install the tank cleaning system in accordance with the Drawings, approved shop drawings, and manufacturer’s installation manual. City of Denton Hazen and Sawyer BID SET 13217-4 Tank Cleaning System 3.03 FIELD ACCEPTANCE TESTS A. Field acceptance tests shall be required for all tank cleaning systems specified herein. All equipment shall be field tested in accordance with the applicable requirements of Section 11000 – General Requirements for Equipment. Field testing shall include mechanical tests as specified below. The manufacturer shall submit information which fully describes the testing procedure. The manufacturer will be provided at least ten days' notice of such tests. In case of failure of any unit to meet the test requirements, the manufacturer shall make such alterations as are necessary, and the tests shall be repeated without additional cost to the Owner until the equipment is satisfactory. Certified reports shall be submitted to the Engineer for approval. B. Mechanical Test: All tank cleaning systems shall be mechanically tested and successfully demonstrate at least two full cleaning cycles (all cleaning system nozzles running concurrently) after initial installation. The test shall be made with water flow being introduced at the design rate and pressure. All equipment shall show evidence of mechanical soundness, no evidence of liquid leaks, and cover and clean the intended tank surface specified herein. E. The manufacturer's representative witnessing the field tests shall furnish the Owner, through the Contractor, a written report certifying that the tank cleaning system: 1. Has been properly installed and accurately aligned. 2. Has been operating at design flow rates and that the unit operates satisfactorily. 3. The Contractor has accurately recorded the data obtained during the field test. 3.04 TOOLS, SUPPLIES AND SPARE PARTS A. The manufacturer shall furnish all recommended spare parts. At a minimum, the tank cleaning system shall include the following spare parts: 1. One (1) set of gaskets for all gasketed covers and connections for each system 2. One (1) set of internal bolts and fasteners for wetted service for each system 3.05 EQUIPMENT IDENTIFICATION A. Each piece of equipment shall be provided with an equipment nameplate in accordance with Section 11000, General Requirements for Equipment, which will be securely fastened in a conspicuous place and clearly inscribed with the manufacturer’s name, year of manufacture, serial number, and principal rating data. City of Denton Hazen and Sawyer BID SET 13217-5 Tank Cleaning System 3.06 MANUFACTURER’S FIELD SERVICES A. The services of a qualified manufacturer’s technical representative shall be provided in accordance with section 11000, Equipment General Provisions and shall include the following visits: Service No. of Trips No. of Days/Trip Installation and Testing 1 1.0 Startup and Training 1 0.5 - END OF SECTION – City of Denton Hazen and Sawyer BID SET 13217-6 Tank Cleaning System This page left blank intentionally City of Denton Hazen and Sawyer BID SET 13252-1 Activated Carbon Odor Control System SECTION 13252 ACTIVATED CARBON ADSORBER ODOR CONTROL SYSTEM PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The manufacturer shall furnish and test one (1) activated carbon adsorber odor control system as shown on the Drawings and as specified herein. The system shall consist of one (1) 4,500 cfm dual deep bed carbon unit and one (1) 4,500 cfm fiberglass fans. B. All equipment located within three (3) feet of the odor control ductwork, odor control system, and exhaust fan, under positive pressure, shall be suitable for a Class I, Division 2, Group D location. 1.02 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. U.S. Department of Commerce Voluntary Product Standard PS-15-69 B. ASTM C581 – Chemical Resistance of Thermosetting Resins used in Glass Fiber Reinforced Structures C. ASTM C582 – Reinforced Plastic Laminates for Self-Supporting Structures in a Chemical Environment D. ASTM D3299 – Filament Wound Thermoset Resin Corrosion-Resistant Tanks E. ASTM D4097 – Contact Molded Glass Fiber Reinforced Thermoset Resin Chemical-Resistant Tanks F. ASTM D6646 – Standard Test Method for Determination of the Accelerated Hydrogen Sulfide Breakthrough Capacity of Granular and Pelletized Activated Carbon. 1.03 SUBMITTALS A. In addition to the submittal requirements specified in Section 01300, Submittals, submit the following for each odor control system: 1. Operation and Maintenance Instructions 2. Complete electrical schematic wiring diagram drawings 3. Horsepower, voltage, and rotative speed of the motor 4. Manufacturer’s literature, illustrations, specifications and engineering data including dimensions, materials, size and weight of all components and complete assembly City of Denton Hazen and Sawyer BID SET 13252-2 Activated Carbon Odor Control System 5. Complete erection, installation, and adjustment instructions and recommendations 6. Drawings showing plans and sections of the equipment to demonstrate proper coordination between components, fabrication methods, assembly and accessories 7. Detailed calculations confirming the structural integrity of the vessel under full water loading conditions and structural design of the vessel 8. Carbon media MSDS and specification sheet 9. Performance test procedures for the systems. 10. Grounding certification. 1.04 MANUFACTURER’S RESPONSIBILITY A. The Manufacturer shall be responsible for coordination of the design and fabrication of the odor control system shown on the Drawings and specified herein. B. The Manufacturer shall coordinate and review installation procedures under other Sections and coordinate the installation of items that must be installed to comply with the requirements of the Work specified under this Section. C. The services of the manufacturer's representative shall be provided in accordance with Section 01650 – Field Testing, Section 01660 – Equipment Testing and Startup, and Section 11000 – Equipment General Provisions. D. Any additional time required to achieve successful installation and operation shall be at the expense of the Contractor. E. A written report covering the representative's findings and installation approval shall be submitted to the Engineer covering all inspection and outlining in detail any deficiencies noted. F. The times specified are exclusive of travel time to and from the facility and shall not be construed as to relieve the manufacturer of any additional visits to provide sufficient service to place the equipment in satisfactory operation. 1.05 QUALITY ASSURANCE A. All components of the activated carbon adsorber odor control system shall be supplied by a single manufacturer fully experienced, reputable, and qualified in the manufacture of the equipment to be furnished. B. Manufacturer shall have at least five (5) years experience in the design and fabrication of the specified odor control system and shall, at the Engineer’s request, provide a list of at least five (5) successful installations operating for a minimum of three (3) years of City of Denton Hazen and Sawyer BID SET 13252-3 Activated Carbon Odor Control System comparable size (greater than or equal to 4,000 cfm) and application, with references including valid current contact names and phone numbers. PART 2 -– MATERIALS 2.01 ACCEPTABLE MANUFACTURERS A. The manufacturer shall be responsible for the coordination of all equipment specified herein. The activated carbon adsorber odor control system shall be a deep bed up flow carbon adsorber as manufactured by Calgon Carbon, Continental Carbon, Daniel Company, Siemens/Evoqua, Pure Air Filtration, Purafil or Biorem Technologies. B. The materials covered by these Specifications are intended to be standard equipment of proven reliability and as manufactured by reputable manufacturers having experience in the production of such equipment. The equipment furnished shall be designed, constructed, and installed in accordance with the best practices and methods and shall operate satisfactorily when installed as shown on the Contract Drawings and operated per manufacturer’s recommendations. 2.02 OVERALL SYSTEM REQUIREMENTS A. Each activated carbon adsorber odor control system shall consist of the principal components listed below: 1. Carbon reactor vessel 2. Activated carbon 3. Exhaust fan 4. Exhaust stack(s) 5. Instrumentation and controls as follows: a. Exhaust fan pressure indicator and switch b. Pressure differential indicators 6. FRP flexible coupling, reducer, and ductwork from exhaust fan discharge to vessel inlet. 7. Odor control system control panel B. All materials shall be new and suitable for the service to which they are subjected. C. Sizes and capacities of equipment components specified shall be understood to establish minimum requirements only and do not relieve the equipment supplier of responsibility for providing a properly functioning system. City of Denton Hazen and Sawyer BID SET 13252-4 Activated Carbon Odor Control System D. The activated carbon adsorber shall be capable of removing hydrogen sulfide and associated sewage odors from the foul air stream by adsorption to the carbon media. E. Operating Conditions System 1 Number of units 1 Type Upflow, Dual Bed Vessel diameter, maximum (feet) 8 Vessel height, maximum (feet) 14 Air flow rate, minimum (scfm) 4,500 Carbon capacity, minimum (lbs) 6,740 Minimum Empty Bed Contact Time (EBCT), seconds 3.0 Air velocity through scrubber, maximum (fpm) 60 Inlet H2S concentration, average (ppm) 5.0 Peak H2S concentration, average (ppm) 12.0 H2S Removal efficiency, minimum (%) 99 Pressure drop through vessel, maximum (inches W.C.) 7 Supply and drain connection size, maximum (inches) 2 Number of exhaust fans 1 Duty Exhaust fan design capacity, Each (scfm) 4,500 Exhaust fan static pressure (inches W.C.) ≥10 Max. Fan Speed (rpm) 3,500 Min. Fan Inlet Diameter (inches) 16 Max. Motor Horsepower (hp) 15 Max. Motor Speed (rpm) 3,500 Drive Belt 2.03 VESSEL CONSTRUCTION A. The vessel shall be designed using a minimum structural safety factor of 10 to 1 for pressure and 5 to 1 for vacuum. The vessel shall have bottom knuckle reinforcement and be designed for hydrostatic head load 10 feet above the top of the inlet. B. Vessel housing shall be designed for full bottom support and shall be provided with a minimum of four (4) Type 316 stainless steel hold down lugs. All hold down lugs shall be designed to account for all anticipated loads and shall comply with local code requirements. Furnish all anchor bolts, nuts, and washers which shall be Type 316 stainless steel. C. The odor control system shall be manufactured of FRP in accordance with these specifications. All integrally molded connections shall be manufactured of the same material. D. Fiberglass Reinforced Plastic (FRP) Vessel Construction: 1. Vessels shall be either contact-molded in accordance with ASTM D4097, Grade I, or Type I, Filament-Wound in accordance with ASTM D3299-88, Grade 1. Portions of the City of Denton Hazen and Sawyer BID SET 13252-5 Activated Carbon Odor Control System vessel, including joints and duct connections shall be fabricated by contact molding. Contact molded laminates shall be in accordance with ASTM C582, Table 1. 2. Vessel wall thickness shall be as required by structural design but not less than ¼ inch. 3. Resins: a. Resins used in laminate shall be premium corrosion resistant and fire retardant brominated bisphenol A vinylester resins to achieve a 25 or less flame spread rating in accordance with NFPA 91. 1) Resin shall be Hetron FR992 or FR992SB, as manufactured by Ashland Chemical Company, DeraKane 510A or 510C, as manufactured by Dow Chemical Company, Dion 9300 FR, as manufactured by Reichold, Vipel K022-CC or K022-CN, as manufactured by AOC, or approved equal. 2) Antimony trioxide may be added to the structural layer, if required to obtain the required Class 1 flame spread rating of 25 or less. Antimony trioxide addition shall not exceed 3% and shall not be added to the interior liner of the vessel. 3) Selected resin shall be used for fabrication throughout the entire vessel. Use of more than one resin during fabrication is not acceptable. 4) No dyes, pigments or colorants shall be used except in the exterior coat. 5) The resin shall not contain fillers or thixotropic agents unless otherwise specified. b. Ultraviolet absorbers shall be added to the surfacing resin to improve weather/UV resistance of the vessel. No fillers or thixotropic agents shall be added. Exterior coating shall not be applied until after inspection of the laminate has been completed. c. All cut edges shall be sealed with a resin coating of the same resin as used in the fabrication. The resin shall contain paraffin. 4. Reinforcement: a. Synthetic surfacing veil shall be Veil-Nexus 1012 (apertured) as manufactured by Burlington Industries. b. Chopped strand mat shall be Type E glass, minimum 1-1/2 ounces per square foot, with silane finish and styrene soluble binder. c. Continuous roving used in chopped gun shall be Type E glass. d. Woven roving shall be Type E glass, nominal 24 ounces per square yard, with a 4 by 5 weave and a silane type finish. City of Denton Hazen and Sawyer BID SET 13252-6 Activated Carbon Odor Control System e. Continuous roving used for filament winding shall be Type E glass, nominal 110 strand yards per pound, with a silane type finish. 5. Laminates: a. Laminates shall consist of a corrosion resistant resin-rich inner surface, an interior corrosion barrier, an interior structural layer and an exterior layer. Composition specified for inner surface and interior corrosion barrier is intended to achieve optimum chemical resistance. b. Corrosion resistant resin-rich inner surface shall be reinforced using a single apertured Nexus synthetic veil. Minimum resin-rich inner surface thickness shall be 10-20 mils. Thixotropic agents shall not be used for this service. Glass content of resin-rich inner surface shall be 10 percent plus or minus 5 percent by weight. c. Interior corrosion barrier shall be a minimum of 100 mils of Type E chopped strand mat to a total of 3 oz/sq. ft. The interior corrosion barrier shall be applied by either the hand laid up technique, filament winding or chopper gun. Chopper gun is only permitted if an automated process is used. Manual operation of chopper gun shall not be permitted. Glass content of interior corrosion barrier shall be 25 percent plus or minus 5 percent by weight. d. Interior structural layer shall be of sufficient thickness to meet minimum thickness requirements as specified. Vessel thickness design should be supported by signed, stamped calculations by a Professional Engineer, which shall be submitted in accordance with Section 01300, Submittals. Glass reinforcements shall be in accordance with the appropriate standards of construction. Interior structural layer shall be fabricated using either the hand lay up, filament wound technique or approved chopper gun technique. Glass content of interior structural layer shall be 60 percent plus or minus 5 percent by weight. e. Exterior layer shall be reinforced using a single “A” glass veil with a layer of surfacing “Nexus” veil followed by a clear resin rich 10 mil thick coating similar to the inner surface. Topcoat shall be pigmented parafinated gel-coat with ultraviolet inhibitors. The pigmentation shall be colored as selected by the Owner. There shall be no glass fibers exposed. f. Vessel shall be cured using a MEKP procedure and in accordance with the recommendations of the resin manufacturer. g. Vessel wall shall be reinforced around all openings and connections. h. Laminates shall meet the requirements of the mechanical properties and visual acceptance criteria in ASTM D2563, Level I. City of Denton Hazen and Sawyer BID SET 13252-7 Activated Carbon Odor Control System 2.05 ACTIVATED CARBON ADSORBER SYSTEM A. The reactor vessel design shall be capable of processing odorous air at such a velocity that the empty bed contact time (EBCT) across the activated carbon bed shall not be less than the value specified above. B. Carbon Vessel 1. Each carbon vessel shall have the following standard features, at a minimum: a. NBS PS 15-69 flanged nozzle air inlet: size as shown on Drawings b. Plain-end nozzle outlet(s) with no-loss discharge stack(s): size as shown on Drawings c. Two (2) Carbon sample ports: 1.5-inch maximum d. Three (3) air sample ports: 1.5-inch maximum, spaced evenly through each carbon bed (two carbon beds) e. Two (2) 0.5-inch taps for differential pressure switches/gauges for each carbon bed (two carbon beds) f. One (1) drain connection with blind flange and ball valve: 2-inch maximum C. The adsorber system shall provide continuous treatment when the fan is in service. The fan shall be supplied as specified herein. D. Carbon Support System - The support system for the carbon bed shall be as recommended by the odor control vessels supplier and approved by the Engineer. The carbon bed shall be supported by a polypropylene screen basket resting on a support system. The carbon bed screen and support system shall be removable through access manways. The support system shall be a system capable of withstanding a load of not less than 300 pounds/square foot with a deflection not greater than 1/4-inch under any operating condition. All components of the support system shall be constructed of materials resistant to the chemical service conditions specified for corrosion. Pall rings or dump packing shall not be used to support the carbon beds. E. The carbon adsorber vessel shall have a minimum of one 24-inch access manways per bed (minimum two total) for ease of carbon removal. 2.06 ODOR CONTROL SYSTEM ACCESSORIES A. All necessary connections for piping, instrumentation, sampling, and ductwork shall be provided as shown on the Drawings or required. Suitable EPDM gaskets shall be provided. The manufacturer shall provide the following appurtenances with the vessel: City of Denton Hazen and Sawyer BID SET 13252-8 Activated Carbon Odor Control System 1. Drain assembly, sized as specified in Paragraph 2.02 E above, with Schedule 80 CPVC ball valve. 2. One (1) 1-1/2-inch diameter sample probe with ball valve adjacent to the carbon bed which shall extend a minimum of 6 inches into the carbon bed. Probe shall be adequate to provide suitable extraction of carbon samples from the carbon bed and be non-binding. Probes shall extend outside the vessel wall and be blocked off with ball valves. One (1) additional 1-inch diameter sample probe with ball valve shall be installed on each discharge stack and tubing shall extend down and adjacent to the other probes and one (1) 1-inch diameter sample probe with ball valve shall be installed on each fan discharge. Probes and ball valves shall be constructed of Schedule 80 CPVC. 3. Manufacturer shall provide factory mounted pipe supports for outlet air sample ports, bottom drain connection, and overflow piping. 4. Flanges for air inlet and outlet shall be manufactured by hand lay-up method and shall conform to NBS-PS 15-69, standard dimensions for bolting, but in no case shall the thickness be less than ¾-inch thick. Flange nozzles for piping connections shall conform to ASTM D 3299, all nozzles up to and including 8 inch diameter shall be reinforced with blade type gussets. Flanges for piping connections shall be ANSI 150-lb dimensions. All flanges shall be pre-drilled. Flanges shall be checked for alignment, thickness and mating prior to shipment to field. Area on the back of all flanges around each bolt hole shall be the diameter of a standard washer and shall be flat and parallel to flange face. This area shall be spot faced, if necessary, to meet this requirement. B. Grounding System: Vessel grounding system, including but not limited to a 3/8-inch diameter Type 316 stainless steel grounding road, shall be provided, subject to Engineer’s approval. Manufacturer shall supply adequate details to demonstrate that the carbon bed will be adequately electrically grounded. Manufacturer to provide grounding certification submitted with shop drawings. C. Lifting Lugs: Lifting lugs shall be capable of withstanding weight of the empty vessel with a minimum safety factor of 5 to 1. A minimum of three lugs shall be furnished per vessel. Lifting lugs shall be Type 316 stainless steel or FRP and attached to the vessel wall with hand lay-up laminate equal to or greater than the vessel wall thickness. D. Mounting Lugs: Mounting lugs shall be suitable for mounting electrical junction boxes. Mounting lugs shall be Type 316 stainless steel or FRP and attached to the vessel wall with hand lay-up laminate equal to or greater than the vessel wall thickness. E. Transition Pieces: Manufacturer shall provide a transition piece for connecting the flanged air inlet on the carbon vessel to the inlet FRP ductwork as shown on the Contract Drawings. F. Interconnecting Ductwork: Ductwork from exhaust fan to the carbon treatment vessel shall be in accordance with Section 15892, FRP Duct Systems. Ducts shall be of sufficient diameter and design to move the air without undue pressure loss or as shown on the Drawings. The pressure loss of the combined odor control system and the duct work shall not exceed the City of Denton Hazen and Sawyer BID SET 13252-9 Activated Carbon Odor Control System maximum pressure available from the blower at the specified air flow rate operating at nonoverloaded conditions. G. Duct Supports: The odor control system manufacturer shall be responsible for the design of all duct supports furnished for the ductwork specified herein. Duct and exhaust stack support details and layout shall be submitted in the shop drawings. Proposed duct supports shall be in accordance with the Drawings and shall comply with Section 15020, Pipe Supports. I. Vessel Grounding System: Manufacturer shall supply adequate details to demonstrate that the carbon bed will be adequately electrically grounded. Submit grounding certification to Engineer with shop drawing. Subject to Engineer’s approval. J. Carbon Sampling Device: One grain thief sampling device shall be provided for each odor control unit. The device shall be a Fisher Scientific Model 14-208Q, or equal. K. Rain Cap: FRP or polyethylene “no loss” high dispersion discharge stack(s), factory installed for each unit. Provide 316 SST Bird Screen on each discharge stack. L. Expansion Joint: As shown on the Drawings, provide in accordance with 15892, FRP Piping Systems. 2.07 ACTIVATED CARBON A. Sufficient activated carbon shall be provided to fill the reactor vessel to the height of the vessel. The activated carbon shall be unimpregnated new granular activated carbon, derived from bituminous coal. The activated carbon shall be suitable for the vapor phase adsorption of sewage treatment odors. No chemical impregnation of the carbon is permitted. B. Activated carbon shall be Midas OCM as manufactured by Siemens Water Technologies, or equal, and shall have the following specifications: 1. Minimum Butane Activity (weight %) 26 2. Minimum Iodine Number, mgl2/g 1,050 3. Maximum Moisture (weight % as packed) 4 4. Minimum Hardness Number 95 5. Minimum Apparent Density (g/mL) 0.48 6. Maximum Mean Particle Diameter (mm) 4.0 7. Minimum H2S Breakthrough Capacity (g H2S removed/cc carbon)1 0.3 1The determination of H2S breakthrough capacity will be made by passing a moist (85% R.H.) air stream containing 1% H2S at a rate of 1,450 cc/min through a 1 inch diameter by 9 inch deep bed of uniformly packed activated carbon and monitored to 50 ppm breakthrough per ASTM D6646. 2.08 CONTROLS A. Field Control Equipment: 1. Odor control system manufacturer shall review the electrical drawings to determine the hazardous area ratings of the area and shall provide appropriately- City of Denton Hazen and Sawyer BID SET 13252-10 Activated Carbon Odor Control System rated instruments of intrinsically-safe barriers as appropriate for the devices located in hazardous areas. 2. Manually-operated dampers shall be provided to allow isolation of the exhaust fan and odor control system as shown on the Drawings. 3. Pressure gauges shall be provided for each system in accordance with Section 17650 – Pressure Gauges: a. Differential pressure gauges PDI-2431 and PDI-2432 shall be provided to measure pressure drop across filter beds. Range to be 0 to 20 in. W.C. b. Pressure gauge PI-2430 (minimum range: 0 to 20 in. W.C.) shall be provided to measure discharge pressure from exhaust fan. 4. Pressure switches shall be provided for each system in accordance with Section 17675 – Pressure Switches: a. Pressure switch PSH-2430 shall be provided to alarm on high pressure from discharge of exhaust fan. Alarm setpoint shall be 4 in. W.C. when the motor is running. 5. Process Tubing for Differential Pressure Instruments: Process tubing shall be 1/4 x 0.065-inch seamless, annealed, ASTM A-269 Type 316L stainless steel with Type 316 - 37 degrees stainless steel flared fittings or Swagelock or Parker- CPI flareless fittings. Provide stainless adaptors as necessary to accommodate process connections to gauges and switches. 6. Valves for Pressure Instruments shall be stainless steel ball valves. 2.09 LOCAL CONTROL PANEL A. Provide one (1) independent control panel to control the odor control system. Panel shall be designated VCP-2030. The control panel shall include a motor circuit protector, NEMA rated contactor, pilot devices, control relays, and other components as specified herein. B. Control Panel Enclosure: 1. Rating: NEMA 4X, 316 stainless steel, metal thickness of 14 gauge. 2. Live front with padlock provisions. 3. Rubber-gasketed, hinged outer door with continuous stainless steel hinge and stainless steel butterfly twist type latches. 4. Stainless steel or copper-free aluminum back panel with provisions to mount control devices and terminal strip for field connections. 5. Control Panel Features: City of Denton Hazen and Sawyer BID SET 13252-11 Activated Carbon Odor Control System a. Main power disconnect switch or circuit breaker device, mechanically interlocked with door so that the main power must be “OFF” before door can be opened. b. Power Requirements: Local Control Panel (LCP) to operate from a single 480-volt, 3-phase power source. c. Control power transformer to be sized for anticipated loads from devices/controls. d. Heater and thermostat for condensation protection. e. NEMA-rated motor starter. f. Panel components are to conform to Division 16 requirements. C. The control panel enclosure shall be wall or stanchion mount type, located as shown on the Drawings. Provide an aluminum or SS sun shield for each enclosure. D. All control wiring shall be No. 14 AWG (minimum). Power wiring shall be No. 12 AWG (minimum). Wiring shall be type MTW rated for 105°C. All wiring shall have not less than 600 volts insulation. Control wiring shall be color coded as specified in Division 16. All connections required to field control components shall be made at approved type terminal blocks with marker strips or similarly approved means. All wires shall be marked at both ends using self-adhering plastic wire markers with heat shrink or clear self-laminating strips. Wire numbers shall be in accordance with the accepted Shop Drawings. E. All conduit, couplings, fittings and fasteners furnished by the equipment manufacturer shall be PVC coated rigid galvanized steel and liquid tight, PVC coated flexible metal conduit. F. A phenolic-type nameplate shall be securely fastened on the door of each control panel and shall identify the specific floating aerator unit associated with the control panel. Each component located within the panel shall be provided with an identification label. G. The starter shall be NEMA rated, full voltage, combination-type, individual magnetic starter complete with motor circuit protectors (MCPs). Starter shall be rated 480VAC, 3-pole, sized for the mixer motor. The starter shall be furnished with a minimum of two spare auxiliary contacts. 1. The starter shall be supplied with a three-pole manual reset overload relay. The relay shall be solid state type, with at least one isolated normally open and one isolated normally closed auxiliary contact. Overload relay shall have phase loss protection built in against motor single phasing. The relay shall have adjustable current range dial. Eutectic alloy and bi-metallic type overload relays shall not be used. 2. Starters shall be provided with all coils and controls for 120 VAC operation. A control power transformer shall be furnished and installed for each motor controller. Refer to specification Division 16, for detailed description. City of Denton Hazen and Sawyer BID SET 13252-12 Activated Carbon Odor Control System 3. Motor starter coil shall be equipped with a surge-suppression device for protection of the solid state equipment (e.g. programmable logic controller), wired as part of the control circuit. H. A molded case motor circuit protector with adjustable instantaneous trip shall be provided for each motor controller. The motor circuit protector shall be externally operable and shall provide clear identification of its position. The motor circuit protector shall have a minimum interrupting capacity as the MCC that feeds it. I. A three-phase Surge Protection Device (SPD) shall be supplied and connected to the load side of the main circuit breaker. The SPD shall protect against damage due to transient voltages and lightning strikes. The SPD shall have a surge current rating of 80 kA per mode for each phase, and shall meet UL 1449. The SPD shall be GE Tranquell, integrally-mounted and shall have an unlimited replacement warranty of at least three years. J. Control Relays (CR) shall be Type D3 as manufactured by Cutler-Hammer, Potter Brumfield equivalent, Allen-Bradley equivalent, Siemens Energy and Automation Inc. equivalent, or equal. Relays shall be general purpose plug-in type with coil voltage as shown on the Drawings and sealed 10 ampere contacts. All relays shall have three SPDT contacts rated 120/240 VAC and 28 VDC minimum. Machine tool relays shall be provided when the contact burden exceeds 10 amperes. Miniature type or “ice cube” relays are not acceptable. Control relay mechanical life expectancy shall be in excess of 10 million operations. Provide time delay relay to allow a staggered start of aerators on restoration of power. The setting of these time delay relays shall be coordinated with the settings of the time clock specified below. K. Pilot device ratings shall meet or exceed the NEMA rating of the control panel enclosure. Pilot lights shall be LED type. Pilot devices shall be heavy duty, oil tight, 30mm components as manufactured by Allen Bradley (#800H) or Square D (#9001SKT), or equal. Pilot lights shall be provided with legend plates, shall be LED-type, and shall be push-to-test. Push buttons and pilot devices shall meet all requirements of Section 17550 - Panel Instruments and Accessories. Lens colors shall be as indicated in Section 17550 - Panel Instruments and Accessories. L. The panel shall have the following front-mounted control devices: 1. Hand-Off-Auto Selector Switch 2. Start-Stop Selector Switch 3. Power On Indicating light 4. Run indicating light 5. Fan Overload indicating light 6. Fan Broken Belt indicating light 7. High Pressure Alarm indicating light City of Denton Hazen and Sawyer BID SET 13252-13 Activated Carbon Odor Control System 8. Carbon Unit Alarm indicating light 9. Alarm Reset pushbutton 10. Emergency stop pushbutton M. Provide dry contacts for remote indication of the following conditions for each system. Conditions identified as alarms shall be normally-closed and open when the alarm condition occurs: 1. Common fail Alarm 2. Fan e-stop Alarm 3. H-O-A switch in Hand position 4. Fan run status 5. High pressure Alarm N. Control panel shall accept the following dry contacts for operation of the system: 1. High discharge pressure 2. Start/ Stop command (from PLC-HCDF) O. A control power transformer shall be mounted in the control panel to reduce the line voltage to 120 V for the control circuit. The transformer shall be rated the necessary KVA. The transformer primary and secondary shall be protected from short circuits and overloads by l circuit breakers or fuses of the proper rating. Provide a separate transformer for the control circuit and the enclosure heater. Provide a spare set of fuses (two minimum) of each type and rating. P. Provide elapsed run time meters (ETM) for each motor. ETM ratings shall meet or exceed the NEMA rating of the control panel enclosure. ETM shall be six digit, non reset type. Q. The control panel shall provide the following control function for each fan: 1. When the HOA switch is in the HAND position, the fan shall run as follows: a. When the Start-Stop switch is in the START position, the fan shall run. b. When the Start-Stop switch is in the STOP position, the fan shall not run. 2. When the HOA switch is in the OFF position, the fan shall not run. 3. When the HOA switch is in the AUTO position, the fan shall be started remotely though PLC-HCDF. City of Denton Hazen and Sawyer BID SET 13252-14 Activated Carbon Odor Control System 4. In either AUTO mode or HAND mode, the fan shall be shut down when the broken belt alarm condition occurs. 5. Broken belt alarm shall be generated by a current trip located in the panel. When a fan is running and the current drawn by the fan motor is below a setpoint determined by the manufacturer as indicating that the fan wheel has been decoupled from its motor, the fan shall be stopped and the broken belt alarm shall be activated. 6. In either AUTO mode or HAND mode, the fan shall be shut down when high discharge pressure alarm condition occurs. 7. Fan motor space heater shall be energized by the control panel when the motor is off. 8. Alarms shall be latched such that the alarm indicator light shall remain energized and alarm contacts shall remain in the alarm state until the Alarm Reset pushbutton has been pressed. R. A space heater or a trickle-charge heating system with transformers, relays, and switches shall be provided in the control panel. 2.09 TIE DOWN SYSTEMS A. Vessel and duct shall withstand horizontal loadings of 40 pounds per square foot or the maximum wind load at the location in accordance with the latest edition of the Building Code in the jurisdiction where the system will be installed, for the area under the worst condition, whichever is greater. Type 316L stainless steel clips, anchor bolts, and accessories shall be provided to securely anchor the vessel and duct to the concrete pad. 2.10 FIBERGLASS REINFORCED PLASTIC FAN A. Provide fiberglass reinforced plastic (FRP) fire retardant fans with an epoxy or UV gel coating to protect against ultraviolet degradation. Fans shall be installed complete with motors, drives, guards, and coatings of sufficient capacity for the duty required. Fans shall operate to draw odorous air from the odor sources and shall exhaust air through the odor control system. 1. Provide fans that are factory-fabricated and assembled, factory-tested, and factory- finished, with indicated capacities and characteristics. 2. Base fan performance at standard conditions (density 0.075 Lb/ft3). 3. Selected fans selected are to be capable of accommodating static pressure and flow variations of +/-15% of scheduled values. City of Denton Hazen and Sawyer BID SET 13252-15 Activated Carbon Odor Control System 4. Fans are to be belt driven, AMCA arrangement 1, unless otherwise shown on the Drawings. 5. Fans are to be equipped with lifting lugs. 6. Nameplate: Each fan to be furnished with a permanently affixed SS nameplate with manufacturer’s name, model number, serial number and electrical data. 7. Mounting: The entire fan and motor assembly is to be mounted on vibration isolators to reduce noise transmission. 8. Rotating Assembly: Statically and dynamically balanced to balance grade G6.3 per ANSI S2.19 and designed for continuous operation at the maximum rated fan speed and motor horsepower. B. Fan shall be constructed such that all surfaces in contact with the corrosive gas stream are made of solid, corrosion resistant FRP, model FE manufactured by The New York Blower Company, Series 41 as manufactured by Hartzell or Model CLUB by Ceilcote/Verantis. All nuts, bolts and fasteners in contact with the gas stream shall be type 316 SST and encapsulated in FRP. C. Performance: Fan ratings shall be based on tests made in accordance with AMCA Standard 210. Fans shall be licensed to bear the AMCA Certified Ratings Seal for Air Performance. Fans not licensed to bear the AMCA Seal for performance shall be tested, at supplier's expense, in an AMCA Registered Laboratory. Fans shall have a sharply rising pressure characteristic extending throughout the operating range to assure quiet and stable operation. Fan speed and motor size shall be selected by the odor control system manufacturer to meet the required conditions of air flow rate and pressure drop across the odor control system and ducting, including the pressure drop in the ducting upstream of the odor control system inlet. Fan speed shall not exceed 85% of the maximum allowable driven speed of the fan. D. Motor: Motor shall meet the requirements specified in the table below and Section 15170 Low Voltage Electric Motors. Motors System 1 Rating 480V, 3 ph, 60 Hz Horsepower (max) 15 Max Speed, rpm 3500 Enclosure TEFC1 Insulation Class F Inverter Duty No Service Factor 1.15 Space Heater Yes Motor Winding Temperature Switches No 1Suitable for Class I, Division 2 Environment. City of Denton Hazen and Sawyer BID SET 13252-16 Activated Carbon Odor Control System E. Sound: Fan manufacturers shall provide sound power level ratings for fans tested and rated in accordance with AMCA Standards 300 and 301. Sound power ratings shall be in decibels (reference lOE-12 watts) in eight octave bands. Rated sound pressure level shall not exceed 88 dBA at 7 ft. F. Bearings: Bearings shall be grease lubricated, precision anti-friction ball, self-aligning, pillow block design. Bearings shall be designed for a minimum L-10 life of 30,000 hours (150,000 hours L-50 life) when rated at the fan's maximum cataloged operating speed. Fan bearings shall be visible and accessible for inspection and maintenance. Bearings enclosed within the fan housing where they can be exposed to the corrosive gas stream are not acceptable. G. Construction: Fan shall be constructed in accordance with the ASTM D-4167 standard specification for fiber-reinforced plastic fans and blowers to ensure structural integrity. All surfaces exposed to the atmosphere shall be resin rich of a paraffinated resin stabilized against ultraviolet degradation and include a reinforcement not to exceed 20% “C” grade fiberglass. All parts exposed to the gas stream shall be constructed of, or encapsulated in, an FRP laminate capable of resisting continuous airstream temperatures of 250 degrees Fahrenheit. All resins shall be clear to allow detection of subsurface imperfections. Use of pigments, gel coats, inhibitors and additives which may disguise flaws in the laminate is prohibited. Other minimum construction requirements shall consist of the following: 1. Housing - Fan housing shall be constructed of a fire retardant polyester resin or Type II PVC with an ASTM E84 Class I rating. Housing laminate construction shall conform to ASTM Standard C-582. Airstream surfaces shall be smooth to minimize resistance and prevent build up of airborne contaminants. Shaft hole openings shall be fitted with a Teflon closure having a maximum clearance of 1/32" to minimize leakage. A flanged inlet and flanged outlet shall be furnished on the fan and shall be of FRP construction. Inlet assembly shall be bolted to permit wheel removal. Fan shall be furnished with an access door, positioned to avoid collection of condensation, and a 1-inch minimum flanged type drain connection, positioned at the lowest portion of the fan scroll. 2. Wheel - Wheel shall be of backwardly inclined non-overloading design for increased efficiency. Wheel shall be fabricated of a fire-retardant vinyl ester resin with an A8TM E84 Class II rating no greater than 30. Wheel hub shall be permanently bonded to the shaft and completely encapsulated in FRP to insure corrosion resistant integrity. Steel wheels coated with FRP or wheels with taper-lock hubs are not acceptable. 3. Shaft - Shaft shall be ASTM A- 108 steel, grade 1040/1045 with an FRP sleeve fixed securely and bonded to the wheel backplate. The sleeve shall extend out through the housing shaft hole for corrosion protection. The shaft first critical speed shall be at least 125 percent of the fan's maximum operating speed. Shaft shall be counter-sunk for tachometer readings. H. Fan wheel shall have true backwardly curved, single thickness air foil type blades which limit load horsepower characteristics, and shall not exceed the brake horsepower shown on the schedule. Fan wheel shall be made of solid fiberglass reinforced polyester with a stainless steel hub, encapsulated within the impeller, to provide a reliable connection with the drive shaft. City of Denton Hazen and Sawyer BID SET 13252-17 Activated Carbon Odor Control System I. Belt Drives: 1. Belt drive components to be sized based on a service factor of 1.4. 2. Pulleys to be of the fully machined cast iron type, keyed and securely attached to the wheel and motor shafts. Motor pulleys to be adjustable for final balancing. 3. Belts: Oil-resistant, non-sparking, and non-static. 4. Belt and Bearing Tube: Furnish unit with heavy gauge belt tube to shield the belts and bearings from the air stream. 5. Belt drives are to be factory-mounted, with final alignment and belt adjustment made after installation. 6. Belt Guard: Provide FRP, OSHA compliant belt guard, on the outside of the fan cabinet. Belt guard or motor cover is to completely cover the motor pulley and belt(s). 7. Furnish one additional complete set of belts for each belt-driven fan. J. Balance and Run Test: The wheel and shaft shall be dynamically balanced on precision balancers. Prior to shipment, completed fans shall receive a final test balance at the specified operating speed. K. Final Inspection: All fans shall receive a final inspection by a qualified inspector prior to shipment. Inspection shall include: fan description and accessories, balance, welding, dimension, bearings, duct and base connection points, paint finish and overall workmanship. L. The fan and motors shall be factory mounted on a structural channel subbase with integral motor slide base. An OSHA approved FRP motor and drive canopy shall be furnished and installed. M. Expansion joints shall be provided on the suction and discharge of each fan. Provide expansion joints in accordance with 15892, FRP Duct Systems. PART 3 -- INSTALLATION 3.01 INSTALLATION A. All equipment shall be assembled and shipped so that field assembly will be minimized and installation can be completed with little or no field fabrication. B. The odor control system will be received, unloaded, stored and installed by a General Contractor. City of Denton Hazen and Sawyer BID SET 13252-18 Activated Carbon Odor Control System 3.02 SHOP TESTING A. Carbon Vessel Shop Tests 1. Provide the services of an independent Testing Inspector to be present at the point of manufacture, upon completion of fabrication and prior to shipment, to perform or witness the following: a. Barcol Hardness measurements per ASTM D2583-87 for each unit b. Acetone sensitivity test for all internal secondary bonds c. Glass content by ignition loss on three cutouts per ASTM D2584 d. Hydrostatic Leak Test: 1) Perform on each vessel. 2) Fill to 3’ above bottom of vessel; allow to stand for 2 hours with no visible leakage. 3.03 FIELD ACCEPTANCE TESTS A. Field acceptance tests shall be required for all odor scrubber equipment specified herein within 6 months of installation of the equipment. All equipment shall be field tested in accordance with the applicable requirements of Section 11000 – General Requirements for Equipment. Field testing shall include mechanical tests and performance tests as specified below. The manufacturer shall submit information which fully describes the testing procedure. The manufacturer will be provided at least ten days' notice of such tests and the Engineer shall have a representative present when acceptance tests are run. In case of failure of any unit to meet the test requirements, the manufacturer shall make such alterations as are necessary, and the tests shall be repeated without additional cost to the Owner until the equipment is satisfactory. Certified reports shall be submitted to the Engineer for approval. B. All ductwork shall be tested and balanced in accordance with 15892, FRP Duct Systems. C. Mechanical Test: The entire odor control system with other associated equipment such as fans, piping and controls shall be mechanically tested for at least 4 hours after initial installation. The test shall be made with airflow being introduced at the design rate. All equipment shall show evidence of mechanical soundness, no evidence of liquid or gas leaks, no undue vibration and generally be structurally rigid when being tested. D. Performance Test: The manufacturer shall test the system to meet the design conditions of service as specified above. Performance testing shall take place in either July or August. The ability of the equipment to meet the performance requirement shall be determined by the capability of reducing H2S by 99.5% of the concentration of hydrogen sulfide in the air at maximum inlet H2S concentration conditions. City of Denton Hazen and Sawyer BID SET 13252-19 Activated Carbon Odor Control System 1. The manufacturer will be furnished the following items by the Contactor for testing: a. Portable manometer: 0 to 10-inches water, for differential pressure loss across reactor vessel. b. Air velocity meter with pitot tube for airflow through reactor. c. H2S portable analyzer: for inlet and outlet gas concentrations – Jerome 631-X, or equal. d. All labor and equipment manufacturer's field engineer for conducting the tests. 2. H2S Test Procedures: The test shall be conducted for a four (4) hour period at design airflows. Influent and effluent samples shall be taken at 15 minute intervals for a period of not less than four (4) hours. H2S sampling methods shall conform to the following standards: a. Influent and outlet H2S concentration shall be demonstrated by mechanical volumetric measurement and high-precision gas sampling system. Differential pressure and airflow rate shall be recorded at each interval. b. H2S analyzer shall be calibrated prior to shipment to job site. Provide calibration certificate in testing report. E. The manufacturer's representative witnessing the field tests shall furnish the Owner, through the Engineer, a written report certifying that the scrubber unit: 1. Has been properly installed and accurately aligned. 2. Is free from any undue stress imposed by connecting piping and/or anchor bolts. 3. Has been operating at design airflow rates and that the unit operates satisfactorily. 4. The Contractor has accurately recorded the data obtained during the field test. 3.04 TOOLS, SUPPLIES AND SPARE PARTS A. The manufacturer shall furnish all recommended spare parts. At a minimum, the odor control system shall include the following spare parts: 1. One (1) set of gaskets for all gasketed covers and connections for each system 2. One (1) set of internal bolts and fasteners for wetted service for each system 3. One (1) set of belts and bearings for each fan City of Denton Hazen and Sawyer BID SET 13252-20 Activated Carbon Odor Control System 3.05 EQUIPMENT IDENTIFICATION A. Each piece of equipment shall be provided with an equipment nameplate in accordance with Section 11000, General Requirements for Equipment, which will be securely fastened in a conspicuous place and clearly inscribed with the manufacturer’s name, year of manufacture, serial number, and principal rating data. 3.06 MANUFACTURER’S FIELD SERVICES A. The services of a qualified manufacturer’s technical representative shall be provided in accordance with section 11000, Equipment General Provisions and shall include the following visits: Service No. of Trips No. of Days/Trip Installation and Testing 1 0.5 Startup and Training 1 0.5 - END OF SECTION – City of Denton Hazen and Sawyer BID SET 14600-1 Cranes and Hoists SECTION 14600 CRANES AND HOISTS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, install and make fully operational the crane and hoist systems in the locations and conditions of service, as shown on the Drawings and as specified in the Crane and Hoist Schedule. B. These Specifications shall be considered as minimum requirements. The Contractor shall add such additional features as are necessary for satisfactory operation. C. Equipment shall be provided in accordance with the requirements of Section 11000 – Equipment General Provisions. D. All equipment supplied under this Specification shall comply in all respects with the provisions of the Occupational Safety and Health Act of 1970, including all standards promulgated under the authority of such Act, and shall also meet all applicable industrial codes in the State in which the project is located. E. The manufacturer and ultimately the Contractor shall be totally responsible for structural design of the crane and hoist systems, for the compatibility of all equipment, and for verification of required operating clearances. F. All parts of the mechanism furnished shall be amply designed and constructed for the maximum stresses occurring during fabrication, erection and continuous operation. All equipment specified herein shall be designed for the Crane Manufacturer's Association of America Duty Classification as specified herein. G. If the Contractor elects to utilize the crane and hoist equipment in any way during the erection of piping and installation of equipment, he shall notify the Owner in writing and shall provide for an inspection by the equipment manufacturer and take any steps necessary to return the equipment to "as new" condition. He shall also obtain recertification by the manufacturer and reinstate all warranties and guarantees. 1.02 CAPACITY AND DESIGN LOADS A. The crane shall be designed to withstand the dead load (caused by the weight of the crane and components themselves), the live load and hoist load, and the inertia forces caused by movement of the crane, components, and loads during standard operation. B. Standard capacity ratings shall represent the net rated load at the hook of any type of trolley hoist with the same load rating installed on the crane having a trolley hoist weight within the established limits. City of Denton Hazen and Sawyer BID SET 14600-2 Cranes and Hoists C. All design loads shall meet CMAA requirements. The design load for stress calculations shall be based upon the capacity plus 15% for the weight of the hoist and trolley and an additional 25% for impact (capacity x 1.4). Design load for deflection calculations shall be based upon the capacity plus 15% for the weight of the trolley hoist (capacity x 1.15). D. The rated load capacity of each crane shall be clearly labeled on each crane using a label size easily read from the floor level and/or loading position. 1.03 CRANE AND HOIST SCHEDULE Location Hickory Creek Detention Facility Pump Station Pecan Creek WRP West Peak Flow Pump Station General Indoor / Outdoor Outdoor Outdoor Capacity, tons 5 7.5 Operating Floor Elevation 580.50 567.00 Crane Crane Type Monorail Monorail Mounting N/A N/A CMAA Duty Classification N/A N/A Span, ft 20’-6” 19’-6” Frame Spread, ft 6 6 Trolley Hoist Trolley Type Electric Electric Hoist Type Electric Electric ASME Duty Classification Class D Class D Hook Elevation High Point 594.50 583.00 Low Point 538.25 530.00 Hook End Approach, in N/A N/A Operating Speeds Trolley Speed, fpm 70 70 Hoist Speed(s), fpm 25 and 6 25 and 6 All elevations and spans are approximate. All equipment shall be installed as shown on the Drawings. City of Denton Hazen and Sawyer BID SET 14600-3 Cranes and Hoists 1.04 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS A. Without limiting the generality of other requirements of the Specifications, all work herein shall conform to the applicable requirements of the following documents. All referenced Specifications, codes and standards refer to the most current issue available at the time of the Bid. 1. CMAA Crane Manufacturers Association of America 2. AISC “Manual of Steel Construction” 3. ASTM A48 Standard Specifications for Gray Iron Castings 4. ANSI B30.11 Safety Code for Underhung Cranes and Monorail Systems 5. ANSI B30.16 Safety Code for Overhead Hoists 6. MMA MH27.1 Monorail Manufacturers Association 7. OSHA 1910-179 Occupation Safety and Health Administration 1.05 SUBMITTALS A. The following items shall be submitted with the Shop Drawings in accordance with, or in addition to the submittal requirements specified in Section 01300, Submittals; and Section 11000, Equipment General Provisions: 1. Certification that the systems have been designed to resist all loads implied herein and loadings stipulated in the State of Texas Building Code. The Certification shall also state that the design has been performed and signed and sealed by a Professional Engineer registered in the State of Texas. B. Certification that the equipment has been field tested and passed. C. Details and design calculations shall be submitted, signed, and sealed by a Professional Engineer registered in the State of Texas for all of the following components furnished by the Manufacturer: 1. Monorail support frame. 2. Monorail runway beam. 3. Monorail suspension systems. 4. End stops and connections. 5. Hoist storage canopy. City of Denton Hazen and Sawyer BID SET 14600-4 Cranes and Hoists 1.06 WARRANTY AND GUARANTEE A. Warranty and Guarantee shall be as specified in Section 11000 with the exception that the warranty period shall be for two (2) years. PART 2 -- PRODUCTS 2.01 ACCEPTABLE MANUFACTURERS A. The equipment covered by these Specifications are intended to be standard equipment of proven reliability and as manufactured by reputable manufacturers having experience in the production of such equipment. 2.02 GENERAL A. The crane system shall be constructed of structural steel, in accordance with current AISC (American Institute of Steel Construction) and ASTM (American Society for Testing and Materials) A-36 specifications minimum. B. All crane components will have properly finished ends and surfaces. C. Welding shall follow the current recommended practices of the AWS (American Welding Society) D14.1 specifications. D. Moving members of the crane shall be separated by a clearance of at least 3 inches vertically from any overhead obstruction, and 2 inches horizontally from any lateral obstruction. 2.03 MONORAILS A. Monorail runway beam and support frame shall be designed by the monorail manufacturer for all loads indicated in Section 1.02 and loads required by the State of Texas Building Code and referenced standards. Design shall include all connections, including the monorail suspension system connection to the monorail support frame. The suspension system shall provide support and bracing of all live, dead, and impact loads. All rails shall be furnished with splices and end stops and shall be designed for spans, thermal expansion and contraction and turning radii as shown on the Drawings. All structural design calculations shall allow for 1/16” corrosion allowance for all carbon steel members. Vertical deflection of the runway beam shall not exceed L/600 and lateral deflection of the runway beam shall not exceed L/400. Monorail support frame columns shall be located as shown on the Drawings. Resistance for lateral loads may be provided by moment connections or by bracing. Bracing shall be located so that it does not interfere with areas indicated on Drawings to remain open. Monorail shall be manufactured by Louden division of ACCO, TC/American Monorail, Cleveland Tramrail division of Gorbel, Tram Beam, or equal. Rated capacity of monorail shall be painted with stencil on both the hoist and the monorail beam. City of Denton Hazen and Sawyer BID SET 14600-5 Cranes and Hoists B. A monorail hoist storage canopy shall be provided by and designed by the monorail manufacturer for all loads required by the State of Texas Building Code. 2.04 TROLLEY HOISTS A. Trolley hoists shall be as manufactured by ACCO Industries, Electrolift, or Yale. B. All load carrying parts shall be of steel. The wheels shall have hardened treads. Wheels and axles shall be equipped with antifriction bearings which are permanently sealed and lubricated. The gear head of the motor shall have an alloy steel, heat-treated gear train operating in a fully enclosed oil bath. The gear shaft shall have precision, oil lubricated ball bearings. Where monorail track as specified or shown on the Drawings is curved, trolleys shall be the swivel-type to negotiate curved sections. 1. Electrically operated trolleys shall include a gear-motor with solid-state soft start with adjustable time and torque, and electric brake. 2. Manual trolleys shall be of hand-driven geared type. C. The hoist drive shall be of the close-headroom, double reeved, cross-mounted type and shall include a geared train with inherent or mechanical load brake, hook, wire rope, and drum. Rated capacity shall be stamped on the hoist frame. The frame shall be oil-tight, of cast steel construction, with no part of the load carried by assembly bolts. Gearing shall be machine cut and heat-treated, and shall operate in an oil bath. Except for the drum pinion, no gears shall be cantilever mounted. Shafting shall be ground and polished and all bearings shall be of the antifriction type. Grease fittings and oil reservoir shall be readily accessible. The drum shall be of the large diameter, guarded, flanged type with machine cut grooves to accommodate the hoist cable without overwrapping. Right- and left-hand drum grooving shall be utilized in close-headroom, double-reeved, cross-mounted hoist applications to provide a true vertical lift. The wire ropes shall be of the preformed extra flexible type, have a safety factor of at least five, and be anchored to the hoist drum. The load block shall be of the safety type with guarded sheaves and forged swiveled hooks. Hooks shall open slowly when subjected to heavy overloads. 1. Electrically driven hoists shall include a two (2) speed, direct coupled motor, electrical controls, and solenoid brake. The solenoid brake shall be spring set with magnetic release operated by and interlocked with the electrical control equipment. Either a worm gear drive with an inherent load brake or a mechanical load brake designed in accordance with the Hoist Manufacturer's Institute standards shall be provided for controlling the speed when lowering, and for holding maximum hook load for any load up to capacity. Stressed parts shall be of cast or forged steel. In the event of a power failure the braking system shall automatically lock the piece of equipment being lifted to prevent further movement. Hoists shall also include either a clutch-type or electric-type overload cut-off device to protect hoist from an overload condition. 2. Manual hoists shall include a handwheel and chain and a clutch-type overload cut-off device to protect hoist from an overload condition. City of Denton Hazen and Sawyer BID SET 14600-6 Cranes and Hoists D. Rated capacity of trolley hoists shall be painted with stencil on the trolley hoist. 2.05 ELECTRICAL AND CONTROL REQUIREMENTS A. Electrical power wiring and connection to the electrical system not integral to the equipment shall be provided under Division 16, Electrical. All other power wiring associated with and integral to the hoist systems shall be furnished and installed under Division 14. B. All electrical appurtenances furnished by the equipment manufacturer shall be rated for installation in classified areas where such areas are indicated on the Drawings or specified herein. C. All wiring between motor, limit switches and starters shall be short, compact and protected by rigid aluminum conduit or flexible steel neoprene jacketed cable. D. The Electrical System providing power to the bridge crane drives, trolley drives, and hoists shall be festoon type as specified herein. 1. Festoon Type: A track supported festoon system shall be supplied where specified herein and shall include trolleys with tandem wheels of a corrosion resistant material which shall provide suitable service with the track that is used. The trolleys shall have saddles for supporting the cables in equal loops not exceeding 9'-0" of cable per loop. The track shall be stainless steel and supported at spans not exceeding 6'-0". The track shall be adequately supported with horizontal arms spanning to the festoon tow bar. The equipment manufacturer shall be fully responsible for the design and suitability of the festoon system. E. Starting equipment shall be integral with the crane drives and/or trolley hoist unit and shall be of the full voltage, magnetic-reversing type with three overload elements. Equipment shall be housed in an enclosure suitable to the conditions of service and as specified herein. F. Hoisting motors shall be a two-speed motors. The trolley motors shall be a single speed squirrel cage induction motors NEMA Design "D". Motors shall be of the totally enclosed type designed for hoist service. The motor rating shall be on a 30-minute 55C, duty cycle basis. City of Denton Hazen and Sawyer BID SET 14600-7 Cranes and Hoists G. Electrical/Control Requirements Hickory Creek Detention Facility Pump Station Pecan Creek WRP West Peak Flow Pump Station Area Classification Unclassified Unclassified NEMA Rating of Components NEMA 4X NEMA 4X Electrical System Festoon Festoon Control System Pendent Pendent Motors Rating 460V, 3 ph, 60 Hz 460V, 3 ph, 60 Hz Trolley Motor HP 0.5 0.5 Hoist Motor HP 10 10 Enclosure TEFC TEFC Insulation Class F Class F Inverter Duty No No Service Factor 1.15 1.15 Space Heater Yes Yes Motor Winding Temperature Switches Yes Yes H. Limit switches shall be approved geared typed, positive in action, compact, oil proof and readily accessible. Solenoid brakes shall be disk type, spring set with magnetic release. Solenoids shall be totally enclosed, protected from oil and moisture, readily accessible for adjustment and maintenance and shall develop the required forces without overheating. I. All electrical and control components shall conform to the applicable standards of UL and NEMA, unless specified otherwise. International Electrotechnical Commission (IEC) standards are not recognized. Equipment designed, manufactured, and labeled in compliance with IEC standards is not acceptable. 2.06 CONTROLS A. The Control System providing control of the bridge crane drives, trolley drives, and hoists shall be through wired pendent controls as specified herein. 1. Pendent controls for lift and travel shall be provided complete with heavy-duty push-button station of constant pressure type with silver-to-silver contact elements, and sufficient control cable and chain for support of the control station at a point 4 feet above the lowest operating floor where multiple levels are to be accessed. A balancer shall be provided which will allow the control pushbutton station to be retracted to a maximum of four feet above the upper operating level. Two speed control of the hoist drive shall be effected by a two-step pushbutton. Pendant controls shall be suspended from the hoist for monorail applications. Pendant controls shall be suspended independently from the hoist using a c- track festoon for bridge crane applications. City of Denton Hazen and Sawyer BID SET 14600-8 Cranes and Hoists B. Control power shall be 120 volt, provided by a control power transformer within the starter units. One side of this transformer shall be grounded, the other side shall be connected via a fuse of adequate rating. PART 3 -- EXECUTION 3.01 MANUFACTURER’S FIELD SERVICES A. The services of a qualified manufacturer's technical representative shall be provided in accordance with Section 11000, Equipment General Provisions and shall include the following site visits for each crane and hoist system: Service Number of Trips Number of Days/Trip Installation and Testing 1 1 Startup and Training 1 1 3.02 INSTALLATION A. All crane equipment shall be installed in accordance with the applicable sections of Division 5 - Metals, Division 16 – Electrical, and the manufacturer's instructions and recommendations. 3.03 FIELD TESTS A. Field tests shall be conducted in accordance with Section 11000 and the manufacturer's instructions and recommendations. Prior to initial use, all cranes shall be proof-tested at 125% of their rated load in accordance with all OSHA requirements. 3.04 PAINTING A. The crane shall be painted OSHA safety yellow before shipment. B. A wire-brushing and/or solvent wipe shall be performed prior to painting to clean and remove debris, mill scale, dirt, and oils. C. At least one spray can of matching color paint shall be shipped with each crane for field touch-ups. D. The crane shall be properly banded and skidded prior to shipment. Any paint damage, scratches, blemishes to the finish of the crane, caused by shipping, transportation via common carrier, etc., shall be repaired by the Contractor. E. Rated capacity of crane system shall be painted with stencil on all components of crane system as specified herein. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 15000-1 Basic Mechanical Requirements SECTION 15000 BASIC MECHANICAL REQUIREMENTS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish and install to the required line and grade, all piping together with all fittings and appurtenances, required for a complete installation. All piping located outside the face of structures or building foundations and all piping embedded in concrete within a structure or foundation shall be considered exterior piping. B. The Contractor shall furnish and install fittings, couplings, connections, sleeves, adapters, harness rods and closure pieces as required to connect pipelines of dissimilar materials and/or sizes herein included under this Section and other concurrent Contracts for a complete installation. C. The Contractor shall furnish all labor, materials, equipment, tools, and services required for the furnishing, installation and testing of all piping as shown on the Drawings, specified in this Section and required for the Work. Piping shall be furnished and installed of the material, sizes, classes, and at the locations shown on the Drawings and/or designated in this Section. Piping shall include all fittings, adapter pieces, couplings, closure pieces, harnessing rods, hardware, bolts, gaskets, wall sleeves, wall pipes, hangers, supports, and other associated appurtenances for required connections to equipment, valves, or structures for a complete installation. D. Piping assemblies under 4-inch size shall be generally supported on walls and ceilings, unless otherwise shown on the Drawings or ordered by the Engineer, being kept clear of openings and positioned above "headroom" space. Where practical, such piping shall be run in neat clusters, plumb and level along walls, and parallel to overhead beams. E. The Contractor shall provide taps on piping where required or shown on the Drawings. Where pipe or fitting wall thicknesses are insufficient to provide the required number of threads, a boss or pipe saddle shall be installed. F. The work shall include, but not be limited to, the following: 1. Connections to existing pipelines. 2. Test excavations necessary to locate or verify existing pipe and appurtenances. 3. Installation of all new pipe and materials required for a complete installation. 4. Cleaning, testing and disinfecting as required. City of Denton Hazen and Sawyer BID SET 15000-2 Basic Mechanical Requirements 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Division 1, General Requirements B. Division 2, Sitework C. Division 9, Finishes D. Division 11, Equipment E. Division 16, Electrical 1.03 MATERIAL CERTIFICATION AND SHOP DRAWINGS A. The Contractor shall furnish to the OWNER (through the Engineer) a Material Certification stating that the pipe materials and specials furnished under this Section conform to all applicable provisions of the corresponding Specifications. Specifically, the Certification shall state compliance with the applicable standards (ASTM, AWWA, etc.) for fabrication and testing. B. Shop Drawings for major piping (2-inches in diameter and greater) shall be prepared and submitted in accordance with Section 01300 – Submittals. In addition to the requirements of Section 01300 – Submittals, the Contractor shall submit laying schedules and detailed Drawings in plan and profile for all piping as specified and shown on the Drawings. C. Shop Drawings shall include, but not be limited to, complete piping layout, pipe material, sizes, class, locations, necessary dimensions, elevations, supports, hanger details, pipe joints, and the details of fittings including methods of joint restraint. No fabrication or installation shall begin until Shop Drawings are approved by the Engineer. PART 2 -- PRODUCTS 2.01 GENERAL A. All specials and every length of pipe shall be marked with the manufacturer's name or trademark, size, class, and the date of manufacture. Special care in handling shall be exercised during delivery, distribution, and storage of pipe to avoid damage and unnecessary stresses. Damaged pipe will be rejected and shall be replaced at the Contractor's expense. Pipe and specials stored prior to use shall be stored in such a manner as to keep the interior free from dirt and foreign matter. B. Testing of pipe before installation shall be as described in the corresponding ASTM or AWWA Specifications and in the applicable standard specifications listed in the following sections. Testing after the pipe is installed shall be as specified in Section 3.09. C. Joints in piping shall be of the type as specified in the appropriate Piping System Schedule in Section 15390, Schedules. City of Denton Hazen and Sawyer BID SET 15000-3 Basic Mechanical Requirements D. ALL BURIED EXTERIOR PIPING SHALL HAVE RESTRAINED JOINTS FOR THRUST PROTECTION UNLESS OTHERWISE SPECIFIED OR SHOWN ON THE DRAWINGS. ALL EXPOSED EXTERIOR PIPING SHALL HAVE FLANGED JOINTS, UNLESS OTHERWISE SPECIFIED OR SHOWN ON THE DRAWINGS. E. The Drawings indicate work affecting existing piping and appurtenances. The Contractor shall excavate test pits as required of all connections and crossings which may affect the Contractor's work prior to ordering pipe and fittings to determine sufficient information for ordering materials. The Contractor shall take whatever measurements that are required to complete the work as shown or specified. F. Fiberglass duct shall be as specified in Section 15892, FRP Ductwork. G. Fiberglass pipe shall be as specified in Section 15017, Fiberglass Reinforced Pipe – Raw Sewage Service. 2.02 WALL PIPES A. Where wall sleeves or wall pipes occur in walls that are continuously wet on one or both sides, they shall have water stop flanges at the center of the casting or as shown on the Drawings. Ends of wall pipes shall be flange, mechanical joint, plain end, or bell as shown on the Drawings, or as required for connection to the piping. Wall pipes shall be of the same material as the piping that they are connected to. If welded waterstop flanges are employed, welds shall be 360 degree continuous on both sides of flange. Unless otherwise shown on the Drawings, waterstop flanges shall conform to the minimum dimensions shown below: Pipe Size Waterstop Flange Diameter Waterstop Flange Thickness 4" - 12" OD + 3.10" 0.50" 14" - 24" OD + 4.15" 0.75" 30" - 36" OD + 4.50" 1.00" 42" - 48" OD + 5.00" 1.25" 54" OD + 5.90" 1.50" 2.03 SLEEVES A. Unless shown otherwise, all piping passing through walls and floors shall be installed in sleeves or wall castings accurately located before concrete is poured, or placed in position during construction of masonry walls. Sleeves passing through floors shall extend from the bottom of the floor to a point 3 inches above the finished floor, unless shown otherwise. Water stop flanges are required on all sleeves located in floors or walls which are continually wet or under hydrostatic pressure on one or both sides of the floor or wall. B. Sleeves shall be cast iron, black steel pipe, or fabricated steel in accordance with details shown on the Drawings. If not shown on the Drawings, the Contractor shall submit to the Engineer the details of sleeves he proposes to install; and no fabrication or installation thereof shall take place until the Engineer's approval is obtained. Steel sleeves shall be fabricated of structural steel plate in accordance with the standards and procedures of AISC City of Denton Hazen and Sawyer BID SET 15000-4 Basic Mechanical Requirements and AWS. Steel sleeve surfaces shall receive a commercial sandblast cleaning and then be shop painted in accordance with Section 09900 – Painting. C. When shown on the Drawings or otherwise required, the annular space between the installed piping and sleeve shall be completely sealed against a maximum hydrostatic pressure of 20 psig. Seals shall be mechanically interlocked, solid rubber links, trade name "Link-Seal", as manufactured by the Thunderline Corp., Wayne, Michigan, or equal. Rubber link, seal-type, size, and installation thereof, shall be in strict accordance with the manufacturer's recommendations. For non-fire rated walls and floors, pressure plate shall be glass reinforced nylon plastic with EPDM rubber seal and 304 stainless steel bolts and nuts. For fire rated walls and floors, two independent seals shall be provided consisting of low carbon steel, zinc galvanized pressure plates, silicon rubber seals and low carbon steel, zinc galvanized bolts and nuts. D. Cast iron mechanical joint adapter sleeves shall be Clow # 1429, as manufactured by the Clow Corp., or equal. Mechanical joint adapter sleeves shall be provided with suitable gasket, follower ring, and bolts to effect a proper seal. In general, sleeves installed in walls, floors, or roofs against one side of which will develop a hydrostatic pressure, or through which leakage of liquid will occur, shall be so sealed. If welded waterstop flanges are employed, welds shall be 360 degree continuous on both sides of flange. 2.04 SOLID SLEEVE COUPLINGS A. Solid sleeve couplings shall be used to connect buried service piping where shown on the Drawings. Solid sleeves shall be ductile iron, long body and shall conform to the requirements of ANSI A21.10 (AWWA C110). Unless otherwise shown or specified, solid sleeve couplings shall be Style A11760 as manufactured by American Cast Iron Pipe Co., or equal. 2.05 FLEXIBLE COUPLINGS A. Flexible couplings shall be as manufactured by the Red Valve Company and shall consist of a molded reinforced fabric of cotton and natural rubber. Galvanized steel retaining rings shall be furnished. End connections shall match ANSI 125 pound flanges with a minimum pressure rating of 140 psi. 2.06 SLEEVE TYPE COUPLINGS A. Sleeve type, flexible couplings shall be furnished and installed where shown on the Drawings or otherwise required to resist internal operating pressures. In addition to that specified herein, harnessed, sleeve type flexible couplings shall be provided on all exposed pipe 3 inches and larger in diameter that spans any expansion joint in a building or structure. B. Materials shall be of high strength steel and couplings shall be rated for the same pressures as the connecting piping. C. Gaskets shall be rubber. Bolts and nuts shall be alloy steel, corrosion-resistant and prime coated. City of Denton Hazen and Sawyer BID SET 15000-5 Basic Mechanical Requirements D. Couplings shall be shop primed with a premium quality primer compatible with the painting system specified in Section 09900 - Painting. Field painting of wetted area shall be done prior to installation. E. Harnessing 1. Harness couplings to adjacent flanges as shown, specified or otherwise required to restrain all pressure piping. 2. Dimensions, sizes, spacing and materials for lugs, tie rods, washers, and nuts shall conform to the standards for the pipe size, and design pressure specified. 3. No less than two (2) bolts shall be furnished for each coupling. 4. Tie bolts, nuts and washers shall be ASTM A 193, Grade B7 steel or better. 5. Harness rods shall have lengths less than 10 feet between adjacent flanged joints on fittings and shall be coated in accordance with Section 09900 – Painting. F. Couplings shall be as manufactured by Dresser Industries, Style 38, EBAA Iron Inc., Series 3800 MEGA-COUPLING, or equal as required and shown on the Drawings. All couplings shall be provided without interior pipe stop. 2.07 FLANGED ADAPTERS A. Flanged adapters shall be furnished as required and as shown on the Drawings. B. All flanged adapters, 12 inches in diameter and smaller, except as shown on the Drawings or directed by the Engineer, shall be locking type flanged adapters. C. Pressure and service shall be the same as connected piping. D. Materials shall be cast iron for pipes up to 12 inch diameter and high strength steel for pipes larger than 12 inch diameter. E. Flanged adapters shall be shop primed with a premium quality primer compatible with the paint system specified in Section 09900 – Painting. Field painting of wetted area shall be done prior to installation. F. Bolts and nuts shall be alloy steel, corrosion-resistant and prime coated. G. Flanged coupling adapters larger than 12 inches in diameter shall be harnessed by tying the adapter to the nearest pipe joint flange using threaded rods and rod tabs. The threaded rods and rod tabs shall be as shown on the Drawings. H. Flanged adapters shall be as manufactured by Dresser Industries, Style 127 or 128, Smith Blair Corporation, or EBAA Iron Inc. Series 1100 MEGALUG, or equal. City of Denton Hazen and Sawyer BID SET 15000-6 Basic Mechanical Requirements 2.08 TAPPING SLEEVES AND TAPPING SADDLES A. Tapping sleeves shall be similar to Mueller Outlet Seal, American Uniseal or Kennedy Square Seal. All sleeves shall have a minimum working pressure of 150 psi. All sleeves larger than twelve (12) inches shall be ductile iron. All taps shall be machine drilled; no burned taps will be allowed. B. Tapping saddles may be used on mains sixteen (16) inches and larger where the required tap size does not exceed one-half the size of the main (i.e. 8-inch tapping saddle for use on a 16-inch main). Tapping saddles shall be manufactured of ductile iron providing a factor of safety of at least 2.5 at a working pressure of 250 psi. Saddles shall be equipped with a standard AWWA C-110-77 flange connection on the branch. Sealing gaskets shall be "O" ring type, high quality molded rubber having an approximate seventy durometer hardness, placed into a groove on the curved surface of the tapping saddles. Straps shall be of alloy steel. The tapping saddle shall be the American tapping saddle, U.S. Pipe tapping saddle, or equal. All taps shall be machine cut, no burned taps will be allowed. 2.09 UNIONS A. For ductile iron, carbon steel, and grey cast iron pipes assembled with threaded joints and malleable iron fittings, unions shall conform to ANSI B16.39. B. For copper piping, unions shall have ground joints and conform to ANSI B16.18. C. For PVC and CPVC piping, unions shall be socket weld type with Viton O-ring. 2.10 THERMOPLASTIC TUBING AND FITTINGS (NOT USED) A. Thermoplastic tubing shall be manufactured from polyallomor tubing. Tubing shall be protected from ultraviolet radiation degradation with a black coating or integral color conforming to ASTM D-1248, Type 1, Class C, Category 3. Fittings and connectors used with thermoplastic tubing shall be the flareless tube type constructed of brass conforming to SAE CA377, SAE CA360 or equal. Brass sleeves shall be used. B. Assembly of the thermoplastic tubing shall consist of pushing the tubing into the fitting and hand tightening the nut with final tightening with a wrench. Care shall be taken not to overtighten the nut. Plastic tube racks and bend holders shall be provided for holding the tubing in position. Needle valves used with thermoplastic tubing shall be the globe type constructed with a brass body, stem and seat and Buna-N "O"-ring seals. Installation shall be in accordance with the manufacturer's recommendations. Thermoplastic tubing, shall be the Impolene (polyallomor) system and needle valves, fittings and connectors shall be the Poly-Flo with 261 UB Universal Nut and Sleeve system as manufactured by Imperial Eastman, or equal. 2.11 HEAT TRACED PIPING (NOT USED) A. Exposed pipes to be insulated shall also be protected from freezing by heat tracing. Freeze protection heat tracing shall consist of twin 16 AWG copper brass wires with a semiconductor polymer core where electrical resistance varies with temperature. The heat City of Denton Hazen and Sawyer BID SET 15000-7 Basic Mechanical Requirements tracing shall have a fluoropolymer outer jacket for corrosion resistance. The heat tracing shall be rated for three (3) watts per foot output, self-regulating with a maximum temperature of 150°F, equal to a Chromalox No. SRL3-1CT383400. Maximum length for tape shall be 300 feet for each circuit. Temperature controller shall be provided to sense pipe temperature to determine on or off condition of the heat tracing. Temperature control shall be equal to a Chromalox No. RTBC-2-384729. The heat tracing system shall operate on 120 VAC. See Drawings for installation detail. Heat tracing of piping shall be provided as specified in Section 15390 – Schedules. 2.12 FLEXIBLE RESTRAINED EXPANSION JOINTS A. Restrained expansion joints shall be manufactured of 60-42-10 ductile iron conforming to material and other applicable requirements of ANSI/AWWA C153/A21.53. B. Each pressure containing component shall be lined with a minimum of 15 mils of fusion bonded epoxy conforming to the materials requirements of, and tested in accordance with, ANSI/AWWA C213 and shall meet or exceed the requirements of ANSI/AWWA C550. C. Seals shall conform to the applicable requirements of ANSI/AWWA C111/A21.11. D. All bolts used in the assemblies shall be stainless steel and shall be coated with a premium quality epoxy. E. Flanged ends shall comply with ANSI/AWWA C110/A21.10, with the addition of O-ring groove and O-ring. F. Mechanical joint ends shall comply with ANSI/AWWA C153/A21.53. G. Restrained expansion joints shall have a minimum pressure rating of 350 psi with a minimum safety factor of 3:1. Each assembly shall be tested at 350 psi before shipment. H. Restrained expansion joints shall provide for self restraint without tie rods and shall provide for expansion and contraction capabilities cast as an integral part of the end connection. I. Flexible restrained expansion joints shall allow for 6-inches (+4"-2") minimum expansion. J. Flexible restrained expansion joints shall consist of an expansion joint designed and cast as an integral part of a ball and socket type flexible joint having a minimum of 15 deflection per ball and a minimum of 10-inches of offset (centerline to centerline). K. Restrained expansion joints shall be the Single Ball or Double Ball FLEX-TEND Expansion Joint as manufactured by EBAA Iron Inc., or equal. PART 3 -- EXECUTION 3.01 INSTALLATION A. All piping shall be installed by skilled workmen and in accordance with the best standard practice for piping installation as shown on the Drawings, specified or recommended by the pipe manufacturer. Proper tools and appliances for the safe and convenient handling and City of Denton Hazen and Sawyer BID SET 15000-8 Basic Mechanical Requirements installing of the pipe and fittings shall be used. Great care shall be taken to prevent any pipe coating from being damaged on the inside or outside of the pipe and fittings. All pieces shall be carefully examined for defects, and no piece shall be installed which is known to be cracked, damaged, or otherwise defective. If any defective pieces should be discovered after having been installed, it shall be removed and replaced with a sound one in a satisfactory manner by the Contractor and at his own expense. Pipe and fittings shall be thoroughly cleaned before they are installed and shall be kept clean until they are accepted in the complete work. All piping connections to equipment shall be provided with unions or coupling flanges located so that piping may be readily dismantled from the equipment. At certain applications, Dresser, Victaulic, or equal, couplings may also be used. All piping shall be installed in such a manner that it will be free to expand and contract without injury to itself or to structures and equipment to which it is connected. All piping shall be erected to accurate lines and grades with no abrupt changes in line or grade and shall be supported and braced against movement, temporary, or permanent. All exposed piping shall be installed with vertical and horizontal angles properly related to adjoining surfaces or pipes to give the appearance of good workmanship. Unless otherwise shown or approved, provided a minimum headroom clearance under all piping of 7 feet 6 inches. B. Unless otherwise shown or specified, all waste and vent piping shall pitch uniformly at a 1/4-inch per foot grade and accessible cleanouts shall be furnished and installed as shown and as required by local building codes. Installed length of waste and vent piping shall be determined from field measurements in lieu of the Drawings. C. All excavation shall be made in such a manner and to such widths as will provide ample room for properly installing the pipe and permit thorough compaction of backfill around the pipe. The minimum trench widths shall be in strict accordance with the "Trench Width Excavation Limits" as shown on the Drawings. All excavation and trenching shall be done in strict accordance with these specifications and all applicable parts of the OSHA Regulations, 29CFR 1926, Subpart P. D. ALL EXCAVATION REQUIRED BY THIS CONTRACT SHALL BE UNCLASSIFIED. NO ADDITIONAL PAYMENT WILL BE MADE FOR ROCK EXCAVATION REQUIRED FOR THE INSTALLATION OF PIPE OR STRUCTURES SHOWN ON THE DRAWINGS. E. Enlargements of the trench shall be made as needed to give ample space for operations at pipe joints. The width of the trench shall be limited to the maximum dimensions shown on the Drawings, except where a wider trench is needed for the installation of and work within sheeting and bracing. Except where otherwise specified, excavation slopes shall be flat enough to avoid slides which will cause disturbance of the subgrade, damage to adjacent areas, or endanger the lives or safety of persons in the vicinity. F. Hand excavation shall be employed wherever, in the opinion of the Engineer, it is necessary for the protection of existing utilities, poles, trees, pavements, or obstructions. G. No greater length of trench in any location shall be left open, in advance of pipe laying, than shall be authorized or directed by the Engineer and, in general, such length shall be limited to approximately one hundred (100) feet. The Contractor shall excavate the trenches to the full depth, width and grade indicated on the Drawings including the relevant requirements for bedding. The trench bottoms shall then be examined by the Engineer as to the condition and bearing value before any pipe is laid or bedding is placed. City of Denton Hazen and Sawyer BID SET 15000-9 Basic Mechanical Requirements H. No pressure testing shall be performed until the pipe has been properly backfilled in place. All pipe passing through walls and/or floors shall be provided with wall pipes or sleeves in accordance with the specifications and the details shown on the Drawings. All wall pipes shall be of ductile iron and shall have a water stop located in the center of the wall. Each wall pipe shall be of the same class, thickness, and interior coating as the piping to which it is joined. All buried wall pipes shall have a coal tar outside coating on exposed surfaces. I. JOINT DEFLECTION SHALL NOT EXCEED 75 PERCENT OF THE MANUFACTURERS RECOMMENDED DEFLECTION. Excavation and backfilling shall conform to the requirements of Section 02200 - Earthwork, and as specified herein. Maximum trench widths shall conform to the Trench Width Excavation Limits shown on the Drawings. All exposed, submerged, and buried piping shall be adequately supported and braced by means of hangers, concrete piers, pipe supports, or otherwise as may be required by the location. J. Following proper preparation of the trench subgrade, pipe and fittings shall be carefully lowered into the trench so as to prevent dirt and other foreign substances from gaining entrance into the pipe and fittings. Proper facilities shall be provided for lowering sections of pipe into trenches. UNDER NO CIRCUMSTANCES SHALL ANY OF THE MATERIALS BE DROPPED OR DUMPED INTO THE TRENCH. K. Water shall be kept out of the trench until jointing and backfilling are completed. When work is not in progress, open ends of pipe, fittings, and valves shall be securely closed so that no water, earth, or other substance will enter the pipes, fitting, or valves. Pipe ends left for future connections shall be valved, plugged, or capped, and anchored as required. L. All piping shall be installed in such a manner that it will be free to expand and/or contract without injury to itself or to structures and equipment to which it is connected. All piping shall be erected to accurate lines and grades with no abrupt changes in line or grade and shall be supported and braced against movement, temporary, or permanent. All exposed piping shall be installed with vertical and horizontal angles properly related to adjoining surfaces or pipes to give the appearance of good workmanship. Pipes crossing within a vertical distance of less than or equal to one (1) foot shall be encased and supported with concrete at the point of crossing to prevent damage to the adjacent pipes as shown on the Drawings. M. The full length of each section of pipe shall rest solidly upon the bed of the trench, with recesses excavated to accommodate bells, couplings, joints, and fittings. Before joints are made, each pipe shall be well bedded on a solid foundation; and no pipe shall be brought into position until the preceding length has been thoroughly bedded and secured in place. Pipe that has the grade or joint disturbed after laying shall be taken up and relaid by the Contractor at his own expense. Pipe shall not be laid in water or when trench conditions are unsuitable for work. N. Proper and suitable tools and appliances for the safe convenient handling and laying of pipe shall be used and shall in general agree with manufacturer's recommendations. O. AT THE CLOSE OF EACH WORK DAY THE END OF THE PIPELINE SHALL BE TIGHTLY SEALED WITH A CAP OR PLUG SO THAT NO WATER, DIRT, OR OTHER FOREIGN SUBSTANCE MAY ENTER THE PIPELINE, AND THIS PLUG SHALL BE KEPT IN PLACE UNTIL PIPE LAYING IS RESUMED. City of Denton Hazen and Sawyer BID SET 15000-10 Basic Mechanical Requirements P. During the laying of pipe, each pipe manufacturer shall provide his own supervisor to instruct the Contractor's pipe laying personnel in the correct procedure to be followed. Q. Ordinarily only full lengths of pipe (as furnished by the pipe manufacturer) shall be used exceptions: closure pieces at manholes and areas where joint deflection is required. R. For gravity sewer installations, the Contractor shall use a laser device to maintain the trench and pipe alignment. The laser device shall be re-checked for correct elevation and pipe alignment prior to pipe installation if the device is left in the pipe overnight. Corrected invert elevations at each manhole and any adjustments will be coordinated and approved by the Engineer. S. ALL PIPING SHALL HAVE TYPE "A" BEDDING AS SHOWN ON THE DRAWINGS, UNLESS OTHERWISE SPECIFIED HEREIN OR INDICATED ON THE DRAWINGS. T. Detector tape shall be installed 12 inches below final grade and directly above all buried potable water piping. The tape shall be blue and silver and shall be clearly and permanently labeled "Water". Detector tape shall be Lineguard III as manufactured by Lineguard, Inc., or equal. 3.02 REINFORCED CONCRETE PIPE, CONCRETE CULVERT, AND DRAIN PIPE A. The laying of reinforced concrete pipe shall conform to the applicable sections of the Concrete Pipe Handbook as published by the American Concrete Pipe Association. 3.03 PRESTRESSED CONCRETE PIPE (NOT USED) A. The laying of prestressed concrete pipe shall be in accordance with the manufacturer's recommendations and shall conform to the applicable sections of AWWA Manual M-9. Prior to assembling the spigot end into the bell end, both ends shall be thoroughly cleaned and the rubber gasket and the bell end of the previously laid pipe shall be coated with vegetable soap furnished by the manufacturer. B. For each crew that is inexperienced in laying this type of pipe, one reliable man shall be furnished by the manufacturer's representative with and instructed in the use of a set of steel inserts and feeler gauge to be used in determining if the rubber gasket is in proper position prior to the joint being pushed or pulled home. An experienced crew may omit the use of a feeler gauge. In either method of operation, the Contractor shall be responsible for a good, proper and sound joint. Any joint found in later tests to be faulty shall be repaired to the satisfaction of the Engineer. C. After the pipe is "home" a cloth diaper (minimum 7-inches wide) supplied by the pipe manufacturer shall be placed and wired around the outside of the pipe at the joint. This diaper shall serve as a form for pouring a 1:2 cement-sand grout in the external recess. D. Great care shall be taken to prevent the concrete core or jacket or the steel bell and spigot rings from being damaged, and any core, jacket or ring damaged in any way shall be repaired or replaced by the Contractor to the satisfaction of the Engineer. City of Denton Hazen and Sawyer BID SET 15000-11 Basic Mechanical Requirements 3.04 DUCTILE IRON PIPE A. Ductile iron pipe (DIP) shall be installed in accordance with the requirements of the Ductile Iron Pipe Handbook published by the Ductile Iron Pipe Research Association, and AWWA C600. B. Where it is necessary to cut ductile iron pipe in the field, such cuts shall be made carefully in a neat workmanlike manner using approved methods to produce a clean square cut. The outside of the cut end shall be conditioned for use by filing or grinding a small taper, at an angle of approximately 30 degrees. C. UNLESS OTHERWISE APPROVED BY THE ENGINEER, FIELD WELDING OF DUCTILE IRON WILL NOT BE PERMITTED. 3.05 PVC/CPVC AND HDPE PIPE A. Polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC) and High Density Polyethylene (HDPE) pipe shall be laid and joints assembled according to the respective manufacturer's recommendation. PVC pipe installation shall comply with applicable sections of the Uni-Bell PVC Pipe Association Recommended Standard Specifications. B. Plastic piping shall not be installed when the temperature is less then 60F except as otherwise recommended by the manufacturer and approved by the Engineer. 3.06 CARBON AND STAINLESS STEEL PIPE (NOT USED) A. Installation of steel pipe shall be by skilled workmen and shall conform to the applicable sections of AWWA Manual M-11. Joints for steel piping shall be either screwed, welded, or flanged as shown on the Drawings or as specified. B. Welding in the field shall be performed only when requested on the shop drawings and permitted by the Engineer for carbon steel pipe. No welding of stainless steel pipe shall be allowed in the field. All field welds shall be radiographically inspected. C. Installation of the steel casing pipe shall be by skilled workmen and in accordance with the best standard practice for steel pipe installation. Joints for steel casing pipe shall be butt welded. 1. The boring equipment to be used for installing the jacked casing shall be of such size and capacity to allow the boring to proceed in a safe and expeditious manner. The installation of the casing and boring of the hole shall be done simultaneously to avoid cave-ins or settlement and for safety of traffic above. 2. The Contractor shall check the vertical and horizontal alignment of the casing by survey instrument at least once during each four feet of advance, or as directed by the Engineer. Pits shall be well sheeted and braced as necessary for safe and adequate access for workmen, inspectors and materials and shall be of a size suitable to equipment and material handling requirements. City of Denton Hazen and Sawyer BID SET 15000-12 Basic Mechanical Requirements 3. Under no conditions shall jetting or wet boring of encasement under pavement be allowed. 4. After installation of the carrier pipe, each end of the casing pipe shall be made watertight with a brick masonry bulkhead. In addition, a Class B concrete cradle shall be provided from each end of the bulkhead to the first pipe joint outside of the bulkhead. 3.07 COPPER PIPE (NOT USED) A. Installation of copper pipe shall be by skilled workman in accordance with the manufacturer's recommendations. Use teflon tape at all fittings unless otherwise required for intended service. Install unions at the connections to each piece of equipment to allow removal of equipment without dismantling connecting piping. B. Wall sleeves shall be provided for all piping passing through exterior walls and shall be of the same material as the piping to which it is joined. All wall sleeves shall be provided with an acceptable waterstop. C. The Contractor shall provide hot and cold water mains with branches and risers complete from point indicated on the Drawings running to all fixtures and other outlets indicated. Mains and branches shall be run generally as shown on the Drawings. The Contractor shall provide all interior water piping, branches, and risers as shown on the Drawing and shall make connections to all plumbing fixtures, hose bibs, wall hydrants, and other points requiring water under this and other Divisions of the Specifications. D. All water mains and branches shall be pitched at least one (1) inch in twenty-five (25) feet toward fixtures. The piping installation shall be arranged so that the entire system can be drained through fixture supply connections. E. Unions shall be installed at the connections to each piece of equipment to allow for removal of equipment without dismantling connecting piping. F. Joints 1-1/4 inches and larger shall be made with silver solder. For joints less than 1-1/4 inches and all valves (regardless of size) use 95/5 solder. Soldered joints shall be prepared with a non-corrosive paste flux in accordance with manufacturer's instructions. All joints shall be thoroughly cleaned with emery cloth and reamed out before assembly. Acid core solder will not be permitted. 3.08 POLYPROPYLENE AND POLYVINYLIDENE FLUORIDE PIPE (NOT USED) A. The pipe and fittings shall be of the same material for both inner and outer walls of the pipe. B. Polypropylene pipe shall be black UV stabilized co-polymer conforming to the requirements of ASTM D-4101. Where used in exterior locations, material shall provide a weathering resistance absent of further coating, covering, or wrapping unless specified herein or shown on the Drawings. City of Denton Hazen and Sawyer BID SET 15000-13 Basic Mechanical Requirements C. Polyvinylidene flouride shall comply with ASTM D-3222. The material shall provide a translucence, thus enabling a visual inspection of liquid in the annular space between the inner and outer walls. D. Where elastomers are selected by the manufacturer, such selection shall be with regard to the application of the chemical solution to be transported. E. Pipe and associated fittings shall be rated for not less than 75 psi at 73°F. F. Double-walled pipe and fittings shall be molded and used throughout. Molded ribs shall maintain permanent alignment of the inner and outer walls of the pipe and fittings. G. Ends of fittings shall be flush, creating a single plane. H. Wall thickness of the inner and outer walls of double-walled pipe shall be identical, providing identical pressure ratings. I. Where shown on the Drawings, a leak detection system of the manufacturer's design shall be supplied, complete with vent pipes, manual drain outlet, and electric float switch. Switch shall be rated for 0.080 amps at 120 VAC. J. Polypropylene and polyvinylidene flouride pipe shall be laid and joints assembled by skilled workers according to the respective manufacturer's recommendations. Joints shall be butt fusion welded. K. Plastic piping shall not be installed when the ambient temperature is less than 60°F except as otherwise recommended by the manufacturer and approved by the Engineer. L. Wall sleeves shall be provided where piping passes through exterior walls. All sleeves shall be provided with an acceptable waterstop. M. Double walled pipe shall be Asahi/American or equal. Pipe shall be furnished complete with flanges or other appurtenant fittings by the same manufacturer and made especially for use with the double walled pipe. 3.09 JOINTS IN PIPING A. Restrained joints shall be provided on all pipe joints as specified herein and shown on the Drawings. Restrained joints shall be made up similar to that for push-on joints. B. Push-on joints include a single rubber gasket which fits into the bell end of the pipe. The gasket shall be wiped clean, flexed and then placed in the socket. Any bulges in the gasket which might interfere with the entry of the plain end of the pipe shall be removed. A thin film of lubricant shall be applied to the gasket surface which will come into contact with the spigot end of the pipe. The lubricant shall be furnished by the pipe manufacturer. The plain end of the pipe, which is tapered for ease of assembly, shall be wiped clean and a thick film of lubricant applied to the outside. The pipe shall be aligned and carefully entered into the socket until it just makes contact with the gasket. The joint assembly shall be completed by entering the pipe past the gasket until it makes contact with the bottom of the socket. The pipe shall be pulled "home" with an approved jack assembly as recommended by the pipe City of Denton Hazen and Sawyer BID SET 15000-14 Basic Mechanical Requirements manufacturer. If assembly is not accomplished by reasonable force, the plain end shall be removed and the condition corrected. C. Flanged joints shall be brought to exact alignment and all gaskets and bolts or studs inserted in their proper places. Bolts or studs shall be uniformly tightened around the joints. Where stud bolts are used, the bolts shall be uniformly centered in the connections and equal pressure applied to each nut on the stud. Pipes in all lines subject to temperature changes shall be cut short and cold sprung into place to compensate for expansion when hot. D. Mechanical joints shall be made up with gaskets, glands and bolts. When a joint is to be made up, the bell or socket and plain end shall be cleaned and washed with a solution of mild soap in water; the gland and gasket shall be slid onto the plain end and the end then entered into the socket until it is fully "home" on the centering ring. The gasket shall then be painted with soapy water and slid into position, followed by the gland. All bolts shall be inserted and made up hand tight and then tightened alternately to bring the gland into position evenly. Excessive tightening of the bolts shall be avoided. All nuts shall be pulled up using a torque wrench which will not permit unequal stresses in the bolts. Torque shall not exceed the recommendations of the manufacturer of the pipe and bolts for the various sizes. Care shall be taken to assure that the pipe remains fully "home" while the joint is being made. Joints shall conform to the applicable AWWA Specifications. E. Threaded and/or screwed joints shall have long tapered full depth threads to be made with the appropriate paste or jointing compound, depending on the type of fluid to be processed through the pipe. All pipe up to, and including 1-1/2-inches, shall be reamed to remove burr and stood on end and well pounded to remove scale and dirt. Wrenches on valves and fittings shall be applied directly over the joint being tightened. Not more than three pipe threads shall be exposed at each connection. Pipe, in all lines subject to temperature changes shall be cut short and cold sprung into place to compensate for expansion when hot. Joints in all piping used for chlorine gas lines shall be made up with a glycerine and litharge cement. Joints in plastic piping (PVC/CPVC) shall be laid and joints made with compounds recommended by the manufacturer. Installation shall conform to the requirements of ASTM D2774 and ASTM D2855. Unions required adjacent to valves and equipment. F. Soldered joints shall have the burrs removed and both the outside of pipe and the inside of fittings shall be thoroughly cleaned by proper tools recommended for that purpose. Flux shall be applied to both pipe and inside of fittings and the pipe placed into fittings and rotated to insure equal distribution of flux. Joints shall be heated and solder applied until it shows uniformly around the end of joints between fitting and pipe. All joints shall be allowed to self-cool to prevent the chilling of solder. Combination flux and solder paste manufactured by a reputable manufacturer is acceptable. Unions required adjacent to valves and equipment. G. Welded joints shall be made by competent operators in a first class workmanlike manner, in complete accordance with ANSI B31.1 and AWWA C206. Welding electrodes shall conform to ASTM A233, and welding rod shall conform to ASTM A251. Only skilled welders capable of meeting the qualification tests for the type of welding which they are performing shall be employed. Tests, if so required, shall be made at the expense of the Contractor, if so ordered by the Engineer. Unions shall be required adjacent to valves and equipment. City of Denton Hazen and Sawyer BID SET 15000-15 Basic Mechanical Requirements H. Copper joints shall be thoroughly cleaned and the end of pipes uniformly flared by a suitable tool to the bevels of the fittings used. Wrenches shall be applied to the bodies of fittings where the joint is being made and in no case to a joint previously made. Dimensions of tubing and copper piping shall be in complete accordance with the fittings used. No flare joints shall be made on piping not suited for flare joints. Installations for propane gas shall be in accordance with NFPA 54 and/or 58. I. Solvent or adhesive welded joints in plastic piping shall be accomplished in strict accordance with the pipe manufacturer's recommendations, including necessary field cuttings, sanding of pipe ends, joint support during setting period, etc. Care shall be taken that no droppings or deposits of adhesive or material remain inside the assembled piping. Solvent or adhesive material shall be compatible with the pipe itself, being a product approved by the pipe manufacturer. Unions are required adjacent to valves and equipment. Sleeve-type expansion joints shall be supplied in exposed piping to permit 1-inch minimum of expansion per 100 feet of pipe length. J. Dielectric unions shall be installed wherever dissimilar metals are connected except for bronze or brass valves in ferrous piping. Unions shall be provided downstream of each valve with screwed connections. The Contractor shall provide screwed or flanged unions at each piece of equipment, where shown, and where necessary to install or dismantle piping. K. Eccentric reducers shall be installed where air or water pockets would otherwise occur in mains because of a reduction in pipe size. L. Joints in polypropylene and polyvinylidelene fluoride pipe shall be butt fusion weld. All butt welding shall follow the requirements of ASTM D-2657 and the manufacturer's recommendations. 3.10 FLUSHING AND TESTING A. All piping shall be properly flushed and tested unless specifically exempted elsewhere in the Specifications or otherwise approved by the Engineer. Air and gas pipelines shall be flushed and tested with compressed air. Gravity sewer piping shall be flushed and tested as specified in Section 02604 - Utility Structures. All other liquid conveying pipelines shall be flushed and tested with water. The Contractor shall furnish and install all means and apparatus necessary for getting the air or water into the pipeline for flushing and testing including pumps, compressors, gauges, and meters, any necessary plugs and caps, and any required blow-off piping and fittings, etc., complete with any necessary reaction blocking to prevent pipe movement during the flushing and testing. All pipelines shall be flushed and tested in such lengths or sections as agreed upon among the Owner, Engineer, and Contractor. Test pressures shall be as specified in Section 15390 – Schedules, and shall be measured at the lowest point of the pipe segment being tested. The Contractor shall give the Owner and Engineer reasonable notice of the time when he intends to test portions of the pipelines. The Engineer reserves the right, within reason, to request flushing and testing of any section or portion of a pipeline. B. The Contractor shall provide water for all flushing and testing of liquid conveying pipelines. Raw water or non-potable water may be used for flushing and testing liquid pipelines not connected to the potable water system. Only potable water shall be used for flushing and testing the potable water system. City of Denton Hazen and Sawyer BID SET 15000-16 Basic Mechanical Requirements C. Air and gas piping shall be completely and thoroughly cleaned of all foreign matter, scale, and dirt prior to start-up of the air or gas system. D. At the conclusion of the installation work, the Contractor shall thoroughly clean all new liquid conveying pipe by flushing with water or other means to remove all dirt, stones, pieces of wood, etc., which may have entered the pipe during the construction period. If after this cleaning any obstructions remain, they shall be corrected by the Contractor, at his own expense, to the satisfaction of the Engineer. Liquid conveying pipelines shall be flushed at the rate of at least 2.5 feet per second for a duration suitable to the Engineer or shall be flushed by other methods approved by the Engineer. E. Compressed/service air and gas piping shall be flushed by removing end caps from the distribution lines and operating one (1) compressor, in accordance with the manufacturer's instructions. F. After flushing, all air piping shall be pressure and leak tested prior to coating and wrapping of welded joints. Immediately upon successful completion of the pressure and leak test, welded joints shall be thoroughly cleaned of all foreign matter, scale, rust, and discoloration and coated in accordance with the Specifications. G. All process air piping shall be leak tested by applying a soap solution to each joint. Leak tests shall be conducted with one (1) blower in service at normal operating pressure. H. During testing the piping shall show no leakage. Any leaks or defective piping disclosed by the leakage test shall be repaired or replaced by the Contractor, at his own expense, and the test repeated until all such piping shows tight. I. All buried process air piping shall be pressurized to 25 psig and tested for leaks by applying a soap solution to each joint. The air supply shall be stopped and the pipe pressure monitored. System pressure shall not fall by more than 0.5% of the 25 psig test pressure over a one-hour test period. Should the system fail to hold the required pressure for one hour, the cause shall be determined and corrected and the test repeated until a successful test of the entire system is obtained. J. Field leakage tests shall be performed for all submerged process air piping. The procedure shall consist of operating the system under clear nonpotable water for visual identification of all leaks. All field leakage tests shall be witnessed by the Engineer. All submerged piping shall be installed free of any leaks. K. After flushing, all liquid conveying pipelines shall be hydrostatically tested at the test pressure specified in the appropriate Piping System Schedule in Section 15390 – Schedules. The procedure used for the hydrostatic test shall be in accordance with the requirements of AWWA C600. Each pipeline shall be filled with water for a period of no less than 24 hours and then subjected to the specified test pressure for 2 hours. During this test, exposed piping shall show no leakage. Allowable leakage in buried piping shall be in accordance with AWWA C600. L. Any leaks or defective pipe disclosed by the hydrostatic test shall be repaired or replaced by the Contractor, at his own expense, and the test repeated until all such piping shows tight. City of Denton Hazen and Sawyer BID SET 15000-17 Basic Mechanical Requirements M. After flushing, all gas piping shall be leak tested in accordance with all local codes and regulations and in conformance with the recommendations or requirements of any National Institute or Association for the specific service application. 3.11 DISINFECTION A. All pipe and fitting connected to and forming a part of a potable water supply shall be disinfected in accordance with the procedures described in AWWA C 651. Disinfection shall also be in accordance with the requirements of the Texas Commission on Environmental Quality (TCEQ) and the Owner. B. Disinfection shall be accomplished after the pipe has been flushed, if applicable, and passed the hydrostatic test. Such piping shall be filled with 50 parts per million (PPM) of chlorine and held in contact for not less than 24 hours. Final tests after 24 hours contact time shall show a minimum residual chlorine content of 10 ppm in all parts of the system. Disinfection shall be repeated as often as necessary, and as directed by the Engineer and/or TCEQ and/or the Owner until the minimum residual chlorine content of 10 ppm has been reached. The Contractor shall obtain certificates of satisfactory bacteriological tests and furnish them to the Owner before the request is made for acceptance of the work. The Contractor shall furnish and install, at his own expense, all means and apparatus necessary for performing the disinfection. The chlorine solution shall be thoroughly flushed out prior to placing the new sections of pipe in service. The Contractor is cautioned that the spent chlorine solution must be disposed of in such a way as not to be detrimental to animal, plant, or fish life. Chlorine residual tests will be made after flushing to assure that residual is not in excess of 1 ppm at any point in system. 3.12 PAINTING AND COLOR CODING SYSTEM A. All exposed piping specified shall be color coded in accordance with the Owner's standard color designation system for pipe recognition and in accordance with Section 15030 – Piping and Equipment Identification Systems. In the absence of a standard color designation system, the Engineer will establish a standard color designation for each piping service category from color charts submitted by the Contractor in compliance with Section 09900 – Painting. B. All piping specified in this Section shall be painted in accordance with Section 09900 – Painting, except as follows: 1. Copper pipe 2. Stainless steel pipe. Flanges and supports or hangers shall be painted. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 15000-18 Basic Mechanical Requirements This page left blank intentionally City of Denton Hazen and Sawyer BID SET 15006-1 Ductile Iron Pipe SECTION 15006 DUCTILE IRON PIPE PART 1 -- GENERAL 1.01 THE REQUIREMENT A. All ductile iron pipe and specials shall be marked with the manufacturer's name or trademark, size, weight, thickness class, the date of manufacture, and the word "Ductile". B. Ductile iron pipe (DIP) of the sizes shown or specified shall conform to ANSI A21.51 (AWWA C151), Grade 60-42-10 for ductile iron pipe centrifugally cast in metal molds or sand-lined molds. All ductile iron pipe shall conform to ANSI A21.50 (AWWA C150) for thickness design and shall be supplied in 18 or 20 foot nominal lengths or as required to meet the requirements of the Drawings. Fittings and specials shall be cast iron or ductile iron, conforming to the requirements of ANSI A21.10 (AWWA C110) or ANSI A21.53 (AWWA C153) and shall have a minimum rated working pressure of 250 psi. C. Minimum Class 53 pipe shall be used for flanged spools. D. Reference Section 15000, Basic Mechanical Requirements PART 2 -- PRODUCT 2.01 DUCTILE IRON PIPE AND FITTINGS A. Linings and Coatings 1. Pipe and fittings shall be cement mortar lined except where ceramic epoxy or glass lining is required otherwise herein or where shown on the drawings. Cement mortar lining shall conform to American Standard Specifications for Cement Mortar Lining for Cast Iron Pipe and Ductile Iron Pipe and Fittings, ANSI A21.4 (AWWA C104) and shall be standard thickness. The mortar lining shall be protected with the bituminous seal coat. 2. Pipe and fittings shall be ceramic epoxy lined where specified or shown on the Drawings. The Standard of Quality is Protecto 401 Ceramic Epoxy. The material shall be an amine cured novalac epoxy containing at least 20% by volume of ceramic quartz pigment. Ceramic epoxy lined pipe and fittings shall be as manufactured by American Cast Iron Pipe Co., or U.S. Pipe and Foundry Co. The lining shall be applied by a certified firm with a successful history of applying linings to the interior of ductile iron pipe and fittings. The ceramic epoxy lining shall cover the inner surface of the pipe as follows: City of Denton Hazen and Sawyer BID SET 15006-2 Ductile Iron Pipe a. Coating of bell sockets and spigot ends require the gasket area and spigot ends up to 6 inches back from the end of the spigot end must be coated with 6 mils nominal, 10 mils maximum using Protecto Joint Compound. b. The Joint Compound shall be applied by brush to ensure coverage. Care should be taken that the Joint Compound is smooth without excess buildup in the gasket seat or on the spigot ends. c. Coating of the gasket seat and spigot ends shall be done after the application of the lining. The lining shall extend from the spigot end through the socket to the edge of the gasket sealing area. d. The lining in fittings shall cover the interior surfaces including the socket areas as defined above. e. The lining in pipe and fittings shall be 40 mils nominal thickness. f. Repair procedures for damaged ceramic epoxy lining shall be made with Protecto Joint Compound in strict accordance with the manufacturer's recommendations. g. Any request for substitution must be accompanied by a successful history of lining pipe and fittings for sewer service, a test report verifying the following properties, and a certification of the test results. i. A permeability rating of 0.00 when tested according to Method A of ASTM E-96-66, Procedure A with a test duration of 30 days. ii. The following test must be run on coupons from factory lined ductile iron pipe: o ASTM B-117 Salt Spray (scribed panel) – Results to equal 0.00 undercutting after two years. o ASTM G-95 Cathodic Disbondment 1.5 volts @ 77°F. Results to equal no more than 0.5 mm undercutting after 30 days. o Immersion Testing rated using ASTM D-714.87. - 20% Sulfuric Acid – No effect after two years. - 140°F 25% Sodium Hydroxide – No effect after two years. - 160°F Distilled Water – No effect after two years. - 120°F Tap Water (scribed panel) - 0.0 undercutting after two years with no effect. o An abrasion resistance of no more than 3 mils (.075mm) loss after one million cycles using European Standard EN 598: 1994 Section 7.8 Abrasion Resistance. City of Denton Hazen and Sawyer BID SET 15006-3 Ductile Iron Pipe 3. All pipe and fittings shall be glass-lined ductile iron pipe where specified herein or shown on the Drawings. The finished glass lining shall be from 0.008-inch to 0.012-inch thick, hardness of 5 to 6 on the Mohs Scale, density of from 2.5 to 3.0 grams per cubic centimeter as measured in accordance with the requirements of ASTM D792 and be capable of withstanding a thermal shock of 350F without crazing, blistering, or spalling. The lining shall be Ervite Type SG-14, as manufactured by the Ervite Corporation, Erie, Pa., Ferrock MEH-32, by Water Works Supply & Mfg., Co., Marysville, CA, or equal. Cutting of glass-lined pipe in the field shall be limited to only one piece per run of pipe, and this shall be for closure purposes only. Spalling of the glass liner shall be no more than 1/8-inch back from the cut. Flanges and bolt holes on spool pieces shall be aligned prior to glassing and shall be sealed and tested prior to shipment in accordance with the manufacturer's recommendation. Warping of flanges and/or pipe may be cause for rejection as determined by the Engineer. 4. All pipe and fittings for buried service shall have a bituminous coating on the exterior surfaces in accordance with ANSI A21.51 (AWWA C151). All pipe and fittings for exposed service shall receive surface preparation and shop priming compatible with the specified field applied coatings. B. Requirements for various types of joints are described in the following paragraphs. UNLESS OTHERWISE NOTED HEREIN OR ON THE DRAWINGS, ALL EXPOSED DUCTILE IRON PIPING SHALL HAVE FLANGED JOINTS. C. Flanged joints and fittings shall have a minimum pressure rating of 250 psi with 125 lb. American Standard flanges. All flanges and fittings shall conform to the requirements of ANSI B16.1. Flanges shall be ductile iron and shall be of the threaded or screw on type. The face of the flanges shall be machined after installation of the flange to the pipe. No raised surface shall be allowed on flanges. Flanged pipe shall conform to the requirements of ANSI Specification A21.15, (AWWA C115). Pipe lengths shall be fabricated to meet the requirements of the Drawings. D. Gaskets shall be the "Ring Gasket" type, 1/8-inch minimum thickness, cloth inserted rubber, red rubber or neoprene and shall be suitable for the service intended. Bolts shall be of the size and length called for and in accordance with the "American Standard" and comply with the requirements of the ANSI/AWWA Standards. The bolts for flanged joints shall be a minimum ASTM A307; Grade B carbon steel and be in accordance with ANSI A21.10, (AWWA C110). The bolts shall have hexagonal heads and nuts, no washers shall be used. E. Bell and spigot pipe shall be provided with push on, O-ring rubber gasket, compression type joints and shall conform to the requirements of ANSI A21.11 (AWWA C111). Fittings and specials shall be supplied with mechanical joints as specified for mechanical joint pipe. If required by installation conditions, pipe shall have cast-on lugs for adequately tying it together. F. Mechanical joints and fittings shall conform to the requirements of ANSI A21.11, (AWWA C111). Joints shall be made employing a tapered rubber gasket forced into a tapered groove with a ductile iron follower ring. If required by installation conditions, pipe and fittings shall have cast-on lugs for adequately tying the pipe and fittings together. These City of Denton Hazen and Sawyer BID SET 15006-4 Ductile Iron Pipe shall be in conformance with standard practice and as outlined under the appropriate AWWA Specifications. G. Bolts for mechanical joints shall be high strength corrosion resistant low-alloy steel tee-head bolts with hexagonal nuts. H. Mechanical coupling joint pipe and fittings shall be split type, shouldered end. Coupling materials shall be malleable iron. Couplings shall have a minimum pressure rating and service equal to that of the connected piping. Gaskets shall be of rubber. Bolts and nuts shall be heat treated carbon steel track bolts and shall be plated. After installation, buried couplings shall receive two heavy coats of coal tar epoxy (min. 24 mil thickness) which is compatible with the finish of the couplings. Couplings shall be as manufactured by Victaulic Company of America Style 31, or equal. I. Restrained joint pipe shall consist of factory manufactured bolted retainer rings, ductile iron locking segments held in place by rubber retainers, or ductile iron retaining rings that lock over the bell of the joint and are secured to prevent rotation, and factory welded retainer beads or rings on the spigot of the pipe. All components of the bolted or snap ring assemblies shall be constructed of corrosion-resistant, high strength, low-alloy steel. Restrained joint pipe shall be Flex-Ring or Lock-Ring type joints as manufactured by American Cast Iron Pipe Company, HP LOK or TR Flex as manufactured by US Pipe, Bolt-Lok or Snap-Lok as manufactured by Griffin Pipe Products, TR Flex or Super Lock as manufactured by Clow Water Systems Co., or approved equal. J. Restrained fittings for piping systems 16-inches in diameter and greater shall have factory restraint systems identical to the factory restrained joint pipe specified in Item J above. All fittings shall be minimum pressure Class 250 unless otherwise specified. K. Restrained fittings for pipe systems 14-inches in diameter and smaller shall be Mechanical Joint fittings with restraint assemblies such as Stargrip by Star Pipe Systems, Mega Lug by EBAA Iron, ONE LOK by Sigma, Grip Ring by Romac, or approved equal. Where threaded-rods are allowed, the rods and tabs shall be designed for the specified restraint system design pressure, shall have lengths less than 10 feet between fittings, and shall be painted with two heavy coats of coal tar epoxy after installation. L. The manufactured systems for thrust restraint indicated above shall be used where restrained joint ductile iron pipe and fittings are specified or indicated on the drawings. Gripping gaskets are not an acceptable form of restraint. Thrust restraint and harnessing systems such as threaded-rods, friction clamps, retainer glands shall be used only where specifically specified herein, indicated on the drawings or if allowed by the Engineer in isolated applications where conditions warrant and necessitate their use. Concrete thrust blocks may be used in accordance with the schedule indicated on the drawings, if applicable. M. Polyethylene encasement shall conform to ANSI/AWWA C105/A21.5 and be provided when specified herein or shown on the Drawings. Polyethylene encasement shall be provided in tube rolls, accordion bundles or sheets, and shall be manufactured of virgin polyethylene material conforming to ANSI/ASTM D1248. The specified nominal thickness for low-density polyethylene film is 0.008 in. (8 mils). The specified nominal thickness for high-density cross-laminated polyethylene film is 0.004 in. (4 mils). The minus thickness tolerance shall not exceed 10% of the nominal thickness on both material types. Joints in the polyethylene City of Denton Hazen and Sawyer BID SET 15006-5 Ductile Iron Pipe encasement shall be taped. Installation of polyethylene encasement shall conform to ANSI/AWWA C105/A21.5 and DIPRA's "Polyethylene Encasement" brochure. N. Cast Iron Soil Pipe shall conform to the standards of the Cast Iron Soil Pipe Institute (CISPI) Specification HS-67, and also ANSI Specification A-112.5.2 for Hub & Spigot pipe or A.112.5.1 for Hub & Spigot pipe or A.112.5.1 for No-Hub Pipe. Pipe class shall be "Extra Heavy: (XH). - END OF SECTION – City of Denton Hazen and Sawyer BID SET 15006-6 Ductile Iron Pipe This page left blank intentionally City of Denton Hazen and Sawyer BID SET 15008-1 PVC Pipe SECTION 15008 PVC PIPE PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Reference Section 15000, Basic Mechanical Requirements. PART 2 -- PRODUCTS 2.01 POLYVINYL CHLORIDE (PVC) PIPE AND FITTINGS A. PVC pipe and fittings shall be manufactured in accordance with ASTM D 1785, D 1784 and F 441, "normal impact" pipe, Schedule 40 or 80 as specified. B. Fittings used with this pipe shall be socket type or flanged type as specified herein, in Section 15390 - Schedules, or indicated on the Drawings. Plastic piping shall be installed in full accordance with the manufacturer's recommendations for the specific installation. No field bending or distortion of the pipe will be permitted. C. PVC pipe shall be Type 1 Grade 1 conforming to ASTM D 1784 and D 1785. Fittings shall conform to the following standard specifications: Socket Type (Schedule 40); ASTM D 2466 Socket Type (Schedule 80); ASTM D 2467 D. Provide flanged fittings of the same material as the specified pipe and material conforming to ANSI B16.5 at all valves and equipment except at true (double) union valves. Flange gaskets shall be natural rubber or other material fully compatible with the fluid being conveyed. E. Solvent cement for socket type joints shall conform to ASTM D 2564 for PVC pipe and fittings. Solvent cement for sodium hypochlorite service shall be Weld-On 724 as manufactured by IPS Corporation, or equal. F. C900-Class 200 shall be in sizes between 4 inches and 12 inches and shall meet the requirements of AWWA C900 "Poly Vinyl Chloride (PVC) Pressure Pipe" and shall conform to all the requirements of ASTM D1784 and ASTM D2241. The pipe shall be a minimum of DR 14 and shall be capable of withstanding the overburden pressures determined by the depth of burial in the field. 1. Pipe material shall be made from clean, virgin, NSF approved Class 12454-A PVC compound conforming to resin specification ASTM D1784. Standard laying lengths shall be 20-feet (±1 inch). Random lengths of not more than 15% of the total footage of each size may be shipped in lieu of the standard lengths. Reruns of reclaimed material shall not be accepted. City of Denton Hazen and Sawyer BID SET 15008-2 PVC Pipe 2. The pipe shall have bell and spigot ends with push-on, O-ring rubber gasket, compression type joints conforming to the requirements of ASTM 2672. Elastomeric gaskets shall conform to the requirements of ASTM F477. 3. Minimum pipe stiffness (F/dY) at 5% deflection shall be 914 psi for all sizes when tested in accordance with D2241. 4. The pipe shall be designed to pass a quick burst test pressure of 985 psi applied in 60 to 70 seconds when tested in accordance with ASTM D1599, as referenced in ASTM D2241. 5. Fittings for C900-Class 200, DR 14 shall be ductile iron, bolted mechanical joint. G. C900-Class 150 shall be in sizes between 4 inches and 12 inches and shall meet the requirements of AWWA C900 "Poly Vinyl Chloride (PVC) Pressure Pipe" and shall conform to all the requirements of ASTM D1784 and ASTM D2241. The pipe shall be a minimum of DR 18 and shall be capable of withstanding the overburden pressures determined by the depth of burial in the field. 1. Pipe material shall be made from clean, virgin, NSF approved Class 12454-A PVC compound conforming to resin specification ASTM D1784. Standard laying lengths shall be 20-feet (±1 inch). Random lengths of not more than 15% of the total footage of each size may be shipped in lieu of the standard lengths. Reruns of reclaimed material shall not be accepted. 2. The pipe shall have bell and spigot ends with push-on, O-ring rubber gasket, compression type joints conforming to the requirements of ASTM 2677. Elastomeric gaskets shall conform to the requirements of ASTM F477. 3. Minimum pipe stiffness (F/dY) at 5% deflection shall be 435 psi for all sizes when tested in accordance with D2241. 4. The pipe shall be designed to pass a quick burst test pressure of 755 psi applied in 60 to 70 seconds when tested in accordance with ASTM D1599, as referenced in ASTM D2241. 5. Fittings for C900-Class 150, DR 18 shall be ductile iron, bolted mechanical joint. H. PVC pressure rated pipe (PR 160) shall be in sizes between 1 1/2 inches and 12 inches and shall conform to all the requirements of ASTM D1784 and ASTM D2241 and shall be a minimum of SDR 26 and shall be capable of withstanding the overburden pressures determined by the depth of burial in the field. 1. Pipe material shall be made from clean, virgin, NSF approved Class 12454-A PVC compound conforming to resin specification ASTM D1784. Standard laying lengths shall be 20-feet (1± inch). Random lengths of not more than 15% of the total footage of each size may be shipped in lieu of the standard lengths. Reruns of reclaimed materials shall not be accepted. City of Denton Hazen and Sawyer BID SET 15008-3 PVC Pipe 2. The pipe shall have bell and spigot ends with push-on, O-ring rubber gasket, compression type joints conforming to the requirements of ASTM 2672. Elastomeric gaskets shall conform to the requirements of ASTM F477. 3. Minimum pipe stiffness (F/dY) at 5% deflection shall be 135 psi for all sizes when tested in accordance with ASTM D2241. 4. The pipe shall be designed to pass a quick burst test pressure of 500 psi applied in 60 to 70 seconds when tested in accordance with ASTM D1599, as referenced in ASTM D2241. 5. The pipe shall be designed to pass for 1000 hours a sustained test pressure of 340 psi when tested in accordance with ASTM D1598, as referenced in ASTM D2241. I. C905-Class 165 shall be in sizes between 14 inches and 36 inches and shall meet the requirements of AWWA C905 "Poly Vinyl Chloride (PVC) Pressure Pipe" and shall conform to all the requirements of ASTM D1784 and ASTM D2241. The pipe shall be a minimum of DR 25 and shall be capable of withstanding the overburden pressures determined by the depth of burial in the field. 1. Pipe material shall be made from clean, virgin, NSF approved Class 12454-A PVC compound conforming to resin specification ASTM D1784. Standard laying lengths shall be 20-feet (±1 inch). Random lengths of not more than 15% of the total footage of each size may be shipped in lieu of the standard lengths. Reruns of reclaimed material shall not be accepted. 2. The pipe shall have bell and spigot ends with push-on, O-ring rubber gasket, compression type joints conforming to the requirements of ASTM D3139. Elastomeric gaskets shall conform to the requirements of ASTM F477. 3. Minimum pipe stiffness (F/dY) at 5% deflection shall be 435 psi for all sizes when tested in accordance with D2241. 4. The pipe shall be designed to pass a quick burst test pressure of 755 psi applied in 60 to 70 seconds when tested in accordance with ASTM D1599, as referenced in ASTM D2241. 5. Fittings for C905-Class 165, DR 25 shall be ductile iron, bolted mechanical joint. J. Fittings for PR 160, SDR 26 shall be PVC and designed for the pipe being supplied. K. Acrylonitrile-butadiene-styrene (ABS) shall conform to the requirements of ASTM D 2661. Pipe and fittings shall have socket type couplings with solvent cement joints. Solvent cement shall conform to ASTM D 2235. L. Type PSM polyvinyl chloride (PVC) pipe and fittings shall conform to the requirements of ASTM D 3034 with a maximum SDR of 35. Pipe and fittings shall have bell and spigot ends with O-ring rubber gasketed, compression type joints. Joints shall conform to the requirements of ASTM Specification D 3212. Reruns of reclaimed materials shall not be accepted. Unless indicated otherwise, PVC wall pipes shall be provided for all piping City of Denton Hazen and Sawyer BID SET 15008-4 PVC Pipe passing through exterior walls. Wall pipes shall have a water stop solvent-welded to the pipe. Each wall pipe shall be of the same class and type as the piping to which it is joined. M. Perforated and closed drainage pipe and fittings shall be rigid PVC pipe, Schedule 40 unless otherwise shown or specified with solvent welded type joints, or approved equal. Pipe shall be slotted or have two rows of 1/4-inch diameter holes spaced 4-inches apart along the circumference of the pipe. Longitudinal spacing of holes shall be 5-inches maximum. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 15012-1 Steel Pipe SECTION 15012 STEEL PIPE FOR WATER AND WASTEWATER PART 1 -- GENERAL 1.01 THE REQUIREMENT A. This specification shall apply to steel and stainless steel pipe for water and wastewater service. B. The AWWA Specifications referenced in this section are supplemented as follows: 1. An affidavit of compliance is required from the pipe manufacturer. 2. The steel manufacturer's certification that the material meets the ASTM Specification will be accepted in lieu of tests on specimens taken from the fabricated pipe. 3. The fabricator may purchase steel plates on the chemical basis only and shall furnish to the Owner certified test reports. C. All parts of the materials furnished shall be amply designed, manufactured, and constructed for the maximum stresses occurring during fabrication, erection and operation. All materials shall be new and both workmanship and materials shall be of the very best quality, shall be entirely suitable for the service to which they will be subjected, and shall conform to all applicable sections of these Specifications. Manufacturer's designs shall accommodate all of the requirements of these Specifications. D. The Contractor shall be responsible for the structural design of the steel and stainless steel pipe, fittings, and couplings. The Contractor shall submit certification that the steel and stainless steel pipe, fittings, and couplings have been designed to resist all loads implied and reasonably anticipated. E. Reference Section 15000 – Basic Mechanical Requirements. PART 2 -- PRODUCTS 2.01 CARBON STEEL PIPE AND FITTINGS A. Steel pipe and fittings for water and wastewater shall conform to AWWA C200. Steel pipe shall meet or exceed the manufacturer and material requirements of ASTM A53, Grade B or ASTM A139, Grade B. B. Steel pipe shall be fabricated by either the spiral weld or single longitudinal seam method and shall be rated for continuous operating pressure of 150 psig and surge pressure of City of Denton Hazen and Sawyer BID SET 15012-2 Steel Pipe 250 psig and 300 degrees Fahrenheit (°F) with a minimum yield strength of 35,000 psi. Design stress in the pipe wall at the design pressure shall not exceed 50 percent of the minimum yield strength of the steel. C. Steel pipe shall be manufactured to the following nominal pipe sizes and minimum wall thicknesses: Nominal Pipe Size (inches) Minimum Sheet or Plate Thickness (inches) 6 or less 0.125 8 to 14 0.250 16 0.250 18 0.250 20 to 24 0.250 30 0.250 36 0.250 42 0.250 48 to 54 0.250 60 to 66 0.312 72 to 84 0.375 90 0.375 D. Fittings shall be fabricated from the pipe specified and shall conform to AWWA C208, Table 1 (Figure 1). Fittings provided for the purpose of transition to other types of piping shall be in accordance with the applicable portions of AWWA C207 and AWWA C208, unless otherwise shown on the Drawings. E. Grooved mechanical coupling joint pipe and fittings shall be split type, shouldered end. Couplings shall consist of two ASTM A-536 ductile iron housing segments, a wide EPDM elastomer pressure responsive gasket, and zinc electroplated carbon steel track head bolts and nuts conforming to the physical and chemical requirements of ASTM A-449 and the physical requirements of ASTM A-183. Couplings shall be as manufactured by Victaulic Company of America W07 AGS Rigid Coupling, or equal. F. Flanges shall be AWWA C207, standard hub type, slip-on welding flanges, Class B, unless otherwise required for connection to equipment. G. Bolts for flanged joints shall be of the size and length called for and in accordance with the "American Standard" and comply with the requirements of the ANSI/AWWA Standards. Bolts shall be a minimum ASTM A307, Grade B, hot-dip galvanized, carbon steel in accordance with ANSI A21.10 (AWWA C110). Bolts shall have hexagonal heads and nuts; no washers shall be used. H. Gaskets for flanged joints shall be Viton or silicone material, "Ring-Gasket” type, 1/8-inch minimum thickness, and suitable for 300 degrees Fahrenheit continuous service at 25 psig. Segmented gaskets will not be acceptable. I. Welded field connections shall not be allowed. City of Denton Hazen and Sawyer BID SET 15012-3 Steel Pipe J. The piping layout shown on the Drawings is based upon typical fittings available in ductile iron piping. Flange joints shown may not be required for steel pipe. Factory welded or grooved mechanical coupling joints shall be substituted for flange joints. Flange joints shall be provided for connecting to flanged valves and couplings. K. Harnessed flexible couplings may also be used in lieu of flanges at locations approved by the Engineer. Lugs shall be welded to the pipe in accordance with the requirements of AWWA Manual M11 for Steel pipe where required for harnessing of flexible couplings. L. Painting for steel pipe and fittings shall be as specified below. 1. Inspection of surface preparation and application of paint shall be in accordance with Section 09900 - Painting. 2. Shop painting and field touch-ups shall be electrically inspected by the use of a holiday detector in accordance with AWWA C209 and Section 09900 - Painting. 3. The interior of all steel pipe and fittings shall be solids epoxy lined where specified or shown on the Drawings. The Standard of Quality is Carboline Plasite 4500 Series or equal. a. The lining shall be applied by a certified firm with a successful history of applying linings to the interior of steel pipe and fittings. The epoxy lining shall cover the inner surface of the pipe as follows: b. The lining in pipe and fittings shall be 40 mils nominal thickness. c. Repair procedures for damaged epoxy lining shall be made in strict accordance with the manufacturer's recommendations. 4. Exterior Painting for Exposed Steel Pipe (Indoor and Outdoor) a. Except for areas of pipe to be welded, the exterior of exposed steel pipe shall receive a prime coat of 5 to 10 mils (dry) of inorganic zinc primer rated for 300°F continuous service and shall be Carbozinc 11 as manufactured by Carboline or equal. b. Areas of pipe to be welded shall receive 1 mil (dry) of weldable primer as manufactured by Carboline, or equal. After welding and pressure and leakage testing are completed, welded joints shall be thoroughly cleaned of all foreign matter and any scale or rust and primed as specified above. d. Over the prime coat shall be a finish coat of 3 to 5 mils (dry) of a high heat polymer coating and shall be Thermaline 4000 as manufactured by Carboline or equal. City of Denton Hazen and Sawyer BID SET 15012-4 Steel Pipe PART 3 -- EXECUTION 3.01 FLUSHING AND TESTING A. Flushing and testing of all installed low pressure air piping shall be performed as specified in Section 15000 – Basic Mechanical Requirements. The field testing procedure for process air piping shall use air pressure only. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 15017-1 FRP Pipe – RS Service SECTION 15017 FIBERGLASS REINFORCED PIPE – RAW SEWAGE SERVICE PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish and install to the required line and grade, all piping together with all fittings and appurtenances, required for a complete installation. This specification designates the manufacturing, design and installation requirements of centrifugally cast fiberglass reinforced polymer mortar pipe gravity sewer pipe for sanitary sewer systems. B. The Contractor shall furnish all labor, materials, equipment, tools, and services required for the furnishing, installation and testing of all piping as shown on the Drawings, specified in this Section and required for the Work. Piping shall be furnished and installed of the material, sizes, classes, and at the locations shown on the Drawings and/or designated in this Section. Piping shall include all fittings, adapter pieces, couplings, closure pieces, hardware, bolts, gaskets, wall sleeves, and other associated appurtenances for required connections to equipment, valves, or structures for a complete installation. C. The work shall include, but not be limited to, the following: 1. Connections to existing pipelines. 2. Test excavations necessary to locate or verify existing pipe and appurtenances. 3. Installation of all new pipe and materials required for a complete installation. 4. Cleaning, testing and disinfecting as required. 1.02 REFERENCES This specification references American Society of Testing and Materials (ASTM) standard specifications, which are made a part hereof by such reference and shall be the latest edition and revision thereof. A. ASTM D3262-01 Standard Specification for Fiberglass (Glass-Fiber-Reinforced Thermosetting-Resin) Sewer Pipe B. ASTM D3681 Standard Test Method for Chemical Resistance of “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe in a Deflected Condition C. ASTM D 4161 Standard Specification for “Fiberglass” (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe Joints Using Flexible Elastomeric Seals City of Denton Hazen and Sawyer BID SET 15017-2 FRP Pipe – RS Service D. ASTM D2412 Standard Test Method for Determination of External Loading Characteristics of Plastic Pipe by Parallel-Plate Loading E. ASTM D638 Standard Test Method for Tensile Properties of Plastics F. ASTM D695 Standard Test Method for Compressive Properties of Rigid Plastics G. ASTM F 477 Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe H. ASTM C 33 Standard specification for concrete aggregates I. ASTM 4253 Standard Test Methods for Maximum Index Density and Unit Weight of Soils Using a Vibratory Table 1.03 RELATED WORK SPECIFIED ELSEWHERE A. Section 02640 – Utility Structures B. Section 15000 – Basic Mechanical Requirements 1.04 MATERIAL CERTIFICATION AND SHOP DRAWINGS A. The Contractor shall furnish to the Owner (through the Owner) a Material Certification stating that the pipe materials furnished under this Section conform to all applicable provisions of the corresponding Specifications. Specifically, the Certification shall state compliance with the applicable standards (ASTM, AWWA, etc.) for fabrication and testing. The requirements for Certifications shall be as specified in Section 01300 – Submittals. PART 2 -- PRODUCTS 2.01 GENERAL A. Every length of pipe and fitting shall be marked with the manufacturer's name or trademark, size, class, and the date of manufacture. Special care in handling shall be exercised during delivery, distribution, and storage of pipe to avoid damage and unnecessary stresses. Damaged pipe will be rejected and shall be replaced at the Contractor’s expense. Pipe and specials stored prior to use shall be stored in such a manner as to keep the interior free from dirt and foreign matter. B. Testing of pipe before installation shall be as described in the corresponding ASTM or AWWA Specifications and in the applicable standard specifications listed in the following sections. Testing after the pipe is installed shall be as specified in Section 3.03. C. The Drawings indicate work affecting existing piping and appurtenances. The Contractor shall excavate test pits as required of all connections and crossings which may affect the Contractor’s work prior to ordering pipe and fittings to determine sufficient information for ordering materials. The Contractor shall take whatever measurements that are required to complete the work as shown or specified. City of Denton Hazen and Sawyer BID SET 15017-3 FRP Pipe – RS Service D. The internal liner shall be a glass reinforced thermoset liner suitable for service in a sewer pipe, and shall be highly resistant to exposure to sulfuric acid as produced by biological activity associated with hydrogen sulfide gases. Pipe shall meet or exceed requirements of ASTM D3681. E. Silica Sand: Sand shall be minimum 98% silica with a maximum moisture content of 0.2% F. Additives: Resin additives, such as curing agents, pigments, dyes, fillers, thixotrophic agents, etc., when used, shall not detrimentally effect the performance of the product. G. Elastomeric Gaskets: Gaskets conforming to ASTM F 477 shall be supplied by the pipe manufacturer H. In carrier pipe installations, Contractor shall install pipe with low profile joints, such as HOBAS Low Profile Bell-Spigot or equal. 2.02 MANUFACTURING AND PRODUCT CONSTRUCTION A. The pipes shall be manufactured in accordance with ASTM D3262. The pipe shall meet the following cell limits: Type 1, glass-fiber-reinforced thermosetting polyester resin mortar (RPMP polyester), Liner 1 or 2, and Grade 1 or 3. B. The pipe shall be field connected with a glass reinforced sleeve coupling that utilizes elastomeric sealing gaskets as the sole means to maintain joint water tightness. The couplings shall be manufactured using the same process as the pipe. The joints shall utilize elastomeric sealing gaskets meeting the performance requirements of ASTM D4161. C. Fiberglass piping shall be minimum Class PN50 with minimum pipe stiffness SN-46. D. Fittings: All fittings shall be fabricated from pipe meeting the requirements of these standards. Ductile iron, stainless steel or fusion bonded epoxy coated steel fittings may also be used when needed to connect pipes of differing material. E. Acceptable manufacturer: Pipe and couplings shall be Centrifugally Cast Fiberglass Reinforced Polymer Mortar Pipe (CCFRPM) as manufactured by HOBAS Pipe USA, FLOWTITE Glass Reinforced Polymer Pipe (GRP), or approved equal. 2.03 DIMENSIONS A. Diameters: The outside diameter of pipe shall be per the ASTM D3262-Table 3. B. Lengths: Pipe shall be supplied in nominal lengths of 10 to 40 feet. Actual lay length shall be nominal ±1 inch. Special short lengths may be used where surface geography or installation conditions require shorter lengths. City of Denton Hazen and Sawyer BID SET 15017-4 FRP Pipe – RS Service C. Wall Thickness: The average wall thickness of the pipe shall not be less than the nominal wall thickness published in the manufacturer’s literature, and the minimum wall thickness at any point shall not be less than 87.5% of the nominal wall thickness. D. End Squareness: All points around each end of a pipe unit shall fall within 1/4 inch or 0.5% of the nominal diameter of the pipe, whichever is greater, to a plane perpendicular to the longitudinal axis of the pipe. 2.04 TESTING A. Pipe shall be manufactured in accordance with ASTM D3262. B. Joints shall meet the requirements of ASTM D4161. C. Each pipe shall have sufficient strength to exhibit the minimum pipe stiffness at 5% deflection as required by the Owner. Stiffness shall be tested in accordance with ASTM D2412. One pipe shall be tested every 100 lengths of each type, grade, and size pipe produced. D. Pipe shall meet or exceed the requirements of ASTM D3262 when tested in accordance with ASTM D3681. E. Minimum 30-days following installation for second deflection test to ensure installed, compacted, and settled pipe has not been deflected beyond design allowable 2.05 CUSTOMER INSPECTION A. The Owner or other designated representative shall be entitled to inspect pipes and witness the manufacturing process. 2.06 PACKAGING, HANDLING, AND SHIPPING A. Handling 1. Fiberglass pipe and fittings shall be handled only from the exterior of the pipe and fittings. No forks, chains, straps, hooks, etc. shall be placed inside the pipe and fittings for lifting, positioning, or laying. Pliable lifting straps or slings shall be used per lining manufacturer’s recommendation. The pipe shall not be dropped or unloaded by rolling. 2. Care should be taken not to let the pipe strike sharp objects while swinging or being off loaded. Ductile iron pipe should never be placed on grade by use of hydraulic pressure from an excavator bucket or by banging with heavy hammers. 3. To ensure control of pipe when lifting, guide ropes and spreader bar two support lift points shall be employed. 4. If at any time during handling or installation of pipe or fittings, damage such as a gouge, crack, fracture of the interior or exterior lining or a point strike occurs, the City of Denton Hazen and Sawyer BID SET 15017-5 FRP Pipe – RS Service pipe or fitting shall be inspected and repaired in accordance with lining manufacturer’s recommendation. B. Storage 1. Fiberglass pipe shall be installed within one year of delivery t project site unless written approval is granted from the lining manufacturer and approved by the Engineer. Approval of an extension in storage time must be requested in writing and accompanied by inspection within two weeks prior to installation by an authorized representative of the manufacturer. 2. Proper long-term above ground storage of fiberglass pipe and fittings shall conform to the following procedure. a. Stock shall be properly rotated in accordance with pipe manufacturer recommendation. b. All fibreglass pipe or fittings shall undergo a thorough visual inspection by the installer to determine that no damage is present prior to installation. 3. Pipe shall be stored on flat timber supports to facilitate placement and removal of lifting slings around pipe. All pipes shall be chocked to prevent rolling in high winds. 4. If stacked, minimum 3” wide timber supports shall be used and placed at the quarter points with chocks. Pipe shall not be stacked higher than 10 feet above the ground. 5. Pipe and Fitting laydown should be relatively flat and free of other potentially damaging debris. Laydown area should have proper drainage. At no time, shall any portion of pipe or fittings be stored in standing water for more than 24 hours. C. Shipping 1. Shipping shall be performed in accordance with the Manufacturer’s instructions. PART 3 -- EXECUTION 3.01 INSTALLATION A. The bedding and burial of pipe and fittings shall be in accordance with the contract drawings and specifications and the manufacturer’s instructions, especially with regard to limiting trench conditions. B. Jointing 1. Clean ends of pipe and coupling components. City of Denton Hazen and Sawyer BID SET 15017-6 FRP Pipe – RS Service 2. Apply joint lubricant to pipe ends and elastomeric seals of coupling. Use only lubricants approved by the pipe manufacturer. 3. Use suitable equipment and end protection to push or pull the pipes together. 4. Do not exceed forces recommended by the manufacturer for coupling pipe. 5. Join pipes in straight alignment then deflect to required angle. Do not allow the deflections angle to exceed the maximum permitted deflection permitted by the manufacturer. 6. Pipe segment shall not be loaded or backfilled above pipe springline until subsequent pipe segment and coupling have been installed and gasket inspected. 3.02 Field Tests: A. Maximum allowable leakage as performed by infiltration/exfiltration test will not exceed 500 gallons per inch diameter per mile of pipe per day (0.066 gallons per minute per inch diameter per 1,000 feet of pipe). B. For nominal pipe diameters smaller than 30-inches, each reach shall be air pressure tested (maximum 5 psi) per manufacturer recommendations. C. For nominal pipe diameters 30-inches and greater, each individual joint shall be air or hydro pressure tested by portable tester, such as Cherne Air-Loc Joint Tester or equal up to a maximum 10 psi for determination of individual pipe joint integrity. D. Maximum allowable long-term deflection (minimum 30-days installed) is 5% of initial diameter and must be confirmed prior to acceptance and put in service. 3.03 Restraint A. Provide thrust blocks at all horizontal fittings. Thrust blocks shall at a minimum be 2,500 psi concrete or flowable fill. Height to be from bottom elevation of pipe to top elevation of pipe, minimum 3 feet thick from centerline of pipe to bare undisturbed earth, and length from fitting joint to nearest joint plus 3 feet on each side, completely surrounding the fitting. Vertical bends shall bear on stone bedding. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 15020-1 Pipe Supports SECTION 15020 PIPE SUPPORTS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Furnish all equipment, labor, materials, and design calculations required to provide pipe supports in accordance with the Contract Documents. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 01350 – Seismic Anchorage and Bracing B. Division 3, Concrete – Appropriate and Related Sections C. Section 05010 – Metal Materials D. Section 05035 – Galvanizing E. Section 05050 – Metal Fastening F. Section 05061 – Stainless Steel G. Section 05120 – Structural Steel H. Section 05500 – Metal Fabrications I. Section 05830 – Bearing Devices and Anchoring J. Section 15000 – Basic Mechanical Requirements 1.03 SUBMITTALS A. Applicable and associated cut sheets and drawings for materials and support components shall be submitted with the Shop Drawings in accordance with or in addition to the submittal requirements specified in Section 01300 – Submittals: Section 15000 - Basic Mechanical Requirements and other referenced Sections above. 1. Catalog cut information on all system components such as pipe supports, hangers, guides, anchors, and channel-type supports. 2. Drawings of the piping support systems, locating each support, brace, hanger, guide, component and anchor. Identify support, hanger, guide and anchor type by catalog number and Shop Drawing detail number. 3. With each piping support system Shop Drawing, the Contractor shall attach calculations prepared and sealed by a Professional Engineer licensed in the State of Texas showing that the piping support system complies with the specified requirements, including all building code and seismic code requirements pertaining City of Denton Hazen and Sawyer BID SET 15020-2 Pipe Supports to support of piping and other non-structural components. See Section 01350 – Seismic Anchorage and Bracing. 4. Table showing the manufacturer’s recommended hanger support spacing for PVC, CPVC and FRP pipe for the services listed in Section 15390 - Schedules. 1.04 QUALITY ASSURANCE A. Piping support systems shall be designed and Shop Drawings prepared and sealed by a Professional Engineer licensed in the State of Texas. PART 2 – PRODUCTS 2.01 GENERAL A. The Contractor shall be responsible for the design of all piping support systems not specifically designed by the Engineer and detailed on the Drawings. The supports typically detailed on the Drawings, not included on Standard Detail Drawings, are designed to resist resulting external thrust forces in addition to gravity, seismic and other applicable loads required by the governing building code. B. No attempt has been made to show all of the required pipe supports either on the main Drawings or on the standard detail drawings. The absence of pipe supports and details on the Drawings shall not relieve the Contractor of the responsibility of providing them throughout the project at no additional cost to the Owner. C. Where special pipe support fabrications are required, products and execution shall be as specified in Section 05500 - Metal Fabrications and other related and referenced Sections of the Specifications. . D. Existing piping support systems to support new piping shall only be used if the Contractor can show and demonstrate by submitting supporting calculations that they are adequate for the additional load imposed by the new piping, or if they are strengthened to support the additional load. E. Design Criteria for Piping Support Systems: 1. Design pipe supports for dead loads imposed by the weight of the pipes filled with water, except for air and gas pipelines, plus the weight of insulation. If applicable by location, ice loads per code shall be applied as indicated in the governing building code. 2. Design for the thermal expansion and contraction of the piping and its associated pipe support and pipe expansion systems and couplers. 3. Design the pipe supports for all seismic loading requirements and conditions as specified in the governing building code and referenced seismic design codes. Refer to Section 01350 - Seismic Anchorage and Bracing and the structural code drawing for seismic design criteria to be used for this particular project. City of Denton Hazen and Sawyer BID SET 15020-3 Pipe Supports 4. A minimum safety factor of 2 or as approved by the Engineer, based upon the yield strength of the support material, shall be used for pipe supports, braces, hangers, and guides as well as for beam and column members used in channel-type support systems. 5. The horizontal pipe hanger and/or floor support spacing shall be as recommended by the pipe and/or hanger manufacturer, but shall not exceed 10 feet on center unless indicated otherwise herein or on the Drawings. 6. Seismic and sway bracing shall be provided at maximum 10-foot centers. 7. The design, sizing and spacing of anchor bolts, including concrete anchors, shall be based on withstanding shear and pullout loads imposed by loading at each particular support. The minimum anchor bolt size shall be ½ inches in diameter. Refer to Section 05830 – Bearing Devices and Anchoring. 2.02 HANGERS AND SUPPORTS A. All piping shall be adequately supported and braced by means of steel hangers and/or supports, concrete piers, supplemental lateral bracing components, pre-fabricated brackets, or otherwise as may be required by the location and forces applied per governing code, including gravity and lateral forces from earthquake and/or wind (if exterior). Generally, concrete supports shall be used where pipe centerline is less than 3 feet above floor, and hangers above 6 feet unless specified or shown otherwise. Supports shall be not more than 10 feet on center for steel and cast iron, 5 feet on center for plastic unless otherwise shown on the Drawings or required by the specific manufacturer. All necessary inserts or appurtenances shall be furnished and installed in the concrete or structures for adequately securing hangers and supports to the structure. Refer to Standard Detail Drawings. 1. Metal pipe support materials, where stainless steel pipe is supported, shall be Type 304 stainless steel meeting the requirements of Section 05061 - Stainless Steel. 2. Metal pipe support materials, where carbon steel, ductile or other ferrous pipe is supported, shall be galvanized carbon steel meeting Section 05120 - Structural Steel and Section 05035 - Galvanizing unless indicated otherwise on the Drawings or in the specifications or by the Engineer. 3. Metal pipe supports indicated as standard type pipe hangers are designed and detailed for gravity loading only. Resulting lateral loads from wind, earthquake, or other lateral loads per code, or special loading conditions during construction, shall be applied to the pipe in accordance with the governing building code. Supplemental lateral stiffening members (when necessary) shall be provided along pipe or at gravity supports using appropriate supplemental members and connections when required by calculations. The Contractor shall include design calculations and details with all pipe hangar and support submissions for review by the Engineer. The main structure and structural components that will support the pipe hangers and other appurtenant components of the facility have been designed to resist all resulting secondary lateral loading from pipe hangers and other non- structural members for gravity and resulting lateral loads. City of Denton Hazen and Sawyer BID SET 15020-4 Pipe Supports B. Hangers and supports shall conform to the following requirements: 1. All fabricated metal hangers and supports shall be capable of adjustment after installation. Different types of hangers and supports along a pipe length, including bends, shall be kept to a minimum. 2. Hanger rods shall be straight and vertical. Chain, wire, strap, or perforated bar hangers shall not be used. Hangers shall not be suspended from other piping. 3. Vertical piping shall be properly supported at each floor and between floors by stays or braces to prevent rattling and vibration. 4. Supports and hangers for plastic and FRP piping shall include wide saddles or bands as recommended by the manufacturer and approved by the Engineer to distribute load and thus avoid localized deformation of the pipe. 5. Hanger and supports shall prevent contact between dissimilar metals by use of copper plated, rubber, vinyl coated or stainless steel hangers. 6. Ferrous pipes to be painted shall be painted in accordance with Section 09900 - Painting. Ferrous pipes that require painting or galvanizing shall be supported by galvanized hangers and supports. Stainless steel piping shall be supported by stainless steel saddles and straps (if required). 7. Copper piping shall be supported by plastic coated or copper plated steel hangers and supports. 8. Plastic piping shall be supported by plastic coated steel hangers and supports. 9. Hangers and supports shall provide for thermal expansion throughout the full operating temperature range. 10. Expansion and adhesive type anchors used for pipe hangers and supports shall be Type 316 stainless steel. C. Metallic hangers and supports may be standard make by Anvil International, Inc., "Witch" by Carpenter & Paterson, Ltd., B-Line Systems, Inc., or equal; and data on the types and sizes to be used shall be furnished to the Engineer for approval. Metallic support system brackets, rods, support clips, clevis hangers, hardware, etc. shall be cast iron or welded steel construction. All gravity type hangers and supports shall be restrained laterally to resist seismic loading and other loading as required by the governing code. D. Non-metallic support system shall be a heavy duty channel framing system. Channel frames shall be manufactured by the pultrusion process using corrosion grade polyester or vinylester resins. All fiberglass construction shall include suitable ultraviolet inhibitors for UV exposure and shall have a flame spread rating of 25 or less per ASTM E84. Piping accessories, pipe clamps, clevis hangers, support posts, support racks, fasteners, etc., shall be constructed of vinylester or polyurethane resin. Non-metallic support systems shall be standard make Aickinstrut by Aickinstrut, Inc., Unistrut Fiberglass by Unistrut, Inc., Enduro Fiberglass Systems, or equal. The Contractor shall submit data on the types and sizes of City of Denton Hazen and Sawyer BID SET 15020-5 Pipe Supports approval. Unless otherwise shown or specified the Contractor shall provide support spacings in the conformance with the pipe and support system manufacturer's requirements. PART 3 -- EXECUTION 3.01 GENERAL INSTALLATION REQUIREMENTS A. Support piping connections to equipment by pipe support and not by the equipment. B. Support large or heavy valves, fittings, flow meters and appurtenances independently of the connected piping. C. Support no pipe from the pipe above it. D. Support piping at changes in direction or in elevation, adjacent to flexible joints, expansion joints, and couplings, and where shown. E. The Contractor shall not install piping supports and hangers in equipment access areas or bridge crane runs. F. Brace hanging pipes against horizontal movement by both longitudinal and lateral sway bracing. G. Install pipe anchors (fixed supports and/or guides) where shown and/or as may otherwise be required to withstand expansion thrust loads and to direct and control thermal expansion. The Contractor may install additional pipe anchors and flexible couplings to facilitate piping installation, provided that complete details describing location, pipe supports and hydraulic thrust protection are submitted. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 15020-6 Pipe Supports This page left blank intentionally City of Denton Hazen and Sawyer BID SET 15030-1 Piping and Equipment Identification Syst. SECTION 15030 PIPING AND EQUIPMENT IDENTIFICATION SYSTEMS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish and install all components of the system for identification of piping and equipment as specified hereinafter. The system shall include the application of color coding to all new and altered plant piping. The Contractor shall paint the equipment and piping of all Contracts in the colors herein specified, and in accordance with the requirements of Section 09900, Painting. B. In addition to the legends specified herein the Engineer may order the Contractor to furnish and install additional identification legends and arrows at no additional cost to the Owner. Such additional signs may be requested near completion of the work and shall be limited to no more than five (5) signs for each type specified herein. The legends and color combinations for additional signs shall conform to the requirements specified herein. C. The Contractor shall submit a schedule of the colors and designations proposed in accordance with Section 01300, Submittals, and this Section. A minimum of four (4) color charts with cross-references to the colors listed herein shall be included with the Submittal. D. Reference Section 15000, Basic Mechanical Requirements. PART 2 -- PRODUCTS 2.01 PIPING BAND A. All new and altered piping shall receive identification bands. Such bands shall be 6-inches wide, neatly made by masking, and spaced at intervals of 30-inches on centers regardless of the diameter of the pipe being painted. The Contractor may use approved precut and prefinished metal bands on piping, in lieu of the masked and painted bands, where approved by the Engineer. 2.02 PIPING IDENTIFICATION LEGEND A. The Contractor shall apply identification legends to all types and sections of piping as shown on the Drawings or as designated by the Engineer. Such legends shall be in the form of plain block lettering giving the name of the pipe content in full or abbreviated form, and showing the direction of flow by arrows. All lettering and arrows shall be of the plastic snap-on type, Seton nameplate "setmarks", or equal, or they shall be formed by stenciling in an approved manner using white or black as directed and shall have an overall height in inches in accordance with the following table: City of Denton Hazen and Sawyer BID SET 15030-2 Piping and Equipment Identification Syst. Diameter of Pipe or Pipe Covering Height of Lettering 3/4 to 1-1/4 inches 1-1/2 to 2-inches 2-1/2 to 6-inches 8 to 10-inches Over 10-inches 1/2-inches 3/4-inches 1-1/4-inches 2-1/2-inches 3-1/2-inches B. Identification lettering shall be located midway between color coding bands where possible. Identification lettering and arrows shall be placed as directed by the Engineer, but shall generally be located each fifteen (15) feet in pipe length, and shall be properly inclined to the pipe axis to facilitate easy reading. In the event lettering and arrow identifications are required for piping less than 3/4-inch in diameter, the Contractor shall furnish and attach approved color coded tags where instructed. C. The colors referenced in the legend are as manufactured by KOP-COAT. They are used for convenience only. D. Piping and Equipment Identification Service Legend Base Raw Sewage RS Grey Potable Water PW Blue Non Potable Water NPW Purple Process Drain PD Grey - END OF SECTION - City of Denton Hazen and Sawyer BID SET 15095-1 Valves, General SECTION 15095 VALVES, GENERAL PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish and install, complete with all assemblies and accessories, all valves shown on the Drawings and specified herein including all fittings, appurtenances and transition pieces required for a complete and operable installation. B. All valves shall be constructed of first quality materials which have strength, wearing, and corrosion resistance characteristics entirely suitable for the types of service for which the individual valves are designated. Except where noted otherwise, valves designated for water service shall conform to pertinent sections of the latest revision of AWWA C500 Specifications. Cast iron valve bodies and parts shall meet the requirements of the latest revision of ASTM Designation A-126, "Standard Specifications for Gray Iron Castings for Valves, Flanges, and Pipe Fittings, Class B." C. All valve body castings shall be clean, sound, and without defects of any kind. No plugging, welding, or repairing of defects will be allowed. D. Valves shall have flanged ends for exposed service and mechanical joint ends for buried service, unless otherwise shown on the Drawings or specified herein. Flanged ends shall be flat-faced, 125 lb. American Standard unless otherwise shown or specified in accordance with ANSI B16.1. All bolt heads and nuts shall be hexagonal of American Standard size. The Contractor shall be responsible for coordinating connecting piping. Valves with screwed ends shall be made tight with Teflon tape. Unions are required at all screwed joint valves. 1.02 SUBMITTALS A. The Contractor shall furnish to the Owner, through the Engineer, a Performance Affidavit where required in individual valve specifications, utilizing the format specified in Section 11000, Equipment General Provisions. Performance tests shall be conducted in accordance with the latest revision of AWWA C500 and affidavits shall conform to the requirements of the Specifications B. Shop Drawings conforming to the requirements of Section 01300, Submittals, are required for all valves, and accessories. Submittals shall include all layout dimensions, size and materials of construction for all components, information on support and anchoring where necessary, pneumatic and hydraulic characteristics and complete descriptive information to demonstrate full compliance with the Documents. Shop Drawings for electrically operated/controlled valves shall include all details, notes, and diagrams which clearly identify required coordination with the electrical power supply and remote status and alarm indicating devices. Electrical control schematic diagrams shall be submitted with the Shop Drawings for all electrical controls. Diagrams shall be drawn using a ladder-type format in accordance with JIC standards. Shop Drawings for pneumatically operated/controlled valves shall City of Denton Hazen and Sawyer BID SET 15095-2 Valves, General include all details, notes, and diagrams which clearly identify required coordination with the compressed air (service air) system and electrical controls. C. Operation and maintenance manuals and installation instructions shall be submitted for all valves and accessories in accordance with the Specifications. The manufacturer(s) shall delete all information which does not apply to the equipment being furnished. 1.03 CONTRACTOR'S RESPONSIBILITIES A. The Contractor shall provide the services of a qualified representative of the manufacturer(s) of the equipment named below to check out and certify the installation(s), to supervise the initial operation, and to instruct the Owner's operating personnel in proper operation and maintenance procedures in accordance with the following schedule: Item Valve/Operator Type Minimum On-Site Time Requirements 1. Motor Operated Modulating Valves One (1) 2-hour day 2. Motor Operated Open-Close Valves One (1) 2-hour day B. Any additional time required to achieve successful installation and operation shall be at the expense of the Contractor. The manufacturer's representative shall sign in and out at the office of the Engineer's Resident Project Representative on each day he is at the project. C. A written report covering the representative's findings and installation approval shall be mailed directly to the Engineer covering all inspection and outlining in detail any deficiencies notes. D. The times specified are exclusive of travel time to and from the facility and shall not be construed as to relieve the manufacturer of any additional visits to provide sufficient service to place the equipment in satisfactory operation. PART 2 -- PRODUCTS 2.01 FLOW INDICATORS A. Flow indicators shall be the Akron ball-type as manufactured by Brooks Instrument Co., Fischer and Porter, or equal, and shall have bronze bodies, glass dome, and plastic ball. 2.02 CORPORATION STOPS A. Corporation stops shall be of bronze with tapered male iron pipe threads on inlets and outlets. Terminal outlets shall have screwed bronze hex head dust plugs or caps. Unions shall be used on all corporation stop outlets with connecting piping. Corporation stops shall have a minimum working pressure rating of 250 psi and shall be as manufactured by Mueller Co., Hays Mfg. Div. of Zurn Industries, or equal. City of Denton Hazen and Sawyer BID SET 15095-3 Valves, General 2.03 FLOOR BOXES A. Floor boxes shall be provided for all nut operated or floor accessed valves. Floor boxes shall be of the adjustable, sliding type, cast iron, suitable to withstand heavy traffic, as manufactured by James B. Clow & Sons, Kennedy Valve Mfg. Co., or equal. The covers shall be marked with appropriate designations of piping contents (i.e.: water, sewer) and bases shall be the round type. All nut operated valves in this Section shall be clearly identified by stainless steel or laminated plastic identification tags. The tags shall be permanently affixed to the inside of the floor boxes, under grating, etc. and shall bear the embossed letters which clearly identify each valve by its appropriate designation. B. Two (2) valve operating wrenches shall be supplied in 4 foot lengths with tee handles for each size nut supplied. Valve wrenches shall be Model No. F-2520 as manufactured by James B. Clow & Sons, Kennedy Valve Mfg. Co., Figure No. 122, or equal. 2.04 VALVE BOXES A. The Contractor shall furnish and install valve boxes as shown on the Drawings and specified herein. B. All valve boxes shall be placed so as not to transmit shock or stress to the valve and shall be centered and plumb over the operating nut of the valve. The ground in the trench upon which the valve boxes rest shall be thoroughly compacted to prevent settlement. The boxes shall be fitted together securely and set so that the cover is flush with the finished grade of the adjacent surface. A concrete pad as detailed on the Drawings shall be provided around the valve box, sloped outwards. C. All valve boxes shall be 2-piece cast iron, sliding type, 5-1/4" shaft, with heavy duty traffic weight collar and the lid marked with the appropriate carrier product (i.e.: WATER). Boxes shall be as manufactured by James B. Clow & Sons, Kennedy Valve Mfg. Co., Charlotte Pipe and Foundry Company, or equal. 2.05 STRAINERS A. Y-Strainers shall be Y-pattern cast iron body, flanged or screwed ends with stainless steel or Monel, 20 mesh strainers. Strainers shall be 200 psi, cold-water service strainers, as manufactured by WATTS, Crane Co., Zurn, or equal. B. Caustic service Y-strainers shall be provided as shown on the drawings. Strainers shall be full port-full flow design manufactured of 304 or 316 stainless steel body. Y-strainers shall be furnished with flanged ends. The strainer screen shall be 1/32-inch perforation, easily removable, manufactured of the same material as the valve body. C. Stainless steel Y-strainers shall be provided as shown on the drawings. Strainers shall be full port-full flow design manufactured of 304 or 316 stainless steel body. Y-strainers shall be furnished with flanged ends. The strainer screen shall be 1/32-inch perforation, easily removable, manufactured of the same material as the valve body. D. PVC and CPVC y-strainers shall be provided in PVC and CPVC piping and as shown on the Drawings. Strainer shall be provided with PVC or CPVC body and end cap, EPDM or Viton City of Denton Hazen and Sawyer BID SET 15095-4 Valves, General seal as required for the chemical service, and 20 mesh screen. Temperature rating shall be 30°F to 140°F, and pressure rating shall be 150 psi @ 70°F, non-shock. PVC and CPVC y- Strainers shall be as manufactured by Asahi/America, Hayward, or equal. E. Manually cleaned strainers shall be the duplex basket tapered plug type. 1. Strainers 3-inches in diameter and larger shall have flanged ends conforming to ANSI B16.1-125/150 pound standard. 2. Strainers less than 3-inches in diameter shall have screwed end connectors, unless otherwise shown on the Drawings. 3. Strainers shall be constructed with an ASTM A48, Class 30 cast iron body, ductile iron trim, removable 0.045 inch staggered hole perforation, 304 stainless steel filter baskets and gauges on the inlet and outlet. 4. All strainers shall be suitable for 125 psi service. 5. Switching flow from one basket to the other shall be accomplished by moving the handle through a 180 arc. The switching operation shall not stop flow through the strainer and shall provide for on-line removal of either basket with the other basket functional. The plug shall be automatically positioned with integral stops and shall be easily lifted and reseated under pressure. 6. The strainer shall be designed to minimize the possibility of material bypassing the plug while being rotated and to prevent debris from building up under the plug. The strainer covers shall be designed for quick opening with swing away yoke. 7. Each basket compartment shall have a side drain outlet. 8. All strainers shall be provided with support legs. 9. Duplex basket strainers shall be similar to the Model 53BTX as manufactured by Hayward, or equal. F. PVC and CPVC simplex basket strainers shall be provided in PVC and CPVC piping as shown on the Drawings. 1/2”-4” strainers shall be one-piece molded body with (3) ports to facilitate straight-thru flow pattern or u-shape flow pattern as required. Connections shall be true union type to ease installation/future maintenance. The cover, vent plug, and drain plug shall all be hand-removable, requiring no tools. EPDM or Viton seals shall be used as required for chemical service, and internal baskets shall be 1/32” perforation (20-mesh) for 1/2”-1” sizes, and 1/8” perforation for 1-1/2”-8” sizes. 6” and 8” strainers shall be fabricated construction and shall contain flanged connections as standard. The pressure rating for 1/2”-8” sizes shall be 150 psi @ 70°F, non-shock. Strainers shall be manufactured by Hayward Industrial Products, or equal. City of Denton Hazen and Sawyer BID SET 15095-5 Valves, General 2.06 QUICK DISCONNECT COUPLINGS A. Quick disconnect type coupling for compressed/service air shall be provided where indicated on the Drawings. Coupling shall provide for instantaneous shutoff in socket end when lines are disconnected. Couplings shall be constructed of 316 stainless steel with a BUNA-N O-ring and integral safety lock. Couplings shall comply with Military Specification 4109 (interchangeable with standard plug of the same size). 2.07 BACKFLOW PREVENTERS A. Backflow preventer shall be the size shown on the Drawings and shall be of the double check valve principle. Backflow preventer installation shall include isolation valves and four test cocks, furnished as an assembly. For backflow preventers less than 2-1/2", the installation assembly also shall include a strainer. Isolation valves for backflow preventers shall be ball valves, except for size 2-1/2" and larger which shall be resilient seat gate valves. Test cocks shall be located as recommended by the manufacturer to facilitate functional testing of the assembly. The backflow preventer shall be a WATTS 709, or equal. B. Reduced Pressure Backflow Preventer shall be of the size shown on the Drawings, and shall be of the reduced pressure principle type in accordance with AWWA Standards C510 and C511, with two (2) independent operating spring loaded check valves and one (1) spring loaded, diaphragm actuated, differential pressure relief valve shall be installed between the check valves. Backflow preventer shall be bronze body construction, with EPT rubber discs and Buna-N and nylon diaphragm. Screws and springs shall be of stainless steel. End connections shall be screwed, unless otherwise specified or shown on the Drawings. Reduced pressure backflow preventer installations shall include isolation valves and four test cocks, furnished as an assembly. For reduced pressure backflow preventers less than 2-1/2" the installation assembly also shall include a strainer. Isolation valves for reduced pressure backflow preventers shall be ball valves, except for sizes 2-1/2" and larger which shall be resilient seat gate valves. Test cocks shall be located as recommended by the manufacturer to facilitate functional testing of the assembly. The reduced pressure backflow preventer shall be as manufactured by Beeco Division, Hersey Products Inc., Aergap Model 6CM, WATTS 909, or equal. PART 3 -- EXECUTION 3.01 INSTALLATION A. Except where noted otherwise herein, all valves shall be installing and tested in accordance with the latest revision of AWWA C500. Before installation, all valves shall be lubricated, manually opened and closed to check their operation and the interior of the valves shall be thoroughly cleaned. Valves shall be placed in the positions shown on the Drawings. Joints shall be made as directed under the Piping Specifications. The valves shall be so located that they are easily accessible for operating purposes, and shall bear no stresses due to loads from the adjacent pipe. The Contractor shall be responsible for coordinating connecting piping. B. All valves shall be tested at the operating pressures at which the particular line will be used. Any leakage or "sweating" of joints shall be stopped, and all joints shall be tight. All motor City of Denton Hazen and Sawyer BID SET 15095-6 Valves, General operated and cylinder operated valves shall be tested for control operation as directed by the Engineer. C. Provide valves in quantity, size, and type with all required accessories as shown on the Drawings. D. Install all valves and appurtenances in accordance with manufacturer's instructions. Install suitable corporation stops at all points shown or required where air binding of pipe lines might occur. Install all valves so that operating handwheels or wrenches may be conveniently turned from operating floor but without interfering with access, and as approved by Engineer. Unless otherwise approved, install all valves plumb and level. Valves shall be installed free from distortion and strain caused by misaligned piping, equipment or other causes. E. Valve boxes shall be set plumb, and centered with the bodies directly over the valves so that traffic loads are not transmitted to the valve. Earth fill shall be carefully tamped around each valve box to a distance of 4 feet on all sides of the box, or to the undisturbed trench face, if less than 4 feet. 3.02 SHOP AND FIELD TESTING A. Shop and field testing of valves shall be as follows: 1. Certified factory testing shall be provided for all components of the valve and operator system. Valves and operators shall be shop tested in accordance with the requirements in the latest revision of AWWA C500, including performance tests, leakage test, hydrostatic tests, and proof-of-design tests. The manufacturer through the Contractor shall submit certified copies of the reports covering the test for acceptance by the Engineer. 2. Shop testing shall be provided for the operators consisting of a complete functional check of each unit. Any deficiencies found in shop testing shall be corrected prior to shipment. The system supplier through the Contractor shall submit written certification that shop tests for the electrical/pneumatic system and all controls were successfully conducted and that these components provide the functions specified and required for proper operation of the valve operator system. 3. The Contractor shall conduct field tests to check and adjust system components, and to test and adjust operation of the overall system. Preliminary field tests shall be conducted prior to start-up with final field tests conducted during start-up. The factory service representative shall assist the Contractor during all field testing and prepare a written report describing test methods, and changes made during the testing, and summarizing test results. The service representative shall certify proper operation of the valve operator system upon successful completion of the final acceptance field testing. 4. Preliminary and final field tests shall be conducted at a time approved by the Engineer. The Engineer shall witness all field testing. 5. All costs in connection with field testing of equipment such as energy, light, lubricants, water, instruments, labor, equipment, temporary facilities for test purposes, etc. shall be borne by the Contractor. The Contractor shall be fully City of Denton Hazen and Sawyer BID SET 15095-7 Valves, General responsible for the proper operation of equipment during tests and instruction periods and shall neither have nor make any claim for damage which may occur to equipment prior to the time when the Owner formally takes over the operation thereof. 6. Preliminary field tests shall be conducted prior to start-up and shall include a functional check of the entire valve operator system and all system components. Preliminary field tests shall demonstrate that the valve operator system performs according to specifications and that all equipment, valves, controls, alarms, interlocks, etc., function properly. The preliminary field test report must be approved by the Engineer prior to conducting final field acceptance tests. Based on results of preliminary field tests, the Contractor shall make any adjustments required to settings, etc., to achieve the required valve closing time and operation specified or otherwise directed by the Engineer. 7. Final field acceptance tests shall be conducted simultaneously with the start-up and field testing of the pumps, air compressors, process air blowers, etc. Field tests shall be conducted for the full range of operating modes and conditions specified and as directed by the Engineer. Each of the valves shall be tested at minimum, maximum, and normal head/flow conditions, and under all specified conditions of opening and closing. Performance of pneumatic valves and compressed air system under normal operating conditions and during simulated power failures shall be checked. 8. Field testing shall include optimization of opening and closing times of the valves. The Contractor shall provide the means for accurate measurement of pipeline pressures as directed by the Engineer. Valve opening and closing times shall be adjusted based on process requirements to optimize operation of the valves. Final valve opening and closing times as determined by field tests shall be approved by the Engineer prior to final acceptance of the system. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 15095-8 Valves, General This page left blank intentionally City of Denton Hazen and Sawyer BID SET 15100-1 Valve Operators and Electric Actuators SECTION 15100 VALVE OPERATORS AND ELECTRIC VALVE ACTUATORS PART 1 - GENERAL 1.01 THE REQUIREMENT A. Equipment shall be provided in accordance with the requirements of Section 11000 – Equipment General Provisions and Section 15000 – Basic Mechanical Requirements. B. Reference Section 15390 – Schedules for additional information on valves and operators/actuators. C. The electric valve actuators shall meet the signal requirements described in Section 17060 – Signal Coordination Requirements, Section 17920 – Control System Input/Output Schedule, and Section 17950 – Functional Control Descriptions. D. Valve operators and electric valve actuators shall be designed to unseat, open or close, and seat the valve under the most adverse operating condition to which the valves will be subjected. E. Operator mounting arrangements shall be as indicated on the Drawings or as directed by the manufacturer and/or Engineer. There shall be no mounting restrictions on the electric valve actuator. F. The valve operators and electric actuators shall be the full and undivided responsibility of the valve manufacturer in order to ensure complete coordination of the components and to provide unit responsibility. 1.02 SUBMITTALS A. The following items shall be submitted with the Shop Drawings in accordance with, or in addition to the submittal requirements specified in Section 01300, Submittals; and Section 11000, Equipment General Provisions: 1. Certification that the force required to operate all valves is as specified herein. PART 2 -- PRODUCTS 2.01 GENERAL A. Electric actuators shall be provided where specified in the Valve Schedule in Section 15390 – Schedules. B. Manual operators shall be provided on all valves which do not receive electric actuators. Manual operator type shall be as specified herein and as shown on the Drawings. City of Denton Hazen and Sawyer BID SET 15100-2 Valve Operators and Electric Actuators C. Quarter turn valves 8” and greater in size shall have geared operators. Gate valves 14” and greater in size shall have geared operators. D. Operators/actuators shall be furnished with conservatively sized extension bonnets, extension stems, or torque tubes, and all required appurtenances required for a complete installation. Operators furnished with extension bonnets shall include stainless steel extension stems, or stainless steel torque tubes. 2.02 MANUAL OPERATORS A. Unless otherwise specified or shown on the Drawings, manual operator type shall be as follows: 1. Buried valves shall be equipped with nut operators, extended stems, and valve boxes. Where the depth of the operating nut is more than 4 feet below finish grade, a valve operator extension shall be provided to bring the operating nut to within 18-24 inches of the surface. 2. Exposed valves up to 6-inch shall be lever operated (except gate valves). 3. Exposed valves 8-inches and larger shall be handwheel operated. 4. Exposed gate valves shall be handwheel operated. 5. Valves with centerline of operator located more than 6-feet above the floor or platform from which it is to be operated shall have a chainwheel operator unless otherwise indicated on the Drawings. B. Manual operators shall be rigidly attached to the valve body unless otherwise specified or shown on the Drawings. C. All operators shall turn counter-clockwise to open and shall have the open direction clearly and permanently marked. D. Valve operators shall be designed so that the force required to operate the handwheel, lever, or chain (including breakaway torque requirements) does not exceed 80 pounds applied at the extremity of handwheel or chainwheel operator. Design pressures for sizing of valve operators shall be the piping test pressure for the piping in which the valve is to be installed as shown in the Piping Schedule in Section 15390 – Schedules. E. Handwheels for valves operators shall not be less than 12 inches in diameter. The maximum diameter of any handwheel shall not exceed 24”. F. Nut operators shall have standard 2-inch square AWWA operating nuts designed in accordance with AWWA C504-94. G. Geared manual operators shall be of the worm gear, traveling nut or scotch yolk type except manual operators for butterfly valves 18-inch in diameter or larger which shall be worm gear, unless otherwise indicated in the individual valve specification. Gear operators shall be of the worm gear or bevel gear type. Gear box designs incorporating City of Denton Hazen and Sawyer BID SET 15100-3 Valve Operators and Electric Actuators end of travel stops in the housing shall be equipped with AWWA input stops. Each gearbox shall require a minimum of 10 turns for 90 degree rotation or full valve stem travel and shall be equipped with a mechanical valve position indicator. H. Manual operators on below grade (and vault installed) valves shall be permanently lubricated and watertight under an external water pressure of 10 psi. 2.03 ELECTRIC VALVE ACTUATORS A. Electric Actuators shall be open/close service or modulating service as specified in the Valve Schedule in Section 15390 – Schedules. 1. Open/Close (non-modulating) valve actuators shall be IQ series as manufactured by Rotork, SA series as manufactured by AUMA, or Series 2000 as manufactured by EIM Controls. 2. Modulating valve actuators shall be Type IQM as manufactured by Rotork, Type SAR as manufactured by AUMA, or Series 2000 Futronic as manufactured by EIM Controls. B. Performance Requirements 1. The actuators shall be designed for indoor and outdoor service and shall be capable of mounting in any position. 2. Torque capacity of the actuators shall be sufficient to operate the valves with the maximum pressure differential, as indicated in the Valve Schedule in Section 15390, with a safety factor of 1.5. Actuators in modulating service will be selected such that the required dynamic valve torque is no more than 60% of the electric actuator’s maximum rated breakaway of torque. 3. Operating time for full limits of travel shall be not more than 2 seconds per inch diameter of the valve, +/- 50 percent through 20 inches; +/- 30 percent for valves 24 inches and larger. Operating time shall not be less than 60 seconds for all modulating valves. 4. Actuators shall be capable of operating in ambient temperatures ranging from 0 degrees F – 160 degrees F. 5. For open/close (non-modulating) actuators, the gearing, motor and contactor shall be capable of 60 starts per hour without overheating. 6. For modulating actuators, the gearing, motor and contactor shall be capable of 1200 starts per hour without overheating. C. The actuators shall include, in one integral housing, individual compartments for the motor, gearing, wiring terminals, and control circuits. The terminal compartment shall be separated from the inner electrical components of the actuator by means of a watertight seal. The inner seal shall protect the motor and all other internal electrical elements of the actuator from entrance of moisture and dust when the terminal cover is removed. City of Denton Hazen and Sawyer BID SET 15100-4 Valve Operators and Electric Actuators Double cartridge shaft seals shall be provided on the hand wheel and output shafts for weatherproof protection. All external fasteners shall be stainless steel. Compartments shall be provided with moisture and dust-proof rigid cast covers meeting NEMA 6, certified to submergence in 6 ft of water for 30 minutes. Actuators located in classified areas shall be suitable for use in Class 1, Division 1, Group D environments. D. The actuators shall be provided with externally operable and lockable 480VAC circuit breakers integral to the control housing. E. All gearing shall be hardened alloy steel or bronze and shall be rated at twice the output torque of the operator and shall be designed to withstand the stall torque of the motor without failure. Output drive gearing shall consist of a worm shaft and worm gear pinion operating in an oil bath. The worm gear pinion shall be alloy bronze. Worm gear drive shall be self-locking to prevent creeping of the valve disc in an intermediate position. Heavy-duty grease shall protect gearing and sealed ball bearings of the main shaft for five years without changing. Motor reduction gearing shall be spur or planetary gearing and shall allow for field repair and change in gear ratio. For quarter turn applications, overtravel of the operator shall be prevented by internal mechanical stops cast into the actuator. F. A mechanical dial position indicator shall be furnished to continuously indicate the position of the valve at and between the fully open and fully closed positions. The indicator shall be driven by gearing driven off of the main worm gear pinion and shall operate when the actuator is in either the electrical mode or manual mode. G. A handwheel shall be permanently attached for manual operation. A gear assembly shall be provided between the handwheel and the worm shaft if required to reduce the force necessary to operate the handwheel to less than 40 pounds. A positive declutch mechanism shall engage the handwheel when required. When the actuator is set in the declutched position for handwheel operation, it shall return automatically to electric operation when actuator motor is energized. The handwheel shall not rotate during electric operation nor shall a fused motor prevent handwheel operation. H. The drive motor shall be specifically designed for actuator service and shall be characterized by high starting torque and low inertia. Motors shall be 460 volts, three phase, 60 Hz AC reversible squirrel cage induction type motors and shall be specifically designed for modulating service where indicated on the Valve Schedule in Section 15390. Motors shall be totally enclosed, non-ventilated, with NEMA Class F insulation minimum (Class H for modulating actuators) and a maximum continuous temperature rating of 120 degree C (rise plus ambient). A 120 VAC space heater shall be provided in the motor compartment. The electric motor shall have a time rating of at least 15 minutes at 104°F (40°C) or twice the valve stroking time, whichever is longer, at an average load of at least 33% of maximum valve torque. Motor bearings shall be permanently lubricated by premium lubricant. The motor shall have plug and socket electrical connection to facilitate easy removal and replacement. The actuator shall include a device to ensure that the motor runs with the correct rotation for the required direction of valve travel with either phase sequence of the three-phase power supply connected to the actuator. The motor shall include single phase protection. A suitable thermal protection device shall be incorporated in the motor or motor starter circuits, connected to a tripping device. Fast acting fuses shall be provided to protect solid state City of Denton Hazen and Sawyer BID SET 15100-5 Valve Operators and Electric Actuators components. The motor shall be capable of starting against the rated load in either the open or close direction when voltage to the motor terminals is plus or minus ten (10) percent of nameplate rating. 1. Open/Close actuators shall be furnished with electro-mechanical reversing starters. 2. Modulating actuators shall be furnished with solid state reversing starters utilizing thyristors. I. Leads from the motor shall be brought to the control circuit (limit switch) compartment without external piping or conduit box. An adequately sized space heater shall be installed in the control circuit compartment to aid in the prevention of damage resulting in from condensation. The following items shall be located in the control circuit compartment. 1. Torque limit switches shall be provided to de-energize the motor control circuit in the event of a stall when attempting to unseat a jammed valve and when torque is exceeded during valve travel. Each actuator shall have an open direction torque switch and a close direction torque switch. The torque switches shall be mechanically operated and able to be set in torque units. Torque switches shall be calibrated prior to the actuator’s assembly to the valve. 2. Travel limit switches shall be provided to de-energize the motor control circuit when the actuator reaches the limits of travel in the open and close directions. The limit switch drive shall be of the counter gear type and “in step’” with the actuator output drive at all times in either the electrical or manual mode of operation. A minimum of six (6) contacts, three (3) normally open and three (3) normally closed, shall be supplied at each end of valve travel. Four (4) additional contacts shall be provided to report end of travel or any desired position between ends of travel. J. Modulating actuators shall have a position feedback potentiometer mounted directly to the valve actuator gearing inside the gearing compartment. The potentiometer shall provide a 4-20 mA signal corresponding to valve position. Modulating valve actuators shall be designed to respond to either a 4-20mADC analog signal or a digital pulse signal as specified herein or as required to coordinate with the requirements of Division 17. 1. Modulating valve actuators designed to respond to a 4-20mADC signal shall be provided with a valve positioner which shall position the valve proportional to an externally generated 4-20mADC signal. The valve positioning control circuitry shall position the valve by comparing the command signal with the present valve position as indicated by the feedback potentiometer. The positioner shall be field adjustable to fail to the “open,” “closed,” or “last” position on loss of 4-20 mADC command signal. 2. Modulating valve actuators designed to respond to “pulse” open/close signals shall operate the valve during the time the open or close pulse signal is high. Modulating actuators designed to respond to “pulse” open/close signals shall have the latching circuitry described above for open/close actuators disabled. City of Denton Hazen and Sawyer BID SET 15100-6 Valve Operators and Electric Actuators K. The electrical terminals shall be housed in a double sealed terminal compartment isolated from the rest of the actuator components. The actuators shall be designed to operate from a single 480VAC, 3-phase source. The actuators shall be furnished with fuses inside of the terminal compartment. A quantity of two – ¾ inch NPT conduit entries shall be furnished. L. Actuators shall contain wiring and terminals for the following control functions. All dry contacts shall be rated for 5A at 250VAC. 1. Open, Close, and Stop commands from external dry contacts (utilizing internal 24VDC power supply) and/or from an external signal of 12V to 120V. The inputs for the open, close, stop signals shall be field selectable to respond to either maintained or momentary remote signals. In momentary mode, the actuator shall have internal latching circuitry that causes the operator to drive the valve to its limit of travel upon receipt of the momentary contact signal unless a stop signal is received. 2. Emergency override input from a normally closed or normally open contact. The actuator shall either open or close (field selectable) upon receiving the emergency override input. 3. Remote Local-Off-Remote selector switch, Open/Close pushbuttons, and Open/Closed pilot lights for a remote manual control station (see below). The remote Local-Off-Remote selector switch and Open/Close pushbuttons shall be a dry contact input to the actuator control circuitry. The Open/Closed pilot lights shall be powered from the valve actuator control power. 4. Four (4) unpowered contacts shall be provided which can be selected to indicate valve “Opened” and “Closed” position, “Remote” status of the actuator, and fail status of the actuator. The fail status contacts shall activate upon motor overtemperature and actuator overtorque as a minimum. 5. Terminals for 4-20mADC position command and 4-20mADC position feedback as described above for modulating actuators. M. Local Controls 1. Actuators shall be furnished with a Local-Off-Remote selector switch; Open, Close, and Stop pushbuttons for local control; a red lamp indicating closed and a green lamp indicating open. L-O-R switch shall be padlockable in any of the three positions. a. When the LOR is in the “Local” position, open/close control shall be by the open and close pushbuttons on the actuator. The stop push button shall stop the actuator travel. b. When the LOR is in the “Off” position, the actuator shall not operate. City of Denton Hazen and Sawyer BID SET 15100-7 Valve Operators and Electric Actuators c. When the LOR is in the “Remote” position, the actuator shall be controlled by remote inputs from the PLC or from the remote manual controls station. 2. The local controls shall be arranged so that the direction of travel can be reversed without the necessity of stopping the actuator. N. Remote Manual Control Station 1. Where indicated in the Valve Schedule in Section 15390 – Schedules, manual actuator controls shall be furnished in a separate NEMA 4X stainless steel enclosure (NEMA 7 if located in a classified area). Manual control station controls shall include Hand–Off-Auto Selector switch; Open, Stop, and Close pushbuttons; a red lamp indicating closed and a green lamp indicating open. a. When the HOA is in the “Hand” position, open/close control shall be by the open and close pushbuttons on the remote manual control station. The stop push button shall stop actuator travel. b. When the HOA is in the “Off” position, the actuator shall not operate. c. When the HOA is in the “Auto” position, the actuator shall be controlled by remote inputs to the valve actuator from the PLC. 2.04 ELECTRIC OPERATORS FOR PVC/CPVC VALVES A. Automatic electric operators shall be provided for PVC/CPVC valves where specified and/or as shown on the Drawings. Operators shall operate on 120 volt AC, single phase, 60 hertz power and be equipped with solid state electronic internal controls. Motors shall be brushless, capacitor-run, reversing type, suitable for high duty cycle applications and shall be specifically designed for open/close service. Motors shall be provided with integral thermal overload protection with auto-reset. Operator gears and shafts shall be constructed of heat treated high-alloy steel. Operator output shaft shall be electro-less nickel plated. Operator gear trains shall be permanently lubricated. The gear train shall withstand operator stall torque. Operator enclosures shall be NEMA 4. Operators shall be provided with internally wired, thermostatically controlled enclosure heaters to maintain an enclosure temperature of at least 40 degrees F. Operators shall be provided with positive visual position indication markings permanently affixed to the operator body and final output shaft. Operator drive output shall be provided with a declutchable manual override. A manual lever shall be provided for manual valve positioning. Operators shall be failsafe, utilizing a mechanical spring with a clutch mechanism to uncouple the motor during spring return operation, allowing the spring to relax and either open or close the valve. Selection of either fail-opened or fail-closed shall be made by selection of field wiring terminals. B. Independently adjustable cam-operated position limit switches shall be provided with dry contacts for remote fully opened and fully closed valve position indication. Operators shall respond to external dry contact open/close controls. The actuator shall have internal latching circuitry that causes the operator to drive the valve to its limit of travel upon receipt of the momentary contact open or close signal unless a stop signal is received. The all actuator control circuitry, including latching circuitry, shall be internal to City of Denton Hazen and Sawyer BID SET 15100-8 Valve Operators and Electric Actuators the valve actuator. Valve control circuits and components mounted in a separate enclosure external to the valve actuator assembly will not be permitted. Connections for external remote controls shall be powered from an internal 24VDC or 120VAC power supply. Limit switches shall be rated for 15 amps at 120 VAC. Valve remote status shall also be provided as specified in Section 17950. The Contractor shall coordinate operator controls with the functional requirements specified in Section 17950 – Functional Control Descriptions. PART 3 -- EXECUTION 3.01 MANUFACTURER’S FIELD SERVICES A. The services of a qualified manufacturer's technical representative shall be provided in accordance with Section 11000, Equipment General Provisions and shall include the following site visits for electric actuators: Service Number of Trips Number of Days/Trip Installation 1 0.5 Startup and Training 1 0.5 3.02 INSTALLATION A. All valve actuators shall be installed in accordance with the manufacturer's published recommendations and the applicable specification sections for valves, and motor controls. B. Valve actuators shall be factory coated in accordance with the manufacturer’s standard paint system. 3.03 SHOP TESTING A. Shop testing shall be in accordance with Section 11000, Equipment General Provisions and with the following additional requirements: 1. Conduct a complete functional check of each unit. Correct any deficiencies found in shop testing prior to shipment. 2. Submit written certification that: a. Shop tests for the electrical system and all controls were successfully conducted; b. Electrical system and all controls provide the functions specified and required for proper operation of the valve operator system. 3. Each actuator shall be performance tested and individual test certificates shall be supplied free of charge. The test equipment shall simulate each typical valve load and the following parameters should be recorded: City of Denton Hazen and Sawyer BID SET 15100-9 Valve Operators and Electric Actuators a. Current at maximum torque setting b. Torque at maximum torque setting c. Flash Test Voltage d. Actuator Output Speed or Operating Time e. In addition, the test certificate should record details of specification, such as gear ratios for both manual and automatic drive, closing direction, and wiring diagram code number. f. Verification of actuator torque rating with valve. 3.04 FIELD TESTS A. Field testing shall be in accordance with Section 11000, Equipment General Provisions and with the following additional requirements: 1. Valve actuators shall be field-tested together with the associated valves. 2. Test all valves at the operating pressures at which the particular line will be used. 3. Test all valves for control operation as directed. 4. Field testing shall include optimization of opening and closing times of the valves. Valve opening and closing times shall be adjusted based on process requirements to optimize operation of the valves. Final valve opening and closing times as determined by field tests shall be approved by the Engineer prior to final acceptance of the system. B. Preliminary Field Tests 1. General: Preliminary field tests shall be conducted prior to start-up and shall include a functional check of the entire valve operator system and all system components. 2. Scope: Preliminary field tests shall demonstrate that the valve operator system performs according to specifications and that all equipment, valves, controls, alarms, interlocks, etc., function properly. 3. Based on results of preliminary field tests, the Contractor shall make any adjustments required to settings, etc., to achieve the required valve closing time and operation, as specified or otherwise directed. C. Final Field Tests 1. Final field tests shall be conducted in accordance with the latest revision of AWWA C500. City of Denton Hazen and Sawyer BID SET 15100-10 Valve Operators and Electric Actuators 2. Final field tests shall be conducted simultaneously with the start-up and field testing of the pumps. 3. Final field tests shall be conducted for the full range of operating modes and conditions specified and as directed by the Engineer. Each of the valves shall be tested at minimum, maximum, and normal head/flow conditions, and under all specified conditions of opening and closing. 4. Certification of Equipment Compliance: After the final field tests are completed and passed, submit affidavit according to Section 11000. - END OF SECTION - BID SET 15101-1 Butterfly Valves SECTION 15101 BUTTERFLY VALVES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Reference Section 15000, Basic Mechanical Requirements. PART 2 -- PRODUCTS 2.01 BUTTERFLY VALVES (WATER SERVICE) A. Butterfly valves (water service) shall be of the rubber-seated, tight-closing type conforming to the latest revision of AWWA C504 Specifications. The manufacturer shall have a minimum of 5 years experience in manufacturing butterfly valves of the sizes required in accordance with AWWA C504 Specifications. All butterfly valves shall be the product of one manufacturer. Butterfly valves shall be as manufactured by Pratt, Mueller Co., DeZurik, or equal. Each valve shall be performance and leak tested as specified in AWWA C504 revised as follows: In addition to the testing requirements of AWWA C504, each butterfly valve shall be thoroughly cleaned and opened and closed at least three (3) times prior to testing. Certified copies of the test results shall be submitted to the Engineer for approval prior to shipment of the valve. B. Butterfly valves shall be Class 150B, unless otherwise indicated in the valve schedules, and of the short body design with mechanical joint or flanged ends, as shown on the Drawings. C. Valve bodies shall be epoxy coated cast iron conforming to ASTM A-126, Grade B, ASTM A-48, Class 40 or Ductile Iron ASTM A536, Grade 65-45-12. Where required to meet design operating conditions, valve bodies shall be manufactured of higher strength materials. Valve bodies shall have integral hubs for housing shaft bearings and seals. D. Butterfly valves shall be of the concentric or eccentric shaft types. Valve discs shall be constructed of epoxy coated ductile iron, ASTM A536, Grade 65-45-12. Disks shall be of the "offset" design to provide a full 360 degree seating surface with no external ribs transverse to flow, and shall comply with the latest revision of AWWA C504 Specifications. The valve manufacturer shall furnish Shop Drawings which include end clearance dimensions when the disc is in the full open position. E. The resilient valve seat shall be synthetic rubber designed to seat against a pressure differential of 150 psi on either side of the valve, unless otherwise indicated. The resilient seat shall be mechanically attached to the valve disc or valve body. Any required seat attachment hardware shall be stainless steel. The resilient seat shall be capable of being adjusted or replaced in the field without moving the valve disc along the shaft axis, or removing the valve from the line. The mating seat surface shall be stainless steel or monel. The seats shall be factory tested as per AWWA C504 at a test pressure of 150 psig, unless otherwise indicated, and post adjusted for differential pressures indicated herein. F. Valve shafts shall be one-piece or two-piece units of stainless steel construction suitably sized to transmit the torques required to operate the valves under the conditions listed in the BID SET 15101-2 Butterfly Valves valve schedule with appropriate safety factor. Shafts shall be securely attached to valve disc by means of conservatively sized corrosion-resistant taper pins, threaded at one end and secured with lockwashers and nuts (i.e.: mechanically attached). Provide O-ring seal on taper pin if required to prevent leakage. Shaft key shall be constructed of corrosion-resistant material. G. Shaft bearings shall be contained in the integral hubs of the valve body and shall be the permanently self-lubricated, corrosion resistant, sleeve type of teflon or heavy-duty bronze. The valve assembly shall be furnished with a factory set two-way thrust bearing designed to center the valve disc in the valve seat at all times. End cover bolts shall be of stainless steel construction. H. The shaft seal shall be either the bronze cartridge type with at least two O-rings, monolithic V-Type, or pull down packing type. If monolithic V-Type or pull down packings are utilized, it shall be self-adjusting, self-compensating type. Packing shall be as manufactured by Chevron, or equal. Butterfly valves with pull down packings shall be designed with an extension bonnet so that repacking can be done without removal of the actuator. For buried valves with pull down packing the packing gland cover assembly shall be heavy duty, soil and water resistant. Stuffing boxes for pull down packing shall have a depth sufficient to accept at least four rings of self-compensating type packing specifically selected for the operating pressures to be encountered. Stuffing box bolts, studs and nuts shall be stainless steel. I. The "O" ring type shaft seal shall be contained in a removable bronze cartridge. The bronze cartridge shall be manufactured from ASTM B505 copper alloy UNS #C93200 and shall meet the requirements of AWWA C504 for bronze, Grade E. The "O" ring material shall be nitrile, BUNA-N rubber, as intended for use with potable water or wastewater and per ASTM D-2000 with a hardness of 70 Shore A Durometer. J. Manual operators for butterfly valves 18-inches in diameter or larger shall be the worm gear type conforming to AWWA C504. Manual operators for butterfly valves mounted above 6 feet from the operating floor shall be equipped with worm gear chainwheel actuators. Operators shall be equipped with adjustable AWWA limit stops, shall be sized according to Table IV for Class 150B, and shall require a minimum of 15 turns for 90 degrees or full stem valve travel. The capacity of the manual operator shall be adequate to drive the valve under the differential pressure of 150 psi and maximum anticipated flow, unless otherwise indicated in the appropriate valve schedule. K. The manufacturer shall certify that the butterfly valves are capable of operating in continuous duty service under these pressures and flow conditions. L. Each valve shall by hydrostatically tested and tested for bubble tightness after the operator has been mounted and adjusted. Copies of the hydrostatic and leakage test certification and certification of conformance shall be submitted to the Engineer prior to shipment. M. All internal and external ferrous components and surfaces of the valves, with the exception of stainless steel and finished or bearing surfaces, shall be shop painted with two coats (10 mils min. dry film thickness) of the manufacturer's premium epoxy for corrosion resistance. Damaged surfaces shall be repaired in accordance with the manufacturer's recommendations. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 15105-1 Check Valves SECTION 15105 CHECK VALVES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Reference Section 15000, Basic Mechanical Requirements. B. Valves intended for chemical service shall be constructed of materials suitable for the intended service. PART 2 -- PRODUCTS 2.01 RUBBER FLAPPER CHECK VALVES (RAW SEWAGE SERVICE) A. Check valves larger than 3-inches shall be rubber flapper check valves rated for a minimum working pressure of 250 psi and shall be of the "Rubber Flapper" type as manufactured by G.A. Industries, Crispin, or equal. B. Valve closure shall be controlled by flow reversal. Valve shall seat on a 45-degree angle. C. Valve bodies and covers shall be constructed of ductile iron fully conforming to the latest revision of ASTM A-536 Grade 65-45-12. Valve covers shall be removable and allow access to flexible disc without removal of the valve from the line. Valve ends shall be Standard American 125 pound flat-faced flanged, in accordance with ANSI B16.1. D. Valve discs shall be constructed of flexible steel-reinforced Buna-N Rubber Flapper with integral O-ring style seat. The disc seat ring shall be made of 80 Durometer rubber. The discs shall conform to AWWA C508, passing a minimum of 1,000,000 cycles with no signs of wear, abrasions, or cracking and be drop-tight at the conclusion of testing. E. Valve seating shall be rubber-to-metal designed for drop-tight shutoff. Body and disc seats shall be renewable. F. With the exception of the valve body and seat, all parts in contact with water shall be manufactured from noncorrosive materials. Internal corrosive surfaces shall be shop painted with two coats of epoxy for corrosion resistance. Exterior surfaces shall be painted in accordance with the requirements of Section 09900, Painting. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 15105-2 Check Valves This page left blank intentionally City of Denton Hazen and Sawyer BID SET 15107-1 Yard Hydrants SECTION 15107 YARD HYDRANTS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Reference Section 15000, Basic Mechanical Requirements. PART 2 -- PRODUCTS 2.01 YARD HYDRANTS A. Service water system hydrants shall be of the 2-inch non-freeze post-yard type with bronze casing, neoprene plunger. The barrel shall be self-draining; operating parts must be removable through the top of the hydrant. B. The cold-rolled steel stem shall operate with a bronze operating nut. Stem threads shall be lubricated through the top of the operating nut tapped for grease fittings. Packing shall be double "O" rings to insure a positive shutoff with a minimum of packing friction when the hydrant is being operated. Each hydrant shall be equipped with suitable adapters to connect 2-inch and 3/4-inch hoses. C. Each hydrant shall be supplied with 10-inch operating hand wheel and a steel post-mounted hose rack. The hydrants shall be Models 71702 as manufactured by Josam, Z-1390 as manufactured by Zurn, 5914 by Smith Company, or equal. PART 3 -- EXECUTION (NOT USED) - END OF SECTION – City of Denton Hazen and Sawyer BID SET 15107-2 Yard Hydrants This page left blank intentionally City of Denton Hazen and Sawyer BID SET 15108-1 Gate Valves SECTION 15108 GATE VALVES (INCLUDING KNIFE GATE VALVES) PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Reference Section 15000, Basic Mechanical Requirements. PART 2 -- PRODUCTS 2.01 GATE VALVES A. Gate valves shall be designed for a minimum working pressure of 100 psi and a test pressure of 250 psi. B. Gate valve body and bonnet shall be cast iron conforming to ASTM A126, Class B with resilient seat gate and O-ring seals. The gate shall be cast iron with a vulcanized rubber coating with no metal to metal contact when in the fully closed position and a smooth unobstructed waterway when in the fully opened position. Gate valves 18 inches and larger shall fully comply with the requirements of AWWA C515 and shall be resilient seated gate valves with spur geared operator, unless otherwise specified or shown on the Drawings. Valves shall be American Darling Series 2500, Mueller A-2361, or equal. C. All internal ferrous components and surfaces of the valves, with the exception of stainless steel and finished or bearing surfaces, shall be shop painted with two coats (10 mils min. dry film thickness) of the manufacturer's premium epoxy for corrosion resistance. Damaged surfaces shall be repaired in accordance with the manufacturer's recommendations. 2.02 KNIFE GATE VALVES A. Knife gate valves shall be cast iron conforming to ASTM A126, Class B with resilient ring seal seat. The gate shall be stainless steel with a beveled, knife-like edge. The knife gate valve shall be flanged in accordance with ANSI B-16.1, 125 pound flange with a handwheel operator as manufactured by DeZurik, or equal. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 15108-2 Gate Valves This page left blank intentionally City of Denton Hazen and Sawyer BID SET 15109-1 Plug Valves SECTION 15109 PLUG VALVES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Reference Section 15000, Basic Mechanical Requirements. PART 2 -- PRODUCTS 2.01 PLUG VALVES A. Plug valves shall be of the non-lubricated, eccentric seating plug type with synthetic rubber-faced plugs as manufactured by DeZurik Company, Pratt/Milliken, Crispin, or equal. All valves shall be provided with limit stops and rotate 90° from fully open to fully shut. The minimum working pressure for all valves shall be 150 psi, and the test pressure shall be at least 270 psi for valves up through 12-inch and at least 230 psi for valves 14-inch and larger. The port area of valves shall be at least 80 percent of full pipe area for valves less than 24-inches and 70 percent for valves 24-inches and larger, unless otherwise specified herein or indicated in the appropriate Valve Schedule in Section 15390, Schedules. The body materials shall be of epoxy coated cast iron or semi-steel, unless specified otherwise. Seats shall have a welded overlay of 90 percent pure nickel and machined to a finish containing no stress cracks. Plug facings shall be of Hycar, or equal and completely suitable for use with domestic sewage. B. The shaft seal shall be either the bronze cartridge type with at least two O-Rings, monolithic V-Type, U-Cup Type, or pull down packing type. If monolithic V-Type, U-Cup Type, or pull down packings are utilized, it shall be self-adjusting, self-compensating type. Packing shall be as manufactured by Chevron, or equal. Plug valves with pull down packings shall be designed with an extension bonnet so that repacking can be done without removal of the actuator. C. All buried valves shall have mechanical joint ends (unless otherwise shown), conforming to ANSI A21.11 (AWWA C 111), and shall be operated with a standard AWWA 2-inch square nut through a totally enclosed worm gear actuator. Valve boxes shall be installed with all buried plug valves and shall be as specified herein. D. Unless otherwise shown, all exposed valves 4-inches in diameter and larger shall have flanged ends conforming to ANSI B16.1-125/150 pound standard with face-to-face dimensions of standard plug valves. Valves smaller than 4-inches in diameter shall have screwed ends, unless otherwise noted. E. Valves 8-inches in diameter and larger shall be handwheel or floorstand operated where required or indicated on the Drawings through totally enclosed worm gear actuators, unless otherwise specified or shown on the Drawings. Valves 6-inches in diameter and smaller shall have lever operators, unless otherwise specified or noted on the Drawings. Manual City of Denton Hazen and Sawyer BID SET 15109-2 Plug Valves operators for plug valves mounted above 6 feet from the operating floor shall be equipped with worm gear chainwheel actuators. F. The manufacturer shall certify that the plug valves are capable of operating in continuous duty service under these pressures and flow conditions. G. Each valve shall by hydrostatically tested and tested for bubble tightness after the operator has been mounted and adjusted. Copies of the hydrostatic and leakage test certification and certification of conformance shall be submitted to the Engineer prior to shipment. H. All internal and external ferrous components and surfaces of the valves, with the exception of stainless steel and finished or bearing surfaces, shall be shop painted with two coats (10 mils min. dry film thickness) of the manufacturer's premium epoxy for corrosion resistance. Damaged surfaces shall be repaired in accordance with the manufacturer's recommendations. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 15114-1 Miscellaneous Valves and Appurtenances SECTION 15114 MISCELLANEOUS VALVES AND APPURTENANCES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The CONTRACTOR shall furnish and install miscellaneous valves as shown and as specified herein, complete and operable including accessories and, where designated, operators, all in accordance with the requirements of the Contract Documents. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 15095 - Valves, General PART 2 -- PRODUCTS 2.01 GATE VALVES (SMALLER THAN 3-INCH) A. Gate valves, smaller than 3-inch, for general purpose use shall be heavy duty type for industrial service, with screwed or soldered ends to suit piping. The bodies shall have screwed tops or union bonnets, of bronze to ASTM B 62, with bronze stems, solid wedges, metal handwheels, and Teflon-impregnated or other acceptable packing. Buried valves shall have non-rising stems. Exposed valves (above ground) shall have rising stems. All valves shall have a minimum pressure rating of 125 psi. B. Suppliers, or Equal: 1. Crane Company; 2. Milwaukee Valve Company; 3. Wm. Powell Company. 2.02 HOSE BIBBS A. Potable Water System: Hose bibbs shall be 3/4-inch brass, rough chrome plated, with vacuum breaker and loose key stop. Hose bibbs shall be Chicago No. 998, Sloan or equal. 2.03 BACKFLOW PREVENTERS (SMALLER THAN 3-INCH) A. Backflow preventers shall be of the reduced pressure assembly type and shall contain two spring loaded check valves and one spring loaded, diaphragm actuated, differential pressure relief valve. The unit shall include tightly closing shut-off valves located at each end of the device and shall be fitted with properly located test cocks. Operation shall be completely automatic. All parts shall be removable or replaceable without removal of the City of Denton Hazen and Sawyer BID SET 15114-2 Miscellaneous Valves and Appurtenances unit from the line. All materials shall be protected against corrosion. The backflow preventer shall be Febco Model 825Y or equal. 2.04 SEWAGE AIR-VACUUM, AIR-RELEASE VALVES AND COMBINATION VALVES A. Air-Vacuum Valves: Air and vacuum valves shall be capable of venting large quantities of air while pipelines are being filled, and allowing air to re-enter while pipelines are being drained. They shall be of size indicated, with flanged or screwed ends to match piping. Bodies shall be of high-strength cast iron. The float, seat, and all moving parts shall be constructed of Type 316 stainless steel. Seat washers and gaskets shall be of a material insuring water tightness with a minimum of maintenance. Valves shall be designed for minimum 150-psi water-working pressure, unless otherwise indicated. B. Air-Release Valves: Air-release valves shall vent accumulating air while system is in service and under pressure and be of the size indicated and shall meet the same general requirements as indicated for air and vacuum valves except that the vacuum feature will not be required. Valves shall be designed for a minimum water-working pressure of 150 psi, unless otherwise indicated. C. Combination Air Valves: Combination air valves shall combine the characteristics of air and vacuum valves and air release valves by exhausting small pockets of air accumulated in systems under pressure and releasing or re-admitting large quantities of air while a system is being filled or drained, respectively. Valves shall have the same general requirements as indicated for air and vacuum valves. D. Valve ends shall be 125 lb ANSI B16.1 flange or 125 lb ANSI B2.1 threaded fittings depending on locations shown on the Drawings. E. Manufacturers, or Equal: 1. APCO (Valve and Primer Corporation), Series 440 SCAV and 400 SARV 2. Crispin (Multiplex Manufacturing Company) 3. Golden-Anderson 4. Val-Matic (Valve and Manufacturing Corporation) 2.05 SMALL PRESSURE REDUCING VALVES (AIR AND WATER) A. Small air and water pressure reducing valves shall be of the spring-loaded diaphragm type with a minimum pressure rating of 250 psi, with bronze body, nickel alloy or stainless steel seat, and threaded ends. Each valve shall be furnished with built-in or separate strainer and union ends. B. The suppliers shall be the following or equal: 1. Mueller Company. City of Denton Hazen and Sawyer BID SET 15114-3 Miscellaneous Valves and Appurtenances 2.06 FLOW CONTROL SLEEVE PINCH VALVE A. Pinch valves shall be self-cleaning, elastomer sleeve type isolating all mechanical parts from process liquids. Pinch valve shall be ductile iron body, EPDM sleeve, ANSI B16.5 Class 150 flanges. Rising stem shall be enclosed with modulating actuator meeting requirements of Section 15100. Pinch valves shall be Red Valve Series 5200E or equal. PART 3 -- EXECUTION 3.01 INSTALLATION A. All valves shall be installed in accordance with the Supplier's printed recommendations. B. All valves shall have piped outlets to the nearest acceptable drain, firmly supported, and installed in such a way as to avoid splashing and wetting of floors. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 15114-4 Miscellaneous Valves and Appurtenances This page left blank intentionally City of Denton Hazen and Sawyer BID SET 15121-1 Piping Expansion Compensation SECTION 15121 PIPING EXPANSION COMPENSATION PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Reference Section 15000, Basic Mechanical Requirements. PART 2 -- PRODUCTS 2.01 RUBBER EXPANSION JOINTS A. Rubber expansion joints shall be of the single wide arch design and shall be rated for 225F (dry) or 210F (wet). Non-submerged units shall be provided with galvanized ductile iron retaining rings. Exposed expansion joints shall be fully resistant to ultra violet degradation. Submerged expansion joints shall be fully resistant to attack from organisms or chemicals found in the associated process liquid. B. Expansion joints shall be located as shown on the Drawings and shall be for either wet (W) or dry (D) service. The performance of the expansion joints shall be as indicated in the following table. Minimum Required Movement Nominal Pipe Diameter (In) Comp. (In) Elong. (In) Lateral (In) 1-1-1/2 5/8 1/4 1/4 2-5 1-3/4 3/4 3/4 6-12 1-3/4 3/4 1 14-20 2 7/8 1-1/8 24-84 2-1/4 1 1-1/8 C. Control rods to prevent over extension shall be provided as indicated on the Contract Drawings or as required by the manufacturer. All expansion joints shall be the product of a single manufacturer. D. Expansion joints shall be Style 1015 as manufactured by General Rubber Corporation, Mercer, or equal. 2.02 BURIED PIPE EXPANSION JOINTS A. Buried pipe expansion joints shall be installed at the locations indicated on the Contract Drawings and shall be manufactured from ductile iron, Grade 60-42-10 and conforming to ANSI A21.53 (AWWA C153). Buried pipe expansion joints shall be capable of axial expansion and contraction with a minimum of 4-inches total movement. All joint assemblies City of Denton Hazen and Sawyer BID SET 15121-2 Piping Expansion Compensation shall be furnished preset for a minimum of 2-inches expansion and 2-inches contraction. All pressure containing parts shall be lined with a minimum of 15 mils of Fusion Bonded Epoxy conforming to AWWA C213. The lining shall also conform to the applicable requirements of ANSI A21.11 (AWWA C111). All bolts used in the assembly shall be stainless steel and coated with coal tar epoxy. The buried pipe expansion joint shall be pressure rated at 350 psi with a minimum safety factor of 3:1, and shall be tested to 350 psi prior to shipment. B. Buried pipe expansion joints shall be similar to the Ex-Tend expansion joint as manufactured by EBAA Iron Inc., Eastland, Texas, or equal. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 15170-1 Low Voltage Electric Motors SECTION 15170 LOW VOLTAGE ELECTRIC MOTORS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish all labor, materials, tools and equipment necessary for furnishing, installing, connecting, testing and placing into satisfactory operation all low voltage electric motors as shown on the Drawings and specified herein. All motors required for this Contract shall comply with this Section unless otherwise noted. 1.02 SUBMITTALS A. In accordance with the procedures and requirements set forth in the General Conditions and Section 01300, Submittals, the Contractor shall obtain from the equipment manufacturer and submit the following: 1. Shop Drawings. 2. Spare Parts List. 3. Special Tools List. B. Each submittal shall be identified by the applicable specification section. 1.03 SHOP DRAWINGS A. Each submittal shall be complete in all respects, incorporating all information and data listed herein and all additional information required for evaluation of the proposed equipment's compliance with the Contract Documents. B. Partial, incomplete or illegible submittals will be returned to the Contractor without review for resubmittal. C. Individual shop drawings for electric motors shall be submitted in accordance with the procedures and requirements set forth in the General Conditions and Section 01300, Submittals, unless submitted as a part of the shop drawings for the driven equipment. D. Shop drawings for electric motors shall include motor data sheets, dimensioned drawings, wiring diagrams (space heaters, temperature devices, etc.) identifying electric characteristics and design, mechanical construction, manufacturer's name, type and pertinent specifications for the use intended, along with the name of the equipment to be driven. For motors rated 50 horsepower or more, submittal of motor data for acceptance shall include, as a minimum, the following: City of Denton Hazen and Sawyer BID SET 15170-2 Low Voltage Electric Motors a. Manufacturer's type and frame designation b. Horsepower rating c. Time rating (per NEMA Standards) d. Ambient temperature rating e. Insulation system designation f. RPM at rated load g. Frequency h. Number of phases i. Rated-load amperes j. Voltage k. Code letter (starting KVA per horsepower) l. Design letter for integral horsepower induction motors (per NEMA Standards) m. Service factor n. Temperature rise at full load and at service factor load o. Efficiency at 1/4, 1/2, 3/4 and full load p. Power factor at 1/4, 1/2, 3/4 and full load q. Motor outline, dimensions and weight r. Insulation system description s. Horsepower required by connected machine at specified conditions (load curves) shall be supplied for all compressors, propeller and positive displacement pumps. The foregoing data shall also be verified after manufacture and shall be included with the information to be furnished in the operation and maintenance manuals specified. E. The shop drawing information shall be complete and organized in such a way that the Engineer can determine if the requirements of these Specifications are being met. Copies of technical bulletins, technical data sheets from "soft-cover" catalogs, and similar information which is "highlighted" or somehow identifies the specific equipment items the Contractor intends to provide are acceptable and shall be submitted. PART 2 -- PRODUCTS 2.01 MANUFACTURERS A. The equipment covered by this Specification is intended to be standard equipment of proven performance as manufactured by reputable concerns. Equipment shall be designed, constructed and installed in accordance with the best practices of the trade, and shall operate satisfactorily when installed as shown on the Drawings. B. Electric motors shall be manufactured by Baldor/Reliance Electric Company; Nidec Motors; Toshiba Industrial and Power Systems, Inc.; Siemens Energy & Automation, Inc.; General Electric Company; or equal. 2.02 MATERIALS AND CONSTRUCTION A. Motors shall be built in accordance with the latest standards of NEMA, including, but not limited to MG-1 and MG-2, IEEE, ANSI and to the requirements specified herein. City of Denton Hazen and Sawyer BID SET 15170-3 Low Voltage Electric Motors B. Type 1. Unless otherwise noted, motors specified herein shall be polyphase squirrel cage, NEMA Design B, or single phase capacitor or repulsion start induction motors. Special equipment requiring a motor drive with unusual characteristics shall be equipped with a definite purpose motor to meet the necessary requirements. 2. Unless otherwise shown or specified, all motors 1/2 horsepower or larger shall be three- phase, 60 Hertz, NEMA Design B, squirrel cage induction motors designed for operation at 480 volts or greater as specified herein or shown on the Drawings. 3. Unless otherwise specified in the individual equipment specification for the driven equipment, or as required by the dynamic characteristics of the load as determined by the manufacturer of the machine to be driven, all polyphase squirrel cage motors shall be designed to withstand the starting voltage shown on the Drawings and shall have torque and locked rotor current characteristics as specified for NEMA Design B motors. 4. All motors 2 horsepower and smaller shall have windings encapsulated with a flexible epoxy compound, or insulated with a flexible epoxy compound, or insulated with the manufacturer's premium quality system which shall be subject to acceptance by the Engineer. 5. All motors above 3 horsepower shall have stator windings vacuum impregnated with a polyester insulation compound. 6. Unless otherwise noted, all motors smaller than 1/2 horsepower shall be standard single-phase capacitor start or repulsion start induction type designed for operation on 120 volts or 208 volts, 60 Hz alternating current. The motor shall deliver rated load without exceeding a 80 degrees C temperature rise while operating in a 40 degrees C ambient temperature. Small fan motors less than 1/4 HP may be split-phase or shaded pole type. Shaded pole motors rated more than 1/4 horsepower will not be approved. Fractional horsepower motors shall be completely equipped with all necessary auxiliary components for starting and labeled as "Thermally Protected". Insulation shall be Class B, except that submersible motors shall have epoxy encapsulation. Unless otherwise noted, the motors shall be totally enclosed. Small fan motors may be of the open type where they are suitably protected from moisture dripping and lint accumulation. Motors shall be provided with sealed ball bearings lubricated for 10 years normal use. 7. Where specified, vertical hollowshaft motors shall be designed to carry the motors', pumps', and associated equipment's full thrust. The motors shall be equipped with grease lubricated spherical roller thrust bearings and lower radial guide bearings. Vertical hollowshaft motors shall be fitted with nonreversing ratchet assemblies where specified. Vertical adjustment shall be provided by means of a lockable nut at the top of the shaft. 8. Vertical hollowshaft motors shall have adequate thrust bearings to carry all motor loads and any other operating equipment loads. Horizontal motors shall not be installed where subjected to external thrust loads. City of Denton Hazen and Sawyer BID SET 15170-4 Low Voltage Electric Motors C. Rating 1. Each motor shall develop ample torque for its required service through its acceleration range and throughout its rated load range. The rating of the motors offered shall in no case be less than the horsepower shown on the Drawings or elsewhere specified. It should be noted that the motor sizes indicated on the Drawings or as otherwise specified herein, are motor sizes required to operate the specific equipment which is specified. Higher rated motor sizes may be determined from the actual equipment submitted, approved, purchased, and installed. Overload protection, starters, disconnect switches, and other necessary equipment shall be furnished and installed for the actual motor sizes required at no additional cost. 2. Motor ratings shall be based on continuous operation in an ambient temperature. The maximum temperature rise for open and drip proof type motors shall not exceed 90 degrees C, and for totally enclosed type motors shall not exceed 80 degrees C. D. Insulation 1. Insulation shall be as specified for each particular type or class of motor. The insulation system shall provide a high dielectric strength, long life covering for the windings which may be required to operate in a continually damp and chemically contaminated environment. The insulation shall be resistant to attack by moisture, acids, alkalies, abrasives, and mechanical and thermal shock. Leads shall be sealed with a non-wicking, non-hydroscopic insulation material. 2. Motor insulation resistance may be checked at any time after delivery to the job site or during the warranty period. Encapsulated motor stators may be subjected to insulation testing while completely submerged in water. Any motor not meeting the requirements specified herein will be rejected and shall be promptly replaced at no cost to the Owner. 3. Torque and locked rotor current characteristics for three phase motors shall be NEMA Design B. The locked rotor KVA/HP input at full voltage for 10 horsepower. motors and larger shall not exceed that permitted for Code Letter "J", except for specialized equipment requiring a motor drive with special definite characteristics. 4. Unless otherwise specified, non-inverter duty motors shall be furnished with a Class F insulation system. Unless otherwise specified, inverter duty motors shall be furnished with a Class H insulation system. In either case, temperature rise shall be limited to that for Class B insulation. Output torque and speed characteristics of each motor shall be suitable to operate the driven equipment through the full range of acceleration and operating load conditions without exceeding the nameplates current rating, and/or temperature rise. E. Nameplates 1. The motor manufacturer's nameplates shall be engraved or stamped on stainless steel and fastened to the motor frame with No. 4 or larger oval head stainless steel City of Denton Hazen and Sawyer BID SET 15170-5 Low Voltage Electric Motors screws or drive pins. Nameplates shall include as a minimum, Items a through m as listed in Article 1.03 in addition to that required by NEMA standards. The nameplate shall be positioned so as to be readily visible for inspection in the completed machine. F. Design 1. Motors shall be designed to accelerate and drive the connected equipment under all normal operating conditions without exceeding nameplate ratings. 2. Motors specified for operation with variable frequency drives shall be inverter duty and shall be designed to output 100 percent of nameplate horsepower under continuous duty service without exceeding the temperature rise specified herein when controlled by the actual drives furnished. Inverter duty motors shall be designed to operate down to 10% of full load speed without the need for a line powered cooling fan. 3. Unless otherwise specified, electric motors shall be furnished with service factors in accordance with NEMA MG-1 as follows: Type of Motor Service Factor Non-inverter Duty 1.15 Inverter Duty 1.0 4. Design selection with respect to the driven machine shall be such that the requirements do not exceed 85 percent of the motors' maximum rating modified by service factor, ambient temperature, enclosure, altitude and electrical service. The electrical service conditions shall be assumed to be 10 percent undervoltage, 5 percent underfrequency, and 3 percent voltage unbalance. Altitude shall be assumed to be the project site elevation plus 10 percent. Ambient temperature shall be assumed to be 95 degrees F in exterior locations, 104 degrees F (40 degrees C) in interior locations, and 122 degrees F (50 degrees C) within housings or enclosures; except where higher temperatures may be encountered within or on individual items of equipment. The applicable paragraphs of NEMA MG-1 shall be used in making the design selection. 5. Motors used with belt drives shall have sliding bases to provide for belt take up. 6. Terminal boxes shall be of sufficient size to accommodate the required quantity and size of conduits. Gasketed terminal boxes shall be furnished with all splash-proof and totally enclosed motors. NEMA ratings of the terminal boxes shall be suited for the application. Motors located in hazardous locations shall be furnished with terminal boxes suitable for the specific Class, Division, and Group suitable for the application. Terminal boxes shall be sized to accommodate accessory equipment such as motor differential current transformers. 7. Terminal boxes for horizontal motors shall be located on the left-hand side when viewing the motor from the drive shaft end and shall be so designed that conduit entrance can be made from above, below, or either side of the terminal box. City of Denton Hazen and Sawyer BID SET 15170-6 Low Voltage Electric Motors 8. Motors larger than 250hp shall be manufactured with the six stator coil leads wired to the motor junction box for application in a differential relay scheme. Current transformers shall be provided by the motor manufacturer and installed in the factory. All ground connections and current transformer connections shall be made in the factory. G. Construction 1. Frames, mounting means, and shafts shall meet NEMA Standards for the horsepower, RPM, and enclosure selected. Enclosures shall be selected according to the degree of mechanical protection required and shall not be of aluminum construction. All motors shall have a manufacturer's standard shop machinery finish, consisting of a rust-resisting priming coat of zinc chromate and a finish coat of alkyd machinery enamel. Reference Section 09900, Painting. 2. Motors shall have cast iron frames and a heavy gauge steel terminal box, with neoprene gaskets between the frame and the box and between the box and its cover. A grounding lug(s) shall be provided inside the terminal box. 3. Motors weighing more than 50 pounds shall be equipped with at least one lifting eye. All lifting hardware shall be corrosion resistant. 4. Motors located in hazardous locations shall be totally enclosed and suitable for the specific Class, Division, and Group suitable for the application. 5. Motors located in Class I or II, Division 1 hazardous locations shall bear a U.L.-844 label and shall be provided with a breather/drain approved for the hazardous location. The U.L. listed breather/drain shall prevent the entrance of contaminants while allowing moisture to drain out of the motor. 6. When located outdoors, or elsewhere if specified, motors shall be totally enclosed, non-ventilated (TENV) or totally enclosed, fan-cooled (TEFC) machines, unless otherwise noted. Totally enclosed motors shall be provided with two (2) 1/4 inch drain holes drilled through the bottom of the frame, which allows complete drainage of the frame. Where specified, TEFC motors controlled by a variable frequency drive shall be provided with a separately powered cooling fan motor that runs at 60HZ to ensure proper cooling of the motor at low speeds. Cooling fan motor shall be suitable for 120VAC, single phase operation. 7. Unless otherwise specified in the equipment specifications, motors rated 100 horsepower or greater located outdoors, in unheated structures, in below grade areas, or as otherwise indicated, shall be furnished with space heaters and embedded motor winding high temperature switches with leads brought out of the motor terminal box. Space heaters shall be suitable for 120VAC operation and for a maximum surface temperature of less than 200 degrees C. Spare heaters shall be of sufficient wattage to maintain the internal temperature of the motor at approximately 10 degrees C above the ambient temperature when the motor is not running. Embedded motor winding temperature switches shall operate at temperatures well below the temperature rating of the motor winding insulation system. Motor winding City of Denton Hazen and Sawyer BID SET 15170-7 Low Voltage Electric Motors temperature switches are not required where other temperature monitoring devices (e.g. RTD's) are required. 8. Unless otherwise specified in the equipment specifications, motors rated 200HP or greater that are controlled by a VFD shall be furnished with resistance thermal detectors (RTD’s) embedded in the stator windings, two per phase. RTD’s shall be pre-wired to terminal blocks located in a separate terminal box as specified herein. 9. Unless otherwise specified in the equipment specifications, motors rated less than 200HP that are controlled by a VFD shall be furnished with motor winding high temperature switches embedded in the stator windings with the leads brought out to the motor terminal box. 10. If so specified and when located in indoor areas which are heated and weatherproof, motors shall be open drip-proof machines. Ventilation openings shall be arranged to prevent the entrance of drops of liquid or solid particles at any angle from zero to 15 degrees downward from vertical. 11. Unless otherwise specified, or required, motors rated less than 200 horsepower shall be furnished with bearings of the grease lubricated, antifriction ball type with conveniently located grease fittings and drain plugs. A means of preventing bearings from becoming overgreased shall be provided. Bearings shall have a minimum B-10 life of 20,000 hours. 12. Rotors shall be statically and dynamically balanced. Rotor windings shall be one-piece cast aluminum. Where applicable, rotors shall be constructed with integral fins. H. Power Factor and Efficiency 1. All motors, including vertical hollowshaft motors, in the range of 1-500 horsepower, inclusive, shall be designed specifically for energy efficiency and high power factor. The motor efficiency and power factor shall meet or exceed the values listed in the table below when the motors are tested in accordance with the NEMA preferred test method IEEE 112A, Method B, Dynamometer. Each motor shall meet the minimum guaranteed efficiency value indicated in the table below. All tests shall be performed in accordance with the procedures contained in NEMA Standard MG1-12.58. City of Denton Hazen and Sawyer BID SET 15170-8 Low Voltage Electric Motors TABLE 12-11 FULL-LOAD EFFICIENCIES OF ENERGY EFFICIENT MOTORS ENCLOSED MOTORS HP 2 POLE 4 POLE 6 POLE 8 POLE Nominal Efficiency Minimum Efficiency Nominal Efficiency Minimum Efficiency Nominal Efficiency Minimum Efficiency Nominal Efficiency Minimum Efficiency 1 75.5 72 82.5 80 80 77 74 70 1.5 82.5 80 84 81.5 85.5 82.5 77 74 2 84 81.5 84 81.5 86.5 84 82.5 80 3 85.5 82.5 87.5 85.5 87.5 85.5 84 81.5 5 87.5 85.5 87.5 85.5 87.5 85.5 85.5 82.5 7.5 88.5 86.5 89.5 87.5 89.5 87.5 85.5 82.5 10 89.5 87.5 89.5 87.5 89.5 87.5 88.5 86.5 15 90.2 88.5 91 89.5 90.2 88.5 88.5 86.5 20 90.2 88.5 91 89.5 90.2 88.5 89.5 87.5 25 91 89.5 92.4 91 91.7 90.2 89.5 87.5 30 91 89.5 92.4 91 91.7 90.2 91 89.5 40 91.7 90.2 93 91.7 93 91.7 91 89.5 50 92.4 91 93 91.7 93 91.7 91.7 90.2 60 93 91.7 93.6 92.4 93.6 92.4 91.7 90.2 75 93 91.7 94.1 93 93.6 92.4 93 91.7 100 93.6 92.4 94.5 93.6 94.1 93 93 91.7 125 94.5 93.6 94.5 93.6 94.1 93 93.6 92.4 150 94.5 93.6 95 94.1 95 94.1 93.6 92.4 200 95 94.1 95 94.1 95 94.1 94.1 93 250 95.4 94.5 95 94.1 95 94.1 94.5 93.6 300 95.4 94.5 95.4 94s.5 95 94.1 350 95.4 94.5 95.4 94.5 95 94.1 400 95.4 94.5 95.4 94.5 450 95.4 94.5 95.4 94.5 500 95.4 94.5 95.8 95 City of Denton Hazen and Sawyer BID SET 15170-9 Low Voltage Electric Motors TABLE 12-12 FULL-LOAD EFFICIENCIES FOR NEMA PREMIUM™ EFFICIENCY ELECTRIC MOTORS RATED 600 VOLTS OR LESS (RANDOM WOUND) OPEN MOTORS HP 2 POLE 4 POLE 6 POLE Nominal Efficiency Minimum Efficiency Nominal Efficiency Minimum Efficiency Nominal Efficiency Minimum Efficiency 1 77 74 85.5 82.5 82.5 80 1.5 84 81.5 86.5 84 86.5 81.5 2 85.5 82.5 86.5 84 87.5 81.5 3 85.5 82.5 89.5 84 88.5 86.5 5 86.5 84 89.5 84 89.5 87.5 7.5 88.5 86.5 91 89.5 90.2 88.5 10 89.5 87.5 91.7 90.2 91.7 90.2 15 90.2 88.5 93 91.7 91.7 90.2 20 91 89.5 93 91.7 92.4 91 25 91.7 90.2 93.6 92.4 93 91.7 30 91.7 90.2 94.1 93 93.6 92.4 40 92.4 91 94.1 93 94.1 93 50 93 91.7 94.5 93.6 94.1 93 60 93.6 92.4 95 94.1 94.5 93.6 75 93.6 92.4 95 94.1 94.5 93.6 100 93.6 92.4 95.4 94.5 95 94.1 125 94.1 93 95.4 94.5 95 94.1 150 94.1 93 95.8 95 95.4 94.5 200 95 94.1 95.8 95 95.4 94.5 250 95 94.1 95.8 95 95.4 94.5 300 95.4 94.5 95.8 95 95.4 94.5 350 95.4 94.5 95.8 95 95.4 94.5 400 95.8 95 95.8 95 95.8 95 450 95.8 95 96.2 95.4 96.2 95.4 500 95.8 95 96.2 95.4 96.2 95.4 NOTES: (1) Motor data for continuous duty, NEMA Design B, 1.15 service factor, 40 degrees Celsius ambient, Class F insulation, 3 phase, 460 volt, at listed speed rating. (2) TEFC efficiencies apply to both horizontal and vertical motors. 2. Motors rated 50 horsepower or greater shall be individually tested at the factory before shipment, with a copy of test results provided for the Engineer, to assure compliance with the efficiency and power factor specifications. City of Denton Hazen and Sawyer BID SET 15170-10 Low Voltage Electric Motors I. Power Factor Correction 1. The power factor shall be corrected as necessary to achieve 85% (minimum) with capacitors sized and installed per manufacturer's recommendations. Capacitors shall be installed such that the motor shall not be damaged by overvoltage or excessive transient electrical torque. The capacitor(s) shall be connected as close as possible or directly to the motor terminals. Any power factor corrections shall not decrease the motor efficiency below the stated minimum requirement of this Specification. All power factor corrections shall be noted on the Shop Drawings submitted to the Engineer for approval. POWER FACTOR CORRECTION, TO ACHIEVE 85%, SHALL BE PROVIDED ON ALL MOTORS ABOVE 15 HORSEPOWER EXCEPT FOR THOSE MOTORS CONTROLLED BY VARIABLE FREQUENCY DRIVES (VFD'S). 2. When required, power factor correction capacitors shall be connected on the line side of any type of reduced voltage starting motor controller (e.g. RVAT, RVSS, Part- Winding, Wye-Delta, etc.). 2.03 TOOLS, SUPPLIES AND SPARE PARTS A. Each motor shall be furnished with all special tools necessary to disassemble, service, repair, and adjust the equipment. All spare parts as recommended by the equipment manufacturer shall be furnished to the Owner by the Contractor. PART 3 -- EXECUTION 3.01 INSTALLATION A. Motors shall be installed as shown on the Drawings and in accordance with the manufacturer's installation instructions. 3.02 DELIVERY, STORAGE, AND HANDLING A. Motors shall be properly protected from weather hazards. Motors shall not be allowed to be wrapped tightly in plastic while outdoors. Motors delivered to the site which will not be put in service for a time in excess of 30 calendar days, whether in storage or installed, shall have the shafts rotated a minimum of five (5) rotations every 30 days. B. Motors provided with space heaters shall have temporary power applied to the heaters no later than 30 calendar days after delivery to the site until permanent power can be applied to the heaters. C. Motors that, in the opinion of the Engineer, have not been properly protected shall be inspected by the manufacturer's representative. Any required electrical corrections for testing shall be made at the Contractor's expense prior to acceptance and/or use. D. All motors shall operate without any undue noise or vibration and shall show no signs of phase unbalance. City of Denton Hazen and Sawyer BID SET 15170-11 Low Voltage Electric Motors 3.03 TESTING A. All tests shall be performed in accordance with the requirements of the General Conditions and Division 1. The following tests are required: 1. Witnessed Shop Tests a. All motors shall be shop tested and inspected in accordance with the equipment manufacturer's standard procedures. Shop tests for motors 100 horsepower and larger may be witnessed by the Engineer. The manufacturer's testing and inspection procedures shall demonstrate that the equipment tested conforms to the requirements specified, all other applicable requirements, and shall be approved by the Engineer. At least 10 days notice shall be given the Engineer prior to tests and inspection dates. b. In addition to the efficiency and power factor testing specified herein, each motor shall be tested to determine compliance with the applicable requirements of the IEEE, ANSI and NEMA. Tests shall be as follows: (1) Motors less than 50 HP (a) Each motor shall be subjected to a standard, short commercial test including the following: i) Running current, no load ii) Locked rotor current iii) High potential iv) Winding resistance v) Bearing inspection (2) Motors between 50 and 100 HP (a) Each motor shall be subjected to the above tests and shall be furnished with certified test results. (3) Motors larger than 100 HP (a) Each motor shall be furnished with certified test results. Each motor shall be subjected to a complete test consisting of full load heat run, percent slip, running load current, locked rotor current, breakdown torque (calculated), starting torque, winding resistance, high potential, secondary current and voltage at collector rings (wound rotor), efficiencies at 100, 75 and 50 percent of full load, power factors at 100, 75 and 50 percent of full load and bearing inspection. Tests will be witnessed by the Engineer where specifically indicated. City of Denton Hazen and Sawyer BID SET 15170-12 Low Voltage Electric Motors (4) Test Reports (a) All test results for motors over 100 horsepower shall be submitted to the Engineer for approval. Copies of witnessed test raw data shall be submitted to the Engineer immediately upon completion of such tests. 2. Field Tests a. Field tests shall be performed in accordance with the requirements specified in the General Conditions, Division 1, and Section 16000, Basic Electrical Requirements. b. All electric motors furnished for this project one (1) horsepower or larger shall have the information required in the following tabulation completed. See Exhibit "A" on following page. c. All field testing shall be witnessed by the Engineer. City of Denton Hazen and Sawyer BID SET 15170-13 Low Voltage Electric Motors (EXHIBIT A) MOTOR TEST RECORD Motor Identification Remarks Location Specified Horsepower Nameplate Horsepower Nameplate Amperage (FLA) Measured Amperage Under Normal Operating Conditions City of Denton Hazen and Sawyer BID SET 15170-14 Low Voltage Electric Motors - END OF SECTION - City of Denton Hazen and Sawyer BID SET 15390-1 Schedules SECTION 15390 SCHEDULES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. Reference Section 15000, Basic Mechanical Requirements. 1.02 PIPING SYSTEM SCHEDULES A. Piping requirements for this Section are outlined on the Drawings, and in the Piping System Schedule. In the absence of a specified test pressure, pipe shall be tested at a pressure 50 percent greater than the normal operating pressure as determined by the Engineer or 10 psig, whichever is greater unless the Schedule indicates that no test is required. B. If the pipe material is not shown on the Piping System Schedule or otherwise specified, the following materials shall be used: Pipe Size Material Type of Joint Class/Design Test Pressure 4-in and larger DIP Flanged (Exposed) Class 53 (1) Restrained (Buried) Pressure Class 350 Less than 4-in PVC Socket Sch 80 (1) (1) Test at 150 percent of normal operating pressure or 10 psi, whichever is greater. C. Non-critical gravity lines such as drains, floor drains, roof drains, etc., do not typically require a pressure test D. All piping indicated by this specification to be restrained shall be restrained at all joints unless indicated otherwise in the Piping Restraint Schedule. This schedule identifies piping where restrained joints shall be provided only at buried reducers, bends, tees, dead ends (plug, cap or blind flange) and in-line valves. The schedule shows the minimum length of pipe to be restrained on either side of these fittings. All joints falling within the specified distance shall be restrained. Location of restrained joints shall be verified by the piping supplier in the laying schedule. 1.03 VALVE SCHEDULES A. Performance Affidavits shall be required for all valves listed in the valve schedule(s). Performance Affidavits shall be provided in accordance with Section 11000, Equipment City of Denton Hazen and Sawyer BID SET 15390-2 Schedules General Provisions and Section 01300, Submittals. All valves shall be tagged by the manufacturer according to the control valve designations listed in the Schedule. B. Valves not listed in the valve schedule(s) shall be manually operated, unless otherwise shown on the Drawings. City of Denton Hazen and Sawyer BID SET 15390-3 Schedules PIPING SYSTEM SCHEDULE PIPING SYSTEM SCHEDULE PIPE DESIGNATION MATERIAL TYPE OF JOINT CLASS/DESIGN RESTRAINT SYSTEM DESIGN (1) PRESSURE TEST PRESSURE INTERIOR COATING FA FRP BUTT WELD JOINT, FLANGED SEE SECTION 15892, FRP DUCT SYSTEMS SEE SECTION 15892, FRP DUCT SYSTEMS SEE SECTION 15892, FRP DUCT SYSTEMS NA RS DIP (EXPOSED) FLANGED (2) PRESSURE CLASS 150, CLASS 53 250 PSI 100 PSI CERAMIC EPOXY GROOVED MECHANICAL COUPLING (2) BLACK STEEL SEE 15012 SOLIDS EPOXY LINING DIP (3) (BURIED) RESTRAINED MECHANICAL JOINT PRESSURE CLASS 150, CLASS 53 CERAMIC EPOXY PVC (BURIED) RESTRAINED BELL & SPIGOT, RESTRAINED MECHANICAL JOINT C905, CLASS 165, DR 25 NA FRP SOCKET SEE SECTION 15017 SEE SECTION 15017 SEE SECTION 15017 NA PD PVC SOCKET, RESTRAINED MECHANICAL JOINT C900, CLASS 150, DR 18 100 PSI 50 PSI NA DIP FLANGED PRESSURE CLASS 150, CLASS 53 CEMENT MORTAR LINED NPW DIP (EXPOSED) FLANGED, MECHANICAL COUPLING JOINT PRESSURE CLASS 150, CLASS 53 250 PSI 150 PSI CEMENT MORTAR LINED PVC (BURIED) SOCKET, RETRAINED MECHANICAL JOINT C900, CLASS 150, DR 18 NA PW DIP (EXPOSED) FLANGED PRESSURE CLASS 150, CLASS 53 250 PSI 150 PSI CEMENT MORTAR LINED PVC (BURIED) SOCKET C900, CLASS 150, DR 18 NA (1) DESIGN PRESSURE SHALL BE USED TO DETERMINE THE SIZE, NUMBER, MATERIAL AND DIMENSIONS OF TABS AND THREADED-RODS FOR PIPING SPECIFIED OR SHOWN TO HAVE THREADED-RODS FOR THRUST RESTRAINT. (2) CONTRACTOR SHALL SUPPLY EITHER FLANGED DUCTILE IRON PIPE OR GROOVED MECHANICAL COUPLING STEEL PIPING. (3) BURIED DUCTILE IRON PIPE SHALL BE POLYETHYLENE ENCASED. CONCRETE ENCASED DUCTILE IRON PIPE SHALL NOT BE POLYETHYLENE ENCASED. SEE DUCTILE IRON PIPE SPECIFICATION. PIPING SYSTEM DESIGNATIONS City of Denton Hazen and Sawyer BID SET 15390-4 Schedules PD PROCESS DRAIN PW POTABLE WATER RS RAW SEWAGE NPW NON POTABLE WATER FA FOUL AIR City of Denton Hazen and Sawyer BID SET 15390-5 Schedules ELECTRICALLY OPERATED VALVE SCHEDULE TAG NO. VALVE TYPE OPERATOR TYPE SIZE (in) FLOW MAX DIFFERENTIAL PRESSURE (psi) CLASS SERVICE LOCATION 2201 SLEEVE PINCH MODULATING 12 0-5 MGD 30 150 PD TANK DRAIN VALVE VAULT 2202 PLUG OPEN/CLOSE 12 3500 GPM 30 150 PD TANK DRAIN VALVE VAULT 3210 PLUG OPEN/CLOSE 36 21,000 GPM 30 150 RS PECAN CREEK WRP FORCE MAIN YARD VALVE (1) PULSE CONTROL – SEE SPECIFICATIONS 15100 AND 17950 (2) PROVIDE REMOTE CONTROL STATION AS SPECIFED IN SECTION 15100 - END OF SECTION - City of Denton Hazen and Sawyer BID SET 15892-1 FRP Duct Systems SECTION 15892 FRP DUCT SYSTEMS PART 1 – GENERAL 1.01 THE REQUIREMENT A. The CONTRACTOR shall furnish and install fiberglass reinforced plastic (FRP) duct, fittings, dampers and all appurtenances, complete and in place, all in accordance with the requirements of the Contract Documents. 1.02 REFERENCED SPECIFICATIONS, CODES, AND STANDARDS A. Codes: All codes, as referenced herein, are specified in Section 01090, Reference Standards. B. Commercial Standards 1. ASTM D 2996 2. ASTM D 3567 3. ASTM D 3982 4. NBS PS 15-69 Specification for Filament-Wound “Fiberglass” (Glass-Fiber-Reinforced-Thermosetting-Resin) Pipe. Practice for Determining Dimensions of “Fiberglass” (Glass-Fiber Reinforced-Thermosetting-Resin) Pipe and Fittings. Contact Molded “Fiberglass” (Glass Fiber Reinforced Thermosetting Resin) Duct and Hoods Custom Contact-Molded Reinforced Polyester Chemical-Resistant Process Equipment 1.03 SUBMITTALS A. Shop Drawings 1. The CONTRACTOR shall submit Shop Drawings of FRP piping systems, including duct, fittings and dampers, in accordance with the requirements in Section 15000, Piping General, and Section 01300, Submittals. a. Dimensioned duct layout showing locations of supports, hangers, anchors, guides and expansion joints, sealed by a Professional Engineer. b. Joint fabrication details. c. Shop testing procedure. d. Detailed shipping and installation instructions. e. Visual inspection checklist. City of Denton Hazen and Sawyer BID SET 15892-2 FRP Duct Systems f. Recommended bolting torque values for flanged joints. g. Details for duct supports. h. Dampers: Submit manufacturer's product data (materials, construction, dimensions, and installation details), including leakage, pressure drop, and maximum pressure data in accordance with AMCA 500 testing. Submit data for full range of damper sizes provided. PART 2 – PRODUCTS 2.01 GENERAL A. Manufacturer: Provide FRP duct as manufactured by one of the following: 1. Augusta Fiberglass 2. Ershigs/Belco 3. Southeastern Fiberglass 4. Industrial Plastic Systems 5. Perry Fiberglass 6. Daniel Company 7. Engineered Composite Systems 8. Ameron International 9. L.F. Manufacturing 10. R.L. Industries Both the Manufacturer and the installer shall demonstrate experience on at least 5 projects requiring similar fabrication and installation methods. B. Service Conditions 1. The FRP piping system shall be designed and fabricated for odor control service to carry warm moisture-laden air with hydrogen sulfide, mercaptans and other organic and inorganic compounds typically associated with wastewater treatment. City of Denton Hazen and Sawyer BID SET 15892-3 FRP Duct Systems 2. The maximum unsupported spans shall be as follows. Maximum hoop deflection at unsupported span lengths shall be 1% of the duct nominal diameter, including all service loads. Duct Inside Diameter (Inches) Maximum Span (Feet) 3 – 14 10 16 – 42 20 3. Duct wall thickness shall be designed by the Manufacturer to meet the criteria specified in this Section. The minimum wall thickness for all FRP duct shall be the greater of the calculated thickness or the following: Duct Inside Diameter (Inches) Wall Thickness (Inches) 3 – 16 0.1875 18 – 36 0.250 42 – 60 0.300 72 – 96 0.375 4. Resin: a. Resin shall be premium corrosion resistant and fire retardant brominated bisphenol-A vinyl ester. Resin shall not contain pigments, dyes or colorants. Fillers are only permitted for flame retardance and shall not exceed 3% by weight. The product shall have a Class 1 flame spread rating (25 or less). The ENGINEER reserves the right to request the CONTRACTOR to submit laminate samples taken from the job site for confirmation that the specified resin was used throughout the laminate. b. Thixotropic agents can be added to control resin viscosity per resin manufacturer’s recommendation. c. Acceptable resins with no more than 3 percent antimony trioxide shall be: i. Reichhold Dion 9300 FR. ii. Interplastics CoRezyn 8440. iii. Ashland Chemical Hetron FR992. iv. AOC Vipel K-022 5. Reinforcement: a. Surfacing veil shall be C glass veil with a silane finish and a styrene soluble binder. b. Chopped strand mat shall be Type E glass minimum 1-1/2 ounces per square foot with silane finish and styrene soluble binder. City of Denton Hazen and Sawyer BID SET 15892-4 FRP Duct Systems c. Continuous roving for chopper gun spray up shall be Type E glass. Chopper gun is only permitted if an automated process is used. Manual operation of chopper gun shall not be permitted. d. Woven roving shall be Type E glass minimum 24 ounces per square yard with a five by four weave. e. Continuous roving for filament winding shall be Type E glass with a silane finish. C. Construction 1. All FRP ductwork shall be of filament wound or hand lay-up construction. 2. Maximum allowable deflection for any size ductwork shall be ½ inch between supports for any size of duct under worst case design conditions. 3. FRP ductwork shall be designed using a safety factor of 10 to 1 for pressure and 5 to 1 for vacuum. FRP ductwork shall be designed for a maximum vacuum pressure of 20” w.c. and a maximum positive pressure of 10” w.c. 4. Out of roundness of duct shall be limited to ± ¼ inch for duct sizes greater than 30 inches in diameter. 5. Length of all flanged duct sections shall not vary more than ± ½ inch at 70°F. 6. All unflanged duct shall be square on the ends in relation to the center axis within ± 1/8 inch up to and including 24-inch diameter and within ± 3/16 inch for all diameters greater than 24 inches. 7. Laminates a. All ductwork shall have a resin-rich inner surface, an interior corrosion barrier, an interior structural layer and an exterior layer. b. Inner surface: Minimum 20 mils thick composed of a single ply of the Type C glass surfacing veil embedded in a resin rich surface. Resin content shall be 90%. c. Interior layer: Minimum of at least two layers of 1 ½ oz per square foot chopped strand mat. Resin content shall be 75%. The combined thickness of the inner surface and interior layer shall be a minimum of 100 mils thick. d. Structural layer: Type E glass to meet minimum wall thickness as specified. The total wall thickness includes the inner surface and inner layer. The total wall thickness does not include the exterior layer. i. Contact molded structural layer shall include alternate layers of chopped strand mat and woven roving. City of Denton Hazen and Sawyer BID SET 15892-5 FRP Duct Systems ii. Filament wound structural layer shall be preceded by a layer of chopped strand mat or spray chop. The structural layer shall consist of a minimum of three complete cross hatched layers of continuous filaments applied in a helix angle per ASTM D3299. e. Exterior layer: Factory applied paraffinated gel coat with UV inhibitors. Pigmentation shall be determined by the ENGINEER. Pigmentation shall not be added to the exterior layer until visual inspection is completed. f. The duct shall have a Barcol hardness of at least 90 percent of the resin manufacturer’s minimum specified hardness for the cured resin when tested in accordance with ASTM D2583. 8. Fittings: a. All fittings shall be hand-lay up construction fabricated from the same resin and having the same strength as the FRP ductwork. b. The internal diameter of all fittings shall be equal to the adjacent duct. c. The tolerance on angles of all fittings shall be ± 1° up to and including 24 inch diameter and ± ½° for 30 inch diameter and above. 9. Elbows: a. The centerline radius of all elbows shall be 1-1/2 times the diameter. b. Elbows 24-inch diameter and small shall be smooth radius. Elbows 30 inches and larger shall be mitered. Provide a minimum of two mitered joints for all elbows.up to and including 45 degrees and four mitered joints for elbows up to and including 90 degrees. 10. Flanges: a. Provide flanged connections to flexible connectors, expansion joints, vessels, demisters, fans, silencers and other locations as shown on the Drawings. b. Flanges shall be hand lay-up construction, fabricated from the same resin and having the same ratings as the FRP ductwork. Dimensions shall be in accordance with NBS PS 15-69. c. Flanges shall be drilled in accordance with NBS PS 15-69 Table 2. Flange faces shall be suitable for use with full face gaskets. Backs of bolt holes shall be spot faced for a standard diameter washer. d. Flange faces shall be perpendicular to the axis of the duct within ½ inch. e. Flange faces shall be flat to within ± 1/32 inch up to and including 18 inch diameter ducts and flat within ± 1/16 inch for 20 inch diameter ducts and larger. City of Denton Hazen and Sawyer BID SET 15892-6 FRP Duct Systems f. Gaskets shall be EPDM, full face and minimum 1/8 inch thickness. g. Provide all Type 316 stainless steel bolts, nuts and washers. 11. Joints: a. Provide all butt and strap joints in accordance with NBS PS 15-69. b. Field weld kits shall be supplied by the duct manufacturer. All necessary fiberglass and reinforcing material shall be supplied pre-cut and individually packaged for each joint. c. All resin, catalyst and putty shall be supplied in bulk to complete all field joints plus 25% extra for waste. 12. There shall be not less than a ¼ inch buildup of FRP over the duct at each duct support. 2.02 EXPANSION JOINTS A. Provide expansion joints where shown on the Drawings and as required to avoid damage to the duct or equipment. B. Type: single arch configuration suitable for service with FRP duct under the conditions specified. C. Material: EPDM. D. Thickness: 0.20 inch, minimum. E. Flanged with 150 lb. ASA Drilling and ductile iron back up rings F. Expansion joints shall be Series 450 by Mercer Rubber, Style 1101 by General Rubber or equal. 2.03 BUTTERFLY DAMPERS A. Round Fiberglass Reinforced Plastic Dampers 1. All round FRP dampers shall be the butterfly type. FRP fabrication shall meet the corrosion requirements specified in this Section for FRP ductwork. 2. Leakage: A. Bubble Tight Dampers: Leakage shall not exceed 0 CFM/ SQ. FT at 30 inches w.g. B. Isolation Dampers: Leakage shall not exceed 5.25 CFM/ SQ. FT at 30 inches w.g. City of Denton Hazen and Sawyer BID SET 15892-7 FRP Duct Systems C. Control Dampers: Leakage shall not exceed 1% of total airflow at 30 inches w.g. 3. Fabrication: a. Frame and Blade: Premium vinyl ester resin with minimum 100 mils corrosion barrier. b. Shaft: Premium vinyl ester for all manually actuated dampers below 30 inches in diameter and Type 316 stainless steel for all dampers 30 inches in diameter and larger. c. Bearings and Bushings: Teflon. d. Pins and all Hardware: Type 316 stainless steel. e. Shaft seals: EPDM. f. Provide all round dampers with a blade stop consisting of FRP angles with full circumference EPDM seals, mechanically fastened to blade (seal not required for control dampers). g. All dampers shall have flanged ends. Flanges per ductwork specification. Provide Type 316 stainless steel bolts, nuts and washers. h. Manual dampers shall be provided with hand quadrant actuators fabricated of Type 316 stainless steel. i. Dampers with centerline of operator located more than 6-feet above the floor or platform from which it is to be operated shall have a chainwheel operator unless otherwise indicated on the Drawings. j. AMCA License: Bubble tight and isolation dampers shall be AMCA licensed. k. FRP dampers shall be manufactured by Swartwout, Division of Phillips Industries, Belco Manufacturing or equal as follows: 1) Bubble Tight: Belco Model 204 or equal. 2) Isolation: Belco Model 203, Swartout Model 914 or equal 3) Control: Belco Model 201, Swartout Model 912 or equal 2.04 DUCT HANGERS AND SUPPORTS A. All duct supports, interior and exterior, shall meet the requirements of Section 15020, Pipe Supports, except that hangers and supports for FRP duct shall as specified in paragraph 2.01 B-2 of this Section. Duct spans shall not exceed the duct manufacturer’s recommendations. City of Denton Hazen and Sawyer BID SET 15892-8 FRP Duct Systems B. Duct supports located on the exterior of the building shall be designed to include the weight of the duct and to withstand all applicable combinations of wind loading in accordance with the Minimum Standard Building Code, latest edition, of the state in which the project is located, as well as any additional local regulations which are in effect at the time of construction. Exterior supports shall be located as shown on the Drawings and shall be of the “type” shown on the Drawings. The locations of duct supports shown on the Drawings are approximate, and the CONTRACTOR shall be required to confirm the support requirements and locations. C. The CONTRACTOR shall note that not all duct support locations are shown on the Drawings, and the CONTRACTOR shall follow the Specifications herein in locating additional supports as required. The CONTRACTOR shall be responsible for the design of additional supports and for the overall stability of the entire support system. Support and hanger details and a detailed layout showing the location of all duct supports and hangers shall be submitted in the Shop Drawings and stamped by a registered Professional Engineer (Structural). D. There shall not be less than ¼ inch buildup of FRP over the duct at each saddle support. E. Duct supports are to be fabricated from the materials shown on the drawings. All fasteners and anchors are to be 316 SST. PART 3 – EXECUTION A. INSTALLATION 1. General: All FRP duct shall be installed in a neat and workmanlike manner, properly aligned, and cut from measurements taken at the site to avoid interferences with structural members, architectural features, openings and equipment. Exposed pipes shall afford maximum headroom and access to equipment, and where necessary, all piping shall be installed with sufficient slopes (minimum 1/8” per foot) for venting or drainage of liquids and condensate to low points. All installations shall be acceptable to the ENGINEER. It is recommended that the CONTRACTOR obtain the assistance of the duct manufacturer’s field representative to instruct the duct fitters in the correct installation and support of all FRP duct. The CONTRACTOR shall obtain training by the duct manufacturer’s field representative in the correct installation and support of all FRP duct. Instruction shall be a minimum of one eight (8) hour day. 2. Supports and Anchors: All piping shall be firmly supported with fabricated or commercial hangers or supports in accordance with the requirements in Section 15020, Pipe Supports. Where necessary to avoid stress on equipment or structural members, the pipes shall be anchored or harnessed. Expansion joints and guides shall compensate for pipe expansion due to temperature differences. B. DUCT PREPARATION 1. Prior to installation, each duct length shall be carefully inspected, flushed clean of any debris or dust, and straightened, if not true. All pipe fittings shall be equally cleaned before assembly. City of Denton Hazen and Sawyer BID SET 15892-9 FRP Duct Systems C. DUCT JOINTS 1. Adhesive Joints: Adhesive joints shall be made with freshly mixed 2-part epoxy on clean dry duct ends. The joints shall be made up at the recommended ambient temperatures, to the duct manufacturer’s written recommendations. All duct ends shall be inserted to the full depth of the socket. 2. Flanged Joints: Flanged joints shall be made up in accordance with Section 15000, Basic Mechanical Requirements. D. INSPECTION AND FIELD TESTING 1. Inspection: All finished installations shall be carefully inspected for proper joints and sufficient supports, anchoring, interference, and damage to duct, fittings, and coating. Damage and leaks shall be repaired to the satisfaction of the ENGINEER. 2. All ductwork shall be leak tested in accordance with SMACNA Air Duct Leakage Test Manual. Duct system shall be sealed to provide a system that is within an allowable leakage limit of 2.5 percent of total air flow at system operating flow and pressure. The ductwork test report shall be submitted to the Engineer. 3. If the system is testing in sections, the leakage rates shall be added to define the performance of the whole system. 4. Check out and certification of the installation, supervision of initial operation, and training related to the FRP butterfly dampers shall be performed in accordance with Section 15095, Valves, General, and 15100, Valve Operators and Electric Valve Actuators, and other applicable Sections of these Specifications. 5. Ductwork system shall be tested, adjusted and balanced (TAB) to provide airflow rates as shown on the Drawings from each individual take-off point. Tolerance is +/- 5%. Testing, Adjusting and Balancing shall be in accordance with the SMACNA HVAC Systems Testing, Adjusting, and Balancing Manual. Submit testing, adjusting, and balancing reports bearing the seal and signature of the Test and Balance Engineer. Mark equipment settings, including damper control positions, valve indicators, fan speed control levers, and similar controls and devices, to show final settings. Mark with paint or other suitable, permanent identification materials. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 15892-10 FRP Duct Systems This page left blank intentionally City of Denton Hazen and Sawyer BID SET 16000-1 Basic Electrical Requirements SECTION 16000 BASIC ELECTRICAL REQUIREMENTS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish all labor, materials, tools, and equipment, and perform all work and services necessary for, or incidental, to the furnishing and installation of all electrical work as shown on the Drawings, and as specified in accordance with the provisions of the Contract Documents and completely coordinate with the work of other trades involved in the general construction. Although such work is not specifically shown or specified, all supplementary or miscellaneous items, appurtenances, and devices incidental to or necessary for a sound, secure, and complete installation shall be furnished and installed as part of this work. The Contractor shall obtain approved Shop Drawings showing wiring diagrams, connection diagrams, roughing-in and hook up details for all equipment and comply therewith. All electrical work shall be complete and left in operating condition in accordance with the intent of the Drawings and the Specifications for the electrical work. B. Reference Section 17000, Control and Information System Scope and General Requirements for scope of work details as they relate to the Division 17 Subcontractor. C. The electrical scope of work for this project primarily includes, but is not limited to, the following: 1. Coordination with the Utility (Denton Municipal Electric) to furnish and install new utility service for two new pump stations. 2. Furnish and installation of new medium voltage liquid-filled, pad-mount style utility transformers. 3. Furnish and installation of new service entrance fused disconnect switches, standby generator connection boxes, and manual transfer switches. 4. Furnish and installation of low voltage motor control equipment including reduced voltage motor starters. 5. Furnish and installation of power panelboards, lighting panelboards, dry-type transformers, and other low voltage electrical power distribution equipment. 6. Furnish and installation of all aboveground raceway systems including conduit, fittings, boxes, supports, and other pertinent components. 7. Furnish and installation of all underground raceway systems including conduit, fittings, manholes, handholes and other pertinent components. City of Denton Hazen and Sawyer BID SET 16000-2 Basic Electrical Requirements 8. Furnish and installation of all low and medium voltage wire and cable resulting in a complete and operable electrical system. 9. Furnish and installation of new lighting systems and wiring devices. 10. Other electrical work as specified herein and indicated on the Drawings. D. All material and equipment must be the product of an established, reputable, and approved manufacturer; must be new and of first class construction; must be designed and guaranteed to perform the service required; and must bear the label of approval of the Underwriters Laboratories, Inc., where such approval is available for the product of the listed manufacturer as approved by the Engineer. E. When a specified or indicated item has been superseded or is no longer available, the manufacturer's latest equivalent type or model of material or equipment as approved by the Engineer shall be furnished and installed at no additional cost to the Owner. F. Where the Contractor's selection of equipment of specified manufacturers or additionally approved manufacturers requires changes or additions to the system design, the Contractor shall be responsible in all respects for the modifications to all system designs, subject to approval of the Engineer. The Contractor's bid shall include all costs for all work of the Contract for all trades made necessary by such changes, additions or modifications or resulting from any approved substitution. G. Furnish and install all stands, racks, brackets, supports, and similar equipment required to properly serve the equipment which is furnished under this Contract, or equipment otherwise specified or indicated on the Drawings. H. All electrical components and systems, including electrical equipment foundations, shall be designed to resist operational forces as well as lateral sway and axial motion from seismic and thermal forces. Seismic support design shall be in accordance with the building code. 1.02 EQUIPMENT LOCATION A. The Drawings show the general location of feeders, transformers, outlets, conduits, and circuit arrangements. Because of the small scale of the Drawings, it is not possible to indicate all of the details involved. The Contractor shall carefully investigate the structural and finish conditions affecting all of his work and shall arrange such work accordingly; furnishing such fittings, junction boxes, and accessories as may be required to meet such conditions. The Contractor shall refer to the entire Drawing set to verify openings, special surfaces, and location of other equipment, or other special equipment prior to roughing-in for panels, switches, and other outlets. The Contractor shall verify all equipment dimensions to ensure that proposed equipment will fit properly in spaces indicated. B. Where outlets are shown near identified equipment furnished by this or other Contractors, it is the intent of the Specifications and Drawings that the outlet be located at the equipment to be served. The Contractor shall coordinate the location of these outlets to be near the final location of the equipment served whether placed correctly or incorrectly on the Drawings. 1.03 LOCAL CONDITIONS A. The Contractor shall examine the site and become familiar with conditions affecting the work. The Contractor shall investigate, determine, and verify locations of any overhead or City of Denton Hazen and Sawyer BID SET 16000-3 Basic Electrical Requirements buried utilities on or near the site, and shall determine such locations in conjunction with all public and/or private utility companies and with all authorities having jurisdiction. All costs, both temporary and permanent to connect all utilities, shall be included in the Bid. The Contractor shall be responsible for scheduling and coordinating with the local utility for temporary and permanent services. B. The Contractor is responsible for coordinating all electric utility equipment installations with the serving electric utility. The Contractor shall furnish and install all electric utility equipment required by the electric utility to be installed by the Contractor whether specifically shown on the Drawings or not. The Contractor shall furnish and install the following electrical utility equipment as a minimum: 1. Concrete transformer pads constructed as instructed by the electric utility. 2. Primary and secondary ductbank and manholes 3. Metering equipment cabinets and/or bases 4. Conduit and wire required from metering cabinet to metering current transformers and potential transformers. 5. Secondary conductors 6. Secondary terminations The electric utility will furnish and install the following equipment: 1. Utility transformer 2. New utility service drop pole 3. Primary conductors and terminations 4. Overhead conductors and utility poles between existing overhead distribution and location of new utility service drop as required. The Contractor is responsible for ensuring all electric utility equipment and construction installed by the Contractor is furnished and installed in accordance with the electric utility’s design specifications and requirements. The Contractor is fully responsible for coordinating his scope of work with the electric utility. Any additional required electric utility construction or equipment not specified herein or shown on the Drawings shall be supplied by the Contractor at no additional cost to the Owner. The contact person at the serving electrical utility is: Donald L. McLaughlin Denton Municipal Electric 215 E. McKinney Street, Denton, TX 76201 940-349-7119 don.mclaughlin@cityofdenton.com City of Denton Hazen and Sawyer BID SET 16000-4 Basic Electrical Requirements 1.04 SUBMITTALS A. In accordance with the procedures and requirements set forth in the General Conditions, Section 01300, Submittals and the requirements of the individual specification sections, the Contractor shall obtain from the equipment manufacturer and submit the following: 1. Shop Drawings 2. Operation and Maintenance Manuals 3. Spare Parts List 4. Proposed Testing Methods and Reports of Certified Shop Tests. 5. Reports of Certified Field Tests. 6. Manufacturer’s Representative’s Certification. B. Submittals shall be sufficiently complete in detail to enable the Engineer to determine compliance with Contract requirements. C. Submittals will be approved only to the extent of the information shown. Approval of an item of equipment shall not be construed to mean approval for components of that item for which the Contractor has provided no information. D. Some individual Division 16 specification sections may require a Compliance, Deviations, and Exceptions (CD&E) letter to be submitted. If the CD&E letter is required and shop drawings are submitted without the letter, the submittal will be rejected. The letter shall include all comments, deviations and exceptions taken to the Drawings and Specifications by the Contractor AND Equipment Manufacturer/Supplier. This letter shall include a copy of this specification section. In the left margin beside each and every paragraph/item, a letter "C", "D", or "E" shall be typed or written in. The letter "C" shall be for full compliance with the requirement. The letter "D" shall be for a deviation from the requirement. The letter "E" shall be for taking exception to a requirement. Any requirements with the letter "D" or "E" beside them shall be provided with a full typewritten explanation of the deviation/exception. Handwritten explanation of the deviations/exceptions is not acceptable. The CD&E letter shall also address deviations, and exceptions taken to each Drawing related to this Specification Section. E. Seismic support design for all nonstructural electrical components (conduit, raceways, freestanding equipment, etc.) shall be in accordance with all applicable federal, state and local building code requirements and the Structural Drawings. City of Denton Hazen and Sawyer BID SET 16000-5 Basic Electrical Requirements 1.05 APPLICABLE CODES AND REQUIREMENTS A. Conformance 1. All work, equipment and materials furnished shall conform with the existing rules, requirements and specifications of the following: a. Insurance Rating Organization having jurisdiction b. The serving electrical utility company c. The currently adopted edition of the National Electrical Code (NEC) d. The National Electric Manufacturers Association (NEMA) e. The Institute of Electrical and Electronic Engineers (IEEE) f. The Insulated Cable Engineers Association (ICEA) g. The American Society of Testing Materials (ASTM) h. The American National Standards Institute (ANSI) i. The requirements of the Occupational Safety Hazards Act (OSHA) j. The National Electrical Contractors Association (NECA) Standard of Installation k. National Fire Protection Association (NFPA) l. International Electrical Testing Association (NETA) m. All other applicable Federal, State and local laws and/or ordinances. 2. All material and equipment shall bear the inspection labels of Underwriters Laboratories, Inc., if the material and equipment is of the class inspected by said laboratories. B. Nonconformance 1. Any paragraph of requirements in these Specifications, or Drawings, deviating from the rules, requirements and Specifications of the above organizations shall be invalid and their (the above organizations) requirements shall hold precedent thereto. The Contractor shall be held responsible for adherence to all rules, requirements and specifications as set forth above. Any additional work or material necessary for adherence will not be allowed as an extra, but shall be included in the Bid. Ignorance of any rule, requirement, or Specification shall not be allowed as an excuse for nonconformity. Acceptance by the Engineer does not relieve the Contractor from the expense involved for the correction of any errors which may exist in the drawings submitted or in the satisfactory operation of any equipment. C. Certification 1. Upon completion of the work, the Contractor shall obtain certificate(s) of inspection and approval from the National Board of Fire Underwriters or similar inspection City of Denton Hazen and Sawyer BID SET 16000-6 Basic Electrical Requirements organization having jurisdiction and shall deliver same to the Engineer and the Owner. 1.06 PERMITS AND INSPECTIONS A. The Contractor shall reference the General Conditions and Section 01010, Summary of Work. 1.07 TEMPORARY LIGHTING AND POWER A. The Contractor shall reference the General Conditions and Section 01510, Temporary Utilities. 1.08 TESTS A. Upon completion of the installation, the Contractor shall perform tests for operation, load (Phase) balance, overloads, and short circuits. Tests shall be made with and to the satisfaction of the Owner and Engineer. B. The Contractor shall perform all field tests and shall provide all labor, equipment, and incidentals required for testing and shall pay for electric power required for the tests. All defective material and workmanship disclosed shall be corrected by the Contractor at no cost to the Owner. The Contractor shall show by demonstration in service that all circuits and devices are in good operating condition. Test shall be such that each item of control equipment will function not less than five (5) times. C. Refer to each individual specification section for detailed test requirements. D. The Contractor shall complete the installation and field testing of the electrical installation at least two (2) weeks prior to the start-up and testing of all other equipment. During the period between the completion of electrical installation and the start-up and testing of all other equipment, the Contractor shall make all components of the Work available as it is completed for their use in performing Preliminary and Final Field Tests. E. Before each test commences, the Contractor shall submit a detailed test procedure, and also provide test engineer resume, manpower and scheduling information for the approval by the Engineer. In addition, the Contractor shall furnish detailed test procedures for any of his equipment required as part of the field tests of other systems. 1.09 INFRARED INSPECTION A. Just prior to the final acceptance of a piece of equipment, the Contractor shall perform an infrared inspection to locate and correct all heating problems associated with electrical equipment terminations. B. The infrared inspection shall apply to all new equipment under this Contract. All heating problems detected with new equipment furnished and installed under the Scope of this Contract shall be corrected by the Contractor. City of Denton Hazen and Sawyer BID SET 16000-7 Basic Electrical Requirements C. The infrared inspection report shall include both digital and IR pictures positioned side by side. Both the digital and IR pictures shall be clear and high quality. Fuzzy, grainy, or poorly illuminated pictures are not acceptable. The IR picture shall be provided with a temperature scale beside it, and an indication of the hot spot temperature in each picture. Reports shall be furnished in a 3-ring binder, with all pages printed in full color, with equipment assemblies separated by tabs. 1.10 PROTECTIVE DEVICE SETTING AND TESTING A. The Contractor shall provide the services of a field services organization to adjust, set, calibrate and test all protective devices in the electrical system. The organization shall be a subsidiary of or have a franchise service agreement with the electrical equipment manufacturer. The qualifications of the organization and resumes of the technicians as well as all data forms to be used for the field testing shall be submitted. B. All protective devices in the electrical equipment shall be set, adjusted, calibrated and tested in accordance with the manufacturers’ recommendations, the coordination study, and best industry practice. C. Proper operation of all equipment associated with the device under test and its compartment shall be verified, as well as complete resistance, continuity and polarity tests of power, protective and metering circuits. Any minor adjustments, repairs and/or lubrication necessary to achieve proper operation shall be considered part of this Contract. D. All solid state trip devices shall be checked and tested for setting and operation using manufacturers recommended test devices and procedures. E. Circuit breakers and/or contactors associated with the above devices shall be tested for trip and close functions with their protective device. F. When completed, the Contractor shall provide a comprehensive report for all equipment tested indicating condition, readings, faults and/or deficiencies in same. Inoperative or defective equipment shall be brought immediately to the attention of the Engineer. G. Prior to placing any equipment in service, correct operation of all protective devices associated with this equipment shall be demonstrated by field testing under simulated load conditions. 1.11 POWER SYSTEM STUDIES A. General 1. The Contractor shall provide Short Circuit Studies, Protective Device Evaluation Studies, Protective Device Coordination Studies, and Arc Flash Studies performed by a professional registered electrical engineer currently registered in the State of Texas for the entire electrical system. The studies shall be performed in accordance with 399-1990, IEEE Recommended Practice for Industrial and Commercial System Power Analysis (IEEE Brown Book). The studies shall be submitted to the Engineer prior to receiving final approval of the distribution equipment shop drawings and/or prior to release of equipment for manufacture. If formal completion of the studies may cause City of Denton Hazen and Sawyer BID SET 16000-8 Basic Electrical Requirements delay in equipment manufacture, approval from the Engineer may be obtained for a preliminary submittal of sufficient study data to insure that the selection of device ratings and characteristics will be satisfactory. 2. The studies shall include all portions of the electrical distribution system from the utility company protective devices, the normal and standby power sources down to and including the 480 volt feeder protective devices for each feeder. The study shall include all low voltage motor controls and panelboards. System connections and those which result in maximum fault conditions shall be adequately covered in the study. 3. In the event that the short circuit study requires a higher interrupting and/or withstand rating of equipment than that which is indicated in the Contract Documents, the Contractor shall furnish and install the equipment as required based on the study with no extra cost to the Owner. 4. In the event that the protective device coordination study indicates that different settings or equipment is required than that which is specified, the Contractor shall furnish and install the equipment based on the study with no extra cost to the Owner. B. Data Collection for the Studies 1. The Contractor shall provide the required data for preparation of the studies. The preparer of the studies shall furnish the Contractor with a listing of the required data immediately after award of the Contract. 2. The Contractor shall expedite collection of the data to assure completion of the studies as required for final approval of the distribution equipment shop drawings and/or prior to release of the equipment for manufacture. C. Short Circuit Study and Protective Device Evaluation Study 1. The short circuit study shall be performed with the aid of a digital computer program and shall be in accordance with the latest editions of IEEE Std. 399 and IEEE Std. 141. 2. The study input data shall include the utility company's short circuit contribution, resistance and reactance components of the branch impedances, the X/R ratios, base quantities selected, and other source impedances. 3. Short circuit close and latch duty values and interrupting duty values shall be calculated on the basis of assumed three-phase bolted short circuits at each bus, distribution panelboard, pertinent branch circuit panel and other significant locations through the system. The short circuit tabulations shall include symmetrical fault currents, and X/R ratios. For each fault location, the total duty on the bus, as well as the individual contribution from each connected branch, shall be listed with its respective X/R ratio. 4. A protective device evaluation study shall be performed to determine the adequacy of circuit breakers, molded case switches, transfer switches, and fuses by tabulating and comparing the short circuit ratings of these devices with the calculated fault City of Denton Hazen and Sawyer BID SET 16000-9 Basic Electrical Requirements currents. Appropriate multiplying factors based on system X/R ratios and protective device rating standards shall be applied. Any problem areas or inadequacies in the equipment due to short circuit currents shall be promptly brought to the attention of the Engineer. 5. All equipment furnished shall meet the requirements of this study, with no extra cost to the Owner. D. Protective Device Coordination Study 1. A protective device coordination study shall be performed to provide the necessary calculations and logic decisions required to select or to check the selection of power fuse ratings, protective relay characteristics and settings, ratios and characteristics of associated current transformers, and low voltage circuit breaker trip characteristics and settings. 2. The coordination study shall include all low voltage classes of equipment from the utility company service protective devices down to and including the main circuit breakers of distribution panelboards. The phase and ground overcurrent protection shall be included as well as settings of all other adjustable protective devices. 3. The time-current characteristics of the specified protective devices shall be drawn on log-log paper. The plots shall include complete titles, representative one-line diagram and legends, significant motor starting characteristics, complete parameters of transformers, complete operating bands of low voltage circuit breaker trip curves and fuses. The coordination plots shall indicate the types of protective devices selected, proposed relay taps, time dial and instantaneous trip settings, transformer magnetizing inrush and ANSI transformer withstand parameters, cable thermal overcurrent withstand limits and significant symmetrical and asymmetrical fault currents. All restrictions of the National Electrical Code shall be adhered to and proper coordination intervals and separation of characteristic curves shall be maintained. The coordination plots for phase and ground protective devices shall be provided on a system basis. A sufficient number of separate curves shall be used to clearly indicate the coordination achieved. 4. The selection and settings of the protective devices shall be provided separately in a tabulated form listing circuit identification, IEEE device number, current transformer ratios and connections, manufacturer and type, range of adjustment and recommended settings. Any discrepancies, problem areas, or inadequacies shall be promptly brought to the attention of the Engineer. E. Arc Flash Hazard Analysis 1. An Arc Flash Hazard Analysis shall be performed with the aid of a digital computer program in accordance with IEEE Std. 1584, “IEEE Guide For Performing Arc Flash Hazard Calculations”, NFPA 70E, and OSHA 29-CFR, Part 1910 Subpart S. 2. Arc Flash Warning Labels and Bus Detail Sheets shall be produced for each bus. Labels shall be printed in color on adhesive backed, UV resistant labels. Labels shall be attached to the doors of the equipment. Each label and detail sheet shall list the following: City of Denton Hazen and Sawyer BID SET 16000-10 Basic Electrical Requirements a. Bus name b. System operating voltage c. Date of issue d. Flash hazard protection boundary e. Limited approach boundary f. Restricted boundary g. Prohibited boundary h. Incident energy level i. Required personal protective equipment class In addition, each Bus Detail Sheet shall list the following: a. Upstream Protective Devices Names, Type and Settings 3. Arc Flash Evaluation Summary Sheets shall be produced. Summary sheets shall list the following: a. Bus name b. Upstream protective device name, type and settings c. Bus line-to-line voltage d. Bus bolted fault e. Protective device bolted fault current f. Arcing fault current g. Protective device trip / delay time h. Breaker opening time i. Solidly grounded column j. Equipment type k. Gap l. Arc flash boundary m. Working distance City of Denton Hazen and Sawyer BID SET 16000-11 Basic Electrical Requirements n. Incident energy o. Required personal protective equipment class 4. Analyze the short circuit, protective device coordination, and arc flash calculations and highlight any equipment that is determined to be underrated or causes an abnormally high incident energy calculation. Propose approaches to reduce the energy levels. Proposed major corrective modifications will be taken under advisement by the Engineer and the Contractor will be given further instructions. F. Study Report 1. The results of the power system studies shall be summarized in a report. The report shall be submitted to the Engineer. The report shall be submitted for review and acceptance prior to submittals for reduced voltage soft starter, panelboards, and similar electrical equipment. 2. The report shall include the following sections: a. Description, purpose, basis and scope of the study and a detailed single line diagram with "nodes" cross-referenced to the calculated values tabulated in the study report of that portion of the power system which is included within the scope of the study. b. Tabulations of circuit breaker, fuse and other protective device ratings versus calculated short circuit duties and commentary regarding same. c. Protective device time versus current coordination curves, tabulations of relay and circuit breaker trip settings, fuse selection, and commentary regarding same. d. Fault current calculations including a definition of terms and guide for interpretation of computer printout. 3. The study shall include a detailed explanation of all software programs and procedures used to arrive at the calculated values, settings, and drawings (e.g. single line diagrams) showing fault valves at all busses. 1.12 MATERIALS HANDLING A. Materials arriving on the job site shall be stored in such a manner as to keep material free of rust and dirt and so as to keep material properly aligned and true to shape. Rusty, dirty, or misaligned material will be rejected. Electrical conduit shall be stored to provide protection from the weather and accidental damage. Rigid non-metallic conduit shall be stored on even supports and in locations not subject to direct sun rays or excessive heat. Cables shall be sealed, stored, and handled carefully to avoid damage to the outer covering or insulation and damage from moisture and weather. Adequate protection shall be required at all times for electrical equipment and accessories until installed and accepted. Materials damaged during shipment, storage, installation, or testing shall be replaced or repaired in a manner City of Denton Hazen and Sawyer BID SET 16000-12 Basic Electrical Requirements meeting with the approval of the Engineer. If space heaters are provided in a piece of electrical equipment, they shall be temporarily connected to a power source during storage. The Contractor shall store equipment and materials in accordance with Section 01550, Site Access and Storage. 1.13 WARRANTIES A. Unless otherwise specified in an individual specification section, all equipment and electrical construction materials furnished and installed under Division 16 shall be provided with a warranty in accordance with the requirements of Section 11000, Equipment General Provisions and the General Conditions. 1.14 TRAINING A. Unless otherwise specified in an individual specification section, all training for equipment furnished and installed under Division 16 shall be provided in accordance with the requirements of Section 11000, Equipment General Provisions. PART 2 -- PRODUCTS 2.01 PRODUCT REQUIREMENTS A. Unless otherwise indicated, the materials to be provided under this Specification shall be the products of manufacturers regularly engaged in the production of all such items and shall be the manufacturer's latest design. The products shall conform to the applicable standards of UL and NEMA, unless specified otherwise. International Electrotechnical Commission (IEC) standards are not recognized. Equipment designed, manufactured, and labeled in compliance with IEC standards is not acceptable. B. All items of the same type or ratings shall be identical. This shall be further understood to include products with the accessories indicated. C. All equipment and materials shall be new, unless indicated or specified otherwise. D. The Contractor shall submit proof if requested by the Engineer that the materials, appliances, equipment, or devices that are provided under this Contract meet the requirements of Underwriters Laboratories, Inc., in regard to fire and casualty hazards. The label of or listing by the Underwriters Laboratories, Inc., will be accepted as conforming to this requirement. 2.02 SUBSTITUTIONS A. Unless specifically noted otherwise, any reference in the Specifications or on the Drawings to any article, service, product, material, fixture, or item of equipment by name, make, or catalog number shall be interpreted as establishing the type, function, and standard of quality and shall not be construed as limiting competition. The Contractor, in such cases may, at his option use any article, device, product, material, fixture, or item of equipment which in the judgment of the Engineer, expressed in writing, is equal to that specified. City of Denton Hazen and Sawyer BID SET 16000-13 Basic Electrical Requirements 2.03 CONCRETE A. The Contractor shall furnish all concrete required for the installation of all electrical work, Concrete shall be Class A unless otherwise specified. Concrete and reinforcing steel shall meet the appropriate requirements of Division 3 of the Specifications. B. The Contractor shall provide concrete foundations for all free standing electrical apparatus and equipment located outdoors or where floors or slabs do not exist and/or are not or provided by others under this Contract. The Contractor shall provide all necessary anchor bolts, channel iron sills, and other materials as required. The location and dimensions shall be coordinated for each piece of equipment well in advance of the scheduled placing of the foundations. Equipment foundations shall be constructed as detailed on the Drawings or if not detailed on the Drawings shall be 6 inches thick minimum reinforced with #4 bars at 12- inch centers each way placed mid-depth. Concrete shall extend 6 inches minimum beyond the extreme of the equipment base and be placed on a compacted stone bed (#57 stone or ABC) 6 inches thick minimum. PART 3 -- EXECUTION 3.01 CUTTING AND PATCHING A. Coordination 1. The Work shall be coordinated between all trades to avoid delays and unnecessary cutting, channeling and drilling. Sleeves shall be placed in concrete for passage of conduit wherever possible. B. Damage 1. The Contractor shall perform all chasing, channeling, drilling and patching necessary to the proper execution of his Contract. Any damage to the building, structure, or any equipment shall be repaired by qualified mechanics of the trades involved at the Contractor's expense. If, in the Engineer's judgment, the repair of damaged equipment would not be satisfactory, then the Contractor shall replace damaged equipment at his own expense. 3.02 EXCAVATION AND BACKFILLING A. The Contractor shall perform all excavation and backfill required for the installation of all electrical work. All excavation and backfilling shall be in complete accordance with the applicable requirements of Division 2. 3.03 CORROSION PROTECTION A. Wherever dissimilar metals, except conduit and conduit fittings, come into contact, the Contractor shall isolate these metals as required with neoprene washers, nine (9) mil polyethylene tape, or gaskets. City of Denton Hazen and Sawyer BID SET 16000-14 Basic Electrical Requirements - END OF SECTION - This page left blank intentionally. City of Denton Hazen and Sawyer BID SET 16111-1 Conduit SECTION 16111 CONDUIT PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish and install conduits and conduit fittings to complete the installation of all electrically operated equipment as specified herein, indicated on the Drawings, and as required. B. Requirements for conduit clamps, support systems, and anchoring are not included in this Section. Reference Section 16190, Electrical Supporting Devices, for these requirements. C. Reference Section 16000, Basic Electrical Requirements. 1.02 CODES AND STANDARDS A. Conduits and conduit fittings shall be designed, manufactured, and/or listed to the following standards as applicable: 1. American National Standards Institute (ANSI) a. ANSI B1.20.1 – Pipe Threads, General Purpose b. ANSI C80.1 – Electrical Rigid Steel Conduit c. ANSI C80.3 – Steel Electrical Metallic Tubing d. ANSI C80.5 – Electrical Rigid Aluminum Conduit e. ANSI FB 1 – Fittings, Cast Metal Boxes, and Conduit Bodies for Conduit, Electrical Metallic Tubing, and Cable 2. Underwriters Laboratories (UL) a. UL 1 – Standard for Flexible Metal Conduit b. UL 6 - Electrical Rigid Metal Conduit-Steel c. UL 6A – Electrical Rigid Metal Conduit-Aluminum, Red Brass, and Stainless Steel d. UL 360 – Standard for Liquid-tight Flexible Metal Conduit e. UL 467 – Grounding and Bonding Equipment f. UL 514B – Conduit, Tubing, and Cable Fittings g. UL 651 – Standard for Schedule 40 and 80 Conduit and Fittings h. UL 1203 - Standard for Explosion-proof and Dust-ignition-proof Electrical Equipment for use in Hazardous (Classified) Locations i. UL 1479 – Standard for Fire Tests of Penetration Fire Stops j. UL 1660 – Liquid-tight Flexible Nonmetallic Conduit City of Denton Hazen and Sawyer BID SET 16111-2 Conduit 3. National Electrical Manufacturer’s Association (NEMA) a. NEMA RN 1 – PVC Externally Coated Galvanized Rigid Steel Conduit b. NEMA TC-2 – Electrical PVC Conduit c. NEMA TC-3 – PVC Fittings for Use with Rigid PVC Conduit and Tubing 4. Others a. ACI-318 – Building Code Requirements for Structural Concrete 1.03 SUBMITTALS A. In accordance with the procedures and requirements set forth in the General Conditions and Section 01300 – Submittals, the Contractor shall obtain from the equipment manufacturer and submit the following: 1. Shop Drawings B. Each submittal shall be identified by the applicable specification section. 1.04 SHOP DRAWINGS A. Each submittal shall be complete in all respects, incorporating all information and data listed herein and all additional information required for evaluation of the proposed equipment's compliance with the Contract Documents. B. Partial, incomplete, or illegible submittals will be returned to the Contractor without review for resubmittal. C. Shop drawings shall include but not be limited to: 1. Product data sheets for conduits and fittings. 2. Conduit identification methods and materials. 3. Evidence of training for all personnel that will install PVC coated rigid metal conduit. 1.05 DEFINITIONS A. Conduits are categorized by the circuit type of the wiring to be installed inside. Conduits are defined as follows: 1. Power Conduits – Conduits that carry AC or DC power wiring from a source to a load. Conduits that carry lighting and receptacle wiring. City of Denton Hazen and Sawyer BID SET 16111-3 Conduit 2. Control Conduits – Conduits that carry AC or DC discrete control wiring between devices and/or equipment. Conduits that carry fiber optic cables between devices and/or equipment. 3. Instrumentation Conduits – Conduits that carry AC or DC analog signal wiring between devices and/or equipment. B. Conduit categories are indicated on the Drawings by the leading letter of the conduit tag. Conduit tag leading letters are defined as follows: 1. P – Power Conduit 2. C – Control Conduit 3. I – Instrumentation Conduit PART 2 – PRODUCTS 2.01 GENERAL A. Conduit and conduit fitting products are specified in the text that follows this article. Reference Part 3 herein for the application, uses and installation requirements of these conduits and conduit fittings. B. All metallic conduit fittings shall be UL 514B and UL 467 Listed, and constructed in accordance with ANSI FB 1. All metallic conduit fittings for use in Class I Division I hazardous areas shall be UL 1203 Listed. All non-metallic fittings shall be UL 651 Listed and constructed in accordance with NEMA TC-3. C. Flexible conduit couplings for use in Class I Division I hazardous areas shall have threaded stainless steel end fittings and a flexible braided core. Flexible braid shall be constructed of stainless steel where available in the conduit trade size required for the application. Where stainless steel braid is not available, the braid shall be provided with a PVC coating. No other braid types or materials are acceptable. D. Where threading is specified herein for conduit fitting connections, the fittings shall be manufactured to accept conduit that is threaded to ANSI B1.20.1 requirements. E. Conduit expansion fittings for all conduit materials of construction shall be capable of 4 inches of movement along the axis of the conduit for trade sizes 2 inches or less. Expansion fittings shall be capable of 8 inches of movement along the axis of the conduit for trade sizes greater than 2 inches. F. Conduit deflection fittings for all conduit materials of construction shall be provided with a flexible neoprene outer jacket that permits up to ¾ inch of expansion/contraction along the City of Denton Hazen and Sawyer BID SET 16111-4 Conduit axis of the conduit as well as up to ¾ inch of parallel misalignment between the conduit axes. Outer jacket shall be secured to the conduit hubs by stainless steel clamps. G. Conduit seals shall either be Listed and labeled for 40% fill, or conduit reducing fittings and a trade size larger conduit seal shall be provided to achieve 25% or less fill within the seal. Percentage fill calculation shall be based on the conductors to be installed. Conduit seals shall be provided with breathers and/or drains where required by the NEC. H. Conduit insulating bushings shall be constructed of plastic and shall have internal threading. I. Additional conduit and conduit fitting requirements are specified in the articles that follow based on the specific conduit material of construction to be used. 2.02 RIGID GALVANIZED STEEL (RGS) CONDUIT AND ASSOCIATED FITTINGS A. Conduit 1. Conduit shall be hot dip galvanized on the inside and outside, and made of heavy wall high strength ductile steel. Conduit shall be manufactured in accordance with ANSI C80.1, and shall be UL 6 Listed. 2. Conduit shall be provided with factory-cut ¾” per foot tapered threads at each end in accordance with ANSI B1.20.1. Threads shall be cut prior to galvanizing to ensure corrosion protection adequately protects the threads. Conduit shall be provided with a matching coupling on one end and a color-coded thread protector on the other. B. Conduit Bodies for use with Rigid Galvanized Steel 1. Conduit bodies shall be constructed of an electro-galvanized malleable iron alloy which is coated with an acrylic paint finish. Conduit bodies shall have integral threaded conduit hubs. 2. Conduit bodies for Class I Division I hazardous areas shall be provided with integrally threaded covers constructed of an electro-galvanized malleable iron alloy which is coated with an acrylic paint finish. 3. Conduit bodies for all other areas shall be provided with covers that are affixed in place by stainless steel screws which thread directly into the conduit body. Covers that utilize wedge nuts or any other method of attachment to the conduit body are not acceptable. Covers shall be constructed of an electro-galvanized malleable iron alloy which is coated with an acrylic paint finish. Covers shall be provided with matching gasket. City of Denton Hazen and Sawyer BID SET 16111-5 Conduit C. Conduit Couplings, Nipples, and Unions for use with Rigid Galvanized Steel 1. Couplings and nipples shall be threaded and shall be constructed of hot dipped galvanized steel. Split-type couplings that use compression to connect conduits are not acceptable. 2. Unions shall be threaded, rain-tight, and constructed of an electro-galvanized malleable iron alloy which is coated with an acrylic paint finish. D. Conduit Expansion and Deflection Fittings for use with Rigid Galvanized Steel 1. Conduit expansion fittings and conduit deflection fittings shall be constructed of an electro-galvanized malleable iron alloy which is coated with an acrylic paint finish. Expansion and deflection fittings shall have threaded conduit connections. 2. Expansion fittings shall have an integral bonding jumper and deflection fittings shall have an external bonding jumper. E. Conduit Seals for use with Rigid Galvanized Steel 1. Conduit seals shall be constructed of an electro-galvanized malleable iron alloy which is coated with an acrylic paint finish. Conduit seals shall have threaded conduit connections. F. Conduit Termination Fittings for use with Rigid Galvanized Steel 1. Conduit hubs shall be constructed of stainless steel and shall have threaded connections to the conduit and enclosure. Hubs shall have a plastic insulated throat and shall be watertight when assembled to an enclosure. 2. Conduit locknuts shall be constructed of zinc plated steel. Locknuts shall have internal threading. Locknuts with integral gasket or seal are not acceptable. Locknuts shall have integral bonding screw where required for proper bonding. 3. Conduit bonding bushings shall be constructed of zinc plated malleable iron. Bonding bushings shall have a threaded conduit connection. Bonding bushing shall be provided with properly sized set screw for connecting bonding conductor and an integral plastic insulator rated for 150 degrees C located in the throat. 2.03 RIGID NONMETALLIC CONDUIT AND ASSOCIATED FITTINGS A. Conduit 1. Conduit shall be Schedule 40 or 80 (dependent on application) polyvinyl chloride (PVC) construction, manufactured in accordance with NEMA TC-2, UL 651 Listed, and suitable for conductors with 90 degree C insulation. City of Denton Hazen and Sawyer BID SET 16111-6 Conduit B. Conduit Bodies for use with Rigid Nonmetallic Conduit 1. Conduit bodies shall be constructed of PVC. Conduit hubs shall be integral to the conduit body and shall be smooth inside to accept a glued conduit connection. 2. Conduit body shall be provided with cover that is affixed in place by stainless steel screws which thread directly into the conduit body. Covers that utilize wedge nuts or any other method of attachment to the conduit body are not acceptable. Covers shall be provided with matching gasket. C. Conduit Couplings and Unions for use with Rigid Nonmetallic Conduit 1. Conduit couplings and unions shall be constructed of PVC and shall be smooth inside to accept a glued conduit connection. D. Conduit Expansion and Deflection Fittings for use with Rigid Nonmetallic Conduit 1. Conduit expansion fittings and conduit deflection fittings shall be constructed of PVC and shall be smooth inside to accept a glued conduit connection. E. Conduit Termination Fittings for use with Rigid Nonmetallic Conduit 1. Conduit hubs shall be constructed of PVC and shall be smooth inside to accept a glued conduit connection. Hubs shall have external threads and an accompanying PVC locknut, and shall be watertight when assembled to an enclosure. 2. Conduit locknuts shall be constructed of zinc plated steel. Locknuts shall have internal threading. Locknuts constructed of PVC and locknuts with integral gasket or seal are not acceptable. 3. Conduit end bells shall be constructed of PVC and shall be smooth inside to accept a glued conduit connection. End bell shall have a smooth inner surface that curves outward towards the edge of the fitting. 2.04 PVC COATED RIGID GALVANIZED STEEL CONDUIT AND ASSOCIATED FITTINGS A. General 1. Where an external coating of polyvinyl chloride (PVC) is specified for conduit and fittings, the coating shall be 40 mil (minimum) thickness. Where an internal coating of urethane is specified for conduit and fittings, the coating shall be 2 mil (minimum) thickness. City of Denton Hazen and Sawyer BID SET 16111-7 Conduit 2. All conduit fittings shall have a sealing sleeve constructed of PVC which covers all connections to conduit. Sleeves shall be appropriately sized so that no conduit threads will be exposed after assembly. B. Conduit 1. Conduit shall be hot dip galvanized on the inside and outside, and made of heavy wall high strength ductile steel. Conduit shall be manufactured in accordance with ANSI C80.1, and shall be UL 6 Listed. 2. Conduit shall be provided with factory-cut ¾” per foot tapered threads at each end in accordance with ANSI B1.20.1. Threads shall be cut prior to galvanizing to ensure corrosion protection adequately protects the threads. Conduit shall be provided with a matching coupling on one end and a color-coded thread protector on the other. 3. Conduit shall be coated on the exterior with a PVC jacket and coated on the interior with a layer of urethane. Conduit shall be manufactured in accordance with NEMA RN-1. C. Conduit Bodies for use with PVC Coated Rigid Galvanized Steel Conduit 1. Conduit bodies shall be constructed of an electro-galvanized malleable iron alloy which is coated on the exterior with a PVC jacket and coated on the interior with a layer of urethane. Conduit bodies shall have integral threaded conduit hubs. 2. Conduit bodies for Class I Division I hazardous areas shall be provided with integrally threaded covers constructed of an electro-galvanized malleable iron alloy which is coated on the exterior with a PVC jacket and coated on the interior with a layer of urethane. 3. Conduit bodies for all other areas shall be constructed of an electro-galvanized malleable iron alloy which is coated on the exterior with a PVC jacket and coated on the interior with a layer of urethane. Covers shall be affixed in place by stainless steel screws which thread directly into the conduit body and have a plastic encapsulated head. Covers that utilize wedge nuts or any other method of attachment to the conduit body are not acceptable. Covers shall be provided with matching gasket. D. Conduit Couplings, Nipples, and Unions for use with PVC Coated Rigid Galvanized Steel Conduit 1. Couplings and nipples shall be threaded and shall be constructed of hot dipped galvanized steel which is coated on the exterior with a PVC jacket and coated on the interior with a layer of urethane. Split-type couplings that use compression to connect conduits are not acceptable. City of Denton Hazen and Sawyer BID SET 16111-8 Conduit 2. Unions shall be threaded, rain-tight, and constructed of an electro-galvanized malleable iron alloy which is coated on the exterior with a PVC jacket and coated on the interior with a layer of urethane. E. Conduit Expansion and Deflection Fittings for use with PVC Coated Rigid Galvanized Steel Conduit 1. Conduit expansion fittings and conduit deflection fittings shall be constructed of an electro-galvanized malleable iron alloy which is coated on the exterior with a PVC jacket and coated on the interior with a layer of urethane. Expansion and deflection fittings shall have threaded conduit connections. 2. Expansion fittings shall have an integral bonding jumper and deflection fittings shall have an external bonding jumper. F. Conduit Seals for use with PVC Coated Rigid Galvanized Steel Conduit 1. Conduit seals shall be constructed of an electro-galvanized malleable iron alloy which is coated on the exterior with a PVC jacket and coated on the interior with a layer of urethane. Conduit seals shall have threaded conduit connections. G. Conduit Termination Fittings for use with PVC Coated Rigid Galvanized Steel Conduit 1. Conduit hubs shall be constructed of an electro-galvanized malleable iron alloy which is coated on the exterior with a PVC jacket and coated on the interior with a layer of urethane. Hubs shall have threaded connections to the conduit and enclosure. Hubs shall have a plastic insulated throat and shall be watertight when assembled to an enclosure. 2. Conduit bonding bushings shall be constructed of zinc plated malleable iron which is coated on the exterior with a PVC jacket and coated on the interior with a layer of urethane. Bonding bushings shall have a threaded conduit connection. Bonding bushing shall be provided with properly sized set screw for connecting bonding conductor and an integral plastic insulator rated for 150 degrees C located in the throat. 2.05 RIGID ALUMINUM CONDUIT AND ASSOCIATED FITTINGS A. Conduit 1. Conduit shall be made of heavy wall high strength 6063 alloy aluminum with temper designation T1. Conduit shall be manufactured in accordance with ANSI C80.5, and shall be UL 6A Listed. City of Denton Hazen and Sawyer BID SET 16111-9 Conduit 2. Conduit shall be provided with factory-cut ¾” per foot tapered threads at each end in accordance with ANSI B1.20.1. Threads shall be cut prior to galvanizing to ensure corrosion protection adequately protects the threads. Conduit shall be provided with a matching coupling on one end and a color-coded thread protector on the other. B. Conduit Bodies for use with Rigid Aluminum Conduit 1. Conduit bodies shall be constructed of copper-free aluminum which is coated with an aluminum enamel finish. Conduit bodies shall have integral threaded conduit hubs. 2. Conduit bodies for Class I Division I hazardous areas shall be provided with integrally threaded covers constructed of copper-free aluminum which is coated with an aluminum enamel finish. 3. Conduit bodies for all other areas shall be provided with stamped copper-free aluminum covers that are affixed in place by stainless steel screws which thread directly into the conduit body. Covers that utilize wedge nuts or any other method of attachment to the conduit body are not acceptable. Covers shall be provided with matching gasket. C. Conduit Couplings, Nipples, and Unions for use with Rigid Aluminum Conduit 1. Couplings and nipples shall be threaded and shall be constructed of heavy wall high strength 6063 alloy aluminum with temper designation T1. Split-type couplings that use compression to connect conduits are not acceptable. 2. Unions shall be threaded, rain-tight, and constructed of copper-free aluminum which is coated with an aluminum enamel finish. D. Conduit Expansion and Deflection Fittings for use with Rigid Aluminum Conduit 1. Conduit expansion fittings and conduit deflection fittings shall be constructed of copper-free aluminum which is coated with an aluminum enamel finish. Expansion and deflection fittings shall have threaded conduit connections. 2. Expansion fittings shall have an integral bonding jumper and deflection fittings shall have an external bonding jumper. E. Conduit Seals for use with Rigid Aluminum Conduit 1. Conduit seals shall be constructed of copper-free aluminum which is coated with an aluminum enamel finish. Conduit seals shall have threaded conduit connections. City of Denton Hazen and Sawyer BID SET 16111-10 Conduit F. Conduit Termination Fittings for use with Rigid Aluminum Conduit 1. Conduit hubs shall be constructed of copper-free aluminum and shall have threaded connections to the conduit and enclosure. Hubs shall have a plastic insulated throat and shall be watertight when assembled to an enclosure. 2. Conduit locknuts shall be constructed of copper-free aluminum. Locknuts shall have internal threading. Locknuts with integral gasket or seal are not acceptable. Locknuts shall have integral bonding screw where required for proper bonding. 3. Conduit bonding bushings shall be constructed of copper-free aluminum. Bonding bushings shall have a threaded conduit connection. Bonding bushing shall be provided with properly sized set screw for connecting bonding conductor and an integral plastic insulator rated for 150 degrees C located in the throat. 2.06 LIQUID TIGHT FLEXIBLE METAL CONDUIT (LFMC) AND ASSOCIATED FITTINGS A. Conduit 1. Conduit shall be manufactured using a single strip of hot dip galvanized high strength steel alloy, helically formed into a continuously interlocked flexible metal conduit. Trade size 1-1/4” and smaller conduits shall be provided with an integrally woven copper bonding strip. 2. Conduit shall be covered with an outside PVC jacket that is UV resistant, moisture- proof, and oil-proof. Conduit shall be UL 360 Listed. B. Conduit Termination Fittings for use with LFMC 1. Conduit termination fittings shall be constructed of either 304 stainless steel or an electro-galvanized malleable iron alloy which is coated on the exterior with a 40 mil (minimum) PVC jacket and coated on the interior with a 2 mil (minimum) layer of urethane. PVC coated fittings shall have a sealing sleeve constructed of PVC which covers the connection to conduit. 2. Termination fittings shall have a threaded end with matching locknut and sealing ring for termination to equipment, and shall have an integral external bonding lug where required for proper bonding. Termination fittings shall have a plastic insulated throat and shall be watertight when assembled to the conduit and equipment. City of Denton Hazen and Sawyer BID SET 16111-11 Conduit 2.07 CONDUIT BENDS A. Rigid conduit bends, both factory fabricated and field fabricated, shall meet the same requirements listed in the articles above for the respective conduit type and material of construction. B. Conduit bend radii for standard radius bends shall be no less than as follows: TRADE SIZE ¾” 1” 1 ¼” 1 ½” 2” 2 ½” 3” 3 ½” 4” 5” 6” MIN. RADIUS 4 ½” 5 ¾” 7 ¼” 8 ¼” 9 ½” 10 ½” 13” 15” 16” 24” 30” C. Conduit bend radii for long radius bends shall be no less than as follows: TRADE SIZE ¾” 1” 1 ¼” 1 ½” 2” 2 ½” 3” 3 ½” 4” 5” 6” MIN. RADIUS N/A 12” 18” 24” 30” 30” 36” 36” 48” 48” 60” 2.08 MISCELLANEOUS A. Conduit Periphery Sealing 1. The sealing of the exterior surface of conduits to prevent water and/or air from passing around the conduit periphery from one space to another (where required) shall be through the use of one of the following: a. A conduit sleeve and pressure bushing sealing system. Acceptable products are FSK by OZ-GEDNEY, Link-Seal by Crouse-Hinds, or Engineer approved equal. b. A conduit sleeve that is two trade sizes larger than the conduit being sealed, with 2-hour fire rated UL 1479 Listed caulk filling the entire void between the conduit and sleeve. This method is only suitable for penetrations in non-fire rated walls and floors between spaces within buildings. This method shall not be used for the sealing of conduits leaving a building and/or structure. 2. Conduit penetrations through fire-rated walls and floors shall be made with an approved UL 1479 Listed product specifically intended for the trade size of the conduit. B. Primer and Cement 1. Nonmetallic conduit shall be cleaned with primer and connected to fittings with the manufacturer’s recommended cement that is labeled Low VOC. C. Galvanizing Compounds 1. Galvanizing compounds for field application shall be the cold-applied type, containing no less than 93% pure zinc. City of Denton Hazen and Sawyer BID SET 16111-12 Conduit D. Conduit Interior Sealing 1. The sealing of the inside of conduits against water ingress shall be achieved through the use of one of the following: a. Two-part expanding polyurethane foam sealing compound, dispensed from a single tube which mixes the two parts as it is injected into the conduit. Expanding foam shall be compatible with the conduit material of construction as well as the outer jacket of the cables in the conduit. Acceptable products are Q-Pak 2000 by Chemque, FST by American Polywater Corporation, or Hydra-seal S-60 by Duraline. b. Inflatable bag that provides seal around cables and around inside diameter of conduit. Provide appropriate quantity of additional fittings for applications with three or more cables in the conduit to be sealed. Acceptable products are Rayflate by Raychem, or Engineer approved equal. This sealing method is only applicable to conduits trade size 2” and larger. c. Neoprene sealing ring provided with the required quantity and diameter of holes to accommodate the cables in each conduit. Sealing ring shall be compressed by two stainless steel pressure plates. Acceptable products are type CSB by OZ-GEDNEY, or Engineer approved equal. This sealing method is only applicable to metallic conduits containing 4 or less cables. 2. The use of aerosol-based expanding foam sealants or any other method of sealing against water ingress not listed above is not acceptable. E. Pull Rope 1. Pull ropes for empty and/or spare conduits shall be woven polyester, ½” wide, with a minimum tensile strength of 1250 lbs. 2. Pull ropes for the Contractors use in installing conductors shall be the size and strength required for the pull, and shall be made of a non-metallic material. PART 3 – EXECUTION 3.01 GENERAL A. Minimum trade size for all rigid conduits shall be ¾ inch in exposed applications and 1 inch in embedded applications. Conduits installed within ductbanks shall be allowed to be increased in size to trade size 2 inch, at the Contractor’s option, to accommodate the saddle size of the ductbank spacers. However, no combining of circuits shall be allowed in the larger conduits. City of Denton Hazen and Sawyer BID SET 16111-13 Conduit B. Minimum trade size for flexible conduits (where specifically allowed herein) shall be ½ inch in all applications. C. Conduit routing and/or homeruns are not shown on the Drawings. Conduits shall be installed concealed wherever practical and within the limitations specified herein. All other conduits not capable of being installed concealed shall be installed exposed. D. Empty and/or spare conduits shall be provided with pull ropes which have no less than 12 inches of slack at each end. E. Nonmetallic conduits for installations requiring less than a factory length of conduit shall be field cut to the required length. The cut shall be made square, cleaned of debris, and primer shall be applied to ready each joint for fusing. Conduits shall then be fused together with the conduit manufacturer’s approved cement compound. F. Metallic conduits for installations requiring less than a factory length of conduit shall be field cut to the required length. The cut shall be made square, be cleaned of all debris and be de-burred, then threaded. Conduit threading performed in the field shall be ¾ inch per foot tapered threads in accordance with ANSI B1.20.1. G. Conduits shall be protected from moisture, corrosion, and physical damage during construction. Install dust-tight and water-tight conduit fittings on the ends of all conduits immediately after installation and do not remove until conductors are installed. H. Conduits shall be installed to provide no less than 12 inches clearance from pipes that have the potential to impart heat upon the conduit. Such pipes include, but are not limited to, hot water pipes, steam pipes, exhaust pipes, and blower air pipes. Clearance shall be maintained whether conduit is installed in parallel or in crossing of pipes. I. Where conduit fittings do not include an integral insulated bushing, an insulated bushing shall be installed at all conduit termination points. J. Conduits which serve multi-section equipment shall be terminated in the section where wiring terminations will be made. K. In no case shall conduit be supported or fastened to another pipe or installed to prevent the removal of other pipe for repairs. Spring steel fasteners are not acceptable. L. All field fabricated threads for rigid galvanized steel conduit shall be thoroughly coated with two coats of galvanizing compound, allowing at least two minutes to elapse between coats for proper drying. M. The appropriate specialized tools shall be used for the installation of PVC coated conduit and conduit fittings. No damage to the PVC coating shall occur during installation. Conduit and conduit fittings with damaged PVC coating shall be replaced at the Contractor’s cost. The use of PVC coating touch-up compounds is not permitted. City of Denton Hazen and Sawyer BID SET 16111-14 Conduit N. Conduits which emerge from within or below concrete encasement shall be PVC coated rigid galvanized steel in accordance with Standard Detail 1611101 where the conduit is not protected by an equipment enclosure that surrounds the conduit on all sides at the point where it emerges from the encasement. O. Aluminum conduits shall not be installed in direct contact with concrete surfaces. Where aluminum conduits are routed along concrete surfaces, they shall be installed with one- hole electro-galvanized malleable iron alloy straps with matching clamp-backs to space the conduit ¼ inch away from concrete surface. Where aluminum conduit passes through concrete, CMU or brick walls, the penetration shall be made such that the aluminum conduit does not come in contact with concrete, CMU, brick or mortar. 3.02 CONCEALED AND EMBEDDED CONDUITS A. Conduits are permitted to be installed concealed and/or embedded with the following requirements: 1. Conduits installed embedded within concrete floors or walls shall be located so as not to affect the designed structural strength of the floor or wall. Embedded conduits shall be installed in accordance with Standard Detail 0331604 and ACI- 318. 2. Where conduit bends emerge from concrete embedment, none of the curved portion of the bend shall be visible. Only the straight portion of the bend shall be visible. 3. Where multiple conduits emerge from concrete embedment or from concealment below a concrete floor, ample clear space shall be provided between conduits to allow for the appropriate and required conduit termination fittings to be installed. 4. Conduits installed embedded within concrete encasement of any kind shall be installed such that conduit couplings for parallel conduits are staggered so that they are not side by side. B. Conduits are NOT permitted to be installed concealed and/or embedded within any water- bearing floors or walls. 3.03 CONDUIT USES AND APPLICATIONS A. Rigid Conduit 1. Rigid conduit for non-hazardous areas shall be furnished and installed in the materials of construction as follows: City of Denton Hazen and Sawyer BID SET 16111-15 Conduit RIGID CONDUIT FOR NON-HAZARDOUS AREAS CONDUIT CATEGORY BY WIRING/CIRCUIT TYPE INSTALLATION AREA DESIGNATION/ SCENARIO Power and Control Instrumentation Exposed in outdoor areas Rigid aluminum conduit Same as Power and Control Concealed within underground direct-bury or concrete-encased ductbanks Schedule 40 rigid non-metallic PVC conduit Rigid galvanized steel conduit Concealed within non-elevated (i.e. "slab-on-grade" construction) concrete slabs Schedule 40 rigid non-metallic PVC conduit Rigid galvanized steel conduit Concealed within elevated concrete slabs Rigid galvanized steel conduit Same as Power and Control Emerging from concealment within or below a concrete floor and transitioning to exposed conduit (Reference Detail 1611101) PVC coated rigid galvanized steel conduit Same as Power and Control 2. Rigid conduit for hazardous areas shall be furnished and installed in the materials of construction as follows: RIGID CONDUIT FOR HAZARDOUS AREAS CONDUIT CATEGORY BY WIRING/CIRCUIT TYPE INSTALLATION AREA HAZARD/SCENARIO Power and Control Instrumentation Exposed in Class I and II areas (Division I and Division II) Rigid aluminum conduit Same as Power and Control Concealed within concrete slabs in Class I and II areas (Division I and Division II) Rigid galvanized steel conduit Same as Power and Control Concealed below concrete slabs encased in at least two inches of concrete and buried 24 inches below top of slab in Class I Division I areas Schedule 40 rigid non- metallic PVC conduit Rigid galvanized steel conduit 3. The tables for the materials of construction for conduits in non-hazardous and hazardous areas are intended to exhaustively cover all possible scenarios and installation areas under this Contract. However, if a scenario or installation area is found that is not explicitly governed by these tables, it shall be assumed for bid purposes that the conduit material of construction is to be rigid aluminum. This discrepancy shall be brought to the attention of the Engineer (in writing) immediately for resolution. City of Denton Hazen and Sawyer BID SET 16111-16 Conduit B. Conduit Bends 1. All conduit bends shall be the same material of construction as the rigid conduit listed in the tables above, with the following exceptions: a. All 90 degree bends or combinations of adjacent bends that form a 90 degree bend where concealed within concrete or below a concrete slab shall be rigid galvanized steel. 2. Field fabricated bends of metallic conduit shall be made with a bending machine and shall have no kinks. Field fabricated standard radius and long radius bends shall have minimum bending radii in accordance with the associated tables in Part 2 herein. 3. Field bending of non-metallic conduits is not acceptable, factory fabricated bends shall be used. 4. Long radius bends shall be furnished and installed for the following specific applications, all other bends shall be standard radius: a. All conduits containing medium voltage cable. b. All conduits containing fiber optic cable. c. Where specifically indicated on the Drawings. C. Flexible Conduit 1. Flexible conduit shall only be installed for the limited applications specified herein. Flexible conduit shall not be installed in any other application without written authorization from the Engineer. Acceptable applications are as follows: a. Connections to motors and engine-generator sets (and similar vibrating equipment) b. Connections to solenoid valves and limit switches c. Connections to pre-fabricated equipment skids d. Connections to instrument transmitters and elements e. Where specifically indicated in the Standard Details 2. Flexible conduit length shall be limited to three (3) feet, maximum. Flexible conduit shall not be installed buried or embedded within any material. 3. Flexible conduit for non-hazardous areas shall be furnished and installed in the materials of construction as follows: City of Denton Hazen and Sawyer BID SET 16111-17 Conduit FLEXIBLE CONDUIT FOR NON-HAZARDOUS AREAS CONDUIT CATEGORY BY WIRING/CIRCUIT TYPE INSTALLATION AREA DESIGNATION/SCENARIO Power and Control Instrumentation Exposed in outdoor areas Liquid-tight flexible metal conduit Same as Power and Control 4. For Class I Division I hazardous areas, the NEC does not permit the installation of flexible conduit. In lieu of flexible conduit in these areas, flexible conduit couplings shall be installed as specified in Part 2 herein. Flexible conduit for all other hazardous areas shall be furnished and installed in the materials of construction as follows: FLEXIBLE CONDUIT FOR HAZARDOUS AREAS CONDUIT CATEGORY BY WIRING/CIRCUIT TYPE INSTALLATION AREA HAZARD/SCENARIO Power and Control Instrumentation Exposed in Class I Division II areas Liquid-tight flexible metal conduit Same as Power and Control 3.04 CONDUIT FITTING USES AND APPLICATIONS A. General 1. Conduit fittings shall be furnished and installed in the materials of construction as indicated in Part 2, herein. Conduit fitting materials of construction are dependent on the material of construction used for the associated conduit. 2. Conduit fittings shall be provided in the trade size and configuration required to suit the application. B. Conduit Bodies 1. Conduit bodies shall be installed where wire pulling points are desired or required, or where changes in conduit direction or breaking around beams is required. 2. Where conduit bodies larger than trade size 2 inches are intended to be used as a pull-through fitting during wire installation, oversized or elongated conduit bodies shall be used. Oversized or elongated conduit bodies shall not be required if the conduit body is intended to be used as a pull-out point during wire installation. City of Denton Hazen and Sawyer BID SET 16111-18 Conduit C. Conduit Nipples and Unions 1. Conduits with running threads shall not be used in place of 3-piece couplings (unions) or close nipples. After installation of a conduit fitting of any kind, there shall be no more than ¼ inch of exposed threads visible. Factory fabricated all- thread nipples may be used between adjacent enclosures, however, the same restriction applies regarding the length of exposed threads that are visible. D. Conduit Expansion and Deflection Fittings 1. Conduit expansion fittings shall be installed where required by the NEC. Expansion fittings shall also be installed for exposed straight metallic conduit runs of more than 75 feet, in both indoor and outdoor locations. Expansion fittings for runs of non-metallic conduit shall be installed in accordance with the NEC. 2. Conduit deflection fittings shall be installed where required by the NEC and where conduits are installed (exposed and concealed) across structural expansion joints. E. Conduit Seals 1. Conduit seals shall be installed for conduits installed within or associated with hazardous areas and other areas as required by the NEC. F. Conduit Termination Fittings 1. Where conduits terminate at enclosures with a NEMA 4, 4X, or 3R rating and the enclosure does not have integral conduit hubs, an appropriately sized watertight conduit hub shall be installed to maintain the integrity of the enclosure. The use of locknuts with integral gasket in lieu of watertight conduit hubs is not acceptable. 2. Where conduits terminate at enclosures that do not require conduit hubs, a two- locknut system shall be used to secure the conduit to the enclosure. One locknut shall be installed on the outside of the enclosure, and the other inside, drawn tight against the enclosure wall. The locknut on the interior of the enclosure shall be the type with integral bonding lug, or a conduit bonding bushing may be used in place of the locknut. 3. Conduits shall not be installed such that conduit fittings penetrate the top of any enclosure located outdoors, except in cases where specifically required by the serving electric utility. Conduits which serve outdoor equipment or an enclosure from above shall instead be routed into the side of the enclosure at the bottom. The conduit termination fitting shall be provided with a conduit drain to divert moisture from the raceway away from the enclosure. City of Denton Hazen and Sawyer BID SET 16111-19 Conduit 3.05 MISCELLANEOUS A. Conduit Periphery Sealing 1. All conduit penetrations through exterior walls shall be sealed around the periphery using the appropriate products specified in Part 2 herein to prevent air and/or water entry into the structure. B. Conduit Interior Sealing 1. All conduits (including spares) entering a structure below grade shall be sealed on the interior of the conduit against water ingress. Sealing shall be at an accessible location in the conduit system located within the building structure and shall be via one of the methods specified in Part 2 herein. If conduit sealing cannot be achieved at an accessible location within the building structure, sealing shall be placed in the conduits in the nearest manhole or handhole outside the structure. 3.06 CONDUIT IDENTIFICATION A. Exposed conduits shall be identified at the source, load, and all intermediate components of the raceway system. Examples of intermediate components include but are not limited to junction boxes, pull boxes, and disconnect switches. Identification shall be by means of an adhesive label with the following requirements: 1. Labels shall consist of an orange background with black text. Text for the label shall be the conduit number as indicated in the conduit and wire schedules. 2. In addition, at the source end of the conduit, a second line of text shall be included to indicate the load equipment name. This second line shall consist of the word “TO:” and the text in the ‘TO’ column of the conduit and wire schedule (e.g. TO: Raw Sewage Pump No. 1). At the load end of the conduit, a second line of text shall be included to indicate the source equipment name. This second line shall consist of the word “FROM:” and the text in the ‘FROM’ column of the conduit and wire schedule (e.g. FROM: SWBD-WPF). This requirement applies only to the source and load ends of the conduit, and not anywhere in between. 3. For conduits trade sizes ¾” through 1½”, the text shall be a minimum 18 point font. For conduits trade size 2” and larger, the text shall be a minimum 24 point font. 4. Label height shall be ¾” minimum, and length shall be as required to fit required text. The label shall be installed such that the text is parallel with the axis of the conduit. The label shall be oriented such that the text can be read without the use of any special tools or removal of equipment. 5. Labels shall be installed after each conduit is installed and, if applicable, after painting. Labels shall be printed in the field via the use of a portable label printing system. Handwritten labels are not acceptable. City of Denton Hazen and Sawyer BID SET 16111-20 Conduit 6. Labels shall be made of permanent vinyl with adhesive backing. Labels made of any other material are not acceptable. B. Conduits that are not exposed but installed beneath free standing equipment enclosures shall be identified by means of a plastic tag with the following requirements: 1. The tag shall be made of white Tyvek material, and have an orange label with black text, as described above, adhered to it. Text for the label shall be the conduit number as indicated in the conduit and wire schedules. 2. The tag shall be affixed to the conduit by means of a nylon cable tie. The tag shall be of suitable dimensions to achieve a minimum text size of 18 points. C. Conduits for lighting and receptacle circuits shall not require identification. D. Any problems or conflicts with meeting the requirements above shall immediately be brought to the attention of the Engineer for a decision. 3.07 TESTING A. All tests shall be performed in accordance with the requirements of the General Conditions and Division 1. The following tests are required: 1. All conduit installed below grade or concrete encased shall be tested to ensure continuity and the absence of obstructions by pulling through each conduit a swab followed by a mandrel 85% of the conduit inside diameter. After testing, all conduits shall be capped after installation of a suitable pulling rope. 3.08 TRAINING OF INSTALLATION PERSONNEL A. All Contractor personnel that install PVC coated RGS conduit shall be trained by the PVC coated RGS conduit manufacturer. Training shall include proper conduit system assembly techniques, use of tools appropriate for coated conduit systems, and field bending/cutting/threading of coated conduit. Training shall have been completed within the past 24 months prior to the Notice to Proceed on this Contract to be considered valid. Contractor personnel not trained within this timeframe shall not be allowed to install coated conduit, or shall be trained/re-trained as required prior to commencement of conduit installation. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 16118-1 Underground Electrical SECTION 16118 UNDERGROUND ELECTRICAL PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish and install underground duct systems, electric manholes, and electric handholes as specified herein and as indicated on the Drawings. The work shall be complete and shall include excavation, concrete construction, backfilling, and all materials, items, and components required for a complete system. B. The provisions of this Division are applicable to all underground conduit work. All work shall be coordinated with that of the various utility companies and other Contractors. The Contractor shall adhere to all utility company requirements including the serving electric utility. C. Reference Section 16000, Basic Electrical Requirements; Section 16111, Conduit; Section 16170, Grounding and Bonding; the applicable sections of Division 2, Sitework; Section 03200, Reinforcing Steel; and 03300, Cast-In-Place Concrete. 1.02 CODES AND STANDARDS A. Products specified herein shall be designed, manufactured, and/or listed to the following standards as applicable: 1. AASHTO H20 2. ANSI/SCTE 77-2010 – Specification for Underground Enclosure Integrity 1.03 SUBMITTALS A. In accordance with the procedures and requirements set forth in the General Conditions and Section 01300, Submittals, the Contractor shall obtain from the equipment manufacturer and submit Shop Drawings. Each submittal shall be identified by the applicable Specification Section. 1.04 SHOP DRAWINGS A. Each submittal shall be complete in all respects, incorporating all information and data listed herein and all additional information required for evaluation of the proposed equipment's compliance with the Contract Documents. B. Partial, incomplete, or illegible submittals will be returned to the Contractor without review for resubmittal. City of Denton Hazen and Sawyer BID SET 16118-2 Underground Electrical C. Shop drawings shall include but not be limited to, the following: 1. Product data sheets. 2. Outline and dimensional drawings including detailed sections of the manholes and/or handholes. 3. Materials specifications and structural calculations for the manholes sealed by a Professional Engineer in the State of Texas. 1.04 IDENTIFICATION A. Each electric manhole and handhole cover shall be lettered with the word “Electric”, the manhole or handhole identification number as indicated on the Contract Drawings (e.g. UMH-1, EMH-1, EHH-1, etc.), manufacturer's name or trademark, and such other information as the manufacturer may consider necessary, or as specified, for complete identification. PART 2 -- PRODUCTS 2.01 MANUFACTURERS A. The material covered by this Specification is intended to be standard material of proven performance as manufactured by reputable concerns. Material shall be fabricated, constructed and installed in accordance with the best practices of the trade, and shall operate satisfactorily when installed as specified herein and indicated on the Drawings. 2.02 DUCT SYSTEM A. Underground duct system shall consist of parallel runs of Schedule 40 PVC conduit or rigid galvanized steel conduit encased in concrete envelopes, unless otherwise specified herein or indicated on the Drawings. B. Nonmetallic conduit joints shall be made with standard Schedule 40 PVC couplings and PVC solvent cement of the same manufacturer as the conduit. All PVC conduit shall be supplied by the same manufacturer. All joints shall be staggered, installed in accordance with the manufacturer’s recommendations, and made watertight. C. Base and intermediate conduit spacers shall be furnished to provide a minimum of two- inch (2”) separation between conduits. Conduit spacers shall be provided in the proper size as required for the conduit that they secure. For example, a 4” conduit spacer shall not be used to secure a 2” conduit. Conduit spacers shall be as manufactured by Carlon Electrical Products Company, Aeroquip Corporation, Underground Devices, Incorporated, or equal. D. All 90 degree conduit elbows and/or combinations of adjacent conduit elbows that form a 90 degree bend shall be rigid galvanized steel conduit. City of Denton Hazen and Sawyer BID SET 16118-3 Underground Electrical 2.03 ELECTRIC MANHOLES A. The concrete manholes shall be complete with metal frames and covers of size and location as specified herein and shown on the Drawings. B. Manhole frames and covers shall be Neenah R-1640C1, or equal, with Type A anchor ring. Entire manhole assembly shall be AASHTO H20 heavy duty rated. Covers shall be furnished with drop handles. C. All electric manholes shall be provided with heavy duty non-metallic cable racks. Cable racks shall be rated for the application, with a minimum loading of 450lbs per rack arm. Cable rack system shall be Heavy Duty type as manufactured by Underground Devices, Incorporated or equal. 2.04 ELECTRIC HANDHOLES A. The electric handholes shall be a precast polymer concrete enclosure suitable for use as part of an underground electric raceway system. The enclosure shall meet or exceed the requirements of ANSI/SCTE 77-2010. B. The enclosure design and test load rating shall be Tier 15. C. The enclosure shall be the straight side design to allow easy adjustment of box to grade. The box shall be stackable for increased depth. D. Handhole opening size shall be as required to suit the application, 6” X 8”, minimum. E. Extra heavy duty covers shall be furnished and installed with Tier 15 enclosures. Covers shall be provided with cover hooks. F. The electric handholes shall be Style “PG” or “PC” (as required) Quazite boxes as manufactured by Hubbell, Pencell Plastics equivalent, Highline Products equivalent, or equal. PART 3 -- EXECUTION 3.01 GENERAL A. The underground duct system, manholes, and handholes shall be installed as specified herein, indicated on the Drawings, and in accordance with manufacturers’ instructions. 3.02 DUCT SYSTEM A. All underground conduit shall be encased in concrete and shall be reinforced. Encasement and reinforcement shall be as indicated in the standard details. Concrete shall be furnished and installed in accordance with Section 03300. Reinforcing steel shall be furnished and installed in accordance with Section 03200. City of Denton Hazen and Sawyer BID SET 16118-4 Underground Electrical B. Concrete pours shall be complete from handhole to handhole and from manhole to manhole where practicable. Partial pours in general shall not be permitted. Where a complete pour is impractical, written authorization shall be obtained from the Engineer for the partial pour. C. Conduit ductbank elevations at the manholes and handholes shall be based on minimum ductbank cover as indicated in the standard details, or deeper to avoid conflicts with other obstacles. Where deviation is necessary to clear unforeseen obstacles, the elevations may be changed after authorization by the Engineer. D. Slope all conduits continuously away from structures and buildings with a minimum slope of 3” per 100’ unless otherwise indicated on the Drawings. E. The minimum clearance from the top of the concrete encasement and finished grade shall be as indicated in the standard details, except where otherwise accepted in writing by the Engineer or shown on the Drawings. F. Care shall be exercised during excavation for the duct banks to prevent digging too deep. Backfilling of low spots with earth fill will not be permitted unless thoroughly compacted and acceptable to the Engineer. G. If a specific ductbank arrangement is shown on the Drawings, the conduits in that ductbank shall be arranged as shown. Where no specific ductbank arrangement is shown on the Drawings, the Contractor shall arrange conduits within each ductbank based on field conditions. Spare conduits shown going from ductbanks into buildings or structures shall be stubbed up in the location(s) as indicated on the Drawings. H. A minimum of one (1) ground rod, furnished in accordance with Section 16170, shall be driven adjacent to each manhole, handhole, or other concrete box. A No. 4/0 AWG bare copper ground cable shall be connected between this rod and the copper ground strap using a silicon bronze connector. All ground rods shall be interconnected by means of the No. 4/0 AWG bare copper ground cable located within each duct bank. The ends of these cables shall also be connected to substation and/or building ground buses where the conduits terminate. I. Care shall be exercised and temporary plugs shall be installed during installation to prevent the entrance of concrete, mortar, or other foreign matter into the conduit system. Conduit spacers shall be utilized to support conduit during the pouring of concrete to prevent movement and misalignment of the conduits. Conduit spacers shall be installed in accordance with manufacturer’s instructions unless otherwise noted. Horizontal spacing of conduit spacers along ductbank shall be as indicated on the Standard Details. J. Large radius elbows shall be used for all 90 degree conduit bends in the duct system. The following shall be the minimum elbow radii: TRADE SIZE 1” 1 ½” 2” 2 ½” 3” 3 ½” 4” MIN. RADIUS 12” 24” 24” 24” 36” 36” 48” K. Prior to pulling cables, the Contractor shall thoroughly clean the inside of each length of conduit by swabbing. City of Denton Hazen and Sawyer BID SET 16118-5 Underground Electrical L. After all cables have been installed, all spare and/or unused conduit openings shall be sealed or plugged as specified in Section 16111. A 250 lb. test pull rope shall be provided in the entire length of all spare and/or unused conduits. M. Construct concrete-encased conduits connecting to underground structures to have a flared section adjacent to the manhole to provide shear strength. Construct underground structures to provide shear strength. Construct underground structures to provide for keying the concrete encasement of the duct line into the wall of the structure. Use vibrators when this portion of the encasement is poured to ensure a seal between the encasement and the wall of the structure. O. Six (6) inches above all duct banks, the Contractor shall furnish and install a two (2) inch wide red plastic electrical hazard tape. Tapes shall be metallic detectable type and shall have a continuous message in bold black letters: “ELECTRIC LINE BURIED BELOW.” Tape shall be Detectable Identoline by Brady, or equal. P. The Contractor shall perform all earthwork including excavation, backfill, bedding, compaction, shoring and bracing, grading and restoration of surfaces and seeded areas disturbed during the execution of the work. 3.03 ELECTRIC MANHOLES A. Electric manholes shall be installed to a sufficient depth to accommodate the required grading of ducts as well as maintaining a minimum distance of 14” from the bottom of the lowest duct centerline entrances to finished floor line and/or highest duct centerline entrance to the roof. All manholes shall be built on, or placed over a 6” layer of well- tamped gravel. B. Duct envelopes and conduit with bell ends shall enter at approximately right angles to the walls, except as may otherwise be shown on the Drawings. C. All concrete work and fully assembled manholes shall be completely watertight and shall be furnished with sloped floors that pitch towards a sump pit. The outside surfaces shall be coated with an approved asphaltic waterproofing compound (all sides, bottom, and roof). Precast concrete manholes may be installed; however, all requirements of this section and other divisions of the Specifications and the details shown on the Drawings shall apply. D. Install pulling eye irons imbedded in walls opposite each duct entrance securely fastened to manhole reinforcing rods. All hardware shall be hot-dipped galvanized steel. Copper bars shall be provided in the walls for grounding. No. 4/0 AWG bare copper cables shall be connected to these bars and all non-current carrying metal parts shall be grounded to these copper bars. E. All cables shall be well supported on walls by nonmetallic cable racks. The cable racks shall be heavy-duty type for medium and low voltage power cables and light duty type for control, signal, communications and similar small conductors. All racks shall be rigidly attached to the wall and equipped with adjustable rack arms. City of Denton Hazen and Sawyer BID SET 16118-6 Underground Electrical 3.04 ELECTRIC HANDHOLES A. Electric handholes shall be installed to a sufficient depth to accommodate the required grading of ducts as well as maintaining a minimum distance of 9” from the bottom of the lowest duct centerline entrances to finished floor line and/or highest duct centerline entrance to roof. All handholes shall be built on, or placed over a 6” layer of well-tamped gravel. B. Duct envelopes and conduit with bell ends shall enter at approximately right angles to the walls, except as may otherwise be shown on the Drawings. C. All fully assembled handholes shall be completely watertight. D. All individual cables and/or bundles of conductors shall be identified and “dressed” along the wall of the enclosure. Cable racks as specified herein shall be provided if any handhole dimension exceeds 24 inches. 3.05 TESTING A. All tests shall be performed in accordance with the requirements of the General Conditions and Division 1. The following tests are required: 1. Field tests a. Field tests for all completed duct systems shall consist of pulling a swab through each conduit followed by a mandrel equal in size to 85% of the conduit inside diameter. b. After testing, all conduits shall be capped after installation of a suitable pull rope. All field tests shall be witnessed by the Engineer. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 16123-1 Low Voltage Wire and Cable SECTION 16123 LOW VOLTAGE WIRE AND CABLE PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, install, connect, test, and place in satisfactory operating condition, all low voltage wire and cable indicated on the Drawings and as specified herein and/or required for proper operation. The work of connecting cables to equipment and devices shall be considered a part of this Section. All appurtenances required for the installation of cable and wire systems shall be furnished and installed by the Contractor. B. The scope of this Section does not include internal wiring factory installed by electrical equipment manufacturers. C. Reference Section 16000, Basic Electrical Requirements; Section 16111, Conduit; Section 16118, Underground Electrical; and Section 16130, Boxes. 1.02 SUBMITTALS A. In accordance with the procedures and requirements set forth in the General Conditions and Section 01300, Submittals, the Contractor shall obtain from the wire and cable manufacturer and submit the following: 1. Shop Drawings 2. Reports of Field Tests 3. Wiring Identification Methods B. Each submittal shall be identified by the applicable specification section. 1.03 SHOP DRAWINGS A. Each submittal shall be complete in all respects, incorporating all information and data listed herein and all additional information required for evaluation of the proposed material's compliance with the Contract Documents. B. Partial, incomplete, or illegible Submittals will be returned to the Contractor without review for resubmittal. C. Shop drawings shall include but not be limited to: 1. Product data sheets. 2. Cable pulling calculations (if required). City of Denton Hazen and Sawyer BID SET 16123-2 Low Voltage Wire and Cable 3. Wiring identification methods and materials. 1.04 IDENTIFICATION A. Each cable shall be identified as specified in Part 3, Execution, of this Specification. 1.05 CABLE PULLING CALCULATIONS A. The Contractor shall submit cable pulling calculations. These calculations, to be performed by a currently registered professional engineer in the State of Texas, shall define pulling tension and sidewall loading (sidewall bearing pressure values) for all installations of 600VAC, #1/0 conductors and larger greater than 200 feet in length. Calculations for straight horizontal installations of 600VAC, #1/0 conductors and larger greater than 200 feet are not required. PART 2 -- PRODUCTS 2.01 MANUFACTURERS A. The wire and cable to be furnished and installed for this project shall be the product of manufacturers who have been in the business of manufacturing wire and cable for a minimum of ten (10) years. Wire and cable shall be designed, constructed and installed in accordance with the best practices of the trade, and shall operate satisfactorily when installed as specified herein and indicated on the Drawings. Only one (1) manufacturer for each wire and cable type shall be permitted. B. The wire and cable manufacturer shall be ISO 9000 registered. 2.02 POWER WIRE AND CABLE A. Power cable and wire shall consist of stranded, copper conductor with insulation type THHN, 90°C for dry locations and THWN, 75°C for wet locations. C. Conductors shall be stranded copper per ASTM-B8 and B-3, and Class B or C stranding contingent on the size unless otherwise specified. Minimum size wire shall be No. 12 AWG. D. Multi-conductor power cable assemblies shall be UL 1277 Listed, provided with a bonding conductor, and furnished with an overall PVC jacket. E. Power wire and cable shall be as manufactured by the Okonite Company, the Southwire Company, General Cable, or equal. 2.03 CONTROL CABLE A. 600 volt control cable shall consist of stranded, copper conductor with insulation type THHN, 90°C for dry locations and THWN, 75°C for wet locations, and 600V. City of Denton Hazen and Sawyer BID SET 16123-3 Low Voltage Wire and Cable B. Conductors shall be stranded copper per ASTM B-8 and B-3, and Class B or C stranding contingent on the size unless otherwise specified. Minimum wire size shall be No. 14 AWG. C. Multi-conductor control cable assemblies shall be UL 1277 Listed, provided with a bonding conductor, and furnished with an overall PVC jacket. D. Control cable shall be as manufactured by the Okonite Company, the Southwire Company, General Cable, or equal. 2.04 LIGHTING AND RECEPTACLE WIRE A. The lighting and receptacle branch circuit wire shall consist of solid, copper conductors with insulation type THHN, 90°C for dry locations and THWN, 75°C for wet locations. B. Conductors shall be solid copper per ASTM- B-3. Minimum size wire shall be No. 12 AWG. C. Lighting and receptacle wire shall be as manufactured by the Okonite Company, the Southwire Company, General Cable, or equal. 2.05 INSTRUMENTATION CABLE A. The instrumentation cable for analog signals shall be single, shielded, twisted pairs or triads with 600 volt insulation and shall have a 75°C (minimum) insulation rating. B. Conductors shall be tin or alloy coated (if available), soft, annealed copper, stranded per ASTM-B8, Class B stranding unless otherwise specified. Minimum size wire shall be No. 16 AWG. C. The instrumentation cable shall be Okoseal-N Type P-OS for single pair or triad applications and Okoseal-N Type SP-OS for multiple pair or triad applications as manufactured by the Okonite Company, Belden equivalent, Southwire Company equivalent, or equal. 2.06 CONDUCTOR IDENTIFICATION A. Conductors shall be identified using a color coding method. Color coding for individual power, control, lighting, and receptacle conductors shall be as follows: 1. 480/277V AC Power Phase A - BROWN Phase B - ORANGE Phase C - YELLOW Neutral – GREY 2. 120/208V or 120/240V AC Power Phase A - BLACK City of Denton Hazen and Sawyer BID SET 16123-4 Low Voltage Wire and Cable Phase B - RED Phase C - BLUE Neutral - WHITE 3. DC Power Positive Lead - RED Negative Lead - BLACK 4. DC Control All wiring - BLUE 5. 120VAC Control 120 VAC control wire shall be RED except for a wire entering a motor control center compartment or control panel which is an interlock. This interlock conductor shall be color coded YELLOW. 6. 24VAC Control All wiring - ORANGE 7. Equipment Grounding Conductor All wiring - GREEN B. Individual conductors No. 2 AWG and smaller shall have factory color coded insulation. It is acceptable for individual conductors larger than No.2 AWG to be provided with factory color coded insulation as well, but it is not required. Individual conductors larger than No.2 AWG that are not provided with factory color coded insulation shall be identified by the use of colored tape in accordance with the requirements listed in Part 3 herein. Insulation colors and tape colors shall be in accordance with the color coding requirements listed above. C. Conductors that are a part of multi-conductor control cable assemblies shall have black insulation. The conductor number shall be printed on each conductor’s insulation in accordance with ICEA S-58-679, Method 4. Each conductor within the cable assembly shall also be identified with a heat shrink tag with color coded background in accordance with the requirements listed in Part 3 herein. Background color shall be in accordance with the color coding requirements listed above. D. Conductors that are a part of multi-conductor power cable assemblies shall have black insulation. The conductor number shall be printed on each conductor’s insulation in accordance with ICEA S-58-679, Method 4. Each conductor No.2 AWG and smaller within the cable assembly shall also be identified with a heat shrink tag with color coded background. Each conductor larger than No.2 AWG within the cable assembly shall also be identified by the use of colored tape. Heat shrink tags and colored tape shall be in accordance with the requirements listed in Part 3 herein. Tape color and heat shrink tag background color shall be in accordance with the color coding requirements listed above. City of Denton Hazen and Sawyer BID SET 16123-5 Low Voltage Wire and Cable 2.08 CABLE PULLING LUBRICANTS A. Cable pulling lubricants shall be non-hardening type and approved for use on the type of cable installed. Lubricant shall be Yellow #77 Plus by Ideal, Cable Gel by Greenlee, Poly-Gel by Gardner Bender, or equal. PART 3 -- EXECUTION 3.01 POWER, CONTROL, AND LIGHTING/RECEPTACLE WIRE AND CABLE INSTALLATION A. The wire and cable shall be installed as specified herein and indicated on the Drawings. B. The cables shall be terminated in accordance with the cable and/or termination product manufacturer's instructions for the particular type of cable. C. To minimize oxidation and corrosion, wire and cable shall be terminated using an oxide-inhibiting joint compound recommended for "copper-to-copper" connections. The compound shall be Penetrox E as manufactured by Burndy Electrical, or equal. D. Splices shall not be allowed in the underground manhole and handhole systems. If splices are required, the Contractor shall obtain approval in writing from the Engineer prior to splicing. Splicing materials shall be barrel type butt splice connectors and heat shrink tubing as manufactured by 3M, Ideal, or equal. No splicing of instrumentation cable is allowed. The use of screw-on wire connectors (wire nuts) shall only be permitted for lighting and receptacle circuits. E. Wire and Cable Sizes 1. The sizes of wire and cable shall be as indicated on the Drawings, or if not shown, as approved by the Engineer. If required due to field routing, the size of conductors and respective conduit shall be increased so that the voltage drop measured from source to load does not exceed 2-1/2%. F. Additional Conductor Identification 1. In addition to the color coding identification requirements specified in Part 2 herein, individual conductors shall be provided with heat shrinkable identification tags. Identification tags for individual conductors shall have a white background where the conductor insulation is colored. Identification tags for individual conductors shall have a colored background where the conductor insulation is black. Background color shall match that of the taping provided on the individual black conductors. 2. Multi-conductor cables shall be provided with heat shrinkable identification tags in accordance with Part 2 herein. 3. All wiring shall be identified at each point of termination. This includes but is not City of Denton Hazen and Sawyer BID SET 16123-6 Low Voltage Wire and Cable limited to identification at the source, load, and in any intermediate junction boxes where a termination is made. The Contractor shall meet with the Owner and Engineer to come to an agreement regarding a wire identification system prior to installation of any wiring. Wire numbers shall not be duplicated. 4. Wire identification shall be by means of a heat shrinkable sleeve with appropriately colored background and black text. Wire sizes #14 AWG through #10 AWG shall have a minimum text size of 7 points. Wire sizes #8 AWG and larger shall have a minimum text size of 10 points. Sleeves shall be of appropriate length to fit the required text. The use of handwritten text for wire identification shall not be permitted. 5. Sleeves shall be suitable for the size of wire on which they are installed. Sleeves shall not be heat-shrunk onto control cables. Tags shall remain loose on cable to promote easier identification. For all other applications, sleeves shall be tightly affixed to the wire and shall not move. Sleeves shall be heat shrunk onto wiring with a heat gun approved for the application. Sleeves shall not be heated by any means which employs the use of an open flame. The Contractor shall take special care to ensure that the wiring insulation is not damaged during the heating process. 6. Sleeves shall be installed prior to the completion of the wiring terminations and shall be oriented so that they can be easily read. 7. Sleeves shall be polyolefin as manufactured by Brady, Seton, Panduit, or equal. 8. Wire identification in manholes, handholes, pull boxes, and other accessible components in the raceway system where the wiring is continuous (no terminations are made) shall be accomplished by means of a tag installed around the bundled group of individual conductors or around the outer conductor jacket of a multi- conductor cable. Identification shall utilize a FROM-TO system. Each group of conductors shall consist of all of the individual conductors in a single conduit or duct. The tag shall have text that identifies the bundle in accordance with the ‘FROM’ and ‘TO’ column for that particular conduit number in the conduit and wire schedule. Minimum text size shall be 10 point. The tag shall be affixed to the wire bundle by the use of nylon wire ties, and shall be made of polyethylene as manufactured by Brady, Seton, Panduit, or equal. 9. Where colored tape is used to identify cables, it shall be wrapped around the cable with a 25% overlap and shall cover at least 2 inches of the cable. H. Wiring Supplies 1. Only electrical wiring supplies manufactured under high standards of production and meeting the approval of the Engineer shall be used. 2. Rubber insulating tape shall be in accordance with ASTM Des. D119. Friction tape shall be in accordance with ASTM Des. D69. City of Denton Hazen and Sawyer BID SET 16123-7 Low Voltage Wire and Cable I. Training of Cable 1. The Contractor shall furnish all labor and material required to train cables around cable vaults within buildings and in manholes and handholes in the outdoor underground duct system. Sufficient length of cable shall be provided in each handhole, manhole, and vault so that the cable can be trained and racked in an approved manner. In training or racking, the radius of bend of any cable shall be not less than the manufacturer's recommendation. The training shall be done in such a manner as to minimize chaffing. Reference Section 16118. 2. Instrumentation cable shall be racked separate from other AC and DC wiring to maintain the required separation as follows: a. 18 inches for 480/277VAC wiring b. 12 inches for 208/120VAC wiring c. 6 inches for 24VDC wiring J. Conductor Terminations 1. Where wires are terminated at equipment which requires lugs, connections shall be made by solderless mechanical lug, crimp type ferrule, or irreversible compression type lugs. Reference individual equipment specification sections as applicable for additional termination requirements. 2. Where enclosure sizes and sizes of terminals at limit switches, solenoid valves, float switches, pressure switches, temperature switches, and other devices make terminations impractical due to the size of the field wiring, the Contractor shall terminate field wiring in an adjacent junction per the requirements of Section 16130, Boxes, complete with terminal strips. Contractor shall install the smaller wiring from the device to the junction box in a conduit, using the terminal strip as the means for joining the two different wire sizes. Splicing of wires in lieu of using terminal strips is not acceptable. 3. All spare conductors shall be terminated on terminal blocks mounted within equipment or junction boxes. Unless otherwise noted, coiling up of spare conductors within enclosure is not acceptable. K. Pulling Temperature 1. Cable shall not be flexed or pulled when the temperature of the jacket is such that damage will occur due to low temperature embrittlement. When cable will be pulled with an ambient temperature of 40°F or less within a three (3) day period prior to pulling, the cable reels shall be stored three (3) days prior to pulling in a protected storage area with an ambient temperature of 55°F or more. Cable pulling shall be completed during the work day for which the cable is removed from the protected storage. Any remaining cable reels shall be returned to storage at the completion of the workday. City of Denton Hazen and Sawyer BID SET 16123-8 Low Voltage Wire and Cable 3.02 INSTRUMENTATION CABLE INSTALLATION A. The Contractor shall install all cable or conductors used for instrumentation wiring (4-20 mA DC, etc.) in conduit as specified in Section 16111 - Conduit. Only instrumentation cable as specified herein shall exclusively occupy these conduits. No other wiring for AC or discrete DC circuits shall be installed in these conduits. B. All shielding shall be continuous and shall be grounded at one point only. C. Where instrumentation cables are installed in panels, manholes, handholes, and other locations, the Contractor shall arrange wiring to provide maximum clearance between these cables and other conductors. Instrumentation cables shall not be installed in same bundle with conductors of other circuits. D. Special instrument cable shall be as specified or recommended by the manufacturer of the equipment or instruments requiring such wiring. Installation, storage, and terminations, shall be per manufacturer's recommendations. 3.03 FIBER OPTIC CABLE INSTALLATION A. The Contractor shall install the fiber optic cable furnished by the General Contractor and/or the Instrumentation and Control Subcontractor. The cable shall be installed in its respective raceway system(s) as specified herein, indicated on the Drawings, and in accordance with the cable manufacturer's instructions. Reference Division 17 for additional information regarding the fiber optic cable. 3.04 TESTING A. All testing shall be performed in accordance with the requirements of the General Conditions and Division 1. The following tests are required: 1. Shop Test a. Cable and wiring shall be tested in accordance with the applicable ICEA Standards. Wire and cable shall be physically and electrically tested in accordance with the manufacturer’s standards. 2. Field Tests a. After installation, all wires and cables shall be tested for continuity. Testing for continuity shall be “test light” or “buzzer” style. b. After installation, some wires and cables shall be tested for insulation levels. Insulation resistance between conductors of the same circuit and between conductor and ground shall be tested. Testing for insulation levels shall be as follows: (1) For #8 AWG and larger 600V power and control cable, apply 1,000 VDC from a Megaohmeter for one (1) minute for all 600V wires and cables installed in lighting, control, power, indication, alarm and City of Denton Hazen and Sawyer BID SET 16123-9 Low Voltage Wire and Cable motor feeder circuits. Resistance shall be no less than 100 Megaohms. Insulation testing is not required for power and control cables smaller than #8 AWG. (2) 600V instrumentation signal cable shall be tested from conductor to conductor, conductor to shield, and conductor to ground using a Simpson No. 260 volt-ohmmeter, or approved equal. The resistance value shall be 200 Megaohms or greater. B. Wires and cables shall be tested before being connected to motors, devices or terminal blocks. C. If tests reveal defects or deficiencies, the Contractor shall make the necessary repairs or shall replace the cable as directed by the Engineer, without additional cost to the Owner. D. All tests shall be made by and at the expense of the Contractor who shall supply all testing equipment. Test reports shall be submitted to the Engineer. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 16123-10 Low Voltage Wire and Cable (EXHIBIT A) TEST DATA - MEGOHMS TEST NO. ____ Date: Company: Time: Location: Circuit: Circuit Length: Aerial: Duct: Buried: No. of Conduc- tors Size: AMG MCM Shld: Insulation Material: Insulation Thickness: Voltage Rating: Age: Type: _____Pothead ______Terminal Location: Indoors______ Outdoors_____ Number and Type of Joints: Recent Operating History: Manufacturer: State if Potheads or Terminals were grounded during test: List associated equipment included in test: Miscellaneous Information: City of Denton Hazen and Sawyer BID SET 16123-11 Low Voltage Wire and Cable (EXHIBIT A) TEST DATA - MEGOHMS TEST NO. ____ Part Tested:Test Made:_______________ Hours/Days:_______________ After Shutdown:_______________ Grounding Time:Dry Bulb Temperature:__________ Wet Bulb Temperature:__________ Test Voltage: Equipment Temperature: ___________ How Obtained: ___________ Relative Humidity: ___________ Absolute Humidity: ___________ Dew Point: ___________ Megohmmeter: Serial Number: __________ Range: ___________ Voltage: ________________ Calibration Date___________ Test Connections To Line To Earth To Ground To Line To Earth To Ground To Line To Earth To Ground Test Connections To Line To Earth To Ground To Line To Earth To Ground To Line To Earth To Ground  Minute 5 Minutes  Minute 6 Minutes 3/4 Minute 7 Minutes 1 Minute 8 Minutes 2 Minutes 9 Minutes 3 Minutes 10 Minutes 4 Minutes 10/1 Minutes Ratio Remarks: City of Denton Hazen and Sawyer BID SET 16123-12 Low Voltage Wire and Cable This page left blank intentionally City of Denton Hazen and Sawyer BID SET 16130-1 Boxes SECTION 16130 BOXES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The scope of work under this Section includes furnishing and installing all pull boxes, junction boxes, and outlet boxes. B. Requirements for other boxes and enclosures are not included in this Section. Reference each specific Division 16 equipment Section for requirements related to that equipment’s respective enclosure. C. Reference Section 16000, Basic Electrical Requirements, and Section 161111, Conduit. 1.02 CODES AND STANDARDS A. Boxes shall be designed, manufactured, and/or listed to the following standards as applicable: 1. UL 514A - Metallic Outlet Boxes 2. UL 514C - Standard for Non-metallic Outlet Boxes, Flush Device Boxes, and Covers 3. UL 50 – Enclosures for Electrical Equipment, Non-environmental Considerations 4. UL 50E - Enclosures for Electrical Equipment, Environmental Considerations 5. UL 1203 – Standard for Explosion-proof and Dust-ignition-proof Electrical Equipment for use in Hazardous (Classified) Locations. 6. NEMA 250 – Enclosures for Electrical Equipment 1.03 SUBMITTALS A. In accordance with the procedures and requirements set forth in the General Conditions and Section 01300, Submittals, the Contractor shall obtain from the equipment manufacturer(s) and submit the following: 1. Shop Drawings B. Each submittal shall be identified by the applicable specification section. City of Denton Hazen and Sawyer BID SET 16130-2 Boxes 1.04 SHOP DRAWINGS A. Each submittal shall be complete in all respects, incorporating all information and data listed herein and all additional information required for evaluation of the proposed equipment's compliance with the Contract Documents. B. Partial, incomplete or illegible Submittals will be returned to the Contractor without review for resubmittal. C. Shop drawings shall include but not be limited to: 1. Product data sheets for boxes, terminal strips, and all accessories 2. Overall bill of material for all boxes included under this Contract to summarize exactly what is being submitted for review. Bill of material shall at a minimum show each box type (i.e. pull, junction, or outlet), quantity, material of construction, dimensions, and proposed installation location. 1.05 OPERATION AND MAINTENANCE MANUALS A. The Contractor shall submit operation and maintenance manuals in accordance with the procedures and requirements set forth in the General Conditions and Division 1. B. As-built drawings showing dimensions, internal box layout, terminal strip information, and terminal strip identification information shall be provided for all junction boxes. As-built drawings are not required for pull boxes or outlet boxes. 1.06 IDENTIFICATION A. Each pull and junction box shall be identified with the box name as indicated on the Contract Drawings (e.g. PPB-1, CPB-1 or as directed by the Engineer. A nameplate shall be securely affixed in a conspicuous place on each box. Nameplates shall be as specified in Section 16195, Electrical – Identification. PART 2 -- PRODUCTS 2.01 MANUFACTURERS A. The equipment covered by this Specification is intended to be standard equipment of proven performance as manufactured by reputable concerns. Equipment shall be designed, constructed, and installed in accordance with the best practices of the trade, and shall operate satisfactorily when installed as shown on the Drawings. 2.02 PULL AND JUNCTION BOXES A. General 1. All pull and junction boxes shall be UL listed and labeled. City of Denton Hazen and Sawyer BID SET 16130-3 Boxes 2. Pull and junction boxes shall not be provided with eccentric or concentric knockouts. 3. Pull and junction boxes mounted embedded in concrete shall be UL listed for embedment. 4. Where metallic boxes are used they shall be of all welded construction. Tack welded boxes are not acceptable. B. Pull Boxes 1. All pull boxes shall be provided with a matching gasketed cover. For covers with dimensions of 24 inches by 24 inches or less, the cover shall be held in place by machine screws. Other screw types are not acceptable. For covers with dimensions greater than 24 inches by 24 inches, the cover shall be hinged and held in place by fast-operating clamp assemblies. Hinge pins shall be removable. Clamp mechanism material of construction shall match that of the associated box. 2. Pull boxes shall not have any wire terminations inside, other than those for grounding/bonding. A ground bar shall be provided with the necessary number of screw type terminals. Twenty (20) percent of the total amount of terminals otherwise required for the pull box (minimum of two) shall be provided as spare terminations. Boxes requiring any other wire terminations shall be furnished and installed in accordance with the requirements for junction boxes herein. 3. Pull boxes shall be 6 inches wide by 6 inches tall by 4 inches deep, minimum. For applications requiring larger boxes, the box shall be sized in accordance with the fill requirements and dimensional requirements of the NEC. 4. Barriers shall be provided in pull boxes to isolate conductors of different voltages, types, and functions. Barrier material of construction shall match that of the box. Isolation shall be provided between the following groups: a. Power wiring b. AC control wiring c. DC control wiring d. Instrumentation wiring C. Junction Boxes 1. Junction boxes used for lighting and receptacle circuits only shall be provided with a matching gasketed cover held in place by machine screws. Other screw types are not acceptable. 2. Junction boxes for all uses other than lighting and receptacle circuits shall be provided with a hinged, gasketed cover. Hinge pins shall be removable. Cover shall be held in place by fast-operating clamp assemblies. Clamp mechanism material of construction shall match that of the associated box. City of Denton Hazen and Sawyer BID SET 16130-4 Boxes 3. Barriers shall be provided in junction boxes to isolate conductors and terminal blocks of different voltages, types, and functions. Barrier material of construction shall match that of the box. Isolation shall be provided between the following groups: a. Power wiring b. AC control wiring c. DC control wiring d. Instrumentation wiring 4. Junction boxes used for lighting and receptacle circuits only shall be allowed to have screw-on (wire nut) type connectors for wire terminations/junctions. 5. Junction boxes for all uses other than lighting and receptacle circuits shall be provided with terminal strips, consisting the necessary number of screw type terminals. Current carrying parts of the terminal blocks shall be of ample capacity to carry the full load current of the circuits connected, with a 10A minimum capacity. Terminal strips shall be rated for the voltage of the circuits connected. A separate ground bar shall be provided with the necessary number of screw type terminals. Twenty (20) percent of the total amount of terminals otherwise required for the junction box (minimum of two) shall be provided as spare terminations. When barriers are provided within the box, separate terminal strips shall be provided in each barrier area. Terminals shall be lettered and/or numbered to conform to the wiring labeling scheme in place on the project. 6. Junction boxes shall be 6 inches wide by 6 inches tall by 4 inches deep, minimum. For applications requiring larger boxes, the box shall be sized in accordance with the fill requirements and dimensional requirements of the NEC. Terminal blocks (including spare terminals) shall be considered when sizing the junction box. D. Enclosure Types and Materials 1. In non-hazardous locations, pull and junction boxes shall be NEMA 4X, Type 304 Stainless Steel. 2. In hazardous locations, pull and junction boxes shall be furnished with the following enclosure type and material of construction, dependent upon the classification of the area in which they are to be installed. Area classifications are indicated on the Drawings. AREA CLASSIFICATION ENCLOSURE TYPE AND MATERIAL Class 1, Division 1, Group D NEMA 7, Die Cast Aluminum Class 1, Division 2, Group D NEMA 4X, Type 304 Stainless Steel 3. Non-metallic enclosures, NEMA 7 enclosures shall be provided with threaded integral conduit hubs. City of Denton Hazen and Sawyer BID SET 16130-5 Boxes 2.03 OUTLET BOXES A. General 1. Reference Section 16141, Wiring Devices, for outlet box trim requirements. An appropriate outlet box trim is required to achieve the NEMA rating of the outlet boxes as specified herein. B. Surface Mount Outlet Boxes 1. Outlet boxes shall be the deep type, no less than 2.5 inches deep. 2. Outlet boxes shall be provided in single or multi-gang configuration as required, sized in accordance with the requirements of the NEC. 3. In non-hazardous locations, outlet boxes shall be NEMA 4X, Cast Aluminum. 4. In hazardous locations, outlet boxes shall be furnished with the following enclosure type and material of construction, dependent upon the classification of the area in which they are to be installed. Area classifications are indicated on the Drawings. AREA CLASSIFICATION ENCLOSURE TYPE AND MATERIAL Class 1, Division 1, Group D NEMA 7, Die Cast Aluminum Class 1, Division 2, Group D NEMA 4X, Cast Aluminum 5. Outlet boxes shall be provided with integral threaded conduit hubs mounted external to the box. Boxes with threaded conduit hubs mounted internal to the box or as a part of the box wall are not acceptable. PART 3 -- EXECUTION 3.01 INSTALLATION A. Pull and Junction Boxes 1. Pull boxes and junction boxes shall be solidly attached to structural members prior to installation of conduit and set true and plumb. Boxes shall not be supported by their associated conduits. 2. Wooden plugs are not permitted for securing boxes to concrete. Appropriately rated anchors specifically suited for use in concrete shall be used. 3. Box penetrations for conduits shall be made with a punch tool, and penetrations shall be of the size required for the conduit entry and/or hub. Oversized penetrations in boxes are not acceptable. 4. Watertight conduit hubs shall be provided for boxes where a NEMA 4X enclosure rating is specified. Reference Section 16111, Conduit, for conduit hub requirements. City of Denton Hazen and Sawyer BID SET 16130-6 Boxes 5. Pull and junction boxes may be installed flush mounted in concrete where appropriate provided that covers are easily removed or opened. 6. Pull and junction boxes shall be provided in the enclosure type and material of construction required for the area in which it is installed. Reference the requirements in Part 2 herein, and the area designations indicated on the Drawings. B. Outlet Boxes 1. Outlet boxes shall be solidly attached to structural members prior to installation of conduit and set true and plumb. Boxes shall not be supported by their associated conduits. 2. Wooden plugs are not permitted for securing boxes to concrete. Appropriately rated anchors specifically suited for use in concrete shall be used. 3. For the below-named items, mounting heights from finished floor, or finished grade to top is applicable, depending on the type of wiring device to be installed in the outlet box. Mounting heights for outlet boxes shall be as follows, unless otherwise specified herein, indicated on the Drawings, or required by the Americans with Disability Act (ADA): a. Light switches, 48 inches b. Receptacles in outdoor locations, 24 inches 4. Outlet boxes shall be provided in the material of construction required for the area in which it is installed. Reference the requirements in Part 2 herein, and the area designations indicated on the Drawings. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 16141-1 Wiring Devices SECTION 16141 WIRING DEVICES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish and install all switches and receptacles of the type and at the locations as shown on the Drawings. B. All switches and receptacles shall be furnished and installed in outlet boxes. Reference Section 16130, Boxes, for outlet box requirements. C. Reference Section 16000, Basic Electrical Requirements, and Section 16123, Low Voltage Wire and Cable. 1.02 CODES AND STANDARDS A. Wiring devices shall be designed, manufactured, and/or listed to the following standards as applicable: 1. UL 20 – General Use Snap Switches 2. UL 498 – Standard for Attachment Plugs and Receptacles 3. UL 943 – Ground Fault Circuit Interrupters 4. UL 1203 – Standard for Explosion-proof and Dust-ignition-proof Electrical Equipment for use in Hazardous (Classified) Locations. 1.03 SUBMITTALS A. In accordance with the procedures and requirements set forth in the General Conditions and Section 01300, Submittals, the Contractor shall obtain from the equipment manufacturer and submit shop drawings. Each submittal shall be identified by the applicable specification section. 1.04 SHOP DRAWINGS A. Each submittal shall be complete in all respects, incorporating all information and data listed herein and all additional information required for evaluation of the proposed equipment's compliance with the Contract Documents. B. Partial, incomplete, or illegible submittals will be returned to the Contractor without review for resubmittal. City of Denton Hazen and Sawyer BID SET 16141-2 Wiring Devices C. Shop drawings shall include, but not be limited to: 1. Product data sheets. 1.05 SPARE PARTS A. The Contractor shall furnish 10% (minimum of 1) spare of each receptacle, switch, and plug furnished and installed for this project. B. Spare parts lists, included with the shop drawing submittal, shall indicate specific sizes, quantities, and part numbers of the items to be furnished. Terms such as "1 lot of packing material" are not acceptable. C. Parts shall be completely identified with a numerical system to facilitate parts inventory control and stocking. Each part shall be properly identified by a separate number. Those parts which are identical for more than one size shall have the same parts number. 1.06 IDENTIFICATION A. Each switch and receptacle shall be identified with the equipment item number, manufacturer's name or trademark, and such other information as the manufacturer may consider necessary, or as specified, for complete identification. PART 2 -- PRODUCTS 2.01 MANUFACTURERS A. The equipment covered by these Specifications is intended to be standard equipment of proven performance as manufactured by reputable concerns. Equipment shall be designed, constructed and installed in accordance with the best practices of the trade, and shall operate satisfactorily when installed as shown on the Drawings. B. The Contractor shall use the products of a single manufacturer for each type of wiring device. C. The Contractor shall use the products of a single manufacturer for all device plates. Plate variations are allowed for the following devices: 1. Where the selected plate manufacturer does not manufacture a suitable finish plate. 2. For heavy-duty receptacles rated at more than 30A. 3. Where non-standard plates are required, specified, or shown. D. The Contractor shall furnish and install all wiring devices and device plates. E. In non-hazardous areas, provide specification grade devices manufactured by Appleton, Crouse-Hinds, Leviton, Hubbell, Pass & Seymour, or Engineer approved equal. City of Denton Hazen and Sawyer BID SET 16141-3 Wiring Devices F. In hazardous areas, provide devices manufactured by Appleton, Cooper Crouse-Hinds, Hubbell-Killark, or Engineer approved equal. 2.02 WIRING DEVICES A. Wall switches for non-hazardous areas shall be rated for the current required to suit the application, but not less than 20A. Double pole, three-way, and four-way switches shall be provided where indicated on the Drawings, and as required. Switches shall be rated for 120-277VAC, and shall be UL 20 Listed. B. Convenience receptacles for non-hazardous areas shall be rated for 20A at 125VAC. Convenience receptacles shall be UL 498 Listed. Tamper resistant receptacles are not acceptable. C. Special purpose receptacles (welders, lab equipment, etc.) shall be provided with the proper NEMA configuration and ampacity as indicated on the Drawings. The coordinating plug for each special purpose receptacle shall be provided with the equipment which it is serving. D. Ground fault circuit interrupter receptacles shall be rated for 20A at 125VAC. Ground fault circuit interrupter receptacles shall be UL 943 Listed. Tamper resistant receptacles are not acceptable. E. All wiring devices shall be approved for use with stranded conductors, if stranded conductors are to be used with the device. Reference Section 16123, Low Voltage Wire and Cable for conductor requirements 2.03 DEVICE PLATES A. Device plates for outdoor installations shall be Appleton Type FSK, Crouse-Hinds #DS185, or equal for wall switches. Device plates for receptacles shall be “in-use” style. “In-use” weatherproof covers shall be rugged, minimum 3 ¼” depth, die-cast aluminum as manufactured by Thomas & Betts "Red Dot," Intermatic International, Inc., or equal. 2.04 PLUGS A. The Contractor shall furnish suitable plugs with equipment furnished under the respective specification Section. Plugs shall be black rubber or plastic. For waterproof receptacles, the plugs shall be similar in construction to the receptacles and shall be encased in corrosion resistant yellow housing provided with clamping nuts and stuffing gland cable outlets. 2.05 PROCESS INSTRUMENTS A. The Contractor shall furnish and install a local disconnect switch at each process instrument (e.g., level transmitter, flow transmitter, analytical instrument etc.,) whether shown on the Drawings or not, to disconnect the 120VAC power supply to the instrument. The device shall be a NSSC series manual motor starting switch without overload protection as manufactured by Crouse-Hinds, Appleton equivalent, or equal. For hazardous locations, the device shall be UL 1203 Listed. City of Denton Hazen and Sawyer BID SET 16141-4 Wiring Devices PART 3 -- EXECUTION 3.01 INSTALLATION A. Where more than one (1) switch occurs at one (1) location, gang plates shall be used. B. All device plates shall be set true and plumb, and shall fit tightly against the finished wall surfaces and outlet boxes. C. Wiring device box (outlet box) mounting heights shall be as specified in Section 16130, Boxes. D. When indicated height would place any of the equipment at an unsuitable location the Contractor shall bring it to the attention of the Engineer for a decision. E. Ground fault circuit interrupter receptacles shall be furnished and installed where indicated on the Drawings, and as required by the NEC. F. All receptacles shall have a self-adhesive label installed on the top at the respective device plate that indicates which panel and which circuit number the receptacle is supplied from. Labels shall have a white background and black lettering in 14 point font. 3.02 CIRCUITING A. Convenience receptacles shall be grouped on circuits separate from the lighting circuits. A maximum of eight (8) convenience receptacles are permitted per 20A, 120V circuit, unless otherwise indicated on the Drawings. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 16170-1 Grounding and Bonding SECTION 16170 GROUNDING AND BONDING PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish and install grounding systems complete in accordance with the minimum requirements established by Article 250 of the NEC. Article 250 of the NEC shall be considered a minimum requirement for compliance with this Specification. B. Grounding of all instrumentation and control systems shall be furnished and installed in accordance with the manufacturer/system requirements and IEEE 1100-92, Powering and Grounding of Sensitive Electronic Equipment. Conflicts shall be promptly brought to the attention of the Engineer. C. In addition to the NEC requirements, structural steel shall be permanently and effectively grounded. D. Reference Section 16000, Basic Electrical Requirements 1.02 CODES AND STANDARDS A. Equipment and materials covered under this Section shall be designed, manufactured, and/or listed to the following standards as applicable: 1. UL 467 – Grounding and Bonding Equipment 2. IEEE 81 – Guide for Measuring Earth Resistivity, Ground Impedance, and Earth Surface Potentials of a Ground System. 1.03 SUBMITTALS A. In accordance with the procedures and requirements set forth in the General Conditions and Section 01300, Submittals, the Contractor shall obtain from the equipment manufacturer and submit the following: 1. Shop Drawings 2. Reports of certified field tests. B. Each submittal shall be identified by the applicable specification section. City of Denton Hazen and Sawyer BID SET 16170-2 Grounding and Bonding 1.04 SHOP DRAWINGS A. Each submittal shall be complete in all respects, incorporating all information and data listed herein and all additional information required for evaluation of the proposed equipment's compliance with the Contract Documents. B. Partial, incomplete, or illegible submittals will be returned to the Contractor without review for resubmittal. C. Shop drawings shall include but not be limited to: 1. Product data sheets. 2. Drawings and written description of how the Contractor intends to furnish and install the grounding system. PART 2 -- PRODUCTS 2.01 MANUFACTURERS A. The equipment covered by these specifications shall be standard equipment of proven performance as manufactured by reputable concerns. Equipment shall be designed, constructed, and installed in accordance with the best practices of the trade, and shall operate satisfactorily when installed as shown on the Drawings. 2.02 GROUND RODS AND GRID A. Ground rods shall be rolled to a commercially round shape from a welded copper-clad steel manufactured by the molten-welding process or by the electro-formed process (molecularly bonded). They shall have an ultimate tensile strength of 75,000 pounds per square inch (psi) and an elastic limit of 49,000 psi. The rods shall be not less than 3/4 inch in diameter by 10 feet in length; and the proportion of copper shall be uniform throughout the length of the rod. The copper shall have a minimum wall thickness of 0.010 inch at any point on the rod. Ground rods shall be UL 467 listed. The ground rods shall be manufactured by Erico Products, Blackburn, or equal. B. Except where specifically indicated otherwise, all exposed non current-carrying metallic parts of electrical equipment, metallic raceway systems, grounding conductors in nonmetallic raceways and neutral conductors of wiring systems shall be grounded. C. The ground connection shall be made at the main service equipment and shall be extended to the ground grid surrounding the structure. The ground grid shall also be connected to the point of entrance of the metallic water service. Connection to the water pipe shall be made by a suitable ground clamp or lug connection to a plugged tee. If flanged pipes are encountered, connection shall be made with the lug bolted to the street side of the flanged connection. City of Denton Hazen and Sawyer BID SET 16170-3 Grounding and Bonding D. Where ground fault protection is employed, care shall be taken so that the connection of the ground and neutral does not interfere with the correct operation of the ground fault protection system. 2.03 FITTINGS A. Grounding connections to equipment shall be bolted. Cable end connections shall be made by hydraulic crimp or exothermically welded. Split bolt type connectors are not acceptable. Fittings shall be UL 467 listed. 2.04 EQUIPMENT GROUNDING CONDUCTORS A. An insulated equipment grounding conductor, which shall be separate from the electrical system neutral conductor, shall be furnished and installed for all circuits. Insulation shall be of the same type as the underground conductors in the raceway and shall be green in color. Equipment grounding conductors shall be furnished and installed in all conduits. Use of conduits as the NEC required equipment grounding conductor is not acceptable. 2.05 EQUIPMENT GROUNDS A. Equipment grounds shall be solid and continuous from a connection at earth to all distribution panelboards. Ground connections at panelboards, outlets, equipment, and apparatus shall be made in an approved and permanent manner. 2.06 EXOTHERMIC WELDS A. All exothermic welding shall be completed per welding kit manufacturer's instructions. Exothermic welds shall be CadWeld by Erico or ThermoWeld. PART 3 -- EXECUTION 3.01 INSTALLATION A. Metal surfaces where grounding connections are to be made shall be clean and dry. Steel surfaces shall be ground or filed to remove all scale, rust, grease, and dirt. Copper and galvanized steel shall be cleaned with emery cloth to remove oxide before making connections. B. Ground Grid 1. A main ground grid shall be provided for each structure and interconnecting structure grids consisting of driven ground rods as shown on the Drawings. The ground rods shall be interconnected by the use of copper cable exothermically welded to the rods. The grounding cables shall be installed after the excavations for the building have been completed and prior to the pouring of concrete for the footings, mats, etc. Copper "pigtails" shall be connected to the ground grid and shall enter the buildings and structure from the outside and shall be connected to steel structures, and equipment as described in this Section and as required to provide a complete grounding system. The copper pigtails shall be exothermically City of Denton Hazen and Sawyer BID SET 16170-4 Grounding and Bonding welded to the ground grid, and connected to building reinforcement steel by hydraulic crimp. 2. Grounding conductors shall be continuous between points of connection; splices shall not be permitted. 3. Where conductors are exposed and subject to damage from personnel, traffic, etc., conductors shall be installed in metal raceway. The raceway shall be bonded to the grounding system. 4. Where subsurface conditions do not permit use of driven ground rods to obtain proper ground resistance, rods shall be installed in a trench or plate electrodes shall be provided, as applicable and necessary to obtain proper values of resistance. 5. Buried exothermic welds and ground ring shall not be backfilled until inspected by Engineer. C. Raceways 1. Conduit which enters equipment such as transformers, switchboards, panelboards, RVSS starters, instrument and control panels, and similar equipment shall be bonded to the ground bus or ground lug, where provided, and as otherwise required by the NEC. 3.02 TESTING A. All tests shall be performed in accordance with the requirements of the General Conditions and Division 1. The following tests are required: 1. Witnessed Shop Tests a. None required. 2. Field Tests a. Field testing shall be done in accordance with the requirements specified in the General Conditions, Division 1, and NETA Acceptance Testing Specifications, latest edition. b. Fall of potential tests shall be performed on the ground grid per IEEE81 recommendations by a third party, independent testing firm. A fall of potential plot shall be submitted at the conclusion of testing for Engineer review. Documentation indicating the location of the rod and grounding system as well as the resistance and soil conditions at the time the measurements were made shall be submitted. Testing shall show that the ground grid has 5 ohms resistance or less. Due to soil conditions and/or unforeseen field conditions, ground resistances greater than 5 ohms may be acceptable if specifically approved in writing by the Engineer. Ground resistance measurements shall be made in normally dry weather not less City of Denton Hazen and Sawyer BID SET 16170-5 Grounding and Bonding than 48 hours after rainfall and with the ground grid under test isolated from other grounds. c. Continuity tests for the grounding electrode conductor shall also be performed. Test will be accepted when a resistance of less than 1 ohm is shown for this conductor. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 16170-6 Grounding and Bonding This page left blank intentionally City of Denton Hazen and Sawyer BID SET 16190-1 Supporting Devices SECTION 16190 SUPPORTING DEVICES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish and install structural supports for mounting and installing all conduit, electrical equipment, lighting, alarm systems, instrumentation, and communications equipment furnished under this Contract. B. Equipment shall be installed strictly in accordance with recommendations of the manufacturer and best practices of the trade resulting in a complete, operable, and safe installation. The Contractor shall obtain written installation manuals from the equipment manufacturer prior to installation. C. Reference Section 16000, Basic Electrical Requirements. 1.02 SUBMITTALS A. In accordance with the procedures and requirements set forth in the General Conditions and Section 01300, Submittals, the Contractor shall obtain from the equipment manufacturer and submit the following: 1. Shop drawings 2. Structural support calculations (if required) B. Each submittal shall be identified by the applicable Specification section. 1.03 SHOP DRAWINGS A. Each submittal shall be complete in all respects, incorporating all information and data listed herein and all additional information required for evaluation of the proposed equipment's compliance with the Contract Documents. B. Partial, incomplete, or illegible submittals will be returned to the Contractor without review for resubmittal. C. Shop drawings shall include but not be limited to: 1. Product data sheets. 2. Complete assembly, layout, installation, and foundation drawings with clearly marked dimensions. City of Denton Hazen and Sawyer BID SET 16190-2 Supporting Devices PART 2 -- PRODUCTS 2.01 MANUFACTURERS A. The equipment covered by this Specification is intended to be standard equipment of proven performance as manufactured by reputable concerns. Equipment shall be designed, constructed, and installed in accordance with the best practices of the trade, and shall operate satisfactorily when installed as shown on the Drawings. 2.02 MATERIALS A. Support channel shall be 1-5/8” by 1-5/8” minimum, with 12 gage material thickness. B. Support channel, support channel fittings, and threaded rod shall be Type 304 Stainless Steel. C. Fastening hardware (bolts, nuts, washers, and screws) shall be Type 304 Stainless Steel. PART 3 -- EXECUTION 3.01 INSTALLATION A. Concrete or Masonry Inserts 1. The Contractor shall be responsible for the furnishing and installation of all conduit sleeves, anchor bolts, masonry inserts, and similar devices required for installation of equipment furnished under this Contract. 2. If a time delay for the arrival of any special inserts or equipment drawings, etc. occurs, the Contractor may, if permitted by the Engineer, make arrangements for providing approved recesses and openings in the concrete or masonry and, upon subsequent installation, the Contractor shall be responsible for filling in such recesses and openings. Any additional costs that may be incurred by this procedure shall be borne by the Contractor. 3. The Contractor shall furnish leveling channels for all switchboards, RVSS enclosures, and similar floor mounted equipment. The leveling channels shall be provided for embedment in the equipment housekeeping pads. Coordination of the installation of these channels with the concrete pad is essential and required. Pad height shall be as required to maintain concrete coverage of the reinforcement bars while not causing associated equipment to exceed the maximum mounting height requirements of the NEC. B. Support Fastening and Locations 1. All equipment fastenings to columns, steel beams, and trusses shall be by beam clamps or welded. No holes shall be drilled in the steel. City of Denton Hazen and Sawyer BID SET 16190-3 Supporting Devices 2. Support channel shall be provided wherever required for the support of starters, switches, panels, and miscellaneous equipment. 3. All equipment, devices, and raceways that are installed on the dry side of a water bearing wall shall not be installed directly onto the wall. Support channel shall be used to allow ventilation air to pass behind the equipment, devices, or raceway. 4. All supports shall be rigidly bolted together and braced to make a substantial supporting framework. Where possible, control equipment shall be grouped together and mounted on a single framework. 5. Aluminum support members shall not be installed in direct contact with concrete. Stainless steel or non-metallic "spacers" shall be used to prevent contact of aluminum with concrete. 6. Actual designs for supporting framework should take the nature of a picture frame of support channels and bracket with a plate for mounting the components. The Contractor is responsible for the design of supporting structure; he shall submit design details to the Engineer for acceptance before proceeding with the fabrication. 7. Wherever dissimilar metals come into contact, the Contractor shall isolate these metals as required with neoprene washers, nine (9) mil polyethylene tape, or gaskets. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 16190-4 Supporting Devices This page left blank intentionally City of Denton Hazen and Sawyer BID SET 16195-1 Electrical - Identification SECTION 16195 ELECTRICAL - IDENTIFICATION PART 1 -- GENERAL 1.01 THE REQUIREMENT A. All electrical equipment shall be properly identified in accordance with these Specifications and the Contract Drawings. All switchboards, panelboards, combination starters, control panels, pull and junction boxes, enclosures, disconnect switches, control stations, and similar equipment shall be identified in the manner described, or in an equally approved manner. B. The types of electrical identification specified in this section include, but are not limited to, the following: 1. Operational instructions and warnings. 2. Danger signs. 3. Equipment/system identification signs. 4. Nameplates. 1.02 SIGNS A. "DANGER-HIGH-VOLTAGE" signs shall be securely mounted on the entry doors of all electrical rooms. 1.03 LETTERING AND GRAPHICS A. The Contractor shall coordinate names, abbreviations, and other designations used in the electrical identification work with the corresponding designations shown, specified or scheduled. Provide numbers, lettering, and wording as indicated or, if not otherwise indicated, as recommended by manufacturers or as required for proper identification and operation/maintenance of the electrical systems and equipment. 1.04 SUBMITTALS A. In accordance with the procedures and requirements set forth in the General Conditions and Section 01300, Submittals, the Contractor shall obtain from the equipment manufacturer and submit shop drawings. Each submittal shall be identified by the applicable specification section. City of Denton Hazen and Sawyer BID SET 16195-2 Electrical - Identification 1.05 SHOP DRAWINGS A. Each submittal shall be complete in all respects, incorporating all information and data listed herein and all additional information required for evaluation of the proposed equipment's compliance with the Contract Documents. B. Partial, incomplete, or illegible submittals will be returned to the Contractor without review for resubmittal. C. Shop drawings shall include but not be limited to: 1. Product data sheets. PART 2 -- PRODUCTS 2.01 MANUFACTURERS A. The material covered by these Specifications is intended to be standard material of proven performance as manufactured by reputable concerns. Material shall be fabricated, constructed, and installed in accordance with the best practices of the trade, and shall operate satisfactorily when installed as specified herein and shown on the Drawings. 2.02 NAMEPLATES A. Nameplates shall be engraved, high pressure plastic laminate, white with black lettering. B. Nameplates shall be attached to NEMA 4X enclosures utilizing UL-recognized mounting kits designed to maintain the overall UL Type rating of the enclosure. Mounting kit fasteners shall be stainless steel Type AHK10324X as manufactured by Hoffman, or equal. 2.03 HIGH VOLTAGE SIGNS A. Standard "DANGER" signs shall be of baked enamel finish on 20 gage steel; of standard red, black and white graphics; 14 inches by 10 inches size except where 10 inches by 7 inches is the largest size which can be applied where needed, and except where a larger size is needed for adequate identification. 2.04 CONDUIT IDENTIFICATION A. Conduit identification shall be as specified in Section 16111, Conduit. 2.05 WIRE AND CABLE IDENTIFICATION A. Field installed wire and cable identification shall be as specified in Section 16123, Low Voltage Wire and Cable. B. A plastic laminate nameplate shall be provided at each panelboard. This nameplate shall be used to clearly convey the conductor identification means used at that piece of equipment (i.e. Phase A=Brown, Phase B=Orange, C = Yellow). City of Denton Hazen and Sawyer BID SET 16195-3 Electrical - Identification C. Wiring identification for factory installed wiring in equipment enclosures shall be as specified in the respective section. 2.06 BOX IDENTIFICATION A. Pull, junction and device box identification shall be as specified in Section 16130 – Boxes. PART 3 -- EXECUTION 3.01 NAMEPLATES A. Nameplates shall be attached to the equipment enclosures with (2) two stainless steel sheet metal screws for nameplates up to 2-inches wide. For nameplates over 2-inches wide, four (4) stainless steel sheet metal screws shall be used, one (1) in each corner of the nameplate. For NEMA 4X enclosures, reference Part 2 for attachment method. The utilization of adhesives is not permitted. 3.02 OPERATIONAL IDENTIFICATION AND WARNINGS A. Wherever reasonably required to ensure safe and efficient operation and maintenance of the electrical systems and electrically connected mechanical systems and general systems and equipment, including prevention of misuse of electrical facilities by unauthorized personnel, install plastic signs or similar equivalent identification, instruction, or warnings on switches, outlets, and other controls, devices, and covers or electrical enclosures. Where detailed instructions or explanations are needed, provide plasticized tags with clearly written messages adequate for the intended purposes. Signs shall be attached as specified above for nameplates. 3.03 POWER SOURCE IDENTIFICATION A. After installation of all field equipment (i.e. valves, motors, fans, instruments, etc) install nameplates at each power termination for the field equipment. Nameplate data shall include equipment designation (tag number), power source (panelboard, etc), circuit number, conduit number from schedule and voltage/phase. B. Contractor to coordinate with the Engineer and the Owner regarding exact nameplate placement during construction. C. Nameplates shall be as specified herein. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 16195-4 Electrical - Identification This page left blank intentionally City of Denton Hazen and Sawyer BID SET 16426-1 Low Voltage Switchboards SECTION 16426 LOW VOLTAGE SWITCHBOARDS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, install, test, and place in satisfactory operation, the low voltage switchboards as specified herein and indicated on the Drawings. B. The line-up shall contain main breaker, feeder breakers, metering equipment, control devices, and all accessories as specified herein, indicated on the Drawings, and as required to result in a complete and operable power distribution equipment assembly. C. The Contractor shall obtain the switchboard from one manufacturer who shall also manufacture the structure and major equipment components, which includes, but is not limited to, circuit breakers, instrument transformers, meters, relays, and controls. Sub-contracting of wiring is not acceptable. D. The switchboard shall be assembled using NEMA rated components. Components designed and built to International Electrotechnical Commission (IEC) standards are not recognized. Equipment designed, manufactured and labeled in compliance with IEC standards is not acceptable. E. Circuit breaker control and relaying/metering circuits shall be wired in accordance with the requirements specified herein or indicated on the Drawings. 1.02 CODES AND STANDARDS A. All equipment shall be listed by and shall bear the label of Underwriter's Laboratories, Incorporated (U.L.). B. The equipment shall comply with the following codes and standards: 1. National Electrical Code (NEC) 2. Institute of Electrical and Electronic Engineers (IEEE) 3. American National Standards Institute (ANSI): a. C12.1 - Code for Electricity Metering b. C57.13 - Instrument Transformers. 4. National Electrical Manufacturer's Association (NEMA): a. AB 1 - Molded Case Circuit Breakers and Molded Case Switches. City of Denton Hazen and Sawyer BID SET 16426-2 Low Voltage Switchboards b. PB 2 - Deadfront Distribution Switchboards. 5. Underwriters Laboratories, Inc. (U.L.): a. U.L. 98 - Enclosed and Dead Front Switches. b. U.L. 489 - Molded Case Circuit Breakers. c. U.L. 891 - Dead-Front Switchboards. 1.03 SUBMITTALS A. In accordance with the procedures and requirements set forth in the General Conditions and Section 01300, Submittals, the Contractor shall obtain from the equipment manufacturer and submit the following: 1. Shop Drawings 2. Operation and Maintenance Manuals 3. Spare Parts List 4. Reports of Certified Shop and Field Tests 5. Manufacturer’s Representatives Installation Certification B. Each submittal shall be identified by the applicable specification section. 1.04 SHOP DRAWINGS A. Each submittal shall be complete in all respects, incorporating all information and data listed herein and all additional information required for evaluation of the proposed equipment's compliance with the Contract Documents. B. Partial, incomplete or illegible submissions will be returned to the Contractor without review for resubmittal. C. Shop drawings for each switchboard assembly shall include but not be limited to: 1. A Compliance, Deviations, and Exceptions (CD&E) letter. If the shop drawings are submitted without this CD&E letter, the submittal will be rejected. The letter shall include all comments, deviations and exceptions taken to the Drawings and Specifications by the Contractor AND Equipment Manufacturer/Supplier. This letter shall include a copy of this specification section. In the left margin beside each and every paragraph/item, a letter "C", "D", or "E" shall be typed or written in. The letter "C" shall be for full compliance with the requirement. The letter "D" shall be for a deviation from the requirement. The letter "E" shall be for taking exception to a requirement. Any requirements with the letter "D" or "E" beside them shall be provided with a full typewritten explanation of the deviation/exception. Handwritten City of Denton Hazen and Sawyer BID SET 16426-3 Low Voltage Switchboards explanation of the deviations/exceptions is not acceptable. The CD&E letter shall also address deviations, and exceptions taken to each Drawing related to this Specification Section. 2. Product data sheets identifying all electrical ratings. 3. Complete assembly, layout, anchoring, and installation drawings with clearly marked dimensions. 4. Approximate total shipping weight of each equipment assembly. 5. Example equipment nameplate data sheet. 6. Plan, front and side view drawings, including overall dimensions of each switchboard assembly. Identify shipping splits and show conduit stub-up area locations on the Drawings. 7. Internal wiring diagram of each low voltage switchboard assembly. Each wiring diagram shall include wire identification and terminal numbers. 8. Internal interconnection wiring diagrams including wiring identification and terminal numbers. 9. Complete single line diagram for each switchboard line-up. The drawing shall indicate devices comprising the switchboard assembly including, but not limited to, circuit breakers, control power and instrument transformers, meters, relays, and control devices. Clearly indicate electrical ratings of all devices. 10. Bill of material list for each switchboard assembly. 11. Nameplate schedule. 12. Manufacturer's installation instructions. 13. Manufacturer's warranty statement. The shop drawing information shall be complete and organized in such a way that the Engineer can determine if the requirements of these specifications are being met. Copies of technical bulletins, technical data sheets from "soft-cover" catalogs, and similar information which is "highlighted" or somehow identifies the specific equipment items the Contractor intends to provide are acceptable and shall be submitted. 1.05 OPERATIONS AND MAINTENANCE MANUALS A. The Contractor shall submit operation and maintenance manuals in accordance with the procedures and requirements set forth in the General Conditions and Division 1. The manuals shall include: 1. Instruction books and/or leaflets. City of Denton Hazen and Sawyer BID SET 16426-4 Low Voltage Switchboards 2. Recommended spare parts list. 3. Final as-built construction drawings included in the shop drawings incorporating all changes made in the manufacturing process and field installation. 1.06 SPARE PARTS A. The switchboard shall be furnished with all spare parts as recommended by the equipment manufacturer. All spaces in switchboards shall be furnished with a spare circuit breaker where indicated on the Drawings. B. The spare parts shall be packed in containers suitable for long term storage, bearing labels clearly designating the contents and the pieces of equipment for which they are intended. C. Spare parts shall be delivered at the same time as the equipment to which they pertain. The Contractor shall properly store and safeguard such spare parts until completion of the Work, at which time they shall be delivered to the Owner. D. Spare parts lists, included with the shop drawing submittal shall indicate specific sizes, quantities, and part numbers of the items to be furnished. Terms such as "1 lot of packing material" are not acceptable. E. Parts shall be completely identified with a numerical system to facilitate parts inventory control and stocking. Each part shall be properly identified by a separate number. Those parts which are identical for more than one size, shall have the same parts number. 1.07 IDENTIFICATION A. Each switchboard assembly shall be identified with the identification name and/or number indicated on the Drawings (e.g., SWBD-HCDF, SWBD-WPF). A nameplate shall be securely affixed in a conspicuous place on each switchboard assembly. Nameplates shall be as specified in Section 16195, Electrical - Identification. PART 2 -- PRODUCTS 2.01 MANUFACTURERS A. The equipment covered by these specifications is intended to be standard equipment of proven performance as manufactured by reputable concerns. Equipment shall be designed, constructed, and installed in accordance with the best practices of the trade, and shall operate satisfactorily when installed as shown on the Drawings. B. It is the intent of these specifications that the switchboard be produced by a single manufacturer who shall be responsible for matching all components and providing equipment which functions together as a system. C. The equipment shall be Pow-R-Line C as manufactured by Eaton, Spectra Series as manufactured by the General Electric Company, Square D Company equivalent, or Siemens Energy & Automation, Inc. equivalent. City of Denton Hazen and Sawyer BID SET 16426-5 Low Voltage Switchboards 2.02 CIRCUIT BREAKER SWITCHBOARD A. General 1. Furnish and install dead-front type, completely metal enclosed, self-supporting electrical equipment including main circuit breaker(s) and molded case branch circuit breaker assemblies of the number, rating and type noted on the Drawings. The equipment shall meet Underwriters' Laboratories requirements and shall be a furnished with a U.L. label. 2. The main breaker section and distribution section shall be NEMA Type 3R industrial use enclosures. The main circuit breaker section shall be totally accessible from the front and the sides. The distribution switchboard shall be totally accessible from the front and the sides. Equipment assemblies requiring rear access are not acceptable. The framework shall be of U.L. gauge steel. Ventilation shall be provided as required. 3. All wire troughs shall have hinged doors. 4. The equipment assemblies shall be suitable for operation at the available fault current, 65 kA (minimum). The equipment assemblies shall be labeled to indicate the maximum available fault current rating, taking into account the structure, bussing, main circuit breaker and switchboard branch circuit devices. The short circuit current rating shall not be less than that specified herein or indicated on the Drawings. The distribution switchboard branch circuit devices short circuit current rating shall be fully rated. 5. All bus shall be tin-plated copper. The bussing shall be of sufficient cross sectional area to meet U.L. standard 891 for temperature rise. The fully rated main bus shall have a maximum ampacity as indicated on the Drawings and extend the full length of the equipment. The main bus shall be 100 percent rated. The ground bus shall be sized per U.L. standard 891, installed in the entire length of the equipment assemblies. The distribution switchboard bus shall be rated as required by the rating of the mounted branch devices, including spares or spaces. Full height vertical bus shall be provided to accommodate future circuit breakers. Less than full height vertical bus which will only accommodate the circuit breakers included for this project is unacceptable. 6. Provide engraved plastic nameplates to identify the main circuit breaker and each branch circuit breaker. The circuit number and circuit name shall appear on the nameplate in accordance with the single line diagram(s) indicated on the Drawings. Nameplates shall be as specified in Section 16195, Electrical - Identification. B. Main Circuit Breaker Section 1. The main circuit breaker section shall be furnished and installed for front and side accessibility. City of Denton Hazen and Sawyer BID SET 16426-6 Low Voltage Switchboards 2. The main circuit breaker shall be a fixed type, molded case manually operated, on- off breaker, 100 percent rated with full-function trip system, sensors, and rating plug. 3. The main circuit breaker shall be Square D Company SED type, Cutler Hammer/Westinghouse SPB type, General Electric Power Break 2, or equal. The breaker shall be rated for 65,000 A RMS symmetrical at 480V. The full function trip system shall be MICROLOGIC by Square D Company, Cutler Hammer/Westinghouse Digitrip RMS 810, or General Electric Company equivalent with adjustable instantaneous, long-time pick-up and delay, short-time pick-up and delay, ground fault pick-up and delay, and trip indicator, minimum. 4. Provide control power and current transformers as required. Provide a minimum of two (2) auxiliary contacts for remote indication of breaker position. Provide other accessories as specified herein or indicated on the Drawings. 5. Provide a power monitor in the main circuit breaker section. Power monitoring system shall include all required PTs, CTs, etc. for a complete system. Power monitor shall be ION7550 as manufactured by the Square D Company, or approved equal. C. Distribution Switchboard 1. The distribution switchboard shall include group-mounted branch circuit breakers which are to be totally front accessible and front connectable. The circuit breaker connections to the distribution panel bussing shall be of bolt-on design such that the connections grip the bus bars firmly under high-fault conditions. 2. The switchboard manufacturer shall provide all the proper lugs for all cable connections as required to avoid field modifications. 3. Branch circuit breakers shall be molded case type with ratings as indicated on the Drawings. Branch circuit breakers shall be rated for 65,000 A RMS symmetrical at 480V. 2.03 SURGE PROTECTIVE DEVICES A. The switchboard shall be furnished with integrated Type II surge protective devices (SPD). SPDs shall be provided in the location and quantity as shown on the Drawings. B. The SPD shall be rated, designed, tested, listed, and labeled in accordance with UL-1449, latest edition. C. The SPD shall be factory installed by the switchboard manufacturer using a direct bus connection. There shall be no cable connection between the bus bar and the SPD device. D. The SPD shall have a fault current rating equal to or greater than that of the fault current rating of the switchboard. The SPD shall employ metal-oxide varistor (MOV) technology. If integral fusing is used, the fuses shall allow the maximum rated surge current to pass without fuse operation. City of Denton Hazen and Sawyer BID SET 16426-7 Low Voltage Switchboards E. The SPD shall have a maximum continuous operating voltage (MCOV) of at least 115% of the nominal voltage of the switchboard. The Voltage Protection Rating (VPR) of each SPD shall not exceed the following: SYSTEM VOLTAGE L-N L-G L-L N-G 208Y/120 700V 700V 1200V 700V 480Y/277 1200V 1200V 1800V 1200V 480 DELTA N/A 1200V 2000V N/A 240 DELTA N/A 1200V 1200V N/A 120/240 700V 700V 1200V 700V F. The Nominal Discharge Current (In) of the SPD shall be 20kA. Peak surge current ratings shall not be used as a basis for applying the SPD to the system. The surge current rating for each SPD shall be as indicated on the Drawings. Surge current ratings are indicated on single line diagrams. Surge current rating indicated is on a per phase basis. G. Each SPD system shall provide surge protection in all possible modes. Surge protection shall be as follows: SYSTEM CONFIGURATION MODES OF PROTECTION NUMBER OF MODES 3-Phase Wye L-N, L-G, N-G 7 3-Phase Delta L-L, L-G 6 3-Phase Impedence Grounded L-L, L-G 6 Single-Phase L-N, L-G, N-G 3 H. The SPD shall be furnished with an audible alarm and silence pushbutton, integral SPD status LEDs (one per phase), and a Form C dry contact for remote indication of alarm. A surge counter shall also be provided. I. The SPD equipment shall be SPD Series by Eaton, SurgeLogic by the Square D Company, Tranquell by the General Electric Company, Siemens Energy and Automation Inc. equivalent, or equal. PART 3 -- EXECUTION 3.01 INSTALLATION A. The switchboard shall be furnished and installed as shown on the Drawings and in accordance with the manufacturer's installation instructions. One (1) copy of these instructions shall be included with the equipment at time of shipment. The equipment shall be suitably protected until accepted by the Owner. City of Denton Hazen and Sawyer BID SET 16426-8 Low Voltage Switchboards B. The equipment shall be installed and checked in accordance with the manufacturer's recommendations. This shall include but not limited to: 1. Checking to ensure that the pad location is level to within .125 inches. 2. Checking to ensure that all bus bars are torqued to the manufacturer's recommendations. 3. Assemble all shipping sections, remove all shipping braces and connect all shipping split mechanical and electrical connections. 4. Secure assemblies to foundation or floor channels. 5. Inspect and install all circuit breakers in their proper places. 3.02 PAINTING A. Prior to final completion of the work, all metal surfaces of the equipment shall be cleaned thoroughly, and all scratches and abrasions shall be retouched with the same lacquer as used for shop finishing coats. 3.03 TESTING A. All tests shall be performed in accordance with the requirements of the General Conditions, and Division 1. The following tests are required: 1. Witness Shop Tests a. Not required. 2. Certified Shop Tests and Reports a. Submit description of proposed testing methods, procedures, and apparatus. Submit notarized and certified copies of all test reports. b. As a minimum, the entire switchboard assembly shall go through a quality inspection before shipment. This inspection shall include, but is not limited to, the following: i. Physical inspection of the structure and the electrical conductors including bussing, general wiring, and units. ii. General electrical tests including power circuit phasing, control circuit wiring, instrument transformers, meters, ground fault system, and device electrical operation. iii. AC dielectric tests of the power circuits and control circuits. iv. Markings/labels, including instructional type, Underwriters Laboratory (U.L.), and inspector's stamps. City of Denton Hazen and Sawyer BID SET 16426-9 Low Voltage Switchboards The manufacturer shall use integral quality control checks throughout the manufacturing process to maintain the correctness of the switchboard. 3. Field Tests a. Field tests shall be performed in accordance with requirements specified in the General Conditions, Division 1, and NETA Acceptance Testing Specifications, latest edition 3.04 SERVICES OF MANUFACTURER'S REPRESENTATIVE A. The Contractor shall provide the services of a qualified, factory-trained manufacturer's technical representative who shall adequately supervise the installation and testing of all equipment furnished under this Contract. The manufacturer's representative shall certify in writing that the equipment has been installed in accordance with the manufacturer's recommendations. No further testing or equipment startup may take place until this certification is accepted by the Owner. B. The manufacturer’s technical representative shall perform startup and functional testing of the switchboard as specified herein. C. The services of the manufacturer's representative shall be provided for a period of not less than as follows: 1. One (1) trip of one (1) working days during the installation of the switchboard. 2. One (1) trip of one (1) working days for the testing and startup of the switchboard. 3. One (1) trip of one (1) working day two (2) months before the warranty expiration to identify any issues to be corrected under warranty. E. Any additional time required to achieve successful installation and operation shall be at the expense of the Contractor. 3.05 FIELD ADJUSTMENTS A. The circuit breaker trip units shall be set in the field by a qualified representative of the manufacturer, or an outside testing company retained by the Contractor, in accordance with the settings designated in the coordination study. See Section 16000 – Basic Electrical Requirements. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 16426-10 Low Voltage Switchboards This page left blank intentionally City of Denton Hazen and Sawyer BID SET 16440-1 Disconnect Switches SECTION 16440 DISCONNECT SWITCHES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish and install separately mounted, individual disconnect switches as specified herein and indicated on the Drawings. B. Disconnect switches for process instruments are not included in the scope of this Section and shall be as specified in Section 16141 – Wiring Devices. 1.02 CODES AND STANDARDS A. Disconnect switches shall be designed, manufactured, and/or listed to the following standards as applicable: 1. UL 98 – Enclosed and Dead-Front Switches 2. NEMA 250 – Enclosures for Electrical Equipment 3. NEMA KS 1 – Heavy Duty Enclosed and Dead-Front Switches 1.03 SUBMITTALS A. In accordance with the procedures and requirements set forth in the General Conditions and Section 01300, Submittals, the Contractor shall obtain from the equipment manufacturer and submit the following: 1. Shop Drawings 2. Spare Parts List B. Each submittal shall be identified by the applicable specification section. 1.04 SHOP DRAWINGS A. Each submittal shall be complete in all respects, incorporating all information and data listed herein and all additional information required for evaluation of the proposed equipment's compliance with the Contract Documents. B. Partial, incomplete or illegible submittals will be returned to the Contractor without review for resubmittal. C. Shop drawings shall include but not be limited to: City of Denton Hazen and Sawyer BID SET 16440-2 Disconnect Switches 1. Product data sheets. 2. Complete layout and installation drawings with clearly marked dimensions for each type/size/rating of disconnect switch. 3. Assembled weight of each unit. D. The shop drawing information shall be complete and organized in such a way that the Engineer can determine if the requirements of these Specifications are being met. Copies of technical bulletins, technical data sheets from "soft-cover" catalogs, and similar information which is "highlighted" or somehow identifies the specific equipment items that the Contractor intends to provide are acceptable and shall be submitted. 1.05 SPARE PARTS A. The equipment shall be furnished with all spare parts as recommended by the equipment manufacturer. B. One (1) complete set of spare fuses for each ampere rating installed shall be furnished and delivered to the Owner at the time of final inspection. C. Spare parts lists, included with the shop drawing submittal, shall indicate specific sizes, quantities, and part numbers of the items to be furnished. Terms such as "1 lot of packing material" are not acceptable. D. Parts shall be completely identified with a numerical system to facilitate parts inventory control and stocking. Each part shall be properly identified by a separate number. Those parts which are identical for more than one size, shall have the same parts number. 1.05 IDENTIFICATION A. Each equipment item shall be identified with a nameplate. The nameplate shall be engraved indicating the circuit number and equipment name with which it is associated. Equipment identification shall be in accordance with Section 16195, Electrical - Identification. PART 2 -- PRODUCTS 2.01 MANUFACTURERS A. The equipment covered by this Specification is intended to be standard equipment of proven performance as manufactured by reputable concerns. Equipment shall be designed, constructed and installed in accordance with the best practices of the trade, and shall operate satisfactorily when installed as shown on the Drawings. B. Switches shall be manufactured by the Square D Company, Eaton, the General Electric Company, or Siemens Energy and Automation, Inc. City of Denton Hazen and Sawyer BID SET 16440-3 Disconnect Switches 2.02 DISCONNECT SWITCHES A. Disconnect switches shall be heavy-duty type and/or as specified in these Specifications. Switches shall be furnished and installed as shown on the Drawings and as required by the NEC. Handles shall be lockable. B. Disconnect switches shall be UL 98 Listed. C. Switches shall meet NEMA Standard KS 1 type HD requirements, be, single-throw, be externally operated, and be fused or non-fused as indicated on the Drawings. Switches shall have the number of the poles, voltage, and ampere ratings as shown on the Drawings. D. Disconnect switches 200A and below shall be NEMA 4X, Type 304 Stainless Steel. E. Disconnect switches above 200A shall be NEMA 3R, Painted Steel. F. Disconnect switches shall be quick-make, quick-break and with an interlocked cover which cannot be opened when switch is in the "ON" position and capable of being locked in the "OPEN" position. G. A complete set of fuses for all switches shall be furnished and installed as required. Time-current characteristic curves of fuses serving motors or connected in series with circuit breakers shall be coordinated for proper operation. Fuses shall have voltage rating not less than the circuit voltage. H. Disconnect switches shall be furnished with a factory installed internal barrier kit that helps prevent accidental contact with live parts and provides “finger-safe” protection when the door of the enclosed switch is open. I. Disconnect switches shall be furnished with a manufacturer-supplied ground lug kit for termination of equipment grounding conductors. Where a grounded (neutral) conductor is shown on the Drawings in the conduits connected to the disconnect switch, a manufacturer- supplied neutral bar shall be furnished for termination of the grounded conductors. Third party ground lug and neutral lug kits not supplied by the disconnect switch manufacturer are not acceptable. J. Fused disconnect switches shall be furnished for motor operated valve and gate actuators where shown on the Drawings. The Contractor shall coordinate the supply of these fused switches with the specific requirements of the actuator. Fuses with fast fault clearing times may be required for modulating valve actuators. K. Disconnect switches 200A and below shall be furnished with a factory installed electrical interlock kit that includes one (1) early-break auxiliary contact rated for 5A (minimum) at 120 VAC. City of Denton Hazen and Sawyer BID SET 16440-4 Disconnect Switches PART 3 -- EXECUTION 3.01 INSTALLATION A. All disconnect switches shall be mounted with the top of the enclosure at five (5) feet above the floor or finished grade, at the equipment height where appropriate, or where shown otherwise. B. Disconnect switches shall be provided in the enclosure type and material of construction required for the area in which it is installed. Reference the requirements in Part 2 herein. 3.02 TESTING A. All tests shall be performed in accordance with the requirements of the General Conditions and Division 1. The following tests are required: 1. Field Tests a. Field testing shall be done in accordance with the requirements specified in the General Conditions, Division 1, and NETA Acceptance Testing Specifications, latest edition. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 16470-1 Panelboards SECTION 16470 PANELBOARDS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish and install panelboards of voltage and current ratings as specified herein and indicated on the Drawings. Panelboards shall be furnished with circuit breaker ratings, number of breakers, number of poles and locations conforming to the panelboard schedules on the Drawings. B. Reference Section 16000, Basic Electrical Requirements; Section 16195, Electrical Identification 1.02 CODES AND STANDARDS A. Panelboards shall be designed, manufactured, and/or listed to the following standards as applicable: 1. Underwriters Laboratories a. UL 50 – Enclosures for Electrical Equipment, Non-environmental Considerations b. UL 67 – Standard for Panelboards c. UL 489 - Molded Case Circuit Breakers, Molded Case Switches, and Circuit Breaker Enclosures d. UL 943 – Ground Fault Circuit Interrupters 2. NEMA PB1 - Panelboards 3. National Electrical Contractors Association (NECA) Standard 407 – Standard for Installing and Maintaining Panelboards 1.03 SUBMITTALS A. In accordance with the procedures and requirements set forth in the General Conditions and Section 01300, Submittals, the Contractor shall obtain from the equipment manufacturer and submit the following: 1. Shop Drawings. 2. Spare Parts List. City of Denton Hazen and Sawyer BID SET 16470-2 Panelboards 3. Operation and Maintenance Manuals. 4. Reports of Field Tests. B. Each submittal shall be identified by the applicable specification section. 1.04 SHOP DRAWINGS A. Each submittal shall be complete in all respects, incorporating all information and data listed herein and all additional information required for evaluation of the proposed equipment's compliance with the Contract Documents. B. Partial, incomplete, or illegible submittals will be returned to the Contractor without review for resubmittal. C. Shop drawings shall include but not be limited to: 1. Product data sheets. 2. Complete assembly, layout, and installation drawings with clearly marked dimensions for each combination power unit. 3. Complete schedules indicating circuit designations as shown on the Drawings for each combination power unit. D. The submittal information shall reflect the specific equipment identification number as indicated on the Drawings (e.g., MPZ-HCDF, MPZ-WPF, etc.). 1.05 OPERATIONS AND MAINTENANCE MANUALS A. The Contractor shall submit operation and maintenance manuals in accordance with the procedures and requirements set forth in the General Conditions and Division 1. The manuals shall include: 1. Instruction books and/or leaflets. 2. Recommended spare parts list. 3. Final as-built construction drawings included in the shop drawings incorporating all changes made in the manufacturing process and during field installation. 1.06 SPARE PARTS A. For each combination power unit, the Contractor shall furnish to the Owner all spare parts as recommended by the equipment manufacturer. All spaces in the panelboards shall be furnished with a spare breaker as indicated in the schedules shown on the Drawings. B. Spare parts lists, included with the shop drawing submittal, shall indicate specific sizes, quantities, and part numbers of the items to be furnished. Terms such as "1 lot of packing material" are not acceptable. City of Denton Hazen and Sawyer BID SET 16470-3 Panelboards C. Parts shall be completely identified with a numerical system to facilitate parts inventory control and stocking. Each part shall be properly identified by a separate number. Those parts which are identical for more than one size shall have the same parts number. 1.07 IDENTIFICATION A. Each combination power unit shall be identified with the identification name/number indicated on the Drawings. A nameplate shall be securely affixed in a conspicuous place on each combination power unit. Nameplates shall be as specified in Section 16195, Electrical - Identification. PART 2 -- PRODUCTS 2.01 MANUFACTURERS A. The Equipment shall be designed, constructed and installed in accordance with the best practices of the trade, and shall operate satisfactorily when installed as shown on the Drawings. 2.02 CONDUCTORS (MAIN BUS AND BRANCH CONNECTORS) A. All main bus shall be copper sized in accordance with UL standards to limit the temperature rise on any current carrying part to a maximum of 50 degrees C above a maximum ambient temperature of 40 degrees C. 2.03 COMBINATION POWER UNITS A. Combination power units shall be installed as specified herein and indicated on the Drawings. The unit shall be a combination of a dry type transformer and a lighting panelboard. Transformer rating and panelboard bus rating shall be as indicated on the Drawings. The transformer and panelboard shall meet the requirements for these products as specified herein and elsewhere in these Specifications. Combination power units located outdoors shall be suitable for outdoor use and be provided in a NEMA 3R enclosure unless otherwise indicated. B. Combination power units shall have all copper windings and terminations, and an 80°C temperature rise. C. The combination power unit shall be a Mini-Power Zone as manufactured by the Square D Company, a Mini-Power Center as manufactured by Eaton, Servicecenter as manufactured by General Electric Company, or Siemens Energy and Automation, Inc. equivalent. D. Circuit Breakers 1. Circuit breakers shall be bolt-on, molded-case type and UL 489 Listed. All circuit breakers shall have quick-make, quick-break, toggle mechanism for manual as City of Denton Hazen and Sawyer BID SET 16470-4 Panelboards well as automatic operation. Tandem or half-size circuit breakers are not acceptable 2. Where indicated on the Drawings, or where required by Code, circuit breakers shall be equipped with integrally mounted ground fault interrupters complete with "TEST" push button and shall be of a type which fit standard panelboard spaces for the breaker continuous current rating required. Ground fault circuit interrupter style circuit breakers shall be UL 943 Listed. Circuit breakers used for lighting circuit switching shall be approved for the purpose and shall be marked "SWD". Where required by Article 440 of the NEC, circuit breakers installed for air conditioning units shall be HACR type. 3. Circuit breaker voltage ratings shall meet or exceed the panelboard voltage indicated on the Drawings. Trip elements of circuit breakers shall be 20A unless otherwise indicated on the Drawings. Circuit breakers shall have an interrupting rating at 240 VAC that matches the panelboard short circuit rating. 4. All branch circuit breakers shall be provided with a padlockable hasp or handle padlock attachment for padlocking in the off position as required to meet the NEC requirement for disconnecting means and/or OSHA lock-out/tagout standard. Locking hardware shall remain in place even when the packlock is removed. Branch circuit breakers shall be provided with a similar lock-on device where indicated on the Drawings. E. Directories 1. Approved directories with noncombustible plastic cover, and with typewritten designations of each branch circuit, shall be furnished and installed in each combination power unit. The Contractor shall maintain in each combination power unit, during the duration of the Contract, a handwritten directory clearly indicating the circuit breakers in service. This directory shall be updated as work progresses, and final, typewritten directories, as specified above, shall be installed at the end of the project. Designations and circuit locations shall conform to the schedules on the Drawings, except as otherwise authorized by the Engineer. PART 3 -- EXECUTION 3.01 INSTALLATION A. Combination power units shall be furnished and installed as shown on the Drawings and as recommended by the equipment manufacturer, and as required by NECA 407. B. Combination power units shall be set true and plumb in locations as shown on the Drawings. The top of combination power unit enclosure shall not exceed six (6) feet above finished floor elevation. C. Enclosures shall not be fastened to concrete or masonry surfaces with wooden plugs. Appropriate cadmium plated or galvanized steel bolts shall be used with expansion shields City of Denton Hazen and Sawyer BID SET 16470-5 Panelboards or other metallic type concrete insert for mounting on concrete or solid masonry walls. Cadmium plated or galvanized steel toggle bolts shall be used for mounting on concrete block or other hollow masonry walls. Bolt diameter shall be as required considering the size and weight of the completed panelboard and enclosure to provide adequate structural support. D. The Contractor shall not use factory furnished knockouts with surface mounted back boxes. The Contractor shall punch or drill required openings during installation and shall equip flush mounted back boxes with manufacturer's standard pattern of knockouts. E. The Contractor shall install cabinets (and other enclosure products) in plumb with the building construction. F. Bus loads in all combination power units shall be balanced between phases to within a tolerance of one (1) KVA. Convenience receptacles shall be distributed evenly among all phase buses as much as practical. G. Prior to final completion of the work, all metal surfaces of the equipment shall be cleaned thoroughly. 3.02 TESTING A. All tests shall be performed in accordance with the requirements of the General Conditions and Division 1. The following tests are required: 1. Field Tests a. Prior to termination of any conductors to the circuit breakers , all bus work and circuit breakers shall be tested from phase to phase and phase to ground with a 1000 VDC megaohmeter for 1 minute in accordance with NECA 407. Resistance values shall be recorded and shall not be less than 100 megohms. b. Prior to terminating any wires to the circuit breakers, the resistance of the connection between the bus work and each circuit breaker shall be tested through the use of a low-resistance ohmmeter. Record the resistance values for each circuit breaker. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 16470-6 Panelboards This page left blank intentionally City of Denton Hazen and Sawyer BID SET 16481-1 Individual Motor Controllers SECTION 16481 INDIVIDUAL MOTOR CONTROLLERS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish and install separately mounted, individual motor controllers for 120 volt single phase, and 208 and 480 volt three phase motors as specified herein and indicated on the Drawings. Individual motor controllers specified in this Section include magnetic motor starters and reduced voltage solid state starters (RVSS). B. Reference Section 16000, Basic Electrical Requirements; Section 16123, Low Voltage Cable; Section 16195, Electrical Identification; and Section 16902, Electric Controls and Relays. 1.02 CODES AND STANDARDS A. Individual motor controllers shall be designed, manufactured, and/or listed to the following standards as applicable: 1. UL 508 – Standard for Industrial Control Panels 2. NEMA 250 – Enclosures for Electrical Equipment 1.03 SUBMITTALS A. In accordance with the procedures and requirements set forth in the General Conditions and Section 01300, Submittals, the Contractor shall obtain from the equipment manufacturer and submit the following: 1. Shop Drawings. 2. Spare Parts. 3. Reports of Certified Shop and Field Tests. 4. Operation and Maintenance Manuals. 5. Manufacturer's Field Startup Report. 6. Manufacturer's Representatives Installation Certification. B. Each submittal shall be identified by the applicable specification section. City of Denton Hazen and Sawyer BID SET 16481-2 Individual Motor Controllers 1.04 SHOP DRAWINGS A. Each submittal shall be complete in all respects, incorporating all information and data listed herein and all additional information required for evaluation of the proposed equipment's compliance with the Contract Documents. B. Partial, incomplete, or illegible submittals will be returned to the Contractor without review for resubmittal. C. Shop drawings shall include but not be limited to: 1. A Compliance, Deviations, and Exceptions (CD&E) letter. If the shop drawings are submitted without this CD&E letter, the submittal will be rejected. The letter shall include all comments, deviations and exceptions taken to the Drawings and Specifications by the Contractor AND Equipment Manufacturer/Supplier. This letter shall include a copy of this specification section. In the left margin beside each and every paragraph/item, a letter "C", "D", or "E" shall be typed or written in. The letter "C" shall be for full compliance with the requirement. The letter "D" shall be for a deviation from the requirement. The letter "E" shall be for taking exception to a requirement. Any requirements with the letter "D" or "E" beside them shall be provided with a full typewritten explanation of the deviation/exception. Handwritten explanation of the deviations/exceptions is not acceptable. The CD&E letter shall also address deviations, and exceptions taken to each Drawing related to this Specification Section. 2. Product data sheets. 3. Complete layout and installation drawings with clearly marked dimensions for each type/size/rating of individual motor controller. For RVSS starters, in free-standing enclosures, show conduit stub-up area locations on the Drawings. 4. Custom wiring diagrams for each individual motor controller. Standard wiring diagrams that are not custom created by the manufacturer for the individual motor controllers for this project are not acceptable. One wiring diagram which is typical for an equipment group (e.g. submersible pump) is not acceptable. Each wiring diagram shall include wire identification and terminal numbers. Indicate all devices, regardless of their physical location, on the diagrams. Identify on each respective wiring diagram specific equipment names and equipment numbers consistent with those indicated on the Drawings. 5. Bill of material list for each individual motor controller. 6. Nameplate schedule for each individual motor controller. 7. Manufacturer’s installation instructions. 8. Time-current curves for each type and size protective device if requested by the Engineer. 9. Approximate total shipping weight of each RVSS. City of Denton Hazen and Sawyer BID SET 16481-3 Individual Motor Controllers D. The shop drawing information shall be complete and organized in such a way that the Engineer can determine if the requirements of these Specifications are being met. Copies of technical bulletins, technical data sheets from "soft-cover" catalogs, and similar information which is "highlighted" or somehow identifies the specific equipment items that the Contractor intends to provide are acceptable and shall be submitted. E. Prior to completion and final acceptance of the project, the Contractor shall furnish and install "as-built" wiring diagrams for individual motor controller. These final drawings shall be plastic laminated and securely placed inside each individual motor controller unit door and included in the O&M manuals. 1.05 OPERATION AND MAINTENANCE MANUALS A. The Contractor shall submit operation and maintenance manuals in accordance with the procedures and requirements set forth in the General Conditions and Division 1. 1.06 SPARE PARTS A. All spare parts as recommended by the equipment manufacturer shall be furnished to the Owner by the Contractor. B. The Contractor shall furnish the following additional spare parts: 1. One (1) solid state overload relay for each type, size, and rating used. 2. One (1) motor circuit protector & motor contactor for each type, size, and rating used. 3. One (1) spare control power transformer for each type and size used. 4. Two (2) spare fuses for each size and type used. C. The spare parts shall be packed in containers suitable for long term storage, bearing labels clearly designating the contents and the pieces of equipment for which they are intended. D. Spare parts shall be delivered at the same time as the equipment to which they pertain. The Contractor shall properly store and safeguard such spare parts until completion of the work, at which time they shall be delivered to the Owner. E. Spare parts lists, included with the shop drawing submittal, shall indicate specific sizes, quantities, and part numbers of the items to be furnished. Terms such as "1 lot of packing material" are not acceptable. F. Parts shall be completely identified with a numerical system to facilitate parts inventory control and stocking. Each part shall be properly identified by a separate number. Those parts which are identical for more than one size, shall have the same parts number. City of Denton Hazen and Sawyer BID SET 16481-4 Individual Motor Controllers 1.07 IDENTIFICATION A. Each equipment item shall be identified with a nameplate. The nameplate shall be engraved with the equipment name and/or number with which it is associated. Equipment identification shall be in accordance with Section 16195, Electrical - Identification. PART 2 -- PRODUCTS 2.01 MANUFACTURERS A. The equipment covered by this Specification is intended to be standard equipment of proven performance as manufactured by reputable concerns. Equipment shall be designed, constructed and installed in accordance with the best practices of the trade, and shall operate satisfactorily when installed as shown on the Drawings. 2.02 INDIVIDUAL MAGNETIC MOTOR STARTERS A. Individual magnetic motor starters shall be combination type complete with motor circuit protectors (MCP's). Starters shall be rated 480 VAC, 3-pole, sized for the intended load unless otherwise indicated. In no case shall a starter smaller than a NEMA Size 1 be used. Each starter shall be furnished with a minimum of two spare auxiliary contacts. B. Motor starters shall be furnished with NEMA 4X, Type 304 Stainless Steel enclosures. C. Starters shall be provided with all coils and controls for 120 VAC operation, unless otherwise indicated on the Drawings. D. The minimum control power transformer VA requirements are as shown below. Control power transformers shall be sized as required for the connected loads, plus 25% spare capacity. Submit calculations for engineer review. Size 1 150 VA Size 2 150 VA Size 3 200 VA Size 4 300 VA Size 5 500 VA The motor controller manufacturer is advised to review the total Contract Documents for additional requirements for space heaters, power factor correction capacitors, and similar equipment which may not be specified in this Division or shown on the Drawings. Control power transformers shall be fused on both the primary and secondary sides. E. Each starter shall be supplied with a manual reset overload relay. Manual reset shall be accomplished by a door mounted overload reset pushbutton. The relays shall be solid state type, with at least one isolated normally open and one isolated normally closed auxiliary contact that operates when a trip condition has occurred. Relays shall be self-powered, have a visible trip indicator, have a trip test function, and have selectable Class 10 or 20 operation. Overload relays shall be set for Class 10 operation unless otherwise City of Denton Hazen and Sawyer BID SET 16481-5 Individual Motor Controllers directed by the Engineer. Overload relay shall have phase loss protection built in to trip the unit and protect the motor against single phasing. The Contractor shall provide the overload relay model with the correct current range for each application. Overload relay shall have adjustable current range dial. Eutectic alloy and bi-metallic type overload relays are not acceptable. F. Control Devices 1, Furnish and install control devices as required and/or shown on the Drawings. The following control devices shall be provided as specified in Section 16902, Electric Controls and Relays: a. Pilot devices (switches, indicating lights, etc) b. Relays and timers c. Control Terminal blocks G. All control wiring shall be No. 14 AWG (minimum) labeled at each end in accordance with the wiring numbers shown on the accepted shop drawings. Power wiring shall be sized to suit the maximum horsepower rating of unit; No. 12 AWG (minimum). Wiring shall be type MTW rated for 105ºC. Wire color coding shall be as specified in Section 16123, Low Voltage Cable. H. Each motor starter coil shall be equipped with a surge-suppression device for protection of the solid state equipment (e.g. programmable logic controller) wired as part of the control circuit. I. Individual magnetic motor starters shall be as manufactured by Eaton using NEMA rated Freedom Series starters and contactors, the General Electric Company equivalent, the Square D Company equivalent, or Siemens Energy & Automation, Inc. equivalent. 2.03 REDUCED VOLTAGE SOLID STATE STARTER A. The solid-state reduced-voltage starter shall be UL Listed. The solid-state reduced-voltage starter shall be an integrated unit with power SCRs, logic board, an integral paralleling bypass contactor, and electronic overload relay enclosed in a single molded housing. The starter shall meet all applicable requirements of this Section and other sections in this Division. B. The RVSS shall be suitable for continuous operation at 115% of its continuous ampere rating. The Contractor is fully responsible for the review of the mechanical specifications to determine specified motor speed, horsepower and full load amperes. This information is available in the applicable mechanical specifications for each piece of equipment (e.g. submersible pump). C. The RVSS shall be suitable for the following environmental conditions: 1. Operating Temperature: 0-50 degrees C City of Denton Hazen and Sawyer BID SET 16481-6 Individual Motor Controllers 2. Humidity: 0-95 percent non-condensing. 3. Altitude: up to 3,300 feet. D. The RVSS shall be suitable for operation on a 480 VAC, 3-phase, 60 Hertz system. E. The SCR-based power section shall consist of six (6) back-to-back SCRs and shall be rated for a minimum peak inverse voltage rating of 1500 volts PIV. Units using triacs or SCR/diode combinations are not acceptable. Resistor/capacitor snubber networks shall be used to prevent false firing of SCRs due to dv/dt effects. F. The paralleling run bypass contactor shall energize when the motor reaches full speed and close/open under one (1) times motor current. G. A full voltage, non-reversing bypass starter shall be provided for the RVSS starters indicated in the Contract Drawings. Bypass starter shall be NEMA rated and shall meet all applicable requirements of this Section. H. The starter shall be provided with electronic overload protection as standard and shall be based on an inverse time-current algorithm. Overload protection shall be capable of being disabled during ramp start for long acceleration loads via a DIP switch setting on the device keypad. Overload protection shall be adjusted via the device keypad and shall have a motor full load ampere adjustment from 30 to 100% of the maximum continuous ampere rating of the starter. The starter shall have selectable overload class setting of 5, 10, 20 or 30 via a DIP switch setting on the device keypad. The starter shall be capable of either an electronic or mechanical reset after a fault. Units using bimetal or eutectic alloy overload relays are not acceptable. I. The starter shall provide protection against the following conditions: 1. Improper line-side phase rotation. The starter shall stop the motor load if a line-side phase rotation other than A-B-C exists. 2. Phase loss or unbalanced conditions. The starter shall stop the motor load if a 50% current differential between any two phases is encountered. 3. Motor stall conditions. 4. Motor jam conditions. J. The starter shall be provided with a form C normally open (NO), normally closed (NC) contact that shall change state when a fault condition exists. The contacts shall be rated 60 VA (resistive load) and 20 VA (inductive load). In addition, an LED display on the device keypad shall indicate the type of fault (Overtemp, Phase Loss, Jam, Stall, Phase Reversal, and Overload). K. The starter shall be provided with an unpowered internal “Run” contact rated for 24VDC or 120 VAC operation. City of Denton Hazen and Sawyer BID SET 16481-7 Individual Motor Controllers L. The following control function adjustments on the device keypad shall be provided: 1. Selectable Torque Ramp Start or Current Limit Start 2. Adjustable Kick Start Time, 0-2 seconds 3. Adjustable Kick Start torque, 0-90% 4. Adjustable Ramp Start Time; 0.5-180 seconds 5. Adjustable Initial Starting Ramp Torque; 0-100% 6. Adjustable Smooth Stop Ramp Time; 0-60 seconds. M. Enclosed units shall include a motor circuit protector (MCP) for short-circuit protection and quick disconnect means. If required, the unit shall include a 24 VDC power supply to be used as the primary control voltage source. A 120 VAC control power transformer, fused on both the primary and secondary sides, shall be provided as an additional control power source to power such devices as motor space heaters, solenoid valves, and similar control elements as required. Input and output isolation contactors shall be furnished as indicated on the Drawings. N. Unless otherwise specified or indicated on the Drawings, the RVSS enclosure shall be dead-front, with front accessibility. The enclosure shall be designed for bottom entry. The enclosure shall be designed so rear access is not required for operations, maintenance, and repair tasks. The doors shall have full length piano type hinges and shall be braced to prevent sag when fully open. Other enclosure requirements are: O. The RVSS shall be furnished with a NEMA 4X, Type 304 Stainless Steel enclosure. P. The complete starter assembly shall be rated per UL 508 for a minimum withstand rating of 65 kAIC rms. Q. Control Devices 1, Furnish and install control devices as required and/or shown on the Drawings. The following control devices shall be provided as specified in Section 16902, Electric Controls and Relays: a. Pilot devices (switches, indicating lights, etc) b. Relays and timers c. Control Terminal blocks R. The reduced voltage solid state starter shall be the SMC-Flex with integral bypass as manufactured by Allen-Bradley, Eaton equivalent, the General Electric Company equivalent, the Square D Company equivalent, or Siemens Energy and Automation, Inc. equivalent. City of Denton Hazen and Sawyer BID SET 16481-8 Individual Motor Controllers PART 3 -- EXECUTION 3.01 INSTALLATION A. All individual motor starters shall be installed as indicated on the Drawings and as recommended by the equipment manufacturer. B. Individual motor starters shall be provided in the enclosure type and material of construction required for the area in which it is installed. Reference the requirements in Part 2 herein, and the area designations indicated on the Drawings. 3.02 TESTING A. All tests shall be performed in accordance with the requirements of the General Conditions and Division 1. The following tests are required: 1. Witnessed Shop Tests a. None required. 2. Field Tests a. Field testing shall be done in accordance with the requirements specified in the General Conditions, Division 1, and NETA acceptance testing specifications, latest edition. 3.03 SERVICES OF MANUFACTURER'S REPRESENTATIVE A. The Contractor shall provide the services of a qualified manufacturer's factory-trained technical representative who shall adequately supervise the installation and startup of the RVSS equipment furnished under this Contract. The manufacturer's representative shall certify in writing that the equipment has been installed in accordance with the manufacturer's recommendations. No further testing or equipment startup may take place until this certification is accepted by the Owner. B. The manufacturer’s technical representative shall perform all startup and field acceptance testing as specified herein. C. The Contractor shall provide training for the Owner’s personnel. Training shall be conducted by the manufacturer's factory-trained representative who shall instruct Owner’s personnel in operation and maintenance of all equipment provided under this Section. Training shall be provided for two (2) sessions of two (2) hours each. Training shall not take place until after the motor controllers have been installed and tested. Training shall be conducted at times coordinated with the Owner. D. The services of the manufacturer's representative shall be provided for a period of not less City of Denton Hazen and Sawyer BID SET 16481-9 Individual Motor Controllers than as follows: 1. One (1) trip of two (2) working days during installation of the motor controllers. 2. One (1) trip of two (2) working days to perform startup and field acceptance testing of the motor controllers. 3. One (1) trip of one (1) working day two (2) months before the warranty expiration to identify any issues to be corrected under warranty. 4. One (1) trip of one (1) working day to perform training as specified herein. E. Any additional time required to achieve successful installation and operation shall be at the expense of the Contractor. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 16481-10 Individual Motor Controllers This page left blank intentionally City of Denton Hazen and Sawyer BID SET 16498-1 Manual Transfer Switch SECTION 16498 MANUAL TRANSFER SWITCH PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, install, connect, test and place in satisfactory operation manual transfer switches as specified herein and indicated in Drawings. B. All devices and components of the manual transfer switch shall be NEMA rated. IEC rated devices are unacceptable and shall be cause for rejection of the submittals/equipment. 1.02 TESTING A. All tests shall be performed in accordance with the requirements of the General Conditions and Division 1. The following tests are required: 1. Witnessed Shop Tests a. Shall be made available at manufacturing facilities if requested. 2. Certified Shop Tests and Reports a. Submit description of proposed testing methods, procedures, and apparatus. Submit notarized and certified copies of all test reports. b. As a minimum, the manual transfer switch shall go through a quality inspection before shipment. This inspection shall include, but is not limited to, the following: i. Physical inspection of the structure and the electrical conductors including bussing, general wiring, and units. ii. General electrical tests including power circuit phasing, control circuit wiring, instrument transformers, meters, and device electrical operation. iii. AC dielectric tests of the power circuits and control circuits. iv. Markings/labels, including instructional type, Underwriters Laboratory (U.L.), and inspector's stamps. The manufacturer shall use integral quality control checks throughout the manufacturing process to maintain the correctness of the manual transfer switch. City of Denton Hazen and Sawyer BID SET 16498-2 Manual Transfer Switch 3. Field Tests a. Field testing shall be done in accordance with the requirements specified in the General Conditions, Division 1, and Section 16000, Basic Electrical Requirements. 1.03 SUBMITTALS A. In accordance with the procedures and requirements set forth in the General Conditions and Section 01300, Submittals, the Contractor shall obtain from the equipment manufacturer and submit the following: 1. Shop Drawings 2. Operation and Maintenance Manuals 3. Spare Parts Lists 4. Special Tools List 5. Reports of certified shop tests shall be submitted which indicates a closing and withstand ampere rating as required based on short circuit study requirements. Rating shall be symmetrical, 3 cycles at 480 VAC. 6. Guarantee/Warranty Program B. Each submittal shall be identified by the applicable specification section. 1.04 SHOP DRAWINGS A. Each submittal shall be complete in all respects, incorporating all information and data listed herein and all additional information required for evaluation of the proposed equipment's compliance with the Contract Documents. B. Partial, incomplete or illegible submittals will be returned to the Contractor for resubmittal without review. C. Shop drawings for each manual transfer switch shall include but not be limited to: 1. A Compliance, Deviations, and Exceptions (CD&E) letter. If the shop drawings are submitted without this CD&E letter, the submittal will be rejected. The letter shall include all comments, deviations and exceptions taken to the Drawings and Specifications by the Contractor AND Equipment Manufacturer/Supplier. This letter shall include a copy of this specification section. In the left margin beside each and every paragraph/item, a letter "C", "D", or "E" shall be typed or written in. The letter "C" shall be for full compliance with the requirement. The letter "D" shall be for a deviation from the requirement. The letter "E" shall be for taking exception to a requirement. Any requirements with the letter "D" or "E" beside them shall be provided with a full typewritten explanation of the deviation/exception. Handwritten explanation of the deviations/exceptions is not acceptable. The CD&E letter shall City of Denton Hazen and Sawyer BID SET 16498-3 Manual Transfer Switch also address deviations, and exceptions taken to each Drawing related to this Specification Section. 2. Product data sheets. 3. Complete assembly, layout, and installation drawings with clearly marked dimensions and conduit entrance locations. 4. Example equipment nameplate data sheet. 5. Manufacturer's standard installation instructions. 6. Manufacturer's standard warranty. D. The shop drawing information shall be complete and organized in such a way that the Engineer can determine if the requirements of these specifications are being met. Copies of technical bulletins, technical data sheets from "soft-cover" catalogs, and similar information which is "highlighted" or somehow identifies the specific equipment items the Contractor intends to provide are acceptable and shall be submitted. E. Prior to completion and final acceptance of the project, the Contractor shall furnish and install "as-built" wiring diagrams for each manual transfer switch. These final drawings shall be plastic laminated and securely placed inside each transfer switch and included in the O&M manuals. 1.05 OPERATION AND MAINTENANCE MANUALS A. The Contractor shall submit operation and maintenance manuals in accordance with the procedures and requirements set forth in the General Conditions and Division 1. 1.06 TOOLS, SUPPLIES AND SPARE PARTS A. The manual transfer switches shall be furnished with all special tools necessary to disassemble, service, repair and adjust the equipment. All spare parts as recommended by the equipment manufacturer shall be furnished to the Owner by the Contractor. B. The spare parts shall be packed in containers suitable for long term storage, bearing labels clearly designating the contents and the pieces of equipment for which they are intended. C. Spare parts shall be delivered at the same time as the equipment to which they pertain. The Contractor shall properly store and safeguard such spare parts until completion of the work, at which time they shall be delivered to the Owner. D. Spare parts lists, included with the shop drawing submittal, shall indicate specific sizes, quantities, and part numbers of the items to be furnished. Terms such as "1 lot of packing material" are not acceptable. E. Parts shall be completely identified with a numerical system to facilitate parts inventory control and stocking. Each part shall be properly identified by a separate number. Those parts which are identical for more than one size, shall have the same parts number. City of Denton Hazen and Sawyer BID SET 16498-4 Manual Transfer Switch 1.07 IDENTIFICATION A. Each manual transfer switch shall be identified with the identification number indicated on the Drawings (e.g. MTS-HCDF, MTS-WPF, etc.). A nameplate shall be securely affixed in a conspicuous place on each switch. Nameplates shall be as specified in Section 16195, Electrical - Identification. 1.08 TRAINING A. The Contractor shall provide training for Owner personnel. Training shall be conducted by the manufacturer's factory trained specialists who shall instruct Owner personnel in operation and maintenance of all equipment provided under this Section. Training shall be in accordance with the requirements of Section 11000, Equipment-General Provisions. PART 2 -- PRODUCTS 2.01 MANUFACTURERS A. The equipment covered by this Specification is intended to be standard equipment of proven performance as manufactured by reputable concerns. Equipment shall be designed, constructed and installed in accordance with the best practices of the trade, and shall operate satisfactorily when installed as shown on the Drawings. B. The equipment described herein, as a minimum, shall meet all of the requirements specified in this Section and shall be a product of a manufacturer who has produced manual transfer switches for a period of at least five (5) years. The equipment shall be compatible with the loads to be served. Assembly of the switches by a fabricator is not acceptable. C. The manual transfer switches shall be molded case circuit breaker design, Type NTV (Non- auto) as manufactured by Eaton, Square D Company equivalent, General Electric equivalent, or approved equal. Contactor-based transfer switches are not acceptable. 2.02 MANUAL TRANSFER SWITCH A. General 1. Switches shall have ampere ratings and number of poles as indicated on the Drawings and shall be suitable for 480 VAC, three-phase, 60 Hertz operation. 2. The transfer switch shall be housed in a NEMA 4X Type 304 Stainless Steel enclosure. The enclosure shall exceed the UL-1008 minimum wire bending space requirements. The enclosure shall be equipped with an internal, welded steel, door- mounted print pocket. 3. The transfer switch shall have both top and bottom mounted cable access. 4. The switch shall be capable of switching all classes of load and rated for continuous duty when installed in a non-ventilated enclosure. City of Denton Hazen and Sawyer BID SET 16498-5 Manual Transfer Switch 5. The three-cycle closing and withstand current rating of the switch shall be 65,000 amperes RMS (minimum). This rating shall not be restricted by the use of a specific manufacturer's circuit breaker. 6. All bolted bus connections shall have Belleville compression type washers. Switches for four-wire systems shall be furnished with a fully rated solid neutral bus. 7. The switch shall be equipped with 90C rated copper/aluminum solderless mechanical type lugs of the proper quantity and size to accommodate the termination of field wiring. 8. Switches shall be capable of normal operation during and after seismic loading. Seismic loading shall not cause false operation. B. Design Requirements 1. Switches shall contain two fixed mounted, molded case circuit breakers with ampere ratings and number of poles as indicated on the Drawings and shall be suitable for 480 VAC, three-phase, 60 Hertz operation. 2. Equip each circuit breaker with an Eaton Digitrip OPTIM 550, Square D Company equal or General Electric Company equal with rating plug size as indicated on the Drawings. The trip units shall be furnished complete with all additional modules required to facilitate all trip unit functions. Trip units shall have adjustable long, short, instantaneous and ground fault functions. 3. The switch shall be totally front accessible. Equipment assemblies requiring rear access are not acceptable. 4. Provide control power transformers as required. C. Sequence of Operation 1. The system shall be completely manual with key interlocks to prevent both circuit breakers from being closed at the same time. No transfer controller shall be required. No source sensing or indicating lights shall be required. 2. Transfer from one source to the other shall require an operator to manually open the Source 1 circuit breaker, remove the interlock key and insert the key into the Source 2 circuit breaker and manually close the Source 2 circuit breaker. D. Controls 1. No automated transfer controls shall be required. 2. Provide key interlocks as indicated on the drawings to prevent both circuit breakers from being closed at the same time. City of Denton Hazen and Sawyer BID SET 16498-6 Manual Transfer Switch PART 3 -- EXECUTION 3.01 INSTALLATION A. Each automatic transfer switch shall be installed as shown on the Drawings and in accordance with the manufacturer's installation instructions. B. The automatic transfer switch shall be provided with adequate lifting means for installation of wall or floor mounted enclosures. C. The Contractor shall tighten all assembled bolted connections to the manufacturer's torque recommendations prior to energizing. D. Install each switch to allow complete door swing required for component removal. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 16500-1 Lighting SECTION 16500 LIGHTING PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish and install all lighting fixtures, labor, and material, in accordance with the preceding Specifications, the requirements of this Section, and as shown on the Drawings. B. Lighting shall be in accordance with the latest requirements of the Illuminating Engineering Society, and all lighting fixtures shall have the Underwriters Laboratories, Inc. label of approval. C. All wiring shall be placed in conduit and shall comply with the Specifications for conduit, outlet boxes, pull and junction boxes, wires and cables, grounding, and other Sections as set forth in these Specifications and as noted herein. D. Reference Section 16000, Basic Electrical Requirements, and Section 16170, Grounding and Bonding. 1.02 CODES AND STANDARDS A. The equipment specified herein shall comply with the following codes and standards, where applicable. 1. Underwriter’s Laboratories, Inc. (UL): a. UL 924 – Emergency Lighting and Power Equipment b. UL 1598 – Luminaires 2. American National Standards Institute (ANSI): a. ANSI C62.41 – Guide for Surge Voltages in Low-Voltage AC Power Circuits 3. National Electrical Code (NEC), latest edition. City of Denton Hazen and Sawyer BID SET 16500-2 Lighting 1.03 SUBMITTALS A. In accordance with the procedures and requirements set forth in the General Conditions and Section 01300, Submittals, the Contractor shall obtain from the equipment manufacturer and submit the following: 1. Shop Drawings 2. Operation and Maintenance Manuals 3. Spare Parts Lists B. Each submittal shall be identified by the applicable specification section. 1.04 SHOP DRAWINGS A. Each submittal shall be complete in all respects, incorporating all information and data listed herein and all additional information required for evaluation of the proposed equipment's compliance with the Contract Documents. B. Partial, incomplete or illegible submittals will be returned to the Contractor for resubmittal without review. C. Shop drawings shall include but not be limited to: 1. Product data sheets. 2. Catalog cuts for each fixture type showing performance and construction details of standard fixtures, and complete working drawings showing all proposed construction details of special or modified standard fixtures. 3. Photometric curves. 4. LED data including efficiency (Efficacy lumens/watt) information. 5. LED Driver information 6. Catalog data including applicable coefficients of utilization tables, isolux chart of illumination on a horizontal plane, beam efficiency, horizontal and vertical beam spread, and beam lumens. 7. Manufacturer’s warranty information 8. System (entire fixture assembly) efficiency data. 9. Pole calculations. D. Shop drawings shall be submitted to the Engineer for review and acceptance for all fixtures before fixtures and poles are manufactured. Substitutions will be permitted only if acceptable to the Engineer. City of Denton Hazen and Sawyer BID SET 16500-3 Lighting E. Manufacturer's catalog number and description in the fixture schedule on the Contract Documents establishes a level of quality, style, finish, etc. The use of a catalog number describing the various types of fixtures shall be used as a guide only, and does not exclude all the required accessories or hardware that may be required for a complete installation. 1.05 OPERATION AND MAINTENANCE MANUALS A. The Contractor shall submit Operation and Maintenance Manuals in accordance with the procedures and requirements set forth in the General Conditions and Division 1. 1.06 SPARE PARTS A. All spare parts as recommended by the equipment manufacturer shall be furnished to the Owner by the Contractor. The following minimum spare parts shall be furnished: 1. A minimum of one (1) LED driver for every ten (10) drivers (of the same type) installed. B. The spare parts shall be packed in containers suitable for long term storage, bearing labels clearly designating the contents and the pieces of equipment for which they are intended. C. Spare parts shall be delivered at the same time as the equipment to which they pertain. The Contractor shall properly store and safeguard such spare parts until completion of the work, at which time they shall be delivered to the Owner. D. Spare parts lists, included with the shop drawing submittal, shall indicate specific sizes, quantities, and part numbers of the items to be furnished. Terms such as "1 lot of packing material" are not acceptable. E. Parts shall be completely identified with a numerical system to facilitate parts inventory control and stocking. Each part shall be properly identified by a separate number. Those parts which are identical for more than one size, shall have the same parts number. 1.07 LIGHTING CONTROLS A. The lighting systems shall be controlled as specified herein and indicated on the Drawings. 1.08 WARRANTY A. The manufacturer's warranty shall in no event be for a period of less than five (5) years from date of delivery of fixtures to the project site and shall include repair labor, travel expense necessary for repairs at the jobsite, shipping costs, expendables used during the course of repair, or complete replacement of the failed lighting unit. B. Warranty for LED fixtures shall be provided for the entire fixture and shall include all parts and accessories. Submittals received without written warranties as specified shall be rejected in their entirety. City of Denton Hazen and Sawyer BID SET 16500-4 Lighting PART 2 -- PRODUCTS 2.01 MANUFACTURERS A. The equipment covered by this Specification is intended to be standard equipment of proven performance as manufactured by reputable concerns. Equipment shall be designed, constructed, and installed in accordance with the best practices of the trade, and shall operate satisfactorily when installed as shown on the Drawings. 2.02 FIXTURES A. Each fixture shall bear the Underwriters Laboratories, Inc. label. All lighting fixtures shall be furnished complete with all fittings and hardware necessary for a complete installation. Lighting fixtures shall have all parts and fittings necessary to completely and properly install the fixtures. B. Fixture leads shall be as required by NEC and shall be grounded by the equipment grounding conductor in the conduit. C. All glassware shall be high quality, homogeneous in texture, uniform in quality, free from defects, of uniform thickness throughout, and properly annealed. Edges shall be well rounded and free from chips or rough edges. D. Fixtures specified to be damp or wet locations rated shall be UL 1598 listed. E. Fixtures shall be as specified in the fixture schedule below. FIXTURE TYPE LAMP/ FIXTURE WATTAGE DESCRIPTION MFR AND MODEL HL7 168W (max) Pole-mounted, 120-277VAC, LED light fixture, color temperature of 4000K, prismatic borosilicate glass lens, 4 LED modules, IESNA Type 5 distribution, 21000 lumen minimum, low tilt range, black die cast aluminum housing, integral photocell, wet location Listed, uplight skirt. Square, black, base mounted, straight, 12ft. anodized aluminum pole. Holophane Mongoose LED Series, Kim Archetype LED Series, or AEL Autobahn LED Series. LC1 61W (max) Ceiling-mounted, 120-277VAC, LED light fixture, color temperature of 4100K, lineal ribbed frosted acrylic lens, general distribution, gasketed fiberglass housing, stainless steel latches, 4ft, 4000 nominal lumen minimum, and wet location Listed. Holophane EMS LED Series, Cooper Vaportite LED Series, or Lithonia FEM LED Series. City of Denton Hazen and Sawyer BID SET 16500-5 Lighting 2.03 LED DRIVERS A. Drivers shall have a voltage range of (120-277) +/- 10% at a frequency 60Hz. B. All drivers shall be designed to a power factor >90% with a total harmonic distortion THD <20% at full load. C. Case temperature shall be rated for -40°C through +80°C. D. Drivers shall have overheat protection, self-limited short circuit protection and overload protected. E. Drivers shall be furnished with a fused primary. F. Drivers shall have an output current ripple <30% G. Drivers shall be manufactured by Advance, Universal or equal. H. Drivers shall be UL Listed for damp location, UL1012, UL935, ROHS. I. Drivers shall meet FCC 47 Sub Part 15. J. All drivers shall be provided with ANSI/IEEE C62.41 Category C (10kV/5kA) surge protection. 2.04 LEDs A. Luminaires provided with LED technology shall utilize high brightness LEDs with a group binning code of P and/or Q. B. Color Temperature: as specified in fixture schedule. C. Junction point shall be designed and manufactured to allow adequate heat dissipation. D. LEDs shall be rated for 50,000 hours of life, minimum (based on IESNA L70). 2.05 POLES A. Poles shall be designed to withstand calculated wind force based on 120 MPH (3-second gust) wind velocity in accordance with the provisions of the Texas Building Code without structural damage. B. Pole mounted fixtures shall be mounted on poles as designated in the fixture schedule or as indicated on the Drawings. Poles shall have adequate handholes and weatherproof receptacles where indicated. All anchor bolts and nuts shall be stainless steel. City of Denton Hazen and Sawyer BID SET 16500-6 Lighting PART 3 -- EXECUTION 3.01 INSTALLATION A. Lighting fixtures shall be located symmetrically with building lines as shown on the Drawings. The Contractor shall furnish and install the lighting fixtures to allow "convenient" access for maintenance such as cleaning and other activities. The fixtures shall be installed to be accessed by a 12 ft. (max.) ladder. Where fixtures are shown in locations on the Drawings where maintenance would be difficult, the Contractor shall notify the Engineer for direction. B. The Contractor shall provide and install all inserts, conduit, structural supports as required, poles, wiring, and any other items required for a complete system. Contractor shall properly adjust and test, to the satisfaction of the Engineer, the entire lighting system. The Contractor shall provide pigtails and flexible conduit connected to an outlet box where necessary or required resulting in a neat and complete installation. C. The Contractor shall protect all fixtures at all times from damage, dirt, dust, and the like. Before final acceptance, all fixtures and devices shall be cleaned of all dust, dirt or other material, and in operating condition to the satisfaction of the Engineer. D. The Contractor shall furnish and install all pendant trapezes and pendant stem hangers with durable swivel or equivalent trapeze hanger permitting normal fixture motion and self-alignment. Fixture pendants shall be Appleton Type UNJ ball type flexible hanger at the fixture and supports from an Appleton JBLX junction box with JBLX hub cover, or equal. Pendant lengths shall be adequate and adjusted to provide uniformity of installation heights above the reference datum. Stems shall be one-piece, with matching canopies and fittings. E. Fixtures located on the exterior of the building shall be provided with neoprene gasket and non-ferrous metal screws finished to match the fixtures. F. The Contractor shall furnish and install all boxes for lighting fixtures such that the box is not the sole support of the fixture. The boxes shall be offset to allow maintenance such that access to wiring within the box can be attained without having to consider supporting (holding) the fixture. G. All lighting units, when installed, shall be set true and be free of light leaks, warps, dents, and other irregularities. All hangers, cables, supports, channels, and brackets of all kinds for safely erecting this equipment in place, shall be furnished and erected in place by the Contractor. H. The Contractor shall install fixtures at mounting heights indicated on the Drawings or as instructed by the Engineer. In areas with exposed ducts and/or piping, installation of lighting fixtures shall be adapted to field conditions as determined by the Engineer. I. The Contractor shall support each fixture securely. The Contractor shall not secure fixtures to the work of other trades, unless specified or noted otherwise, and shall not support fixtures from plaster. The Contractor shall furnish and install all steel members and supports as required to fasten and suspend fixtures from the structure. City of Denton Hazen and Sawyer BID SET 16500-7 Lighting J. In all mechanical equipment areas, the Contractor shall install lighting fixtures on the ceiling after all piping and equipment therein has been installed. Exact locations for such fixtures may be determined by the Engineer on the site during the course of the work. K. Upon completion of work, and after the area is broom clean, all fixtures shall be made clean and free of dust and all other foreign matter both on visible surfaces, and on surfaces that affect the lighting performance of the fixture including diffusers, lenses, louvers, reflectors, etc. L. All fixtures that require physical adjustment shall be so adjusted in accordance with the directions of the Engineer. The Contractor shall also adjust angular direction of fixtures, as directed. M. Relamping access of fixtures shall require no special tools. All optical control surfaces such as lenses and reflectors shall be safely and securely attached to fixtures and shall be easily and quickly removed and replaced for cleaning without the use of special tools. No fixture part that may be removed, for maintenance, shall be held in place by metal tabs that must be bent to remove said part. N. The Contractor shall furnish and install a concrete foundation for the pole mounted fixtures as indicated on the Drawings and as required. This applies to foundations for pole mounted fixtures located in the yard (i.e. site lighting) and foundations that are part of a structure. Foundation shall be designed and approved by a professional structural engineer currently registered in the State of Texas. The wind design shall be in accordance with ASCE 7 and the Texas Building Code. Pole structure/foundation shall be able to handle fixture/pole weight and withstand wind velocity of up to 110 MPH with a 1.3 gust factor. Provide calculations signed and sealed by a Professional Structural Engineer for review. O. One (1), ¾” diameter, 10’-0” long ground rod, furnish in accordance with Section 16170, shall be driven adjacent to each pole. The pole, anchor bolts, steel reinforcement bar in the base, and equipment grounding conductor shall all be bonded to the ground rod as indicated in the standard details. 3.02 TESTING A. All tests shall be performed in accordance with the requirements of the General Conditions and Division 1. The following tests are required: 1. Certified Shop Tests a. The lighting fixtures shall be given routine factory tests in accordance with the requirement of ANSI, NEMA and Underwriters Laboratories standards. 2. Field Tests a. Field testing shall be done in accordance with the requirements specified in the General Conditions, Division 1, and NETA Acceptance Testing Specifications, latest edition. City of Denton Hazen and Sawyer BID SET 16500-8 Lighting - END OF SECTION - City of Denton Hazen and Sawyer BID SET 16670-1 Lightning Protection Systems SECTION 16670 LIGHTNING PROTECTION SYSTEMS PART 1 – GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, install, test, and place in satisfactory operation a complete lightning protection system as specified herein. This is a performance specification. The Drawings do not show a complete lightning protection system design. The Contractor shall retain the services of a firm specializing in the design, installation, and testing of lightning protection systems. 1.02 CODES AND STANDARDS A. The system shall comply with the following codes and standards: 1. Underwriters Laboratories, Inc. (U.L.): a. U.L. 96 - Lightning System Components b. U.L. 96A - Installation Requirements for Lightning Protection Systems c. U.L. 467 – Grounding and Bonding Equipment 2. National Fire Protection Association (NFPA): a. ANSI/NFPA 780 - Lightning Protection Code 3. Lightning Protection Institute (LPI): a. LPI-175 - Standard of Practice 1.03 SUBMITTALS A. In accordance with the procedures and requirements set forth in the General Conditions and Section 01300, Submittals, the Contractor shall obtain from the equipment manufacturer and submit the following: 1. Shop Drawings 2. Operation and Maintenance Manuals 3. Spare Parts List 4. Test Reports 081215BR City of Denton Hazen and Sawyer BID SET 16670-2 Lightning Protection Systems 5. UL Master Label Certification 1.04 SHOP DRAWINGS A. Each submittal shall be complete in all respects, incorporating all information and data listed herein and all additional information required for evaluation of the proposed equipment's compliance with the Contract Documents. B. Partial, incomplete or illegible submittals will be returned to the Contractor without review for resubmittal. C. Shop drawings for each lightning protection system shall include, but not be limited to: 1. Product data sheets. 2. Complete U.L. approved, full size layout and installation drawings/details with clearly marked dimensions. Drawings shall indicate the exact location of all system components. Drawings shall be signed by a full-time employee of the lightning protection system manufacturer who is in responsible charge of this project and has been engaged in the business for at least ten (10) years. 3. Weights of major all components. 4. Bill of material list for each lightning protection system. 5. Manufacturer's installation instructions. 6. Manufacturer's and installer's standard warranty. 7. Evidence of the designer/installers UL listing. D. The shop drawing information shall be complete and organized in such a way that the Engineer can determine if the requirements of these specifications are being met. Copies of technical bulletins, technical data sheets from "soft-cover" catalogs, and similar information which is "highlighted" or somehow identifies the specific equipment items the Contractor intends to provide are acceptable and shall be submitted. 1.05 OPERATIONS AND MAINTENANCE MANUALS A. The Contractor shall submit operation and maintenance manuals in accordance with the procedures and requirements set forth in the General Conditions and Division 1. The manuals shall include: 1. Instruction books and/or leaflets. 2. Recommended spare parts list. 3. Final as-built construction drawings included in the shop drawings incorporating all changes made during the installation. City of Denton Hazen and Sawyer BID SET 16670-3 Lightning Protection Systems 4. All other information that was included in the shop drawing submittal. 1.06 SPARE PARTS A. The lightning protection system shall be furnished with all spare parts as recommended by the equipment manufacturer. In addition to the manufacturer recommended spare parts, the Contractor shall furnish the following minimum spare parts for each structure provided with a lightning protection system under this Contract: No. Required Descriptions 2 Air Terminals 2 Point Tip Protectors B. The spare parts shall be packed in containers suitable for long term storage, bearing labels clearly designating the contents and the pieces of equipment for which they are intended. C. Spare parts shall be delivered at the same time as the equipment to which they pertain. The Contractor shall properly store and safeguard such spare parts until completion of the Work, at which time they shall be delivered to the Owner. D. Spare parts lists, included with the shop drawing submittal shall indicate specific sizes, quantities, and part numbers of the items to be furnished. Terms such as "1 lot of packing material" are not acceptable. E. Parts shall be completely identified with a numerical system to facilitate parts inventory control and stocking. Each part shall be properly identified by a separate number. Those parts which are identical for more than one size, shall have the same part number. PART 2 -- PRODUCTS 2.01 MANUFACTURERS A. The lightning protection systems covered by this Specification shall be furnished using standard components of proven performance as manufactured by reputable concerns. The systems shall be designed, constructed and installed in accordance with the best practices of the trade, and shall operate satisfactorily when installed. B. The lightning protection systems shall be furnished and installed by A-C Lightning Security, Inc., Thompson Lightning Protection, Inc, Lightning Elimination and Consultants, Modern Lightning Protection Company, Inc. or approved equal. C. System designer/supplier qualifications shall be as follows: 1. System components shall be manufactured by a company specializing in lightning protection equipment with a minimum of 5 years documented experience. Company shall be listed in the Section entitled "Lightning Conductor, Air Terminals and City of Denton Hazen and Sawyer BID SET 16670-4 Lightning Protection Systems Fittings" of the U.L. "Electrical Construction Materials Directory" for at least 5 years previous to this Contract's bid opening date. 2. The system designer/installer shall be an authorized installer of manufacturer with a minimum of 5 years of documented experience. Designer/Installer shall be listed in the section entitled "Lightning Protection Installation" of the U.L. "Electrical Construction Materials Directory" for at least 5 years previous to this Contract's bid opening date. 2.02 LIGHTNING PROTECTION SYSTEMS A. General 1. All components and parts of the lightning protection system shall be as specified herein. The materials used shall meet or exceed the material specification requirements of the Underwriters Laboratories, Inc. All materials shall be marked with a UL label or stamp. 2. The complete lightning protection system shall be inspected and included in the Master Label certification. B. Conductors 1. Conductors shall be aluminum cable, consisting of a minimum of 24 strands of No. 14 AWG aluminum wire. Copper conductors shall be furnished and installed only where required and when in contact with the earth. Where termination of copper conductors is required to aluminum parts, suitable bi-metallic connectors approved for the purpose shall be furnished and installed. C. Fittings 1. Fittings shall be the bolted type with stainless steel bolts, nuts, and washers. Fittings shall be of cast metal construction specifically designed for the application. Crimp-type fittings are not acceptable. Bi-metallic type fittings shall be furnished where required. D. Fasteners 1. Fasteners shall be manufactured from non-corrosive material of ample strength and rigidity for the application. E. Bases 1. Bases shall be bolted style provided with the model to suit the application (i.e. parapet, standing seam, etc.). Bolts, nuts, and washers shall be made of stainless steel. Bases shall be of aluminum or bronze construction, compatible with the material of the surface to which it is attached. Crimp-type bases are not acceptable. City of Denton Hazen and Sawyer BID SET 16670-5 Lightning Protection Systems F. Ground Rods 1. Ground rods shall be 3/4-inch by 10-foot 0-inch sectional type copper-clad steel rods; as specified in Section 16170, Grounding and Bonding; quantity as required. Ground rods and all associated hardware shall be UL 467 listed. G. Air Terminals 1. Air terminals shall be solid aluminum. Air terminals shall be tapered or blunt tip type to suit the application and furnished with air terminal bases and safety tips (ball or bullet type) for impalement protection. H. Thru-Roof Hardware 1. Thru-roof penetrations shall have stainless steel nuts, bolts, and washers. Sealing washers and sealing boots shall be provided as required and shall be compatible with the roofing material. Conductor connections to this roof hardware shall be by bolted connection. Crimp type connections are not acceptable. PART 3 -- EXECUTION 3.01 INSTALLATION A. The lightning protection system shall be furnished and installed in accordance with the manufacturer's installation instructions. One (1) copy of these instructions shall be included with the system components at time of shipment. The system components shall be suitably protected until accepted by the Owner. B. The equipment shall be installed in accordance with the manufacturer's recommendations. This shall include, but not be limited to the following: 1. Course all main down conductors to maintain a downward or horizontal run free of pockets or sags. Maintain an eight-inch (8") minimum radius and make no bend greater than 90 degrees. Follow the most direct route with inductance bonding conductors maintaining the horizontal or downward course of the main conductor. Interconnect roof conductors to provide at least two paths to ground from each terminal and to form closed loops. Follow the most direct path possible with down conductors between roof conductors and ground terminals. All down conductors for new occupiable buildings shall be placed in a concealed manner. Down conductors for existing occupiable structures, tanks, basins, and other non-occupiable structures may be installed exposed. 2. Install ground connections at no less than 60-foot intervals and at each down conductor on perimeter. If the structure has a ground grid, the ground rods from that grid may be used for connection to the down conductors. At each ground connection, determine the extent of the grounding arrangement according to the volume and type of soil encountered and the lowest expected moisture content. Have the Owner's representative observe each ground connection. Bond together all electrical service, telephone service, and lightning protection grounds to all underground metallic piping systems as required by Article 250 of the NEC. City of Denton Hazen and Sawyer BID SET 16670-6 Lightning Protection Systems 3. The structural steel frame (where provided) may substitute for main down conductors provided the frame is electrically continuous and of adequate cross-section. Where the steel frame is utilized, connect the roof conductor to steel at least as often and at the same column as the ground connections. Make connections to steel with exothermic welds wherever possible. Provide bonding as required to make the entire metal frame continuous. 4. Bond all sizable metal objects within 6-feet of down, roof, or grounding conductors to the system. Use only approved fittings and conductors. 5. Wherever possible problems with corrosion are encountered, use substitute approved materials and/or provide corrosion protection. Use bimetallic or other specially designed and approved connectors where dissimilar metals are to be joined. 6. Install air terminals within 2-feet of the edge of structure and at intervals not greater than 20-feet along perimeter and peak. Provide additional terminals to limit spacing across roof to 50-feet maximum. Bond any exposed metallic object or surface to the roof conductor. Flash all terminal or conductor penetrations in the roof to conform to the roofer's requirements. 7. Record each ground connection location and mark up a reproducible copy of the approved shop drawings with their location. Also, indicate any substantial field modifications on these drawings. These drawings shall be included in the O&M manual. 8. Log all continuity tests of metal framing, ground grid connections, bonding, and similar connections. Indicate the location of tests or plans. Include test results in the O&M manual. 9. Retain U.L. to make an inspection of the completed installation and issue a Master Label Certification. Furnish a copy of the Certification to the Owner upon receipt. 3.02 TESTING A. All tests shall be performed in accordance with the requirements of the General Conditions and Division 1. The following tests are required: 1. Certified Shop Tests and Reports a. None Required. 2. Field Tests a. After installation, the lightning protection system shall be tested for continuity to the ground grid. The tests shall be made by the lightning protection system installer. Test shall be as follows: City of Denton Hazen and Sawyer BID SET 16670-7 Lightning Protection Systems i. Record the resistance between each down conductor and the ground grid to ensure a suitable low-resistance connection. All resistance values shall be 1 ohm or less. Test shall be made after the ground grid has been installed and tested per the requirements of Section 16170, Grounding and Bonding. -END OF SECTION- City of Denton Hazen and Sawyer BID SET 16902-1 Electric Controls and Relays SECTION 16902 ELECTRIC CONTROLS AND RELAYS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, install, test, and place in satisfactory operation all electric controls and relays as specified herein and indicated on the Drawings. B. Electrical control and relay systems shall be assembled using NEMA rated components. Components designed and built to International Electrotechnical Commission (IEC) standards are not recognized. Equipment designed, manufactured and labeled in compliance with IEC standards is not acceptable. C. Reference Section 16000, Basic Electrical Requirements and Section 16195, Electrical Identification. 1.02 CODES AND STANDARDS A. Products specified herein shall be in conformance with or listed to the following standards as applicable: 1. NEMA 250 – Enclosures for Electrical Equipment 2. UL 508A – Standard for Industrial Control Panels 3. UL-1203 – Standard for Explosion-proof and Dust-ignition-proof Electrical Equipment for use in Hazardous (Classified) Locations. 4. ANSI/ISA 12.12.01-2013 – Nonincendive Electrical Equipment for use in Class I and II, Division II Hazardous (Classified) locations. 1.03 SUBMITTALS A. In accordance with the procedures and requirements set forth in the General Conditions and Section 01300, Submittals, the Contractor shall obtain from the equipment manufacturer and submit the following: 1. Shop Drawings 2. Spare Parts List B. Each submittal shall be identified by the applicable specification section. City of Denton Hazen and Sawyer BID SET 16902-2 Electric Controls and Relays 1.04 SHOP DRAWINGS A. Each submittal shall be complete in all respects, incorporating all information and data listed herein and all additional information required for evaluation of the proposed equipment's compliance with the Contract Documents. B. Partial, incomplete or illegible submittals will be returned to the Contractor without review for resubmittal. C. Shop drawings shall include but not be limited to: 1. Product data sheets. D. The shop drawing information shall be complete and organized in such a way that the Engineer can determine if the requirements of these Specifications are being met. Copies of technical bulletins, technical data sheets from "soft-cover" catalogs, and similar information which is "highlighted" or somehow identifies the specific equipment items the Contractor intends to provide are acceptable and shall be submitted. 1.05 SPARE PARTS A. All spare parts as recommended by the equipment manufacturer shall be furnished to the Owner by the Contractor. In addition to the manufacturer recommended spare parts, the following spare parts shall be provided for the local control stations: 1. One (1) contact block of each type furnished on the project 2. One (1) indicating light lens of each color furnished on the project 3. One (1) LED lamp of each color furnished on the project B. The spare parts shall be packed in containers suitable for long term storage, bearing labels clearly designating the contents and the pieces of equipment for which they are intended. C. Spare parts shall be delivered at the same time as the equipment to which they pertain. The Contractor shall properly store and safeguard such spare parts until completion of the work, at which time they shall be delivered to the Owner. D. Spare parts lists, included with the shop drawing submittal, shall indicate specific sizes, quantities, and part numbers of the items to be furnished. Terms such as "1 lot of packing material" are not acceptable. E. Parts shall be completely identified with a numerical system to facilitate parts control and stocking. Each part shall be properly identified by a separate number. Those parts which are identical for more than one size, shall have the same part number. City of Denton Hazen and Sawyer BID SET 16902-3 Electric Controls and Relays PART 2 -- PRODUCTS 2.01 CONTROL COMPONENTS A. Manufacturers 1. Control components shall be manufactured by Eaton, The Square D Company, General Electric, Allen-Bradley, Siemens Energy and Automation, or Engineer approved equal. B. Pilot Devices 1. General a. All pilot devices shall be provided with a legend plate. Legend plates shall have a white background and black lettering and indicate the function of the respective pilot device. The text shown on the Drawings or indicated in the specifications shall be used as the basis for legend plate engraving (i.e. HAND-OFF-AUTO, RUN, EMERGENCY STOP, etc). b. All pilot devices shall be selected and properly installed to maintain the NEMA 250 rating of the enclosure in which they are installed. All pilot devices shall be UL 508 Listed. c. All pilot devices shall be 30.5mm in diameter, unless otherwise indicated. 22mm devices are not acceptable. d. Pilot devices for all electrical equipment under this Contract shall be of the same type and manufacturer unless otherwise specified herein or indicated on the Drawings. e. In Class 1 Division 2 hazardous locations, pilot devices shall be the hermetically-sealed type, constructed in accordance with ANSI/ISA 12.12.01. 2. Pushbuttons a. Pushbuttons shall be non-illuminated, black in color, and have momentary style operation unless otherwise indicated on the Drawings. b. Pushbuttons shall have the quantity of normally closed and/or normally open contacts as indicated on the Drawings and as required. In addition to the required contacts, one (1) spare normally open and one (1) spare normally closed contact shall be installed at each pushbutton. Contacts shall be rated for 5A at 250VAC/DC (minimum), but no less than required for the application. c. Pushbuttons shall be provided with a full guard around the perimeter of the button. Where a lockout style pushbutton is specified or indicated on the Drawings, provide a padlockable guard. City of Denton Hazen and Sawyer BID SET 16902-4 Electric Controls and Relays 3. Selector Switches a. Selector switches shall be non-illuminated, black in color, and have the number of maintained positions as indicated on the Drawings and as required. Handles shall be the extended type that provide a greater surface area for operation. b. Selector switches shall have the quantity of normally closed and/or normally open contacts as indicated on the Drawings and as required. In addition to the required contacts, one (1) spare normally open and one (1) spare normally closed contact shall be installed at each selector switch. Contacts shall be rated for 5A at 250VAC/DC (minimum), but no less than required for the application. c. Where indicated in the Drawings or Specifications, provide spring return positions. d. Selector switches shall be provided with an indexing component that fits into the keyed portion of the cutout for the device and prevents the switch from spinning when operated. 4. Indicating Lights a. Indicating lights shall LED type, with the proper voltage rating to suit the application, and push-to-test feature. b. Indicating light lens colors shall be as required in equipment specifications and/or as indicated on the Drawings. If lens colors are not indicated, the following colors shall be used: Green - "Run", "On", “Open” Red - "Off", “Closed” Amber - "Alarm", "Fail" White - “Control Power On” 5. Emergency Stop Switches a. Emergency stop switches shall be non-illuminated, red in color, with a minimum 35mm diameter mushroom head. Once activated, switch shall maintain its position and require a manual pull to release/reset. b. Emergency stop switches shall have the quantity of normally closed and/or normally open contacts as indicated on the Drawings and as required. In addition to the required contacts, one (1) spare normally open and one (1) spare normally closed contact shall be installed at each switch. Contacts shall be rated for 5A at 250VAC/DC (minimum), but no less than required for the application. City of Denton Hazen and Sawyer BID SET 16902-5 Electric Controls and Relays C. Relays and Timers 1. General a. Relays and timers shall be furnished with an integral pilot light for positive indication of coil energization. b. Relays and timers shall have tubular pin style terminals with matching 11-pin DIN rail mount socket. Spade or blade style terminals are not acceptable. c. Relays and timers for all electrical equipment under this Contract shall be of the same type and manufacturer unless otherwise specified herein or indicated on the Drawings. 2. Control and Pilot Relays a. Miniature or “ice-cube” type relays are not acceptable. b. Relays shall have coil voltage as required to suit the application and/or as indicated on the Drawings. c. Relays shall be provided with contacts rated for 10A (resistive), minimum, at 120/240 VAC and 28 VDC. Relays shall have 3-pole, double-throw (3PDT) contact arrangement. 3. Time Delay Relays a. Timers delay relays shall utilize electronic timing technology. Mechanical timing devices are not acceptable. b. Relays shall have coil voltage as required to suit the application and/or as indicated on the Drawings. c. Relays shall be provided with contacts rated for 10A (resistive), minimum, at 120/240 VAC and 28 VDC. Relays shall have double-pole double-throw (DPDT) contact arrangement. d. Time delay ranges shall be as indicated on the Drawings and/or as required to suit the application. Timing range shall be adjustable from the front of the relay. On delay and off delay timer configurations shall be provided as indicated on the Drawings and/or as required to suit the application. 4. Elapsed Time Meters a. Elapsed time meters shall be non-resettable type with no less than a 4 digit display. Coil voltage shall be as required to suit the application and/or as indicated on the Drawings. City of Denton Hazen and Sawyer BID SET 16902-6 Electric Controls and Relays D. Control Terminal Blocks 1. Control terminal blocks shall be assembled on non-current carrying galvanized steel DIN mounting rails securely bolted to the enclosure or subpanel. Terminals shall be tubular screw type with pressure plate that will accommodate wire size range of #22 - #8 AWG. 2. Control terminal blocks shall be single tier with a minimum rating of 600 volts and 20A. Separate terminal strips shall be provided for each type of control used (i.e. 120VAC vs. 24VDC). Quantity of terminals shall be provided as required to suit the application. In addition, there shall be a sufficient quantity of terminals for the termination of all spare conductors. 3. Terminals shall be marked with a permanent, continuous marking strip, with each terminal numbered. One side of each terminal shall be reserved exclusively for incoming field conductors. Common connections and jumpers required for internal wiring shall not be made on the field side of the terminal. 2.02 LOCAL CONTROL STATIONS A. Local control stations shall be furnished and installed complete with pushbuttons, selector switches, indicating lights, and other devices as indicated on the Drawings. B. Specific devices installed in local control stations shall be provided in accordance with the requirements specified elsewhere in this Section. C. In non-hazardous locations, local control stations shall be NEMA 4X, Type 304 Stainless Steel. D. In hazardous locations, local control stations shall be furnished with the following enclosure type and material of construction, dependent upon the classification of the area in which they are to be installed. Area classifications are indicated on the Drawings. AREA CLASSIFICATION ENCLOSURE TYPE AND MATERIAL Class 1, Division 1, Group D NEMA 7, Die Cast Aluminum Class 1, Division 2, Group D NEMA 4X, Type 304 Stainless Steel E. Non-metallic enclosures, NEMA 7 enclosures shall be provided with threaded integral conduit hubs. Conduit hubs shall be external to the enclosure. F. Local control stations for use in non-hazardous locations shall be UL-508 Listed. Local control stations for use in Class 1 Division 1 hazardous locations shall be UL-1203 Listed. Local control stations for use in Class 1 Division 2 hazardous locations shall be in accordance with ANSI/ISA 12.12.01-2013. G. Provide a nameplate on each local control station in accordance with Section 16195, Electrical Identification. The name and/or number of the equipment associated with each control station shall be engraved on the nameplate, followed by the words “LOCAL CONTROL STATION”. City of Denton Hazen and Sawyer BID SET 16902-7 Electric Controls and Relays PART 3 -- EXECUTION 3.01 INSTALLATION A. Local control stations shall be provided in the enclosure type and material of construction required for the area in which it is installed. Reference the requirements in Part 2 herein, and the area classifications indicated on the Drawings. B. All control components shall be mounted in a manner that will permit servicing, adjustment, testing, and removal without disconnecting, moving, or removing any other component. Components mounted on the inside of panels shall be mounted on removable plates and not directly to the enclosure. Mounting shall be rigid and stable unless shock mounting is required otherwise by the manufacturer to protect equipment from vibration. Component's mounting shall be oriented in accordance with the component manufacturer's and industries' standard practices. C. Pilot devices shall be properly bonded to the equipment enclosure door where they are installed. If proper bonding cannot be achieved through the locknuts that affix the device in place, a green colored bonding screw shall be provided on the pilot device. The bonding screw shall be bonded to the equipment enclosure through the use of an insulated green bonding conductor. D. Local control station covers shall be bonded to the local control station enclosure through the use of an insulated green bonding conductor. E. Wiring to devices at each local control station shall be provided with enough slack to permit the local control station cover to be removed and pulled at least 6 inches away from the enclosure. F. Terminal strips, relays, timers, and similar devices shall not be installed on the rear of the panel/cabinet doors. Terminal strips, relays, timers, and similar devices shall not be installed on the side walls of panel/cabinet interiors without written permission from the Engineer. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 16902-8 Electric Controls and Relays This page left blank intentionally City of Denton Hazen and Sawyer BID SET 17000-1 Control and Information System Scope and General Requirements SECTION 17000 CONTROL AND INFORMATION SYSTEM SCOPE AND GENERAL REQUIREMENTS PART 1 -- GENERAL 1.01 SCOPE A. The Contractor shall provide, through the services of an instrumentation and control system subcontractor, all components, system installation services, as well as all required and specified ancillary services in connection with the Instrumentation, Control and Information System. The System includes all materials, labor, tools, fees, charges and documentation required to furnish, install, test and place in operation a complete and operable instrumentation, control and information system as shown and/or specified. The system shall include all measuring elements, signal converters, transmitters, local control panels, digital hardware and software, operator workstations, remote telemetry units, signal and data transmission systems, interconnecting wiring and such accessories as shown, specified, and/or required to provide the functions indicated. B. The scope of the work to be performed under this Division includes but is not limited to the following: 1. The Contractor shall retain overall responsibility for the instrumentation and control system as specified herein. 2. Furnish and install process instrumentation and associated taps and supports as scheduled or shown on the Drawings, unless otherwise noted or supplied by equipment vendors. 3. Furnish and install local control panels, field panels and associated cabinets and panels as shown on the Drawings and as specified in Division 17. 4. Furnish and install digital control system hardware and software as specified in Division 17. 5. Final termination and testing of all instrumentation and control system signal wiring and power supply wiring at equipment furnished under Division 17. 6. Furnish, install and terminate all special cables (instruments, printers, telemetry, etc.). Furnish and terminate control system communication network cables. 7. Furnish and install surge protection devices for all digital equipment, local control panels, remote telemetry units, and instrumentation provided under this Division, including connections to grounding system(s) provided under Division 16. City of Denton Hazen and Sawyer BID SET 17000-2 Control and Information System Scope and General Requirements 8. Coordinate grounding requirements with the electrical subcontractor for all digital equipment, local control panels, remote telemetry units, and instrumentation provided under this Division. Terminate grounding system cables at all equipment provided under this Division. 9. Provide system testing, calibration, training and startup services as specified herein and as required to make all systems fully operational. C. It is the intent of the Contract Documents to construct a complete and working installation. Items of equipment or materials that may reasonably be assumed as necessary to accomplish this end shall be supplied whether or not they are specifically stated herein. 1.02 RELATED ITEMS A. Field mounted switches, torque switches, limit switches, gauges, valve and gate operator position transmitters, sump pump controls and other instrumentation and controls furnished with mechanical or electrical equipment not listed in the instrument schedule shall be furnished, installed, tested and calibrated as specified under other Divisions. B. Additional and related work performed under Division 16 includes the following: 1. Instrument A.C. power source and disconnect switch for process instrumentation, A.C. grounding systems, and A.C. power supplies for all equipment, control panels and accessories furnished under Division 17. 2. Conduit and raceways for all instrumentation and control system signal wiring, grounding systems, special cables and communication network cables. 3. Instrumentation and control system signal wiring. 4. Install control system communication network cables. 5. Furnish and install grounding systems for all digital equipment, local control panels, remote telemetry units, and instrumentation provided under Division 17. Grounding systems shall be complete to the equipment provided under Division 17, ready for termination by the instrumentation subcontractor. 6. Termination of all instrumentation and control system signal wiring at all equipment furnished under other divisions of the Specifications. 7. Final wiring and termination to A.C. grounding systems and to A.C. power sources (e.g. panelboards, motor control centers, and other sources of electrical power). C. The new Programmable Logic Controller’s (PLC’s) furnished under this Contract as well as the Owner’s existing control system Human-Machine Interface (HMI) software will be programmed/configured by the City of Denton. The Contractor and instrumentation subcontractor will not be responsible for the programming of these systems, but shall provide assistance with testing and startup of these systems. City of Denton Hazen and Sawyer BID SET 17000-3 Control and Information System Scope and General Requirements 1.03 GENERAL INFORMATION AND DESCRIPTION A. Where manufacturers are named for a particular item of equipment, it is intended as a guide to acceptable quality and performance and does not exempt such equipment from the requirements of these Specifications or Drawings. In order to centralize responsibility, it is required that all equipment (including field instrumentation and control system hardware and software) offered under this Division shall be furnished and installed by the instrumentation subcontractor, or under the supervision of the instrumentation subcontractor, who shall assume complete responsibility for proper operation of the instrumentation and control system equipment, including that of coordinating all signals, and furnishing all appurtenant equipment. B. The Contractor shall retain total responsibility for the proper detailed design, fabrication, inspection, test, delivery, assembly, installation, activation, checkout, adjustment and operation of the entire instrumentation and control system as well as equipment and controls furnished under other Divisions of the Specifications. The Contractor shall be responsible for the delivery of all detailed drawings, manuals and other documentation required for the complete coordination, installation, activation and operation of mechanical equipment, equipment control panels, local control panels, field instrumentation, control systems and related equipment and/or systems and shall provide for the services of a qualified installation engineer to supervise all activities required to place the completed facility in stable operation under full digital control. C. The instrumentation and control system shall be capable of simultaneously implementing all real-time control and information system functions, and servicing all operator service requests as specified, without degrading the data handling and processing capability of any system component. D. Control system inputs and outputs are listed in the Input/Output Schedule. This information, together with the functional control descriptions, process and instrumentation diagrams, and electrical control schematics, describes the real-time monitoring and control functions to be performed. In addition, the system shall provide various man/machine interface and data reporting functions as specified in the software sections of this Specification. E. The mechanical, process, and electrical drawings indicate the approximate locations of field instruments, control panels, systems and equipment as well as field-mounted equipment provided by others. The instrumentation subcontractor shall examine the mechanical, process and electrical drawings to determine actual size and locations of process connections and wiring requirements for instrumentation and controls furnished under this Contract. The instrumentation subcontractor shall inspect all equipment, panels, instrumentation, controls and appurtenances either existing or furnished under other Divisions of the Specifications to determine all requirements to interface same with the control and information system. The Contractor shall coordinate the completion of any required modifications with the associated supplier of the item furnished. City of Denton Hazen and Sawyer BID SET 17000-4 Control and Information System Scope and General Requirements F. The instrumentation subcontractor shall review and approve the size and routing of all instrumentation and control cable and conduit systems furnished by the electrical subcontractor for suitability for use with the associated cable system. G. The Contractor shall coordinate the efforts of each supplier to aid in interfacing all systems. This effort shall include, but shall not be limited to, the distribution of approved shop drawings to the electrical subcontractor and to the instrumentation subcontractor furnishing the equipment under this Division. H. The Contractor shall be responsible for providing a signal transmission system free from electrical interference that would be detrimental to the proper functioning of the instrumentation and control system equipment. I. The Owner shall have the right of access to the subcontractor's facility and the facilities of his equipment suppliers to inspect materials and parts; witness inspections, tests and work in progress; and examine applicable design documents, records and certifications during any stage of design, fabrication and tests. The instrumentation subcontractor and his equipment suppliers shall furnish office space, supplies and services required for these surveillance activities. J. The terms "Instrumentation", "Instrumentation and Control System", and "Instrumentation, Control and Information System" shall hereinafter be defined as all equipment, labor, services and documents necessary to meet the intent of the Specifications. 1.04 INSTRUMENTATION AND CONTROL SYSTEM SUBCONTRACTORS A. Instrumentation and control system subcontractors shall be regularly engaged in the detailed design, fabrication, installation, and startup of instrumentation and control systems for water and wastewater treatment facilities, remote telemetry systems for water supply/distribution systems, and remote telemetry systems for wastewater collection systems. Instrumentation and control system subcontractors shall have a minimum of five years of such experience, and shall have completed a minimum of three projects of similar type and size as that specified herein. Where specific manufacturers and/or models of major hardware or software products (PLC, HMI software, LAN, etc.) are specified to be used on this project, the instrumentation and control system subcontractor shall have completed at least one project using that specified hardware or software. As used herein, the term “completed” shall mean that a project has been brought to final completion and final payment has been made. Any instrumentation and control system subcontractor that has been subject to litigation or the assessment of liquidated damages for nonperformance on any project within the last five calendar years shall not be acceptable. B. Acceptable instrumentation and control system subcontractors shall be Prime Controls or equal. City of Denton Hazen and Sawyer BID SET 17000-5 Control and Information System Scope and General Requirements 1.05 DEFINITIONS A. Solid State: Wherever the term solid state is used to describe circuitry or components in the Specifications, it is intended that the circuitry or components shall be of the type that convey electrons by means of solid materials such as crystals or that work on magnetic principles such as ferrite cores. Vacuum tubes, gas tubes, slide wires, mechanical relays, stepping motors or other devices will not be considered as satisfying the requirements for solid state components of circuitry. B. Bit or Data Bit: Whenever the terms bit or data bit are used in the Specification, it is intended that one bit shall be equivalent to one binary digit of information. In specifying data transmission rate, the bit rate or data bit rate shall be the number of binary digits transmitted per second and shall not necessarily be equal to either the maximum pulse rate or average pulse rate. C. Integrated Circuit: Integrated circuit shall mean the physical realization of a number of circuit elements inseparably associated on or within a continuous body to perform the function of a circuit. D. Mean Time Between Failures (MTBF): The MTBF shall be calculated by taking the number of system operating hours logged during an arbitrary period of not less than six months and dividing by the number of failures experienced during this period plus one. E. Mean Time to Repair (MTTR): The MTTR shall be calculated by taking the total system down time for repair over an arbitrary period of not less than six months coinciding with that used for calculation of MTBF and dividing by the number of failures causing down time during the period. F. Availability: The availability of a non-redundant device or system shall be related to its MTBF and MTTR by the following formula: A = 100 x (MTBF/(MTBF + MTTR)) Percent The availability of a device or system provided with an automatically switched backup device or system shall be determined by the following formula: A = A2 + 1 - ((1-A1) x (1-A1)) where: A1 = availability of non-redundant device or system A2 = availability of device or system provided with an automatically switched backup device or system G. Abbreviations: Specification abbreviations include the following: A - Availability City of Denton Hazen and Sawyer BID SET 17000-6 Control and Information System Scope and General Requirements ADC - Analog to Digital Converter AI - Analog Input AO - Analog Output AVAIL - Available BCD - Binary Coded Decimal CSMA/CD - Carrier Sense Multiple Access/Collision Detect CPU - Central Processing Unit CRC - Cyclic Redundancy Check CRT - Cathode Ray Tube CS - Control Strategy DAC - Digital to Analog Converter DBMS - Data Base Management System DI - Discrete Input DMA - Direct Memory Access DO - Discrete Output DPDT - Double Pole, Double Throw DVE - Digital to Video Electronics EPROM - Erasable, Programmable Read Only Memory FDM - Frequency Division Multiplexing FSK - Frequency Shift Keyed HMI - Human Machine Interface (Software) I/O - Input/Output LAN - Local Area Network LDFW - Lead-Follow MCC - Motor Control Center MTBF - Mean Time Between Failures MTTR - Mean Time To Repair OS - Operating System PAC - Programmable Automation Controller PCB - Printed Circuit Board PID - Proportional Integral and Derivative Control PLC - Programmable Logic Controller PROM - Programmable Read Only Memory City of Denton Hazen and Sawyer BID SET 17000-7 Control and Information System Scope and General Requirements RAM - Random Access Memory RDY - Ready RMSS - Root Mean Square Summation RNG - Running ROM - Read Only Memory RTU - Remote Telemetry Unit SPDT - Single Pole, Double Throw ST/SP - Start/Stop TDM - Time Division Multiplexing UPS - Uninterruptible Power Supply H. To minimize the number of characters in words used in textual descriptions on CRT displays, printouts and nameplates, abbreviations may be used subject to the Engineer's approval. If a specified abbreviation does not exist for a particular word, an abbreviation may be generated using the principles of masking and or vowel deletion. Masking involves retaining the first and last letters in a word and deleting one or more characters (usually vowels) from the interior of the word. 1.06 ENVIRONMENTAL CONDITIONS A. Instrumentation equipment and enclosures shall be suitable for ambient conditions specified. All system elements shall operate properly in the presence of telephone lines, power lines, and electrical equipment. B. Inside control rooms and climate-controlled electrical rooms, the temperature will normally be 20 to 25 degrees C; relative humidity 40 to 80 percent without condensation and the air will be essentially free of corrosive contaminants and moisture. Appropriate air filtering shall be provided to meet environmental conditions (i.e., for dust). C. Other indoor areas may not be air conditioned/heated; temperatures may range between 0 and 40 degrees C with relative humidity between 40 and 95 percent. D. Field equipment including instrumentation and panels may be subjected to wind, rain, lightning, and corrosives in the environment, with ambient temperatures from -20 to 40 degrees C and relative humidity from 10 to 100 percent. All supports, brackets, interconnecting hardware, and fasteners shall be aluminum, type 316 stainless steel, or metal alloy as otherwise suitable for chemical resistance within chemical feed/storage areas shown on the installation detail drawings. City of Denton Hazen and Sawyer BID SET 17000-8 Control and Information System Scope and General Requirements PART 2 -- PRODUCTS 2.01 NAMEPLATES A. All items of equipment listed in the instrument schedule, control panels, and all items of digital hardware shall be identified with nameplates. Each nameplate shall be located so that it is readable from the normal observation position and is clearly associated with the device or devices it identifies. Nameplates shall be positioned so that removal of the device for maintenance and repair shall not disturb the nameplate. Nameplates shall include the equipment identification number and description. Abbreviations of the description shall be subject to the Engineer's approval. B. Nameplates shall be made of 1/16-inch thick machine engraved laminated phenolic plastic having white numbers and letters not less than 3/16-inch high on a black background. C. Nameplates shall be attached to metal equipment by stainless steel screws and to other surfaces by an epoxy-based adhesive that is resistant to oil and moisture. In cases where the label cannot be attached by the above methods, it shall be drilled and attached to the associated device by means of stainless steel wire. PART 3 -- EXECUTION 3.01 SCHEDULE OF PAYMENT A. Payment to the Contractor for Control and Information System materials, equipment, and labor shall be in accordance with the General and Supplementary Conditions. The schedule of values submitted as required by the General and Supplementary Conditions shall reflect a breakdown of the work required for completion of the Control and Information System. The breakdown shall include sufficient detail to permit the Engineer to administer payment for the Control and Information System as outlined below. B. The following payment schedule defines project milestones that will be used for establishing maximum partial payment amounts for the Control and Information System. Payment for field instruments, field wiring, fiber optic network cable and similar items will be made in addition to the payment for the scopes of services incorporated into the schedule below. Task Completed Maximum Cumulative % Request for Payment Mobilization 3% Preliminary Design Review 5% Approved Submittals 20% Hardware Purchase (excludes field instruments) 40% Factory Acceptance Test 60% Loop Checkout 70% City of Denton Hazen and Sawyer BID SET 17000-9 Control and Information System Scope and General Requirements Control System Start-up and Test 80% Plant Start-up 90% Final System Acceptance Test 95% Final Acceptance 100% C. Requests for payment for materials and equipment that are not installed on site, but are required for system construction and the factory acceptance test (e.g., digital hardware), or are properly stored as described in the General and Supplementary Conditions and herein, shall be accompanied by invoices from the original supplier to the instrumentation subcontractor substantiating the cost of the materials or equipment. D. Any balance remaining within the schedule of values for field instruments and other materials installed on the site, or for other materials for which payment is made by invoice, will be considered due upon completion of the Final Acceptance test. 3.02 CLEANING A. The Contractor shall thoroughly clean all soiled surfaces of installed equipment and materials. B. Upon completion of the instrumentation and control work, the Contractor shall remove all surplus materials, rubbish, and debris that has accumulated during the construction work. The entire area shall be left neat, clean, and acceptable to the Owner. 3.03 FINAL ACCEPTANCE A. Final acceptance of the Instrumentation, Control and Information System will be determined complete by the Engineer, and shall be based upon the following: 1. Receipt of acceptable start up completion and availability reports and other documentation as required by the Contract Documents. 2. Completion of the Availability Demonstration. 3. Completion of all specified control system training requirements. 4. Completion of all punch-list items that are significant in the opinion of the Engineer. B. Final acceptance of the System shall mark the beginning of the extended warranty period. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 17000-10 Control and Information System Scope and General Requirements This page left blank intentionally City of Denton Hazen and Sawyer BID SET 17030-1 Control and Information System Submittals SECTION 17030 CONTROL AND INFORMATION SYSTEM SUBMITTALS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall submit for review complete Shop Drawings for all equipment in accordance with the General Conditions and Division 1 of the Specifications. All submittal material shall be complete, legible, and reproducible, and shall apply specifically to this project. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 01300 – Submittals B. Section 17000 – Control and Information System Scope and General Requirements 1.03 DIGITAL HARDWARE SUBMITTALS A. Submit system block diagram(s) showing: 1. All equipment to be provided. 2. All interconnecting cable. 3. Equipment names, manufacturer, and model numbers. 4. Equipment locations. B. Submit information for all digital equipment including, but not limited to, the following: 1. Bill of materials with equipment names, manufacturers, complete model numbers and locations. 2. Catalog cuts, including complete part number breakdown information. 3. Complete technical, material and environmental specifications. 4. Assembly drawings. 5. Mounting requirements. 6. Color samples. 7. Nameplates. City of Denton Hazen and Sawyer BID SET 17030-2 Control and Information System Submittals 8. Environmental requirements during storage and operation. 1.04 SOFTWARE SUBMITTALS A. Software submittals shall include the following as a minimum: 1. Bill of materials with software names, vendors, and complete listings of included software modules. 2. Standard manufacturer's literature describing the products. 3. Description of function of software in Control and Information System. 4. Limitations or constraints of software. 5. Minimum system (processor and memory) requirements. 6. Operation and maintenance requirements. 1.05 CONTROL PANEL SUBMITTALS A. Submittals shall be provided for all control panels, and shall include: 1. Exterior panel drawings with front and side views, to scale. 2. Interior layout drawings showing the locations and sizes of all equipment and wiring mounted within the cabinet, to scale. 3. Panel area reserved for cable access and conduit entry. 4. Location plans showing each panel in its assigned location. B. Submit information for all exterior and interior panel mounted equipment including, but not limited to, the following: 1. Bill of materials with equipment names, manufacturers, complete model numbers and locations. 2. Catalog cuts, including complete part number breakdown information. 3. Complete technical, material and environmental specifications. 4. Assembly drawings. 5. Mounting requirements. 6. Color samples. City of Denton Hazen and Sawyer BID SET 17030-3 Control and Information System Submittals 7. Nameplates. 8. Environmental requirements during storage and operation. C. Submit panel wiring diagrams showing power, signal, and control wiring, including surge protection, relays, courtesy receptacles, lighting, wire size and color coding, etc. 1.06 INSTRUMENT SUBMITTALS A. Submit information on all field instruments, including but not limited to the following: 1. Product (item) name and tag number used herein and on the Contract Drawings. 2. Catalog cuts, including complete part number breakdown information. 3. Manufacturer's complete model number. 4. Location of the device. 5. Input - output characteristics. 6. Range, size, and graduations. 7. Physical size with dimensions, NEMA enclosure classification and mounting details. 8. Materials of construction of all enclosures, wetted parts and major components. 9. Instrument or control device sizing calculations where applicable. 10. Certified calibration data on all flow metering devices. 11. Environmental requirements during storage and operation. 12. Associated surge protection devices. B. Where multiple instruments are included in the same submittal, instrument data sheets shall be included in the same binder section as the backup information (cut sheets, etc.). 1.07 WIRING AND LOOP DIAGRAMS A. Submit interconnection wiring and loop diagrams for all panels and signals in the Control and Information System. B. Electrical interconnection diagrams shall show all terminations of equipment, including terminations to equipment and controls furnished under other Divisions, complete with equipment and cable designations. Where applicable, interconnection wiring diagrams City of Denton Hazen and Sawyer BID SET 17030-4 Control and Information System Submittals shall be organized by input/output card. Interconnecting diagrams shall be prepared in a neat and legible manner on 11 X 17-inch reproducible prints. C. Loop drawings shall conform to the latest version of ISA Standards and Recommended Practices for Instrumentation and Control. Loop Drawings shall conform to ISA S5.4, Figures 1-3, Minimum Required Items. D. Loop drawings shall not be required as a separate document provided that the interconnecting wiring diagrams required in Paragraph B., above, contain all information required by ISA 5.4. 1.08 OPERATION AND MAINTENANCE MANUALS A. The Contractor shall deliver equipment operation and maintenance manuals in compliance with Section 01300 - Submittals. Operation and maintenance (O&M) manuals shall consist of two basic parts: 1. Manufacturer standard O&M manuals for all equipment and software furnished under this Division. 2. Custom O&M information describing the specific configuration of equipment and software, and the operation and maintenance requirements for this particular project. B. The manuals shall contain all illustrations, detailed drawings, wiring diagrams, and instructions necessary for installing, operating, and maintaining the equipment. The illustrated parts shall be numbered for identification. All modifications to manufacturer standard equipment and/or components shall be clearly identified and shown on the drawings and schematics. All information contained therein shall apply specifically to the equipment furnished and shall only include instructions that are applicable. All such illustrations shall be incorporated within the printing of the page to form a durable and permanent reference book. C. The manuals shall be prepared specifically for this installation and shall include all required cuts, drawings, equipment lists, descriptions, etc. that are required to instruct operation and maintenance personnel unfamiliar with such equipment. The maintenance instructions shall include troubleshooting data and full preventive maintenance schedules. The instructions shall be bound in locking 3-D-ring binders with bindings no larger than 3.5 inches. The manuals shall include 15% spare space for the addition of future material. The instructions shall include drawings reduced or folded and shall provide the following as a minimum. 1. A comprehensive index. 2. A functional description of the entire system, with references to drawings and instructions. City of Denton Hazen and Sawyer BID SET 17030-5 Control and Information System Submittals 3. A complete "as-built" set of all approved shop drawings, which shall reflect all work required to achieve final system acceptance. 4. A complete list of the equipment supplied, including serial numbers, ranges, and pertinent data. 5. Full specifications on each item. 6. Detailed service, maintenance, and operation instructions for each item supplied. 7. Special maintenance requirements particular to this system shall be clearly defined, along with special calibration and test procedures. 8. Complete parts lists with stock numbers and name, address, and telephone number of the local supplier. 9. References to manufacturers' standard literature where applicable. 10. Warning notes shall be located throughout the manual where such notes are required to prevent accidents or inadvertent misuse of equipment. D. The operating instructions shall clearly describe the step-by-step procedures that must be followed to implement all phases of all operating modes. The instructions shall be in terms understandable and usable by operating personnel and maintenance crews and shall be useful in the training of such personnel. As-built color copies of all system graphic displays shall be included with and referenced in the operating instructions. E. The maintenance instructions shall describe the detailed preventive and corrective procedures required, including environmental requirements during equipment storage and system operation, to keep the System in good operating condition. All hardware maintenance documentation shall make reference to appropriate diagnostics, where applicable, and all necessary wiring diagrams, component drawings and PCB schematic drawings shall be included. F. The hardware maintenance documentation shall include, as a minimum, the following information: 1. Operation Information - This information shall include a detailed description of how the equipment operates and a block diagram illustrating each major assembly in the equipment. 2. Preventive-Maintenance Instructions - These instructions shall include all applicable visual examinations, hardware testing and diagnostic routines, and the adjustments necessary for periodic preventive maintenance of the System. 3. Corrective-Maintenance Instructions - These instructions shall include guides for locating malfunctions down to the card-replacement level. These guides shall include adequate details for quickly and efficiently locating the cause of an City of Denton Hazen and Sawyer BID SET 17030-6 Control and Information System Submittals equipment malfunction and shall state the probable source(s) of trouble, the symptoms, probable cause, and instructions for remedying the malfunction. 4. Parts Information - This information shall include the identification of each replaceable or field-repairable component. All parts shall be identified on a list in a drawing; the identification shall be of a level of detail sufficient for procuring any repairable or replaceable part. Cross-references between equipment numbers and manufacturer's part numbers shall be provided. 1.09 FINAL SYSTEM DOCUMENTATION A. All documentation shall be delivered to the Owner prior to final system acceptance in accordance with the Contract Documents. As a minimum, final documentation shall contain all information originally part of the control system submittals. B. If any documentation or other technical information submitted is considered proprietary, such information shall be designated. Documentation or technical information which is designated as being proprietary will be used only for the construction, operation, or maintenance of the System and, to the extent permitted by law, will not be published or otherwise disclosed. C. Provide a complete set of detailed electrical interconnection diagrams required to define the complete instrumentation and control system. All diagrams shall be 11 X 17-inch original reproducible prints. All diagrams shall be corrected so as to describe final "as-built" hardware configurations and to reflect the system configuration and control methodology adopted to achieve final system acceptance. D. Provide system software documentation for the operation and maintenance of all system software programs provided as a part of the digital system. All system software documentation shall be amended as required to delineate all modifications and to accurately reflect the final as-built software configurations. E. O&M documentation shall be amended with all final, adjusted values for all setpoints and other operating parameters for Owner reference. F. The Owner recognizes the fact that not all possible problems related to real-time events, software interlocks, and hardware maintenance and utilization can be discovered during the Acceptance Tests. Therefore, the instrumentation subcontractor through the Contractor shall investigate, diagnose, repair, update, and distribute all pertaining documentation of the deficiencies that become evident during the warranty period. All such documentation shall be submitted in writing to the Owner within 30 days of identifying and solving the problem. 1.10 PROGRAMS AND SOURCE LISTINGS A. Provide one copy of all standard, of-the-shelf system and application software (exclusive of firmware resident software) on original media furnished by the software manufacturer. City of Denton Hazen and Sawyer BID SET 17030-7 Control and Information System Submittals 1.11 SUBMITTAL/DOCUMENTATION FORMAT A. All drawing-type submittals and documentation shall be rendered and submitted in the latest version of AutoCAD. B. All textual-type submittals and documentation shall be rendered and submitted in the latest version of Microsoft Word or in Searchable Adobe Portable Document Format (.pdf). 1.12 ELECTRONIC O&M MANUALS A. Subject to acceptance by the Owner and Engineer, the O&M information may be submitted in part or in whole in an electronic format on optical media. B. Electronic O&M manuals shall contain information in standard formats (Searchable Adobe PDF, Word, AutoCAD, HTML, etc.) and shall be easily accessible through the use of standard, “off-the-shelf” software such as an Internet browser. PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION – City of Denton Hazen and Sawyer BID SET 17030-8 Control and Information System Submittals This page left blank intentionally City of Denton Hazen and Sawyer BID SET 17040-1 Control and Information System Training Requirements SECTION 17040 CONTROL AND INFORMATION SYSTEM TRAINING REQUIREMENTS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. To familiarize the Owner's personnel with the process control system and field instrumentation, training shall be provided as detailed hereunder. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements 1.03 SUBMITTALS A. A minimum of 60 days prior to beginning training, submit a detailed training plan describing the following: 1. A listing of all courses to be conducted. 2. Course content. 3. Applicability of each course to management, operations, maintenance, laboratory, etc., personnel. 4. Course schedules. 5. Qualifications and experience of individual(s) providing training. B. A minimum of 14 days prior to beginning each training course, submit documentation for use by the Owner's personnel during training. The training documentation shall be specific to the particular course, and shall include the following: 1. A listing of all subjects to be covered. 2. Course schedule. 3. Documentation/lesson plans covering all subjects to be covered during the course instruction. Information shall be in a "how to" format, with sufficient background documentation and references to manufacturer literature to provide a thorough and clear understanding of the materials to be covered. 1.04 GENERAL REQUIREMENTS A. All costs of providing the training courses shall be borne by the Contractor. City of Denton Hazen and Sawyer BID SET 17040-2 Control and Information System Training Requirements B. As used herein, the term "day" shall mean an eight-hour day, and the term "week" shall mean a five-day, 40-hour week. C. Training courses, especially those for operator training, may be required to be scheduled during non-standard business hours (i.e., not between the hours of 8:00 am and 5:00 pm) to accommodate the working schedule of the Owner’s personnel. No additional compensation will be awarded to the Contractor for training at non-standard hours. D. All training courses shall complement the experience and skill levels of the Owner's personnel. E. Training courses shall be structured in order of increasing capability or security levels. The purpose of this requirement is to allow personnel with lesser training requirements or security password levels to drop out of the training at certain times while the training continues for personnel with greater requirements or higher security levels. F. All training courses shall include lecture as well as "hands on" experience for each of the attending personnel. The Contractor shall provide sufficient equipment for this to be accomplished. For example, training in which the instructor uses the computer and the Owner's personnel passively observe as the instructor demonstrates system functions shall not be acceptable. G. Unless otherwise specified, all training courses shall be conducted in the Owner's facilities. H. All training shall be completed prior to system acceptance. I. Standard manufacturer training courses are acceptable pending approval by the Engineer and Owner. 1.05 SYSTEM SUPERVISOR/ENGINEER TRAINING A. Provide manufacturer standard training in the use and configuration of the specified operator workstation (HMI or SCADA) software. B. System supervisor/engineer training shall be performed a minimum of 30 days prior to system startup. C. Training shall be provided in the following subjects: 1. System overview and capabilities. 2. Database configuration. 3. Graphic display configuration, including linking of data to displays. 4. Historical data configuration (collection, manipulation, and display). 5. Real-time and historical trending. City of Denton Hazen and Sawyer BID SET 17040-3 Control and Information System Training Requirements 6. Report configuration, generation, printing, and customization. 7. Alarm configuration and management. 8. System security. 9. I/O driver use and configuration. 10. System backup and recovery. 11. DDE linking, where applicable. 12. System command language. 13. Troubleshooting. 14. System optimization. 15. System startup and shutdown procedures. 16. LAN and WAN communications, as appropriate. D. The course shall be structured as follows: 1. Fundamentals - One four-day course (minimum) shall be provided for up to eight persons which shall serve as a digital control system familiarization course for project management personnel, engineers, and key operating/maintenance personnel. This course shall be a prerequisite for the advanced course described below in Item 2. 2. Advanced - One four-day (minimum) digital system configuration and operating course shall be provided for up to four persons. The level of training shall be sufficient to familiarize the Owner's personnel with the configuration and application of all system programs. All essential system operating procedures shall be described as required to enable the Owner's personnel to operate the system via the various workstations and local control panels. 3. Historical – One two-day course to instruct a minimum of four persons in the use and configuration of the historical data archival system. Training shall include creation, viewing, and printing of trends, charts, and reports. Training shall include all database maintenance and archival functions necessary to maintain the facility’s data on both short and long term basis, including periodic archival to optical media. City of Denton Hazen and Sawyer BID SET 17040-4 Control and Information System Training Requirements 1.06 OPERATOR TRAINING A. Two two-week courses comprised of daily half-day (four-hour) sessions for up to ten persons each shall be conducted to provide instruction in the use of the Control and Information System to monitor and control the facility. B. Operator training shall include familiarization training covering the Control and Information System. Operators shall be instructed in the names, locations, functions, and basic operation of all items of digital equipment and associated software. C. Operator training shall cover process and equipment operation both individually and collectively as an operating system. Normal as well as abnormal operating conditions shall be covered, including the response to failure occurrences and system alarms. All operator/system interactions shall be described. D. Operators shall be trained to instruct other operators and shall be provided with all course materials. 1.07 MAINTENANCE TRAINING A. A three-day course shall be conducted for at least six persons prior to the start-up of digital equipment at the Owner's plant. Instruction shall be provided in the following: 1. Operating all digital equipment, including system start-up and shutdown procedures. 2. The use of hardware diagnostic routines, test equipment and test procedures as required to enable the Owner's personnel to detect and isolate system faults to the circuit board or module level and to implement repairs by replacing failed circuit boards or modules. 3. Calibration and routine maintenance procedures for all analog and digital equipment. B. Step by step written procedures shall be provided for all preventive maintenance tasks and for identifying hardware faults to the circuit board or module level for all items of digital equipment. C. All digital equipment preventive and corrective maintenance training activities shall be limited to the use of commercially available off-the-shelf test equipment and to the use of diagnostic routines and hardware items which are the same as those to be provided as part of the system. 1.08 INSTRUMENT TRAINING A. A three-day course shall be provided at the Owner's facilities no more than three months prior to system start-up to instruct a minimum of five persons each in the calibration and preventive maintenance of the field instruments provided under this Contract. City of Denton Hazen and Sawyer BID SET 17040-5 Control and Information System Training Requirements 1.09 PLC TRAINING A. One minimum three-day manufacturer standard training course shall be provided in the programming and use of PLC's to implement monitoring and control functions such as those provided for this project. Training shall cover all aspects of the PLC hardware and software, including specified programming software. This training shall be provided by the PLC manufacturer or, as directed by the manufacturer, by the authorized distributor engaged by the manufacturer to perform this training. B. One three-day course of specific training shall be provided by the instrumentation subcontractor in the use and modification of all control strategies provided under this Division. 1.10 GENERAL REFRESHER TRAINING A. A one-week general refresher training course shall be provided for up to ten persons 3-6 months after final system acceptance. Instruction shall be given in all aspects of the complete instrumentation and control system. Instructor(s) shall be capable of answering questions related to all aspects and details of the complete system. PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION – City of Denton Hazen and Sawyer BID SET 17040-6 Control and Information System Training Requirements This page left blank intentionally City of Denton Hazen and Sawyer BID SET 17050-1 Tools, Supplies and Spare Parts SECTION 17050 TOOLS, SUPPLIES AND SPARE PARTS - GENERAL PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall provide tools, supplies, and spare parts as specified herein for the operation and maintenance of the Control and Information System. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 01300 – Submittals B. Section 17000 – Control and Information System Scope and General Requirements PART 2 -- PRODUCTS 2.01 TOOLS A. Provide special tools, other than those normally found in an electronic technician's tool box, required to test, diagnose, calibrate, install, wire, connect, disconnect, assemble and disassemble any digital equipment, instrument, panel, rack, cabinet or console mounted equipment for service and maintenance. This shall include, but not be limited to, the following: connector pin insertion and removal tools, wire crimping tools, special wrenches, special instrument calibrators, indicator lamp insertion and removal tools, etc. B. Provide tools and test equipment together with items such as instruction manuals, carrying/storage cases, unit battery charger where applicable, special tools, calibration fixtures, cord extenders, patch cords and test leads, which are not specified but are necessary for checking field operation of equipment supplied under this Division. 2.02 SUPPLIES A. The Contractor shall provide supplies as specifically required in other Sections of Division 17 2.03 SPARE PARTS A. Provide spare parts for items of control and instrumentation equipment as recommended by the manufacturer and in accordance with the Contract Documents. B. Furnish all spares in moisture-proof boxes designed to provide ample protection for their contents. Label all boxes to clearly identify contents and purpose. City of Denton Hazen and Sawyer BID SET 17050-2 Tools, Supplies and Spare Parts C. The Contractor shall replace all spare parts consumed during installation, testing, start-up, the system availability demonstration, and the guarantee period. D. Refer to individual digital hardware and instrument sections for additional requirements specific to those devices. PART 3 -- EXECUTION (NOT USED) - END OF SECTION - City of Denton Hazen and Sawyer BID SET 17060-1 Signal Coordination Requirements SECTION 17060 SIGNAL COORDINATION REQUIREMENTS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall conform to the signal coordination requirements specified herein. B. The Contractor shall be responsible for coordinating signal types and transmission requirements between the various parties providing equipment under this Contract. This shall include, but not be limited to, distribution of appropriate shop drawings among the equipment suppliers, the electrical subcontractor, the HVAC subcontractor, and the instrumentation subcontractor. C. Analog signals shall be signals for transmitting process variables, etc. from instruments and to and from panels, equipment PLC's and Control System PLC's. D. Discrete signals shall consist of contact closures or powered signals for transmitting status/alarm information and control commands between starters, panels, equipment PLC's, the Control System, etc. 1.02 ANALOG SIGNAL TRANSMISSION A. Signal transmission between electric or electronic instruments, controllers, and all equipment and control devices shall be individually isolated, linear 4-20 milliamperes and shall operate at 24 volts D.C. B. Signal output from all transmitters and controllers shall be current regulated and shall not be affected by changes in load resistance within the unit's rating. C. All cable shields shall be grounded at one end only, at the control panel, with terminals bonded to the panel ground bus. D. Analog signal isolation and/or conversion shall be provided where necessary to interface with instrumentation, equipment controls, panels, and appurtenances. E. Non-standard transmission systems such as pulse duration, pulse rate, and voltage regulated shall not be permitted except where specifically noted in the Contract Documents. Where transmitters with nonstandard outputs do occur, their outputs shall be converted to an isolated, linear, 4-20 milliampere signal. F. The Contractor shall provide 24 V power supplies for analog signals and instruments where applicable and as required inside panels, controls, etc. City of Denton Hazen and Sawyer BID SET 17060-2 Signal Coordination Requirements G. Where two-wire instruments transmit directly to the Control and Information System, the instrumentation subcontractor shall provide power supplies at the PLC-equipped control panels for those instruments. H. Where four-wire instruments with on-board loop power supplies transmit directly to the Control and Information System, the instrumentation subcontractor shall provide necessary signal isolators or shall otherwise isolate the input from the Control and Information System loop power supply. Similar provisions shall be made when a third element such as a recorder, indicator, or single loop controller with integral loop power supply is included in the loop. 1.03 DISCRETE INPUTS A. All discrete inputs to equipment and Control and Information System PLC's, from field devices, starters, panels, etc., shall be unpowered (dry) contacts in the field device or equipment, powered from the PLC's, unless specified otherwise. B. Sensing power (wetting voltage) supplied by the PLC shall be 24 VDC. 1.04 DISCRETE OUTPUTS A. All discrete outputs from local control panels and Control and Information System PLC's to field devices, starters, panels, etc., shall be 24 VDC powered (sourced) from PLC's [dry contact relay outputs]. B. PLC powered discrete outputs shall energize 24 VDC pilot relay coils in the field devices, starters, panels, etc. which in turn open or close contacts in the associated control circuit. The 24 VDC relay coil, contacts, and associated control circuitry shall be furnished integral with the field device, starter, panel, etc. by the supplier and contractor furnishing the field device, starter, or panel. C. Where required or specified herein, discrete outputs from equipment and Control and Information System PLC's to field devices, starters, panels, motor operated valves, etc., shall be dry contact or relay outputs. 1.05 OTHER DISCRETE SIGNALS A. Discrete signals between starters, panels, etc. where no 24 VDC power supply is available may be 120 VAC, as long as such contacts are clearly identified in the starter, panel, etc. as being powered from a different power supply than other starter/panel components. B. Where applicable, warning signs shall be affixed inside the starter, panel, etc. stating that the panel is energized from multiple sources. C. Output contacts in the starter, panel, etc., that are powered from other locations shall be provided with special tags and/or color-coding. Disconnecting terminal strips shall be provided for such contacts. D. The above requirements shall apply to all starters and panels, regardless of supplier. City of Denton Hazen and Sawyer BID SET 17060-3 Signal Coordination Requirements PART 2 -- PRODUCTS 2.01 PILOT RELAYS A. Pilot relays shall be supplied with the following: 1. 24 VDC or 120 VAC coils, as required. 2. At a minimum, DPDT contacts rated at 5 A, 120 VAC or 28 VDC. 3. Sockets for 24 VDC and 120 VAC relays shall be of different configurations. 4. Clips for attachment to sockets. 5. Indicator lights that glow when the relay coil is powered. B. Pilot relays shall be as manufactured by Square D, Allen Bradley, Potter & Brumfield, or equal. PART 3 -- EXECUTION (NOT USED) - END OF SECTION – City of Denton Hazen and Sawyer BID SET 17060-4 Signal Coordination Requirements This page left blank intentionally City of Denton Hazen and Sawyer BID SET 17070-1 Control and Information System Testing SECTION 17070 CONTROL AND INFORMATION SYSTEM TESTING - GENERAL PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall test the Control and Information System as specified herein to demonstrate compliance with the Contract Documents. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17071 – Factory Acceptance Test C. Section 17072 – Field Testing D. Section 17073 – Final Acceptance Test 1.03 SUBMITTALS A. For each of the specified tests, submit a test plan to the Engineer at least one month in advance of commencement of the tests. The test plan shall contain the following at a minimum: 1. A schedule of all testing to be conducted. 2. A brief description of the testing to be performed 3. Test objectives. 4. Testing criteria per the Specifications. 5. Check lists and procedures for performing each of the specified tests. 6. Sample test result documentation. 7. Requirements for other parties. 1.04 GENERAL REQUIREMENTS A. All system start-up and test activities shall follow detailed test procedures; check lists, etc., previously approved by the Engineer. The Engineer shall be notified at least 21 days in advance of any system tests and reserves the right to have his and/or the Owner's representatives in attendance. City of Denton Hazen and Sawyer BID SET 17070-2 Control and Information System Testing B. The Contractor shall provide the services of experienced factory trained technicians, tools and equipment to field calibrate, test, inspect, and adjust all equipment in accordance with manufacturer's specifications and instructions. C. The Contractor (or designee) shall maintain master logbooks for each phase of installation, startup and testing activities specified herein. Each logbook shall include signal, loop or control strategy tag number, equipment identification, description and space for sign-off dates, Contractor signature and Engineer signature. Example test documentation specific to each phase of testing shall be approved prior to initiation of that testing, as specified hereinabove. D. All test data shall be recorded on test forms, previously approved by the Engineer. When each test has been successfully completed, a certified copy of all test results shall be furnished to the Engineer together with a clear and unequivocal statement that all specified test requirements have been met and that the system is operating in accordance with the Contract Documents. E. The Engineer will review test documentation in accordance with the Contract Documents and will give written notice of the acceptability of the tests within 10 days of receipt of the test results. F. The Contractor shall independently inspect the control system components and associated electrical systems for proper installation, calibration, adjustment and functionality on a loop-by-loop and component-by-component basis prior to requesting Engineer/Owner inspection and approval. This testing shall be performed using Owner- provided application software, but the testing is not intended to test the software functionality. The Contractor shall complete and submit Engineer-approved testing forms and reports for Engineer and Owner review and verification after completion of independent testing. G. The Contractor shall allow sufficient time during field testing for application software testing by the Owner. 1. Owner software testing activities shall include but not be limited to: a. Software loading and debugging b. Software configuration changes c. Retesting functionality 2. Refer to Section 17072 for specified time allowances. 3. Exclude from these time allowances, time delays to Owner’s activities caused by substituted equipment or altered equipment electrical or control interfaces. 4. The specified time allowances shall be provided in the Contractor’s schedule for each field testing activity. City of Denton Hazen and Sawyer BID SET 17070-3 Control and Information System Testing PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION – City of Denton Hazen and Sawyer BID SET 17070-4 Control and Information System Testing This page left blank intentionally. City of Denton Hazen and Sawyer BID SET 17071-1 Factory Acceptance Test SECTION 17071 FACTORY ACCEPTANCE TEST PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall perform a Factory Acceptance Test on the Control and Information System as specified herein to demonstrate compliance with the Contract Documents. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17070 – Control and Information System Testing, General C. Section 17072 – Field Testing D. Section 17073 – Final Acceptance Test 1.03 FACTORY ACCEPTANCE TEST A. The Control and Information System equipment shall not be shipped until the Contractor receives notice of acceptability of the factory tests. B. Each item of equipment shall be fully factory inspected, calibrated and tested for function, operation and continuity of circuits. Exceptions shall be approved in writing by the Engineer. C. Each subsystem shall be fully factory tested for function and operation. D. System performance shall be tested using a fully integrated system, including all software and hardware. To achieve this, the entire control system, including all peripheral devices and all interconnecting cables (field instruments are not included in this requirement), shall be assembled on the factory test floor and the complete operational program loaded and simulated inputs applied. E. The Contractor shall provide for testing of the system using a temporary network and HMI application provided by the Owner’s programmer, and shall support the Owner’s programmer in all testing activities. This shall include, but not be limited to: 1. Providing power, network, and working facilities. 2. Simulation of I/O. City of Denton Hazen and Sawyer BID SET 17071-2 Factory Acceptance Test 3. Advance schedule coordination to ensure the overall construction schedule is met. The Owner’s programmer shall be continuously updated as to the construction schedule throughout the duration of construction activities. F. All hardware and software required to perform the specified testing shall be furnished by the Contractor at no additional cost to the Owner. G. The factory testing shall demonstrate all aspects of system sizing and timing including: 1. Monitoring and control scan times at the PLC level. 2. Response times at the operator workstation level. H. The overall system as well as individual component hardware shall be tested under conditions of power failure to ensure proper response as specified herein. I. PLC Operation - The following shall be demonstrated: 1. On-line and off-line diagnostics. 2. For redundant units, fail-over operation and reconfiguration. 3. System initialization and restart. 4. Network communications, including fieldbus communications where required. 5. Non-volatility of memory. J. Process I/O Simulation - Process input/output simulation for PLC's shall be performed with a manual simulation control panel, a separate programmable logic controller, network- based simulation software, analog signal generators, and/or jumpering of discrete signals between outputs and associated inputs, or some combination of these. Alternate process I/O systems such as plug-in circuit cards or I/O test modules may be utilized subject to approval by the Engineer to provide the specified simulation functions. The simulation system shall provide analog and discrete I/O hardware devices in sufficient quantity to allow complete and thorough testing of the control strategies and functions of the system. The process I/O simulation system shall be used in several ways as follows: 1. To provide a means of communications checkout from the operator workstations through the various levels of software in the PLC's and to the process, i.e., the simulation panel. Likewise, a discrete or analog input shall be initiated from the simulation panel and the result monitored at the workstations. 2. Alarm response to discrete status changes or analog value limits shall be verified. Database entries or attributes such as engineering units and conversion equations shall be verified by varying analog inputs. 3. To provide data for use at all levels of the control system at the time of system integration. City of Denton Hazen and Sawyer BID SET 17071-3 Factory Acceptance Test PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION – City of Denton Hazen and Sawyer BID SET 17071-4 Factory Acceptance Test This page left blank intentionally City of Denton Hazen and Sawyer BID SET 17072-1 Field Testing SECTION 17072 FIELD TESTING PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall perform field testing on the Control and Information System as specified herein to demonstrate compliance with the Contract Documents. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17070 – Control and Information System Testing, General C. Section 17071 – Factory Acceptance Test D. Section 17073 – Final Acceptance Test 1.03 GENERAL REQUIREMENTS A. Control system start-up and testing shall be performed to ensure that all plant processes shall be systematically and safely placed under digital control in the following order: 1. Primary elements such as transmitters and switch devices shall be calibrated and tested as specified in Sections 17600 and 17700. 2. Each final control element shall be individually tested as specified hereinafter. 3. Each control loop shall be tested as specified hereinafter. 4. Each control strategy shall be tested under automatic digital control as specified hereinafter. 5. The entire control system shall be tested for overall monitoring, control, communication, and information management functions, and demonstrated for system availability as specified hereinafter. B. System start-up and test activities shall include the use of water, if necessary, to establish service conditions that simulate, to the greatest extent possible, normal operating conditions in terms of applied process loads, operating ranges and environmental conditions. C. Each phase of testing shall be fully and successfully completed and all associated documentation submitted and approved prior to the next phase being started. Specific City of Denton Hazen and Sawyer BID SET 17072-2 Field Testing exceptions are allowed if written approval has been obtained in advance from the Engineer. 1.04 CONTRACTOR'S RESPONSIBILITIES A. The Contractor shall ensure that all mechanical equipment, equipment control panels, local control panels, field instrumentation, control system equipment and related equipment and/or systems are tested for proper installation, adjusted and calibrated on a loop-by-loop basis prior to control system startup to verify that each is ready to function as specified. Each test shall be witnessed, dated and signed off by both the Contractor (or designee) and the Engineer upon satisfactory completion. B. The Contractor shall be responsible for coordination of meetings with all affected trades. A meeting shall be held each morning to review the day's test schedule with all affected trades. Similarly, a meeting shall be held each evening to review the day's test results and to review or revise the next day's test schedule as appropriate. C. The Contractor shall ensure that the electrical subcontractor conforms to the start-up, test and sign-off procedures specified herein to assure proper function and coordination of all motor control center control and interlock circuitry and the transmission of all discrete and/or analog signals between equipment furnished by the electrical subcontractor and the control system specified herein. D. The Contractor shall ensure that the HVAC subcontractor conforms to the start-up, test and sign-off procedures specified herein to assure proper function of all HVAC system control and interlock circuitry and the transmission of all discrete and/or analog signals between HVAC equipment and controls and the control system specified herein. 1.05 FINAL CONTROL ELEMENT TESTING A. The proper control of all final control elements shall be verified by tests conducted in accordance with the requirements specified herein. B. All modulating final control elements shall be tested for appropriate speed or position response by applying power and input demand signals, and observing the equipment for proper direction and level of reaction. Each final control element shall be tested at 0, 25, 50, 75, and 100 percent of signal input level and the results checked against specified accuracy tolerances. Final control elements, such as VFD’s, that require turndown limits shall be initially set during this test. C. All non-modulating final control elements shall be tested for appropriate position response by applying and simulating control signals, and observing the equipment for proper reaction. 1.06 LOOP CHECKOUT A. Prior to control system startup and testing, each monitoring and control loop shall be tested on an individual basis from the primary element to the final element, including the operator workstation or loop controller level, for continuity and for proper operation and calibration. City of Denton Hazen and Sawyer BID SET 17072-3 Field Testing B. Signals from transducers, sensors, and transmitters shall be utilized to verify control responses. Simulated input data signals may be used subject to prior written approval by the Engineer. All modes of control shall be exercised and checked for proper operation. C. The accuracy of all DAC's shall be verified by manually entering engineering unit data values at the operator workstation and then reading and recording the resulting analog output data. D. The accuracy of all ADC's shall be verified using field inputs or by manually applying input signals at the final controller, and then reading and recording the resulting analog input data at the operator workstation. E. Each loop tested shall be witnessed, dated and signed off by both the Contractor (or designee) and the Engineer upon satisfactory completion. 1.07 CONTROL SYSTEM STARTUP AND TESTING A. Control system startup and testing shall be performed to demonstrate complete compliance with all specified functional and operational requirements. Testing activities shall include the simulation of both normal and abnormal operating conditions. B. All digital hardware shall be fully inspected and tested for function, operation and continuity of circuits. All diagnostic programs shall be run to verify the proper operation of all digital equipment. C. Final control elements and ancillary equipment shall be tested under start-up and steady-state operating conditions to verify that proper and stable control is achieved using local area control panels, motor control center circuits, and local field mounted control circuits. All hardwired control circuit interlocks and alarms shall be operational. The control to final control elements and ancillary equipment shall be tested using both manual and automatic (where provided) control circuits. D. Signals from transducers, sensors, and transmitters shall be utilized to verify control responses for final control elements. Simulated input data signals may be used subject to prior written approval by the Engineer. E. Each control strategy shall be tested to verify the proper operation of all required functions. The control system start-up and test activities shall include procedures for tuning all control loops incorporating PID control modules, and for adjusting and testing all control loops as required to verify specified performance. F. The control system start-up and test activities shall include running tests to prove that the Instrumentation, Control and Information System is capable of continuously, safely and reliably regulating processes, as required by the Contract, under service conditions that simulate, to the greatest extent possible, normal plant operating ranges and environmental conditions. G. A witnessed functional acceptance test shall be performed to demonstrate satisfactory performance of individual monitoring and control loops and control strategies. At least City of Denton Hazen and Sawyer BID SET 17072-4 Field Testing one test shall be performed to verify that the control and instrumentation system is capable of simultaneously implementing all specified operations. H. Each loop and control strategy test shall be witnessed and signed off by both the Contractor (or designee) and the Engineer upon satisfactory completion. 1.08 FACILITY STARTUP COORDINATION A. Facility start-up shall comply with requirements specified in the Contract Documents and those requirements specified herein. Facility start-up shall commence after all previously described start-up and test activities have been successfully completed and shall demonstrate that the Instrumentation, Control and Information System can meet all Contract requirements with equipment operating over full operating ranges under actual operating conditions. B. The control system start-up period shall be coordinated with process startup activities and shall be extended as required until all plant processes are fully operational and to satisfy the Engineer that all control system Contract requirements have been fulfilled in accordance with the Contract Documents. C. The instrumentation subcontractor's personnel shall be resident at the facility to provide both full time (eight hours/day, five days/week) and 24 hours on call (seven days/week) support of operating and maintenance activities for the duration of the start-up period. D. At least one qualified control systems technician shall be provided for control system startup and test activities (at least two when loop checkout is being performed). PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION - City of Denton Hazen and Sawyer BID SET 17073-1 Final Acceptance Test SECTION 17073 FINAL ACCEPTANCE TEST PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall perform the Final Acceptance Test on the Control and Information System as specified herein to demonstrate compliance with the Contract Documents. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17070 – Control and Information System Testing, General C. Section 17071 – Factory Acceptance Test D. Section 17072 – Field Testing 1.03 AVAILABILITY DEMONSTRATION AND FINAL SYSTEM ACCEPTANCE A. Upon completion of all control system startup activities and prior to final system acceptance, the Contractor shall demonstrate that the availability of the entire control system, including operation under conditions of digital equipment fail-over, initiated either automatically or manually, shall be not less than 99.8 percent during a 30-day availability test period. The Owner shall be given two (2) weeks notice of the starting date of the 30- day availability test. B. For purposes of determining availability figures, downtime of each system or portions of each system resulting from the causes specified hereunder will not be considered system failures. 1. Downtime of any network-connected device that is automatically backed-up upon failure shall not be considered a system failure provided that the downtime of the failed component does not exceed 24 hours. 2. Downtime of a PLC that is not automatically backed-up shall be considered a system failure if the downtime of the failed controller exceeds one (1) hour. 3. Downtime of a portion of the system resulting from failure of any field sensor shall not be considered a system failure provided that the system operates as specified under this condition. 4. Downtime of the following devices shall not be considered a system failure provided the failed device is repaired within the specified time: City of Denton Hazen and Sawyer BID SET 17073-2 Final Acceptance Test a. Hard disc (one day) b. Workstations (one day) c. Communication interfaces (eight hours) d. Printer (three days) e. Process control system networks (eight hours) f. Off-line (optical, etc.) storage units (one day) g. UPS unit (one day) 5. Total shutdown of a single PLC resulting from a software fault shall be considered a system failure. 6. An erroneous command to the process that can be specifically related to a software fault shall be considered as one (1) hour of downtime. 7. The inoperability of any subsystem resulting from a software fault shall be considered a system failure. 8. The failure of the same component more than one time during the 30-day test shall be considered a system failure. C. If the system fails the 30-day availability test, the 30-day test period shall be restarted after the failed component or software is repaired/replaced and full operation is restored. The system shall be demonstrated for the full 30-day period following the restart. D. The Contractor shall submit an availability demonstration report that shall state that all system availability requirements have been met. PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION - City of Denton Hazen and Sawyer BID SET 17080-1 Quality Assurance SECTION 17080 QUALITY ASSURANCE PART 1 -- GENERAL 1.01 THE REQUIREMENT A. It is the intent of these Specifications and Drawings to secure high quality in all materials, equipment and workmanship in order to facilitate operations and maintenance of the facility. The Contractor shall provide equipment and services to meet this intent. 1.02 REFERENCE SPECIFICATIONS, CODES AND STANDARDS A. All work shall be installed in accordance with the National Electric Code, National Electric Safety Code, OSHA, State, local and other applicable codes. 1.03 QUALITY ASSURANCE - GENERAL A. All equipment and materials shall be new and the products of reputable recognized suppliers having adequate experience in the manufacture of these particular items. B. For uniformity, only one manufacturer will be accepted for each type of product. C. All equipment shall be designed for the service intended and shall be of rugged construction, of ample strength for all stresses that may occur during fabrication, transportation, and erection as well as during continuous or intermittent operation. They shall be adequately stayed, braced and anchored and shall be installed in a neat and workmanlike manner. Appearance and safety, as well as utility, shall be given consideration in the design of details. D. All components and devices installed shall be standard items of industrial grade, unless otherwise noted, which shall be of sturdy and durable construction and be suitable for long, trouble-free service. E. Electronic components shall be de-rated to assure dependability and long-term stability. F. Printed circuit boards in field mounted equipment shall be suitable for the specified environmental conditions. G. Alignment and adjustments shall be non-critical, stable with temperature changes or aging and accomplished with premium grade potentiometers. H. Components of specially selected values shall not be inserted into standard electronic assemblies in order to meet the performance requirements of this specification. City of Denton Hazen and Sawyer BID SET 17080-2 Quality Assurance 1.05 OPTIONAL EQUIPMENT A. Optional or substituted equipment or both requiring changes in details or dimensions required to maintain all structural, mechanical, electrical, control, operating, maintenance or design features incorporated in these Specifications and Drawings shall be made at no additional cost to the Owner. In the event that the changes are necessary, calculations and drawings showing the proposed revisions shall be submitted for approval. The Contractor shall coordinate all changes with other affected trades and contracts and pay all additional charges incurred. 1.06 GUARANTEE A. The instrumentation subcontractor through the Contractor shall install, maintain and guarantee the Instrumentation, Control and Information System as specified under the General Conditions and Division 1 of the Specifications. Maintenance personnel provided by the instrumentation subcontractor shall instruct the Owner's personnel in the operation, adjustment, calibration and repair of the equipment being serviced. All preventive and corrective activities shall be documented with service reports, which shall identify the equipment being serviced, state the condition of the equipment, describe all work performed and list materials used. A copy of all service reports shall be delivered to the Owner on the day the work is performed. B. The instrumentation subcontractor shall provide the services of factory-trained service technician(s) at least twice during the guarantee period, for the purpose of performing preventive hardware maintenance. C. Corrective hardware and software maintenance during the guarantee period shall be performed in accordance with the requirements of Division 1 and, in addition, shall meet the following requirements: 1. Corrective hardware maintenance shall be performed by factory-trained service technician(s) specifically trained to service the digital equipment provided. Technicians possessing suitable training and experience shall be provided to perform corrective maintenance on all other equipment. The hardware service technician(s) shall be available on-site within 24 working hours after notification by the Owner. 2. Corrective software maintenance shall be performed for software provided by the instrumentation subcontractor and incorporated into the system prior to the completion of system commissioning. Software service programmer(s) shall be available for consultation within four business hours and, if required, on-site within 16 business hours after notification by the Owner. Corrective software maintenance shall include the supply, installation and startup of all application software upgrades released during the guarantee period. 3. Corrective hardware and software maintenance performed during the guarantee period shall be performed at no cost to the Owner. 4. As used herein, the term "working hours" shall be defined as those of the treatment facility (seven days per week, 24 hours per day). The term "business hours" shall City of Denton Hazen and Sawyer BID SET 17080-3 Quality Assurance be defined as the hours between 8:00 a.m. and 5:00 p.m., local time, Monday through Friday; excluding holidays. 5. The guarantee period shall commence upon final acceptance of the completed treatment facility in accordance with the provisions of the Contract Documents. D. The instrumentation subcontractor shall submit to the Owner a proposed maintenance agreement incorporating the following features: 1. Extension of preventive hardware maintenance services as described above for a period of up to five years from the expiration of the warranty period. 2. Provisions for corrective hardware and/or software maintenance work on a will-call basis for a period of up to five years from the expiration of the warranty period. Corrective maintenance work shall be performed by properly trained personnel as described above. E. The proposed agreement shall include provisions for payment based upon an annual fee for preventive maintenance and cost plus expenses for corrective maintenance work. The portion dealing with corrective maintenance shall be written to include corrective maintenance caused by actions of the Owner during the warranty period and shall contain clauses for re-negotiation of contract prices based upon changes in recognized economic indicators published by the United States Department of Commerce. 1.07 SHIPPING HANDLING AND STORAGE A. In addition to shipping, handling and storage requirements specified elsewhere in the Contract Documents, air conditioning/heating shall be provided for storage of all field instrumentation, panels, digital equipment and ancillary devices to maintain temperatures between 20 and 25 degrees C and relative humidity 40 to 60 percent without condensation. The air shall be filtered and free of corrosive contaminants and moisture. 1.08 FABRICATION A. Fabrication of all equipment shall conform to the codes and standards outlined in this Section, and other portions of the Contract Documents. B. The Engineer may inspect the fabricated equipment at the factory before shipment to job site. The Contractor shall provide the Engineer with sufficient prior notice so that an inspection can be arranged at the factory. Inspection of the equipment at the factory by the Engineer will be made after the manufacturer has performed satisfactory checks, adjustments, tests and operations. C. Equipment approval at the factory only allows the equipment to be shipped to the project site. The Contractor shall provide for the proper storage, installation and satisfactory start-up and operation of the equipment to the satisfaction of the equipment manufacturer, the instrumentation subcontractor, and the Engineer. City of Denton Hazen and Sawyer BID SET 17080-4 Quality Assurance 1.09 INSTALLATION A. All instrumentation and control system installation work, whether new construction or modifications to existing equipment/panels/structures, shall conform to the codes and standards outlined in this Section, and other portions of the Contract Documents. B. The instrumentation subcontractor shall assign a competent representative who shall provide full time coordination and supervision of all on-site instrumentation and control system construction work from commencement of construction through completion and final acceptance. C. All labor shall be performed by qualified craftsmen in accordance with the standards of workmanship in their profession and shall have had a minimum of three years of documented experience on similar projects. D. All equipment and materials shall fit properly in their installations. Any required work to correct improperly fit installations shall be performed at no additional expense to the Owner. E. All work shall be performed in a neat and workmanlike manner. All hardware and instrumentation shall be installed in accordance with requirements specified herein, in accordance with industry best practices, in accordance with manufacturers’ recommendations, and in a manner suitable for ease of operation, inspection, and maintenance. All wiring shall be neatly bundled, run in wireway, and terminated. All spare wiring shall be neatly coiled and clearly labeled at both ends for future use by the Owner. Any work not meeting these requirements shall be corrected at no expense to the Owner. F. Sufficient common-mode and differential-mode noise rejection shall be provided to insure operation of the plant process control system to meet all specification requirements. General practice shall include: 1. Maintaining crossings between noisy wires and signal wires at right angles. 2. Maintaining separation between noisy wires and signal wires as wide as practical. 3. Grounding all signals, shields and power supplies at the process control unit or local control panel. 4. Providing passive filters on signals with time constant compatible with scan intervals and overvoltage protection. 5. Eliminating cable splices. All splices in instrumentation and control system signal and network cables shall be approved in advance by the Engineer. 6. Providing a floating output for transmitters that have their own power sources. G. DC and AC power grounding shall be performed in accordance with the digital hardware manufacturer's recommendations as well as all applicable code requirements. City of Denton Hazen and Sawyer BID SET 17080-5 Quality Assurance H. The case of each field instrument and control panel shall be grounded in compliance with the National Electric Code. I. Power wires shall be separated from parallel-running signal wires by the following minimum spacing: CIRCUIT VOLTAGE (VAC) MINIMUM SPACING (IN.) 120 12 240 18 480 18 2000 and above 24 J. The Contractor shall provide all required cutting, drilling, inserts, supports, bolts, and anchors, and shall securely attach all equipment and materials to their supports. Embedded supports for equipment furnished under this Division shall be provided and installed as shown specified herein and shown on the Drawings. K. Following acceptance of the factory tests by the Engineer, and in accordance with the construction schedule, the Contractor shall commence installation of the digital control system hardware. Digital system equipment items shall not be installed, however, until all architectural, mechanical, HVAC and electrical work has been completed in the equipment rooms, MCC's, control rooms and all structural and/or mechanical work has been completed within 50 feet of equipment locations. L. Upon completion of the above construction work, the Contractor shall request an inspection of the above-named areas. The Engineer will issue a written approval to proceed with delivery and installation only after being satisfied that all work described above has been properly performed. Digital equipment shall remain at the factory site or storage prior to approval for delivery to the project site. Partial shipments may be required to meet construction schedule requirements. PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION – City of Denton Hazen and Sawyer BID SET 17080-6 Quality Assurance This page left blank intentionally City of Denton Hazen and Sawyer BID SET 17100-1 Control and Information System Hardware, General SECTION 17100 CONTROL AND INFORMATION SYSTEM HARDWARE, GENERAL PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The process control system is physically and functionally distributed between PLC equipped control panels, motor control panels, field panels, operator workstations and appurtenances. B. Although manual control facilities shall be provided adjacent to each final control element or in local control panels, such facilities are for testing, maintenance and local monitoring purposes only and shall not be regarded as backup to the PLC-based control system. C. PLCs may be categorized as either “process PLCs” that are provided by the instrumentation subcontractor or “equipment control PLCs” provided by equipment manufacturers for the operation of their equipment (blowers, centrifuges, chemical systems, filters, etc.). Unless otherwise specified, all PLCs provided under this Contract shall conform to the requirements specified in this Division. D. Major plant control system digital equipment items are described in the Specifications and shown on the Drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17120 – Programmable Logic Controllers B. Section 17180 – Process Control System Networks 1.03 DIGITAL HARDWARE CONFIGURATIONS A. The digital hardware configuration shown on the Control System Architecture Drawing depicts overall system configuration requirements. System design shall be based upon this concept and shall provide an overall digital system availability of 99.8 percent under the conditions specified in Section 17073. Unless otherwise specified, designs that vary from this concept will be rejected. B. All discrete and analog data acquisition, pre-processing, storage and process control functions shall be performed at the PLC level. Run time and flow accumulations shall be performed at the PLC level. Except for minimal calculations related to report-specific functions such as minimum, maximum, average, etc., operator workstations shall not be used to perform calculation for the process control system. Operator workstations shall be fully independent devices, individually connected to the plant control system networks. 061917BR City of Denton Hazen and Sawyer BID SET 17100-2 Control and Information System Hardware, General C. No other exceptions will be considered. PART 2 -- PRODUCTS 2.01 GENERAL SYSTEM HARDWARE REQUIREMENTS A. Unless otherwise specified, all hardware shall be rated for industrial use, resistant to shock, vibration, electromagnetic interference, static discharge, and suitable for the environmental conditions described elsewhere in this Division. Commercial or office grade equipment shall not be accepted. B. Unless otherwise specified, modular construction shall be employed to simplify maintenance and to provide for future hardware expansion. Plug-in, modular PCB's or modules shall be employed for easy removal to permit exposure of circuit wiring, components and test points. Extender boards shall be provided if necessary to permit PCB's to be completely exposed for testing purposes. C. Keying schemes shall be used to prevent PCB misplacement. D. The temperature inside each enclosure containing digital hardware (i.e., cabinet, panel or console) shall be continuously monitored and shall generate an alarm to the nearest PLC if the temperature rises to an adjustable, preset high temperature. 2.02 DIGITAL SYSTEM FAILURE DETECTION AND FAIL-OVER REQUIREMENTS A. No degradation in control system performance shall occur when the system is operating in a partial failure or an equipment fail-over mode. Likewise, no degradation of system performance shall occur while a backed up system component is undergoing preventive or corrective maintenance. B. All devices connected to the plant control system network shall be self-checking and shall report their operational status to the operator workstations as either "normal" or "failed". A graphic display based on the system architecture drawing shall be furnished with the control and information system showing this information along with current communication status of each device. PART 3 -- EXECUTION 3.01 REQUIREMENTS A. Refer to Section 17000, Part 3. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 17120-1 Programmable Logic Controllers SECTION 17120 PROGRAMMABLE LOGIC CONTROLLERS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation all programmable logic controllers, with all spare parts, accessories, and appurtenances as herein specified and as shown on the Drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17060 – Signal Coordination Requirements C. Section 17100 – Control and Information System Hardware - General D. Section 17180 – Process Control System Networks E. Section 17190 – Uninterruptible Power Systems F. Section 17500 – Enclosures, General 1.03 TOOLS, SUPPLIES AND SPARE PARTS A. Tools, supplies and spare parts shall be provided as specified in Section 17050 - Tools, Supplies, and Spare Parts. In addition, the following specific spare parts items shall be provided: 1. One of each type and size of module for PLC equipment furnished under this Contract. 2. One of each type and size of PLC and equipment power supply furnished under this Contract. PART 2 -- PRODUCTS 2.01 PROGRAMMABLE LOGIC CONTROLLERS - GENERAL A. The instrumentation subcontractor shall furnish programmable controllers (PLC's) as specified herein and as shown on the Drawings. PLC's shall be provided complete with backplane, power supply, I/O cards, special function cards, instructions, memory, input/output capacity, and appurtenances to provide all features and functions as described herein. No substitutions will be permitted. City of Denton Hazen and Sawyer BID SET 17120-2 Programmable Logic Controllers B. All components of the PLC system shall be of the same manufacturer; who shall have fully tested units similar to those being furnished in an industrial environment with associated electrical noise. The PLC system shall have been tested to meet the requirements of NEMA Standard ICS 2-230 (Arc Test) and IEEE C37.90.1 (SWC). The processing unit shall perform the operations functionally described herein based on the program stored in memory and the status of the inputs and outputs. C. Programmable controllers shall be designed to operate in an industrial environment. The PLC shall operate in an ambient temperature range of 0-60C and a relative humidity of 5-95 percent, non-condensing. The PLC shall operate on supply voltages of 24 VDC and provided with a battery backup system. An integral fuse shall be provided on the power supply for short circuit protection and shall be front panel accessible. Integral overcurrent and undervoltage protection shall be provided on the power supply. D. Where applicable, the minimum PLC backplane size shall be 7 slots, not including power supply slots. All input/output modules shall be hot-swappable. E. System configuration shall be as shown on the Control System Architecture Drawing. PLC types shall be designated on the Control System Architecture Drawing and correspond to the specifications herein. Only a single type of processor shall be supplied for all PLCs of a designated type. Memory and processor shall be adequate for all control functions specified. PLC processors and components shall be as follows: PLC- Schneider Electric- SCADAPAK334 2.02 PROCESSORS A. The processor and its associated memory shall be enclosed in a modular enclosure. A multiple-position selector switch or equivalent shall be used to select processor operating mode. LED-type indicating lights shall be provided to indicate processor, memory, and battery status. Errors in memory shall be recognized and shall activate the memory error indicating lights. The PLC processor shall monitor the internal operation of the PLC for failure and provide an alarm output. Nonvolatile memory in the form of a manufacturer supplied industrial CompactFlash card or equivalent technology shall be required to maintain the entire current program and firmware of the controller in the event of power loss. The program shall be updated onto the flash memory each time a program change such as an online edit or tag value is changed. When nonvolatile memory (flash memory) is not available for certain controller models as offered by the PLC manufacturer, lithium batteries shall be used to maintain process RAM memory for at least one year in the event of power loss. The lithium battery unit shall be an externally mounted battery assembly with the highest available capacity. The PLC shall send an alarm to the plant control system if battery level is low. B. The instruction set for the PLC shall conform to the requirements of IEC 61131-3. Each PLC shall have the capability to run all five of the standard IEC 61131-3 languages simultaneously. These five languages shall be: 1. Ladder Diagram 2. Structured Text City of Denton Hazen and Sawyer BID SET 17120-3 Programmable Logic Controllers 3. Instruction List 4. Function Block Diagram 5. Sequential Function Chart C. Additional co-processors or modules may be necessary and shall be furnished as required to meet the functions specified herein and in Section 17950 – Functional Control Descriptions. D. PLC processors shall be provided with substantial user program, data and logic memory to allow for future expansion of the overall system. The total memory used on each processor shall be less than 60% of available memory at project completion. 2.03 COMMUNICATIONS A. PLC communications shall be provided as specified in Section 17180 - Process Control System Networks and as shown on the Control System Architecture Drawing. B. In addition to a communications port for the control system network, communication ports shall be provided for any other devices required (i.e., operator interface unit) plus an additional communication port for connection to a notebook computer. C. The PLC shall be able to support various types of fieldbus communication systems for data links to field instruments (where specified) in addition to connected equipment such as power monitors, VFDs, motor protection monitors, etc. As a minimum, Profibus DP, Foundation Fieldbus, Modbus RTU Master and Slave, TCP/IP Ethernet shall be supported. The Contractor shall coordinate the efforts of the necessary parties (instrumentation subcontractor and equipment suppliers) to accomplish the required device and data table addressing between each PLC and the associated connected equipment. D. Additional communication modules or protocol gateways may be required to support specific communication protocols required under this Contract, and shall be supplied at no extra cost to the Owner. 2.04 INPUT/OUTPUT SUBSYSTEMS A. Input/output hardware shall be plug-in modules in associated I/O backplane or DIN-rail mounting assemblies. Each unit shall handle the required number of process inputs and outputs plus a minimum of 10 percent active pre-wired spares for each I/O type furnished, plus a minimum of 20 percent spare I/O module space for the addition of future circuit cards or modules. B. Discrete inputs shall be 24 VDC. Discrete outputs shall be 24 VDC sourced from the PLC, or dry relay contacts (2A minimum) as required. Refer to Section 17060 – Signal Coordination Requirements for further details of discrete signal type and voltage requirements. The PLC shall provide momentary and latched outputs as required to interface with motor controls and external devices. Interposing relays shall be provided where required to interface with field equipment. Interposing relays shall be as specified in Section 17550. Electrical isolation shall be provided where required. Maximum density for discrete I/O modules shall be 32 per input module and 16 per output module. City of Denton Hazen and Sawyer BID SET 17120-4 Programmable Logic Controllers C. Analog input circuits shall be isolated, minimum 16-bit resolution type. Analog input hardware shall be provided as required for all types of analog inputs being transmitted to the PLC. In general, analog input modules shall be capable of receiving 4-20 mA signals. Where required, RTD input modules shall have a minimum resolution of 0.15C and be capable of accepting signals from 100-ohm Platinum RTD’s. Analog outputs shall be coordinated with the receivers but shall generally be isolated 24 VDC 4-20 mA outputs powered from the PLC. Each input/output circuit shall have optical isolation to protect the equipment against high voltage transients. Optical isolation shall be rated at not less than 1500 V RMS. Lightning/surge protection shall be provided as specified in Section 17560 - Surge Protection Devices. Maximum density for analog I/O modules shall be 8 per module. D. Input/output modules shall be configured for ease of wiring and maintenance. The modules shall be connected to wiring arms that can be disconnected to permit removal of a module without disturbing field wiring. Covers shall be provided to prevent operator personnel from inadvertently touching the terminals. The process interface modules shall be provided with screw-type terminal blocks with barriers between adjacent terminals for connection of field inputs. Terminals shall be suitable for accepting up to and including No. 14 AWG wire. All DC output circuits to the field shall include fuses, either integral or at the terminal strip. Output failure mode shall be selectable so that upon station or communication system failure all outputs shall be placed either in the non-conducting mode, or remain as were prior to failure. Light-emitting diodes shall be provided for status indication for each input and output point. E. External power supplies shall be provided with the PLC as required to meet specified installed I/O power requirements plus spares. Power supplies shall be modular units, shall be fully redundant and shall alarm the PLC upon failure. Power supplies shall have a line regulation of 0.05% and meet the environmental and power requirements specified herein for the PLC. 2.05 REMOTE I/O SUBSYSTEMS A. Remote I/O shall be provided as designated on the Control System Architecture Drawing. Remote I/O shall be either PLC backplane type I/O or field modules as manufactured by the PLC manufacturer. Field modules shall meet the requirements of Subsection 2.04, Input/Output Subsystems. Remote I/O processor or communication modules shall be modular and individually replaceable. B. Remote I/O shall communicate with the PLC using the PLC manufacturer’s standard protocol or an open standard network such as DeviceNet, Ethernet IP, ProfiNet, Foundation Fieldbus, Modbus TCP/IP, or equal. 2.06 INPUT/OUTPUT CIRCUIT ARRANGEMENT A. Signal and control circuitry to individual input/output boards shall be arranged such that board failure shall not disable more than one half of the control loops within any group of controlled equipment (e.g., one pump out of a group of three pumps, two pumps out of four, etc.). Where possible, individual control loops and equipment shall be assigned to City of Denton Hazen and Sawyer BID SET 17120-5 Programmable Logic Controllers individual boards such that failure of the board will disable only one loop or piece of equipment. 2.07 PROGRAMMING SOFTWARE A. The PLC programming and configuration software shall be the manufacturer's latest, full- featured version, Windows-based, and shall be fully compliant with IEC 61131-3 standards. The software package shall consist of all programming, configuration, and documentation software needed to place the control and information system in satisfactory operation. The software shall allow on-line and off-line program development and documentation. PLC programming software shall include DVD-ROM documentation. B. A minimum of one copy of the PLC programming software shall be purchased by the instrumentation subcontractor and registered to the Owner. C. All configuration and programming software necessary shall be provided on the computer specified in Section 17170 - Portable Notebook Computers for connection to the PLC processor via a communications port. All necessary hardware required to allow the notebook computer to perform PLC configuration and programming shall be provided. D. If available, the configuration and programming software shall support communication over the network specified in Section 17180 – Process Control System Networks to implement its functions remotely from an operator workstation. All configuration and programming software necessary to implement this functionality shall be provided on the HMI Server operator workstations specified in Section 17140 – Operator Workstations. All necessary hardware required to have the operator workstation perform PLC configuration and programming shall be provided. PART 3 - EXECUTION 3.01 REQUIREMENTS A. PLC programming shall be furnished to perform all functions described in Section 17950 – Functional Control Descriptions, including global functions. In addition, PLCs shall be programmed to provide additional functions described in other sections of this Division. B. PLC programming shall make use of the various IEC languages as appropriate to the specific task, and shall be performed in a modular style making extensive use of program blocks (subroutines) and program variables to be passed to the program blocks for specific equipment. It is the intent of this requirement to allow for enhanced readability and ease of modification of the program code through the elimination of multiple instances of repeated code for the same function in a “hard-coded” style. C. Extensive comments shall be placed in the program code to describe the functions of all elements of the program code. PLC code that does not contain comments shall be rejected. City of Denton Hazen and Sawyer BID SET 17120-6 Programmable Logic Controllers D. Refer to Section 17000, Part 3 for additional requirements. 3.02 REQUIREMENTS FOR MANUFACTURER-SUPPLIED PLCs A. PLCs that are supplied for equipment local control panels by individual equipment manufacturers or suppliers shall, where so indicated on the Control System Block Diagram, be integrated into the plant control system. The manufacturer-supplied PLC shall be furnished, installed and programmed by the manufacturer. The PLC shall continuously monitor and control the associated system and at the same time shall provide all the required alarms, indications of system parameters, equipment status, etc. to the main control system at the plant. B. Where required as described above, each manufacturer-supplied PLC shall be connected to the Ethernet process control network for access from the plant control system HMI servers, as specified in Section 17180, and shall contain a fiber optic Ethernet switch identical to those provided for the rest of the network-connected PLCs. C. Each equipment manufacturer shall provide all monitoring and control data to be transferred between the PLC and the plant control system in contiguous blocks of PLC registers to facilitate block read and write commands for efficient scanning by the control system SCADA servers. These contiguous registers shall be arranged in a single data transfer area, which shall be divided into eight distinct areas with an emphasis on flexibility and future expansion. The distinct areas shall be arranged by data type (analog or discrete), transfer direction (server to PLC or PLC to server), and, where applicable, implementation schedule (current or future). Where required, peer-to-peer communication between PLCs shall likewise be accomplished using separate blocks of contiguous registers. Where individual equipment PLCs are not required to be connected to the plant control system via the data highway network, they shall provide the individual hardwired signals as specified in the Contract Documents. Data and commands for connection to the control system are described in the Drawings, the Input/Output Schedule, the individual equipment specification sections, and in Section 17950 – Functional Control Descriptions. D. The operator interface for control of each individual system shall be performed by local operator interface units as specified in Section 17125 or individual pilot devices on the equipment local control panel, as specified in the associated equipment specification section. Additional operator interface functions shall be provided through the plant control system as specified in the respective equipment specifications and in Section 17950. E. Where operator interface and control functions are required to be provided through the plant control system, the individual system supplier shall be responsible for coordination with the instrumentation subcontractor to provide a complete and working equipment control system. The individual equipment supplier shall also be responsible for limiting the access of the plant control system to the equipment PLC code so as to prevent malfunctions of the equipment and any failure to continuously perform its intended functions. The equipment supplier shall be responsible for ensuring that no actions by the plant control system can damage or otherwise adversely affect the operation of the associated equipment or the safety of personnel working on or near that equipment. City of Denton Hazen and Sawyer BID SET 17120-7 Programmable Logic Controllers The equipment supplier shall also provide direction in the configuration of the SCADA software’s security system by the instrumentation subcontractor to limit access to the control functions of the equipment control system to authorized personnel only. The equipment supplier shall coordinate testing of the completed system with the instrumentation subcontractor, which shall conform to the requirements of Section 17072 – Field Testing. F. The Contractor, equipment supplier and instrumentation subcontractor shall coordinate testing and startup of the equipment provided by the equipment supplier with the plant control system, including but not limited to the following tasks: 1. Provide assistance with control system testing of inputs, outputs, and control strategies as needed. 2. Provide support or interface work necessary to perform physical checkout and field testing to the final field devices. The schedule may require the instrumentation subcontractor and equipment manufacturer personnel to perform loop checks simultaneously, as directed by the Engineer. 3. Coordinate and assist as needed to maintain I/O connectivity throughout the system. 4. Ensure personnel safety while equipment is exercised via the plant control system. 5. Ensure that process, instrumentation, and control equipment are not damaged while equipment is exercised via the plant control system. 6. Provide temporary modifications to field devices and their terminations, if needed. 7. Providing labor and supervision, which may include, but is not limited to, the following: electricians, instrument technicians, manufacturer’s representatives, and individual(s) knowledgeable about process startup and operation. 8. Operation of process equipment for verification of each plant control system input and output. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 17120-8 Programmable Logic Controllers This page left blank intentionally City of Denton Hazen and Sawyer BID SET 17135-1 Radio Telemetry System (Licensed) SECTION 17135 RADIO TELEMETRY SYSTEM (LICENSED) PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation the licensed radio telemetry system, with all spare parts, accessories, and appurtenances as herein specified and as shown on the Drawings. B. The Contractor shall provide complete assistance to the Owner to obtain necessary FCC licensing. The Contractor shall retain a suitable firm to perform a radio frequency search and coordination following acceptance of the radio path analysis by the Engineer. The Contractor shall complete all applications and acquire all necessary licenses in accordance with all applicable rules and regulations including, but not limited to, FCC Part 90. The Owner will pay all licensing fees and the cost of the frequency coordination. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17100 – Digital System Hardware Configuration C. Section 17120 – Programmable Logic Controllers D. Section 17500 – Enclosures, General 1.03 TOOLS, SUPPLIES AND SPARE PARTS A. Tools, supplies and spare parts shall be provided as specified in Section 17050 - Tools, Supplies and Spare Parts. Where equipment is furnished under other Sections of the Specifications, spares requirements shall be as specified in those Sections. In addition, the following specific spare parts items shall be provided: 1. One of each type of printed circuit board used in telemetry equipment furnished under this Contract. Complete devices shall be provided where individual circuit boards are impractical (e.g., radios). 2. One of each type of miscellaneous hardware device for telemetry equipment furnished under this Contract (lightning arresters, set of N type connectors, etc.). 1.04 SUBMITTALS A. Details of antenna supporting systems, support structure design and details, and support structure embedment design calculations and details signed and sealed by a Professional Engineer currently registered in Texas. City of Denton Hazen and Sawyer BID SET 17135-2 Radio Telemetry System (Licensed) PART 2 -- PRODUCTS 2.01 GENERAL A. The Contractor shall provide a licensed radio telemetry system that operates and is fully functional within the confines of the Owner's FCC license. B. All communications equipment shall be installed in accordance with the manufacturer's recommendations, FCC rules and regulations, and details on the Contract Drawings. C. Radio telemetry equipment shall have a minimum of 30 minutes back-up power. D. All radio telemetry equipment power and signal lines that extend or are located outside of an enclosed structure shall be protected from lightning and voltage surges in accordance with the requirements of Section 17560 – Transient Voltage Surge Suppression Devices. E. Although system configuration may be shown on the Control System Block Diagram, the radio telemetry system shall be implemented in conjunction with the radio path survey and actual installation conditions to provide a trouble-free and reliable transmission system. 2.02 ANTENNAS AND APPURTENANCES A. Directional antennas shall be yagi type, rated for a minimum of 10 dB gain with an N-type connector. Directional antennas shall be as manufactured by Celwave, or equal. Directional antennas shall utilize a low-loss coaxial transmission line of ½-inch heliax w/foam dielectric for distances less than or equal to 50 ft. Cable for distances greater than 50 ft shall be 7/8-inch heliax w/foam dielectric. B. Omni-directional antennas for master station radios or repeaters shall be collinear fiberglass, rated for a minimum of 10 dB gain. Omni-directional antennas shall be Celwave Model PD455, or equal. Omni-directional antennas shall utilize a low-loss 7/8-inch jacketed heliax transmission line equal to an Andrew Model LDF5-50A. C. Installations shall include grounding kit and polyphaser coaxial protection. C. Antennas shall be rated for 100 mph wind velocity. D. Antenna shall be mounted to the pole at a height of 65 feet above finished grade. F. Support structures shall be designed to withstand earthquake, wind and ice loads in accordance with the Telecommunications Industry Association (TIA) Structural Standards for Steel Antenna Towers and Antenna Supporting Structures. Support structure shall be a direct embed monopole designed in accordance with ANSI/TIA/EIA-222-F with 3/4” radial ice and to ANSI/TIA-222-G (Class II, Exposure C, Topographic Category 2). Wind loads shall also be calculated in accordance with the Texas Building Code, except the basic wind speed used for calculating wind loads shall be 100 mph (service level). The worst case loads from the TIA standards and the Texas Building Code shall be used for design. The sway limit shall be 2 degrees as defined by ANSI/TIA-222-G. See structural drawings for seismic City of Denton Hazen and Sawyer BID SET 17135-3 Radio Telemetry System (Licensed) parameters. Tower shall include a safety climb support brackets, grounding attachment clips, means for routing antenna cables internally and all necessary accessories for the antenna system. Tower members and fasteners shall be galvanized after fabrication. Monopole shall be manufactured by ROHN Products, LLC, Valmont Industries Inc. or Sabre Industries. G. Antenna masts shall be attached to the support structure. Only bolted stainless steel mountings shall be used, as manufactured by Tesco, Decibel Products, or equal. 2.03 LICENSED REMOTE RADIO TRANSCEIVERS/MODEMS A. Licensed radio transceivers shall use frequency modulation to transmit and receive telemetry data. The transceivers shall be completely compatible with the control and information system's hardware and communication protocols. B. Licensed radio transceivers shall be Model CDM1250 manufactured by Motorola or equal by Motorola. Licensed radios shall have the following operation and performance specifications: 1. Environmental a. Temperature Range: -30°C to +60°C b. Humidity: 95% at 40°C; non condensing 2. Power Supplies a. Input Power: 24 VDC or 120 VAC b. Transceiver Primary Power: Voltage 13.8 VDC nominal (10.5 to 16 VDC operating range) c. Tx Current: 2A Typical at 5 Watts d. Rx Current: 125 mA e. Sleep Mode: <12 mA (Stand By) 3. General Radio Specifications (VHF) a. Frequency Range: 403 to 512 MHz b. Frequency Programmability: 12.5 kHz increments C. Performance deviations shall be allowed for special high power transceivers with written approval of the Engineer. 2.04 LICENSED FREQUENCY MASTER STATION RADIOS AND REPEATERS A. Licensed frequency master station radios and repeaters shall be as manufactured by Microwave Data Systems, or equal by Motorola and shall have the same operation and performance requirements as remote radio transceivers, as applicable. In addition, master station radios and repeaters shall meet the following operation and performance requirements: 1. Continuous duty cycle City of Denton Hazen and Sawyer BID SET 17135-4 Radio Telemetry System (Licensed) 2. Diagnostic interface (RS-232) 3. Continuous, external, or keyed-on-squelch keying 4. Modular (replaceable) component design PART 3 -- EXECUTION 3.01 REQUIREMENTS A. After the radios have been installed, the instrumentation subcontractor shall test the following items and make all necessary adjustments: 1. Supply voltage (In keyed and de-keyed positions) 2. Regulated voltage (In keyed and de-keyed positions) 3. Lock voltage 4. Signal strength 5. Forward power 6. Reverse power 7. Standing wave ratio (SWR) 8. Radio temperature 9. Loop back code (if applicable) 10. Software revision 11. Hardware revision 12. Time out timer setting 13. Squelch tail eliminator 14. Soft carrier de-key setting 15. Push to test delay testing B. The instrumentation subcontractor shall test the integrity of the radio cable after installation to ensure that the insertion losses are not excessive. The lock voltage, regulated voltage, etc. shall be checked by keying and then de-keying the radio to ensure proper functioning of the radio hardware. C. Refer to Section 17000, Part 3 for additional requirements. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 17180-1 Process Control System Networks SECTION 17180 PROCESS CONTROL SYSTEM NETWORKS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation IEEE 802.3 Ethernet local area network(s) for communications among plant devices. B. Local area network shall be provided with all spare parts, accessories, and appurtenances as herein specified. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17120 – Programmable Logic Controllers 1.03 TOOLS, SUPPLIES AND SPARE PARTS A. The following specific spare parts items shall be provided: 1. A termination tool kit shall be provided containing all required tools and consumables for up to 25 connections of each connection type furnished. Termination kit shall be as manufactured by Black Box, Corning Cable Systems, Optical Cable Corporation, or equal. PART 2 -- PRODUCTS 2.01 LOCAL AREA NETWORK (LAN) A. An IEEE 802.3 Ethernet local area network shall be used for communications between plant devices. B. Network wiring shall be unshielded, twisted-pair copper cables for connections within buildings. Fiber optic media shall be used for all inter-device communication links extended outside of a building, unless specifically noted. Cables shall be as specified herein. C. The Contractor may provide a network configuration different from that shown in the Contract Drawings with written approval of the Engineer, but the Contractor shall coordinate with all affected trades and pay for all additional charges incurred. D. The Contractor shall supply all hardware, cables, connectors, and software to implement a network as specified herein and shown on drawings. 062617BR City of Denton Hazen and Sawyer BID SET 17180-2 Process Control System Networks 2.02 MODEM A. Modem shall be Model 5902 by Schneider Electric. No substitutions. 2.05 UNSHIELDED TWISTED PAIR CABLE A. Unshielded twisted pair cable for drops within buildings shall consist of 4 pair of 24 AWG copper conductors in a flame-retardant jacket. Cable shall be plenum rated (UL 910) and meet EIA/TIA-568 Category 6 specifications. Unshielded twisted pair cable shall be Hyper Grade Extended Distance cable as manufactured by Berk-Tek, Belden equivalent, or equal. Connectors shall be modular RJ-45 plug. PART 3 -- EXECUTION 3.01 REQUIREMENTS A. The destination of all network data cables (both copper and fiber) leaving an enclosure, patch panel, or building shall be labeled at each end using industry-standard wire markers. B. Refer to Section 17000, Part 3 of the Specifications for additional requirements. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 17190-1 Uninterruptible Power Systems SECTION 17190 UNINTERRUPTIBLE POWER SYSTEMS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation all uninterruptible power systems, with all spare parts, accessories, and appurtenances as herein specified and as shown on the Drawings. B. One UPS shall be provided for each operator workstation and its peripherals (i.e. printer, network equipment, radio, etc.) provided under this Contract. C. One UPS shall be provided for each programmable logic controller (PLC) or remote telemetry unit (RTU) and its appurtenant equipment provided under this Contract. However, courtesy receptacles in PLC and RTU cabinets shall not be powered by the UPS. D. UPS’s shall be mounted in or near enclosures containing digital hardware, unless otherwise specified or shown on the Drawings, as follows: 1. UPS’s for operator’s consoles shall be mounted within the consoles. 2. UPS’s for control panels containing PLCs shall be mounted either within the cabinet or in an adjacent cabinet of suitable environmental rating. 3. UPS’s for RTUs shall be mounted within the RTU cabinet. 4. Where the UPS is mounted within a dedicated enclosure, that enclosure shall be properly sized for heat dissipation and all other applicable requirements as specified in Section 17500 and its subordinate Sections. 5. Where the UPS is mounted within the PLC or RTU cabinet, it shall not interfere with access to other equipment or wiring within the panel (i.e., it shall not be necessary to move or remove the UPS to remove or service other panel-mounted equipment). For floor-mounted PLC cabinets with bottom wiring access (including those cabinets with legs), the UPS shall be placed on a dedicated shelf within the cabinet. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17100 – Control and Information System Hardware, General C. Section 17120 – Programmable Logic Controllers 020705BR City of Denton Hazen and Sawyer BID SET 17190-2 Uninterruptible Power Systems 1.03 SUBMITTALS A. The Contractor shall submit UPS sizing calculations for all UPS’s furnished under this Contract in accordance with Section 17030 - Control and Information System Submittals. PART 2 -- EQUIPMENT 2.01 UNINTERRUPTIBLE POWER SYSTEMS A. Each UPS shall consist of a freestanding UPS module and battery modules as required to meet backup run time requirements. B. UPS's shall be true on-line type. Each UPS shall be sized to match the maximum power requirements of the associated digital equipment, control panel power supplies and accessories. Under normal operation, the AC power shall be converted to DC. The DC power from the battery charger shall supply an inverter and maintain the battery module at full charge. The AC output from the inverter shall be fed to the associated digital equipment power supply unit and/or other equipment power supplies as appropriate. Upon loss of the AC supply, the inverter shall continue to supply normal power to the device, drawing DC from the batteries. C. An automatic bypass switch shall be provided on UPS's of greater than 2 kVA capacity. The transfer switch shall be of the solid state, make-before-break type and shall automatically transfer load from the inverter to the AC line in the event of an inverter malfunction. The total transfer time shall be 5 milliseconds or less. The transfer switch shall be provided with a manual override. D. A manually operated maintenance bypass switch shall be provided for each UPS installation to allow hardware to be powered while the UPS is removed for maintenance. The bypass switch shall be the make-before-break type to ensure continuous power to the associated PLC. E. Loss of AC power shall be monitored on the line side of the UPS and reported via normally closed (fail safe) unpowered contacts to the associated PLC/RTU. F. Each UPS shall meet the following requirements: 1. Input voltage shall be 117 VAC, single phase, 60 Hz. 2. Voltage regulation shall be +/-5 percent for line and load changes. 3. The output frequency shall be phase-locked to the input AC line on AC operation and shall be 60 hertz +/-0.5 percent when on battery operation. 4. The batteries shall be of the sealed, lead acid or lead calcium gelled electrolyte type, or VRLA absorbed glass mat (AGM) type. The battery modules shall have a minimum full load backup time of 30 minutes for PLC-based control panels, and 1 hour for remote telemetry units. City of Denton Hazen and Sawyer BID SET 17190-3 Uninterruptible Power Systems 5. A status monitoring and control panel shall be provided and shall include the following: a. Status indicating lights for both normal and abnormal conditions. b. Individual alarm contacts that shall close upon loss of the AC line, low battery level or operation of the static transfer switch. Contacts shall be wired to the closest discrete input subsystem. Alternatively, an RS-232 or USB port shall provide UPS status to an operator workstation. All required interface software and hardware shall be provided. c. Circuit breaker for the AC input. 6. Sound absorbing enclosure. 7. EMI/RF noise filtering. 8. Surge protection shall be provided on the AC input circuit, which shall have a UL TVSS clamping voltage rating of 400 V with a <5 ns response time. G. UPS systems shall be Model GXT2 as manufactured by Liebert, equivalent by Powerware, MGE UPS Systems, GE Digital Energy, or equal. PART 3 -- EXECUTION 3.01 REQUIREMENTS A. Refer to Section 17000, Part 3 of the Specifications. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 17190-4 Uninterruptible Power Systems This page left blank intentionally City of Denton Hazen and Sawyer BID SET 17200-1 Control and Information System Software Requirements SECTION 17200 CONTROL AND INFORMATION SYSTEM SOFTWARE REQUIREMENTS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation all control and information system software with all required programming and software appurtenances as herein specified and as shown on the Drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17920 – Control System Input/Output Schedule C. Section 17950 – Functional Control Descriptions PART 2 -- PRODUCTS 2.01 SOFTWARE REQUIREMENTS A. The Owner’s existing SCADA (Human-Machine Interface or HMI) software, including but not limited to all relevant displays, alarm summary pages, data collection, and historical trending/reporting, shall be modified to include all work performed under this Contract. B. The Owner’s existing control system shall be modified to include the inputs and outputs specified in the Input/Output Schedule and in other Sections of this Division. 2.02 OVERALL SYSTEM CONFIGURATION A. All HMI software configuration performed under this Contract shall be coordinated with the Owner and shall match in all possible respects the “look and feel” of the Owner’s existing system. Major HMI software scope of work shall include but shall not be limited to the following: 1. Create new graphic displays showing the new facilities and functions described herein complete with all associated equipment and instrumentation. 2. Modify the existing plant overview display(s) for the SCADA system to include the new facilities and equipment, and create links to the new screens. 3. Modify existing alarm summary pages to incorporate new monitoring data into the alarm displays. City of Denton Hazen and Sawyer BID SET 17200-2 Control and Information System Software Requirements 4. Modify existing reports to include the additional monitoring points specified under this Contract. 5. Create new real-time and historical trends, and coordinate with the Owner appropriate grouping of the trend charts. 6. Update the system status display to include new hardware provided under this Contract. B. Ladder logic resident in existing PLCs shall be configured to perform the functions described as specified herein and in Specification Section 17950. Specifically, the existing PLCs shall be programmed to accept the inputs specified in the Input/Output Schedule and to make this data readily available to the plant network, and shall be programmed to execute the logic necessary to implement all control functions associated with the scope of work specified under this Contract. C. All discrete and analog data acquisition, pre-processing, storage and process control functions shall be performed at the PLC level. The HMI software shall not be used for this purpose. PART 3 -- EXECUTION 3.01 REQUIREMENTS A. Software design, implementation and checkout shall satisfy the requirements specified in the various Sections of Division 17. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 17500-1 Enclosures, General SECTION 17500 ENCLOSURES, GENERAL PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation the control enclosures, with all spare parts, accessories, and appurtenances as specified herein and as shown on the Drawings. B. Control enclosures shall be assembled, wired, and tested in the instrumentation subcontractor's own facilities, unless specified otherwise. All components and all necessary accessories such as power supplies, conditioning equipment, mounting hardware, signal input and output terminal blocks, and plug strips that may be required to complete the system shall be provided. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17510 – Cabinets and Panels C. Section 17520 – Field Panels D. Section 17550 – Panel Instruments and Accessories E. Section 17560 –Surge Protection Devices F. Refer to Division 16 for additional requirements for cable, circuit breakers, disconnect switches, etc. 1.03 GENERAL INFORMATION AND DESCRIPTION A. The cabinet itself and all interior and exterior equipment shall be identified with nameplates. The equipment shall be mounted such that service can occur without removal of other equipment. Face mounted equipment shall be flush or semi-flush mounted with flat black escutcheons. All equipment shall be accessible such that adjustments can be made while the equipment is in service and operating. All enclosures shall fit within the allocated space as shown on the Drawings. B. Either manufacturer-standard or custom cabinetry may be furnished subject to the requirements of the Contract Documents and favorable review by the Owner. C. Due consideration shall be given to installation requirements for enclosures in new and existing structures. The Contractor shall examine plans and/or field inspect new and existing structures as required to determine installation requirements, and shall City of Denton Hazen and Sawyer BID SET 17500-2 Enclosures, General coordinate the installation of all enclosures with the Owner and all affected contractors. The Contractor shall be responsible for all costs associated with installation of enclosures, including repair of damage to structures (incidental, accidental or unavoidable). 1.04 TOOLS, SUPPLIES AND SPARE PARTS A. Tools, supplies and spare parts shall be provided as specified in Section 17050 - Tools, Supplies and Spare Parts. In addition, the spare parts items shall be provided as specified in the individual cabinet and panel specification sections (175XX). PART 2 -- PRODUCTS 2.01 TERMINAL BLOCKS A. Terminal blocks shall be assembled on non-current carrying galvanized steel DIN mounting rails securely bolted to the cabinet subpanel. Terminals shall be of the screw down pressure plate type as manufactured by Phoenix Contact, Weidmuller, Wieland, Square D, or equal. B. Power terminal blocks for both 120 VAC and 24 VDC power shall be single tier with a minimum rating of 600 volts, 30 amps. C. Discrete signal terminal blocks shall be 2-tier with a minimum rating of 600 volts, 20 amps. One terminal block shall be used for each signal. The hot wire shall be installed on the top terminal. D. Analog signal terminal blocks shall be 3-tier with a minimum rating of 600 volts, 20 amps. One terminal block shall be used for each signal. The + wire shall be installed on the top terminal and the shield wire shall be installed on the bottom terminal. PART 3 -- EXECUTION 3.01 FABRICATION A. Enclosures shall provide mounting for power supplies, control equipment, input/output subsystems, panel-mounted equipment and appurtenances. Ample space shall be provided between equipment to facilitate servicing and cooling. B. Enclosures shall be sized to adequately dissipate heat generated by equipment mounted inside the panel. If required, one or more of the following shall be provided to facilitate cooling: 1. Louvered openings near the bottom and top (NEMA 12 cabinets only). 2. Thermostatically controlled, low noise internal air blowers (initial setpoint 75F) to circulate air within the enclosure, maintaining a uniform internal temperature. City of Denton Hazen and Sawyer BID SET 17500-3 Enclosures, General 3. Thermostatically controlled, low-noise cooling fans to circulate outside air into the enclosure, exhausting through louvers near the top of the cabinet (NEMA 12 cabinets only). Air velocities through the enclosure shall be minimized to assure quiet operation. 4. All openings in cabinets and panels shall be fitted with dust filters. C. Enclosures shall be constructed so that no screws or bolt heads are visible when viewed from the front. Punch cutouts for instruments and other devices shall be cut, punched, or drilled and smoothly finished with rounded edges. D. The temperature inside each enclosure containing digital hardware (i.e., cabinet, panel or console) shall be continuously monitored and shall generate an alarm to the nearest PLC if the temperature rises to an adjustable, preset high temperature. This thermostat shall be independent and separate from the thermostat used to control the temperature in the enclosure described above. Enclosure interior temperature alarm shall be displayed on the HMI. E. Intrusion alarm switches shall be provided on all enclosures containing digital hardware and shall generate an alarm to the nearest PLC when any enclosure door is opened. F. Terminals shall be marked with a permanent, continuous marking strip. One side of each terminal shall be reserved exclusively for field incoming conductors. Common connections and jumpers required for internal wiring shall not be made on the field side of the terminal. Subject to the approval of the Engineer, a vendor's pre-engineered and prefabricated wiring termination system will be acceptable. G. Wiring within cabinets, panels, and consoles shall be installed neatly and shall comply with accepted standard instrumentation and electrical practices. Power, control and signal wiring shall comply with Division 16 of the Specifications, except that the minimum wire size for discrete signal wiring may be 16 AWG, and for analog wiring may be 18 AWG. For each pair of parallel terminal blocks, the field wiring shall be between the blocks. H. Separate terminal strips shall be provided for each type of power and signal used within each cabinet. Where applicable, terminal strips for different voltages of discrete signal wiring shall also be separated. Terminal strips shall be labeled as to voltage and function. I. All wiring shall be bundled and run open or enclosed in vented plastic wireway as required. Wireways shall be oversized by a minimum of 10%; overfilled wireways shall not be acceptable. All conductors run open shall be bundled and bound at regular intervals, not exceeding 12 inches, with nylon cable ties. Care shall be taken to separate electronic signal, discrete signal, and power wiring. J. Spare field wiring shall be bundled, tied, and labeled as specified above, and shall be neatly coiled in the bottom of the cabinet. City of Denton Hazen and Sawyer BID SET 17500-4 Enclosures, General K. All installed spare I/O hardware shall be wired along with live I/O wiring to the field wiring terminal blocks within the cabinet. L. A copper ground bus shall be installed in each cabinet, and shall be connected to the building power ground. M. Interior panel wiring shall be tagged at all terminations with machine-printed self- laminating labels. Labeling system shall be Brady TLS 2200 Printer with TLS 2200®/TLS PC Link™ labels, or equivalent system by Seton or Panduit. The wire numbering system and identification tags shall be as specified in Section 16123 - Building Wire and Cable. Field wiring terminating in panels shall be labeled in accordance with the requirements of Section 16123. Where applicable, the wire number shall be the ID number listed in the input/output schedules. N. Wires shall be color coded as follows: Equipment Ground - GREEN 120 VAC Power - BLACK 120 VAC Power Neutral - WHITE 120 VAC Control (Internally Powered) - RED 120 VAC Control (Externally Powered) - YELLOW 24 VAC Control - ORANGE DC Power (+) - RED DC Power (-) - BLACK DC Control - BLUE Analog Signal – BLACK/WHITE or BLACK/RED O. Enclosures shall be provided with a main circuit breaker and a circuit breaker on each individual branch circuit distributed from the panel. Main breaker and branch breaker sizes shall be coordinated such that an overload in a branch circuit will trip only the branch breaker but not the main breaker. P. Enclosures with any dimension larger than 36 inches shall be provided with 120-volt duplex receptacles for service equipment and LED service lights. Power to these devices shall be independent from the PLC power supply and its associated uninterruptible power system. Q. Where applicable, enclosures shall be furnished with red laminated plastic warning signs in each section. The sign shall be inscribed "WARNING - This Device Is Connected to Multiple Sources of Power". Letters in the word "WARNING" shall be 0.75 inch high, white. R. The interconnection between equipment and panel shall be by means of flexible cables provided to permit withdrawal of the equipment from the cabinet without disconnecting the plugs. City of Denton Hazen and Sawyer BID SET 17500-5 Enclosures, General 3.02 PAINTING/FINISHING A. All steel enclosures shall be free from dirt, grease, and burrs and shall be treated with a phosphatizing metal conditioner before painting. All surfaces shall be filled, sanded, and finish coated by spraying a 1-2 mil epoxy prime coat and smooth, level, high grade textured finish between flat and semi-gloss shine. The colors shall be selected by the Owner from a minimum of six color samples provided. Refer to Division 9 for additional requirements. B. Materials and techniques shall be of types specifically designed to produce a finish of superior quality with respect to adherence, as well as impact and corrosion resistance. C. Panels fabricated from stainless steel shall not be painted. D. Panels fabricated from non-metallic materials (e.g., FRP) shall be gel-coated and shall not be painted. 3.03 INSTALLATION A. Refer to Section 17000 for additional requirements. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 17500-6 Enclosures, General This page left blank intentionally City of Denton Hazen and Sawyer BID SET 17510-1 Cabinets and Panels SECTION 17510 CABINETS AND PANELS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation the cabinets and panels, with all spare parts, accessories, and appurtenances as specified herein and as shown on the Drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17100 – Control and Information System Hardware, General C. Section 17500 – Enclosures, General D. Section 17900 – Schedules and Control Descriptions, General PART 2 -- PRODUCTS 2.01 CABINETS AND PANELS A. Cabinets and panels shall be formed or welded construction, reinforced with Unistrut, Powerstrut, or equal to facilitate mounting of internal components or equipment. Sufficient access plates and doors shall be provided to facilitate maintenance and testing of the cabinet's equipment. Doors shall be removable. Cabinets and panels with any dimension 36 inches or greater shall be provided with removable lifting lugs designed to facilitate safe moving and lifting of the panel during installation. All doors shall be fitted with common-keyed locks. B. Minimum panel size shall be 36”W x 36”H x 12”D. C. Cabinets and panels shall be minimum 14 USS gauge. Cabinets and panels with any dimension greater than 36 inches shall be 12 USS gauge. D. Cabinets and panels located inside buildings, but located in areas other than climate controlled (heated and air conditioned) electrical or control rooms, shall be as a minimum 316 stainless steel NEMA 4X construction, or as specified or shown on the Drawings for hazardous area classification (Class, Division, Group), or submersible (NEMA 6) applications. Epoxy coated cast copper-free aluminum construction shall also be acceptable for NEMA 4, 6 and 7 applications. Cabinets located in storage/feed areas for chlorine or other applicable corrosive chemicals shall be of non-metallic construction, rated NEMA 4X, and fully compatible with the associated chemical. Commented [JVA1]: I recommend combining this spec with 17500 City of Denton Hazen and Sawyer BID SET 17510-2 Cabinets and Panels E. Cabinets and panels within climate controlled (heated and air-conditioned) electrical or control rooms shall be all steel fully enclosed NEMA 12 units with gasketed doors. F. Cabinets and panels shall have doors on the front and shall be designed for front access. NEMA 12 cabinets shall be fitted with three-point door latches. Doors for NEMA 4X cabinets shall be all stainless steel with piano hinges and three-point latches. Door hardware on NEMA 4X cabinets located in chlorine storage/feed areas shall be non-corrosive in that environment. G. Panels and cabinets located outside fence-secured areas shall be fitted with padlockable latch kits. H. All cabinets and panels shall be provided with drawing pockets for as-built panel drawings. One copy of the appropriate panel as-built drawings shall be furnished and left in the pocket of each panel. I. Panels with any dimension greater than 36 inches that contain a programmable controller (PLC) shall be provided with a folding laptop programmer shelf on the inside of the door. When deployed, the laptop shelf shall not be greater than 48 inches above finished floor. Laptop shelf shall be fitted to door with factory applied weld-studs. Weld discoloration and enclosure penetrations will not be accepted. J. Unless otherwise noted, panel-mounted control devices (OIUs, hand switches, etc.) requiring operator access shall be mounted between 48 and 60 inches above the floor or work platform. K. Cabinets and panels shall be prefabricated cabinets and panels by Hoffman or Saginaw Control and Engineering (SCE). The Contractor may optionally provide cabinets that are custom-fabricated by the instrumentation subcontractor or by a reputable panel fabrication shop acceptable to the Engineer. PART 3 -- EXECUTION 3.01 REQUIREMENTS A. Refer to Section 17500 for additional requirements. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 17520-1 Field Panels SECTION 17520 FIELD PANELS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation the field panels, with all spare parts, accessories, and appurtenances as specified or shown. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17500 – Enclosures, General C. Section 17900 – Schedules and Control Descriptions, General PART 2 -- PRODUCTS 2.01 FIELD PANELS A. Field panels for outdoor service shall be suitable for wall or pipe mounting. Panels shall have the following features: 1. Type 316L stainless steel NEMA 4X construction unless located in chlorine environments. Chlorine environment shall be nonmetallic NEMA 4X construction. 2. Hinged and foamed-in-place continuous gasketed door(s). Door material shall match enclosure and shall have piano hinge(s) and three-point latches. 3. Field panels located outside fence-secured areas shall be fitted with staple and hasp. Provide padlock and coordinate keying with Owner. 4. Thermal insulation and thermostatically controlled space heaters where required to prevent condensation or maintain environmental conditions for installed components. 5. External sun shields or shades constructed of the same materials as the associated enclosure, unless otherwise specified. Sun shield or shade shall be fitted to enclosure supports and not to enclosure. Sunshield or shade shall have a slightly sloped top to shed water and shall extend past the front of the enclosure by at least 6 inches and extend down the side and back of enclosure. B. All external sample/process piping, including valves and appurtenances, shall be insulated with weather-proof insulation and heat-taped to prevent freezing. Heat taping City of Denton Hazen and Sawyer BID SET 17520-2 Field Panels shall be thermostatically controlled and self-regulating, and shall adjust its heat output to the temperature of the lines. Heat tape shall be powered from a GFCI circuit from within panel, unless otherwise shown or specified. C. Field panels shall be adequately sized to house instruments, power supplies, surge protection, and appurtenant equipment required for operation. Sufficient space shall be provided for servicing instruments without removal of equipment from the enclosure. D. Field panels shall be as manufactured by Hoffman, Saginaw Control and Engineering (SCE), or equal. PART 3 -- EXECUTION 3.01 REQUIREMENTS A. Refer to Section 17500 for additional requirements. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 17550-1 Panel Instruments and Accessories SECTION 17550 PANEL INSTRUMENTS AND ACCESSORIES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation the panel instruments and accessories, with all spare parts, accessories, and appurtenances as specified herein and as shown on the Drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17100 – Control and Information System Hardware, General C. Section 17500 – Enclosures, General D. Section 17900 – Schedules and Control Descriptions 1.03 GENERAL INFORMATION AND DESCRIPTION A. All equipment mounted on the face of a panel shall conform to the same NEMA rating specified for the panel construction. 1.04 TOOLS, SUPPLIES AND SPARE PARTS A. Tools, supplies and spare parts shall be provided as specified in Section 17050 - Tools, Supplies and Spare Parts. In addition, the following specific spare parts items shall be provided: 1. One of each type of panel mounted equipment (i.e., indicators, signal converters, etc.) provided under this Contract. 2. Five of each type of interposing relay provided under this Contract. 3. One year's supply of disposable pens and charts for each chart recorder furnished under this Contract. PART 2 -- PRODUCTS 2.01 ELECTRONIC INDICATORS A. Electronic indicators shall be 3.5 or 6 digit, as appropriate, with 0.56" high red LED display. Indicators shall be provided with nameplate and scale calibrated to match the City of Denton Hazen and Sawyer BID SET 17550-2 Panel Instruments and Accessories calibration of the primary element. The unit shall be designed primarily for use with 4-20 mA current loop signal circuits. Indicator operating voltage shall be 115 VAC 10%, 60 Hz. Indicator controls shall include three (3) front-panel pushbuttons for modifying alarm values and other indicator setup. Two (2) form-C relays shall be provided for each indicator. Relay contact outputs shall be rated 5A, 120/240 VAC, resistive load. Where required, a regulated and isolated 24 V excitation power supply shall be provided. Indicators shall be suitable for indoor or outdoor service as required and shall have the same NEMA enclosure rating as the associated enclosure. Indicators shall be Red Lion Model IMP or APLCL, or equal. 2.02 SIGNAL CONVERTERS A. Signal converters shall be provided as required to provide control functions and to interface instrumentation and controls, equipment panels, motor control centers and other instrumentation and controls supplied under other Divisions to the controls provided herein. B. General Requirements – Converters shall be of the miniature type, utilizing all solid state circuitry suitable for mounting within new or existing cabinetry. Where sufficient cabinet space is not available, sub panels or supplemental enclosures shall be provided. Power supply shall be 120V, 60 hertz where required by the converter. Repeatability shall be 0.1% of span, deadband shall be 0.1% span, maximum. Where specific converters are not listed, but are required to interface with the process control system, they shall comply with the general requirements stated herein. C. Current to Current Isolators – Current to current isolators shall be furnished where necessary to provide an isolated current loop, calculations or signal amplification between the plant process control system and instrumentation and control loops. Isolators shall be sized such that resistance of existing loops shall not exceed maximum rated resistance. Isolators shall be as manufactured by AGM, Moore Industries, Rochester Instrument Systems (RIS), Phoenix Contact, Weidmuller, Acromag, or equal. D. Voltage to Current Transducers – Voltage to current (or current to voltage) transducers shall convert a voltage signal of one magnitude to a 4-20 milliamp DC current signal. The output current shall be directly proportional to the input signal voltage. Transducers shall be sized such that loop resistance does not exceed maximum rated resistance. Transducers shall be as manufactured by AGM, Moore Industries, Rochester Instrument Systems (RIS), Phoenix Contact, Weidmuller, Acromag, or equal. E. Frequency to Current Transducers – Frequency to current transducers shall convert pulse-rate and pulse-duration signals to 4-20 mA, 24 VDC analog signals. Converters shall include field-adjustable input frequency range. Converter power shall be 120 VAC, 60 hertz. Transducers shall be sized such that loop resistance does not exceed maximum rated resistance. Transducers shall be suitable for signal transmission via leased telephone lines. Transducers shall be Series 5100 as manufactured by AGM, or equivalent by Moore Industries, Rochester Instrument Systems (RIS), Phoenix Contact, Weidmuller, Acromag, or equal. F. Current to Frequency Transducers – Current to frequency transducers shall convert 4-20 mA, 24 VDC analog signals to pulse-rate and pulse-duration signals. Converters shall City of Denton Hazen and Sawyer BID SET 17550-3 Panel Instruments and Accessories include field-adjustable output frequency range. Converter power shall be 120 VAC, 60 hertz. Transducers shall be sized such that loop resistance does not exceed maximum rated resistance. Transducers shall be suitable for signal transmission via leased telephone lines. Transducers shall be Series 5016 as manufactured by AGM, Moore Industries, Rochester Instrument Systems (RIS), Phoenix Contact, Weidmuller, Acromag, or equal. G. Integrators – Integrators shall be provided as interchangeable plug-in modules with zero and span adjustment available on the front plate of the units. Output shall range from 0 to 0.1 through 0 to 10 pulses per second. Accuracy shall be + 0.1% of input span. Integrators shall convert linear analog signals to pulse rate and provide a solid-state output. Integrators shall be as manufactured by AGM Electronics, Moore Industries, Rochester Instrument Systems (RIS), Phoenix Contact, Weidmuller, Acromag, or equal. H. Electronic Switches (Alarm Relays) – Electronic switches shall be furnished with a calibrated dial for adjusting set points. The input to the switch shall be 4-20 mADC, and the set point shall be adjustable over the full range. Unless otherwise noted, the dead band shall be fixed at less than 2 percent of span. The set point stability shall be +0.1% per degree F. The repeatability shall be +0.1% of span. The units shall be furnished with SPDT relays rated at 10 amperes at 115 VAC. Electronic switches shall be as manufactured by AGM, Moore Industries, Rochester Instrument Systems (RIS), Phoenix Contact, Weidmuller, Acromag, or equal. I. RTD to Current Signal Converters – RTD to current signal converters shall convert a 3- wire RTD input signal to an isolated 4-20 mADC output signal. Each converter shall operate from a 120 VAC power source. Accuracy shall be 0.10 percent of span or better. Calibrated span of each converter shall be as indicated on the instrument list. The Contractor shall coordinate calibration of the signal converters with existing RTD elements. The signal converters shall be furnished in the manufacturer's standard enclosure for installation in an existing indoor electrical cabinet. Signal converters shall be as manufactured by AGM, Moore Industries, Rochester Instrument Systems (RIS), Phoenix Contact, Weidmuller, Acromag, or equal. J. Interposing Relays – Where required to interface between motor control centers, equipment controls, and control panels, interposing relays and associated control wiring circuitry shall be furnished and installed to provide the monitoring and/or control functions specified herein. Interposing relays shall be small format type, DPDT, minimum 10 amp, 120 VAC contact rating. Relay coils shall be 120 VAC or 24 VDC as required. Relays shall have a flag indicator to show relay status, a pushbutton to allow manual operation of the relay, and an internal pilot light to indicate power to the coil. Relays shall be as manufactured by Square D, Potter & Brumfield, Allen-Bradley, or equal. K. Timing Relays – Timing Relays (TR) shall be the general purpose plug-in type, Type JCK as manufactured by Square D Company, Cutler-Hammer/Westinghouse Electric Corporation equivalent, Allen-Bradley equivalent, or equal. Timing relays shall be electronic type with 120 VAC coils unless otherwise specified or indicated on the Drawings. Timers shall be provided with a minimum of two SPDT timed output contacts and instantaneous contacts where required. Contact ratings shall be the same as for interposing relays as specified above. City of Denton Hazen and Sawyer BID SET 17550-4 Panel Instruments and Accessories L. Intrinsically Safe Relays and Barriers – Intrinsically safe relays and barriers shall be provided where required to interface with equipment such as float level switches that are located in NFPA-classified hazardous areas. Intrinsically safe relays and barriers shall be FM approved and shall be manufactured by Pepperl and Fuchs, Crouse Hinds, Square D, or equal. 2.03 TOTALIZERS A. Totalizing counters shall be provided for flush panel, spring-clip mounting. Face dimensions of the totalizing counters shall be no larger than 1-1/8-inches high by 2-inches wide. Totalizing counters shall contain eight digits. Height of the digits shall not be less than 5/32-inch. Numerals shall be white on a black background. The counter shall be non-resettable and shall be totally compatible for operation on the pulses supplied by the associated instrument or integrator. The totalizing counter shall be capable of a maximum count rate of 25 counts/second. B. Legend plates shall be provided for each of the totalizing counters with white letters on a black background with legends as specified below. C. Totalizing counters shall be manufactured by Kessler-Ellis, or equal. 2.04 ACCESSORIES A. Control operators such as pushbuttons (PB), selector switches (SS), and pilot lights (PL) shall be Cutler-Hammer/Westinghouse Type E34, Square D Company Type SK, or equal. Control operators shall be 30.5 mm, round, heavy-duty, oil tight NEMA 4X corrosion resistant. B. Pushbuttons shall be non-illuminated, spring release type. Pushbuttons shall include a full guard. Panic stop/alarm pushbuttons shall be red mushroom type with manual-pull release. Selector switches shall be non-illuminated, maintained contact type. Pilot lights shall be of the proper control voltage, push-to-test LED type with light lens colors as specified below. Color Function Red Running (Open) Green Stopped or Off (Closed) Amber Fault White Other C. Control operators shall have legend plates as specified herein, indicated on the Drawings, or otherwise directed by the Engineer. Legend plates shall be plastic, black field (background) with white lettering. Engraved nameplates shall be securely fastened above each control operator. If adequate space is not available, the nameplate shall be mounted below the operator. D. Control operators for all equipment shall be as specified herein and of the same type and manufacturer unless otherwise specified or indicated on the Drawings. City of Denton Hazen and Sawyer BID SET 17550-5 Panel Instruments and Accessories E. Alarm horns shall be general-purpose type, panel-mounted, and shall be suitable for indoor or weatherproof service, as required. Power supply shall be either 115 VAC or 24 VDC. Horns shall be capable of producing 100 dB at 10 feet, and shall have adjustable volume. Horns shall be Vibratone series as manufactured by Federal Signal Corporation, McMaster-Carr equivalent, Edwards Signaling Company equivalent, or equal. 2.05 STRIP CHART RECORDERS A. Strip chart recorders shall be of the single pen, null balance, servo-operated, compact strip chart type furnished with disposable fiber tip pens. Systems employing capillary pens are not acceptable. Each pen shall have its own indicator scale, calibrated in engineering units. The charts shall travel at less than 1 inch per hour. Approximately 1 hour of recorded data shall be displayed. Charts shall be 4 inches wide, have time markings at two-hour intervals and shall indicate AM and PM times. An On-Off chart drive switch shall be provided. Recorder input signal circuits shall be electronically isolated. Input signal shall be 4-20 mA, 24 VDC. Zero and span adjustments shall be provided. Accuracy shall be ±0.5% of span, repeatability ±0.25% of span, with a maximum 7-second full-scale travel slew speed. Instruments shall be mounted on pullout chassis. All components shall be integrally mounted in the recorder case. Recorders shall be supplied with panel mounting enclosures. Mounting hardware and umbilical cords and all accessories for connections shall be provided. Power supply shall be 120 VAC, 60 Hertz. Recorders shall be Foxboro Series 760 R, Chessell, ABB/Fischer & Porter, or equal. 2.06 CIRCULAR CHART RECORDERS A. Circular chart recorders shall be single pen, servo-operated, circular chart type furnished with solid state plug-in circuit modules and disposable fiber-tip pens. Systems employing capillary pens are not acceptable. Chart drives shall be 7-day, with direct drive synchronous motor. Charts shall be 10 inches in diameter and calibrated in engineering units. Input signal shall be 4-20 mA, 24 VDC. Accuracy shall be 0.5% of span, repeatability 0.25% of span, and sensitivity 0.1% of span. Recorder shall have 40-character digital fluorescent display. Recorders shall be designed for flush-panel mounting with slide tray for access. All components shall be integrally mounted in the recorder case. Mounting hardware, umbilical cords, and all accessories for connections shall be provided. Power supply shall be 115 VAC, 60 Hz. Recorder shall be Model C1900 as manufactured by ABB/Fischer & Porter, Foxboro, Chessell or equal. 2.07 ELECTRONIC BAR GRAPH INDICATORS A. Electronic bar graph indicators shall be solid-state and shall be provided with one input circuit for indication of one process variable. Process variable shall be indicated on a vertical bar graph. Glowing bars consisting of 101 individual segments shall be provided through the use of electronic gas-discharge display units and shall be easily viewed under all types of lighting. The bar color shall be red. The indicator shall not use any electro-mechanical movements, linkage, or other moving parts in its operation. Transparent slip-in scales shall be provided, graduated in engineering units. Scales graduated as 0-100% will not be accepted (except for speed or valve position indication). City of Denton Hazen and Sawyer BID SET 17550-6 Panel Instruments and Accessories An electronic digital LED display shall be provided on the face of the indicator, sealed to match the analog bar graph display. B. The panel face and background for the indicator shall be black with black case trim. An individual indicator shall have overall panel-mounting dimensions not exceeding 3 inches wide by 6 inches high. Horizontal groupings of indicators shall be self-mounted. The indicator chassis shall be capable of being withdrawn from the case for service without disconnection from the terminals. Connection between the chassis and the case-mounted terminal block shall be accomplished by the use of an "umbilical" cord-type, multiple-conductor flat cable. The "umbilical" connection shall be self-retracting when the chassis is fully plugged in. C. Accuracy of the indicator shall be ±0.5% of span with repeatability of 0.1% of span and a resolution of 0.5% of span. Effective indicator scale length shall be nominally 4 inches. The indicator shall remain within ±0.1% of span for a +10% or –15% change from the nominal power supply voltage. D. The unit shall be capable of normal operation in an ambient temperature range of 40°F- 120°F. Power supply shall be 120 VAC, 60 Hz. E. Electronic bar graph indicators shall be Model PC-101 by Weschler Instruments, or equal. 2.08 DIGITAL SINGLE LOOP CONTROLLERS A. Digital single loop controllers shall be provided as specified herein and as shown on the Contract Drawings. Controllers shall be microprocessor-based, self contained single loop digital controllers, Model 352B as manufactured by Moore Products Co., or equal. B. Controllers shall be front panel mounted and shall have LED bar graph display for process and setpoint values and for valve position. Controller shall have a 4 1/2-digit LED numeric display to monitor process, setpoint, valve position values and two user- defined variables. Pushbuttons shall be provided to select the value being displayed. A four character alphanumeric display shall be included to indicate status and alarm condition. An alarm acknowledge pushbutton shall be provided. C. Pushbuttons shall be provided for changing the setpoint or manual output, capable of rapid full-scale changes or precise incremental changes. An integral mode switch shall be included to manually control the loop. Integral keypad switches shall be provided for configuration and operating functions. Controller shall operate on 120-volt single-phase power. D. Controllers shall be provided with two analog and two discrete inputs, and with one analog and two discrete outputs. Controllers shall also be provided with a minimum of 23 programmable function blocks, which may be configured by the user to perform control strategies. The instrumentation subcontractor shall perform control strategy configuration for the single loop controllers to enable them to perform all functions specified herein. City of Denton Hazen and Sawyer BID SET 17550-7 Panel Instruments and Accessories E. Controllers shall be provided with a digital communications network supplied by the controller manufacturer. All controllers shall be provided with all hardware and software required to communicate via this network. Interconnecting cables shall be provided by the instrumentation subcontractor, as recommended by the controller manufacturer. The digital communications network shall employ a global database with peer-to-peer communication over a token passing bust at 500 K bits/sec. The global database shall be updated every 0.5 seconds for every device on the network regardless of plant operating situation. The network shall be self-configuring and shall recognize the addition or removal of any network device without disrupting normal operations. The network shall utilize a passive bus, which shall operate normally following failure of any connected device. Communications protocol shall be HDLC, or equal. The digital communications network shall be the Local Instrument Link by Moore Products, or equal. F. Controllers shall be provided with PC-based configuration software capable of running on MS-Windows-based microcomputers. The configuration software shall be capable of creating, editing and storing on disc for later retrieval controller configuration via the controller's digital communications network, and of uploading and downloading these configurations to/from any particular controller on the network. Hardware shall be provided to interface the microcomputer with the digital communications network, including all required communications cables. The configuration software shall be menu-based, with "help" screens for each menu selection. Configuration software shall be Moore Products Mycro 352 Configuration Management Software, with Model 320 Independent Computer Interface, or equal. G. Software shall be provided and configured such that the controller's digital communications network is available on-line at the operator workstations through the controller configuration interface hardware. The controller configuration software shall be available through a window on the operator workstations, and all on-line network- based configuration functions shall be executable across the network. 2.09 ANNUNCIATOR SYSTEMS A. The annunciator systems shall be installed as specified herein and as shown on the Drawings. Annunciator systems shall be of the all-silicon, solid state type furnished with a separately mounted alarm horn, logic circuitry, a DPDT auxiliary output relay, translucent windows and white lamps. Acknowledge and test switches shall be of the heavy-duty oil-tight type. B. The system shall include filter networks on the power supply and each input point. Each point shall be provided with a two-position switch to allow the annunciator to operate with either normally open or normally closed field contact. Maximum field contact interrogation voltage shall be 24 VDC. Each point shall be equipped with a DPDT repeater relay. C. The auxiliary output relay shall normally be energized whenever the horn is sounded. When the test circuit is energized, all components except the auxiliary relay shall be energized. City of Denton Hazen and Sawyer BID SET 17550-8 Panel Instruments and Accessories D. The lamps shall be operated at reduced voltage and shall be rated for 50,000 hours. The lamps shall be easily replaceable as an off-the-shelf item from at least two manufacturers. E. The system shall be capable of operation in an ambient temperature of 0 to 150 degrees F, with a line voltage variation of ± 10 percent. F. The system shall be capable of operating with a lock-in alarm sequence, as indicated on the following table: Field Contact Normal Field Contact Abnormal Return to Normal Before Acknowledge Alarm Acknowledge Return to Normal Lamp: OFF FLASHING ON ON OFF Horn: OFF ON OFF OFF OFF G. The system shall be as manufactured by Ronan Engineering Company, or Panalarm Division of Ametek, Inc., or equal. H. Each system shall be furnished with at least 10% but not less than two spare (active) points, with a minimum of 10% but not less than six (boxed) spare lamps. PART 3 -- EXECUTION 3.01 REQUIREMENTS A. Refer to Section 17500 for additional requirements. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 17560-1 Surge Protection Devices SECTION 17560 SURGE PROTECTION DEVICES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, install and place in satisfactory operation the surge protection devices (SPDs) as specified herein and as shown on the Drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17500 – Enclosures, General 1.03 GENERAL INFORMATION AND DESCRIPTION A. All surge protectors of each type provided under this Contract shall be furnished by a single manufacturer. 1.04 TOOLS, SUPPLIES AND SPARE PARTS A. Tools, supplies and spare parts shall be provided as specified in Section 17050 - Tools, Supplies and Spare Parts. In addition, the following specific spare parts items shall be provided: 1. Five of each type of surge protection device provided under this Contract. PART 2 -- PRODUCTS 2.01 SURGE PROTECTION, GENERAL A. All electrical and electronic elements shall be protected against damage due to electrical transients induced in interconnecting lines from lightning discharges and nearby electrical systems. B. Manufacturer's Requirements: All surge protection devices shall be manufactured by a company that has been engaged in the design, development, and manufacture of such devices for at least 5 years. Acceptable manufacturers shall be Phoenix Contact, Weidmuller, Transtector, or equal. C. Surge protection device installations shall comply with UL 94, the National Electric Code (NEC), and all applicable local codes. City of Denton Hazen and Sawyer BID SET 17560-2 Surge Protection Devices D. Surge protection devices shall be installed as close to the equipment to be protected as practically possible. E. Device Locations: As a minimum, provide surge protection devices at the following locations: 1. At any connections between ac power and electrical and electronic equipment, including panels, assemblies, and field mounted analog transmitters. 2. At both ends of all analog signal circuits that have any portion of the circuit extending outside of a protecting building. 3. At both ends of all copper-based communication cables which extend outside of a building, including at field instruments and the field side of analog valve position signals. 4. On all external telephone communication lines. 2.02 AC POWER PROTECTION A. Surge protection device assemblies for connections to AC power supply circuits shall: 1. Be provided with two 3-terminal barrier terminal strips capable of accepting No. 12 AWG solids or stranded copper wire. One terminal strip shall be located on each end of the unit. 2. Have a nonflammable enclosure that meets or exceeds UL 94 V0 flammability requirements. The surge protection device shall be provided with provisions for mounting to interior of equipment racks, cabinets, or to the exterior of freestanding equipment. 3. Be constructed as multistage devices consisting of gas tube arrestors, high energy metal oxide varistors, or silicon avalanche suppression diodes. Assemblies shall automatically recover from surge events, and shall have status indication lights. 4. Comply with all requirements of UL 1449, latest edition. 5. Be able to withstand a peak surge current of 10,000 amps based on a test surge waveform with an 8-microsecond rise time and a 20-microsecond exponential decay time, as defined in UL 1449. 6. Have the following characteristics: a. Maximum Continuous Operating Voltage: 150VAC b. Maximum Operating Current: 20 amps c. Ambient Temperature Range: -20 degrees C to +65 degrees C d. Response Time: 5 nanoseconds City of Denton Hazen and Sawyer BID SET 17560-3 Surge Protection Devices 2.03 ANALOG SIGNAL CIRCUIT PROTECTION A. Surge protection device assemblies for analog signal circuits shall: 1. Have four lead devices with DIN Rail mounting. 2. Have a nonflammable enclosure that meets or exceeds UL 94 V0 flammability requirements. 3. Be constructed as multistage devices consisting of gas tube arrestors and silicon avalanche suppression diodes. Gas tube arrestors and diodes shall be separated by a series impedance of no more than 20 ohms. Assemblies shall automatically recover from surge events. 4. Comply with all requirements of UL 497B. 5. Be able to withstand a peak surge current of 10,000 amps based on a test surge waveform with an 8-microsecond rise time and a 20-microsecond exponential decay time, as defined in UL 1449. 6. Limit line-to-line voltage to 40 volts on 24VDC circuits. 7. Have the following characteristics: a. Maximum Continuous Operating Voltage: 28VDC b. Ambient Temperature Range: -20 degrees C to +65 degrees C c. Response Time (Line-to-Line): 5 ns 2.04 COMMUNICATION CIRCUIT PROTECTION A. Surge protection devices for copper-based data communication circuits shall: 1. Be designed for the specific data communication media and protocol to be protected (i.e. telephone, serial, parallel, network, data highway, coax, twinaxial, twisted pair, RF, etc.). 2. Provide protection of equipment to within the equipment’s surge withstand levels for applicable standard test wave forms of the following standards: a. IEC 60-1 / DIN VDE 0432 part 2 b. CCITT K17 / DIN VDE 0845 part 2 c. IEEE C62.31 3. Have a nonflammable enclosure that meets or exceeds UL 94 V0 flammability requirements. 4. Provide automatic recovery. City of Denton Hazen and Sawyer BID SET 17560-4 Surge Protection Devices PART 3 -- EXECUTION 3.01 REQUIREMENTS A. Refer to Section 17500 for additional requirements. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 17600-1 Unpowered Instruments SECTION 17600 UNPOWERED INSTRUMENTS, GENERAL PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The instrumentation subcontractor shall furnish, install, test and place in operation process instrumentation (flow elements, pressure switches, etc.) as scheduled herein together with all signal converters, transmitters, isolators, amplifiers, etc. to interface all instrumentation, panels, controls and process equipment control panels with the process controls as shown on the Drawings and as specified. The Contractor may elect to install primary elements (flowmeters, etc.) on process lines provided that the instrumentation subcontractor provides full on-site supervision during installation. Mounting of associated transmitters, indicators, power supplies, brackets and appurtenances shall be provided as specified herein and shown on the Drawings. B. It is the intent of the Contract Documents that all process taps, isolation valves, nipples, penetrations, embedded instrumentation supports, conduit, wiring, terminations, and the installation of process instrumentation on process lines shall be provided under this Contract. The instrumentation subcontractor shall supervise installation of equipment provided under this Division where installation is provided by others. C. Tapping and connections for primary process sensors shall be sized to suit each individual installation and the requirements of the instrument served. The Contractor shall ensure that the location, supports, orientation and dimensions of the connections and tapping for instrumentation furnished under this Division are such as to provide the proper bracing, the required accuracy of measurement, protection of the sensor from accidental damage and accessibility for maintenance while the plant is in operation. Isolation valves shall be provided at all process taps. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17500 – Enclosures, General C. Section 17698 – Instrumentation and Control System Accessories D. Section 17700 – Powered Instruments, General E. Unpowered instruments furnished with mechanical equipment shall be furnished, installed, tested and calibrated as specified elsewhere in the Contract Documents. 1.03 TOOLS, SUPPLIES AND SPARE PARTS A. Tools, supplies and spare parts shall be provided as specified in Section 17050. City of Denton Hazen and Sawyer BID SET 17600-2 Unpowered Instruments B. In addition to the above requirements, the instrumentation subcontractor shall provide spare parts as specified in individual instrument specification sections. PART 2 -- PRODUCTS 2.01 GENERAL A. Unless otherwise specified, instruments shall be provided with enclosures to suit specified environmental conditions. Field-mounted devices shall be rugged and mounted on walls or pipe stanchions. PART 3 -- EXECUTION 3.01 INSTALLATION A. Equipment shall be located so that it is accessible for operation and maintenance. The instrumentation subcontractor shall examine the Drawings and Shop Drawings for various items of equipment in order to determine the best arrangement for the work as a whole, and shall supervise the installation of process instrumentation supplied under this Division. B. Field equipment shall be wall mounted or mounted on two-inch diameter pipe stands welded to a 10-inch square 1/2-inch thick base plate unless shown adjacent to a wall or otherwise noted. Materials of construction shall be aluminum or 316 stainless steel. Instruments attached directly to concrete shall be spaced out from the mounting surface not less than 1/2-inch by use of phenolic spacers. Expansion anchors in walls shall be used for securing equipment or wall supports to concrete surfaces. Unless otherwise noted, field instruments shall be mounted between 48 and 60 inches above the floor or work platform. C. Embedded pipe supports and sleeves shall be Schedule 40, Type 316 stainless steel pipe, ASA B-36.19, with stainless steel blind flange for equipment mounting as shown on the Drawings. D. Materials for miscellaneous mounting brackets and supports shall be 316 stainless steel construction. E. Pipe stands, miscellaneous mounting brackets and supports shall comply with the requirements of Division 5 of the specifications. 3.02 ADJUSTMENT AND CLEANING A. The instrumentation subcontractor shall comply with the requirements of Division 1 of these Specifications and all instrumentation and control system tests, inspection, and calibration requirements for all instrumentation and controls provided under this Contract and specified herein. The Engineer, or his designated representative(s), reserves the right to witness any test, inspection, calibration or start-up activity. Acceptance by the Engineer of any plan, report or documentation relating to any testing or commissioning activity specified herein shall not relieve the Contractor of his responsibility for meeting all specified requirements. City of Denton Hazen and Sawyer BID SET 17600-3 Unpowered Instruments B. The instrumentation subcontractor shall provide the services of factory trained technicians, tools and equipment to field calibrate, test, inspect and adjust each instrument to its specified performance requirement in accordance with manufacturer's specifications and instructions. Any instrument which fails to meet any Contract requirements, or any published manufacturer performance specification for functional and operational parameters, shall be repaired or replaced, at the discretion of the Engineer, at no cost to the Owner. The Contractor shall bear all costs and provide all personnel, equipment and materials necessary to implement all installation tests and inspection activities for equipment specified herein. C. At least 60 days before the anticipated initiation of installation testing, the Contractor shall submit to the Engineer a detailed description, of the installation tests to be conducted to demonstrate the correct operation of the instrumentation and control system. D. Field instrument calibration requirements shall conform to the following: 1. The instrumentation subcontractor shall provide the services of factory trained instrumentation technicians, tools and equipment to field calibrate each instrument supplied under this Contract to its specified accuracy in accordance with the manufacturer's specification and instructions for calibration. 2. Each instrument shall be calibrated at 0, 25, 50, 75 and 100 percent of span using test instruments to simulate inputs and read outputs. Test instruments shall be rated to an accuracy of at least five (5) times greater than the specified accuracy of the instrument being calibrated. Where applicable, such test instruments shall have accuracy’s as set forth by the National Institute for Standards and Technology (NIST). 3. The instrumentation subcontractor shall provide a written calibration sheet to the Engineer for each instrument, certifying that it has been calibrated to its published specified accuracy. The Contractor shall submit proposed calibration sheets for various types of instruments for Engineer approval prior to the start of calibration. This sheet shall include but not be limited to date, instrument tag numbers, calibration data for the various procedures described herein, name of person performing the calibration, a listing of the published specified accuracy, permissible tolerance at each point of calibration, calibration reading as finally adjusted within tolerance, defect noted, corrective action required and corrections made. 4. If doubt exists as to the correct method for calibrating or checking the calibration of an instrument, the manufacturer's printed recommendations shall be used as an acceptable standard, subject to the approval of the Engineer. 5. Upon completion of calibration, devices shall not be subjected to sudden movements, accelerations, or shocks, and shall be installed in permanent protected positions not subject to moisture, dirt, and excessive temperature variations. Caution shall be exercised to prevent such devices from being subjected to overvoltages, incorrect voltages, overpressure or incorrect air. Damaged equipment shall be replaced and recalibrated at no cost to the Owner. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 17600-4 Unpowered Instruments This page left blank intentionally City of Denton Hazen and Sawyer BID SET 17650-1 Pressure Gauges SECTION 17650 PRESSURE GAUGES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation the pressure gauges, with all spare parts, accessories, and appurtenances as herein specified and as shown on the Drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17600 – Unpowered Instruments, General C. Section 17698 – Instrumentation Accessories PART 2 -- PRODUCTS 2.01 PRESSURE GAUGES A. All gauges shall be designed in accordance with the ASME B40.1 entitled, "Gauges, Pressure, Indicating Dial Type - Elastic Element". B. All gauges shall be direct reading type. Snubbers shall be provided on all gauges. Gauge full-scale pressure range shall be selected such that the maximum operating pressure shall not exceed the approximately 75% of the full-scale range. C. Features 1. Mounting: ½” NPT, lower stem mount type 2. Accuracy: 0.5% full scale 3. Case: Solid front, black phenolic material 4. Dial: White background and black letters 5. Glass: Shatterproof 6. Blow-out protection: Back 7. Pressure element: stainless steel bourdon tube 8. Movement: Stainless steel, Teflon coated pinion gear and segment 9. Gaskets: Buna-N D. Liquid-filled or equivalent mechanically-damped gauges shall be used if the gauges are installed with pumps, or where gauges are subjected to vibrations or pulsation. Filling fluid shall be silicone unless oxidizing agents such as sodium hypochlorite are present, where halocarbon shall be used. City of Denton Hazen and Sawyer BID SET 17650-2 Pressure Gauges E. Gauge size shall be 2" for line sizes up to 3" and 4½" for line sizes of 4" or greater. F. Diaphragm seals and isolating ring seals shall be furnished in accordance with the requirements specified under Section 17698 - Instrumentation and Control System Accessories. G. The complete gauge assembly and appurtenances shall be fully assembled and tested prior to field mounting. A ½” isolation stainless steel ball valve shall be provided for each gauge assembly. H. Pressure and vacuum gauges shall be Ashcroft Duragauge Model 1279, Ametek-U.S. Gauge Division, H.O. Trerice Co., WIKA Instrument Corporation, or equal. PART 3 -- EXECUTION 3.01 REQUIREMENTS A. Refer to Section 17600, Part 3. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 17660-1 Vane Operated Flow Switches SECTION 17660 VANE OPERATED FLOW SWITCHES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation all vane operated flow switches, with all spare parts, accessories, and appurtenances as herein specified and as shown on the Drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 - Control and Information System Scope and General Requirements B. Section 17600 - Unpowered Instruments, General PART 2 -- PRODUCTS 2.01 VANE OPERATED FLOW SWITCHES A. Vane operated flow switches shall consist of a paddle or vane, a magnet that moves with the paddle or piston and a reed switch. Motion from the vane shall be passed through a sealed, magnetically coupled mechanism to actuate the switch. B. Vane operated flow switches shall have the following specifications: 1. Temperature Limit: 275o F 2. Max. Operating Pressure: 1,000 psig 3. Switch Type: SPDT snap action micro switch 4. Switch Rating: 10 A, 125 VAC; 106 cycle contact life 5. Body Type/Material: Single piece milled, bored brass 6. Enclosure Classification: Class I, Groups C, D Class II, Groups E, F, G 7. Vane Type/Material: Layered, 316 stainless steel C. Manufacturer/Model: Model V4-2-U Flotect by W.E. Anderson, or equal. PART 3 -- EXECUTION 3.01 REQUIREMENTS A. Refer to Section 17600, Part 3 of the Specifications. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 17660-2 Vane Operated Flow Switches This page left blank intentionally City of Denton Hazen and Sawyer BID SET 17670-1 Level Switches (Suspended Float Type) SECTION 17670 LEVEL SWITCHES (SUSPENDED FLOAT TYPE) PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation the float level switches, with all spare parts, accessories, and appurtenances as herein specified and as shown on the Drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17600 – Unpowered Instruments, General PART 2 -- PRODUCTS 2.01 LEVEL SWITCHES (SUSPENDED FLOAT TYPE) A. Level switches of the direct acting float-operated design shall be comprised of a hermetically sealed, approximately 5 inch diameter plastic casing float, containing microswitches and flexibly supported by means of a heavy neoprene or PVC jacket, with three conductor cable a minimum of 20 feet in length. Unless otherwise specified, media specific gravity is 0.95 to 1.05. Microswitches shall be one normally open and one normally closed, 5A-115V AC capacity. Float hangers and supports shall be provided as shown on the installation detail drawings. Float switches shall be Model ENM as manufactured by Flygt, or equal. PART 3 -- EXECUTION 3.01 REQUIREMENTS A. Refer to Section 17600, Part 3 of the specifications. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 17670-2 Level Switches (Suspended Float Type) This page left blank intentionally City of Denton Hazen and Sawyer BID SET 17675-1 Pressure Switches SECTION 17675 PRESSURE SWITCHES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation the pressure switches, with all spare parts, accessories, and appurtenances as herein specified and as shown on the Drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 - Control and Information System Scope and General Requirements B. Section 17600 - Unpowered Instruments, General PART 2 -- PRODUCTS 2.01 PRESSURE SWITCHES A. Pressure, vacuum, and differential pressure switches shall be single or dual action with an adjustable setpoint for the process requirement and/or as specified herein. Switches shall be diaphragm or piston operated and activate S.P.D.T. snap action switches on increasing or decreasing pressure. Minimum differential shall be less than 10 percent of the range. Deadband shall be adjustable. Allowable surge pressure shall be a minimum 1.5 times the range. Each pressure switch shall have visible scale. B. Pressure switches shall have a contact rating of 10 amperes at 120 volts AC. Pressure switches shall be in NEMA 4X enclosures. Switches shall have a repeatable accuracy of 1 percent of range. Pressure switches shall be isolated from the process fluid by a diaphragm seal or an isolation ring in locations as shown on the Contract Drawings and/or as specified. Wetted parts materials shall be compatible with the process fluid for corrosion resistance. Pressure switches shall be manufactured by ASCO, SOR, Inc., Ashcroft, or equal. PART 3 -- EXECUTION 3.01 REQUIREMENTS A. Refer to Section 17600 Part 3. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 17675-2 Pressure Switches This page left blank intentionally City of Denton Hazen and Sawyer BID SET 17698-1 Instrumentation and Control System Accessories SECTION 17698 INSTRUMENTATION AND CONTROL SYSTEM ACCESSORIES PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation the instrumentation and control system accessories with all spare parts, and appurtenances as herein specified and as shown on the Drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17600 – Unpowered Instruments, General C. Section 17700 – Powered Instruments, General D. Section 16902 – Electric Controls and Relays PART 2 -- PRODUCTS 2.01 INSTRUMENTATION AND CONTROL SYSTEM ACCESSORIES A. General: Accessories include various items of equipment that may be required in the system but are not scheduled. Accessories are shown on details, flow sheets or plans. Accessories are also called out in specifications for scheduled instruments and in the installation specifications. It is not intended, however, that each piece of hardware required will be specifically described herein. This subarticle shall be used as a guide to qualify requirements for miscellaneous hardware whether the specific item is described or not. B. Process Tubing: Process tubing shall be 1/2 x 0.065-inch seamless, annealed, ASTM A-269 Type 316L stainless steel with Type 316 - 37 degrees stainless steel flared fittings or Swagelock or Parker-CPI flareless fittings. C. Power, Control and Signal Cables: Power, control and signal wiring shall be provided under Division 16 of the Specifications. D. Chemical Diaphragm Seals: Diaphragm seals shall be provided for isolation of pressure gauges, switches and transmitters attached to systems containing chemical solutions or corrosive fluids. As a minimum, seals shall be of all 316 stainless steel construction. In general, diaphragms shall be 316L stainless steel for operating pressures at or above 15 psi and elastomers for operating pressures below 15 psi. However, all components shall be non-reactive with the process fluid in all cases. Refer to the Instrument Schedules for City of Denton Hazen and Sawyer BID SET 17698-2 Instrumentation and Control System Accessories specific materials requirements. Seal shall have fill connection, 1/4-inch NPT valved flush port and capable of disassembly without loss of filler fluid. Where specified, diaphragm seals shall comply with the above requirements and shall be provided with 316 SS factory filled capillaries. Seals shall be Helicoid Type 100 HA, Mansfield & Green, Ashcroft, or equal. E. Isolating Ring Seals: For solids bearing fluids, line pressure shall be sensed by a flexible cylinder lining and transmitted via a captive sensing liquid to the associated pressure sensing instrument(s). 1. Full Line Size Isolating Ring Seals - For all grit/sludge/slurry/scum applications or wherever the associated pressure instrument is used for control purposes, the sensor body shall be full line size wafer design. Except where noted on the Drawings and/or Instrument Schedule, full line size ring seals will not be required for return activated sludge (RAS) lines, but will have tapped ring seals as specified in Item 2, below. Full line size isolating ring seals shall have 316 stainless steel housing and assembly flanges and Buna N flexible cylinder lining for in-line mounting. The wafer shall have through bolt holes or centerline gauge for positive alignment with the associated flanged piping. The captive liquid chamber and associated instrument(s) shall be furnished with threaded drain tap and plug. Isolating ring seals shall be RED Valve Series 40, Ronningen-Petter Iso-Ring, Moyno RKL Series W, Onyx Isolator Ring, or equal. 2. Tapped Isolating Ring Seals - For all other solids bearing fluids, pressure shall be sensed via a minimum 1/2" diameter spool-type isolating ring seal mounted on a 1/2" pipe nipple at 90 from the process piping. An isolation ball valve shall be provided between the process piping and the ring seal, and a cleanout ball valve shall be provided between the ring seal and the atmosphere. The pressure instrument shall be back or side mounted to the ring seal such that the gauge or readout may be viewed normally. Tapped isolating ring seals for solids service shall be Red Valve Series 42/742, Ronningen-Petter Iso-Spool, Onyx Isolator Ring, or equal. F. Filling Medium: The filling medium between instruments, isolating ring seals and diaphragm seals shall be a liquid suitable for operation in an ambient temperature ranging from -10F to +150oF. Filling medium shall be silicone unless oxidizing agents such as sodium hypochlorite are present, where halocarbon shall be used. G. Isolation Valves: Isolation valves shall be 1/2 - inch diameter ball valves with 316 stainless steel body, 316 stainless steel ball, except that materials of construction shall be suitable for the associated process fluid where applicable (i.e., chemical service). H. Sirens: Sirens shall be UL Listed, heavy duty, AC motor driven, weatherproof type capable of producing a minimum of 111 dBA at 10 feet. Power supply shall be 120 VAC, 60 hertz. Siren shall be McMaster-Carr Model 6392T11, Federal Signal Corporation equivalent, Edwards Signaling Company equivalent, or equal. I. Strobe Lights: Strobe lights shall be high profile with Type 304 stainless steel base. Light is rated NEMA 4. Light shall have an outer dome to provide extra lens protection. Lens color shall be as indicated on the Drawings. [Available lens colors are amber, blue, clear, and City of Denton Hazen and Sawyer BID SET 17698-3 Instrumentation and Control System Accessories red]. Surface mount hardware shall be included. Power supply shall be 120 VAC, 60 hertz. Strobe light shall be McMaster-Carr Model 5848T71, Federal Signal Corporation equivalent, Edwards Signaling Company equivalent, or equal. PART 3 -- EXECUTION 3.01 REQUIREMENTS A. Refer to Section 17600, Part 3 of the specifications. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 17698-4 Instrumentation and Control System Accessories This page left blank intentionally City of Denton Hazen and Sawyer BID SET 17700-1 Powered Instruments, General SECTION 17700 POWERED INSTRUMENTS, GENERAL PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The instrumentation subcontractor shall furnish, install, test and place in operation powered process instrumentation (flow elements, level transmitters, etc.) as scheduled herein together with all signal converters, transmitters, isolators, amplifiers, etc. to interface all instrumentation, panels, controls and process equipment control panels with the process control system as shown on the Drawings and as specified. Powered instruments are those instruments that require power (120 VAC or 24 VDC loop power) to operate. The Contractor may elect to install primary elements (flowmeters, etc.) on process lines provided that the instrumentation subcontractor provides full on-site supervision during installation. Mounting of associated transmitters, indicators, power supplies, brackets and appurtenances shall be provided as specified herein and shown on the Drawings. B. It is the intent of the Contract Documents that all process taps, isolation valves, nipples, penetrations, embedded instrumentation supports, conduit, wiring, terminations, and the installation of process instrumentation on process lines shall be provided under this Contract. The instrumentation subcontractor shall supervise installation of equipment provided under this Division where installation is provided by others. C. Tapping and connections for primary process sensors shall be sized to suit each individual installation and the requirements of the instrument served. The Contractor shall ensure that the location, supports, orientation and dimensions of the connections and tapping for instrumentation furnished under this Division are such as to provide the proper bracing, the required accuracy of measurement, protection of the sensor from accidental damage, and accessibility for maintenance while the plant is in operation. Isolation valves shall be provided at all process taps. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17500 – Enclosures, General C. Section 17600 – Unpowered Instruments, General D. Section 17698 – Instrumentation and Control System Accessories E. Powered instruments furnished with mechanical equipment shall be furnished, installed, tested and calibrated as specified elsewhere in the Contract Documents. City of Denton Hazen and Sawyer BID SET 17700-2 Powered Instruments, General 1.03 TOOLS, SUPPLIES AND SPARE PARTS A. Tools, supplies and spare parts shall be provided as specified in Section 17050. B. In addition to the above requirements, the instrumentation subcontractor shall provide one remote handheld configuration device for communication with all "smart" instruments furnished under this Contract. The devices shall be capable of performing configuration, test, and format functions from anywhere on the 4-20 mA signal loop for a particular transmitter or by direct connection. The configuration device shall be Fischer & Porter Model 50HC1000, Rosemount Model 375, or equal. PART 2 -- PRODUCTS 2.01 GENERAL A. All instrumentation supplied shall be the manufacturer's latest design. Unless otherwise specified, instruments shall be solid state, electronic, using enclosures to suit specified environmental conditions. Microprocessor-based equipment shall be supplied unless otherwise specified. All instruments shall be provided with mounting hardware and floor stands, wall brackets, or instrument racks as shown on the Drawings, or as required. B. Equipment installed in a hazardous area shall meet Class, Group, and Division as shown on the Drawings, to comply with the National Electrical Code. C. All field instrumentation for outdoor service shall be provided with enclosures which are suitable for outdoor service, as follows: 1. Where the manufacturer's enclosures are suitable for outdoor service, they shall be provided with instrument sunshades. Sunshades shall be Style E as manufactured by O'Brien Corporation, or equal. Where possible, these instruments shall be mounted in a north facing direction. 2. Where the manufacturer's standard enclosures are not suitable for outdoor service, instruments shall be mounted in Field Panels in accordance with Section 17520, Field Panels, or may be furnished with Vipak instrument field enclosures as manufactured by O'Brien Corporation, equivalent by Intertec, or equal. It shall not be necessary to provide the manufacturer's NEMA 4 or 4X enclosures for instruments that will be subsequently mounted in separate field panels. D. All instruments shall return to accurate measurement without manual resetting upon restoration of power after a power failure. E. Unless otherwise shown or specified, local indicators shall be provided for all instruments. Where instruments are located in inaccessible locations, local indicators shall be provided and shall be mounted as specified in Subsection 3.01 (B) herein. All indicator readouts shall be linear in process units. Readouts of 0-100% shall not be acceptable (except for speed and valve position). Isolated outputs shall be provided for all transmitters. City of Denton Hazen and Sawyer BID SET 17700-3 Powered Instruments, General F. Unless otherwise specified, field instrument and power supply enclosures shall be 316 stainless steel, fiberglass or PVC coated copper-free cast aluminum NEMA 4X construction. G. Where separate elements and transmitters are required, they shall be fully matched, and unless otherwise noted, installed adjacent to the sensor. Special cables or equipment shall be supplied by the associated equipment manufacturer. H. Electronic equipment shall utilize printed circuitry and shall be coated (tropicalized) to prevent contamination by dust, moisture and fungus. Solid-state components shall be conservatively rated for long-term performance and dependability over ambient atmosphere fluctuations. Ambient conditions shall be -20 to 50 degrees C and 20 to 100 percent relative humidity, unless otherwise specified. Field mounted equipment and system components shall be designed for installation in dusty, humid, and corrosive service conditions. I. All devices furnished hereunder shall be heavy-duty type, designed for continuous industrial service. The system shall contain products of a single manufacturer, insofar as possible, and shall consist of equipment models that are currently in production. All equipment provided, where applicable, shall be of modular construction and shall be capable of field expansion. J. All non-loop-powered instruments and equipment shall be designed to operate on a 60 Hz AC power source at a nominal 117 V, plus or minus 10 percent, except where specifically noted. All regulators and power supplies required for compliance with the above shall be provided. Where equipment requires voltage regulation, constant voltage transformers shall be supplied. K. All analog transmitter and controller outputs shall be isolated, 4-20 milliamps into a load of 0-750 ohms, unless specifically noted otherwise. All switches shall have double-pole, double-throw contacts rated at a minimum of 600 VA, unless specified otherwise. L. Materials and equipment used shall be UL approved wherever such approved equipment and materials are available. PART 3 -- EXECUTION 3.01 INSTALLATION A. General 1. Equipment shall be located so that it is accessible for operation and maintenance. The instrumentation subcontractor shall examine the Drawings and shop drawings for various items of equipment in order to determine the best arrangement for the work as a whole, and shall supervise the installation of process instrumentation supplied under this Division. 2. Electrical work shall be performed in compliance with all applicable local codes and practices. Where the Contract Documents do not delineate precise installation procedures, API RP550 shall be used as a guide to installation procedures. City of Denton Hazen and Sawyer BID SET 17700-4 Powered Instruments, General B. Equipment Mounting and Support 1. Field equipment shall be wall mounted or mounted on two-inch diameter pipe stands welded to a 10-inch square by 1/2-inch thick base plate unless shown adjacent to a wall or otherwise noted. Materials of construction shall be aluminum or 316 stainless steel. Instruments attached directly to concrete shall be spaced out from the mounting surface not less than 1/2-inch by use of phenolic spacers. Expansion anchors in walls shall be used for securing equipment or wall supports to concrete surfaces. Unless otherwise noted, field instruments shall be mounted between 48 and 60 inches above the floor or work platform. 2. Embedded pipe supports and sleeves shall be schedule 40, 316 stainless steel pipe, ASA B-36.19, with stainless steel blind flange for equipment mounting as shown on the Drawings. 3. Materials for miscellaneous mounting brackets and supports shall be 316 stainless steel construction. 4. Pipe stands, miscellaneous mounting brackets and supports shall comply with the requirements of Division 5 of the specifications. 5. Transmitters shall be oriented such that output indicators are readily visible. C. Control and Signal Wiring 1. Electrical, control and signal wiring connections to transmitters and elements mounted on process piping or equipment shall be made through liquid-tight flexible conduit. Conduit seals shall be provided where conduits enter all field instrument enclosures and all cabinetry housing electrical or electronic equipment. 3.02 ADJUSTMENT AND CLEANING A. General 1. The instrumentation subcontractor shall comply with the requirements of Division 1 of these Specifications and all instrumentation and control system tests, inspection, and calibration requirements for all instrumentation and controls provided under this Contract and specified herein. The Engineer, or his designated representative(s), reserves the right to witness any test, inspection, calibration or start-up activity. Acceptance by the Engineer of any plan, report or documentation relating to any testing or commissioning activity specified herein shall not relieve the Contractor of his responsibility for meeting all specified requirements. 2. The instrumentation subcontractor shall provide the services of factory trained technicians, tools and equipment to field calibrate, test, inspect and adjust each instrument to its specified performance requirement in accordance with manufacturer's specifications and instructions. Any instrument which fails to meet any Contract requirements, or any published manufacturer performance specification for functional and operational parameters, shall be repaired or replaced, at the discretion of the Engineer, at no cost to the Owner. The Contractor shall bear all City of Denton Hazen and Sawyer BID SET 17700-5 Powered Instruments, General costs and provide all personnel, equipment and materials necessary to implement all installation tests and inspection activities for equipment specified herein. 3. At least 60 days before the anticipated initiation of installation testing, the Contractor shall submit to the Engineer a detailed description, of the installation tests to be conducted to demonstrate the correct operation of the instrumentation supplied hereunder. B. Field Instrument Calibration Requirements 1. The instrumentation subcontractor shall provide the services of factory trained instrumentation technicians, tools and equipment to field calibrate each instrument supplied under this Contract to its specified accuracy in accordance with the manufacturer's specification and instructions for calibration. 2. If the manufacturer's recommendations require calibration, each instrument shall be calibrated at 0, 25, 50, 75 and 100 percent of span using test instruments to simulate inputs and read outputs. Test instruments shall be rated to an accuracy of at least five (5) times greater than the specified accuracy of the instrument being calibrated. Where applicable, such test instruments shall have accuracy’s as set forth by the National Institute for Standards and Technology (NIST). 3. The instrumentation subcontractor shall provide a written calibration sheet to the Engineer for each instrument, certifying that it has been calibrated to its published specified accuracy. The Contractor shall submit proposed calibration sheets for various types of instruments for Engineer approval prior to the start of calibration. This sheet shall include but not be limited to date, instrument tag numbers, calibration data for the various procedures described herein, name of person performing the calibration, a listing of the published specified accuracy, permissible tolerance at each point of calibration, calibration reading as finally adjusted within tolerance, defect noted, corrective action required and corrections made. 4. If doubt exists as to the correct method for calibrating or checking the calibration of an instrument, the manufacturer's printed recommendations shall be used as an acceptable standard, subject to the approval of the Engineer. 5. Upon completion of calibration, devices calibrated hereunder shall not be subjected to sudden movements, accelerations, or shocks, and shall be installed in permanent protected positions not subject to moisture, dirt, and excessive temperature variations. Caution shall be exercised to prevent such devices from being subjected to overvoltages, incorrect voltages, overpressure or incorrect air. Damaged equipment shall be replaced and recalibrated at no cost to the Owner. 6. After completion of instrumentation installation, the instrumentation subcontractor shall perform a loop check. The Contractor shall submit final loop test results with all instruments listed in the loop. Loop test results shall be signed by all representatives involved for each loop test. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 17700-6 Powered Instruments, General This page left blank intentionally City of Denton Hazen and Sawyer BID SET 17740-1 Ultrasonic Liquid Level Measurement Systems SECTION 17740 ULTRASONIC LIQUID LEVEL MEASUREMENT SYSTEMS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation the ultrasonic liquid level measurement systems, with all spare parts, accessories, and appurtenances as herein specified and as shown on the Drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17700 – Powered Instruments, General 1.03 TOOLS, SUPPLIES AND SPARE PARTS A. Furnish one hand-held programmer under this Contract to calibrate and configure the level controllers specified herein. The programmer shall be furnished complete with battery plus one spare battery, carrying case and accessories. Programmer shall be furnished by the level instrument manufacturer, and shall be fully matched to the instrument furnished. PART 2 -- PRODUCTS 2.01 ULTRASONIC LEVEL CONTROLLERS A. Each ultrasonic level monitoring system shall include one ultrasonic level sensor and an "intelligent" transmitter (controller). The ultrasonic level monitoring system shall be required to monitor the level of process liquids or solids as shown on the Drawings and/or as specified herein. Location of the sensor and transmitters shall be as shown on the Drawings and/or as specified. B. For outdoor installation, the use of approved watertight conduit hub/glands shall be required. Tank mounting applications shall include mounting flange adapter supplied by the manufacturer, which is compatible with the process media and the tank flange connection. Channel or wall mounting applications shall include mounting bracket supplied by the manufacturer and constructed of 316 stainless steel material. Sensor mounting thread shall be 1" NPT. C. The level sensor shall be unaffected by moisture droplets on the transducer face and operate on the ultrasonic echo ranging principle. The sensor shall also be fully submersible and resistant to corrosive materials. Sensor accuracy shall be a minimum of 0.25 percent of level measurement range, and include integral temperature compensation with an accuracy City of Denton Hazen and Sawyer BID SET 17740-2 Ultrasonic Liquid Level Measurement Systems of 0.09% of range. Resolution shall be at least 0.1 percent of full range or 0.08 inches, whichever is greater. D. The transmitter shall be programmable by using a hand-held programmer. Display shall be LCD with backlighting, shall have the capability to display a minimum of 4 characters at one time, and shall be shielded from direct sunlight. The units shall have as a minimum, the required number of programmable set points to perform the functions specified. Each set point shall operate a set of contacts rated at 5 amps, 250 VAC, non-inductive. E. The transmitter shall compensate for changes in temperature and air density. The controller shall be capable of performing the following functions: level monitor, both linear and nonlinear level to flow relationships, volumetric, open channel flow monitoring, differential control, and control of up to 6 pumps, alarms, monitor pump runtime and pump sequencing. Output level signal shall be linear, isolated 4-20 mA DC. Power requirement for the transmitter shall be 120 VAC, 60 Hz. The units shall have a NEMA 4X stainless steel or nonmetallic enclosure. F. Ultrasonic level measurement system shall be the Pulsar dB25 Transducer and Pulsar Ultra 5 Transmitter system. No substitutions. PART 3 -- EXECUTION 3.01 REQUIREMENTS A. Where two or more ultrasonic level instruments are mounted in close proximity to each other, the transmitters shall coordinate operation to prevent interference from adjacent units. Coordination shall be accomplished via an interconnecting communication cable furnished by the manufacturer. B. Where level transducers may become submerged, provide a manufacturer-supplied submergence hood. C. Where ultrasonic level systems are used on solids measurement applications, provide a swiveling aiming device to allow easy adjustment of beam direction. D. For open channel flow applications where the transducer is subject to direct sunlight, use an externally mounted temperature compensator mounted out of direct sunlight. E. Refer to Section 17700, Part 3 of the specifications for additional requirements. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 17749-1 Submersible Level (Pressure) Sensors SECTION 17749 SUBMERSIBLE LEVEL (PRESSURE) SENSORS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation the submersible level (pressure) sensors, with all spare parts, accessories, and appurtenances as herein specified and as shown on the Drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 - Control and Information System Scope and General Requirements B. Section 17700 - Powered Instruments, General PART 2 -- PRODUCTS 2.01 SUBMERSIBLE LEVEL (PRESSURE) SENSORS A. Submersible level (pressure) sensors shall consist of a pressure-sensing probe assembly with a depth cable molded directly to the probe body. Sensing probe housing shall be fabricated of titanium or 316 stainless steel. The depth support cable shall be polyurethane and shall contain a Kevlar strength member, a vent tube, and conductors for electrical power and signal. B. The sensor shall contain an encapsulated pressure sensing element which is electrically and physically isolated from the media via a ceramic or titanium isolation diaphragm. The pressure sensing connection shall be protected from damage by a removable acetal nose cone or equivalent guard. C. Each submersible level transducer shall be provided with a NEMA 4X termination/junction box and aneroid bellows to prevent moisture from entering the vent tube. City of Denton Hazen and Sawyer BID SET 17749-2 Submersible Level (Pressure) Sensors D. Sensor specifications shall be as follows: 1. Sensor Rating: NEMA 6 (IP68), loop-powered 2. Output Signal: 4-20 mA, 2-wire design 3. Accuracy: + 0.25%, F.S. (full scale) 4. Long Term Stability: + 0.1% F.S./year 5. Zero Offset and Span Setting: + 0.25% F.S., max. 6. Operating Temperature: -20 to +60 degrees C 7. Compensated Temperature: -2 to +30 degrees C 8. Overpressure Limits: At least 2x full scale range 9. Cable Length: As required E. Submersible level (pressure) sensors shall be WaterPilot Model FMX21 by Endress & Hauser, equivalent by Druck, KPSI or Devar, or equal. PART 3 -- EXECUTION 3.01 REQUIREMENTS A. Refer to Section 17700, Part 3 of the Specifications. - END OF SECTION - City of Denton Hazen and Sawyer BID SET 17760-1 Pressure Indicating Transmitters SECTION 17760 PRESSURE INDICATING TRANSMITTERS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation the pressure indicating transmitters, with all spare parts, accessories, and appurtenances as herein specified and as shown on the Drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17000 – Control and Information System Scope and General Requirements B. Section 17700 – Powered Instruments, General PART 2 -- PRODUCTS 2.01 GAUGE PRESSURE INDICATING TRANSMITTERS A. Gauge pressure transmitters shall be of the capacitance type with a process-isolated diaphragm with silicone oil fill, microprocessor-based "smart" electronics, and a field adjustable rangeability of 100:1 input range. Span and zero shall be continuously adjustable externally over the entire range. Span and zero adjustments shall be capable of being disabled internally. Transmitters shall be NEMA 4X weatherproof and corrosion resistant construction with low-copper aluminum body and 316 stainless steel process wetted parts. Accuracy, including nonlinearity, hysteresis and repeatability errors shall be plus or minus 0.025 percent of calibrated span, zero based. The maximum zero elevation and maximum zero suppression shall be adjustable to anywhere within sensor limits. Output shall be linear isolated 4-20 milliamperes 24 VDC. Power supply shall be 24 VDC, two-wire design. Each transmitter shall be furnished with a 4-digit LCD indicator capable of displaying engineering units and/or milliamps and mounting hardware as required. Overload capacity shall be rated at a minimum of 25 MPa. Environmental limits shall be -40 to 85 degrees Celsius at 0-100% relative humidity. Each transmitter shall have a stainless steel tag with calibration data attached to body. B. The piezoresistive silicon pressure sensor shall be mechanically, electrically, and thermally isolated from the process and the environment, shall include an integral temperature compensation sensor, and shall provide a digital signal to the transmitter's electronics for further processing. Factory set correction coefficients shall be stored in the sensor's non-volatile memory for correction and linearization of the sensor output in the electronics section. The electronics section shall correct the digital signal from the sensor and convert it into a 4-20 mA analog signal for transmission to receiving devices. The electronics section shall contain configuration parameters and diagnostic data in non-volatile EEPROM memory and shall be capable of communicating, via a digital signal superimposed on the 4-20 mA output signal, with a remote interface device. Output signal City of Denton Hazen and Sawyer BID SET 17760-2 Pressure Indicating Transmitters damping shall be provided, with an adjustable time constant of 0-36 seconds. Total long term stability (frequency of calibration) shall be not less than 0.20% URL for 15 years. C. Where scheduled, gauge pressure indicating transmitters shall be calibrated in feet of liquid for liquid level service. D. Gauge pressure indicating transmitters shall be Model 3051S1TG as manufactured by Emerson Process Management (Rosemount), or equal. 2.02 DIFFERENTIAL PRESSURE INDICATING TRANSMITTERS A. Differential pressure indicating transmitters shall be the same as the gauge pressure transmitters except for body specifications. Differential pressure units shall be furnished with close coupled stainless steel three valve manifold assembly. B. The electronics sections of differential pressure transmitters shall contain user-selectable square root extractors to provide a linear 4-20 mA DC output proportional to flow, when activated. Square root extractor circuitry shall be activated only for incompressible fluid flow applications (i.e., water). Flow rates for compressible fluids (i.e., air) shall be calculated externally using line temperature and static pressure corrections as specified elsewhere in Division 17. In addition, each flow transmitter shall be furnished with laminated flow versus differential pressure curves wall mounted adjacent to the transmitter. C. Differential pressure indicating transmitters shall be Model 3051S1CG as manufactured by Emerson Process Management (Rosemount), or equal. 2.03 FLANGE MOUNTED LEVEL INDICATING TRANSMITTERS A. Flange-mounted tank liquid level indicating transmitters shall be the same as gauge pressure transmitters except for body type. B. The flange-mounted sensor shall consist of a special non-corrosive isolating diaphragm with fill fluid in a sealed capillary system to transmit liquid pressure to the sensing element. A second isolating diaphragm shall transmit pressure through the fill fluid to the sensing diaphragm in the center of the capacitance cell. An isolating diaphragm and fluid fill shall also be provided on the opposite side of the sensing diaphragm to convey atmospheric or reference pressure. C. All mounting flanges, diaphragms, O-rings and materials used in construction shall be non-corroding, compatible with each other, and compatible with the liquid being measured. D. Flange-mounted liquid level transmitters shall be Model 3051S Level Transmitter as manufactured by Emerson Process Management (Rosemount), or equal. City of Denton Hazen and Sawyer BID SET 17760-3 Pressure Indicating Transmitters PART 3 -- EXECUTION 3.01 REQUIREMENTS A. Refer to Section 17700, Part 3 of the Specifications. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 17760-4 Pressure Indicating Transmitters This page left blank intentionally City of Denton Hazen and Sawyer BID SET 17900-1 Schedules and Control Descriptions SECTION 17900 SCHEDULES AND CONTROL DESCRIPTIONS, GENERAL PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation all hardware and software required to provide the Control And Information System as specified herein and as shown on the Drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17910 – Instrument Schedule B. Section 17920 – Control System Input/Output Schedule C. Section 17950 – Functional Control Descriptions PART 2 -- CONVENTIONS 1.01 PLANT NUMBERING SYSTEM A. The plant equipment numbering system is based on a 5-digit code preceded by an equipment identification prefix and followed by a parallel designation suffix. The numbering system is broken down as follows: XXXX - X X XXX XXX │ │ │ │ │ Equipment │ │ │ │ │ Parallel Designation Prefix (1)──┘ │ │ │ └────Suffix (5) │ │ │ Major Process │ │ │ Individual Equipment or Area (2)───────┘ │ └─────────Item Number (4) │ Sub-Process (3)──────┘ 1. Prefix letters are added as required to label a piece of equipment or describe instrumentation/control signal types. Instrumentation prefixes shall use the convention shown in the following table. City of Denton Hazen and Sawyer BID SET 17900-2 Schedules and Control Descriptions INSTRUMENT PREFIX LETTERS FIRST LETTER SUCCEEDING LETTERS LETTER MEASURED OR INITIATING VARIABLE MODIFIER READOUT OR PASSIVE FUNCTION OUTPUT FUNCTION MODIFIER A ANALYSIS ALARM OR PLC/DCS DISCRETE ALARM INPUT B BURNER, COMBUSTION USER'S CHOICE USER'S CHOICE USER'S CHOICE C CONDUCTIVITY (ELECTRICAL) CONTROL OR PLC/DCS ANALOG OUTPUT D DENSITY (MASS) OR SPECIFIC GRAVITY DIFFERENTIAL E VOLTAGE (EMF) PRIMARY ELEMENT F FLOW RATIO (FRACTION) G USER'S CHOICE GLASS OR VIEWING DEVICE H HAND (MANUALLY INITIATED) HIGH I CURRENT (ELECTRICAL) INDICATE OR PLC/DCS ANALOG INPUT J POWER SCAN K TIME OR TIME SCHEDULE TIME RATE OF CHANGE CONTROL STATION L LEVEL LIGHT (PILOT) LOW M MOISTURE OR HUMIDITY MOMENTARY MIDDLE OR INTERMEDIATE N USER'S CHOICE NOTIFY OR PLC/DCS DISCRETE STATUS INPUT USER'S CHOICE USER'S CHOICE O USER'S CHOICE ORIFICE (RESTRICTION) P PRESSURE OR VACUUM POINT (TEST CONNECTION) Q QUANTITY INTEGRATE OR TOTALIZE INTEGRATE OR TOTALIZE R RADIATION RECORD OR PRINT S SPEED OR FREQUENCY SAFETY SWITCH T TEMPERATURE TRANSMIT U MULTIVARIABLE MULTIFUNCTION MULTIFUNCTION MULTIFUNCTION V VIBRATION OR MECHANICAL ANALYSIS VALVE, DAMPER OR LOUVER W WEIGHT OR FORCE WELL X UNCLASSIFIED X AXIS UNCLASSIFIED UNCLASSIFIED OR PLC/DCS DISCRETE OUTPUT UNCLASSIFIED Y EVENT, STATE OR PRESENCE Y AXIS RELAY, COMPUTE, OR CONVERT Z POSITION, DIMENSION Z AXIS DRIVE, ACTUATOR OR UNCLASSIFIED FINAL CONTROL ELEMENT 2. Major process areas and associated sub-processes shall use the following numbering convention: First Digit Second Digit Description 1 - HICKORY CREEK DETENTION FACILITY PUMP STATION 2 - HICKORY CREEK DETENTION FACILITY STORAGE TANK AND DIVERSION STRUCTURE 3 - WEST PEAK FLOW PUMP STATION 3. Individual equipment item numbers are assigned per equipment type and shall use City of Denton Hazen and Sawyer BID SET 17900-3 Schedules and Control Descriptions the following numbering convention: 000-099 Mechanical Equipment 100-199 Gates 200-399 Valves 400-599 Instrumentation 600-799 Electrical 800-899 HVAC 900-999 Miscellaneous 4. The parallel designation suffix shall be used to differentiate items of similar function and service that would otherwise have the same number. The suffix shall use the following conventions depending on application: a. {none} b. A, B, C,... c. A1, A2, A3,...B1, B2, B3,...C1, C2, C3,... - END OF SECTION - City of Denton Hazen and Sawyer BID SET 17900-4 Schedules and Control Descriptions This page intentionally left blank City of Denton Hazen and Sawyer Bid set 17910-1 Instrument Schedule SECTION 17910 INSTRUMENT SCHEDULE PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation all instrumentation as herein specified and as shown on the Drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17900 – Schedules and Control Descriptions B. Section 17920 – Control System Input/Output Schedule C. Section 17950 – Functional Control Descriptions PART 2 -- INSTRUMENT SCHEDULE 2.01 See attached. - END OF SECTION - INSTRUMENT LISTPressure Gauges ‐ 17650TagService DescriptionRange/SetpointSizeP&IDCommentPI-1401 HCPF Pump No. 1 Discharge Pressure GaugeI-HC-01Full line isolating ring sealPI-1402 HCPF Pump No. 2 Discharge Pressure GaugeI-HC-01Full line isolating ring sealPI-1403 HCPF Pump No. 3 Discharge Pressure GaugeI-HC-01Full line isolating ring sealPI-1404 HCPF Pump No. 4 Discharge Pressure GaugeI-HC-01Full line isolating ring sealPI-3401 WPF Pump No. 1 Discharge Pressure GaugeI-PC-01Full line isolating ring sealPI-3402 WPF Pump No. 2 Discharge Pressure GaugeI-PC-01Full line isolating ring sealPI-3403 WPF Pump No. 3 Discharge Pressure GaugeI-PC-01Full line isolating ring sealPage 1 of 360702-001/17910/07-14-2017PISCATAWAY WWTP RWWPS 100% SUBMITTAL Level Switches (Suspended Float Type) ‐ 17670TagService DescriptionRange/SetpointSizeP&IDCommentLSH-1400 HCDF Wet Well High Level Level Switches (Suspended Float Type)I-HC-01Provide intrinsically safe barrierLSL-1400 HCDF Wet Well Low Level Level Switches (Suspended Float Type)I-HC-01Provide intrinsically safe barrierLSHH-2400 Storage Tank High Level Level Switches (Suspended Float Type)I-HC-02Provide intrinsically safe barrierLSH-3400 WPF Wet Well High Level Level Switches (Suspended Float Type)I-PC-01Provide intrinsically safe barrierLSL-3400 WPF Wet Well Low Level Level Switches (Suspended Float Type)I-PC-01Provide intrinsically safe barrierUltrasonic Liquid Level Measurement Systems ‐ 17740TagService DescriptionRange/SetpointSizeP&IDCommentLE-1400 HCDF Wet Well Ultrasonic Level Transducer0-40 ftI-HC-01Provide sunshade and surge protectionLIT-1400 HCDF Wet Well Level Indicating Transmitter0-40 ftI-HC-01Provide sunshade and surge protectionLE-2400 Storage Tank Level Ultrasonic Level Transducer0-50 ftI-HC-02Provide sunshade and surge protectionLIT-2400 Storage Tank Level Ultrasonic Level Indicating Transmitter0-50 ftI-HC-02Remote mount; Provide sunshade and surge protectionLE-3400 WPF Wet Well Ultrasonic Level Transducer0-40 ftI-PC-01Provide sunshade and surge protectionLIT-3400 WPF Wet Well Level Indicating Transmitter0-40 ftI-PC-01Provide sunshade and surge protectionPage 2 of 360702-001/17910/07-14-2017PISCATAWAY WWTP RWWPS 100% SUBMITTAL Submersible Level (Pressure) Systems ‐ 17749TagService DescriptionRange/SetpointSizeP&IDCommentPE/LT-2500 Diversion Structure Submersible Level (Pressure) Transmitter0-15 ftI-HC-01Provide surge protectionPressure Indicating Transmitters ‐ 17760TagService DescriptionRange/SetpointSizeP&IDCommentPSH-1401 HCPF Pump No. 1 Discharge Pressure SwitchI-HC-01Full line isolating ring sealPSH-1402 HCPF Pump No. 2 Discharge Pressure SwitchI-HC-01Full line isolating ring sealPSH-1403 HCPF Pump No. 3 Discharge Pressure SwitchI-HC-01Full line isolating ring sealPSH-1404 HCPF Pump No. 4 Discharge Pressure SwitchI-HC-01Full line isolating ring sealPSH-3401 WPF Pump No. 1 Discharge Pressure SwitchI-PC-01Full line isolating ring sealPSH-3402 WPF Pump No. 2 Discharge Pressure SwitchI-PC-01Full line isolating ring sealPSH-3403 WPF Pump No. 3 Discharge Pressure SwitchI-PC-01Full line isolating ring sealPage 3 of 360702-001/17910/07-14-2017PISCATAWAY WWTP RWWPS 100% SUBMITTAL City of Denton Hazen and Sawyer BID SET 17920-1 Control System Input/Output Schedule SECTION 17920 CONTROL SYSTEM INPUT/OUTPUT SCHEDULE PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation all control system inputs and outputs as herein specified and as shown on the Drawings. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 17900 – Schedules and Control Descriptions B. Section 17910 – Instrument Schedule C. Section 17950 – Functional Control Descriptions PART 2 -- CONTROL SYSTEM INPUT / OUTPUT SCHEDULE 2.01 See attached. Notes: 1. Input/Output types are as follows: DI - Discrete Input DO - Discrete Output AI - Analog Input AO - Analog Output RS485 - Serial Communications Link - END OF SECTION - CONTROL SYSTEM INPUT/OUTPUT LISTSORTED BY NODE AND I/O TYPEPLC I/OTypeService Description FunctionI/O TagP&IDCommentsPLC-HCDFAIDiversion Structure LevelLI-2500 I-HC-01PLC-HCDFDIHCDF Pump No. 1 Pump FailYA-1001AI-HC-01PLC-HCDFDIHCDF Pump No. 1 High Motor TempYA-1001BI-HC-01PLC-HCDFDIHCDF Pump No. 1 In HandYN-1001AI-HC-01PLC-HCDFDIHCDF Pump No. 1 RunYN-1001BI-HC-01PLC-HCDFDIHCDF Pump No. 1 In BypassYN-1001CI-HC-01PLC-HCDFDOHCDF Pump No. 1 Start/StopYN-1001 I-HC-01PLC-HCDFDIHCDF Pump No. 1 Discharge High Pressure AlarmPAH-1401 I-HC-01PLC-HCDFDIHCDF Pump No. 2 Pump FailYA-1002AI-HC-01PLC-HCDFDIHCDF Pump No. 2 High Motor TempYA-1002BI-HC-01PLC-HCDFDIHCDF Pump No. 2 In HandYN-1002AI-HC-01PLC-HCDFDIHCDF Pump No. 2 RunYN-1002BI-HC-01PLC-HCDFDIHCDF Pump No. 2 In BypassYN-1002CI-HC-01PLC-HCDFDOHCDF Pump No. 2 Start/StopYN-1002 I-HC-01PLC-HCDFDIHCDF Pump No. 2 Discharge High Pressure AlarmPAH-1402 I-HC-01PLC-HCDFDIHCDF Pump No. 3 Pump FailYA-1003AI-HC-01PLC-HCDFDIHCDF Pump No. 3 High Motor TempYA-1003BI-HC-01PLC-HCDFDIHCDF Pump No. 3 In HandYN-1003AI-HC-01PLC-HCDFDIHCDF Pump No. 3 RunYN-1003BI-HC-01Page 1 of 560702-001/17920/07-14-2017CITY OF DENTON100% SUBMITTAL PLC I/OTypeService Description FunctionI/O TagP&IDCommentsPLC-HCDFDOHCDF Pump No. 3 Start/StopYN-1003 I-HC-01PLC-HCDFDIHCDF Pump No. 3 Discharge High Pressure AlarmPAH-1403 I-HC-01PLC-HCDFDIHCDF Pump No. 4 Pump FailYA-1004AI-HC-01PLC-HCDFDIHCDF Pump No. 4 High Motor TempYA-1004BI-HC-01PLC-HCDFDIHCDF Pump No. 4 In HandYN-1004AI-HC-01PLC-HCDFDIHCDF Pump No. 4 RunYN-1004BI-HC-01PLC-HCDFDOHCDF Pump No. 4 Start/StopYN-1004 I-HC-01PLC-HCDFDIHCDF Pump No. 4 Discharge High Pressure AlarmPAH-1404 I-HC-01PLC-HCDFAIHCDF Wet Well LevelLI-1400 I-HC-01PLC-HCDFDIHCDF Wet Well Level Alarm HighLAH-1400 I-HC-01PLC-HCDFDIHCDF Wet Well Level Alarm LowLAL-1400 I-HC-01PLC-HCDFAIBooster Pump Discharge Header Low Flow AlarmFAL-2440 I-HC-02PLC-HCDFAIBooster Pump Discharge Header PressurePI-2440 I-HC-02PLC-HCDFDIBooster Pump No. 1 FailYA-2010AI-HC-02PLC-HCDFDIBooster Pump No. 1 Common AlarmYA-2010BI-HC-02PLC-HCDFDIBooster Pump No. 1 In HandYN-2010AI-HC-02PLC-HCDFDIBooster Pump No. 1 RunYN-2010BI-HC-02PLC-HCDFDIBooster Pump No. 1 E-StopYN-2010CI-HC-02PLC-HCDFDOBooster Pump No. 1 Start/StopHS-2010 I-HC-02PLC-HCDFDIBooster Pump No. 1 Discharge High Pressure AlarmPAH-2410 I-HC-02PLC-HCDFDIBooster Pump No. 2 FailYA-2020AI-HC-02Page 2 of 560702-001/17920/07-14-2017CITY OF DENTON100% SUBMITTAL PLC I/OTypeService Description FunctionI/O TagP&IDCommentsPLC-HCDFDIBooster Pump No. 2 Common AlarmYA-2020BI-HC-02PLC-HCDFDIBooster Pump No. 2 In HandYN-2020AI-HC-02PLC-HCDFDIBooster Pump No. 2 RunYN-2020BI-HC-02PLC-HCDFDIBooster Pump No. 2 E-StopYN-2020CI-HC-02PLC-HCDFDOBooster Pump No. 2 Start/StopHS-2020 I-HC-02PLC-HCDFDIBooster Pump No. 2 Discharge High Pressure AlarmPAH-2420 I-HC-02PLC-HCDFDIOdor Control Exhaust Fan FailYA-2030 I-HC-02PLC-HCDFDIOdor Control Exhaust Fan In HandYN-2030AI-HC-02PLC-HCDFDIOdor Control Exhaust Fan RunYN-2030BI-HC-02PLC-HCDFDIOdor Control Exhaust Fan E-StopYN-2030CI-HC-02PLC-HCDFDOOdor Control Exhaust Fan Start/StopHS-2030 I-HC-02PLC-HCDFDIOdor Control Exhaust Fan Discharge High Pressure AlarmPAH-2430 I-HC-02PLC-HCDFAIStorage Tank LevelLI-2400 I-HC-02PLC-HCDFDIStorage Tank Level Alarm High-HighLAHH-2400 I-HC-02PLC-HCDFAIStorage Tank Drain Valve Position FeedbackZI-2202 I-HC-02PLC-HCDFAOStorage Tank Drain Valve Position CommandZC-2202 I-HC-02PLC-HCDFDIStorage Tank Drain Valve In RemoteYN-2202 I-HC-02PLC-WPFDIStorage Tank Drain Isolation Valve In RemoteYN-2201 I-HC-02PLC-WPFDIStorage Tank Drain Isolation Valve ClosedZIC-2201 I-HC-02Page 3 of 560702-001/17920/07-14-2017CITY OF DENTON100% SUBMITTAL PLC I/OTypeService Description FunctionI/O TagP&IDCommentsPLC-WPFDIStorage Tank Drain Isolation Valve OpenedZIO-2201 I-HC-02PLC-WPFDOStorage Tank Drain Isolation Valve Close CommandHSC-2201 I-HC-02PLC-WPFDOStorage Tank Drain Isolation Valve Open CommandHSO-2201 I-HC-02PLC-WPFDIWPF Discharge Valve In RemoteYN-3210 I-PC-01PLC-WPFDIWPF Discharge Valve ClosedZIC-3210 I-PC-01PLC-WPFDIWPF Discharge Valve OpenedZIO-3210 I-PC-01PLC-WPFDOWPF Discharge Valve Close CommandHSC-3210 I-PC-01PLC-WPFDOWPF Discharge Valve Open CommandHSO-3210 I-PC-01PLC-WPFDIWPF Pump No. 1 Pump FailYA-3001AI-PC-01PLC-WPFDIWPF Pump No. 1 High Motor TempYA-3001BI-PC-01PLC-WPFDIWPF Pump No. 1 In HandYN-3001AI-PC-01PLC-WPFDIWPF Pump No. 1 RunYN-3001BI-PC-01PLC-WPFDIWPF Pump No. 1 In BypassYN-3001CI-PC-01PLC-WPFDOWPF Pump No. 1 Start/StopYN-3001 I-PC-01PLC-WPFDIWPF Pump No. 1 Discharge High Pressure AlarmPAH-3001 I-PC-01PLC-WPFDIWPF Pump No. 2 Pump FailYA-3002AI-PC-01PLC-WPFDIWPF Pump No. 2 High Motor TempYA-3002BI-PC-01PLC-WPFDIWPF Pump No. 2 In HandYN-3002AI-PC-01PLC-WPFDIWPF Pump No. 2 RunYN-3002BI-PC-01Page 4 of 560702-001/17920/07-14-2017CITY OF DENTON100% SUBMITTAL PLC I/OTypeService Description FunctionI/O TagP&IDCommentsPLC-WPFDOWPF Pump No. 2 Start/StopYN-3002 I-PC-01PLC-WPFDIWPF Pump No. 2 Discharge High Pressure AlarmPAH-3002 I-PC-01PLC-WPFDIWPF Pump No. 3 Pump FailYA-3003AI-PC-01PLC-WPFDIWPF Pump No. 3 High Motor TempYA-3003BI-PC-01PLC-WPFDIWPF Pump No. 3 In HandYN-3003AI-PC-01PLC-WPFDIWPF Pump No. 3 RunYN-3003BI-PC-01PLC-WPFDOWPF Pump No. 3 Start/StopYN-3003 I-PC-01PLC-WPFDIWPF Pump No. 3 Discharge High Pressure AlarmPAH-3003 I-PC-01PLC-WPFAIWPF Wet Well LevelLI-3400 I-PC-01PLC-WPFDIWPF Wet Well Level Alarm HighLAH-3400 I-PC-01PLC-WPFDIWPF Wet Well Level Alarm LowLAL-3400 I-PC-01Page 5 of 560702-001/17920/07-14-2017CITY OF DENTON100% SUBMITTAL City of Denton Hazen and Sawyer BID SET 17950-1 Functional Control Descriptions SECTION 17950 FUNCTIONAL CONTROL DESCRIPTIONS PART 1 -- GENERAL 1.01 THE REQUIREMENT A. The Contractor shall furnish, test, install and place in satisfactory operation all equipment as herein specified and as shown on the Drawings. THE CONTRACTOR SHALL BE RESPONSIBLE FOR FURNISHING COMPLETE FUNCTIONING SYSTEMS AS DESCRIBED HEREIN. B. Together with the control system input/output schedule, the equipment specifications (including functional descriptions for local equipment control panels), and the Drawings, the functional control descriptions describe the required operation, monitoring, and control of the facilities included in this Contract. C. THE FUNCTIONAL DESCRIPTIONS CONTAIN REQUIREMENTS FOR FURNISHING AND INSTALLING LABOR AND MATERIALS THAT MAY NOT APPEAR ELSEWHERE IN THE CONTRACT DOCUMENTS. D. All equipment and services required in equipment local control panels provided to implement the monitoring and control functions described herein or in the process input/output schedules shall be provided by the Contractor through individual equipment suppliers. E. Unless specifically stated otherwise, all interconnected wiring between all instruments, panels, controls, and other devices listed in the functional descriptions as required to provide all functions specified herein shall be furnished by the Electrical Contractor under Division 16. The Electrical Contractor shall provide all cable and conduit required to carry all signals listed in the process input/output schedules. Special cables that are required for interconnection between sensors or probes and transmitters or signal conditioners shall be furnished with the instrumentation devices by the equipment supplier. 1.02 RELATED WORK SPECIFIED ELSEWHERE A. Section 01520 – Maintenance of Utility Operations During Construction B. Section 17900 – Schedules and Control Descriptions, General C. Section 17910 – Instrument Schedule D. Section 17920 – Control System Input/Output Schedule City of Denton Hazen and Sawyer BID SET 17950-2 Functional Control Descriptions PART 2 -- FUNCTIONAL CONTROL DESCRIPTIONS, GENERAL 2.01 DEFINITIONS A. RUNNING status signals shall be from auxiliary contacts provided with the motor control equipment (i.e., starter, VFD, SCR, etc.). B. AUTO status signals shall be defined as HAND-OFF-AUTO switch in the AUTO position or process control system in AUTO (versus MANUAL). C. FAIL status signals shall be defined as motor overload and/or any other shut down mode such as overtorque, overtemperature, low oil pressure, high vibration, etc. D. READY status signal shall be defined as all conditions, including equipment control power, satisfied to permit remote control of the equipment. 2.02 CONVENTIONS A. Operator workstation graphic display symbols and indicator lights on all MCC's, control panels, starter enclosures, etc. shall conform to the following color convention: Condition Color Running/On/Open Red Auto/Ready White Stopped/Off/Closed Green Fail/Alarm Amber Generic Status Blue or White 2.03 PROCESS CONTROL A. Where setpoints, operating limits, and other control settings are provided by the functional descriptions, these settings shall be initial settings only and shall be used for assistance in the initial startup of the plant. All such settings shall be fully adjustable and, based on actual operating conditions, the instrumentation subcontractor shall make all necessary adjustments to provide smooth, stable operation at no additional cost to the Owner. B. Provision shall be made in PLC logic to suppress nuisance alarms and control actions by the following means: 1. For alarms and control actions derived from analog input signals, use adjustable time delays and deadbands. 2. For alarms and control actions derived from discrete input signals, use adjustable time delays. 3. Initial settings for time delays shall be 10 seconds (range 0-120 seconds). Initial settings for deadbands shall be 5% of span (range 0-100%). City of Denton Hazen and Sawyer BID SET 17950-3 Functional Control Descriptions 4. Equipment that is started or stopped manually by the operator shall start or stop immediately, with no time delay. C. All setpoint control shall be by PID control algorithms. Where only proportional control is specified, tuning constants shall be used to reduce the Integral and Derivative functions to zero. All setpoints, sequence times, sequence orders, dead bands, PID tuning parameters, PLC delay timers, variable speed operating range limits, and similar control constants shall be accessible and alterable from the operator workstations. D. Unless otherwise specified, all equipment shall automatically restart after a power failure utilizing adjustable start delay timers in PLC control logic. Unless otherwise specified, all PLC control strategies shall be based upon automatic restart after a power failure and shall return to a normal control mode upon restoration of power. E. The PLC shall be capable of receiving initial run-time values for existing and proposed equipment. Initial run-time shall not automatically be assumed to be zero. F. Equipment failure shall be generated through the PLC for any drive, motor, etc. for which a command has been issued, but for which the PLC is not receiving a confirming status signal (e.g., start command with no run feedback). The failure shall be logged. G. Instrument failure shall be generated via the operator work stations for any instrument which is generating a signal which is less than 4 mA or greater than 20 mA. H. A control program that controls multiple pieces of equipment shall not be prevented from running because not all of the equipment is in AUTO. If equipment within an equipment chain is required to be running for program operation and it is running in HAND or MANUAL, then the program shall run and control the other equipment that is in AUTO. I. All PLC wait states (internal time delays, etc.) after an operator action shall be displayed on the operator workstation. PART 3 -- FUNCTIONAL CONTROL DESCRIPTIONS – HICKORY CREEK DETENTION FACILITY PART 3 – TABLE OF CONTENTS 3.01 3.02 3.03 3.04 3.05 DIVERSION STRUCTURE SUBMERSIBLE NON-CLOG PUMPS STORAGE TANK ODOR CONTROL SYSTEM TANK WASHDOWN SYSTEM 3.01 DIVERSION STRUCTURE A. Process Overview One new diversion structure shall be provided. B. Control Equipment City of Denton Hazen and Sawyer BID SET 17950-4 Functional Control Descriptions 1. One submersible level (pressure) sensor and associated equipment shall be provided as specified in Section 17749. 3.02 SUBMERSIBLE NON-CLOG PUMPS A. Process Overview Four (three duty and one standby) submersible non-clog pumps shall be provided for Hickory Creek Detention Facility Pump Station as specified in Section 11130. B. Control Equipment 1. Reduced Voltage Soft Starter (RVSS) units provided for each pump under Division 16 shall include: a. RVSS starter b. HAND-OFF-AUTO selector switch c. START-STOP selector switch d. POWER ON indication light e. RUN indication light f. MOTOR HIGH TEMP indication light g. MOISTURE ALARM indication light h. BYPASS selector switch (HCDF-PMP-01 and HCDF-PMP-02 only) i. IN BYPASS indication light (HCDF-PMP-01 and HCDF-PMP-02 only) j. Dry contacts and interposing relays as required to interface with the PLC 2. Each pump shall be provided with a discharge pressure switch and pressure gauge under Division 17. 3. The pump station wet well shall be provided with two level switches (suspended float type) as specified in Section 17670. 4. The pump station wet well shall be provided with one ultrasonic level transmitter and associated transducer as specified in Section 17740. 5. PLC-HCDF shall monitor and control the submersible non-clog pumps and related equipment (see Section 17920 Input/Output Schedule). 6. A backup level switch relay control panel shall be provided under Division 16. C. Control Operation 1. When the RVSS H-O-A switch is in HAND, the local START-STOP switch shall start and stop the pump. If the local START-STOP switch is in the STOP position the pump shall not operate regardless of H-O-A switch position. 2. When the RVSS H-O-A switch is in AUTO, the PLC shall control the pumps. The control system shall allow control of the pumps either manually via the OWS or automatically. The operator shall select the operating mode via the OWS. City of Denton Hazen and Sawyer BID SET 17950-5 Functional Control Descriptions 3. Under PLC control, if a pump fails to start or fails while operating, it shall be placed in standby and another pump shall immediately be started in its place. Initial starting of a replacement pump due to the failure of another pump shall occur in accordance with the wet well level control set points described herein. 4. If a "Fail" or "Fail to START" alarm is indicated at the PLC for a given pump, the PLC shall remove the START or RUN command from that pump. The PLC shall prohibit the starting of a given pump when a “Fail” alarm is being indicated to the PLC for that pump. 5. Pumps shall be stopped in all operating modes upon high discharge pressure signal or any failure condition detected by the motor protection relay, including thermal overload and motor over-temp. Manual reset shall be required after failure conditions. 6. If the ultrasonic level transmitter fails or reports loss of signal to the PLC, the pumps shall be controlled by the backup level switches (LSH-1400 and LSL-1400) via a relay panel. Relay panel shall be provided under Division 16. 7. Pumps No. 1 (HCPF-PMP-01) and No. 2 (HCPF-PMP-02) shall have the ability to bypass the RVSS. This control shall be manually initiated at the respective control panels. D. PLC Pump Control 1. In AUTO mode, the pump station shall operate as follows. The pumps in HCDFPS will be operated at constant speed in a fill draw mode based on water levels in the wet well provided by the ultrasonic level transmitter (LE/LIT-1400). When the water reaches a pre-determined elevation, a single pump will start and draw the water level down to a pump shut-off level. If the water level continues to rise with one pump operating, a second pump will start and additional pumps as necessary will start until the water level in the wet well drops. As the water level drops in the wet well, the pumps will shut down at incremental shut-off levels, so the pumping rate decreases slowly rather than all pumps shutting off simultaneously. The pump that has been running the longest will shut down first to prevent cycling of a single pump. Using this approach, the amount of flow coming to the pump station will dictate how many pumps will operate. 3.03 STORAGE TANK A. Process Overview One new storage tank shall be provided. B. Control Equipment 1. Local controls provided under other Divisions shall include City of Denton Hazen and Sawyer BID SET 17950-6 Functional Control Descriptions a. LOCAL-OFF-REMOTE selector switch at each tank drain motor operated valve b. POSITION hand switch at tank drain flow valve c. OPEN-CLOSE hand switch at tank drain isolation valve 2. One level switch (suspended float type) shall be provided as specified in Section 17670. 3. One ultrasonic level transmitter and associated transducer shall be provided as specified in Section 17740. 4. PLC-HCDF shall monitor and control the storage tank draining and related equipment (see Section 17920 Input/Output Schedule). C. Control Operation 1. For MOV-2202, when the L-O-R switch is in LOCAL, the local POSITION switch shall control the position of the tank drain flow control valve. When the L-O-R switch is in REMOTE, the valve shall be controlled by the PLC. 2. For MOV-2201, when the L-O-R switch is in LOCAL, the local OPEN-CLOSE switch shall control the position of the tank drain isolation valve. When the L-O-R switch is in REMOTE, the valve shall be controlled by the PLC. 2. Under PLC control, the tank drain sequence shall operate as follows. D. PLC Storage Tank Drain Control 1. In REMOTE mode, the tank drain sequence shall be started remotely through SCADA. The tank drain valve shall initially open to an adjustable “start-up” position. When the tank drain valve has reached its “start-up” position, the tank drain isolation valve shall open. After a time delay (adjustable), the tank drain valve shall modulate to maintain a level set point in the diversion structure based on the level feedback from PE/LT-2500. The tank drain sequence shall be stopped and the tank drain valve shall close when the level in the storage tank reaches a low level set point from the ultrasonic level transmitter LE/LIT-2400. 3.04 ODOR CONTROL SYSTEM A. Process Overview 1. An activated carbon odor control system, including fan and associated control panel shall be provided under Division 13. B. Control Equipment 1. See specification Section 13252 for manufacturer supplied control equipment. C. Control Operation City of Denton Hazen and Sawyer BID SET 17950-7 Functional Control Descriptions 1. In AUTO mode, the odor control system shall start when the pump station comes online and shall run until an operator manually shuts it down after the tank washdown cycle is complete. 2. See Section 13252 for manufacturer provided system protection interlocks. 3.05 TANK WASHDOWN SYSTEM A. Process Overview 1. Tank washdown system, including booster pump skid and tank cleaning system, shall be provided under Division 11 and Division 13, respectively. B. Control Equipment 1. See specification Section 11901 and 13217 for manufacturer supplied control equipment. C. Control Operation 1. The washdown cycle shall be a manually initiated cycle, either locally or through SCADA. When booster pumps are in AUTO mode, the washdown cycle can be initiated through SCADA and will run for an adjustable time period (initially set at _?). When the booster pumps are in HAND mode, the pumps shall be operated by locally through Start/Stop switches located on VCP-2000. 2. See Section 11901 for manufacturer provide control panel pump protection interlocks. PART 4 -- FUNCTIONAL CONTROL DESCRIPTIONS – WEST PEAK FLOW PUMP STATION PART 4 – TABLE OF CONTENTS 4.01 4.02 DIVERSION STRUCTURE SUBMERSIBLE NON-CLOG PUMPS 4.01 DIVERSION STRUCTURE A. Process Overview One new diversion structure shall be provided. 4.02 SUBMERSIBLE NON-CLOG PUMPS A. Process Overview City of Denton Hazen and Sawyer BID SET 17950-8 Functional Control Descriptions Three (two duty and one standby) submersible non-clog pumps shall be provided for West Peak Flow Pump Station as specified in Section 11130. B. Control Equipment 1. Reduced Voltage Soft Starter (RVSS) units provided for each pump under Division 16 shall include: a. RVSS starter b. HAND-OFF-AUTO selector switch c. START-STOP selector switch d. POWER ON indication light e. RUN indication light f. MOTOR HIGH TEMP indication light g. MOISTURE ALARM indication light h. BYPASS selector switch (WPF-PMP-01 only) i. IN BYPASS indication light (WPF-PMP-01 only) j. Dry contacts and interposing relays as required to interface with the PLC 2. Each pump shall be provided with a discharge pressure switch and pressure gauge under Division 17. 3. The pump station wet well shall be provided with two level switches (suspended float type) as specified in Section 17670. 4. The pump station wet well shall be provided with one ultrasonic level transmitter and associated transducer as specified in Section 17740. 5. PLC-WPF shall monitor and control the submersible non-clog pumps and related equipment (see Section 17920 Input/Output Schedule). 6. A backup level switch relay control panel shall be provided under Division 16. C. Control Operation 1. When the RVSS H-O-A switch is in HAND, the local START-STOP switch shall start and stop the pump. If the local START-STOP switch is in the STOP position the pump shall not operate regardless of H-O-A switch position. 2. When the RVSS H-O-A switch is in AUTO, the PLC shall control the pumps. The control system shall allow control of the pumps either manually via the OWS or automatically. The operator shall select the operating mode via the OWS. 3. Under PLC control, if a pump fails to start or fails while operating, it shall be placed in standby and another pump shall immediately be started in its place. Initial starting of a replacement pump due to the failure of another pump shall occur in accordance with the wet well level control set points described herein. 4. If a "Fail" or "Fail to START" alarm is indicated at the PLC for a given pump, the PLC shall remove the START or RUN command from that pump. The PLC shall prohibit City of Denton Hazen and Sawyer BID SET 17950-9 Functional Control Descriptions the starting of a given pump when a “Fail” alarm is being indicated to the PLC for that pump. 8. Pumps shall be stopped in all operating modes upon high discharge pressure signal or any failure condition detected by the motor protection relay, including thermal overload and motor over-temp. Manual reset shall be required after failure conditions. 9. If the ultrasonic level transmitter fails or reports loss of signal to the PLC, the pumps shall be controlled by the backup level switches (LSH-3400 and LSL-3400) via a relay panel. Relay panel shall be provided under Division 16. 10. Pump No. 1 (WPF-PMP-01) shall have the ability to bypass the RVSS. This control shall be manually initiated at the respective control panels. D. PLC Pump Control 1. In AUTO mode, the pump station shall operate as follows. The pumps in WPFPS will be operated at constant speed in a fill draw mode based on water levels in the wet well provided by the ultrasonic level transmitter (LE/LIT-3400). When the water reaches a pre-determined elevation, a single pump will start and draw the water level down to a pump shut-off level. If the water level continues to rise with one pump operating, a second pump will start and additional pumps as necessary will start until the water level in the wet well drops. As the water level drops in the wet well, the pumps will shut down at incremental shut-off levels, so the pumping rate decreases slowly rather than all pumps shutting off simultaneously. The pump that has been running the longest will shut down first to prevent cycling of a single pump. Using this approach, the amount of flow coming to the pump station will dictate how many pumps will operate. - END OF SECTION – City of Denton Hazen and Sawyer BID SET 17950-10 Functional Control Descriptions This page left blank intentionally