Loading...
The URL can be used to link to this page
Your browser does not support the video tag.
BCRUA_R-23-03-22-6C - 3/22/2023
REQUEST FOR COMPETITIVE SEALED PROPOSALS (RFP) FOR BCRUA PHASE 1D WATER TREATMENT PLANT EXPANSION ISSUED FOR BID Date Issued: January 17, 2023 Due Date: February 28, 2023 Time Due: 2:00 PM CST Location: 221 E. Main St. Round Rock, TX 78664 TBPE Registration No. 8053 Texas Registered Engineering Firm F-2144 01-17-2023 1 3 BCRUA – Phase 1D WTP Expansion Section 00001 – Titles and Certifications Issued for Bid Page - 1 - of 1 Titles and Certifications ENGINEER Walker Partners, LLC 6504 Bridge Point Parkway, Suite 200 Austin, Texas 78730 Firm Registration Number: 8053 Freese and Nichols, Inc. 10431 Morado Circle, Suite 300 Austin, Texas 78759 Firm Registration Number: 2144 Schnabel Engineering, LLC 12301 Research Blvd, Bldg 4, Suite 150 Austin, TX 78759 Firm Registration Number: 17846 BCRUA – Phase 1D WTP Expansion Section 00002 – Table of Contents Issued for Bid Page - 1 - of 7 TABLE OF CONTENTS INTRODUCTORY INFORMATION 00000 Title Page 00001 Titles and Certifications 00002 Table of Contents DIVISION 00 – PROPOSAL REQUIREMENTS, CONTRACT FORMS, & CONDITIONS OF THE CONTRACT 00100 Advertisement for Proposals (Revised by AD-01 & AD-02) 00200 Instructions to Proposers (Revised by AD-02) 00220 Geotechnical Data Phase 1D Geotechnical Memorandum 00300 Proposal Form (Reissued by AD-02) 00300A Conflict of Interest Questionnaire 00300B Certificate of Interested Parties 00400 Statement of Proposer’s Experience TWDB-0459 Vendor Compliance with Reciprocity on Non-Resident Bidders TWDB-0552 Supplemental Contract Conditions and Instructions 00500 Agreement ED-103 Contractor’s Act of Assurance ED-104 Contractor’s Act of Assurance Resolution 00510 Notice of Award 00520 Notice to Proceed 00610 Performance Bond 00620 Payment Bond 00700 General Conditions 00700A General Conditions - Exhibit A – Owner’s Insurance Requirements Certificate of Liability Insurance 00800 Supplemental General Conditions 00900 Addenda 01 - 03 DIVISION 01 – GENERAL REQUIREMENTS 01 10 00 Summary of Work and Operational Requirements 01 20 00 Price and Payment Procedures 01 21 00 Proposal Items: Scope of Work 01 25 00 Substitution Procedures 01 30 00 Administrative Requirements 01 32 16 Construction Progress Schedule 01 33 00 Submittal Procedures 01 40 00 Quality Requirements 01 40 01 IBC Special Inspections 01 50 00 Temporary Facilities and Controls (Revised by AD-03) 01 60 00 Product Requirements 01 61 03 Common Requirements for Equipment 01 70 00 Execution and Closeout Requirements 01 73 20 Openings and Penetrations in Construction 01 73 29 Demolition, Cutting and Patching 01 91 00 Facility Commissioning BCRUA – Phase 1D WTP Expansion Section 00002 – Table of Contents Page - 2 - of 7 Issued for Bid DIVISION 03 – CONCRETE 03 11 00 Concrete Forming 03 21 00 Reinforcing Steel 03 30 00 Cast-In-Place Concrete DIVISION 05 – METALS 05 50 00 Metal Fabrications 05 52 00 Metal Railings DIVISION 07 – THERMAL AND MOISTURE PROTECTION 07 92 00 Joint Sealants DIVISION 09 – FINISHES 09 96 00 High-Performance Coatings DIVISION 10 – SPECIALTIES 10 14 00 Identification for Process Piping and Equipment DIVISION 23 – HEATING, VENTILATING, AND AIR CONDITIONING (HVAC) 23 00 00 Heating, Ventilating and Air Conditioning 23 05 13 Common Motor Requirements for HVAC Equipment 23 05 53 Identification for HVAC 23 05 93 Testing, Adjusting, and Balancing for HVAC 23 21 13 Condensate Piping 23 74 09 Rooftop Air Conditioners DIVISION 26 – ELECTRICAL 26 01 26 Testing of Electrical Systems (Revised by AD-02) 26 05 00 Common Work Results for Electrical 26 05 19 Low Voltage Electrical Conductors and Cables (Revised by AD-02) 26 05 26 Grounding and Bonding for Electrical Systems 26 05 29 Hangers and Supports for Electrical Systems 26 05 33 Raceway and Boxes for Electrical Systems 26 05 53 Identification for Electrical Systems 26 05 73 Power System Study 26 22 00 Low Voltage Transformers 26 24 19 Low Voltage Motor Control Centers 26 27 26 Wiring Devices 26 28 16 Enclosed Switches and Circuit Breakers 26 29 13.01 Industrial Control Panels 26 29 23 Low Voltage Variable Frequency Drives (Revised by AD-02) 26 41 13 Lightning Protection for Structures 26 50 00 Lighting BCRUA – Phase 1D WTP Expansion Section 00002 – Table of Contents Page - 3 - of 7 Issued for Bid DIVISION 31 – EARTHWORK 31 05 13 Topsoil 31 10 00 Site Clearing 31 23 10 Structural Excavation and Backfill 31 23 15 Trench Safety Systems 31 23 17 Trenching 31 23 23 Fill 31 23 24 Flowable Fill 31 25 12 Storm Water Pollution Prevention DIVISION 32 – EXTERIOR IMPROVEMENTS 32 05 16 Aggregates for Civil Site Improvements 32 11 23 Flexible Base 32 12 16 Hot Mix Asphaltic Concrete Paving 32 13 13 Concrete Paving 32 91 19 Landscape Grading 32 92 19 Seeding DIVISION 33 – UTILITIES 33 05 17 Precast Concrete Valve Vaults 33 13 13 Potable Water Facility Disinfection 33 16 33 Prestressed Concrete Water Storage Tanks (Revised by AD-02) DIVISION 40 – PROCESS INTEGRATION 40 05 00 Common Requirements for Process Piping (Revised by AD-02) 40 05 06 Couplings, Adapters, and Specials for Process Piping 40 05 07 Hangers and Supports for Process Piping 40 05 17 Copper Process Pipe and Tubing 40 05 19 Ductile Iron Process Pipe 40 05 23 Stainless Steel Process Pipe and Tubing 40 05 24 Steel Process Pipe 40 05 31 Thermoplastic Process Pipe 40 05 40 Process Piping Leakage Testing and Disinfection 40 05 51 Common Requirements for Process Valves 40 05 57 Actuators for Process Valves 40 05 59.23 Fabricated Stainless Steel Slide Gates (Reissued by AD-02) 40 05 59.33 Cast Iron Slide Gates (Revised by AD-02) 40 05 61 Gate Valves 40 05 62 Plug Valves 40 05 63 Ball Valves 40 05 64 Butterfly Valves 40 05 65 Check Valves 40 05 81 Miscellaneous Valves 40 42 13 Process Piping Insulation 40 90 00 Process Control and Instrumentation Systems - General Provisions 40 90 01 Instrumentation (Revised by AD-02) 40 90 02 Supervisory Control and Data Acquisition (SCADA) System (Revised by AD-02 & 03) BCRUA – Phase 1D WTP Expansion Section 00002 – Table of Contents Page - 4 - of 7 Issued for Bid 40 90 02.01 SCADA Loop Descriptions (Reissued by AD-02) DIVISION 41 – MATERIAL PROCESSING AND HANDLING EQUIPMENT 41 12 13 Shaftless Screw Conveyors (Revised by AD-02) DIVISION 43 – PROCESS GAS AND LIQUID HANDLING, PURIFICATION AND STORAGE EQUIPMENT 43 21 00 Common Requirements for Pumping Equipment 43 41 43 Crosslinked Polyethylene Tanks DIVISION 46 – WATER AND WASTEWATER EQUIPMENT 46 25 40 Rotating Pipe Skimmer 46 33 44 Peristaltic Transfer Pumps 46 33 73 Liquid Chemical Diffusers 46 41 34 Vertical Shaft Flocculators 46 43 11 Chain and Flight Sludge Collection Equipment (Revised by AD-02) 46 61 01 Filter Underdrain System 46 61 13 Filter Media 46 61 19 Wash Water Troughs 46 71 13 Circular Gravity Thickener Equipment (Revised by AD-02) 46 76 21 Belt Filter Press (Revised by AD-02 & AD-03) BCRUA – Phase 1D WTP Expansion Section 00002 – Table of Contents Page - 5 - of 7 Issued for Review THE FOLLOWING SPECIFICATIONS WERE PREPARED BY ME OR UNDER MY DIRECTION: DIVISION 01 – GENERAL REQUIREMENTS 01 40 01 IBC Special Inspections DIVISION 03 – CONCRETE 03 11 00 Concrete Forming 03 21 00 Reinforcing Steel 03 30 00 Cast-In-Place Concrete DIVISION 05 – METALS 05 50 00 Metal Fabrications 05 52 00 Metal Railings DIVISION 07 – THERMAL AND MOISTURE PROTECTION 07 92 00 Joint Sealants DIVISION 31 – EARTHWORK 31 23 10 Structural Excavation and Backfill 10/24/2022 Freese and Nichols, Inc. Texas Registered Engineering Firm F-2144 01/12/2023 Issued for Bid BCRUA – Phase 1D WTP Expansion Section 00002 – Table of Contents Page - 6 - of 7 Issued for Bid THE FOLLOWING SPECIFICATIONS WERE PREPARED BY ME OR UNDER MY DIRECTION: DIVISION 23 – HEATING, VENTILATING, AND AIR CONDITIONING (HVAC) 23 00 00 Heating, Ventilating and Air Conditioning 23 05 13 Common Motor Requirements for HVAC Equipment 23 05 53 Identification for HVAC 23 05 93 Testing, Adjusting, and Balancing for HVAC 23 21 13 Condensate Piping 23 74 09 Rooftop Air Conditioners 01/12/2023 BCRUA – Phase 1D WTP Expansion Section 00002 – Table of Contents Page - 7 - of 7 Issued for Bid THE FOLLOWING SPECIFICATIONS WERE PREPARED BY ME OR UNDER MY DIRECTION: DIVISION 26 – ELECTRICAL 26 01 26 Testing of Electrical Systems 26 05 00 Common Work Results for Electrical 26 05 19 Low Voltage Electrical Conductors and Cables 26 05 26 Grounding and Bonding for Electrical Systems 26 05 29 Hangers and Supports for Electrical Systems 26 05 33 Raceway and Boxes for Electrical Systems 26 05 53 Identification for Electrical Systems 26 05 73 Power System Study 26 22 00 Low Voltage Transformers 26 24 19 Low Voltage Motor Control Centers 26 27 26 Wiring Devices 26 28 16 Enclosed Switches and Circuit Breakers 26 29 13.01 Industrial Control Panels 26 29 23 Low Voltage Variable Frequency Drives 26 41 13 Lightning Protection for Structures 26 50 00 Lighting DIVISION 40 – PROCESS INTEGRATION 40 90 00 Process Control and Instrumentation Systems - General Provisions 40 90 01 Instrumentation 40 90 02 Supervisory Control and Data Acquisition (SCADA) System 40 90 02.01 SCADA Loop Descriptions 01-13-2023 PROPOSAL REQUIREMENTS, CONTRACT FORMS, & CONDITIONS OF THE CONTRACT SECTIONS 00100 - 00900 PHASE 1D - WATER TREATMENT PLANT EXPANSION BCRUA – Phase 1D WTP Expansion Section 00100 – Advertisement for Proposals Issued for Bid (Revised by AD-01 & AD-02) Page 1 of 2 ADVERTISEMENT FOR PROPOSALS (Revised by AD-01 & AD-02) The BRUSHY CREEK REGIONAL UTILITY AUTHORITY (OWNER) will receive COMPETITIVE SEALED PROPOSALS for the Phase 1D Water Treatment Plant Expansion until 2:00 PM local time on February 21, 2023 February 28, 2023 (AD-02), at the City of Round Rock City Hall, 221 E. Main St., Round Rock, Texas, 78664. The PROPOSALS shall be sealed and addressed to: Brushy Creek Regional Utility Authority Attn: Karen Bondy, General Manager 221 E. Main St. Round Rock, TX 78664 The PROPOSALS will be publicly opened and read aloud at the City Hall in Round Rock, Texas on February 21, 2023 February 28, 2023 (AD-02), at 2:00 PM local time. PROPOSALS received after this time will not be accepted. PROPOSALS are invited for the items and scope of work as follows: The Work includes furnishing of labor, materials, equipment, and services for construction of an expansion to the existing Brushy Creek Regional Utility Authority (BCRUA) Water Treatment Plant (WTP) from a current rated capacity of 32.5 million gallons per day (MGD) to a proposed capacity of 42 MGD, as specified and detailed in the Contract Documents. Instructions to Proposers, Proposal Forms, Specifications, and Contract Documents may be examined or obtained electronically beginning January 17, 2023, at www.civcastusa.com (Project Name = “BCRUA Phase 1D WTP Expansion”) or for viewing only at the City of Round Rock City Hall, 221 E. Main St., Round Rock, Texas, 78664. Construction services for this project will be selected through competitive sealed proposals in accordance with Chapter 2269, of the Texas Government Code. The Owner will evaluate and rank the contractors based on the following selection criteria: 30% Contractor Relevant Experience and References, 60% Cost Proposal and 10% proposed schedule. The Owner shall select the contractor that offers the best value as determined by the selection criteria and ranking evaluation. The estimated total construction budget for this project is $18 Million. Owner reserves the right to reject any or all Proposals. Each PROPOSAL must be accompanied by Proposal Security made payable to OWNER in an amount of five percent (5%) of PROPOSER's total amount Proposal and in the form of a certified or cashier's check or a Bond issued by a surety meeting the requirements of Paragraph 6.01 of the General Conditions. BCRUA – Phase 1D WTP Expansion Section 00100 – Advertisement for Proposals Issued for Bid (Revised by AD-01 & AD-02) Page 2 of 2 A mandatory Pre-Proposal Conference for this project will be held on January 31, 2023 February 7, 2023 (AD-01), at 2:00 p.m. local time at the BCRUA WTP, 1906 Hur Industrial Blvd, Main Conference Room, Cedar Park, Texas, 78613. A voluntary site visit will be conducted after the Pre-Proposal Conference. During the pendency of this RFP, Proposer shall not contact any Owner staff except those designated herein this RFP or subsequent addenda or correspondence. Any questions or concerns should be submitted via the CIVCAST website after the Advertisement and at least five (5) business days prior to the Due Date (on or before Tuesday, February 14, 2023 Tuesday, February 21, 2023 (AD-02)). The Contract Documents referenced in the Request for Competitive Sealed Proposals, and which are the subject of a Proposal submitted in response thereof, including but not limited to the form of the Agreement and the General Conditions, are forms adopted by the Brushy Creek Regional Utility Authority and are not subject to negotiation, modification or change unless the Brushy Creek Regional Utility Authority, in its sole discretion, agrees to do so. Paragraph 6.01 of the General Conditions set forth OWNER’S requirements as to performance and payment Bonds. When the Successful PROPOSER delivers the executed Agreement to ENGINEER, the required Bonds must be delivered in accordance with Paragraph 2.01 of the General Conditions. This contract is contingent upon release of funds from the Texas Water Development Board. Additionally, Owner intends to use American Rescue Plan funds for fees and costs associated with this Project. The Owner will be required to comply with the requirements of 2 CFR Part 200 and other applicable federal requirements related to the procurements and expenditure of fees and costs related to this Project. Brushy Creek Regional Utility Authority BCRUA – Phase 1D WTP Expansion Section 00200 – Instructions to Proposers Issued for Bid (Revised by AD-02) Page 1 of 11 INSTRUCTIONS TO PROPOSERS (Revised by AD-02) 1. Defined Terms Terms used in these Instructions to Proposers are defined in Section 00700 - General Conditions of the Construction Contract. Certain additional terms used in these Instructions to Proposers have the meanings indicated below which are applicable to both the singular and plural thereof. 1.1. PROPOSER - one who submits a Proposal directly to OWNER as distinct from a sub-PROPOSER, who submits a Proposal to a PROPOSER. 1.2. Issuing Office - the office from which the Proposal Documents are to be issued and where the Proposal procedures are to be administered. 1.3. Successful PROPOSER - the PROPOSER to whom OWNER (on the basis of OWNER's evaluation as hereinafter provided) makes an award. 2. Copies of Proposal Documents 2.1. Complete sets of the Proposal Documents may be obtained in accordance with the Advertisement for PROPOSALS. 2.2. Complete sets of Proposal Documents must be used in preparing PROPOSALS; neither OWNER nor ENGINEER assume any responsibility for errors or misinterpretations resulting from the use of incomplete sets of Proposal Documents or otherwise associated with the Proposal Documents. 2.3. OWNER and ENGINEER, in making copies of Proposal Documents available on the above terms, do so only for the purpose of obtaining PROPOSALS for the Work and do not confer a license or grant for any other use. Ownership of the Proposal Documents shall remain with the OWNER. 3. Qualifications of PROPOSERS To demonstrate qualifications to perform the Work, each PROPOSER must submit with PROPOSAL, detailed written evidence such as previous experience, present commitments, any pending litigations related to construction contracts, and proof that the PROPOSER has the personnel, equipment, and material to execute the work required by the Contract Documents or any other such data as may be called for below. PROPOSER is to provide a list of projects completed within the last 5 years, which are comparable to this project. Each PROPOSAL must contain evidence of PROPOSER'S qualification to do business in the area where the Project is located. Contractor must provide experience and qualifications of key personnel including the Project Manager or BCRUA – Phase 1D WTP Expansion Section 00200 – Instructions to Proposers Issued for Bid (Revised by AD-02) Page 2 of 11 Superintendent. Contractor must ensure company employee (Project Manager or Superintendent) is available on-site during all construction activities. 4. Examination of Contract Documents and Site 4.1. It is the responsibility of each PROPOSER, before submitting a PROPOSAL: 4.1.1. To examine thoroughly the Contract Documents and other related data identified in the Proposal Documents (including "technical data" referred to below); 4.1.2. To visit the site to become familiar with and satisfy PROPOSER as to the general, local, and site conditions that may affect cost, progress, performance, or furnishing of the Work; 4.1.3. To consider federal, state, and local Laws and Regulations that may affect cost, progress, performance, or furnishing of the Work; 4.1.4. To study and carefully correlate PROPOSER's knowledge and observations with the Contract Documents and such other related data; and 4.1.5. To promptly notify ENGINEER and OWNER of all conflicts, errors, ambiguities or discrepancies which PROPOSER has discovered in or between the Contract Documents and such other related documents. 4.2. Reference is made to the General Conditions for identification of: 4.2.1. Those reports of explorations and tests of subsurface conditions at or contiguous to the site which have been utilized by ENGINEER in preparation of the Contract Documents. PROPOSER may rely upon the general accuracy of the "technical data" contained in such reports but not upon other data, interpretations, opinions, or information contained in such reports or otherwise relating to the subsurface conditions at the site, nor upon the completeness thereof for the purposes of Proposal or construction. OWNER AND ENGINEER EXPRESSLY DISCLAIM ANY AND ALL WARRANTIES THAT THE INFORMATION, DATA, INTERPRETATIONS, AND OPINIONS SHOWN, INDICATED, OR CONTAINED IN THE PLANS ARE ACCURATE, CORRECT, COMPLETE, OR FIT FOR THEIR INTENDED PURPOSES. 4.2.2. Those drawings of physical conditions in or relating to existing surface and subsurface structures (except Underground Facilities), which are at or contiguous to the site that have been utilized by ENGINEER in BCRUA – Phase 1D WTP Expansion Section 00200 – Instructions to Proposers Issued for Bid (Revised by AD-02) Page 3 of 11 preparation of the Contract Documents. PROPOSER may rely upon the general accuracy of the "technical data" contained in such drawings but not upon other data, interpretations, opinions, or information shown or indicated in such PLANS or otherwise relating to such structures, nor upon the completeness thereof for the purposes of Proposal or construction. OWNER AND ENGINEER EXPRESSLY DISCLAIM ANY AND ALL WARRANTIES THAT THE INFORMATION, DATA, INTERPRETATIONS, AND OPINIONS SHOWN, INDICATED, OR CONTAINED IN THE DRAWINGS ARE ACCURATE, CORRECT, COMPLETE, OR FIT FOR THEIR INTENDED PURPOSES. Copies of such reports and PLANS will be made available by OWNER to any PROPOSER on request. Those reports and drawings are not part of the Contract Documents, but the "technical data" contained therein upon which PROPOSER is entitled to rely as provided in Paragraph 5.03 of the General Conditions. PROPOSER is responsible for any interpretation or conclusion drawn from any "technical data" or any such data, interpretations, opinions, or information. 4.3. Information and data shown or indicated in the Contract Documents with respect to existing Underground Facilities at or contiguous to the site is based on information and data furnished to OWNER and ENGINEER by owners of such Underground Facilities or others, and OWNER and ENGINEER do not assume responsibility for the accuracy or completeness thereof. OWNER AND ENGINEER EXPRESSLY DISCLAIM ANY AND ALL WARRANTIES THAT THE INFORMATION, DATA, INTERPRETATIONS, AND OPINIONS SHOWN, INDICATED, OR CONTAINED IN THE PLANS ARE ACCURATE, CORRECT, COMPLETE, OR FIT FOR THEIR INTENDED PURPOSES. 4.4. Provisions concerning responsibilities for the adequacy of data furnished to prospective PROPOSERs with respect to subsurface conditions, other physical conditions and Underground Facilities, and possible changes in the Contract Documents due to differing or unanticipated conditions appear in Paragraph 5.03 through 5.06 of the General Conditions. 4.5. Before submitting a PROPOSAL, each PROPOSER will be responsible to obtain such additional or supplementary examinations, investigations, explorations, tests, studies, and data concerning conditions (surface, subsurface and Underground Facilities) at or contiguous to the site or otherwise, which may affect cost, progress, performance, or furnishing of the Work, or which relate to any aspect of the means, methods, techniques, sequences, or procedures of construction to be employed by PROPOSER and safety precautions and programs incident thereto or which PROPOSER deems necessary to determine its PROPOSAL for performing and furnishing the Work in accordance with the time, price, and other terms and conditions of the Contract Documents. BCRUA – Phase 1D WTP Expansion Section 00200 – Instructions to Proposers Issued for Bid (Revised by AD-02) Page 4 of 11 4.6. On request, OWNER will provide each PROPOSER access to the site to conduct such examinations, investigations, explorations, tests, and studies as each PROPOSER deems necessary for submission of a PROPOSAL. PROPOSER must fill all holes and clean up and restore the site to its former condition upon completion of such explorations, investigations, tests, and studies. 4.7. Reference is made to the Contract Documents for the identification of the general nature of work to be performed at the site by OWNER (if applicable) or others (such as utilities and other prime contractors) that relates to the Work for which a PROPOSAL is to be submitted. On request, OWNER will provide to each PROPOSER for examination, access to, or copies of, Contract Documents (other than portions thereof related to price) for such work. 4.8. The submission of a PROPOSAL will constitute an incontrovertible representation by PROPOSER that PROPOSER has complied with every requirement of this Article 4, that, without exception, the PROPOSAL is premised upon performing and furnishing the Work required by the Contract Documents, and applying the specific means, methods, techniques, sequences, or procedures of construction (if any) that may be shown or indicated or expressly required by the Contract Documents, the PROPOSER has given ENGINEER written notice of all conflicts, errors, ambiguities, and discrepancies that PROPOSER has discovered in the Contract Documents, and written resolutions thereof by ENGINEER are acceptable to PROPOSER, that the Contract Documents are generally sufficient to indicate and convey understanding of all terms and conditions for performing and furnishing the Work, that the PROPOSER has no questions regarding the Work, that the PROPOSER has all information necessary to make a fully informed PROPOSAL, and that the PROPOSER has conducted all tests at the site it deems necessary. 4.9. The provisions of 4.1 through 4.8, inclusive of this Article, do not apply to Asbestos, Polychlorinated biphenyls (PCBs), Petroleum, Hazardous Waste, or Radioactive Material covered by Paragraph 5.06 of the General Conditions. 5. Availability of Lands for Work, etc. The lands upon which the Work is to be performed, rights-of-way and easements for access thereto and other lands designated for use by CONTRACTOR in performing the Work are identified in the Contract Documents. All additional lands and access thereto required for temporary construction facilities, construction equipment, or storage of materials and equipment to be incorporated in the Work are to be obtained and paid for by CONTRACTOR. Easements for permanent structures or permanent changes in BCRUA – Phase 1D WTP Expansion Section 00200 – Instructions to Proposers Issued for Bid (Revised by AD-02) Page 5 of 11 existing facilities are to be obtained and paid for by OWNER unless otherwise provided in the Contract Documents. 6. Interpretations and Addenda 6.1. All questions about the meaning or intent of the Proposal Documents are to be directed to ENGINEER through the CIVCAST website (www.civcastusa.com). Interpretations or clarifications considered necessary by ENGINEER in response to such questions will be issued by Addenda and posted on the CIVCAST website. Questions received less than five (5) days prior to the date for opening of PROPOSALS may not be answered. Only questions answered by formal written Addenda will be binding. Oral and other interpretations or clarifications may not be relied upon and will not be binding upon OWNER or ENGINEER or legally effective. 6.2. Addenda may also be issued to modify the Proposal Documents as deemed advisable by OWNER or ENGINEER. 6.3 Addenda will be issued through the CIVCAST website. 7. Proposal Security 7.1. Each PROPOSAL must be accompanied by Proposal Security made payable to OWNER in an amount of five percent (5%) of PROPOSER's total amount Proposal and in the form of a certified or cashier's check or a Bond issued by a surety meeting the requirements of Paragraph 6.01 of the General Conditions. If a bid bond is provided, the Proposer shall utilize a surety company which is authorized to do business in Texas in accordance with Surety Bonds and Related Instruments, Chapter 3503 of the Insurance Cod. 7.2. The Proposal Security of Successful PROPOSER will be retained until such PROPOSER has executed the Agreement, furnished the required contract security, and met the other conditions of the Notice of Award, whereupon the Proposal Security will be returned. If the Successful PROPOSER fails to execute and deliver the Agreement and furnish the required contract security within ten (10) days after the Notice of Award, OWNER may annul the Notice of Award, and the Proposal Security of that PROPOSER will be forfeited. The Proposal Security of other PROPOSERs whom OWNER believes to have a reasonable chance of receiving the award may be retained by OWNER until the earlier of the seventh day after the Effective Date of the Agreement or the thirty-sixth day after the PROPOSAL opening, whereupon Proposal Security furnished by such PROPOSERs will be returned. Proposal Security with PROPOSALS which are not competitive will be returned within fourteen (14) days after the PROPOSAL opening. BCRUA – Phase 1D WTP Expansion Section 00200 – Instructions to Proposers Issued for Bid (Revised by AD-02) Page 6 of 11 8. U.S. Iron and Steel The contract awarded under this Request for Proposals is not subject to the United States Iron and Steel requirements of Texas Water Code 17.183 and/or Texas Government Code, Chapter 2252, Subchapter F, as amended by SB 1289, 85th Legislative Session because the TWDB funds were committed before May 1, 2019 (AD-02). 9. Contract Times The Contract Times are set forth in the Agreement. 10. Liquidated Damages Provisions for liquidated damages are set forth in the Agreement. 11. Substitute and "Or-Equal" Items The Contract, if awarded, will be on the basis of materials and equipment described in the PLANS or specified in the Specifications without consideration of possible substitute or "or-equal" items. Whenever it is indicated in the PLANS or specified in the Specifications that a substitute or "or-equal" item of material or equipment may be furnished or used by CONTRACTOR if acceptable to ENGINEER, application for such acceptance will not be considered by ENGINEER until after the Effective Date of the Agreement. The procedure for submission of any such application by CONTRACTOR and consideration by ENGINEER is set forth in Paragraphs 7.04 and 7.05 of the General Conditions. 12. Subcontractors, Suppliers, and Others 12.1. If the General Conditions require the identity of certain Subcontractors, Suppliers, and other persons and organizations (including those who are to furnish the principal items of material and equipment) to be submitted to OWNER in advance of a specified date prior to the Effective Date of the Agreement, apparent Successful PROPOSER, and any other PROPOSER so requested, shall submit with the Proposal a list of all such Subcontractors, Suppliers, and other persons and organizations proposed for those portions of the Work for which such identification is required. Such list shall be accompanied by an experience statement with pertinent information regarding similar projects and other evidence of qualification for each such Subcontractor, Supplier, person, or organization if requested by OWNER. An OWNER or ENGINEER who, after due investigation, has reasonable objection to any proposed Subcontractor, Supplier, other person, or organization may, before the Notice of Award is given, request the apparent Successful PROPOSER to submit an acceptable substitute without an increase in Proposal Price. BCRUA – Phase 1D WTP Expansion Section 00200 – Instructions to Proposers Issued for Bid (Revised by AD-02) Page 7 of 11 If the apparent Successful PROPOSER declines to make any such substitution, OWNER may award the contract to the next highest ranked PROPOSER that proposes to use acceptable Subcontractors, Suppliers, and other persons and organizations. Declining to make requested substitutions will not constitute grounds for sacrificing the Proposal Security of any PROPOSER. Any Subcontractor, Supplier, other person, or organization listed and to whom OWNER or ENGINEER does not make written objection prior to the giving of the Notice of Award will be deemed acceptable to OWNER and ENGINEER subject to revocation of such acceptance after the Effective Date of the Agreement as provided in the General Conditions. 12.2. The apparent Successful PROPOSER, prior to the Notice of Award, shall identify in writing to OWNER those portions of the Work that such PROPOSER proposes to subcontract and after the Notice of Award may only subcontract other portions of the Work with OWNER's written consent. 12.3. No CONTRACTOR shall be required to employ any Subcontractor, Supplier, other person, or organization against whom CONTRACTOR has reasonable objection. 13. Proposal Form 13.1. The Proposal Form is included with the Proposal Documents; additional copies may be obtained from the Issuing Office(s) described in the Request for Proposal. 13.2. All blanks on the Proposal Form must be completed by printing or typing in black ink. 13.3. PROPOSALS by corporations must be executed in the corporate name by the president or a vice-president (or other corporate officer accompanied by evidence of authority to sign) and the corporate seal must be affixed and attested by the secretary or an assistant secretary of the corporation. The corporate address and state of incorporation must be shown below the signature. If Corporation does not have a seal, a copy of the Corporate Resolution shall be attached. 13.4. PROPOSALS by partnerships must be executed in the partnership name and signed by a partner, whose title must appear under the signature, and the official address of the partnership must be shown below the signature. 13.5. All names must be typed or printed in black ink below the signature. BCRUA – Phase 1D WTP Expansion Section 00200 – Instructions to Proposers Issued for Bid (Revised by AD-02) Page 8 of 11 13.6. The PROPOSAL shall contain an acknowledgment of receipt of all Addenda (the numbers of which must be filled in on the Proposal Form). 13.7. The street and/or post office box address and telephone and/or fax number for communications regarding the PROPOSAL must be shown. 13.8. When applicable, evidence of authority to conduct business as an out-of- state corporation in the state where the Work is to be performed shall be provided in accordance with Paragraph 3 above. State contractor license number, if any, must also be shown. 14. Submission of PROPOSALS Each PROPOSAL shall be submitted at the time and place indicated in the Request for Proposal and shall be enclosed in an opaque sealed envelope, marked with the Project title and name and address of PROPOSER and accompanied by the Proposal Security and other required documents. If the PROPOSAL is sent through the mail or other delivery system, the sealed envelope shall be enclosed in a separate envelope with the notation "PROPOSAL ENCLOSED" on the face of it. 15. Modification and Withdrawal of PROPOSALS 14.1. PROPOSALS may be modified or withdrawn by an appropriate document duly executed (in the manner that a PROPOSAL must be executed) and delivered to the place where PROPOSALS are to be submitted at any time prior to the opening of PROPOSALS. 14.2. If, within twenty-four (24) hours after PROPOSALS are opened, any PROPOSER files a duly signed, written notice with OWNER and promptly thereafter demonstrates to the reasonable satisfaction of OWNER that there was a material and substantial mistake in the preparation of its PROPOSAL, that PROPOSER may withdraw its PROPOSAL and the Proposal Security will be returned. Thereafter, that PROPOSER will be disqualified from further Proposal on the Work to be provided under the Contract Documents. 16. Opening of PROPOSALS PROPOSALS will be opened and read aloud publicly at the place where PROPOSALS are to be submitted. An abstract of the amounts of the base PROPOSALS and major alternates (if any) will be made available to PROPOSERs after the opening of PROPOSALS. BCRUA – Phase 1D WTP Expansion Section 00200 – Instructions to Proposers Issued for Bid (Revised by AD-02) Page 9 of 11 17. PROPOSALS to Remain Subject to Acceptance All PROPOSALS will remain subject to acceptance for sixty (60) days after the day of the PROPOSAL opening, but OWNER may, in its sole discretion, release any PROPOSAL and return the Proposal Security prior to that date. 18. Award of Contract 18.1 This contract is contingent upon release of funds from the Texas Water Development Board. Any contract or contracts awarded under this Competitive Sealed Proposal is expected to be funded in part by a loan or grant from the Texas Water Development Board. Neither the state of Texas, nor any of its departments, agencies, or employees are or will be a party to this Request for Proposal or any resulting contract. 18.2. OWNER reserves the right to reject any or all PROPOSALS, including without limitation the right to reject any or all nonconforming, non-responsive, unbalanced, or conditional PROPOSALS and to reject the PROPOSAL of any PROPOSER if OWNER believes that it would not be in the best interest of the Project to make an award to that PROPOSER, whether because the PROPOSAL is not responsive or the PROPOSER is unqualified or of doubtful financial ability or fails to meet any other pertinent standard or criteria established by OWNER. OWNER also reserves the right to waive all informalities not involving price, time, or changes in the Work and to negotiate contract terms with the Successful PROPOSER. Discrepancies between the multiplication of units of Work and unit prices will be resolved in favor of the price that is most advantageous to the OWNER. Discrepancies between the indicated sum of any column of figures and the correct sum thereof will be resolved in favor of the correct sum. 18.3. In evaluating PROPOSALS, OWNER will consider the qualifications of PROPOSERs, whether or not, the PROPOSALS comply with the prescribed requirements, and such alternates, unit prices, and other data, as may be requested in the Proposal Form or prior to the Notice of Award. 18.4. OWNER may consider the qualifications and experience of Subcontractors, Suppliers, and other persons and organizations proposed for those portions of the Work as to which the identity of Subcontractors, Suppliers, and other persons and organizations must be submitted as provided in the General Conditions. OWNER also may consider the operating costs, maintenance requirements, performance data, and guarantees of major Items of materials and equipment proposed for incorporation in the Work when such data is required to be submitted prior to the Notice of Award. BCRUA – Phase 1D WTP Expansion Section 00200 – Instructions to Proposers Issued for Bid (Revised by AD-02) Page 10 of 11 18.5. OWNER may conduct such investigations as OWNER deems necessary to assist in the evaluation of any PROPOSAL and to establish the responsibility, qualifications and financial ability of PROPOSERs, proposed Subcontractors, Suppliers and other persons and organizations to perform and furnish the Work in accordance with the Contract Documents to OWNER's satisfaction within the prescribed time. 18.6. The OWNER may rank the PROPOSERS and award the Contract on the basis of any combination of Base Proposal items and additive alternative Proposal items consistent with the OWNER's available budget for the project. If the contract is to be awarded, it will be awarded, in accordance with Paragraph 1.3, to the highest ranked PROPOSER whose evaluation by OWNER indicates to OWNER that the award will be the best value to the OWNER. 18.7 Award of the contract, if awarded, will be made based upon the criteria set forth in Section 2269 of the Texas Government Code and any applicable requirements of 2 CFR Part 200 and any other applicable federal requirements. 18.8. If the contract is to be awarded, OWNER will give Successful PROPOSER a Notice of Award within sixty (60) days after the day of the PROPOSAL opening. 18.9 A governmental entity may not award a governmental contract to a nonresident bidder unless the nonresident underbids the lowest bid submitted by a responsible resident bidder by an amount that is not less than the amount by which a resident bidder would be required to underbid the nonresident bidder to obtain a comparable contract in the state in which the nonresident's principal place of business is located. A non-resident bidder is a Contractor whose corporate offices or principal place of business is outside of the state of Texas (Source: Texas Government Code, Chapter 2252, Subchapter A, Nonresident Bidders, §2252.002). The bidder will complete form TWDB-0459, Vendor Compliance with Reciprocity on Non-Resident Bidders, which must be submitted with the bid. 19. Contract Security Paragraph 6.01 of the General Conditions set forth OWNER's requirements as to performance and payment Bonds. When the Successful PROPOSER delivers the executed Agreement to ENGINEER, the required Bonds must be delivered in accordance with Paragraph 2.01 of the General Conditions. 20. Signing of Agreement When OWNER gives a Notice of Award to the Successful PROPOSER, it will be accompanied by the required number of unsigned counterparts of the Agreement with BCRUA – Phase 1D WTP Expansion Section 00200 – Instructions to Proposers Issued for Bid (Revised by AD-02) Page 11 of 11 all other written Contract Documents attached. Within ten (10) days thereafter, CONTRACTOR shall sign and deliver the required number of counterparts of the Agreement and attached documents to ENGINEER with the required Bonds. 21. Pre-Proposal Conference A mandatory Pre-Proposal conference will be held for this project. ENGINEER will transmit to all prospective PROPOSERs of record such Addenda as ENGINEER considers necessary in response to questions that arise during the Proposal process. Oral statements and other interpretations or clarifications not contained in an Addenda may not be relied upon and will not be binding on OWNER or ENGINEER or legally effective. 22. Taxes 21.1. CONTRACTOR shall pay all applicable sales, consumer, use, and other similar taxes except as exempted. 21.2. Sales tax. CONTRACTOR shall obtain the necessary documentation so that any sales tax exemptions due to the nature of the Work performed by CONTRACTOR or Subcontractors pursuant to this Agreement shall be applied to this Agreement, and these cost savings due to the Project's exempted status shall be passed on to OWNER. CONTRACTOR and each of its Subcontractors or sub-Subcontractors must obtain a Texas Limited Sales, Excise and Use Tax Permit for all materials required to be purchased in connection with the Project. 23. Retainage Provisions concerning retainage are set forth in the Agreement. 24. American Rescue Plan The OWNER intends to use American Rescue Plan funds for fees and costs associated with the contract. The OWNER will be required to comply with the requirements of 2 CFR Part 200 and other applicable federal requirements related to the procurements and expenditure of fees and costs related to the project. The Successful Proposer will be required to cooperate fully with the OWNER to comply with the applicable requirements. END OF SECTION BCRUA – Phase 1D WTP Expansion Section 00220 – Geotechnical Data Issued for Bid Page 1 of 1 GEOTECHNICAL DATA Depending on Project requirements, OWNER may have obtained geotechnical information, which may include laboratory test results, logs of borings, and recommendations from geotechnical consultants. Any information obtained was solely for use by ENGINEER in design of project and is not part of Contract. If soil borings have been prepared, they will be included in this section or on plans. Any geotechnical information included is for information only. OWNER does not guarantee accuracy or validity of soil investigation data, nor does OWNER assume any responsibility for CONTRACTOR interpretation or conclusions drawn from data. The CONTRACTOR is to be familiar with the subsurface materials and conditions on the Project and knowledgeable of how they will affect the Work. Information about subsurface materials and conditions is available from the following: a. Subcontractors familiar with local ground conditions; b. Local consulting geologists and geotechnical engineers; and c. Geotechnical information obtained by the OWNER for the design phase of the Project. A geotechnical study dated April 21, 2022 was performed by Schnabel Engineering. The report is titled “PHASE 1D GEOTECHNICAL MEMORANDUM” and it is attached to this Section. The CONTRACTOR may make his own subsurface investigations with approval of the Owner. End www.walkerpartners.com TBPE Registration No. 8053 │ TBPLS Registration Nos. 10032500 │ 10194373 │ 10194317 TECHNICAL MEMORANDUM Date: April 21, 2022 Project: BCRUA Phase 1D WTP Expansion To: Walker Partners, LLC From: Schnabel Engineering | Kemp Lewis, P.E. PHASE 1 D GEOTECHNICAL MEMORA NDUM 1.0 SCOPE OF SERVICES This draft technical memorandum covers two objectives: 1. Extract geotechnical data from the 2008 report prepared by Fugro Consultants, Inc. (Fugro) for Phase 1A of the Brushy Creek Regional Utility Authority (BCRUA) Water Treatment Plant (WTP). Using these data, evaluate the suitability of relevant recommendations in the Fugro report for the specific facilities to be constructed under the Phase 1D WTP expansion. A site visit to the WTP was also conducted to see the specific site and existing conditions. 2. Present the results of an additional geotechnical investigation conducted specifically for two Raw Water Head Tanks, which were not covered by the 2008 Fugro report. Provide geotechnical recommendations accordingly and in general conformance with the 2008 Fugro report for consistency across the project. 2.0 PROPOSED FACILITIES AND SITE DESCRIPTION 2.1 Proposed Facilities The Phase 1D WTP expansion includes the following facilities: Sedimentation Basin 4C, approximately 260 by 60 feet in plan area 1st Stage Sludge Thickener, approximately 60 feet in diameter Two Raw Water Head Tanks of 0.5 MG capacity each, 60 feet in diameter by 24 feet high The 225-foot diameter, 6 MG Clearwell was initially included in the Phase 1D expansion but has since been moved to a future phase. Our geotechnical review and recommendations of this structure are included herein in accordance with the agreed-upon scope of services. If there are changes to the structure size, location, or other critical details we should be consulted to review and revise our recommendations accordingly. Facility locations are shown on Figure 1 and specific conditions at each of the sites are shown in Photos 1-4. 4/21/2022 Firm No. 17846 – 2 – April 21, 2022 2.2 Site Description Site information for the water treatment plant was obtained from the BCRUA Phase 1C WTP Expansion Record Drawings plan dated August 15, 2018, prepared by Walker Partners and Freese and Nichols; from the BCRUA WTP Phase 1A Geotechnical Investigation report prepared by Fugro Consultants, Inc. dated June 2008 (included herewith as Appendix A); and through the site visits conducted on January 19 and March 17, 2022. The 75.1-acre site is located at the north terminus of Hur Industrial Boulevard, north of FM 1431. The original development at the site was the existing wastewater lift station located at the southern entrance onto the site at Hur Industrial Boulevard. Phase 1C construction added the new Sedimentation Basin 3C structure, Sludge Vault No. 2C, and various other ancillary structures. Sedimentation Basin 4C (see Photo 1) of the Central Treatment Structure, though covered by the Fugro Report, was not part of Phase 1C construction. In this area, fill was placed in accordance with the grading plan up to elevations between 1067 and 1073 feet. Per sheet SA-4, the structural fill for the Basin 3C foundation extends 10 feet beyond the edge of Basin 3C into the proposed Basin 4C footprint below the elevation of the Basin 4C bottom slab. The record drawings indicate that the remaining fill that was placed to achieve final grade outside of Basin 3C consists of compacted onsite soils. Sludge Vault No. 2C was constructed as part of Phase 1C construction and is approximately 4 feet outside the proposed south edge of Sedimentation Basin 4C according the sheet SA-2. According to the Sludge Vault No. 2C section view on sheet SA-10, structural fill was placed beneath the sludge vault at elevation 1058.2 feet to the top of weathered limestone. Photo 1. Looking west in the area of the proposed Sedimentation Basin 4C. EDGE OF SEDIMENTATION BASIN 3C APPROX LOCATION OF PROPOSED SEDIMENTATION BASIN 4C Sludge Vault No. 2C – 3 – April 21, 2022 During the site visit, the location of the proposed 6 MG Clearwell was also observed. The site appeared generally flat, dry, and covered with grass and a few trees as shown in Photo 2. An examination of historical Google Earth images shows that there was some material stockpiled at this site during WTP plant construction. However, based on the consistent presence of some of the mature trees observed in the images, it does not appear that the original site condition and grade have been markedly altered since the time of the Fugro report. Photo 2. Looking west in the area of the proposed 6 MG Clearwell During the site visit, the location of the proposed 1st Stage Sludge Thickener was also observed. The site appeared generally flat, dry, and covered with grass and a few trees as shown in Photo 3. This 1st Stage Sludge Thickener was addressed in our Phase 1C Geotechnical Memorandum dated October 3, 2017 and it appears that the site is generally in the same condition and grade as at the time of our Phase 1C Geotechnical Memorandum and the Fugro Report. This conclusion is strengthened by examination of historical Google Earth images, which show consistent presence of some of the original tree cover, indicating no significant modification of original ground contours. APPROX LOCATION OF PROPOSED 6 MG Clearwell – 4 – April 21, 2022 Photo 3. Looking north in the area of the proposed 1st Stage Sludge Thickener The location of the two Raw Water Head Tanks was observed during drilling of the geotechnical borings in January 2022. The site appeared generally flat, dry, and covered with grass as shown in Photo 4. Plant personnel reported that the site is muddy following rain events. The Raw Water Head Tanks will connect to existing 72-inch diameter raw water lines running east-west to the north of the tanks, at a clear distance of 12 feet. Phase 1C improvements included excavations up to the edge of the proposed Raw Water Head Tanks to install 72-inch diameter water lines in preparation for the future connections with the tanks. Site grades were returned to existing elevations as shown on the Phase 1C Record Drawings. 2nd STAGE SLUDGE THICKENER APPROX LOCATION OF PROPOSED 1st STAGE SLUDGE THICKENER – 5 – April 21, 2022 Photo 4. Looking west in the area of the proposed Raw Water Head Tanks while drilling B-2. 3.0 SUBSURFACE EXPLORATION PROGRAM The 2008 Phase 1A Fugro report (Appendix A) addressed exploration and recommendations for the construction of all four Sedimentation Basins of the Central Treatment Structure, for the 6 MG Clearwell, and for the 1st Stage Sludge Thickener. Table 1 lists the boring numbers applicable to these structures. For the two Raw Water Head Tanks which were not considered in the 2008 Fugro report, our subcontractor, Austin GeoLogic, drilled two test borings to a depth of 25 feet under our observation on January 19th, 2022. The Standard Penetration Test (SPT) was performed in accordance with ASTM D-1586 at selected depths in the borings. Where encountered, intact limestone rock was continuously core sampled in the borings. Appendix B includes the boring logs and general notes describing nomenclature for the boring logs and soil and rock identification and classification guidelines, and sampling protocols. Figure 1, included at the end of this report, indicates the approximate test boring locations. Summary information about these borings is included in Table 1. We will retain soil samples up to 45 days beyond the issuance of this report, unless you request other disposition. APPROX LOCATIONS OF PROPOSED Raw Water Head Tanks – 6 – April 21, 2022 Table 1: Borings Summary Boring Surface Elevation (ft) Drilled Depth (ft) Location Drill Date BTS-4 1061.2 29.5 Southwest End of Central Treatment Structure 5/22/2007 BTS-5 1062.9 29.5 South-central end of Central Treatment Structure 5/22/2007 BTS-6 1064.8 29.5 Southeast End of Central Treatment Structure 5/17/2007 CLL-1 1052 49.5 NW end of 6 MG Clearwell Structure 8/20/2007 CLL-2 1053 49.5 SE end of 6 MG Clearwell Structure 8/20/2007 ST1-1 1058.8 19.5 1st Stage Sludge Thickener 3/26/2008 B-1 1071.5± 25 Western Raw Water Head Tank 1/19/2022 B-2 1072.5± 25 Eastern Raw Water Head Tank 1/19/2022 GPS coordinates (WGS 84 datum) were obtained for borings B-1 and B-2 using a handheld device accurate to within 12 feet and are provided below in Table 2 below. Table 2: Boring Coordinates Boring Latitude Longitude B-1 30.52226° -97.87221° B-2 30.52207° -97.87198° 3.1 Central Treatment Plant – Sedimentation Basin No. 4C Borings BTS-1 through BTS-6 were drilled within the proposed footprint of the Central Treatment Structure as shown in Figure 1. Borings BTS-4 through BTS-6, along the southwestern edge of the treatment structure, were closest to planned Sedimentation Basin No. 4C. From the reported surface elevations and as noted in the Fugro report, site grades ranged from about 1060 to 1065 feet at the time of the exploration. Fugro’s report notes that the borings encountered surficial fill material and potentially expansive residual soils (dark brown fat clay) to depths of 0.3 to 5 feet below the then-existing grade with corresponding elevations of 1063.9 to 1056.2 feet. Completely weathered limestone consisting of tan sandy lean clay or clayey sand was encountered beneath surficial fill and fat clay. Tan limestone of the Edwards Formation was encountered at depths of 5.8 to 9.0 feet below the then-existing grade with corresponding elevations of 1059.4 to 1053.4 feet. Borings BTS-4 through BTS-6, encountered completely weathered limestone at depths of 2 to 5 feet below the then-existing grade with corresponding elevations of 1056.2 to 1062.8 feet. 3.2 6 MG Clearwell Borings CLL-1 and CLL-2 were drilled at the proposed 6 MG Clearwell as shown in Figure 1. Fugro’s report notes that the boring encountered 0.5 to 3 feet of surficial fill soil (tan silty sand and light – 7 – April 21, 2022 brown clayey gravel) underlain by tan limestone of the Edwards Formation encountered at elevation 1052.5 to 1049.0 feet. 3.3 1st Stage Sludge Thickener Boring ST1-1 was drilled at the proposed 1st Stage Sludge Thickener as shown in Figure 1. Fugro’s report notes that the boring encountered 0.5 feet of surficial dark brown fat clay (residual soil) underlain by tan limestone of the Edwards Formation, which was encountered at elevation 1058.3 feet. 3.4 Raw Water Head Tanks Borings B-1 and B-2 were drilled at the proposed Raw Water Head Tanks as shown in Figure 1. The borings encountered 2.5 to 4 feet of surficial dark brown fat clay with sand and gravel content generally increasing with depth. The surficial fat clay is underlain by disintegrated rock (completely weathered limestone) to a depth of 5 feet in both borings. The weathered limestone is further underlain by intact limestone of the Keys Valley Marl and Edwards Limestone, both members of the Fredericksburg Group. Groundwater was not observed during drilling of either boring. Borings were backfilled upon completion: thus, long-term water level readings were not obtained. Our subcontractor, TRI Environmental performed laboratory tests on selected samples obtained during the subsurface exploration. The testing aided in the classification of materials encountered in the subsurface exploration and provided data for use in the development of recommendations for design of foundations and earthwork. We performed natural moisture content, Atterberg Limit, and gradation tests on two samples of soil, the results are presented in Table 3, and shown on the boring logs. These laboratory tests indicate these soils exhibit a high to very-high potential for moisture-related volume change (shrink/swell behavior). Table 3: Soil Laboratory Test Results Boring Sample Depth (ft) Liquid Limit Plastic Index % Gravel % Sand % Fines Moisture Content (%) B-1 0-1.5 72 41 2.7 13.5 83.8 31.0 B-2 2-3.5 70 41 10.5 40.6 48.9 27.0 Unconfined compressive strength testing was performed on intact limestone samples, the results are presented in Table 4. Table 4: Unconfined Compressive Strength of Intact Rock Core Results Boring Sample Depth (ft) Unconfined Compressive Strength (tsf) Dry Density (pcf) Moisture Content (%) B-1 11-11.5 173 143.7 5.7 B-1 22-22.5 72 113.2 7.5 B-2 7-7.5 175 142.2 4.6 B-2 17.5-18.0 110 139.8 2.8 – 8 – April 21, 2022 4.0 RECOMMENDATIONS 4.1 Central Treatment Plant - Sedimentation Basin No. 4C As described in Section 2.0 above, the site for this basin was filled in accordance with grading plans to elevations of 1067 to 1073 feet. Drawings SA-4 and SA-10 of the Phase 1C WTP Record Drawings indicate removal of existing residual soils and replacement with compacted select fill below the bottom slab elevations to a distance of 10 feet outside the face of the existing Basin 3C and Sludge Vault No. 2C. The record drawings indicate remaining fill above the select fill pads consists of compacted site soils, and the ground between the select fill pads of Sedimentation Basin 3C and Sludge Vault No. 2C consists of native soil and compacted fill. Fugro reported site grades at the time of the exploration as ranging from about 1060 to 1066 feet elevation, and record drawings show that current site grades range from approximately 1065 to 1074 feet elevation. We understand from communication with Walker Partners that planned foundation subgrade elevations range from 1058.17 to 1066.83, essentially at the same level as those of Sedimentation Basin 3C. We understand from Walker Partners that structural loadings described in the Fugro report are still appropriate, namely perimeter and interior wall loads of 3 to 4 kips per linear foot, and slab loads of 0.9 to 1.2 ksf. The Fugro report recommended support of continuous foundations and slabs using shallow foundations bearing on properly compacted select fill or on completely weathered limestone. Allowable bearing pressures of 3 ksf and 4 ksf were recommended for support on compacted fill and on completely weathered limestone, respectively. Our analysis of Borings BTS-4 through BTS-6 supports Fugro’s identification of completely weathered limestone at elevations varying from 1056.2 to 1062.9 feet. It appears that, based on planned foundation subgrade elevations as described above, excavation of 2 to 8 feet of existing soils will be required to expose the completely weathered limestone. This would be followed by placement of select fill with proper compaction in accordance with project specifications to foundation subgrade elevation. The fact that top of rock is subject to variation in elevation between boreholes may result in some differences from the conditions described here. For preparation of building pads, Fugro recommended removing and disposal of all existing fill, fat clay (residual soil), organics, or other deleterious soils or materials to expose the completely weathered limestone for bearing or as a subgrade for fill placement. This recommendation applied to an area within the footprint of the buildings and for a distance of 5 feet outside of the footprint. We support application of this recommendation to the proposed Sedimentation Basin No. 4C site. Any residual soils and unverified fill should be removed and replaced with properly compacted select fill under the structure and to at least 5 feet outside of the footprint of the structure where possible without undercutting existing adjacent structures. We recommend benching the proposed select fill into the existing select fill associated with Sedimentation Basin 3C and Sludge Vault No. 2C, the bench width should be a minimum of 2 feet and the bench height should be a maximum of 2 feet. – 9 – April 21, 2022 It is recommended that the excavation of soils in this area be monitored by a geotechnical engineer (or their representative) to verify that select fill has been placed to the minimum limits recommended in the Fugro report and as indicated on the Phase 1C WTP Record Drawings. Should the existing compacted select fill not extend at least 10 feet from the footprint of Sedimentation Basin 3C and Sludge Vault No. 2C, it may be necessary to excavate closer to the existing structures. If compacted select fill is not encountered within 5 feet of the existing structures, it may be necessary to provide positive excavation support or perform the excavation in limited sections along to permit proper compaction of the select fill at the margin of the excavation and thereby avoid undermining the bearing support of the existing adjacent structures. The on-site monitoring will aid in assessing the actual subsurface conditions and whether changes to the recommended approach to excavating close to Basin 3C are necessary. 4.2 6 MG Clearwell We understand that this structure has been removed from the Phase 1D expansion and will be considered in a future phase; accordingly, we should be made aware of any changes made to the location, size, or other critical details of this structure and should be allowed to review and revise our recommendations. The Fugro report described the existing site grade at the 6 MG Clearwell to be approximately 1052 feet to 1053 feet. We understand from communication with Walker Partners that the proposed finished floor elevation of 1042 feet described by Fugro is still applicable, therefore the foundation would bear approximately 7 to 9 feet into the tan Edwards Limestone stratum. We also understand from communication with Walker Partners that Fugro’s described structural loading for perimeter walls of 2 kips per linear foot is still applicable. Fugro provided an allowable bearing pressure of 8 ksf for design of the continuous footing for the perimeter wall bearing at or below elevation 1042 feet. Considering the reported unconfined compressive strengths of intact limestone core samples of 72 tsf and 114 tsf, we see the recommended allowable bearing pressure at this level as applicable and appropriate. Fugro also recommended that the foundation subgrade should be observed by the geotechnical engineer prior to placing reinforcing steel due to the possibility for clay-filled voids and other solution features, which may require structural mitigation techniques including backfilling with flowable fill or lean concrete. We also concur with this recommendation. 4.3 1st Stage Sludge Thickener We understand from communication with Walker Partners that Fugro’s reported existing site grade of approximately 1059 feet and proposed finish floor elevation of 1051.67 are still applicable. Therefore, the foundation would bear approximately 7 feet into the tan Edwards Limestone stratum. We also understand that Fugro’s reported structural loading for perimeter walls of 2 kips per linear foot are still applicable. Fugro provided an allowable bearing pressure of 8 ksf for design of the continuous footing for the perimeter wall bearing at or below elevation 1051 feet. – 10 – April 21, 2022 Considering the reported unconfined compressive strengths of intact limestone core samples of 64 tsf and 210 tsf, we see the recommended allowable bearing pressure at this level as applicable and appropriate. 4.4 Raw Water Head Tanks According to the Phase 1C WTP Record Drawings, the existing site grades for the Raw Water Head Tanks range from approximately 1071 feet to 1073 feet and the proposed finished floor elevation is 1072 feet, therefore up to 1 foot of cut and up to 1 foot of fill will be required to achieve grade. Pipe modifications to a 72-inch diameter raw water pipe were also made in the vicinity of these Raw Water Head Tanks during Phase 1C construction. Surface elevations for borings B-1 and B-2 were interpolated from the Phase 1C WTP Record Drawings and are 1071.5 and 1072.5, respectively. We understand from Walker Partners that structural loading is anticipated to consist of perimeter loads of 3 to 4 kips per linear foot and slab loads of 1.5 to 1.7 ksf. Prior to placement of required fill to design grade elevations, we recommend removal and disposal of all existing uncontrolled fill, fat clay (residual soil), organics, or other deleterious soils or materials to expose the completely weathered limestone for bearing or as a subgrade for fill placement. Fill associated with the 72-inch diameter pipe modifications should be verified for suitable compaction and may require removal and replacement with flowable fill to allow for proper compaction of new fill for the tank foundation. Fill compacted in accordance with construction specifications is recommended to extend to at least 5 feet outside the planned exterior footprint of the tanks prior to beginning the tank pad side slopes. Continuous and spread footings may be sized using an allowable bearing pressure of 3 ksf for bearing in compacted select fill. 4.5 Support of Excavation Fugro’s report contains a section explaining that the design of construction slopes and support of excavation systems are the sole responsibility of the contractor. They also describe the OSHA requirements and process for classifying the soil and rock. They suggest that for planning purposes the fill material be classified as Type C (maximum allowable slopes for excavations less than 20 feet deep are 1.5 horizontal to 1 vertical); that the completely weathered limestone be Type B (maximum allowable slopes for excavations less than 20 feet deep are 1 horizontal to 1 vertical); and that the limestone be considered "stable rock" where vertical sidewalls are permitted. We agree with their assessment and stress that this is for planning purposes only and that the design and safety of excavation slopes and support of excavation systems is the responsibility of the contractor. Where excavations would exceed 20 feet in depth, we recommend requiring that the slopes be designed by a licensed professional engineer in the state of Texas. If space does not allow for laying back slopes to the required configuration, then a support-of-excavation system for the contractor’s planned configuration should be designed by a professional engineer licensed in the state of Texas. 4.5 Foundation Support Elements Design and Construction Foundations should be designed and constructed in accordance with the Continuous and Spread Foundations, Slab-on-Ground, and Drilled Shaft Foundations recommendations included in the – 11 – April 21, 2022 Foundation Recommendations section of the Fugro report. These recommendations include specifications for preparation of the subgrade prior to pouring footings. In particular they state: The bottom of the excavation for footings should expose select fill or undisturbed completely to highly weathered limestone. Any loose or disturbed materials encountered at the bottom of the excavation should be removed. In addition, there should not be any free water standing in the excavation at the time of concrete placement. The exposed bearing subgrade should be observed by the geotechnical engineer prior to construction of the foundation to confirm suitable bearing. The BCRUA WTP Phase 1A plans prepared by CDM Smith and dated June 8, 2009 specified a 2-inch lean concrete seal slab below footings. It is of our opinion that a seal slab is not necessarily needed, provided that the contractor can meet the conditions of the above recommendation to provide safe and working conditions and to adequately prevent rebar from becoming contaminated with soil/mud. Below grade walls and below grade drainage considerations should be designed in accordance with the Below Ground Walls section of the Fugro report. 5.0 LIMITATIONS We based the analyses and recommendations submitted in this report on the information revealed by our limited exploration of two borings for the proposed Raw Water Head Tanks, and on our review of Fugro’s Phase 1A Geotechnical Report for the BCRUA WTP site for the other facilities proposed for Phase 1D. Fugro’s exploration was performed in 2008, before plant construction. We sought, through review of Google Earth historical images and through site visits and discussions with WTP personnel, to ascertain the extent of any changes to original site grade that could affect the applicability of the Fugro recommendations. We attempted to provide for normal contingencies, but the possibility remains that undetected changes may have occurred and/or that there may be other unexpected conditions may be encountered during construction. This report has been prepared to aid in the evaluation of this site and to assist in the design of the project. It is intended for use concerning this specific project. We based our recommendations on information on the site and proposed construction as described in this report. Substantial changes in loads, locations, or grades should be brought to our attention so we can modify our recommendations as needed. We would appreciate an opportunity to review the plans and specifications as they pertain to the recommendations contained in this report, and to submit our comments to you based on this review. Fugro’s report recommended observation of certain construction operations by a geotechnical engineer, and we concur with those recommendations, as described herein, to aid in detection of any conditions different from the interpreted conditions on which this report is based. We have endeavored to complete the services identified herein in a manner consistent with that level of care and skill ordinarily exercised by members of the profession currently practicing in the same locality and under similar conditions as this project. No other representation, express or – 12 – April 21, 2022 implied, is included or intended, and no warranty or guarantee is included or intended in this report or other instrument of service. © Schnabel Engineering 2022 All Rights Reserved BCRUA Phase 1D WTP Expansion Cedar Park, Texas Project No. 22640001 FIGURE 1 Proposed Phase 1D Facilities and Boring Locations Site plan from “BCRUA WTP Phase 1A Geotechnical Investigation” report prepared by Fugro Consultants, Inc. dated June 2008, overlaid in Google Earth Professional. APPENDIX A BCRUA WATER TREATMENT PLANT PHASE 1A GEOTECHNICAL INVESTIGATION REPORT FUGRO CONSULTANTS, INC. JUNE 2008 8077-59989 Brushy Creek Regional Utility Authority Brushy Creek Regional Water Treatment Plant Phase 9 A SECTION 1170A GEOTECHNICAL INVESTIGATION BRUSHY CREEK REGIONAL UTILITY AUTHORITY WATER TREATMENT PLANT TRAVIS AND WILLIAMSON COUNTIES,TEXAS CDM,INC AUSTIN,TEXAS SUBMITTED BY: FUGRO CONSULTANTS, INC. REPORT NO. 04, 10013647 JUNE 2008 A4416-01170A-BCRWrF 01170A ostz�zoos THIS PAGE LEFT BLANK INTENTIONALLY ■ i} a a irh. P� 1' I i _i•. 1.- � -�.r � ,f.� _. - Arai". tiM "fist-•. � THIS PAGE LEFT BLAND INTENTIONALLY -fuGgain atils cm pm FUGRG CONSULTANTS, INC. v® 8613 Cross Park Drive Austin,Texas 78754 Phone: 512-977.1800 Fax: 512-973-9966 Camp dresser and McKee, Inc. Report No. 04.10013647 12357-A Riata Trace Parkway, Suite 210 June 17, 2008 Austin, Texas 78726 Attention: Mr. Allen D. Woelke, P.E. Geotechnical Investigation Brushy Creek Regional utility Authority Water Treatment Plant Travis and Williamson Counties, Texas Fugro Consultants, Inc. (Fugro) is pleased to submit this report of geotechnical investigation for the proposed Brushy Creek Regional Utility Authority (BCRUA) Water Treatment Plant to be located in Travis and Williamson Counties, Texas. In brief, this report contains a plan of borings, boring logs with laboratory test results, and descriptions of subsurface conditions. Based on the findings, geotechnical design and construction recommendations are set forth for the proposed Water Treatment Plant structures. Fugro has issued two previous geotechnical reports dated July 5, 2007 (draft) and December 3, 2007 (draft) for the subject project. This final report presented herewith includes all previous field and laboratory data obtained during the previous three phases of the project, and supercedes previous correspondence. We sincerely appreciate the opportunity to provide these engineering services to CDM, and look forward to our continued association. Sincerely, SUL TS, INC. Rebecca A. Russo, P.E. t e � Project Manager AEBECCA A,FiUSSa WL/[� 91271 rye John A. Wooley, P.E. `�r•�yFN50:Now a Senior Vice President 1%� Attachments Distribution: Addressee(Woelke)(4)(email) CDM(Lynk)(email) Jose I. Guerra(Luke)(email) File(2) A member of the Fugro group of companies with offices throughout the world, THIS PAGE LEFT BLANK INTENTIONALLY Ello GEOTECHNICAL INVESTIGATION BRUSHY CREEK REGIONAL UTILITY AUTHORITY WATER TREATMENT PLANT TRAVIS AND WILLIAMSON COUNTIES, TEXAS Report to: CDM, INC. Austin, Texas Submitted By: FUGRO CONSULTANTS, INC June 20D8 i THIS PAGE LEFT ELAND FNTENTIQNALLY Report No.64.10013647 CONTENTS PAGE INTRODUCTION ........................................................................................................................... 1 AUTHORIZATION.......................................................................................................................... 1 PURPOSEAND SCOPE ............................................................................................................. 2 FIELD INVESTIGATION............................................................................................................... 3 Borings..........................,..,.................,............................................................................... 3 Piezometer.........................................................................................................................4 ResistivitySounding Surveys.............................................................................................4 DrillingNotes...................................................................................................................... 5 LABORATORYTESTING............................................................................................................. 5 Natural Water Content{ASTM ❑ 2216) ............................................................................. 5 Atterberg Limits (ASTM ❑ 4318).—.................................................................................... 5 Sieve Analysis (ASTM D 422)............................................................................................ 6 Unconsolidated-Undrained Triaxial Compression Test (ASTM D 2850)............................6 Unconfined Compression Strength of Intact Rock Core Specimens (ASTM D 7012)........6 AnalyticalTesting............................................................................................................... 6 StrataDescriptions............................................................................................................. 7 SITE AND SUBSURFACE CONDITIONS .................................................................................. 7 Physiography..................................................................................................................... 7 Geology.............................................................................................................................. 7 Generalized Site Stratigraphy and Engineering Properties................................................ 8 Groundwater...................................................................................................................... 9 DESCRIPTION OF STRUCTURES AND FOUNDATIONS..................................................... 10 2MGElevated Storage Tank............................................................................................ 10 Central Treatment Structure............................................................................................. 11 WashwaterDecant Basin...............................................................................................- 13 Washwater Settling Basin ................................................................................................ 14 4 MG Clearwell and 6 MG Clearwell................................................................................ 14 DisinfectionBasin.........................,................................................................................... 15 DisinfectionFacility .......................................................................................................... 16 BoosterPump Station ...................................................................................................... 17 SludgePump Station ....................................................................................................... 18 1ST Stage Sludge Thickener...........................................................................................1. 19 2nd Stage Sludge Thickener............................................................................................. 19 SludgeDewatering Facility............................................................................................... 20 WastewaterLift Station.................................................................................................... 21 -i -Fumwn Report No.44.10013647 s ElectricalBuilding............................................................................................................. 21 FOUNDATION RECOMMENDATIONS...................................................................................... 22 BuildingPad Preparation ................................................................................................. 26 Slab/Mat Foundations...................................................................................................... 27 Continuous and Spread Footings..................................................................................... 29 Grid-Beam Stiffened Slabs-on-Ground ............................................................................ 29 DrilledShaft Design ......................................................................................................... 30 Drilled Shaft Construction ................................................................................................ 30 SeismicDesign ................................................................................................................ 31 BELOW GROUND WALLS........................................................................................................ 32 CONSTRUCTION CONSIDERATiONS.............. ....................................................................... 34 Site Grading and Drainage............................................................................................... 34 Utility Bedding and Backfill............................................................................................... 34 ExcavationPotential......................................................................................................... 34 Temporary Construction Slopes....................................................................................... 35 Mitigationof Voids............................................................................................................ 35 ConstructionMonitoring ................................................................................................... 36 STORMWATER DETENTION PONDS ..................................................................................... 37 Design Recommendations............................................................................................... 37 Construction Recommendations...................................................................................... 39 SOIL CORROSION POTENTIAL................................................................................................ 41 Corrosion of Steel .................................................................................. . 41 Degradationof Concrete.................................................................................................. 42 PAVEMENT RECOMMENDATIONS.......................................................................................... 43 PavementDesign............................................................................................................. 43 FlexiblePavement............................................................................................................ 44 RigidPavement................................................................................................................45 Pavement Drainage and Groundwater Control................................................................ 46 CONDITIONS ..............................................................................................................................46 - ii - ARD Report No.04.10613647 ILLUSTRATIONS PLATE VICINITYMAP................................................................................................................... I PLAN OF BORINGS ............. 2a -2b GEOLOGICMAP............................................................................................................... 3 APPENDICES APPENDIX A— BORING LOGS Keys to Terms and Symbols Used on the Boring Logs Boring Logs (27) APPENDIX B — FIELD RESfSTIV€TY AND CORROSION TESTING Plan of Field Resistivity Lines Table of Field Resistivity Results (3 lines) Laboratory Test Results (4) for Electrical Resistivity, pH, Soluble Chloride, Soluble Sulfate, Sulfide and REDOX Potential - iii - THIS PAGE LEFT BLANK INTENTIONALLY -funRo Report No.04.10013647 INTRODUCTION Fugro Consultants, Inc. (Fugro) has conducted a geotechnical investigation for the proposed Brushy Creek Regional Utility Authority (BCRUA) Water Treatment Plant. The investigation was conducted in three phases with all field and laboratory data included herein. The 75.1-acre site is located at the north terminus of Mur Industrial Boulevard, north of FM 1431, as shown on the Vicinity Map, Plate 1. The site is mostly undeveloped, although the eastern portion of the site was previously used for stockpiling of earthen and construction materials and quarry activity. An existing wastewater lift station is located at the southern entrance onto the site at Hur Industrial Boulevard. We understand that a force main extends from the existing lift station northeast across the site. Proposed construction will include a new Regional Water Treatment Plant. The planned structures include: • 2MG Elevated Storage Tank • Booster Pump Station • Central Treatment Structure ■ Sludge Pump Station • Washwater Decant Basin • 1" Stage Sludge Thickener • Washwater Settling Basin ■ 2 n Stage Sludge Thickener • 4 MG Clearwell ■ Sludge Dewatering Facility • 6 MG Ciearwell ■ Recycle Meter Vault ■ Disinfection Basin ■ Lift Station • Disinfection Facility • Electrical Building ■ Finished Water Meter Vault • Driveways and Pavements The Brushy Creek Regional Utility Authority (BCRUA) is the owner of the project, and CDM, Inc. is providing the civil design engineering services. ,Jose I. Guerra is providing the structural design services for most of the structures, although the 2MG Elevated Storage Tank and offsite transmission main are being designed by Lockwood, Andrews, & Newnam, (LAN). Fugro Consultants, Inc.was retained by CDM to provide geotechnical engineering services. AUTHORIZATION The investigation was authorized by issuance of the Standard Form of Agreement Between Engineer and Subcontractor for Professional Services dated June 18, 2407, between CDM and Fugro Consultants, Inc. The Agreement includes our specific geotechnical scope of services and compensation requirements as Exhibit A. Additional services including site clearing -1- —fiJ13RD Report No.04.10013647 activities and additional borings were authorized and conducted in accordance with the fee requirements presented in Exhibit A. PURPOSE AND SCOPE The purpose of the investigation is to obtain subsurface Information adequate for 1) the selection of suitable types of foundations with respect to cost and performance, compatible with the proposed structures, 2)the formulation of design criteria for the types of foundations selected, 3) the selection of materials and compaction requirements for earth construction, and 4) pavement thickness design and construction recommendations. The project included three phases of investigation, referred to as Phase 1, Phase 2 and this final Phase 3. Phase 'I services were associated with the Treatment Structure, and six borings were drilled for that structure. A Geotechnical Design Memorandum was issued July 5, 2007 (Draft). Phase 2 included eighteen borings associated with most of the proposed structures for the proposed plant. The data and recommendations for Phases 1 and 2 were issued in report dated December 3, 2007 (draft). A third phase consisting of three borings drilled for a new proposed Clearwell and expansion to the Disinfection Basin was Initiated in March of 2008. All field and laboratory data obtained during each of the Phases is included herein. The recommendations presented herein are consistent with previous correspondence and supersede previous reports. Each investigation included: 1) a field investigation for determining subsurface conditions and obtaining representative samples for classification and testing, 2) a laboratory testing program to aid in the classification and strength of the substrata and to provide geotechnical design parameters, and 3) engineering analyses and evaluations of the results of the field and laboratory data to aid in assessing geotechnical design recommendations and construction Issues. Field sampling methods, laboratory testing procedures, soil classifications and strata descriptions were in general accordance with methods, procedures, and practices set forth by the American Society for Testing and Materials, 2007 Annual Book of ASTM Standards, where applicable. -2- TUorRo Report No. 04.10013647 FIELD INVESTIGATION Borings The field investigation consisted of drilling a total of six (6) borings for Phase 1, eighteen (18) borings for Phase 2, and three (3) borings for Phase 3. Boring numbers were designated in accordance with their structure location, as summarized in the table below, Also shown is the boring depth. Baring Summary Table Boring Drilled Depth Location BTS-1 29 ft Central Treatment Structure BTS-2 29.5 ft Central Treatment Struoture BTS-3 30.9 ft Central Treatment Structure BTS-4 29.5 ft Central Treatment Structure BTS-5 29.5 ft Central Treatment Structure BTS-6 29.5 ft Central Treatment Structure EST-1 49.5 2MG Gallon Elevated Storage Tank EST-249.5 2MG Gallon Elevated Storage Tank WDB-1 29.5 Washwater Decant Basin WSB-1 29.5 Washwater Settling Basin CLL-1 49.5 6 MG Clearwell CLL-2 49.5 6 MG Clearwell CLL-3 49.5 4 MG Clearwell CLL-4 49.5 4 MG Clearwell D6-1 24 Disinfection Basin DS-2 24.5 Disinfection Basin DF-1 19.5 Disinfection Facility 6PS-1 49.5 Booster Pump Station SLPS-1 49.5 Sludge Pump Station ST1-1 19.5 1St Stage Sludge Thickener ST2-1 19.5 2nd Stage Sludge Thickener SDF-1 19.5 Sludge Dewatering Facility EB-1 19.5 Electrical Building WWLS-1 29.5 Lift Station RW-1 14.5 Raw Water Line PAID-1 14.5 Detention Pond PND-2 14.5 Detention Pond -3- `�6RR Report No.04.10013547 Boring locations were selected and indicated by CDM and staked in the field by The Wallace Group, Inc. surveyors. Boring locations are shown on the Plan of Borings, Plate 2a (aerial) and Plate 2b (contour), Detailed descriptions of the subsurface materials encountered at the boring locations are presented on the Logs of Borings included in Appendix A. Keys to Terms and Symbols used on the boring logs precede the boring fogs in the Appendix. The boring logs are presented in alphabetical order in Appendix A. Pocket penetrometer values, in tons per square foot (tsf), Standard Penetration Test N-values in blows per foot (bpf), and core recovery and Rock Quality Designation (ASTM D 5032) values in percent, are also shown on the logs of borings. Groundwater and drilling fluid notes are presented at the bottom of the boring logs. Boring elevations shown on the boring logs were interpolated from the 1-ft contour pian shown on the Plan of Barings, Plate 2b, and should be considered approximate. The borings were drilled using a truck-mounted drill rig equipped with 1) continuous flight augers for advancing the holes dry and recovering disturbed samples (ASTM D 1452), 2) seamless push-tubes for obtaining samples of cohesive strata (ASTM D 1587), 3) split-barrel samplers and drive-weight assembly for obtaining representative samples and measuring the penetration resistance of noncohesive strata (ASTM D 1586), and 4) double-tube wireline core barrels equipped with diamond and/or carbide bits for obtaining 2-inch diameter rock cores (ASTM D 2113). Piezometer One piezometer was installed in boring WWLS-1 to monitor stabilized groundwater conditions. The piezometer consists of a 2-inch diameter plastic slotted pipe in the lower 20 ft, and solid pipe in the upper 10 feet, The annular space around the slotted pipe was backfilled with sand and then grouted to the ground surface. The top of the piezometer is locked and protected with a 12-inch diameter flush-mount steel manhole and concrete pad. Groundwater level measurements are presented on the bottom of the boring log and are further discussed in the Groundwater section of this report. Resistivity Sounding Surveys Three resistivity sounding surveys were conducted within the proposed Central Treatment Structure location. A plan showing the sounding locations is presented on the Resistivity Line Plan Included in Appendix B. Measured resistivity values are also included in Appendix B. The testing was performed using the Wenner Array with "a" spacings varying from 5 to 50 feet. The -4- "f 1GRO Report No.04.10013647 resistivity soundings were performed in general accordance with ASTM G 57. Resistivity results are further discussed in the Soil Corrosion Potential section of this report. Drilling Notes On the boring logs, miscellaneous drilling notes are included where appropriate. These notes were recorded during the drilling operation and were observed by the driller or logger. These notes include such items as water loss. If water loss notes are not indicated on the logs, it should not be concluded that water was not lost during the drilling operation, but rather that no appreciable amount was observed by the driller or logger. LABORATORY TESTING The laboratory testing program included identification and classification testing of all strata encountered in the subsurface. Soil classifications tests, including Atterberg limit determinations (ASTM D 4318) and partial grain-size analyses (ASTM ❑ 422), were conducted on representative soil samples. Unconfined compression strength tests (ASTM D 7012) were conducted on intact rock cores. The classification and unconfined compression tests included natural water content determinations (ASTM D 2216). The unconfined compression tests also included unit dry weight determinations. The results of the tests are tabulated on the boring logs under the appropriate columns at the respective sample depth. A brief description of the laboratory test is provided in the following sections. Natural Water Content (ASTM D 2216) Natural water content tests were performed on samples in which classification andlor strength tests were performed. Each sample was visually classified in the laboratory. Natural water contents are tabulated at the sample depth on the boring logs. Atterberg Limits (ASTM D 4318) Atterberg limit tests are classification tests that determine the liquid limit and plastic limit of the soil fraction finer than the No. 40 sieve. The Atterberg limits are approximate water contents at which the soil tested behaves in a specified manner. The liquid limit is determined by measuring, in a standard device, the water content and number of blows required to close a specific width groove cut in a remolded soil sample a specified length, The plastic limit is determined by measuring the water content when threads of soil 118-inch in diameter begin to crumble. The plasticity index, defined as the difference between the liquid and plastic limits, indicates the degree of plasticity or the magnitude of the water content over which the soil -5- Tualan Report No.04.10013647 remains plastic. Liquid limit and plasticity index values are tabulated at sample depths on the boring logs. Sieve Analysis (ASTM D 422) Grain-size characteristics of the natural soils were investigated by the determination of the percent of soil passing the No. 4, 40 and 200 sieves. These tests were performed by washing or sieving material through the respective sieves. The results are tabulated at sample depth on the boring logs for the percent passing the Nos. 4 and 200 sieves. Unconsolidated-Undrained Triaxial Compression Test (ASTM D 2850) In the unconsolidated-undrained triaxial compression test, a specimen is subjected to a confining pressure, typically the overburden pressure, in a triaxial chamber. The specimen is sheared in compression without drainage at a constant rate of axial deformation of about 1 percent strain per minute to produce failure in a test time between about 15 to 20 minutes. The soil and shale core samples tested had diameters of about 2.8 and 2.0 inches and heights of about 5.6 and 4.0 inches, respectively. The measured applied load was recorded for selected increments of deformation. Results of these tests, including compressive strength, water content and unit dry weights, are tabulated on boring logs at specimen recovery depth. The compressive strength of the sample determined using this test is followed by a "Q" on the boring logs. Unconfined Compression Strength of Intact Rock Core Specimens (ASTM ❑ 7012) In the unconfined compression test of intact rock core specimens, a laterally unsupported cylindrical rock specimen is loaded axially in compression to failure. The axial load is applied at a constant rate of deformation to produce failure in a test time between 2 and 15 minutes. The limestone cores tested were about 2 inches in diameter by 4 inches in length. The measured applied load at failure is recorded. Results of these tests, including unconfined compressive strength, water content, and unit dry weights, are tabulated on boring logs at core recovery depth. The compressive strength of the sample determined using this test is followed by a "U" on the boring log. Analytical Testing In addition to classification and strength testing, four (4) soil samples were tested for(Box) Electrical Resistivity, pH, Soluble Chloride, Soluble Sulfate, Sulfide and REDOX potential. The laboratory tests were performed by Fugro's analytical laboratory in Corpus Christi, Texas, to assess the potential of the on-site soils to corrode buried steel and degrade buried concrete. The results of the analytical laboratory test results are presented in Appendix B, and are further discussed in the Soil Corrosion Potential section of this report. -6- �r_a Report No.04.10013647 Strata Descriptions Descriptions of strata made in the field at the time the borings were drilled were modified in accordance with results of laboratory tests and visual examination in the laboratory. All recovered soil samples were examined and classified in general accordance with ASTM D 2487 and described as recommended in ASTM D 2488. Rock strata were classified in general accordance with "Rock Classification and Description", Chapter 1, Section 5, NAVFAC DM-71 . Classifications of the soils and finalized descriptions of both rock and soil strata are shown on the boring logs. SITE AND SUBSURFACE CONDITIONS Physiography The proposed Brushy Creek Regional Water Treatment Plant site consists of a 75.1-acre parcel comprised of two separate properties referred to as the "Hur" property and the "Rudd" property. The Hur property consists of 56.9 acres, and is covered by mostly tall grasses and brush on the east side and heavily wooded on the west side. The eastern portion of the site has previous grading activity including quarry and earthen construction materials stockpiling, although the area was fairly level at the time of our field exploration. This portion of the site also includes a small detention pond with earthen embankment and a concrete wall, and an existing wastewater lift station and force main transecting the site. The site includes two gravel roads which provide access to an offsite LCRA facility to the north, and access to the adjoining Rudd property, The Rudd property consists of approximately 21.8 acres of heavily wooded land owned by private individuals. The property includes an abandoned residential trailer, areas (piles) of domestic debris, and a stockpile of earthen material near the middle of the site. In general, the site topography slopes down to the southwest with ground surface elevations generally ranging from about 1070 ft at the northeast corner of the site to about 1050 ft at the southwest corner of the site. As described above, the site includes cleared and wooded areas, existing utilities and a detention pond, and gravel roads and a fence line. Geology According to published geologic mapping2, the WTP site is underlain by weathered remnants and limestone of the Walnut and Edwards Formations, undivided, both being of the U.S. Navy(1971)Design Manual-Soil Mechanics, Foundations,and Earth Structures,NAVFAC DM-7. 2 Collins, E.W. (2002), "Geologic Map of the West Half of the Taylor, Texas, 30 x 60 Minute Quadrangle. Central Texas Urban Corridor, Encompassing Round Rock, Georgetown, Salado, Briggs, Liberty Hill, and Leander" published by the Bureau of Economic Geology,The University of Texas at Austin. -7- TU r. O Report No.04.10013647 Fredericksburg Group of limestone. To better define area geology, a Geologic Map is presented on Plate 3. The Fredericksburg Group is defined by three limestone Formations, listed from youngest to oldest: Edwards, Comanche Peak, and Walnut. The Edwards consists of hard, crystalline, solution featured limestone, with chert nodules. The Comanche Peak Formation consists of fine to very fine-grained, fairly hard, nodular limestone and marly limestone that is generally light gray in color and weathers white. Portions of the Comanche Peak are extensively burrowed with burrow fillings slightly coarser and darker. The Walnut is subdivided into five members, youngest to oldest, Keys Valley, White Stone, Cedar Park, Bee Cave, and Buil Creek. Of the Walnut Group, the Keys Valley Member (KWk,) is mapped along the majority of the alignment, and consists of relatively soft, argillaceous, marly (clayey) limestone with some limestone. Where distinguishing characteristics of the core samples were not observed, the limestone was referred to as "Fredericksburg Group"on the boring Jogs. Most of the limestone encountered in the borings was interpreted as Edwards limestone, with the exception of 3 borings at depths of 42.5 to 46.5 ft where the limestone was classified as gray Fredericksburg. The Edwards Formation is of Cretaceous age and consists of relatively soft to extremely hard limestone, dolomitic limestone and dolomite. The limestone is vuggy, honeycombed and porous, oftentimes having solution cavities and voids (karst), and chert. The dolomite and dolomitic limestone of the Edwards is typically softer and when exposed to weathering may take on a soil-like consistency. It should be noted that it was sometimes difficult to distinguish between Edwards limestone and Walnut limestone. Generalized Site Stratigraphy and Engineering Properties Subsurface conditions can best be understood by a thorough review of the boring logs presented in Appendix A. Specific subsurface conditions encountered at each structure are discussed in further detail in the subsequent Description of Structures and Foundations section of this report. The following paragraphs present a generalized summary of the overburden soils and limestone conditions. Twenty-seven (27) borings were drilled across the proposed WTP site. The borings encountered surficial fill, residual soils, and completely to slightly weathered tan and gray limestone of the Fredericksburg Group. The following can be summarized about the generalized subsurface conditions: • Fill material was encountered in 8 of the 27 borings, and ranged in depth from 0.4 to 8 ft (boring DF-1) at the boring locations, but was typically less than 3 ft thick. -8- Report No.04.10093647 $ ■ Residual soil consisting of reddish brown to dark brown fat clay was encountered in nearly all of the borings and ranged in thicknesses from 0.3 to 4.2 (DB-2) ft with an average thickness of 1.5 feet. ■ Standard Penetration Test (SPT) blow counts in surficial overburden soils ranged from 7 bpf to 50 blows for 3 inches of penetration, but were typically below 30 bpf. ■ Measured liquid limits of overburden soils samples ranged from 25 to 98 (average 55), plasticity indices ranged from 4 to 68 (average 37), and percent fines (material passing the No. 200 sieve) ranged from 19 to 99. ■ Tan limestone of the Edwards formation was encountered in all of the borings at depths of 0.5 to 11.5 ft (average 3.5 ft) below existing grade with corresponding elevations of 1049 to 1087.7 feet. • The Edwards limestone typically consisted of two prominent strata. (1) the upper member described as hard, pitted, vuggy, containing red-stained solution features, discontinuities, chert, and fossils, and (2) the lower member consisting of medium hard to hard, fine to medium grained with occasional solution features, fossils, and dolomitic layers. ■ Gray limestone, referred to as Fredericksburg Group, was encountered in three of the borings {CLL-1, CLL-2, CLL-3, CLL-4, and BPS-1} at depths of 42 to 46.5 ft below existing grade with corresponding elevations of 1011.1 to 1007.8 feet. • Rock core recovery of the limestone strata ranged from 21 to 100 percent with an average of 90 percent. • Rock Quality Designation (RQ D) of the limestone strata ranged from 0 to 100 percent with an average of 64 percent. • Unconfined compressive strengths of intact limestone core samples ranged from 18 to 229 tsf with an average of 104 tsf. Groundwater Groundwater was not encountered in any of the borings during dry advancement. Water was introduced into the borings to promote the coring operation, therefore, groundwater may have been present but not detected. Notes of drilling fluid losses are presented on the boring logs and may be indicative of discontinuities, features, and/or fractures capable of transmitting groundwater. R piezometer was installed at boring WWLS-1. Groundwater measurement information at the piezometer is presented in the following table. -9- Report No.04.18013647 Measured Groundwater Depth,ft Piexometerl (Groundwater Elevation,ft) Boring At the time of drilling 11/29/67 12130107 installed 916107 28.3 28.5 WWLS-1 Not encountered (1038.7) (1038.5) Groundwater will likely be encountered in excavations extending into the limestone stratum, Oftentimes, perched or transient groundwater is encountered in the lower elevations of the overburden soils atop the underlying, harder limestone stratum. Groundwater may also be encountered within fractures, solution features, andlor discontinuities in the limestone. Typically, groundwater within fractures of the limestone can be handled by Bumping and pumping. However, groundwater may be present in significant volumes within the more vuggy, solution featured limestone, and may be particularly severe following rain events. Further, below grade structures will require permanent below grade drainage systems or be designed for buoyant forces. DESCRIPTION OF STRUCTURES AND FOUNDATIONS The proposed WTP will include the following structures: • 2MG Elevated Storage Tank ■ Booster Pump Station ■ Central Treatment Structure • Sludge Pump Station ■ Washwater Decant Basin • 1"Stage Sludge Thickener • Washwater Settling Basin ■ 2�d Stage Sludge Thickener • 4 MG Clearwell and 6 MG Clearwell ■ Sludge Dewatering Facility ■ Disinfection Basin ■ WW Lift Station • Disinfection Facility ■ Electrical Building Descriptions of each of the structures and associated subsurface conditions are presented in the following subsections. Our understanding of the proposed construction and structural loading was based on the plans and information provided by CDM, Jose f. Guerra, and LAN. 21VIG Elevated Storage Tank A 2 Million Gallon (MG) Elevated Storage Tank is planned at the north end of the site. According to preliminary information provided by LAN, the tank will be approximately 84 ft tall with a 11 0-ft diameter bowl, and 54 to 60-ft diameter reinforced concrete pedestal. Based on our -10- Report No. 04.10013647 experience with similar structures, anticipated foundation loads will consist of about 20,000 kips of total load. To accommodate overturning loads and piping , the foundation is typically 6 to 8 ft be low grade. Borings EST-1 and EST-2 were drilled within the proposed 2MG EST footprint. The borings encountered sha ll ow surficial soils over tan limestone at a depth of 3 feet. Highly weathered, fractured limestone was encountered to a depth of 6.5 ft In boring EST-2, further underlain by more competent, hard limestone. Based on our understanding of the proposed construction and anticipated foundation loading, we recommend that the 2MG EST be supported by a ring foundation bearing a minimum of 6.5 ft below existing grade with a corresponding e levation of 1057 feet. Foundations bearing at this elevation may be sized using an allowable bearing pressure of 8 ksf. If additional capacity is needed , foundations bearing at a depth of at least 8 ft below existing grade w ith a corresponding elevation of approximately 1055.5 ft may be sized using an allowab le bearing pressure of 1 O ksf. Typically, the dead weight of the foundation will res ist overturning loads of the superstructure; however, if additional uplift capacity is needed , Fugro should be contacted to provide additional recommendations for uplift drilled shafts. Foundations should be designed in accordance with the Continuous and Spread Footing recommendations presented in the subsequent Foundation Recommendations section of this report. Central Treatment Structure A Centra l Treatment Structure is planned near the middle of the site. The structure has approximate plan dimensions of 400 ft by 250 ft and is composed of varying levels of interior structures with interior partition walls . According to the plans provided by COM and Jose I. Guerra, we understand that the structure will have finished floor elevations of approximately 1066.0 on the eastern side, and 1059.0 at the tank farm on the western side of the structure. Structural loading will consist of perimeter and interior wa ll loads of 3 to 4 kips per linear ft, and slab loads of 0 .9 to 1.2 ksf. The western portion of the structure will have interior columns with reported loads of 255 kips per column , and the tank farm will have a dead load of 1 OOk of over a s lab area of 110 ft by 40 feet. Borings BTS-1 through BTS-6 were drilled with in the proposed footprint of the Central Treatment Structure. The borings encountered surficia l fill material and potentia ll y expansive residual soils (dark brown fat clay) to depths of 0.3 to 5 ft be low existing grade with corresponding elevations of 1063.9 to 1056.2 feet. Completely weathered limestone consisting of tan sandy lean clay or clayey sand was encountered beneath surficial fill and fat clay. Tan limestone of the -11- Report No. 04.10013647 Edwards formation was encountered at depths of 5.8 to 9.0 ft below existing grade with corresponding elevations of 1059.4 to 1053.4 feet. Existing site grades ranged from about 1060 to 1066 feet. Based on proposed finished floor elevations of 1059 to 1066 for the Treatment Structure, cuts and fills on the order of 3 to 5 ft will be necessary to achieve grade. Further, potentially compressible soils (existing fill material) and potentially expansive soils (dark brown fat clay residual soils) are present beneath the proposed FFE and should be removed. Based on the boring data, suitable bearing material (completely weathered limestone) for the anticipated loadings is present at or near elevations 1056.2 to 1063.9 feet. We recommend that the continuous foundations and s labs be supported by shallow foundations bearing in the complete ly weathered li mestone (tan sandy lean clay or clayey sand ) stratum or in properly compacted select fill. Wall foundations bearing in select fill may be sized using an allowable bearing pressure of 3,000 psf. Wall foundations bearing in tan completely weathered limestone may be sized using an allowable bearing pressure of 4,000 psf. Associated settlement for foundations bearing in properly compacted select fill or tan completely weathered limestone should be 1 inch or less. Slabs may be designed to bear on grade provided the subgrade is brought to grade in accordance with the recommendations included herein . Settlement associated with slab loads on the order of 0.9 to 1.2 ksf should be 1 inch or less. Column supports may be founded either by spread footings bearing in select fill or tan completely weathered limestone, or by drilled shafts bearing in the tan limestone stratum. For the proposed column loads of 255 kips, drilled shafts embedded in the tan limestone are the most likely feasible support option. Dri lled shafts should be embedded Into the tan moderately weathered limestone stratum and sized using an allowable skin friction resistance of 3.0 ksf, neglecting the upper 5 ft of limestone embedment. End bearing capacity is available; however, probe holes would be required at each shaft location to confirm the presence of suitable bearing and absence of voids at or below the bearing elevation. Spread footings, if selected, may be sized in accordance with the above recommended bearing capacities and specified bearing material. Foundations should be designed and constructed in accordance with the Continuous and Spread Foundations , Slab-on-Ground, and Drilled Shafts recommendations incl uded in the Foundation Recommendations section of this report. Be low grade walls and below grade -12- Report No. 04.10013647 drainage considerations shou ld be designed in accordance with the Below Ground Walls section of this report. Washwater Decant Basin The Washwater Decant Basin will consist of a 100-ft diameter circular basin with a finished floor elevation of 1039.5 feet. With existing site grades rang ing from 1053.5 to 1056.5 ft, the basin will be approximately 14 to 17 ft below existing grade. Information provided to us indicates structural loading for the slab of 1.2 ksf and perimeter wall loads of 3.6 ksf. Boring WDB-1 was drilled at the proposed Washwater Decant Basin. The boring encountered 2.1 ft of surficial dark brown fat clay (residual soil) underlain by tan limestone of the Edwards formation. Limestone was encountered at elevation 1052 .9 ft, therefore, approximately 14 ft of limestone excavation will be required . The unconfined compressive strengths of the limestone at that boring ranged from 64 to 216 tsf which is typical of the hard and soft layered limestone. Further, a 2-ft thick clay layer was encountered at a depth of about 24 ft (elevation 1030 .6 ft) and is likely representative of c lay-filled voids which are often lenticular within the Edwards formation. Based on our understanding of the proposed construction and the subsurface conditions encountered in boring WDB-1, we recommend that the basin structure bear in tan Edwards limestone. Perimeter walls may be s ized using an allowable bearing pressure of 8 ksf for bearing at or below elevation 1039.5 feet. Foundations should be designed and constructed in accordance with the Continuous and Spread Foundations and Slab-on-Ground recommendations included in the Foundation Recommendations section of this report. Below grade walls and below grade drainage considerations should be designed In accordance with the Below Ground Walls section of this report. Contract provisions should be made for the possible presence of voids and/or clay filled voids at the foundation bearing elevation . These provis ions would Incl ude engineering inspection of the foundation subgrade by the geotechnical engineer prior to reinforcing steel p lacement, and mitigation techniques such as excavation of clay-filled voids , and backfilling of voids with flowable fill or lea n concrete. It should be noted that mitigation techniques presented herein are "structura l" methods for proper support of the structure. Fugro is not quali fied to provide environmental provisions or protocols for backfilling voids, if encountered. -13- -fur.R0 Report No. 04.10013847 1 Washwater Settling Basin The Washwater Settling Basin will consist of a 60-ft diameter circular basin with a finished floor elevation of 1039.5 feet. With existing site grades ranging from 1053.9 to 1056 ft, the basin will be approximately 14 to 17 ft below existing grade. Structural loading information provided to us indicates a slab load of 1.2 ksf and perimeter wail loads of 3.6 ksf. Boring WSB-1 was drilled at the proposed Washwater Decant Basin. The boring encountered 2.0 ft of surficial dark brown fat clay (residual soil) underlain by tan limestone of the Edwards formation. Limestone was encountered at elevation 1053.5 ft, therefore, approximately 14 ft of limestone excavation will be required. The unconfined compressive strengths of the limestone at that boring ranged from 41 to 104 tsf which is typically of the hard and soft layered limestone. Further, clay-filled voids were encountered in nearby borings which is typical of the Edwards formation. Based on our understanding of the proposed construction and the subsurface conditions encountered in boring WSB-1, we recommend that the basin structure bear in tan Edwards limestone. Perimeter walls may be sized using an allowable bearing pressure of 8 ksf for bearing at or below elevation 1039.5 feet. Foundations should be designed and constructed in accordance with the Continuous and Spread Foundations and Slab-on-Ground recommendations included in the Foundation Recommendations section of this report. Below grade walls and below grade drainage considerations should be designed in accordance with the Below Ground Walls section of this report. Contract provisions should be made for the possible presence of voids and/or clay filled voids at the foundation bearing elevation, These provisions would include engineering inspection of the foundation subgrade by the geotechnical engineer prior to reinforcing steel placement, and mitigation techniques such as excavation of clay-filled voids, and backfilling of voids with flowable fill or lean concrete, It should be noted that mitigation techniques presented herein are "structural" methods for proper support of the structure. Fugro is not qualified to provide environmental provisions or protocols for backfilling voids, if encountered. 4 MG Clearwell and 6 MG Clearwell Two C€earwells are planned: a 4 MG 185-ft diameter circular tank, and a 6 MG 225-ft diameter circular tank. We anticipate that the 4 MG Clearwell will be constructed first, and the 6 MG Clearwell will be constructed at a later date when demand rises. The proposed finished floor elevation for the Clearwells will be 1042 feet. With existing site grades ranging from about 1056 to 1054.3 ft, the structures will be founded approximately 8 to 12 ft below existing grade. -14- Report ND.04.10013647 w We have not been provided with proposed structural loading; however, we anticipate that slab loads and perimeter wall loads will be on the order of 1.5 ksf and 3 to 4 kips per linear foot. Borings CLL-1 and CLL-2 were drilled within the proposed 6 MG Clearwell footprint and borings CLL-3 and CLL-4 were drilled within the proposed 4 MG Clearwell footprint. Borings CLL-1 and CLL-2 encountered 0.5 and 3.0 ft of existing fill material, and borings CLL-3 and CLL-4 encountered 1.2 ft of surficial fat clay, all underlain by tan limestone at elevations 1049 and 1052.5 feet. Unconfined compressive strengths of intact limestone core samples ranged from 68 to 130 tsf with an average value of 99 tsf. A 3-ft thick clay layer was encountered in borings CLL-2 and CLL-3 at a depth of about 18.5 to 21 ft (elevation 1033.5 to 1032 ft). Although the clay layer encountered in the two borings is similar in thickness and elevation, clay layers and voids within the Edwards formation are typically lenticular in nature and not stratigraphically bedded. Based on a FFE of 1042 ft, the excavation will extend through surficial fill soils and 7 to 11 ft into the limestone stratum. Accordingly, foundations bearing at or below elevation 1042 ft in tan limestone may be sized using an allowable bearing pressure of 8 ksf. Foundations should be designed and constructed in accordance with the Continuous and Spread Foundations and Slab- on-Ground recommendations included in the Foundation Recommendations section of this report. Below grade walls and below grade drainage considerations should be designed in accordance with the Below Ground Walls section of this report. Contract provisions should be made for the possible presence of voids and/or clay filled voids at the foundation bearing elevation. These provisions would include engineering inspection of the foundation subgrade by the geotechnical engineer prior to reinforcing steel placement, and mitigation techniques such as excavation of clay-filled voids, and backfilling of voids with flowable fill or lean concrete. It should be noted that mitigation techniques presented herein are "structural" methods for proper support of the structure. Fugro is not qualified to provide environmental provisions or protocols for backfilling voids, if encountered. Disinfection Basin The Disinfection Basin will consist of a 110-ft wide rectangular basin with three approximately 45-ft wide bays. With a planned finished floor elevation of 1050 ft and existing site grades of 1055.5 to 1059 ft, the basin will bear 5.5 to 9 ft below existing grade. We have not been provided with proposed structural loading; however, we anticipate that slab loads and perimeter and interior wall loads will be on the order of 1.5 ksf and 3 to 4 kips per linear foot. Borings DB-1 and DB-2 were drilled within the proposed Disinfection Basin footprint. The borings encountered 2.5 ft and 4.2 ft of surficial dark brown fat clay (residual soil) underlain by tan -15- Report No.04.10013647 =� limestone at elevation 1053.5 and 1053.8 feet. Based on the planned FFE, excavations into the Edwards limestone will be on the order of 3 to 4 ft for the structure, Measured unconfined compressive strengths of intact limestone core samples ranged from 75 to 137 tsf. Based on our understanding of the proposed construction and anticipated foundation loading, we recommend that the Disinfection Basin foundation loads bear in tan limestone. Foundations may be sized using an allowable bearing pressure of 6 ksf for foundations bearing at or below elevation 1050 feet. Associated settlements will be on the order of 1 inch or less. Foundations should be designed and constructed in accordance with the Continuous and Spread Foundations and Slab-on-Ground recommendations included in the Foundation Recommendations section of this report. Below grade walls and below grade drainage considerations should be designed in accordance with the Below Ground Walls section of this report. Contract provisions should be made for the possible presence of voids and/or clay filled voids at the foundation bearing elevation, These provisions would include engineering inspection of the foundation subgrade by the geotechnical engineer prior to reinforcing steel placement, and mitigation techniques such as excavation of clay-filled voids, and backfilling of voids with flowable fill or lean concrete. It should be noted that mitigation techniques presented herein are "structural" methods for proper support of the structure. Fugro is not qualified to provide environmental provisions or protocols for backfilling voids, if encountered. Disinfection Facility The Disinfection Facility will consist of a 130-ft by 70 ft rectangular structure with a planned finished floor elevation of 1062 feet. With existing site grades of 1058 to 1069 ft, cuts and fills on the order of {-}7 and (t)4 ft will be necessary to achieve final grade. According to available structural load information, the facility will include maximum column loads on the order of 125 kips, and two tank pads with loads of 120 kips over a slab area of 40 ft by 62 ft, and 75 kips over a slab area of 22 ft by 40 feet. Boring DF-1 was drilled within the proposed Disinfection Facility footprint. The boring encountered 8 ft of existing fill material, underlain by about 3.5 ft of dark brown fat clay, further underlain by tan limestone at a depth of 11.5 ft with a corresponding elevation of 1054.5 feet. Potentially compressible soils (existing fill material) and potentially expansive soils (dark brown fat clay residual soils) are present beneath the proposed FFE and should be removed. Based on the boring data, suitable bearing material for the intended loading is at or near elevation 1054.5 feet. With a planned FFE of 1062 ft, approximately 7,5 ft of select fill will be needed to -16- "��R17 r r Report No.04.10013647 replace excavated fill soils and fat clay. The select fill should consist of a limestone derivative crushed limestone material meeting the plasticity, gradation, and compaction requirements included in the following Building Pad Preparation section of the Foundation Recommendations section. Based on our understanding of the proposed loading and anticipated subsurface conditions, the structure may be supported by shallow foundations bearing in compacted select fill. Continuous foundations bearing in select fill may be sized using an allowable bearing pressure of 3,000 psf. Associated settlement should be 1 Inch or less. Column supports may be founded either by spread footings bearing in select fill or by drilled shafts bearing in the tan limestone stratum. Spread footings, if selected, may be sized as recommended above. Drilled shafts, if selected, should extend through the select fill material and be embedded into the tan moderately weathered limestone stratum and sized using an allowable skin friction resistance of 3 ksf, neglecting the upper 5 ft of limestone embedment. End bearing capacity is available; however, probe holes would be required at each shaft location to confirm the presence of suitable bearing and absence of voids at or below the bearing elevation. Foundations should be designed and constructed in accordance with the Continuous and Spread Foundations, Slab-on-Ground, and/or Drilled Shaft recommendations included in the Foundation Recommendations section of this report. Booster Pump Station The Booster Pump Station will consist of a rectangular structure with a proposed finished floor elevation of 1455.5 feet. With existing site grades of 1054 to 1055 ft, the structure will be constructed at or near existing grade. We have not been provided with specific structural load information; however, we anticipate that the housing structure will be slab on grade construction, and the individual pumps and piping will extend some depth below grade. Boring BPS-1 was drilled at the proposed Booster Pump Station location. The boring encountered 0.5 ft of existing fill and 2 ft of potentially expansive fat clay (residual soil), underlain by tan limestone at a depth of 2.5 ft below existing grade with a corresponding elevation of 1051.8 feet. Potentially compressible soils (existing fill material) and potentially expansive soils (dark brown fat clay residual soils) are present beneath the proposed FFE and should be removed. Based on the boring data, suitable bearing material for the intended loading is at or near elevation 1051.8 feat. With a planned FFE of 1055.5 ft, approximately 4 ft of select fill will be needed to -17- -FURIWO Report No.04.10013647 a M replace excavated fill soils and fat clay. The select fill should consist of a limestone derivative crushed limestone material meeting the plasticity, gradation, and compaction requirements Included in the following Building Pad Preparation section of the Foundation Recommendations section. Based on our understanding of the proposed loading and anticipated subsurface conditions, the structure may be supported by shallow foundations bearing in compacted select fill. Continuous foundations bearing in select fill may be sized using an allowable bearing pressure of 3,004 psf. Associated settlement should be 1 inch or less. Foundations should be designed in accordance with the recommendations presented in the Foundation Recommendations section of this report. Sludge Pump Station The Sludge Pump Station is shown as a small rectangular structure with pian dimensions of about 25 ft by 15 ft, and a finished floor elevation of 1028 feet. The existing site grade is approximately 1050 ft, therefore, the pump station will be about 32 ft below grade. Boring SLPS-1 was drilled at the proposed Sludge Pump Station. The boring encountered 2 ft of surficial dark brown fat clay underlain by limestone at elevation 9058 feet. Unconfined compressive strengths of intact limestone core samples from the boring ranged from 18 to 113 tsf with an average of 84 tsf. A 1-ft thick clay layer was encountered at a depth of about 33.5 ft {elevation 1025.5 ft} and is likely representative of clay-filled voids which are often lenticular in the Edwards formation. The Sludge Pump Station foundation will bear approximately 30 ft into the tan Edwards limestone stratum. The slab/mat foundation may be design using an allowable bearing pressure of 10 ksf for bearing at or below elevation 1028 feet. Foundations should be designed and constructed in accordance with the Mat/Slab Foundation recommendations included in the Foundation Recommendations section of this report. Below grade walls and below grade drainage considerations should be designed in accordance with the Below Ground Walls section of this report. Due to the possible presence of clay-filled voids or voids at or below the proposed bearing elevation (see boring SLPS-1), we recommend that probe holes are drilled at least 10 ft below the planned bearing elevation. At least 3 probe holes should be drilled within the proposed bearing area of the foundation. Probe hole advancement should be observed and documented by the geotechnical engineer or his representative. Probe hole explorations should be performed in -18- Report No. 04.10013647 if DAD imil accordance with the guidelines presented in the Mitigation of Voids section in the Construction Considerations section of this report. 1sr Stage Sludge Thickener The 1st Stage Sludge Thickener will consist of a 60-ft diameter circular basin with a proposed finished floor elevation of 1051.67 feet. With existing site grades ranging from 1058.5 to 1059.6 ft, the basin will be approximately 7 to 8 ft below existing grade. Available structural loading indicates perimeter wall loads of 2 kips per linear foot. Boring ST1-1 was drilled at the proposed 111 Stage Sludge Thickener basin. The boring encountered 0.5 ft of surficial dark brown fat clay (residual soil) underlain by tan limestone of the Edwards formation. Limestone was encountered at elevation 1058.5 ft, therefore, approximately 7 ft of limestone excavation will be required . The unconfined compressive strengths of intact limestone core samples were 64 and 210 tsf. The 1st Stage Sludge Thickener foundation will bear approximately 7 ft into the tan Edwards limestone stratum. The perimeter wall continuous foundation may be designed using an allowable bearing pressure of 8 ksf for bearing at or below elevation 1051 feet. Foundations should be designed and constructed in accordance with the Continuous and Spread Foundations recommendations included in the Foundation Recommendations section of this report. Be low grade walls and below grade drainage considerations should be designed in accordance with the Below Ground Walls section of this report. 2nd Stage Sludge Thickener The 2nd Stage Sludge Thickener wlll consist of a 60-ft diameter circular basin with a proposed finished floor elevation of 1050.67 feet. With existing site grades ranging from 1057.9 to 1059.2 ft, the basin will be approximately 7.5 to 9 ft below existing grade. Available structural loading indicates perimeter wall loads of 2 kips per linear foot. Boring ST2-1 was drilled at the proposed 2nd Stage Sludge Thickener basin. The boring encountered 1.2 ft of surflcial dark brown fat clay (residual soil) underlain by 3.8 ft of tan clayey sand (noted as moist) further underlain by tan limestone of the Edwards formation. Limestone was encountered at elevation 1053.4 ft, therefore, approximately 3 ft of limestone excavation will be required. The unconfined compressive strengths of intact limestone core samples were 89 and 128 tsf. -19- Report No.04.10013647 The 2 d Stage Sludge Thickener foundation will bear approximately 4 ft into the tan Edwards limestone stratum. The perimeter wall continuous foundation may be designed using an allowable bearing pressure of 6 ksf for bearing at or below elevation 1051 feet. Foundations should be designed and constructed in accordance with the Continuous and Spread Foundations recommendations included in the Foundation Recommendations section of this report. Below grade walls and below grade drainage considerations should be designed in accordance with the Below Ground Walls section of this report. Sludge Dewatering Facility The Sludge Dewatering Facility will consist of a 95-ft by 60 ft rectangular structure with a planned finished floor elevation of 1060 feet and vehicular drive-under port. With existing site grades of 1058 to 1059.5 ft, fills on the order of 1 to 2 ft are planned to achieve final grade. According to provided structural load information, the facility will include maximum column loads an the order of 25 kips. Boring SDF-1 was drilled within the proposed Sludge Dewatering Facility and encountered 0.5 ft of surficial dark brown fat clay underlain by limestone at an elevation of 1058.7 feet. A 0.7-ft thick clay layer was encountered at a depth of about 4.5 feet. Potentially compressible and expansive soils should be removed from beneath the proposed building footprint and at least 3 ft beyond. Based on the boring data, suitable bearing material for the intended loading is at or near elevation 1058.7 feet. With a planned FFE of 1060 ft, approximately 2.5 ft of select fill will be needed to replace excavated unsuitable soils. The select fill should consist of a limestone derivative crushed limestone material meeting the plasticity, gradation, and compaction requirements included in the following Building Pad Preparation section of the Foundation Recommendations section. Foundations may consist of a grid-beam stiffened slab on grade atop a select fill pad, with widened beam intersections at column locations. Continuous or spread footings bearing in select fill may be sized using an allowable bearing pressure of 3,000 psf. Alternatively, column loads may be supported by drilled shafts bearing in the tan limestone stratum. Drilled shafts may be sized using an allowable skin friction resistance of 3 ksf, neglecting the upper 5 ft of limestone embedment. Foundations should be designed and constructed in accordance with the Building Pad Preparation, Continuous and Spread Foundations, and/or Drilled Shaft recommendations included in the Foundation Recommendations section of this report. -20- fa R Cl Report No. 04.10013547 Wastewater Lift Station The Wastewater Lift Station has a proposed finished floor elevation of 1037.6 feet. The existing site grade is approximately 1067 ft, therefore, the wet well will be about 30 ft below grade. Boring WWLS-1 was drilled at the proposed Wastewater Lift Station. The boring encountered 1 ft of surficial dark brown fat clay underlain by limestone at elevation 1066 feet. Unconfined compressive strengths of intact limestone core samples from the boring ranged from 75 to 148 tsf. The boring was terminated at elevation 1037.5 ft in fossiliferous limestone. The Wastewater Lift Station foundation will bear approximately 28 ft into the tan Edwards limestone stratum. The slab/mat foundation may be design using an allowable net bearing pressure of 10 ksf for bearing at or below elevation 1037 feet. It should be noted that the boring was terminated near the proposed bearing elevation. Therefore, probe holes are recommended to confirm the presence of competent hearing material (limestone), and to explore for potential voids at or near the bearing elevation, as encountered in nearby borings. At least 3 probe holes are recommended and the probe holes should be drilled at least 10 ft below planned bearing elevation. Probe hole advancement should be observed and documented by the geotechnical engineer or his representative. Probe hole explorations should be performed in accordance with the guidelines presented in the Mitigation of Voids in the Construction Considerations section of this report. Foundations should be designed and constructed in accordance with the Mat/Slab Foundation recommendations included in the Foundation Recommendations section of this repoft. Below grade walls and below grade drainage considerations should be designed in accordance with the Below Ground Walls section of this report. Electrical Building The Electrical Building will consist of a 60 ft by 35 ft rectangular structure with a proposed finished floor elevation of 1062 feet. According to provided pians, the Electrical Building will be partially situated over an existing detention pond embankment and small concrete walls. With existing grades ranging from about 1057 ft at the toe of the existing embankment structure to about 1062 ft at the crest of the earthen structure, site grading will include mostly fill on the order of 5 ft to achieve final grade. The electrical building will be consist of a CMU building with perimeter wall loads on the order of 3.5 kips per linear foot and slab loads on the order of 150 psf. -21- -runlaa Report No.44.10013647 a Boring EB-1 was drilled within the propose Electrical Building footprint. The boring encountered 0.4 ft of fill material, underlain by about 1 ft of dark brown fat clay material, further underlain by tan limestone at a depth of 1.4 ft with a corresponding elevation of about 1055.6 feet. Based on our understanding of the proposed construction and the subsurface conditions encountered, we recommend that the Electrical Building foundation consist of a grid-beam stiffened slab bearing atop a select fill pad. All existing fill (associated with the existing embankment), concrete wails, fences, and surficial fat clay should be removed from beneath the building footprint and at least 3 ft beyond thereby exposing tan weathered limestone. Based on the boring data, tan limestone should be at or near elevation 1055.6 ft which would require as much as 6.4 ft of select fill to achieve planned grade. The select fill should consist of a limestone derivative crushed stone meeting specific plasticity, gradation and compaction recommendations presented in the Building Pad Preparation section of the Foundation Recommendations section. FOUNDATION RECOMMENDATIONS As outlined in the previous Details of Structures and Foundations section of this report, the proposed Water Treatment Plant structures will mostly be supported by Slabs-on-Grade support atop a select fill pad, Continuous and Spread Footings, Mats/Slab Foundations, and/or Drilled Piers. A table summarizing the proposed structures and salient foundation issues is presented on the following pages. Summary of Structures and Salient Foundation issues + Structure ProposedFIFEFoundation Recommendations and Salient Issues 21VIG EST foundation will likely consist of a Ring Foundation bearing approximately 6 to 9 ft below existing grade in the tan limestone. 21VIG Elevated Foundations bearing at least 6.5 ft below grade in tan limestone may Storage Tank -� be sized using an allowable net bearing pressure of 8 ksf. If additional capacity is needed, foundations bearing at least 8 ft below grade in tan limestone may be sized using an allowable bearing pressure of 10 ksf. -22- �C.RO Report No,44,10013647 p, Summary of Structures and Salient Foundation Issues Structure ProposedFFE Foundation Recommendations and Salient Issues Foundations will consist of Continuous and Spread footings, Slabs-on- Grade, and Drilied Piers bearing in select fill and natural weathered limestone. Continuous and Spread footings may be sized using an Central Treatment 1059-1066 allowable net bearing pressure of 3 ksf for bearing in select fill, and 4 Structure ft ksf for bearing in completely weathered limestone. Drilled piers may be sized using a skin frictional resistance of 3 ksf, neglecting the upper 5 ft of embedment in the moderately weathered limestone stratum. End hearing is available; however, probe holes would be necessary. Both the Washwater Decant Basin and the Washwater Settling Basin will be founded about 14 to 17 ft below grade in tan limestone. Accordingly, perimeter wall Continuous Footings may be sized using Washwater an allowable net bearing pressure of 8 ksf. It should be noted that clay Decant Basin and 1039.5 ft filled-voids and other solution features may be present at the Washwater foundation bearing elevation and should be observed by the Settling Basin geotechnical engineer prior to reinforcing steel placement. If present, structural mitigation techniques may include backfilling with flowable fill or lean concrete. Environmental concerns associated with the presence and backfilling of voids will be addressed by others. The 4MG and 6 MG Clearwell basins will be founded about 8 to 12 ft below grade in tan limestone. Accordingly, perimeter wall Continuous Footings may be sized using an allowable net bearing pressure of 8 4MG and 6MG ksf. Clay filled-voids and other solution features may be present at the Ciearwells 1042 ft foundation bearing elevation and should be observed by the geotechnical engineer prior to reinforcing steel placement. if present, structural mitigation techniques may include backfilling with flowable filf or lean concrete. Environmental concerns associated with the presence and backfilling of voids will be addressed by others. -23- W Report No.44.10013647 Summary of Structures and Salient Foundation Issues Structure ProposedFFE Foundation Recommendations and Salient Issues The Disinfection Basin will be founded about 5.5 to 9 ft below grade in tan limestone. Accordingly, Continuous Footings may be sized using an allowable net bearing pressure of 6 ksf. Clay filled-voids and other solution features may be present at the foundation bearing elevation Disinfection Basin 1050 ft and should be observed by the geotechnical engineer prior to reinforcing steel placement. If present, structural mitigation techniques may include backfilling with flowable fill or lean concrete. Environmental concerns associated with the presence and backfilling of voids will be addressed by others. Foundation subgrade consists of 11.5 ft of existing fill and fat clay unsuitable for the intended support. Foundations will consist of a Continuous and Spread Footings and Slabs-on-Grade atop a select fill Disinfection 1002 ft pad approximately 7,5 fit thick. Continuous and Spread footings may Facility be sized using an allowable net bearing pressure of 3 ksf for bearing in select fill. Drilled piers may be sized using a skin frictional resistance of 3 ksf, neglecting the upper 5 ft of embedment in the moderately weathered limestone stratum. Booster Pump Foundation subgrade will consist of a 4 ft select fill pad. Continuous 1055.5 ft and Spread Footings may be sized using an allowable net bearing Station pressure of 3 ksf for bearing in select fill. The Sludge Pump station will be founded about 32 ft below grade in tan limestone. Accordingly, Mat/Slab foundations may be sized using an allowable net bearing pressure of 10 ksf, Because of a clay filled Sludge Pump void in boring SLIPS-11, probe holes are recommended to explore Station 1028 ft bearing material beneath mat/slab foundation. We recommend at least 3 probe holes extending at least 10 ft below bearing elevation. if voids are present, structural mitigation techniques may include backfilling with Plowable fill or lean concrete. Environmental concerns associated with the presence and backfilling of voids will be addressed by others. -24- Report No.04.10013647 Summary of Structures and Salient Foundation Issues Structure ProposedF1=E Foundation Recommendations and Salient Issues The 1$' Stage Sludge Thickener will be founded about 7 to 8 ft below grade and about 7 ft into tan limestone. Accordingly, foundations may be sized using an allowable net bearing pressure of 8 ksf. Clay filled- 15t Stage Sludge voids and other solution features may be present at the foundation Thickener 9051.67 bearing elevation and should be observed by the geotechnical engineer prior to reinforcing steel placement. If present, structural mitigation techniques may include backfilling with flowable fill or lean concrete. Environmental concerns associated with the presence and backfilling of voids will be addressed by others. The 2"d Stage Sludge Thickener will be founded about 7.5 to 9 ft below grade and about 4 ft into fan limestone. Accordingly, foundations may be sized using an allowable net bearing pressure of 6 ksf. Clay filled- 2"e Stage Sludge voids and other solution features may be present at the foundation Thickener 1050.67 bearing elevation and should be observed by the geotechnical engineer prior to reinforcing steel placement. If present, structural mitigation techniques may include backfilling with flowable fill or lean concrete. Environmental concerns associated with the presence and backfilling of voids will he addressed by others. Foundatlon subgrade will consist of about 2.5 ft of select fill. Continuous and Spread Footings may be sized using an allowable net Sludge bearing pressure of 3 ksf for bearing in select fill. If needed, column Dewatering 1050 ft loads may be supported by drilled shafts penetrating the limestone Facility stratum. Drilled shafts may be sized using a skin frictional resistance of 3 ksf, neglecting the upper 5 ft of embedment in the moderately weathered limestone stratum. The WW Lift Station wet well will be founded about 30 ft below grade in tan limestone, Accordingly, Mat/Slab foundations may be sized using an allowable net bearing pressure of 10 ksf. Probe holes are Wastewater Lift recommended to explore bearing material beneath mat/slab Station 1037.6 ft foundation. We recommend at least 3 probe holes, at least 10 ft Below bearing elevation, If voids are present, structural mitigation techniques may include backfilling with flowable fill or lean concrete. Environmental concerns associated with the presence and backfilling of voids will be addressed by others. -25- Report No.04.10013647 Summary of Structures and Salient Foundation Issues Structure ProposedFFE Foundation Recommendations and Salient Issues Foundation subgrade will consist of a 6.4 ft thick select fill pad. Electrical 1062 ft Foundation should consist of a Grid Beare Stiffened Slab. Beams Building should be sized for an allowable bearing pressure of 3 ksf for bearing in select fill. The following sections present our recommendations for Building Pad Preparation, Mat/Slab Foundations, Continuous and Spread Footings, Grid-Beam Stiffened Slab, and Drilled Shaft Design and Construction. Building Pad Preparation 1. Within the footprint of the structure and for a distance 5 ft outside the footprint, remove and dispose of all existing fill material, surficial fat clay (residual soil, if present), organics, other deleterious materials, and at feast 6 inches of the surficial soil; thereby exposing tan completely to highly weathered limestone. 2, If the excavation encounters slightly to moderately weathered limestone, remove any additional depth to allow for at least 8 inches of select fill beneath the slab and/or mat and stiffening elements. Mat and grid-beam stiffened slab foundations should bear in similar stiffness materials. 3. If the cut subgrade is soil-like, scarify at least 6 inches of the cut soil subgrade and recompact to a minimum of 95% of the maximum dry density as determined using the Texas Department of Transportation (TxDDT) Test Method TEX-113-E. Hold water contents within x-2% of the optimum water content. 4. Proof roll the subgrade in accordance with City Of Austin Standard Specifications Item 236S, Proof Rolling. Undercut soft areas and replace with compacted select fill. The proof rolling operation should be observed by a representative of the geotechnical engineer. 5. Bring the building/basin pad to grade with select crushed limestone generally conforming to the following gradation: Retained on 2-1/2" screen 0% Retained on 7/8" screen 5% - 50% Retained on 318" screen 25% -65% Retained on No. 4 sieve 35% - 75% Retained on No. 40 sieve 60% -90% -26- �ra�o Report No. 04.10013647 Material passing the No. 40 sieve shall meet the following plasticity requirements: Passing Maximum Minimum No. 40 Sieve Plasticity Index Plasticity index 25% -40% 15 3 10% -25% 20 4 6. Compact select fill to at least 95% of the maximum dry density as determined using TxDOT Test Method TEX-113-E. Hold water contents within ±2% of the optimum water content, and maintain compacted lift thicknesses to six inches or less. 7. If moisture migration through the slab is a potential problem, place a capillary moisture barrier/drainage layer (minimum thickness of four inches) atop the compacted select fill. The material should consist of free-draining, clean, crushed stone with sizes ranging mostly between 1/4 and % inch. A material conforming to ASTM C 33, Grade 67, is suggested since it is readily available in the central Texas area. The purpose of this layer is to break the transmission of capillary moisture to the underside of the slab. 8. For closed-in buildings, place a vapor barrier with sufficient strength and durability to resist puncture during reinforcing steel and concrete placement beneath the concrete slab. Placement of the vapor barrier should be in accordance with manufacturer's recommendations. Slab/Mat Foundations The structural engineer should design the slab/mat foundations in accordance with the following design parameters, provided the subgrade preparation and select fill pad recommendations herein are followed. Foundation Depth. All slab/mat foundations should be founded on either select fill or completely to highly weathered limestone. Exterior foundations should be at least 2 ft below final grade. Allowable Net Bearing Pressure. The slab/mat foundations should be proportioned so that the maximum contact pressure under dead loads, sustained loads and transient loads does not exceed the allowable net bearing pressure for the foundation soil. Foundations should be founded on either select fill placed in accordance with recommendations included herein or completely to highly weathered limestone. The mat foundations should be designed for an allowable net bearing pressure of 3,000 psf for bearing in select fill, and 4,000 psf for bearing in completely to highly weathered limestone. -27- Report No, 04.10013647 Resistance to Lateral Loads. Horizontal loads acting on the foundations will be resisted by friction between the foundation material and the base of the foundation and by passive resistance of the soil adjacent to the foundation. For design purposes, the resistance due to passive soil pressure should be neglected due to potential shrinkage of the soil away from the foundation. For concrete foundations poured in good contact with either select fill or completely to highly weathered limestone, an allowable coefficient of friction of 0.37 may be used for sliding resistance in select fill, and 0,55 for sliding resistance in completely to highly weathered limestone. Resistance to Uplift Loads. After construction of below grade structures, the groundwater level could rise to the ground surface within the backfilled excavations if not properly and permanently drained. The resulting buoyancy potential should be accounted for in the design of the structure where required. The ultimate uplift capacity of mat foundations is usually limited to the weight of the foundation plus the weight of any soil directly above the foundation. If additional uplift capacity is required, one or more of the following options can increase the capacity: • Extending a perimeter "lip" of sufficient size around the base of proposed below- ground structures to use the submerged unit weight of the backfill soil directly above the lip; • Structurally connecting below-ground structures to associated large above grade structures, if applicable; or ■ Using tension piles or soil/rock anchors to resist uplift forces. The calculated ultimate uplift capacity should be reduced by an appropriate factor of safety to compute the allowable uplift resistance. Modulus of Subgrade Reaction for Mat Foundations. The design of mat foundations generally requires a modulus of subgrade reaction, k5, the ratio between unit soil pressure and the corresponding settlement. It has been found that bending moments and the computed soil pressure are not very sensitive to ks values because the structural member stiffness is usually 10 or more times as great as the soil stiffness as defined by ks.3 Recognizing this, a value estimated from allowable bearing pressures is generally acceptable.¢ Therefore it is recommended that a value of 75 pci may be used for bearing on the select fill and a value of 150 pci may be used for bearing on completely to highly weathered limestone. a Bowles,J.E., (1982), Foundation Analysis and Design,Third Edition,New York,McGraw dill, y�.. .. pp.323-325. a Bowles,J.E., (1982), Foundation_Analysis and Design,Third Editlon, New York,McGraw HIII, pp. 503. -28- =1■ Report No.04,10013647 WWL Continuous and Spread Footings For the proposed bearing elevations and loadings as defined in the Detains of Structures and Foundations section of this report, continuous and spread footings bearing in select fill may be sized using an allowable bearing pressure of 3,000 psf. Footings bearing in tan completely weathered limestone may be sized using an allowable bearing pressure of 4,000 psf. Foundations bearing in moderately weathered limestone may be sized using an allowable bearing pressure of 6,000 psf to 10,000 psf, depending on the structure bearing elevation and embedment into the limestone stratum. Continuous and spread footings should penetrate the limestone at least 2 feet. Continuous and spread footings should be at least 30 inches wide and 2 ft deep. Exterior footings should be founded at least 2 ft below final grade. Settlement of footings designed in accordance with the recommendations included herein will be on the order of 1 inch or less for foundations bearing in select fill, on the order of % inch or less for foundations bearing in completely weathered limestone, and less than %4 inch for foundations bearing in highly to slightly weathered limestone. The bottom of the excavation for footings should expose select fill or undisturbed completely to highly weathered limestone. Any loose or disturbed materials encountered at the bottom of the excavation should be removed. In addition, there should not be any free water standing in the excavation at the time of concrete placement. The exposed bearing subgrade should be observed by the geotechnical engineer prior to construction of the foundation to confirm suitable bearing. Grid-Beam Stiffened Slabs-on-Ground The structural engineer should design grid-beam stiffened slabs-on-ground including: beam depth, spacing and reinforcement, and the slab thickness and reinforcement, based on the following soil parameters. 1. Beams should be founded in either select fill placed in accordance with the recommendations herein andlor completely to highly weathered limestone. The beams should be sized for an allowable bearing pressure of 3,000 psf for bearing in select fill. A higher bearing capacity of 4,000 psf is available for bearing in weathered limestone. Beams widths should be at least 18 inches. 2. Ensure that any concentrated loads are centered at the intersection of beams. Beneath concentrated loads, beam intersection should be widened and sized for an allowable bearing pressure of 3,000 psf. -29- Report No. 04.10013547 011 O 3. Potential vertical movements should be 1 inch or less, provided preparation of the building/basin pads is performed in accordance with the recommendations presented herein. 4. If the slab-on-ground design requires a modulus of subgrade reaction, use 75 poi. 5. At a minimum, place stiffening beams along the perimeter of the slab. The perimeter beam should be at least 30 inches wide and extend at least 2 ft below the surrounding ground surface. Depending on Interior wall and equipment loads, the interior of the slab should be stiffened with grid-beams on a regular grid pattern or thickened, as required. Drilled Shaft Design 1. The drilled shafts should penetrate tan moderately hard to hard, moderately weathered limestone at least 5 ft, and be designed using an allowable skin friction of 3.0 ksf for the portion of the shaft below 5 ft of penetration into the limestone stratum. 2. If uplift is needed, drilled shafts may be designed for an allowable uplift resistance of 1.5 ksf for the portion of the shaft penetrating the slightly to moderately weathered limestone, and neglecting the upper 5 ft of limestone embedment. 3. A minimum shaft diameter of 24 inches and a minimum reinforcement steel area of 0.5 percent of the gross area of the shaft are recommended. 4. The structural capacities of the drilled shafts should be checked for allowable stresses In the concrete, total downward axial loads, tension forces, lateral forces, and moments produced by dead plus probable maximum live loads. 5. Maintain a minimum clear spacing between drilled shafts of at least three shaft diameters. If the minimum spacing cannot be maintained, the geotechnical engineer should be retained to consider the group effect of the closely spaced shafts. S. Settlement of drilled shafts designed and constructed in accordance with these recommendations should be less than 0.5 inches. Drilled Shaft Construction 1. Since some variation in drilled shaft depths may be required due to the character of the limestone strata and the possible presence of fractured zones, clay layers or lenses, or other defects such as solution features, contract documents should include pay items for constructing drilled shafts on a unit price basis for Moth shaft quantities in soil and rock. -30- Report No.04.10013647 2. Contract documents should provide for the use of temporary casing for proper installation of drilled shafts should detrimental groundwater or caving soil conditions (such as existing fill) be encountered. A unit price for the use of casing should be identified on the bid tabulation form in the contract documents. 3. To prevent deterioration of the sides and bottoms of shaft excavations, reinforcement and concrete should be placed the same day drilling operations are completed. Before placement, shafts should be inspected to assure bottoms and sidewalls are free of deleterious spall and free water, 4. In order to promote shaft-to-soil bonding, drilled-shaft concrete should be specified as a high slump concrete (7- to 8-inch slump, preferably superplasticized), which stili has the proper characteristics of normal concrete such as workability, durability, cohesiveness, and strength. 5. Centralizing chutes, tremies, and/or concrete pumps may be necessary to prevent the concrete from striking the sides of reinforcement and thus segregating. The desired maximum free fall of concrete should be about 10 ft, but greater heights are allowable if segregation can be eliminated and if the shaft hole is dry. 6. The drilled shaft operations should be inspected, on a full-time basis, by a qualified representative of the geotechnical engineer to (a) verify desired penetration into the bearing stratum, (b) verify shaft dimensions and proper reinforcement, (c) monitor cleanness and amount of water in shaft excavations, (d) monitor placement of concrete and use of tremie or pumps, and (e) monitor the extraction of casing, if used. 7. As the design of any foundation relies heavily on generalizations drawn from subsurface conditions determined at a limited number of boring locations, verification of these generalizations at any given location should not be dictated by criteria based on depth or drilling resistance. Instead, the sides and bottoms of shafts should be examined by the geotechnical engineer of record to assure that shaft bottoms bear in the desired stratum. The bottom of the drilled shaft excavations should be cleaned as If the shafts were designed for end-bearing. 8. In addition to construction recommendations contained herein, the shafts shoctd be constructed in general accordance with ACI 335.38, Chapters 4 and 5. Seismic Design Based on the soil boring and rock core information, the site classifies as Site Class 8 in accordance with Table 1615.1.1 of the 2003 International Building Code. -31- Report No. 04.10013647 U WIN BELOW GROUND WALLS The deformation condition imposed by a wall on the soil it retains has a significant influence on the coefficient of horizontal earth pressure. The two general deformation conditions are "yielding" and "nonyielding". Yielding walls are those that move enough to allow the retained soil to reach a state of limit equilibrium. The active state of limit equilibrium is approached as the wall moves away from the retained soil. Nonyielding walls are those that do not move or move very little usually because of restraint at the top so that they are not free to tilt. Since deformation is prevented, the state of limit equilibrium is not approached, the shear strength of the soil is not developed and the earth pressure remains equal to the at-rest pressure, The type of backfill also has an important influence on the coefficient of horizontal earth pressure. A clean, granular, free-draining material is the preferred backfill. Additionally, the accumulation of water in the backfilled cuts adjacent to the structure walls will influence the horizontal earth pressure. The high permeability of clean, granular, free-draining materials combined with adequate drainage above the water table prevents the buildup of hydrostatic pressure. Use the recommended equivalent fluid unit weights set forth below for nonyielding below ground walls along with the required type of backfill and geometry, and drainage noted. 1. With the use of granular free-draining material, selected in accordance with Item 4 below and placed in the zone extending upward from at least 2 ft behind the wall to the backfill surface at an angle of 60 degrees from horizontal, use an equivalent fluid unit weight of 50 pcf if the backfill is fully drained and 90 pcf if not drained. 2. With the use of granular, free-draining material, selected in accordance with Item 4 below and placed in a 2-ft thick (minimum) zone behind the wall, use an equivalent fluid unit weight of 60 pcf if fully drained and 100 pcf if not drained. 3. The Sludge Pump Station (32 ft below grade) and the WW Lift Station (30 ft below grade) will be mostly embedded in limestone. Assuming these below grade structures will not be drained, we recommend using an equivalent fluid unit weight of 75 pcf for the at-rest, undrained condition. Buoyancy effects should be accounted for as recommended in the Slab/Mat foundation recommendation section. A high groundwater condition of one-half the height of the below grade structure should be assumed for buoyancy considerations. 4. With the use of on-site material, that classifies as a CL, CL-ML, or SC material, use an equivalent fluid unit weight of 110 pcf for the undrained condition. If on-site material is used as backfill, the backfill should have a PI between 5 and 20, a maximum particle -32- p 11 Report No. 04.10013647 size of 3 inches, be free of organics and/or deleterious material, and be approved by the geotechnical engineer. 5. The free-draining backfill should be a washed, crushed, coarse-grained material with sizes ranging mostly between '/4 and 1/2 inch, and no more than 5% passing the No. 200 sieve. An acceptable gradation would be similar to that of the ASTM C33 Size No. 67 gradation. 6. If used, the free-draining material should be placed in maximum 6 inch lifts and compacted with a minimum of four complete overlapping passes over the entire surface with a vibratory plate compactor until further passes will not result in greater densification. This process should be observed by a representative of the geotechnical engineer. 7. If on-site clay soils are used as backfill, compact the fill material to at least 95% of the maximum dry density as determined using TxDOT Test Method TEX-113-1=. Hold water contents within ±2% of optimum, and maintain compacted lift thicknesses to 6 inches or less. Confined excavations may require smaller lift thicknesses to achieve specified compaction. 8. If the design involves any uniform vertical surcharge adjacent to the wall, use a coefficient of horizontal earth pressure of 0.50. 9. If below grade drainage is planned, place a minimum 4-inch diameter perforated pipe system near the bottom of the exterior footing or about 1-ft below the finished floor elevation, whichever is lower, to prevent buildup of hydrostatic pressures and for perimeter drainage. Perforations should be placed downwards and the pipe should be wrapped with a suitable filter fabric to prevent clogging. The perforated pipe should be tied to a solid pipe discharging into sump(s) equipped with a pump{s} discharging into an approved disposal or discharge system. 10. The free-draining backfill should be capped with 12 inches of on-site clay having a plasticity index of between 15 and 30. Compact the lean clay to 95% of the maximum dry density determined using TxI7OT Test Method TEX-114-E. Hold compacted lift thicknesses to 6 inches or less and water contents within t2% of the optimum water content. A filter fabric should be placed between the clay cap and the free-draining backfill. -33- -ruaRA Report No. 04.10013647 CONSTRUCTION CONSIDERATIONS Site Grading and Drainage Grading around the structures should be such that future ponding or standing water around the structures does not occur. All surface drainage measures should be designed to positively direct water well away from the structures. Utility Badding and Backfill Successful installation of associated plumbing will depend on a number of factors including the available support from the surrounding soils and rock and the type of bedding material used. Proposed utilities should be bedded and backfilled in accordance with the City of Austin Standard Specifications, Section 510, August 2004. Trench excavations may be backfilled with the excavated material provided the material is processed and placed in compliance with the following: 1. Excavated trench material should be free of debris, clay lumps, excessive organics, and other deleterious material, and be screened to limit the maximum particle size to 3 inches; and 2. Compact the backfill to 95% of the maximum dry density determined using TxDOT Test Method TEX-114-E for clayey soils and TEX-113-E for gravelly soils. Compacted lift thicknesses should not be more than 6 inches. Water contents of the compacted backfill should be within f2% of optimum. 3. Density testing should be performed on the backfill after each horizontal lift and not by "potholing." This requirement will necessitate protection for density testing technician in trenches deeper than 5 ft by some means of trench safety system. Excavation Potential Excavation through the surficial reddish brown (residual) soils and fill should proceed without significant difficulty. Excavation of existing fill at the Raw Water Intake and Pump Station site may encounter large cobbles and boulders which may present transportation and/or disposal issues. Advancement through the tan completely weathered limestone, and highly to slightly weathered limestone will proceed with greater difficulty. Limestone cobbles, boulders, and layers should be anticipated within the completely weathered limestone stratum. Assessments of rippability, based on inspection of cores and estimated P-wave velocities indicate that the tan highly to slightly weathered limestone is rippable with a Caterpillar D9N or equivalent, equipped -34- Report No. 04.1 0013647 with a multi or single shank ripper.5 As a result of weathering and j ointing and the presence of occasional soft layers, portions of the limestone may be mo re easily ripped or excavated. Harder, more resistance limestone may require use of heavy duty track-mounted rock excavation equipment, rock trenche rs (rock saws), and hoe-rams. Varying degrees of difficu lty will be experienced during excavation for the Washwater Equalization Bas in. Temporary Construction Slopes The design of construction slopes and temporary retainage systems are the sole responsibility of the contractor. The suggestions set forth herein are for estimating purposes, and do not, in any way, change the sole re sponsibility of the contractor for design. According to OSHA regulations6 for classifying soil and rock, overburden soils consisting of dark brown fat clay (res idual soi ls) and tan sandy lean clay and c layey sand (completely weathered li mestone) can be classified as Type B soil. As such, the maximum allowable slopes in Type B soil for excavations less than 20 ft deep are 1 horizontal to 1 vertical (1H:1V). Classification of fill material is more difficult to assess . For planning purposes, fill soils should be considered Type C, where maximum allowable slopes in Type C soll for excavations less than 20 ft deep are 1.5 horizontal to 1 vertical (1.5H :1V). A lternatives for sloping and benching for excavations deeper than 20 ft should be designed by a licensed professional engineer in the state of Texas . Limestone may be considered "stable rock" where vertical sidewalls are permitted per OSHA regu lations. However, if the rock is faulted, jointed, or includes incl ined discontinuities, flatter slopes will be required to maintain safe excavations. Type A should be assumed for planning purposes, w ith permissible side slopes of 0.75H to 1V. Mitigation of Voids Based on proposed bearing elevations and bo ring data, excavations will mostly extend through the vuggy, solution-featured Edwards limestone formation . As d iscussed in t he Description of Structures and Foundations section of this report, clay-fi ll ed voids and voids may be encountered at or below foundation bearing elevations . These solution features may also be encountered in trenches during utility installation. The voids may be as large as 2 to 5 ft in height and lenticular in nature, thereby extending horizontally several feet from the excavation . If sizeable, these voids will have to be mitigated In a manner to allow successful foundation and util ity installation . The C ity of Austin has specifications for "Void and Water Flow Mitigation " Caterp ill ar Perfo rmance Handbook, 23rd Ed ition, Octobe r 1992, pub li shed by Ca terpilla r, Inc., Peoria , Illi no is. Code of Federa l Regu lation s Title 29 Part 1926 (200 3), "Labo r", Occupational Safety and Health Ad ministration , Department of Labor, Subpart P -Excavations , pgs 373 -41 0. -35- RRo Report No.04.10013547 contained in the Standard Specifications Item No. 6585, and also in the Environmental Criteria Manual ECM 1.12.0. In the past, the following methods of mitigating voids in excavations have been employed to minimize disruption to the contractor: • Placement of sand bags in the excavation blocking the void feature, and backfilling with flowable fill; • Backfilling with excess bedding material (utility trenches only); • Placement of low slump flowable fill in stages; + Use of geotextile fabrics; or + Combination of the above. The best method for mitigation should be decided on a case by case basis depending on the geometry and size of the void in question, and intended loading. For bidding purposes, it may be prudent to include an allowance for special mitigation procedures that may be required by the contractor. In addition, it may be necessary to make contact with the Texas Commission on Environmental Quality (TCEQ) prior to construction, to develop a mitigation plan in the event that a critical environmental feature (cave) is encountered. As previously stated in this report, Fugro can provide "structural" mitigation recommendations for voids, if encountered; however, we are not the appropriate party to provide provisions, recommendations or guidelines as to the satisfactory environmental protocols relating to voids and/or caves, if encountered. Construction Monitoring It is recommend that the Geotechnical Engineer of record, or a qualified representative, be present on-site during construction to observe, monitor construction activities and perform quality control tests. Construction monitoring performed by qualified personnel independent of the Contractor is recommended because the performance of foundations and other structures constructed during this project will be directly related to the Contractor's adherence to the recommendations presented in this report and to the specifications prepared by the Designer, Additionally, unanticipated soil and/or groundwater conditions may be encountered during construction. Qualified geotechnical personnel observing construction on-site can monitor construction activities and may aid in recognizing unanticipated subsurface conditions and assist in reconciling these conditions with design recommendations. -36- " GRD Report No.04.10013647 g STORMWATER DETENTION PONDS Barings PND-1 and PND-2 were drilled within the proposed Stormwater Detention Pond areas. The borings encountered 1 to 1.5 ft of surficial dark brown fat clay underlain by tan limestone of the Edwards formation. Following drilling of the borings, the Detention Ponds were relocated to the southern end of the site. Therefore, boring data is not available at the currently proposed locations. However, based on the 27 borings drilled across the site, excavation of the Detention Ponds will likely encountered existing fill, surficial residual soils, and completely to highly weathered limestone. The proposed Detention Ponds consist of two ponds with lake bottom elevations of 1053 to 1054 ft at the upper pond, and 1047 to 1051 at the lower pond. Based on existing site grades, proposed cuts will range from about 4 to 13 feet. Further, proposed cuts along the pond sidewaIIs and proposed embankments have side slopes of about 3H to 1V 0 flatter. Design recommendations for slopes, embankment material, and the clay liner are presented in the following section. Design Recommendations Stability of Embankment and Cut Slopes. Based on provided plans, the proposed cuts and embankment fills for the channel and water quality pond will be constructed at 3H to 1V side slopes. Based on the subgrade conditions encountered at the site and anticipated embankment construction, slope configurations of 3H to 1 V or flatter are typically adequate with regard to slope stability, provided the embankment materials and construction are carried out as recommended herein. Further, steeper slopes in the out limestone may be designed as 1H to 1V and should be adequate with regard to slope stability. If maintenance (mowing) of the slopes will be required, consideration should be given to flattening all slopes to 3H:1 V or flatter. Maintenance of stable construction slopes for the safety of workers is the responsibility of the contractor. All temporary excavations made by the contractor should be in accordance with current OSHA regulations on trench safety. The slope ratios discussed herein are intended to be the steepest permissible for the long-term performance of the earthen-structures. The contractor is required to evaluate the suitability of all slopes for construction safety purposes and to construct flatter slopes where required. Embankment Materials. The materials used for embankment construction may be obtained from lean clay and limestone excavation of the pond area and/or from an off-site borrow source. The following recommendations are presented to guide selection and processing of -37- Report No. 04,10013647 L embankment material. It should be noted that some processing of the cut limestone will be required to meet the following specification. 1. Maximum Plasticity Index: 20. 2. Maximum Particle Size: 8 inches. 3. Maximum Passing No. 4 Sieve: 70%. 4. Minimum Passing No. 200 Sieve: 10%. 5. All material should be placed free from organic material, debris, or other deleterious matter and should be processed before placement on the embankment so it is reasonably uniform in composition and moisture content. Clay Liner Material. The project site is partially located within the "Contributing Zone to the Edwards Aquifer" in accordance with the Texas Commission in Environmental Quality (TCEQ). According to the Edwards Aquifer Technical Guidance Manual', clay liners for Stormwater Detention Ponds should be at least 12 inches thick and meet the fallowing specifications. • Minimum Liner Thickness: 1 ft. • Minimum Liquid Limit: 30. ■ Minimum Plasticity Index: 15. • Minimum Percent Passing the No. 200 Sieve: 30. • Maximum Permeability: 1 x 10"6 cm/sec. However, based on our experience with clay liner construction and performance, we recommend the following slightly more stringent requirements be used for design: • Minimum Thickness: 18 inches, capped with 5 inches of topsoil as a protective cover. • Minimum Liquid Limit. 30. • Minimum Plasticity Index: 15. ■ Minimum Percent Passing the No. 200 Sieve: 50. • Maximum Permeability: 1 x 10"'cm-sec. Barrett, M., PhD, PE (2005), "Edwards Aquifer'technical Guidance Manual", prepared for Texas Commission on Environmental Quality, Center for Research in Water Resource Engineering, University of Texas at Austin, June 20,2005. -38- RME RA Report No. 04.10013647 The enhanced clay liner requirements are based on prior experience with clay liners constructed in formations similar to the Fredericksburg Group. It should be noted that all liners will leak, and it may take several months for the water content within the clay to equilibrate after the pond is filled, Consideration should also be given to surveying the ground surface before and after the clay liner is placed to verify liner thickness. Laboratory testing indicates that surficial dark brown fat clay encountered on-site meets the clay liner plasticity, gradation, and permeability requirements set forth by the TCEQ, although sufficient quantities of on site material may not be available for liner construction. Upon excavation, liner material will require processing, prewetting, and screening of shell materials, gravel and/or limestone fragments. The topsoil "protective" cover should be free of roots and limestone fragments larger than 3 inches in diameter. Top Soil. Across the site, the surficial 6 to 8 inches of dark brown surficial soils containing organic materials should be removed from within the channel and embankment footprints and borrow areas. This material may be stockpiled and used to promote vegetative slope protection for the slope faces of the embankments. Slope Protection. All permanent slope faces should be protected from erosion by placement of at least 6 inches of topsoil with vegetative cover. Alternate slope protection systems such as concrete lining, stone riprap, or erosion-control geotextiles, should be considered in critical areas depending on water velocities and design aesthetics. Embankment slopes protected by vegetation should be periodically inspected and repaired if necessary. Some minor, shallow sloughing and gullying should be expected and planned for in the owners maintenance budget. Construction Recommendations Stripping and Surface Preparation. The ground surface within the pond footprint, particularly beneath the proposed embankments, will require preparation prior to the start of construction. All trees, stumps, roots, brush and surficial soils should be grubbed and removed from the embankment areas. The finished subgrade will consist of weathered limestone and should be proof rolled to identify any soft areas that should be over-excavated and replaced with embankment material, most notably in the upper detention pond area where existing fill may be present. Excavation Potential. Excavation through the surficial fat clay and sandy lean clay (completely weathered limestone) should proceed without significant difficulty. Advancement through the tan and/or gray limestone will proceed with greater difficulty. The rock encountered -39- Report No.04.10013647 at the site exhibited unconfined compressive strengths of limestone core samples ranging between 18 to 229 tsf with an average of 103 tsf. Assessments of rippability, based on inspection of cores and estimated P-wave velocities indicate that the limestone is " rippable to marginally rippable" with a Caterpillar D9 or equivalent, equipped with a multi or single shank ripper.' As a result of weathering and jointing and the presence of occasional soft layers, portions of the limestone may be more easily ripped or excavated than at other locations. Varying degrees of difficulty will be experienced during excavation of the ponds. The contractor should be prepared to use heavy duty track-mounted rock excavation equipment, rock trenchers (rock saws), and hoe-rams. Fiat Placement and Compaction. The materials used for embankment construction may be obtained from excavation of the pond area or from an off-site borrow source, All material used for embankment construction should be non-dispersive, free of organic material (trees, stumps and roots), debris, or other deleterious matter and should be processed before placement on the embankment so it is reasonably uniform in composition and moisture content. Embankments should be constructed in lifts such that all lifts are bonded together, the specified density is met throughout each lift, the moisture content is uniform throughout the fill, and clods are broken down and bonded into the rest of the lift without nesting and voids. The embankment material should be compacted to at least 95 percent of the maximum dry density as determined by TxDOT Test Method TEX-113-E. Maintain moisture contents to within ±2 percent of optimum and compacted lift thicknesses to 6 inches. Borrow soils more than 3 percent dry of optimum should be prewetted in the borrow area, and should not be placed on the fill until their moisture contents have equilibrated. Clay Liner Placement and Compaction. The materials used for the clay liner may be available on site, but may not be present in sufficient quantities which would require importing of additional material. The clay liner material should be non-dispersive, free of organic material (trees, stumps and roots), debris, or other deleterious matter and should be processed before placement on the embankment so it is reasonably uniform in composition and moisture content. The clay liner should be constructed in lifts such that all lifts are bonded together, the specific densities are met throughout each lift, and the moisture content is uniform throughout the liner. The clay liner material should be compacted to at least 95 percent of the maximum dry density as determined by TxDOT Test Method TEX-114-E. Maintain moisture contents to within 0 to +3 percent of optimum water content and compacted lift thicknesses to 6 inches or less. Clay soils more than 3 percent dry of optimum should be prewetted in the borrow area, and should not be placed in the liner until their moisture contents have equilibrated. The clay should be compacted to a moisture content wet of optimum with a sheepsfoot or pad type compactor. e Caterpillar Performance Handbook, 23rd Edition,October 4992, published by Caterpillar, Inc., Peoria, Illinois. -40- Report No. 04.10013647 i Observations and Testing. A comprehensive testing program should be established to provide quality control on a full time basis during construction. These services should be performed by an independent testing laboratory contracted by the owner. The purpose of this quality control function is to assure 1) the use of proper materials, 2) proper moisture content and compacted densities, and 3) proper subgrade preparation, to name a few. Nuclear moisture/density tests should be performed on the each lift of embankment material and ctay liner at a frequency of about 1 test per 5,000 square feet. Further, random samples should be pulled of the embankment and liner material to verify compliance with material specifications. SOIL CORROSION POTENTIAL Steel and concrete elements in contact with soil, whether part of a foundation or part of the supported structure, are subject to degradation due to corrosion or chemical attack. Therefore, buried steel and concrete elements should he designed to resist corrosion and degradation based on accepted practices. General discussions regarding the corrosion of steel and the degradation of concrete with respect to the results of the analytical tests and field soil resistivity tests are provided below. Corrosion of Steel Corrosion is a major factor in the life of steel elements in contact with soil, Corrosion is caused by migration of electrons from the steel into the surrounding soil. Three measurable soil properties that indicate the corrosion potential for steel in contact with soil are: 1) soluble chloride, 2) pH, and 3) electrical resistivity. Analytical test results are presented earlier in this report in the "Laboratory Testing" section. Field electrical resistivity test results are presented on Plate 28. It is generally accepted that corrosion of steel is most likely to occur in environments that have chloride ions (even in low concentrations), low pH, and/or low resistivity. The following table presents some general guidelines concerning the corrosion potential of soil on steel pipe as a function of soluble chloride and electrical resistivity. If the pH is less than 7 the soil is acidic and corrosive conditions are indicated9. 9 Johnson Division, UUP Inc., (1875),Ground Water and wells,Saint Pau[, Minnesota,pg. 194. -41- 120"n m Report No.04.10013647 W Soluble Chlorlde Concentration'9 Electrical Resistivity" Corrosion (ppm) (ohm-cm) Potential > 500 0- 1,000 Very Severe 100-500 1,000-2,000 Severe 26- 100 2,000--5,000 Moderate 10-25 5,000- 10,000 Mile! ------- 10,000+ Very Mild Each variable should be used independently of the others when evaluating soil corrosion potential, For example, it is not necessary to have a resistivity between 0 and 1,000 ohm-cm and a pH of 2.0 to indicate a very high potential for corrosion potential. The field resistivity testing results are presented in Appendix B. The measured Apparent Resistivity ranged from 160 to 1,436 ohm-cm which indicate that the corrosion potential of steel in contact with the soil at the site is "very severe to severe". Electrical Resistivity tests performed on 4 soil samples in the laboratory resulted in measured resistivities of 1,145 to 3,379 ohm-cm which would be in the "severe to moderate" range for steel corrosion potential. The laboratory test results of the 4 soil samples tested indicated that the pH ranged from 8.1 to 8.7, and the soluble Chloride Concentration was less than 100 ppm (below detectible limits) which indicates the soils have a "mild to moderate" corrosion potential. A Corrosion Engineer should review the test results discussed herein when designing appropriate methods of protecting buried steel. Degradation of Concrete The degradation of concrete is caused by chemical agents in the soil or groundwater that react with concrete to either dissolve the cement paste or precipitate larger compounds which cause cracking and flaking. The concentration} of water-soluble sulfates in the soils is a good indicator of the potential for chemical attack of concrete. The soluble sulfate content in soil can be used to evaluate the need for protection of concrete based on the following table: 19 Department of the Navy, Bureau of Yards and Docks, Design Manual, Civil Engineering, NAVDDCKS DM-5, Y 9 9 9. pg. 5-9- 63. " Palmer,J.F.,"Soil Resistivity Measurements and Analysis,"Materials Performance,Vol, 13,January 1974. -42- Report No.04.10013647 11 Water Soluble Sulfate Content Water Soluble Sulfate Content Degradation In Sall', (percent) In Sail, (ppm) Potential > 2.0 >20,000 Very Severe 0.2-2.0 2,000—20,000 Severe 0.1 —0.2 1,000—2,000 Moderate 0.0-0.1 0- 1,000 Mild Laboratory test results of 4 soil samples resulted in measured Soluble Sulfates of less than 100 ppm (below detectible limits) which would indicate that the potential for the degradation of concrete is generally "low" or "mild" at the site. A Corrosion Engineer should be consulted to determine if sulfate resistant concrete is warranted, PAVEMENT RECOMMENDATIONS Pavement Design Pavement design loading is a function of anticipated or measured traffic load distribution, frequency, and duration (i,e. design life). Oftentimes, assumptions are made with respect to anticipated design parameters to arrive at an Equivalent Single 18-kip Axle Loading (ESAL) for use in pavement thickness design. In previous reports for this project, assumptions were made for typical ESAL values for anticipated traffic loading consisting of a "light duty" pavement section with 10,000 ESALs and a "heavy duty" section consisting of 100,000 ESALs. These ESAL values were arrived at using Balser (1975)'3 for assumed traffic load distribution and 20-year design life. Subsequently, alternative pavement sections were requested by the design team, including a reduced design Iife of 10-and 'I5-years and estimated "heavy duty" traffic loading of 5 fully loaded 18-wheelers per week. Accordingly, four traffic conditions and ESAL loadings were analyzed for the flexible pavement sections developed in the following section. As noted in previous correspondence, rigid pavements should be used in areas where heavy traffic or tight maneuvering of large trucks is anticipated. Recommendations for flexible and rigid pavement sections are provided in the following sections based on a subgrade condition consisting of soil subgrade similar to that encountered in our borings. 12 American Concrete institute, ACI Manual of Concrete Practice, 1998, Part 1, Materials and Genoral Properties of Concrete,Section 201.2R-10. 13 Baker, R.E., et al, (1975y, Handbook of HighwayEn ineerin , Robert F, Baker, Editor, Van Nostrand, New York, Chapter 16. -43- —rul nn Report No.04.10013847 Flexible Pavement The 1993 AASHTO procedure 14 was used to develop pavement sections using the traffic loading selected, associated 18-kip equivalent single axle loads (ESAL) over the design life noted, and an assumed subgrade resilient modulus of 3,000 psi. Recommended thicknesses of crushed limestone base material (CLBM) and hot mix asphaltic concrete (HMAC) are presented in the following table for the selected traffic categories. Also presented is a pavement thickness option using asphalt stabilized base (ASB) in lieu of CLBM for the heavy duty pavement section, as requested. Recommended Flexible Pavement Sections ASB CLBM HMAC Traffic Estimated 18-Kip Estimated Thickness Thickness ThicknessCondition ESALs Design Life (inches) (inches) (Inches) Light Duty 10,000 20-year --- 10 2.0 (parking stalls) Heavy Duty 30,000—40,000 10-year --- 10 2.0 Heavy Duty 60,000—70,000 15-year --- 12 2.5 - 14 2.5 Heavy Duty 100,400 20-year --- 12 3.0 8 --- 1.5 Construction of the flexible pavement should proceed in accordance with the City of Austin Standard Specifications: Item No. 1025, Clearing and Grubbing; Item No. 1325, Embankment; Item No. 201S, Subgrade Preparation; Item No. 2065, Asphalt Stabilized Base; Item No. 2105, Flexible Base; Item No. 2365, Proofrolling; and Item No. 340, Hot Mix Asphaltic Concrete Pavement. Project specifications should dictate that the recommended CLBM and HMAC thicknesses are minimums, not averages. 14 American Association of State Highway and Transportation Officials, A_A_SHTO Guide for Design of Pavement Structures 1993. Washington, D.C. -44- �i3Rq Report No.04.10013647 Rigid Pavement Using the 1993 AASHTO procedure and Portland Cement Association procedure, rigid pavement sections consisting of Portland cement concrete (PCC) over crushed limestone base material (CLBM) were developed for the selected traffic categories and anticipated subgrade condition. Our recommended rigid pavement sections are provided in the following table. Recommended Rigid Pavement Thicknesses Traffic Category 18-kip CLBIVI Thickness PCC*Thickness ESAL (inches) (inches) Light Duty 10,000 4 6 Heavy Duty 50,000— 100,000 6 7 Note: The Portland cement concrete pavement should have a 28-day compressive strength of at least 4,000 psi and be reinforced with a minimum of No. 4 bars on 18-inch centers, each way. Construction of the rigid pavement should proceed in accordance with the pertinent City of Austin Standard Specifications listed above for the flexible pavement, Item 360 "Concrete Pavement", and the following recommendations: 1. Space transverse and longitudinal contraction joints (induced cracks) at intervals not exceeding 12 feet. The contraction joint pattern should divide the pavement into panels that are approximately square, with the length of any panel no more than 20 percent greater than its width. Depth of joints must be at least one-quarter of the slab thickness. The joints must be saw cut as soon as the concrete has hardened and will not tear or ravel when cut, and not more than 16 hours after placement. Frequent depth checks of the joints is recommended by an independent quality control agency during the saw cutting operation. 2. Support reinforcement steel with chairs or precast concrete blocks about 1 inch below the bottom of the planned contraction joints. 3. Provide load transfer at the interface between areas of concrete placed at different times using tied and keyed construction joints. Place construction joints at planned contraction joint locations. (See ACI Manual of Concrete Practice, Part 2, for further guidance.) 4. All joints should be sealed in accordance with Item 360 of the current City of Austin Standard Specifications. 5. Stage pavement construction such that construction traffic, including concrete trucks, do not travel on newly placed concrete pavement until the concrete achieves at least 75 percent of the design strength, usually 7 days. -45- Report No.04.10013647 Pavement Drainage and Groundwater Control It should be noted that control of surface drainage and groundwater is important to the performance and life of pavements. Infiltration of water into the pavement subgrade and pavement structure will result in premature loss of serviceability. Adequate drainage provisions should be included in the pavement design. Additionally, the placement of curbs, islands and irrigation systems should be carefully planned in a manner that will not lead to ponding and saturation of pavement base materials that extend into island areas. CONDITIONS Since some variation was found in subsurface conditions at boring locations, all parties involved should take notice that even more variation may be encountered between boring locations. Statements in the report as to subsurface variation over given areas are intended only as estimations from the data obtained at specific boring locations. It is recommended that, upon completion of the plans and specifications and the incorporation of the recommendations herein, the geotechnical engineer be retained to review such pians to ensure proper interpretation and implementation of his recommendations in the interest of the best compromise between cost and performance. The professional services that form the basis for this report have been performed using that degree of care and skill ordinarily exercised, under similar circumstances, by reputable geotechnical engineers practicing in the same locality. No warranty, expressed or implied, is made as the professional advice set forth. Fugro's scope of work does not include the investigation, detection, or design related to the presence of any biological pollutants. The term 'biological pollutants' includes, but is not limited to, mold, fungi, spores, bacteria, and viruses, and the byproducts of any such biological organisms, The results, conclusions, and recommendations contained in this report are directed at, and intended to be utilized within, the scope of work contained in the agreement executed by Fugro Consultants, Inc. and client. This report is not intended to be used for any other purposes. Fugro Consultants, Inc. makes no claim or representation concerning any activity or condition falling outside the specified purposes to which this report is directed, said purposes being specifically limited to the scope of work as defined in said agreement. Inquiries as to said scope of work or concerning any activity or condition not specifically contained therein should be directed to Fugro Consultants, Inc. for a determination and, if necessary, further investigation. -46- Been Report No.04.10613647 A PLATES THIS PAGE LEFT BLANK INTENTIONALLY i •.. . li 11 .r • d���'.;,` .Vii'::'• _ I '��� .i ;.�. .r ''. L. �.i'. 'Iry•"�: C rel.. .-:a+ ti.�_ A cl 'f w ,•. '.L'=�:•'r� �� -S;. •f/., � r�l.•' r jF�•� 'rI�T] I. .� �`• r•3 . �: •ti'~ (4.yr �['," 5'5`•.1• '+r r'�.s'I 'L.- 1'Yf'• .1'� .Y"' .,,. :y Ir Z.• .. 1 .�li\ti. nY J -^ ! `�. � i. i; rA,f .. - ".'�;:. #,1 }''�i:;�y� �•.. ••yam' Y:;:3 j.• ''f.�.LEta i=ii;L. ,:�a•- :. '�-:s 7'�� '+,�c a',; -..r.- .a ,���• �f ms's' r({�' es r_.rs... ,. 1 ?;�'.}[ fir:,. %i�.` ;�� x`r. c4• :.'' - �is'.a::'=�. '= .:t 'µ,+;-..1 : I '�ti-,;. �,�lr r�...:.;, •'��jq'-''. L a - ',tip `,�•`'.}t. -,,,•[: �i�: •4�e s"• 1..:-r.r.f 1:; � .l' .. .!S,q"l.} [J'f��`''.f:i �� �- r b '��' _ �;:!�7;, w tilt• '1�:.:'� ,+ ,•.."�-'�,p}-�c.,� .:: tT ?y�:Y `�2 _ .,� :d� ,.-at JIB .y _.�. t. .}' �'�';-•�;: - F J�� [ �L rte'. 's fig^ 1 .. .. .. ��'r.. M1{� ; :.rvti�"4"'� i - K `''�• •t��... ,F+y 5� •�, SLY •�_ ' Si •'�4 ~fir. sta.'• `Y �y i!' .'t, L•- �x.. I��Ci:1j rjFF��,.: :';�y� r i,iFr,� ,�-: i r�1r.�;_ �'�,iy L rL,' •s[� ;r� •,..Y�L,�i:N �aAF .iR .. , �..n.• 'r �,`��� 4444• '. _ r•' ``;�•.' `: r7:, 4• : •./,,.•f.•1 !: ....... ,.+'. •�...�i,-�1.y,L�1.u`y L �f..y'4 }S°',•i. ��•� ��� y,• ••4.ti., -'1ii, } LI (• ;k,, `'•�,.,.y,,�+ ! '+r• rr Ili_ �� •J.:_ y� ,+4u ,u t r[ -. 1 ; i. [:, ,i i.a ti .�•��51ti' •v•'N _ :i •'tr' tif'�1 .'�._ '�5.�' .�;.; -•r' +[[ :� f'.1�^`', ..�'�, ,.y,; �:�,'�., ;.F; 'i�� ;:r-"r ',•f r _ 't'- ,tiy:,L i_;:xc.•$r':!i•,�.�. .1�'�•� ii` .s`,:7F �;,�' L�V'1.,,,�. _ .l"'-ti �• �s �..•. .� •{ .�'{ Y •yl� '..�, '� r t:• :l 1 'ti r� '� .s y JI •• v :r �r�'1• '�`•:'i Edd,r_:.,''ti. 1.:;.�r -�ti'%r � E .�• ' S.•.' _: - +_ 1,•..:i�'{k•':,•yr. F�.�i �.r- f-t:rY: .4- �•�'��.... �j Yy;. r ;C .�f 3- y�,i'.k::,ir, '•�.�.i T'�" ��� '�':'lf�� r+;w ua' ti f�e�.`:T R� '�r'•4 ?'� !:�•r ;1, t -°! ji��. � -i'�'4,st"y���r ':!il,.-. .-f:: � :f-'�"�� �f�a.F:•i. �; c ;S:�'�� •"-( ���'r i' '[ s •�' �:: -1....�s•t'�'�'g'+': j ' M ,'�,Fasst•,.- 'i �I -,I A �� �• _ �'• � `�o.,i int, _ r.'. �.." � .i.YI:r.: ..p. }j:y r:s . i"[ {' rr•; + 1• "is t; a r '��� 1. _ [[ .t,?�<...•1�, _ 1' , M1.,jr';[.1:,rY� -t +•,�%'••:�: r•r-e ' �.ti 1'. •y:, i.• .s �r y:lli•9.1"! •'�,•• •J, .r,J - 1S•l' .!. `T..',i,.} .t� %� '+''• ''7. ,T "r`;.,.j \ .'''•;'� '•I'�3 �'y i j., ' •{t•1 .G1�� � "if- •. ,i'-}•, _ + ..:r1 .., ii:ti.-:_ry:.;. �;)',• _ V,'.°� y '}`� •.,r,...'. �+c'•i•` i� i� �•i +J: a + •.•f',s.r i' K..5.'.Y'r�i'-~iY� - 4�'�'' .•f, �"'s..••k _s�. '�'•:.- >i. ,.�' -'r. \., _(,�..,; `ti. 3 .;+fin�1• ��` 14•'�'`.. ,• _�" '1'. '�, E'..',� �ti ate. ,�t� y _ w.:, �•C�'.• -$ �', �, .. � 1 .o ,.�'';��' t'W �; ., �• ''s' Vii: — Sy fir, 11 1.•�J�'Ij. _ `'1 s rr .F�� 4 �,�..r••� - l•. ,��ri� "�, •5! ''',�•• r�' _ [A —•`. ..• 111 - 5� �'r• �t' "��• i�` ••R�'t •.x.:y. �.]5�. +t": .S'•sy. x:;;777 ��r��°< •;.• ''�, •r'' - •l� �i. 't-+ i �"7 ':�. .•�•. �,• •S•�� .F:,-:�r -.:� IY 4` 'i_•7 '�.t .\r- +T,r �-5 if'.:r� ,�[:�;. •6;''•47[' .�� S� }`u,. ,'�}`� _,• ��%�y -•ti's .C � Yij!':."..' :i.•:•r':'S ��. '•1�'pp r�f ;[$�'rl."�:J i'{'~ �• **I'-:- •"_f' {;� _ ,t.•y.i °ti' ,5yt,_ '`� _��'�'' ;'�. •-.�:7, '�� a 3• ]•�,�.• S'75'� s Y '3:•�'-r�• rk' 'y-• t�•S .x': ;sS' '�':i. ,i'. :r. ��:�: �'moi:r•c"� m �� :�S s�!s °�� s_r.t:-.,' _ ''..tea _•�' r,..�f- p. F.,.q- r. 'j..1.. •.yy' •..i e. •"t J�1 ,ii•'f• ■ THIS PAGE LEFT BLANK INTENTIONALLY Report No: 64.10073647 PNB-2 EST-1 , — } 2 STUFACE TANKk FF»T08�A \■ �� f, s - 'JiJ➢ PVCMLE STAGE null '�^�x 'f• +;'r 1 NAIRT �. THO� � -3 Tr-msa.V LIP$ S ,sT sT►cE SLI, c• - zo stup9E DESWIT�i - •1 _ � , TWG[Q7EA • FACIIIt]' _ - r� FF-10S5.67 Y -��^ •® 160. RWA Pl1pP — "-}e. r '^ 5fRYCR1Hf SMZIOl1 �g7'A-'�FWDI 1-1 1013-11 $1. DECANT � F B 5 BTS i x TaYYl—,on CAVE - ,�, r� FF�50i2.0 CLUMELL PETER• y VAULT I .. C+I-�-4 13 r CtFL tt 110 !0 o em 1 104" i - ,�..� 4 1 ' Bo9STfh --- CLL-1 srn k CLL-2 IX .15 V 1 t - UErT,r=X PLAN OF BORINGS Brushy Creek Regional Utility Authority _ Water Treatment Plant Travis and Williamson Counties,Texas SaurpR:Saw Map?rorldeQ 6y CDM.Inc.aM IC2piltriws. PLATE ffi - [.c-•{ =L� .-:. - _}. ter.•_�_''� .- i ,� � 'C, _ ,., ...: -..; . . s` •`�-"pyo ��5•+,- .� ' v-,.•;s�-�• — . -_ � �`y•-)f — •r r�. ff ^I j .a ,� .;:}'r�:�'. - ,� .. �•--,., ,� _ - a :a- .a`;3.T-rf�,w.:.a i�.'��f('•' '•.•F'- .'.5,..+'r '��,�• t'+ a 'i'.':°sem r7,i Y �� '•fi�:��ilk d•' r1 ,�a;F� rr' � t. � t- r� ' � f . .., i L.•.. rr i 'ice, i����ia;�p yY,•,L:k� 'i��,�, �• � nPk`.� 1 +�-lr�i }'�� .,r �� w� '_.���r�JJV4� .f�,� ,+w� ,!rr�.-•�3-ti'_��a��..�` �c''r'}�r`.��. J �• ''F. wl� �•... � �- �f } ,r fa' if• + � _ �i �.�,��„ f:3 tJ:Y,f«1.'d:+r,�,rr'Jvi''''•f.��� •- +, � fi. 'r. j�„"" r1 +�3 �`�'" 9�[.':•• ;k •w 4bt� aNr R r tide ���firr���1`}•'.�Y`�y..� ,' •s•. t +' -' y 1'&�(`�-`rt., c! .�" Y I i,�� ! 7Z;�t-�[[''-'��.r �p .4�•�{� �, p [�.� {�' r� tir.[4t�7r.I. � {.,� � � 3r .� aLJ-�'J-, P. 7�-p, [.. :J..r��- ,h. r a ..�r •I r i t• � ••yµ•i�A"i .�•. zR S.! .r•3'��y+f p.S.} _�Y 14�,fr {�.�,'....Y }}}}{{`� � - .J ,, (�Yy' f,+ .R-' �•lr: .r„�, a- �- Nit � - ��, 4 i •fir+�1, {.�J�rrF`,�Jaf-�}li� f�;[•�"Yr..i�� �7"�fi'p yl k 3�; i _ -'� � X .. �. � Y�•�`�'+1�^�!lrrl trW�,�•l.y�rMrl /,y' �"Y���'e 17�/ r� 'f�� f� ry • �.�r[, id ��r+:��+^'a�, +���s'i 5���;f ice.;'�'�".' .[ �• �,� � } ,#. r.4•S•' r-'KS •} rr•kmsyr 5, r r .r i. ' .f Cyt S p,a. lC�,.!''''r T''[ "�,cJ+. -n [[�''7 a'rM>i iy.h jr!"s •g r. C� �' ,Ir,=i•�.,..r��'+" :y � _Et'!1r `',..� .i..y .� Yr?,` S. J�;:� ��•.R3�•i,}�r{M `.;L•^';lY r�F`�'; rC '�f'�wv.:',Y}e +�_ � I '�� H � • ■. .�{,A'y'M e!' f*•�1 rr�,Ai Tl�f: 4.a�- �+y' ,rY•':?b• J F _ tiJ. 1 gJ } 9 ra x Ir, .r��'[���?,�'�!�'%-{!}rt~'S.''Lr F ,1 it •reC Ilk!_l. +��-,�•Z~-i,'�T.f�'.•�+.�.'f'Ir.N L�„���,dR;'TF-'� i r�'+f•"' � ''� - .-� ,:ly I-.r� L{ I� :f+ •p �� 1�� ',�:!7 •1"'��'i�� L• �:li�+• ''� IPPP `'=+""�'•`'J' "�'•i='S�-�' .�rGl,•�i r,�g ;'�Q.trrs� �e, ',�. `'y+�r�•,.,1,,,, _� : •� r .J C,� k, � �' Yfirra� /rt.•e�J t`.bl„ �. � J ' yy "a•,r � �"l+ �l .r� 'o: N L'' I+'• •;�E��•i-'• � � �i'�! •S?•.'+ Y � �} -� r+.� f�•Jti,�i, ?} ; THIS PAGE LEFT BLANK INTENTIONALLY Report No. 04.10013647 APPENDICES THIS PAGE LEFT BLANK INTENTIONALLY Tmran Report No. 04.10013647 APPENDIX A BORING LOGS Keys to Terms and Symbofs Used on the Boring Logs Boring Logs (27) THIS PAGE LEFT BLANK INTENTIONALLY TERMS & SYMBOLS USED ON BORING LOGS FOR SOIL GRO SOIL TYPES SAMPLER TYPES CH,Fat ClayL. SP,Poorly-Graded GP,Poorly-Graded Sand • Gravei Seamless Push Tube Core CL,Lean Clay SC,clayey Sand GC,Clayey Gravel Standard Penetration Auger Test ML,Silt SM,Silly Sand GM,Silty Gravel 5W,5ell-Graded GW,Wefl-Graded Pe HO Cone Auger Sample Fill,UnclassifiedPenetrometer Test nd Gravel SOIL GRAIN SIZE U.S.STANDARD SIEVE 61, 3" 3/4" 4 10 40 200 GRAVEL SAND C013BLES BOULDERS 1 SILT CLAY COARSE I FINE COARSE MEDIUM I FINE I 15Z 7152 191 4.fb 2.1JU U.42U 0.074 0.002 SOIL GRAIN SIZE IN MILLIMETERS STRENGTH OF CORESIVESOMDENSITY OF GRANULAR SOILS COMPRESSIVE CONSISTENCY STRENGTH NUMBER OF BLOWS RELATIVE Tons Per Sq.R, PER FT.,N DENSITY Very Soft Less Than 0.25 0-4 Very Loose Soft 0.25 to 0.50 4-10 Loose Firm 0,50 to 1.013 10-30 Medium Stiff 1.00 to 2.00 30-50 Dense Very Stiff 2,00 to 4.00 Over 50 Very Dense Hard Greater Than 4.00 1) Peck,Hanson,and Thornburn,(1974), Foundation Enpirleering. ASTM D 2488 Note 15 Critefla.for Describing Percentages ASTM D 2488 TABLE 7,Criteria for Describing Structure of Gravel,Sand and Fines Description Criteria Description Criteria Stratified Alternating layers of varying material or color with layers at least 6 mm thick;note thickness Trace Particles are present but estImaled to be less than 5% Laminated Alternating layers of varying material or color wl th the Few 6 to 10% layers less than 6mm thick;note thickness Little 15 to 25% Fissured Breaks ab)g definite planes of fracture with little Some 30 to 45% resistance to fracturing Mostly 50 to 100% SlickensIded Fracture planes appear polished or glossy, sometimes striated Blocky Cohesive soil that can be broken down into small angular lumps which resist further breakdown Lensed I n c I uslon of small pockets of d Iffefent soils,such as small lenses of sand scattered through a mass of Criteria for Describing Inclusions clay;note thickness Homogeneous Same color and appearance throughout Description Criteria Parting Inclusion<118"thick extending through sample ASTM D 2488,TAB LE 3-Criteria for Describing M olstu re Condition Seam Inclusion 118"10 3'thick extending through sample Description Criteria Layer Inclusion>3"thick extending through sample Dry Absence of moisture,dusty,dry io the touch Moist Damp but no visible water Wet Visible free water,usually soil Is below water table GRG TERMS & SYMBOLS USED ON BORING LUGS FOR ROCK ROCK TYPES SAMPLER TYPES ®LIMESTONE ®DOLOMITE ®SANDSTONE 'Seamless Push Tube Care HfGHLY®LIMESTONE 7HEREb ®❑OLOMITHIGHLY�EATHERED ©SHALE �Standard Penetration P Auger ®LIMESTONE Im GRANITE ®CLAYSHALE PeneettTrationTest Auger Sample HARDNESS WEATHERING GRADES OF ROCKMASS{ Friable Crumbles under hand pressure TERM DESCRIPTION Low Hardness Can be carved with a knife Moderately Hard Can be scratched easily with a knife Slightly Discoloration indicates weathering of rock Hard Can be scratched with a knife with difficulty material and discontinuity surfaces. Moderately Less than half of the rock material is SOLUTION&VOID CONDITTONS decomposed or disintegrated to a soil Void interstice;a general term for pare space or other opening Highly More than half of the rock material is in rock. decomposed or disintegrated to a soil. Cavities Small solutional concavities. Completely All rock material Is decomposed andlor disintegrated to soil. The original mass Vuggy Containing small cavities,usually lined with a mineral of structure is still largely intact. different composition from that of the surrounding rock. Residual Soil All rock material Is converted to soil. The Vesicular Containing numerous smali,unlined cavities,formed by mass structure and material fabric are expansion of gas bubbles or steam during solidification of destroyed. the rock. (2l Porous Containing pare,Interstices,or other openings which may BEDDING THICKNESS or may not Interconnect. Very Thick >4' Cavernous Containing cavities or cavems,sometimes qulte large. Thick 2'-4' Most frequent in limestones and dolomites. Thin 2"-2' Very Thin 112"-2" Laminated 0.08"-112" Thinly-Laminated <0.08" JOINT DESCRIPTION SPACING INCLINATION SURFACES Very Close a2" Horizontal 0-5 5lickensided-Polished,grooved Close 2'-12" Shallow 5-35 Smooth-Planar Medium Close 12"-3' Moderate 35-55 Irregular-Undulating or granular Wide>3' Steeply 65-85 Rough-.fagged or pitted Vertical 85-90 REFERENCES: 1}British Standard(1981) Qgde.of Practice f ite Investigation ,BS 5930 2]The Bridge Div.,Tx.Highway Depi. Foundation Exploration&Design Manuel 2nd Edition,revised June,1974. SRO LOG OF BORING BPS-01 _= Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/We(Rotary LOCATION: Booster Pump Station 0 P-M LAYER C] �• z' a� in p., :�P 3p a STRATUM DESCRIPTION FLFV./ a" �� � �, M 0 O C S. DEPTH 4� � '4� �`r L) a. SURF EL. 1054.3 ft+ Job No. 1001-3647 U a �N a �' _ Brown sandy lean CLAY with gravel,stiff. (Fill) 18 41 21 81 51 Dark brown fat CLAY,hard.CH(Residual Soil) 0.5 - 1051.8 - 92 Tan LIMESTONE,moderately hard to hard,slightly 2.5 — (79) weathered,medium to fine grained,wlowasional 5 100 solution features,discontinuities,dolomitic layers, (78) and fossils. (Edwards) 9 128 135M - 10- 92 (42) - 15 100 13 124 I25 (72) 2Q I00 (813) -25- 100 - (63) 14 118 68(U) -30- 80 (47) [100%water loss at 31.5 ft] -35 -1 95 15 119 1 78(U) COMPLETION DEPTH: 49.5 ft DEPTH TO WATER: See Note U=Unconfined P=Pocket Penetrometer Q=Unconsoii&led T-Torvane DRILL DATE: 8118107 Undrained Triaxinl APPENDIX 1a SRO LOG OF BORING BPS-01 Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sam lefWet Rotary LOCATION: Booster Pwnp Station Q D o C; U. W `xA LATER H 3 Z a � � �0 EUV./ C 25 � � A �O DEPTH30 v,V) V) W c c4 D on SURF EL. 1054.3 fft+ .Iob'\o. 1001-3647 97 Tan LIMESTONE,moderately hard to hard,slightly - (28) weathered,meditun to fine grained,wloccasionaI solution features,discontinuities,dolomitic layers, I and fossils.(Edwards) - - -nodular from 36.0 to 46.5 ft -45- 100 (87) I007.8 10 I30 79 Gray LMESTONE,moderately hard to hard, 45.5 medium to fine grained,nodular,w/discontinuities, _ and marly searns and layers. (Fredericksburg) 1004.8 - 50 - -- ------------------------- 49.5 - NOTES. 1) Boring was advanced dry to the 2.5-ft depth and groundwater was not encountered above that depth. r -55 - 2) On completion of the drilling operation the hole was open to 31.0 ft and the water surface(drilling - fluid)was noted at the 29.0-ft depth. 3) N10163978.43,E3070908.18 -60- 7 i i -70- -75 - COMPLETION 0-75COMPLETION DEPTH: 49.5 R DEPTH TO WATER: See Note U=Unconfined P=Pocket Penetrometer Q=Unconsolidated T=Torvane DRILL DATE: 8118107 Undmined'rnaxinl APPENDIX ib DRO LOG OF BORING BTS-'I Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: See Plate 2 ��A LAYER 9H �� a Z, Z a�4O coF CY H 3 0 STRATUM DESCRIPTION ELEVJ d aH w 7 7-� A x ObW DEPTH tn v,00 C7 w tpr U p+z P„ SURF EL. I061.9 fly Job No. 1001-3647 v 8 Dark brown fat CLAY with sand,stiff,wllimestone 1060,4 fragments.CH(Residual Soil) 1 5 31 Tan sandy silty CLAY with gravel,hard,calcareous, 12 25 7 76 50 wllinzestone fragments.CL-ML(Completely - 5 3 Weathered Limestone) 1055.3 67 Tan LE\ ESTONE,hard to moderately hard, 6.6 (13) moderately to highly weathered,fossiliferous, wlpits,rugs,red-stained solution features and - 10 82 discontinuities,and chert. (Edwards) (82) 7 122 119(U) X50%water loss at 13.0 f] - 15 40 (0) [100%water doss at 18.0 ft] 1042.9 -20- 98 Tan LYKE,STONE,moderately hard to hard,slightly 19.0 15 It 15 90 (98) weathered,medium to fine grained,wlfossils, occasional solution features,and discontinuities. - (Edwards) -25 - 100 (100) 10 120 81(LT) _ 1032.9 -30- T 29.0 NOTES: 1) Boring was advanced dry to the 6.5-ft depth and groundwater was not encountered above that depth, 2) On completion of the drilling operation the hole 35 was open to 28.0 ft and the water surface(drilling fluid)was noted at the 28.0-ft depth. COMPLETION DEPTH. 29.0 ft DEPTH TO WATER: See Note U=Unconfined P=Pocket Penetrometer Q=Unconsolidated T=Torvane DRILL DATE: 5117107 Undrained Triaxial APPENDIX 2 �GRO LOG OF BORING BTS-2 =-= --� Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TI PE: Sample/Wet Rotary LOCATION: See Plate 2 0 �p� LAYER �a- w a oSTRATUM DESCRII'TION ELEV.1 � a t u, g u Co DEPTH a Q ra cn v} SURF EL. 1064.1 ftf Job No. 1001-3647 tark reddish brown fat CLAY,w/sand and mestone fragments.CH(Residual Soil) D.3 20 Tan sandy lean CLAY,w/red staining and limestone - fragments, CL(Completely Weathered Limestone) $ 56 57 :1056.6 33 Tan LRAESTONE,hard to moderately hard, 7.5 - 0 moderately to highly weathered,fossiliferous, 10 � w/pits,vugs,red-stained solution features and - (67) discontinuities,and chert. (Edwards) 7 129 136(ti) 15 104 - (88) 20 95 12 112 64 (58) [100%water loss at 21.5 ft] 1041.6 - Tan LIMESTONE,moderately hard to hard,slightly 22.5 - weathered,medium to fine grained,w/fossi[s, 25 100 . occasional solution features,and discontinuities. (100) (Edwards) 11 119 88(iJ) 1034.6 30 ------------ 29.5 NOTES: 1) Boring was advanced dry to the 8.0-ft depth and - groundwater was not encountered above that depth. _35- 2) On completion of the drilling operation the hole was open to 29.2 ft and the water surface(drilling fluid)was noted at the 21.9-ft depth. COMPLETION DEPTH: 29.5 ft DEPTH TO WATER: See Note U=Unconfined P=Pocket Penetrometer Q=Unconsolidated T=Torvnne DRILL DATE: 5/21/07 Undrained Triaxial APPENDIX 3 �Qa LOG OF BORING BTS-3 r = Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: See Plate 2 ad F" "a . a du 7 LAYER 04 ; CY a o STRATUM DESCRIPTION ELEV.1 ¢w r > t7 z 04 F x W rn DEPTH 9� .a 1Q 'n v, a U 0.z Qom' �� ❑ren SURF EL. 1065.3 ft± rob No. 1001-3647 ° °' 3 U 15 Dark reddish brown clayey SAND with gravel, 1063 9 18 77 46 74 27 medium dense,wllimestone fragments. SC 1.4 25 (Residual Soil) 5016" Tars clayey SAND,very dense,w/linnestone 28 fragments. SC(Completely Weathered Limestone) - 5 5016" 1059.4 53 Tan LIMESTONE,hard to moderately hard, 5.9 (0) moderately to highly weathered,fossiliferous, w/pits,vugs,red-stained solution features and discontinuities, and chert. (Edwards) - 10 93 (77) _ f - 5 148 116M. 15 95 t (45) -20- 9 120 57(U) 98 1042.8 Tan LMESTONE,moderately hard to hard,slightly 72.5 weathered,medium to fare grained,wlfossils, -25 - occasional solution feawes,and discontinuities. (Edwards) 100 (100) 14 119 91(U} 30 ----- ---------- 1034.4 30.9 NOTES: 1) Boring was advanced dry to the 5.9-ft depth and -35- groundwater was not encountered above that depth. 2) On completion of the drilling operation the hole was open to 27.3 ft and the water surface(drilling fluid)was noted at the 3.0-11 depth. ------ T� Hi I COMPLETION DEPTH: 30.9 ft DEPTH TO WATER: See Note u=Unconfincd P=Pocky Penetrometer Q-Unconsolidated T=Toraane DRILL DATE: 5121107 Undrained Triakial APPENDIX 4 LOG OF BORING BTS-4 oRo Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: See Plate 2 oo GAFo, `� ZW �0. UO moo© LAYER Wz �`. �y� caw 0> x v,0W 3 aL STRATUM DESCRCPTION LEW w z� 4� M H su ,, Qca DEPTH �z �� uio SURF EL. 1061.2 fLL Joh No. 1001-3647 23 Brown clayey GRAVEL intermixed with tan sandy - clay. (Fill) 10 1057.2 5 44 Dark reddish brown fat CLAY,hard,wlsand and 4.0 limestone fragments.CH(Residual Soil) 1056.2 18 Tan sandy lean CLAY,hard,calcareous, 5.0 wllirnestone fragments.CL(Completely Weathered 1053.4 89 Limestone) 7.9 (72) Tan LM ESTOI4'E,hard to moderately hard, 6 126 135 - 10 100 moderately weathered,fossiliferous,wlpits,vugs, (90) red-stained solution features and discontinuities, _ and chert. (Edwards) -moderate discontinuity at 11.3 ft [100%water lass ai 13.5 fl] - 15 100 (57) 17 112 780 -moderate discontinuity at 18.9 ft 1041.7 20 (�) Tan LEMESTONE,moderately hard to hard,slightly 1 g'S _ weathered,medium to fine grained,wlfossils, occasional solution features,and discontinuities. (Edwards) -moderate discontinuity at 22.5 ft -25 3881 13 125 97" ( ) -wlnumerous solution features from 25.5 to 26.8 fl 1031.7 -30 29.5 NOTES: 1) Boring was advanced dry to the 8.0-ft depth and - groundwater was not encountered above that depth. -35 - 2) On completion of the drilling operation the hole was open to 29.2 fl:and the water surface(drilling fluid)was noted at the 20.4-ft depth. COMPLETION DEPTH: 29.5 ft DEPTH TO WATER: See Note U=Unconfined P=Pocket Penetrometer Q=Unconsolidated T=Tomne DRILL DATE: 5122107 Undrained Triaxial APPENDIX 5 aRa LOG OF BORING BTS-5 :__- �:- Brushy Cleek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: See Plate 2 O Oq LAYER C);L Z 04 p 0 aVO4 STRATUM DESCRIPTION $LEVJ o A cw DEPTH 3 a ,� SURF EL. 1062.9 f}L Job No. 1001-3647 U " rq UVJ 13 Dark brown fat CLAY,wlsand and gravel. (Fill) I1 _ 1058.9 5 jjjj� 46 Tan sandy silty CLAY,hard,calcareous, 4.0 12 26 4 93 56 wllimestane fragments.CL-ML(Completely 1057.1 21 A Weadiered Limestone) 5.8 (0) Tan LM ESTONE,hard to moderately hard, moderately to highly weathered,fossiliferous, wlpits,vugs,red-stained solution features and - 10 100 discontinuities,and chert, (Edwards) (100) 5 134 205" [100%water loss at 13.5,t] - 15 100 (70) 1044.1 14 112 36(U) Tan LIMESTONE,moderately hard to hard,slightly 18.8 --- -20- 100 weathered,medium to fine grained,wlfossils, (100) occasional solution features,and discontinuities, - (Edwards) -25 - 100 13 123 114 (100) __ ..-__ ---------------- 1033.4 12 124 113 M j 34 29.5 NOTES: 1) Boring was advanced dry to the 6.0-ft depth and groundwater was not encountered above that depth. -35 2) On completion of the drilling operation the Bole - was open to 29.3 ft and the water surface(drilling fluid)was noted at the 23.3-ft depth. COMPLETION DEPTH: 29.5 ft DEPTH TO WATER: See Note U=Unconfined P=Pocket Penetrometer Q=Unconsolidated T='.'orvane DRILL DATE: 5122/07 Undrained Triaxial APPENDIX 6 non LOG OF BORING BTS-6 Brushy Creek.Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: See Plate 2 G oez 0 LAYER FEF , z� Z w p a STRATUM DESCRIP' ON ELEV.1 u! o W z F Fc� 0 flQ DEPTf€ 3d 1a �A riu cno SURF EL. 1064.8 ft= rob No. 1001-3647 ° 15 Brown clayey GRAVEL,wlsand.(Fill) 1063.4 - Dark reddish brown fat CLAY,wlsand and 1.4 10 limestone fragments.CH(Residual Soil) 1062.9 Tan sandy lean CLAY,very stiff to hard,calcareous, 1.9 - 5 30 wllimestone fragments.CL(Completely Weathered Limestone) 31 5016" 40 1055.8 10 Tan LHAESTONE,hard to moderately hard, 9.0 moderately to highly weathered,fossiliferous, wlpits,vugs,red-stained solution features and 97 discontinuities,and chert. (Edwards) - (86) - 15 62 9 120 81 (45) -partial clay-filled void from 16.5 to 19.0 f: [50%water loss at 16.5 f!] I045.8 -20- 90 19.0 (62) -clay-filled void from 21.8 to 22.3 if 1442.5 22.3 14 121 91(U) -25 - 100 (75) - __ --- ------ 1035.3 -30 29.5 17 116 53(U) NOTES: 1) Boring was advanced dry to the 11.5-ft depth and groundwater was not encountered above that 35 depth. 2) On completion of the drilling operation the hole was open to 21.7 ft and the water surface(drilling _ fluid)was noted at the 19.6-ft depth. I I tt-l-' CON PLETION DEPTH: 29.5 ft DEPTH TO WATER See Note U=Unconfined P=PanketPmetrometer Q=Unconsofidated T=Torvane DRILL DATE: 5117107 Undrained Triaxial APPENDIX 7 ©RD LOG OF BORING CLL-01 , Brushy Cicek Regional Utility Authority Water Treatment.Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotaiy LOCATION: Fnhtre 6MG Cif-AruwPll O 0.0 LAYER �=a Azwa o o STRATUM DESCRIPTTON ELEV./ oyq Q X uz� A rr, 006 DEPTH .�� SURF EL. 1052 ft} Job No. 1001-3547 U o 18 Light brown clayey GRAVEL with sand,medium 8 34 13 47 20 dense. (Fill) _ 1049.0 94 Tan LIMESTONE,moderately hm-d to hard, 3.0 (94) moderately to highly weathered,wlpits,pugs,red 5 100 stained solution features,discontinuities,chert,and 10 1124 128(LD (83) fossils.(Edwards) - [.50%water loss at 5.5 f1] - to 95 - (78) . fJ00%water loss at 13.0 ft] 12 124 72(U) I 15 100 (82) 1033.0 -20- 95 Tan LIlYMSTONE,moderately hard to hard, 19.0 (72) medium to fine vained,wloccasional red stained solution features,discontinuities,dolomitic layers, and fossils. (Edwards) _ 13 1118 81([7) ` I -25 70 - (40) _30- 83 (58) 35 97 -clay layer from 33.8 to 34.5 ft 1037. 5 7 140 114(LD , (87} COMPLETION DEPTH: 49.5 ft DEPTH TO WATER: See Note u=Unconfined P=Pocket Penetrometer Q=Unconsolidated T=To"ne DRILL BATE: 8/20/07 undrained Triaxiai APPENDIX 8a R1iR0 LOG OF BORING CLL-01 Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: Future 6MG Clearwell Ca. L AIYER a .. 2e Z 310-s STRATUM DESCRIPTION ELEV� P IZP dQt� �BPTH ap a Q We �j� a a.. Cn Q SURF.EL, 1452 f� Job No. 1001-3647 � P. N 98 - (78) 1008.7 Gray LIlVIESTONE,moderately hard to hard, 43.3 -45 - 95 medium to fine grained,nodular,w/discontinuities, 9 134 114(U) - (95) and marly warns and layers,(Fredericksburg) 1002.5 -50- 49.5 - NOTES: 1) Boring was advanced dry to the 3.0-ft depth and groundwater was not encountered above that depth. - 55- 2) On completion of the dulling operation the hole was open to 49.0 ft and the water surface(drilling fluid)was noted at the 37.0-ft depth. 3) N10164024.48,E3070705.26 60 -6S -70 -75 COMPLETION DEPTH: 49.5 ft DEPTH TO WATER: See Note u=Unconfined P-Pocket Penetmmeter Q=Unconsolidated T=Torvane DRILL DATE: 8120147 Undrained Triaxial APPENDIX 8b LOG OF BORING CLL-02 PRO Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: Future FMr Clearwell o e y.o dove U LAYER qa U^ W 4a F-4 STRATUM DESCRIPTION ELEVI a w > N A z A dwi3 DEPTH 30 .a �q rn5 rro der d SURF EL. 1053 ftt ,lob No. 1001-3647 w � 0 71 Tan silty SAND.(Fill) Tan LIMESTONE,moderately hard to hard,slightly 0.5 (54) weathered,medium to fine grained,wloccasional 10 127 1.08P solution features,discontinuities,dolomitic layers, and fossils. (Edwards) - 5 100 -clay seams from 1.2 to 2.7 ft _ (62) -fossiliferous from 70 to&.b ft 1045.5 7.5 Tan LIMESTONE,moderately hard to hard,wlpits, vugs,red stained solution features,discontinuities, 10 100 chert,and fossils.(Edwards) (62) 100%water loss at 11.5ft] -clay seam at 11.6 ft 11 124 78(U) _ -fossiliferous from 11.6 to 12.0 ft 15 100 -clay seam at 120 ft (82) f i -20 40 12 117 80(L) (27) _clay layer from 21 to 24 ft 1029.0 -25- 83 24.0 (35) -30- 100 (83) 15 i I17 75 35 100 (70) 11 126 106M COMPLETION DEPTH: 49.5 ft DEPTH TO WATER: See Note U=umonflord P=Porkel Penetrometer Q=Unconsolidated T=Torvane DRILL DATE: 8/20107 Undrained Triaxial APPENDIX 9a can LOG OF BORING CLL-02 A -_`-_ ] E - Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: Future 6MG Clearwell LAYERI; _ U 900 DEPTH < coo C> STRATUM DESCRIPTION ELV J �� a:0 SURF EL. 1053 ftp Jot?No. 1001-3647 90 Tan LIldESTONE,moderately hard to hard,wlpits, - (70) vugs,red stained solution features,discontinuities, chert,and fossils,(Edwards) r 1014.5 - Gray LIMESTONE,moderately hard to hard, 42.5 medium to fine grained,nodular,wldiscontinuities, 45 100 and marly seams and layers.(Edwards) (65) -clay seam from 44.5 to 44.7 ft 1003.5 134 99 -50- ------ 49.5 NOTES: - 1) Boring was advanced dry to the 0.5-ft depth and groundwater was not encountered above that depth. 55 2) On completion of the drilling operation the hole was open to 48.4 ft and the water surface(drilling fluid)was noted at the 28.7_f{depth. 3) N10163947.49,E3070744.63 _60 55 -70 75 COMPLETION DEPTH: 49.5 ft DEPTH TO WATER: See Nota U=Unconfined P=Pocket Penetrometer Q=Unconsolidated T=Torvane DRILL DATE: 8120107 Undrained Triaxial APPENDIX 9b bGRn LOG OF BORING CLL-03 ' _- Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: 5ampleVet Rotary LOCATION: 4MG Clearwell x v e [ C O P V o :L p W wQA LAYER 7 z a z F ��-el C7 0 STRATUM DESCRIPTION El,[-;V./ 00z)- DEPTH < SURF EL. 1052 f+ Joh No. 100 1-3 647 4111" Dark brown fat CLAY,firm,wlsand,limestone 1050.8 - fragments,and roots. CH(Residual Soil) 1.2 84 Tan LIMESTONE,slightly weathered,hard, (40) moderately fractured,wlpits,wigs,red-stained - - solution fears res,discontinuities,chert,and - 5 87 fossils. (Edwards) (35) 5 130 IQ3(Cr} [100%water loss at 7.5 f] - 10 100 fossiliferous from 11.0 to 11.3 ft 11 122 92(U) -fossiliferous fiDrn 13.2 to 14.0 ft - 15 100 (78) -reddish brown clay layer b-om 18.5 to 21.5 ft -20 80 (25) 1030.5 14 115 68(U) 21.5 -25 - 97 (27) -3092 (7) 35 93 (33) - T] 1 1128 1 130(L)] COMPLETION DEPTH: 49.5 ft DEPTH TO WATER: See Note u=Unconfined P a Pocket Penetrometer Q=UnconsolidHied T-Tervane DRILL DATE: 3126108 Undrained Triaxial APPENDIX 10a LOG OF BORING CLL-03 �Rn Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: 4MG Clearwell 0 da 7 LAYER 04 �: o -� v, pp a az STRATUM DESCRIPTION RLEVJ �� `' z A w DEPTH 3 ZN d q "'ren vi c t7 ca z SURF EL. 1052 ftt rob No. 1001-3647 � o, 97 Tan LM ESTONE,slightly weathered,hard., (85) moderately fractured,w/pits,vugs,red-stained 1009.8 - solution feartures,discontinuities,chert,and 42.2 fossils.(Edwards) Gray LPVIESTONE,hard,slightly fractured. 45 100 (Edwards) 9 129 I00 (80) " - 1002.5 -50 -- -------------�-_�_____.-^_ 49.5 NOTE.- 1) Boring was advanced dry to the 2.0-ft depth and groundwater was not encountered above that dept -55- 2) On completion of the drilling operation the hole was open to 48.0 J?and the water surface(drilling fluid)was noted at the 31.3 ft depth. -60- -65- -70- -75 - L 065-7075 COMPLETION DEPTH: 49.5 R DEPTH TO WATER See Note U a Unconfined P=Pocket Penetrometer Q=Unconsolidated T=Tomne BRILL DATE: 3/26108 [Undrained Triaxial APPENDIX 10b LOG OF BORING CLL-04 �Rn [ - Brushy Greek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPED Sam lelWet Rotary LOCATION: 4MG Clearwell ci o °a LAYER w " gg U �` x� w � 1 "N" 43 0 STRATUM DESCRIPTION ELEV �c �E i '� _o DEPTH 3 0 ��' �o SURF EL, 1053.1 ftp Job No. 1001-3647 0 a °�'N U 17 Dark brawn fat CLAY,stiff,wlsand,limestone 1051.9 fragments,and roots. CH(Residual Soil) FI.2 67 Tan L 1E.STONE,slightly weathered,hard,slightly (17) to moderately fractured,wlpits,►rugs,rid-stained solution features,discontinuities,chert,and fossils. — 5 92 (Edwards) (45) -fossiliferous from 7.2 to 7.6 ft i0 104 10 122 125 (78) 7 130 112(U) 15 104 (93) 20 77 (10) --25- 72 13 121 104 (23) [100%water loss at 2 7.5 f] -30- 90 (g) - -fossiliferous from 33.0 to 34.8 ft -35- 92 (7) COMPLETION DEPTH: 49.5 ft DEPTH TO WATER: See Note u=unconfined P-Pocket Penetrometer Q=Unconsolidated T—Torvane DRILL DATE: 3125108 Undrained Triaxial APPENDIX 1la 1080 LOG OF BORING CLL-04 y� A - - Brushy Geek Regional Utility Authority Water Treatment Plant Trmvis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: 4MG,Clearwell aop, LAYERw g STRATUM DESCRIPTION BLEW �� �� N� �� �� �� N� IMPTH A SURF EL. 1053.1 ft± Job No. 1001-3647 �. 87 Tan LIMESTONE,slightly weathered,hard,slightly (13) to moderately fractured,wlpits,pugs,red-stained 1011.1 - solution features,discontinuities,chert,and fossils. 42.0 (Edwards) Gray LDV ESTONE,hard,moderately fractured —45- 100 (Edwards) (73) 8 133 83(U) 1003.5 —50 --___--_-----------__--------- 49.5 1V07F. 1) Boring was advanced dry to the 2.0-ft depth and groundwater was not encountered above that dept _55- 2) On completion of the drilling operation the hole woos open to 24.3 ft. --6Q 65 —70 —75 CONTLETION DEPTH: 49.5 ft DEPTH TO WATER: See Note U=Unconfined P=Pocket Penetrometer Q-Unmisolidated T=Torvane DRILL DATE: 3125108 Undrained Triaxial APPENDIX 11b GRO LOG OF BORING DB-01 =4 Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: Disinfection Basin a , o u, y .a P4 ❑ aC)Q LAYER � Q� �. Zw >- V1 H o Cn STRATUM DESCRIPTTON ELEV./ .35 CV W P� z y � Q x �z L6 DEPTH �� SURF EL. 1056 ft± Job No. 1001-3647 U °�" °"�' �'� o 4n Dark brown fat CLAY,hard,wlsand,roots,and 29 75 46 00 98 4,0(P) limestone fragments.CH(Residual Soil) 4.5(P) - 1053.5 - 100 Tan LIMESTONE,hard to moderately hard, 2.5 (75) moderately weathered,w/pits,vugs,red stained _ 5 93 solution features,discontinuities,chert,and fossils. (68) (Edwards) -fossiliferous from 6.0 to 6.8 ft 6 124 75(u) - 10 100 (70) -red clay layer htom 10,3 to 10.7 ft fossiliferous from 10.3 to 13.5 ft 1043.5 Tan LIN ESTONE,moderately hard to hard, 12.5 100 medium.to fine grained,wlfossils,occasional _ 15 solution features,discontinuities,and dolomitic (100) layers,(Edwards) ]1 126 137(U) -20- 100 (100) 1032.0 25 - --------------------------- 24.0 IO 125 I09(LT) NOTES: 1) Boring was advanced dry to the 2.5-ft depth and groundwater was not encountered above that depth. - 2) On completion of the drilling operation the hole - 30- was open to 23.0 ft and the water surface(drilling _ fluid)was noted at the 7.0-ft depth. 3) N10164120.95,E3071145.12 -35 CONIPLETION DEPTH: 24.0 ft DEPTH TO WATER: See Note U=Unconfined P=Pocket Penetrometer Q=Unconsolidated T=Torme BRILL DATE: $122107 Undrained Triaxial APPENDIX 12 LOG OF BORING OB-02 bona Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION; Disinfection Basin ❑, De i4 { G4 d Gl LAYER � \ �.re Z� Z T y U]l 3 F STRATUM DESCRIPTION ELEV./ ` zDEFM } SURF EL. 1058 f}f .Fob No, 1.001-3647 8 Dark brown fat CLAY,stiff,wlsand,limestone fragments,and roots.CH(Residual Soil) 21 1053.8 5 Tan LIN ESTONE,moderately weathered, 4.2 29 98 68 00 95 80 moderately hard to hand,slightly fractured,wlpits, (52) vugs,red-stained solution features,discontinuities, - chert and fossils. (Edwards) 5 121 131 10 93 [10 0016 water loss at 9,d fa] (63) 15 80 (32) 20 92 (37) 1033.6 10 135 107" —25 --- — -------------------.�_—�.� 24.4 NOTES: 1) Boring was advanced dry to the 4.5-ft depth and - groundwater was not encountered above that depth. 30 2) On completion of the dritling operation the hole was open to 24.4 ft and the water surface(drilling fluid)was noted at the 18.0-R depth. —3S COMPLETION DEPTH: 24.4 ft DEPTH TO WATER: See Nate U L Urnconfnod P=Pocket Penewmeter Q=Unwnsolidated T—Tornm DRILL DATE: 3126109 Undmined Triaxial APPENDIX 13 olra�o LOG OF BORING DF-01 - Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sam lelWet Rotary LOCATION: Disinfection Facility a00 f:) LAYER Ez Q° Z p Z ulf }a aSTRATUM DESCRIPTION ELEV. a PX � M x � Ln 0ac� DEPTH <q Cn v,a R w SURF EL. 1066 f� Job No. 1001-3647 N 7 0 Reddish brown clayey GRAVEL with sand,lard, 10 35 18 52 29 4.5+(P) wllimestone fragments.(Fill) 1064.0 7 Light brown clayey SAND,loose,wllimestone 2.0 - f-agments and calcareous nodules. (Fill) - 5 9 _ 9 1058.0 21 Dark brown fat CLAY,very stiff,wllimestone 8.0 l t7 fragments.CH(Residual Soil) - 1054.5 Tan LIMESTONE,weathered.(Edwards) 11.5 50/2" 1051.5 - 15 100 Tan LIMESTONE,moderately hard to hard,wlpits, 14.5 (90) vugs,red stained solution features,discontinuities, chert,and fossils.(Edwards) 7 117 82 1046.5 20 -_ --_ -----------------------W-- 19.5 NOTES: 1) Boring was advanced dry to the 14,5-ft depth and groundwater was not encountered above that - 25 - depth. 2) On completion of the drilling operation the hole was open to 19.1 R and the water surface(drilling fluid)was noted at the 5.2-ft depth. 3) N10164224.13,E3071248.00 -30 35 -- COMPLETION DEPTH: 19.5 ft DEPTH TO WATER: See Note U=Uneonemed P=Pockel Penetrometer Q=Unconsolidated T=Tomne DRILL DATE: 8124107 Undrained Tri nxiat APPENDIX 14 1�Ra LOG OF BORING EB-DSI Bnishy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: Electrical Building Lr.. p LAYER +x C] -r-�'-' ' 7 rn '--t vi CY W U c% a L7 7 L7 u o STRATUM DESCRIPTION ELEV.� ¢ a z A z p > 0 2 C 3 DEPTH S co p a � SURF EL. 1057 ftp Joh No. 1001-3647 U `" °�' �R o Light brown SAND,loose.(Fill) T937F 20 57 35 96 183 _ 50131,1Dark drown fat CLAY with sand,hard. CH 0.4 I00 Lgesidual Soil) 1055.6 (90) Tan LIMESTONE,moderately hard to hard,slightly 1'4 weathered,medium to fine grained,w/occasional - 5 300 solution features,discontinuities,dolomitic layers, 9 118 117M (93) and fossils. (Edwards) - 10 100 11046.5 - TrMT Tan LIlVIESTONE,moderately hard to hard,wlpits, 10.5 vugs,red stained solution features,discontinuities, chert,and fossils.(Edwards) 15 118 90(U) - 15 - 100 - (g3) [100%water lass at 16.0 f] - __ ------------_....__.�_-_.�____ 1037.5 8 128 144(U) --20 19.5 NOTES: 1) Boring was advanced dry to the 2.0-ft depth and groundwater was not encountered above that depth. -25- 2) On completion of the drilling operation the hole was open to 18.7 ft and the water surface(drilling - fluid)was noted at the 16.8-ft depth. 3) N10163906.42,E3071055,96 -30 35 COMPLETION DEPTH: 19.5 ft DEPTH TO WATER: See Note U=Unconfined P=Pocket Penetrometer Q=Unconsolidated T=Tonne DRILL DATE: 8124107 Undrained Triaxial APPENDIX 15 GRD LOG OF BORING EST-01 = Brushy Creels Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: Elevated Storage Tank p w P& o . 00 3 0 STRATUM DESCRIPTION E a� Cn p60Op�tj DEPTH �0 :dA r�'n Qo Wf- U SURF L. 1063.5 L Job No. 1041-3647 a °'N o Ef Tan clayey GRAVEL with sand,dense,w/limestone - fragments. (Completely Weathered Limestone) 30 IMIA" 1464.5 7 29 11 51 19 67 Tan LEAESTONE,moderately hard to hard, 3.0 - 5 67 moderately weathered,wlpits,vugs,red stained solution features,discontinuities,chert,and fossils. 83 (Edwards) - to- 104 (52) 1054.0 - Tan LIMESTONE,moderately hard to hard,wlpits, 1 13.5 - 15 140 vugs,red stained solution features,discontinuities, (92) chert,and fossils.(Edwards) 4 145 229(CT) 20 104 (100) 1041.4 Tan LAvMSTONE,moderately hard to hard, 22.5 17 114 90(U) medium to fine grained,w/occasional solution -25 - 144 features,discontinuities,dolomitic layers,and (100) fossils. (Edwards) [25%water loss at 24.0 ft] -30- 100 (100) (95) 13 127 76C-J) 140 - -4TI 1 14 1 1 118 95(U) COMPLETION DEPTH: 49.5 ft DEPTH TO WATER: See Note U=Unconfined P-Pocket Penetrometer Q=Unconsolidated T=Torvano DRILL DATE: 8/22107 Undrained Triaxial APPENDIX 16a GRo LOG OF BORING EST-01 = Brushy Creek Regional Utility Authority Water Treatment Plant Travis and WiIliatnson Counties,Texas TYPE; Sam le/Wet Rata LOCATION: Elevated Storage Tarek Q LAYER S �� z x a 30� SfRATL1MDESCRIPIIUN ELEVJ a�" r � � a� � DEPTH SURF EL. 1063.5 ft+- Job No. 1001-3647 _ 100 Tan LUvIESTONE,moderately hard to hard, (93) medium to fine grained,wloccasional solution features,discontinuities,dolomitic layers,and fossils.(Edwards) 45 100 (83) 16 lis 106P _� �-------------r___�—��—__ 1014.0 50 49.5 NOTES: 1) Boring was advanced dry to the 3.5-ft depth and groundwater was not encountered above that depth. 55 2) On completion of the drilling operation the bole was open to 48.6 ft and the water surface(drilling fluid)was noted at the 26.3-ft depth. 3) N10164460.21,E3071479.34 60- -65- '70 0-6570 —75 COMPLETION DEPTH: 49.5 ft DEPTH TO WATER: See Note U=Unconfined P-Pocket Penetrometer Q=Unconsolidated T—Torvane DRILL DATE: 8122/07 Undrained Triaxial APPENDIX 16b �Ro LOG OF BORING EST-02 J Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: Elevated Storage Tank C) a 0 I Al R � 4 z � 30� ELEV.1 Q 7!ri � ��Z"STRAT1M DESCRIPTION � woo �'w DEPTH � 9 p ' ';L0SURF EL, 1e63.5 TobNa. 1001-3647 � Dark brown fat CLAY,haul,w/sand and limestone 21 74 45 93 187 1 4.5(P) fragments. CH(Residual Soil) 1062.0 1.5 T46Tan clayey SAND,dense wllimestone fragments. 050.5 3.0 Tan LIMESTONE,moderately hard,highly 5 weathered.(Edwards) 1057.0 Tan LHOESTONE,moderately hard to hard, 6.5 moderately weathered,w/pits,vugs,red stained solution features,discontinuities,chert,and fossils. 10- loo (Edwards) (3 g) I 1050.0 - Tan LIMESTONE,moderately hard to hard,wlpits, 13.5 5 141 157 - 15 100 vugs,red stained solution features,discontinuities, (98) chert,and fossils. (Edwards) 20 92 [I00%wafer loss at 19.Oft� 1043.0 - Tan LIMESTONE,moderately hard to hard, 20.5 medium to fine grained,wloccasional solution features,discontinuities,dolomitic layers,and fossils.(Edwards) -25 100 15 119 I3$ - (100) - 30- 100 (100) 13 124 128 -35 - 104 (67) 13 119 82{1, COMPLETION DEPTH: 49,5 ft DEPTH TO WATER: See Note u=Unconfined P=Pocket Penelromefer Q=Unconsolidated T=Torvane DRILL DATE: $122107 Undmined Triaxial APPENDIX 17a LOG OF BORING EST-02 MRO Brushy Creck Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: Elevated Storage Tank oa - o w �O+a LAYER x� A� �^ z� z g a STRATUM DESCRIPTION ELEVJ ¢H P X DEPTH 3 SURF EL.. 1063.5 ftp Job No. 1001-3647 � �� �� °�'g =) o 68 -clay layer from 40.1 to 4l.8 ft (60) Tan L]NIESTONE,moderately hard to hard, 1021.7 medium to fine grained,wloccasional solution 41.8 features,discontinuities,dolomitic layers,and fossils.(Edwards) -45- 100 (95) 1014.0 - 501" 50 49.5 14 11$ 112([i) NOTES: 1) Boring was advanced dry to the 4.041 depth and groundwater was not encountered above that depth. -55 2) On completion of the drilling operation the hole was open to 44,0 ft and the water surface(drilling fluid)was noted at the 27.0-ft depth. 3) N 10164427.81,E3071515.68 -60 -65 - 70 75 COMPLETION DEPTH: 49.5 ft DEPTH TO WATER: See Note U=unconfined P=Porker Penetrometer Q=unconsch&ted T=Torvane DRILL DATE: 8122107 Undrained Triaxial APPENDIX 17b LOG OF BORING PND-01 >oRn Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: Detention Pond y. w b N aW.0 LAYER c F. ❑_e t�'�—tet z� a s a 3Faa� H LIP) ELEV.�STRATLM DESCRIPTION Ew z i F- w b DEPTH 3 7- V) q m � SURF EL. 1065 ftf Job No. 1001-3647 "2 °� pw$ E3 8V) Dark brown fat CLAY,hard,wlsand,and limestone 1064.0 4.5+(P) gg fragments.CH(Residual Soil) 1.0 (10) Tan LEVESTONE,moderately hard to hard, moderately weathered,wired stained solution features.(Edwards) 5 95 4 146 217(U) (38) 1056.4 - To- 100 Tan LRYMSTONE,moderately hard to hard, 9.0 (75} medium to fine grained,wldolomitic layers,and discontinuities.(Edwards) 15 - -- ------------------------- 1014.5 8 137 188 MOTES: 1) Boring was advanced dry to the 1.0-ft depth and groundwater was not encountered above that depth. -20- 2) On completion of the chilling operation the hole was open to 14.0 ft and the water surface(drilling fluid)was noted at the ground surface. 3) N10164756.34,E3071149.51 -25 -3D -35 COMPLETION DEPTH: 14.5 ft DEPTH TO WATER: See Note U=Unconfined P=Pocket Penetrometer Q=Unconsolidated T=Torvane DRJLL DATE: 8122107 Undmined Triaxial APPENDIX 18 GRD LOG OF BORING PND-02T-vi ' Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: Detention Pond p P'S LAYER P4 F' 2�CP4Uw Z` p ren a 3 a STRATUM DESCRIPTION [EV./ w w x Z w „ 00U DEPTH 3� 3a �Q U'� v,o SURF EL. 1065 ft-i .lob No, 1001-3647 N o Dark reddish brown fat CLAY,hard,w/limestone 26 69 44 00 99 4.5+(P) fragments. CH(Residual Soil) 1063.5 (19) Tan LDJESTONE,moderately hard to hard, 1.5 moderately weathered,wired clay seams,red stained solution features,and discontinuities. 5 (Edwards) 1060.0 (23) Tan LIMESTONE,moderately hard to hard, 5.0 meditun to fine grained,w/dolomitic layers,and discontinuities, (Edwards) 10 100 - (77) - 15 -- -- ---------------------------- 1050.5 14.5 6 NOTES: 1) Boring was advanced dry to the 1.5-ft depth and groundwater was not encountered above that depth. 20 2) On completion of the drilling operation the hole was open to 14.0 ft and the water surface(drilling fluid)was noted at the ground surface. 3) N10164664.0,E3071267,57 —25 -- 30 —35 COMPLE'T'ION DEPTH: 14.5 ft DEPTH TO WATER: See Note U-Unconfined P=Pocket Penetrometer Q=Unonsolidaled T-Tarvane DRILL DATE: 8/22107 Undrained Triaxial APPENDIX 19 LOG OF BORING RW-01 �Ra Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: Raw Water ¢ A LAYER F P ❑ Q A ELEV./ p H3oa STRATUM DESCRIPTION l �oncZ rnnooc) co ��° �Q 3 SURF EL. 1069.7 f� U Job No. 1001-3647 � �� "' ❑ Dark brown sandy fat CLAY,hard,wlroots,and 26 71 43 100 55 4.5}(P) limestone fragments.CH(Residual Soil) 1067.? 100 Tan LMESTONE,moderately hard to hard, 2,0 (13) moderately weathered,wired stained solution 100 features,discontinuities,and chert. (Edwards) 5 (82) 7 142 s 74(U) 1060,2 - 10 100 Light reddish brown LIMESTONE,moderately hard 9.5 (100) to hard,w/discontinuities,and manly scams and layers.(Edwards) -- -- 14.5 ----------------- .2 15 148 136 23 - NOTES: 1) Boring was advanced dry to the 2.0-ft depth and grourtdwater was not encountered above that depth. 20 2) On completion of the drilling operation the hole was open to 13.8 ft and the water surface(drilling fluid)was noted at the ground surface. 3) N10163649.85,E3071775.09 -25- 30 2530 -35 --------------- COMPLETION DEPTH: 14.5$ DEPTH TO WATER: See Note U=Unconfined P=Pocket Penetrometer Q=Unconsolidated T=Torvane DRILL DATE: 8125107 Undrained Triaxial APPENDIX 20 GRO LOG OF BORING SBF-01 Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: Sludge Dewatering Facility o 0 0' �- C) w w p C7 LATER �'- •: Z, Z� 'y av rrl o STRATUM DESCRIPTION ELEV./ ¢w d� i-� ' � 7 w O 0 t� DEPTH 3 z ^� ' cn �+ en .4w �R rn SURF EL. 1059.2 fly Job No. 1001-3647 � � � °�"� ° g �� �t' - 27 Dark brown fat CLAY,hard,w/limestone 4.5(P) (0) fragments.CH(Residual Soil) 0.5 Tan LIMESTONE,highly weathered,wired stained solution features. (Edwards) 1054.7 — 5 72 -tan clay filled void,moist,wllimestone fragments 4.5 _ (45) from 4.5-5.2 feet. 1054,0 Tan LIMESTONE,moderately hard to hard,wlpits, 5.2 vugs,red stained solution features,discontinuities, 3 152 175" chert,and fossils. (Edwards) — IU too (92) 1045.8 Tan LTMESTONE,moderately hard to hard, 13.4 — 15 98 medium to fine grained,wloccasional solution (98) features,discontinuities,dolomitic layers,and fossils,(Edwards) 1039.7` 15 112 102(U) 20 19.5 - NOTES: 1) Boring was advanced dry to the 0.5-ft depth and groundwater was not encountered above that depth. 25 2) On completion of the drilling operation the hole was open to 18.9 ft and the water surface(drilling fluid)was noted at the 6.2-ft depth. 3) N10164404.76,E3071138.36 —30 — 35 COMPLETION DEPTH: 19.5 ft DEPTH TO WATER: See Note U=umonrinw P=Pocket Penetrometer Q=Unconsolidated T=Torvane DRILL DATE: $!24107 Undrained Triaxial APPENDIX 21 an LOG OF BORING SLPS-01 Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas E. Sarnple/Wet Rotary LOCATION: Sludge Pump Station �, � CeK e = �"a 0 ❑v L4 ss O o, On LAYER g O� STRATUM DESCRIPTION ELEV./ p F X 2 A :n O0L) nt;Prx 3 SURF EL. 1060 ft-1 Job No. 1001-3647 °�" `"a 3 Ute' Dark brown to reddish bro-wn fat CLAY,very stiff, 2.5(P) wlroots,and limestone fragments.CH(Residual 1058.0 Soil) 2.0 50 Tan LIMESTONE,moderately hard to hard,highly (0) weathered,wired clay staining,and chert. - 5 33 (Edwards) (25) 1052.5 Tan LIMESTONE,moderately hard to hard,wlpits, 7.5 6 105 18 - vugs,discontinuities,chert,and fossils.(Edwards) - to- 100 (95) 1046.0 - 15 100 Tan LDAESTONE,moderately hard to hard, 14.0 - (100) medium to fine grained,wloccasional solution features,discontinuities,and fossils.(Edwards) 14 118 91([T} -20 100 (15) -25- 100 - (45) l4 119 113(0) 30 80 - (68) - [790%water lass at 33.0 ft] 1025.7 -clay layer from 33.5 to 34.3 f; - 35 92 34.3 (70) 17 lI5 98(CJ) COMPLETION DEPTH: 49.5 ft DEPTH TO WATER: See Note U n uncollraiw P=Packet Penetrometer Q=Unconsol idated T=Torvanc DRILL DATE: 8122107 undrained Triaxial APPENDIX 22a CRO LOG OF BORING SLPS-01 " Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: Sludge Pump Station pA LAYER ,x� o � zo oQ STRATUM DESCRIPTION EL�v.� w a w z> R; 'z0 SR DEPTH .�� ri'a W co SURF EL. 1060 fif rob No. 1001-3647 88 Tan LIMESTONE,moderately hard to hard, (36) medium to fine grained,wloccasionai solution features,discontinuities,and fossils.(Edwards) -45- 100 (72) 12 123 62M 1410.5 50 - -- ---�----------------------- 49.5 NOTES: 1) Boring was advanced dry to the 2.5-ft depth and groundwater was not encountered above that depth. _ 55 2) On completion of the drilling operation the hole was open to 46.7 ft and tyre water surface(drilling fluid)was noted at the 36.4 ft depth. 3) N10164533.56,E3071019.37 i -60 -65 70 -75 COMPLETION DEPTH: 49.5 ft DEPTH TO WATER: See Note U=Unconfined P=Pocket Penetrometer Q s Unconsolidated T x Torvane DRILL DATE: 8122J07 Undrained Triaxial APPENDIX 22h 6R0 LOG OF BORING STI-01 Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE; Sample/Wet Rotary LOCATION: 1st Stage Sludge Thickener �o a boa [ASR w� s� �� 0� `" F- STRATUM DESCRIPTION ELEVJ ¢W a P w Z� �. 00U DEPTH �0 <q m V, U)a a < SURF EL. 1058.8 ftp Job No. 1001-3647 46 Dark brown fat CLAY,very stiff,wlroots,and 3.0(P) limestone fragments.CH(Residual Soil) 0.5 (0) Tan and light gray LIMESTONE,moderately hard - to Bard,highly weathered,wired stains,pits,vugs, - and chert.(Edwards) 1054.3 - 5 1 70 Tan LIMESTONE,moderately hard to hard,wlpits, 4.5 (53) vugs,red stained solution features,discontinuities, 2 155 1210(U) cher!,and fossils.(Edwards) - 10- 100 (100) _1444.3 -- 15- 97 Tan LIN ESTONE,moderately hard to hard, 14.5 14 11 d 64([J} (97) medium to fine grained,wloccasional solution _ features,discontinuites,dolomitic layers,and fossils.(Edwards) 1039.3 -20 19.5 NOTES: 1) Boring was advanced dry to the 0.5-ft depth and _ groundwater was not encountered above that depth. -25 - 2) On completion of the drilling operation the hole was open to 17.5 ft and the water surface(drilling fluid)was noted at the 0.5 ft depth. 3) N10164522.04,E3070942.64 -30- 35 COMPLETION DEPTH: 19.5 ft DEPTH TO WATER. See Note U=Unconfined P=Pocket Penelmmetet Q=Unconsol!dated T—Torvane DRILL DATE: $121107 Undrained Triaxial APPENDIX 23 ©RD LOG OF BORING ST2-01 - Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: Sample/Wet Rotary LOCATION: 2nd Stage Sludge Thickener 6 p a 0-p LAYER A4 Up z a �F- H o x STRATUM DESCRIPTION ELEV./ a z� z w R Qp� DEPTHa �q w `* 3 SURF'EL. 1058,4 ft+ .Fob No. 1001-3647 U o� _ Dark brown fat CLAY,hard,w/limestone 1057.2 4.0(P) fragments.CH(Residual) 1.2 Light brown silty,clayey SAND,moist,wllimestone fr-agments.CL(Completely Weathehe�d Limestone) - 5 1053.4 0.0(P) 83 Tan LIMESTONE,moderately hard to hard,wlpits, 5.0 (72) vugs,occasional red stained solution features, 6 133 128M discontinuities,chert, and fossils.(Edwards) - 10 92 (92) 1043.9 - 15 100 Tan LIMESTONE,moderately hard to hard, 14.5 23 108 89(U) (95) medium to fine grained,wloccasional red stained _ solution features,discontinuities,dolomitic layers, and fossils.(Edwards) -- --------------------------- 1038.9 -20 19.5 - NOTES: 1) Boring was advanced dry to the 5.0-ft depth and groundwater was not encountered above that depth. 25 2) On completion of the drilling operation the hale was open to 19.0 ft and the water surface(drilling fluid)was noted at the 14.0 ft depth, 3) N10164473,46,E3070991.29 - 30- 35- J 3035 COMPLETION DEPTH: 19.5 ft DEPTH TO WATER: See Note U=Unconfined P=pocket Penetrometer Q=Uncoimlidated T=Torvane DRIL..L..DATE: 8121/07 Undrained Triaxial APPENDIX 24 DRO LOG OF BORING WDB-01 = - Brushy Creek Regional U lity Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE; Sample/wet Rotary LOCATION: Washw//ater Decant Basin O 6I/I0A LAYER F+Ln P,x STRATUM DESCRIPTION ELEV./ ¢ R-g E-) !j4z w N w N �aw DEPTH �7 ,la dp CZr7i rr» A h� Q .az v �o SURF EL. 10551tf Job No. 1061-3647 a �` N a Dark brown sandy fat CLAY,hard,w/limestone 30 77 45 99 55 4,5+(P) AM- fi-agments. CH(Residual Soil) 1052.9 Il ' Tan LIMESTONE,moderately hard to hard, 2.1 _ 79 moderately weathered,wlpits,vugs,red stained (54) solution features,discontinuities,chert,and fossils. - 5 100 (Edwards) 7 117 64(U) - (67) [25%water loss at 5.Oft] - 14 1045.0 (53} Tan LIMESTONE,moderately hard to hard, 10.0 medium to fine grained,wloccasional red stained solution featww,discontinuities,dolomitic layers, and fossils.(Edwards) - 15 97 (93) S 1115 216(U) -20- 98 (83) 25 97 -clay layer from 24.4 to 26.3 ft - (63) [100%water loss at 24.5 f1J 1028.7 26.3 16 113 66(U) - 1025.5 -30 __ _ _-.----------------- 29.5 - NOTES: 1) Boring was advanced dry to the 2.5-ft depth and groundwater was not encountered above that depth. ' -35 2) On completion of the drilling operation the hole was open to 28.5 ft and the water surface(drilling fluid)was noted at the 27.3 ft depth. 3) N10164388.76,E3070887.22 COMPLETION DEPTH: 29.5 ft DEPTH TO WATER. See Note U=Unconfined P=Po&es Peneiroinotes Q�Uneansolldated T=Torvane DRILL DATE. 8121147 Undrained Triaxial APPENDIX 25 GRD LOG OF BORING WSB-01 Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: SarnpleVet Rotary LOCATION: Washwater Settling Basin p aa.<) LAYER F-' �' �" w A cm 0.1 '-� � a' 2 �" U� t7� C7� � �'L7 cz. o x STRATUM DESCRIPTION ELEV./ > tnQ Q Cn A ooh DEPTH 3 as ¢� SURF EL. 1055,5 ftt .lob No. 1001-3647 6 Dark brown fat CLAY,stiff,w/ mestone fragments. CH(Residual Soil) 1053.5 010.3' Tan LIMESTONE,moderately hard to hard,wlpits, 2.0 - 61 vugs,red stained solution features,discontinuities, - (47) chert,and fossils.(Edwards) - 5 100 (88) 7 1118 89M -manly seam at 8.5 ft 10 100 (100) 1042.1 14 106 41(U) - Tan LMIESTONE,moderately hard to hard, 13.4 15 100 medium to fine grained,w/occasional solution (140) features,discontinuities,doloinitic layers,and fossils.(Edwards) -20- 98 (98) 11 123 I04(U) 25 92 (65) 17 112 48(U) - �--------marlyseamat283ft 1026.0 NOTES: 1) Boring was advanced dry to the 3.0-ft depth and groundwater was not encoiuitered above that depth. -35 2) On completion of the drilling operation the hole was open to 28.8 ft and the water surface(drilling fluid)was noted at the 28.6 ft depth. 3) N10164327.04,E3070971.54 COMPLETION DEPTH: 29,5 ft DEPTH TO WATER: See Note U=UnconfaW P=Pocket Penetrometer Q=[Unconsolidated T=Torvane DRILL DATE: $121107 Undrained Trinxiat APPENDIX 26 G1�0 LOG OF BORING WWLS-01 5Y= Brushy Creek Regional Utility Authority Water Treatment Plant Travis and Williamson Counties,Texas TYPE: SarnplelWet Rotaiy LOCATION: Lift Station R'e o o a > 0 0\ [L p w n p R LAYER C] o$ STRATUM DESCRIPTION Cy- P w w w U DEPTH a;� Q q cin o7 0 p ° SURF EL. 1067 fl± Job No, 1001-3647 0 - o Dark brown fat CLAY,hard,wllimestone 1056.0 25 74 148 100 99 4.5(P) fragments. CH(Residual Soil) 1.0 - 57 Tarr MIESTONE,moderately hard to hard, (0) moderately weathered,wired stained solution features,clay seams and layers,and chert. 5 92 (Edwat)ds) (0) - 10- 90 (27) 1454.0 Tan LIMESTONE,moderately hard to hard, 13.0 medium to fine grained,wloccasional solution 4 i 138 148(0) - 15 100 features,discontinuities,dolomitic layers,and (75) fossils.(Edwards) [100%water lass at 16.0.x] -20- 98 -fossiliferous from 19.2 to 20.0 ft (82) g 1 133 132(U} -25 - 97 - (97). 1037.5 -30 - -- - fossilifero--- 29.0 to- 29.5ft _-_-_--_- 29.5 12 115 75 NOTES: 1) Boring was advanced dry to the 2.0-ft depth and groundwater was not encountered above that depth. 2) On completion of the drilling operation the hole was open to 18.0 ft and the water surface(dniffing _ 35 fluid)was noted at the 17.2 ft depth. 3) N10163730,36,E3071648.31 4) A piezometer was installed kn the borehole on 91612407. The groundwater level was measured at a depth of 28.3 ft on 1112912007. COMPLETION DEPTH: 29.5 ft DEPTH TO WATER: See Note U=Unconfined P=Pocket Nne[romew Q=Unconsoiidnled T=Torvane DRILL DATE: 8124107 Undrained Triaxial APPENDIX 27 THIS PAGE LEFT BLANK INTENTIONALLY -fliGIR" Report No.04.10013647 APPENDIX B FIELD RESISTIVITY AND CORROSION TESTING Plan of Field Resistivity Lines Table of Field Resistivity Results (3 tests) Laboratory Corrosion Test Results (4 samples) THIS PAGE LEFT BLANK INTENTIONALLY Report No: 1001-7647-1 ORO fP 17 �1 SEE,a s,oe,.,z ■ ho ■ - - - 1 Rt-2 r E — -- — — E II r ' I pO i Q T p o I I E 171 16 Q f r y I � F7 ST T3OM 60371riG G N�Q363025.1 S " s M. E 1440= Y.161 763-15 £—307 i?5.53 66 Site plan provided by COM.June 11,20W RESISTIVITY LINES NTS Brushy Creek Regional Utility Authority Water Treatment Plant-Prase'i Travis and Williamson Counties,Texas THIS PAGE LEFT BLANK INTENTIONALLY Report No. 1001.3647 Resistivity Apparent Alignment a-spacing Resistivity Resistivity Number (feet) (ohm) (ohm-cm) R1 5 0.33 311 R1 10 0.34 654 R1 15 0.23 670 R1 20 0.23 862 R1 25 0.22 1037 R1 30 0.19 1101 R1 35 0.18 1373 R1 40 0.16 1213 R1 45 0.15 1293 R1 50 0.15 1436 R2 5 0.23 215 R2 10 0.17 319 R2 15 0.16 455 R2 20 0.14 543 R2 25 0.14 678 R2 30 4.13 766 R2 35 0.13 894 R2 40 0.13 958 R2 45 0.12 1005 R2 50 0.12 1117 R3 5 0.17 160 R3 10 0.14 271 R3 15 0.14 407 R3 20 0.14 543 R3 25 0.13 638 R3 30 0.12 670 R3 35 0.12 782 R3 40 0.12 894 R3 45 0.11 934 R3 50 0.11 1037 NOTES: 1) Test Procedure-ASTM G 57 "Field Measurement of Soil Resistivity Using the Wenner Four-Eiectrode Method" 2) See Plan of Resistivity Lines for approximate resistivity alignment locations. MEASURED RESISTIVITY VALUES BCRUA Regional Water Treatment Plant . Williamson County, Texas THIS PAGE LEFT BLAND INTENTIONALLY I FUGRO CONSULTANTS,INC. CRD GULF COAST TESTING LABORATORY 1205 NORTH TANCAHUA CORPUS CHRISTI,TEXAS 78401 PHONE(361)882-5411 FAX(361)883.7933 or 882.4028 RESULTS OF TESTS SAMPLE ID: BTS-1 4- 5.5 REPORT DATE: 07-18.07 CLIENT NUMBER: JOS NUMBER: 1001.3647 FOR: FUGRO CONSULTANTS, INC. REPORT NUMBER: AUSTIN,TX DATE SAMPLED: TIME SAMPLED: REPORTED TO: R. RUSSO SAMPLED BY: CLIENT DATE RECEIVED: 07-06-07 TIME RECEIVED: 1000 LAB NUMBER: 0706019 RECEIVED BY: SR SAMPLE I❑ Ri=SULTS UNITS METHODTfMEIDATE ANALYST Electrical Resistivity 3,379 1 ❑hn-cm L ASTM G-57 1 1100107-09-D7 Sb H 8.6 SU ASTM G 51 1130/07-09-07 SD Soluble Chloride E 100 * m Ik ASTM D 512 0834107-10-D7 SD Soluble Sulfate < 100 * mg/kg ASTM D 516 0700107-10-07 SD Suffide < 0.2D0 mg/kg EPA 9031 2300107-09-07 LAB { REDOX 365 mV ASTM D1498-93 1 1730107-10-07 LAB SO4 452-07 SCL 034-07 " Dry weight basis Respectfully submitted, SteveDe reg ria Chemist -SDlmn I THE RESULTS RELATE AS TO THE LOCATION TESTED AND NO OTHER REFERENCE SHALL BE MADE, THIS REPORT SHALL NOT BE REPRODUCED EXCEPT IN FULL WITHOUT THE WRITTEN APPROVAL DF THE LABORATORY FUGRG CONS ULTANTS,INC. �Rp GULF COAST TESTING LABORATORY 1205 NORTH TANCAHUA CORPUS CHRIST],TEXAS 78401 PHONE(361)882.5411 FAX(361)883-7133 or 882-4028 RESULTS OF TESTS SAMPLE ID: BTS-2 2-3.5 REPORT DATE: CLIENT"NUMBER: JOB NUMBER: 1401.3647 FOR: FUGR❑ CONSULTANTS, INC. REPORT NUMBER: AUSTIN, TX DATE SAMPLED: TIME SAMPLED: REPORTED TO: R. RUSSO SAMPLED BY: CLIENT DATE RECEIVED: 07-06-07 TIME RECEIVED: 1000 LAS NUMBER. 0706020 RECEIVED BY: SID SAMPLE ID RESULTS UNITS METHOD TIME/DATE ANALYST Electrical Resistivit 3,815 ohn-cm ASTM G-57 1200107-09-07 SD H 8.7 SU ASTM G 51 1130197-09-07 SD Soluble Chloride < 100 * rrI Ik ASTM D 512 0830107-10-07 SD Soluble Sulfate < 100 * m Ik ASTM D 516 0700107-10-07 SD Sulfide e 0,200 m.2/k,, EPA 9031 2300107-09-07 LAB REDOX 317 mV ASTM 01498-93 1730107-1007 LAB Soo 052-07 SCL 034-07 * Dry weight basis Respectfully submitted, SteveVegori Chem SDImn THE RESULTS RELATE AS TO THE LOCATION TESTED AND NO OTHER REFERENCE SHALL BE MADE. THIS REPORT SHALL NOT BE REPRODUCED EXCEPT IN FULL WITHOUT THE WRITTEN APPROVAL OF THE LABORATORY t FUGRO CONSULTANTS,INC, ORB GULF COAST TESTING LABORATORY 1 1205 NORTH TANCAHUA CORPUS CHRISTI,TEXAS 78401 PHONE(361)882-5411 FAX(361) 883.7133 or 882.4028 RESULTS OF TESTS SAMPLE ID: BTS-3 4--5 REPORT DATE: CLIENT NUMBER: JOB NUMBER: 1001-3647 FOR: FUGRO CONSULTANTS, INC. REPORT NUMBER: AUSTIN, TX DATE SAMPLED: TIME SAMPLED: REPORTED TO: R. RUSSO SAMPLED BY: CLIENT DATE RECEIVED: 07-06-07 TIME RECEIVED: 1000 LAB NUMBER: 0706021 RECEIVED BY: SD AMPLE ID RI=SULTS UNITS Mr^THDt7 TIMEIDATE ANALYST Efectrical Resistivity 2,453 ahn-cm ASTM G-57 1330107-09-07 S❑ H 8.5 SU ASTM G 51 1130107-09-07 SD Soluble Chloride < 100 " mg/kg ASTM D 512 0830/07-10-07 SD Soluble Sulfate < 100 * m Jk ASTM ❑ 515 9700107-10-07 SD Sulfide 0.200 mq/k =m /k= EPA 9031 2300107-09-07 LAB REDOX 390 mV ASTM D1498-93 1730107-10-07 LAB SO4 452-07 SCL 034-07 Dry weight basis Respectfully submitted, i. Steve DeGreg ria Chemist is SDImn THE RESULTS RELATE AS TO THE LOCATION TESTED AND NO OTHER REFERENCE SHALL BE MADE, THIS REPORT SHALL NOT BE REPRODUCED EXCEPT IN FULL WITHOUT THE WRITTEN APPROVAL OF THE LABORATORY FUGRO CONSULTANTS,INC. [�Rp GULF COAST TESTING LABORATORY I 1205 NORTH TANCAHUA CORPUS CHRIST[,TEXAS 78401 PHONE(361)882-5411 FAX(361)883-7133 or 882-4028 i RESULTS OF TESTS SAMPLE ID: BTS-5 2—3.5 REPORT DATE: CLIENT NUMBER: JOB NUMBER: 1001.3$47 FOR; FUGRO CONSULTANTS, INC. REPORT NUMBER; AUSTIN, TX DATE SAMPLED: TIME SAMPLED: REPORTED TO: R. RUSSO SAMPLED BY: CLIENT DATE RECEIVED: 07-06-07 TIME RECEIVED: 1000 LAB NUMBER: 0706022 RECEIVED BY: SD SAMPLE ID RESULTS UNITS METHOD TIME/DATE ANALYST Electrical Resistivity 1,145 ohn-cm ASTM G-57 1500107-09-07 S❑ H 8.1 SU ASTM G 51 1130107-09-07 SD Soluble Chloride E 100 " rng/kj=ASTM D 512 0630/07-10-07 SD Soluble Sulfate < 100 * mgt:k6=ASTM D 516 0700/07-10-07 SD Sulfide r 0.200 m /k EPA 9031 2300107-09-07 LAS REDOX 315 mV ASTM D1498-93 1730107-10-07 LAB SO4 ase-07 SGL 034-07 * Dry weight basis Respectfuily submitted, StevADeG pori Chemist SD/rntn ;-THE RESULTS RELATE AS TO THE LOCATION TESTED AND NO OTHER REFERENCE SHALL BE MADE, THIS REPORT SHALL NOT BE REPRODUCED EXCEPT IN FULL WITHOUT THE WRITTEN APPROVAL OF THE LABORATORY APPENDIX B SUBSURFACE EXPLORATION DATA FOR CURRENT GEOTECHNICAL INVESTIGATION General Notes for Subsurface Exploration Logs Identification of Soil Descriptive Criteria for Rock Core Logging Boring Logs, B-1 and B-2 GENERAL NOTES FOR SUBSURFACE EXPLORATION LOGS 1. Numbers in sampling data column next to Standard Penetration Test (SPT) symbols indicate blows required to drive a 2-inch O.D., 1⅜-inch I.D. sampling spoon 6 inches using a 140 pound hammer falling 30 inches. The Standard Penetration Test (SPT) N-value is the number of blows required to drive the sampler 12 inches, after a 6-inch seating interval. The Standard Penetration Test is performed in general accordance with ASTM D1586. 2. Visual classification of soil is in accordance with terminology set forth in “Identification of Soil.” The ASTM D2487 group symbols (e.g., CL) shown in the classification column are based on visual observations. 3. Estimated water levels indicated on the logs are only estimates from available data and may vary with precipitation, porosity of the soil, site topography, and other factors. 4. Refusal at the surface of rock, boulder, or other obstruction is defined as an SPT resistance of 50 blows for 1 inch or less of penetration. 5. The logs and related information depict subsurface conditions only at the specific locations and at the particular time when drilled or excavated. Soil conditions at other locations may differ from conditions occurring at these locations. Also, the passage of time may result in a change in the subsurface soil and water level conditions at the subsurface exploration location. 6. The stratification lines represent the approximate boundary between soil and rock types as obtained from the subsurface exploration. Some variation may also be expected vertically between samples taken. The soil profile, water level observations and penetration resistances presented on these logs have been made with reasonable care and accuracy and must be considered only an approximate representation of subsurface conditions to be encountered at the particular location. 7. Key to symbols and abbreviations: S-1, SPT Sample No., Standard Penetration Test 5+10+1 Number of blows in each 6-inch increment Run #1, CORE Core No., Rock Core Run = 5.0 ft Run length in feet REC = 60", 100% Recovery in inches, Percent Recovery RQD = 60", 100% RQD in inches, Percent RQD LL Liquid Limit MC Moisture Content (percent) PL Plastic Limit %Passing#200 Percent by weight passing a No. 200 Sieve IDENTIFICATION OF SOIL I. DEFINITION OF SOIL GROUP NAMES (ASTM D2487) SYMBOL GROUP NAME Coarse-Grained Soils More than 50% retained on No. 200 sieve Gravels – More than 50% of coarse fraction retained on No. 4 sieve Coarse, ¾” to 3” Fine, No. 4 to ¾” Clean Gravels Less than 5% fines GW WELL GRADED GRAVEL GP POORLY GRADED GRAVEL Gravels with fines More than 12% fines GM SILTY GRAVEL GC CLAYEY GRAVEL Sands – 50% or more of coarse Fraction passes No. 4 sieve Coarse, No. 10 to No. 4 Medium, No. 40 to No. 10 Fine, No. 200 to No. 40 Clean Sands Less than 5% fines SW WELL GRADED SAND SP POORLY GRADED SAND Sands with fines More than 12% fines SM SILTY SAND SC CLAYEY SAND Fine-Grained Soils 50% or more passes the No. 200 sieve Silts and Clays – Liquid Limit less than 50 Low to medium plasticity Inorganic CL LEAN CLAY ML SILT Organic OL ORGANIC CLAY ORGANIC SILT Silts and Clays – Liquid Limit 50 or more Medium to high plasticity Inorganic CH FAT CLAY MH ELASTIC SILT Organic OH ORGANIC CLAY ORGANIC SILT Highly Organic Soils Primarily organic matter, dark in color and organic odor PT PEAT II. DEFINITION OF SOIL COMPONENT PROPORTIONS (ASTM D2487) Examples Adjective Form GRAVELLY SANDY >30% to <50% coarse grained component in a fine-grained soil GRAVELLY LEAN CLAY CLAYEY SILTY >12% to <50% fine grained component in a coarse-grained soil SILTY SAND “With” WITH GRAVEL WITH SAND >15% to <30% coarse grained component in a fine-grained soil FAT CLAY WITH GRAVEL WITH GRAVEL WITH SAND >15% to <50% coarse grained component in a coarse-grained soil POORLY GRADED GRAVEL WITH SAND WITH SILT WITH CLAY >5% to <12% fine grained component in a coarse-grained soil POORLY GRADED SAND WITH SILT III. GLOSSARY OF MISCELLANEOUS TERMS SYMBOLS ........................ Unified Soil Classification Symbols are shown above as group symbols. A dual symbol “-” indicates the soil belongs to two groups. A borderline symbol “/” indicates the soil belongs to two possible groups. FILL .......................................Man-made deposit containing soil, rock and often foreign matter. PROBABLE FILL ...................Soils that contain no visually detected foreign matter but which are suspect with regard to origin. DISINTEGRATED ROCK (DR) ....................................... Residual materials with a standard penetration resistance (SPT) between 60 blows per foot and refusal. Refusal is defined as an SPT of 100 blows for 2" or less penetration. PARTIALLY WEATHERED ROCK (PWR) ......................... Residual materials with a standard penetration resistance (SPT) between 100 blows per foot and refusal. Refusal is defined as an SPT of 100 blows for 2" or less penetration. BOULDERS & COBBLES ......Boulders are considered rounded pieces of rock larger than 12 inches, while cobbles range from 3 to 12-inch size. LENSES ................................0 to ½-inch seam within a material in a test pit. LAYERS ................................½ to 12-inch seam within a material in a test pit. POCKET ................................Discontinuous body within a material in a test pit. MOISTURE CONDITIONS ......Wet, moist or dry to indicate visual appearance of specimen. COLOR ..................................Overall color, with modifiers such as light to dark or variation in coloration. DESCRIPTIVE CRITERIA FOR ROCK CORE LOGGING Rock is defined as natural subsurface material yielding SPT blow counts of N 100/2 inches (Martin, 1977). Rock descriptions may include the following descriptive elements, as applicable, generally in the order indicated. Supplemental descriptors may also be used, depending on project performance objectives and available information. ROCK TYPE, strength, weathering, fracturing, color, recovery, RQD Rock Type General terms are used following the NRCS (2001) rock type classification chart based on visual identification. Some of the NRCS rock types common to our geographic area of practice are listed below. Mineralogical modifiers may be added where they help define distinct units (e.g., Garnet-Muscovite Schist). Sedimentary: Conglomerate, Sandstone, Mudstone, Siltstone, Claystone, Shale, Limestone, Dolomite, Coal, Chert Igneous: Pegmatite, Granite, Diorite, Gabbro, Diabase, Rhyolite, Monzonite, Andesite, Basalt Metamorphic: Gneiss, Schist, Phyllite, Slate, Quartzite, Marble, Amphibolite, Hornfels Strength (modified from Hoek, 2001) The estimated Uniaxial Compressive Strength associated with each rock strength term is based on the field strength index test for intact rock samples as follows. Extremely Strong >36,000 psi Specimen can only be chipped with a geological hammer. Very Strong 15,000 - 36,000 psi Specimen requires many blows of a geological hammer to fracture it. Strong 7,500 - 15,000 psi Specimen requires more than one blow of a geological hammer to fracture it. Medium Strong 3,500 - 7,500 psi Specimen cannot be peeled with a pocket knife; can be fractured with one blow from a geological hammer. Weak 700 - 3,500 psi Specimen can be peeled with a pocket knife with difficulty; shallow indentation made by firm blow with point of a geological hammer. Very Weak 150 - 700 psi Material crumbles under firm blows with point of a geological hammer; can be peeled with a pocket knife. Weathering (modified from ACOE, 1994; and USBR, 2001) Fresh Mineral crystals appear bright and show no discoloration. Fractures show little or no staining on their surfaces. Discoloration does not extend into intact rock. Slightly Weathered Rock is generally fresh except along fractures. Some fractures are stained and discoloration may extend up to 0.5 inches into rock. Moderately Weathered Significant portions of rock appear dull and discolored. Rock may be significantly weaker than in its fresh state near fractures. Soil zones of limited extent may occur along some fractures. Highly Weathered Rock appears dull and discolored throughout. Majority of rock mass is significantly weaker than in its fresh state. Isolated zones of stronger rock and/or soil may occur throughout. Severely Weathered Significant portions of rock mass essentially weathered to soil. Rock fabric may still be discernable (i.e., saprolite). Isolated zones of stronger rock may occur locally. Quartz may be present as hard, fractured dikes or veins. Fracturing (from ACOE, 1994) Very Slightly Fractured > 6.5 ft Slightly Fractured 2 ft - 6.5 ft Moderately Fractured 8 inch - 2 ft Highly Fractured 2.5 inch - 8 in Intensely Fractured < 2.5 in Color (from Munsell Color System; and GSA, 1995) Color descriptions include a primary color and up to two shade or secondary color modifiers, and may also include a color pattern term to define the relationship between multiple colors. Shade: Light, Dark Secondary: Blackish, Brownish, Grayish, Greenish, Reddish, Yellowish, Orangeish Primary: Black, Brown, Gray, Green, Red, Yellow, Orange, White Pattern: and, to, with mottles of, with speckles of, with streaks of, with bands of Recovery is defined as the total length of recovered core in a core run divided by the total length of the core run, times 100 percent. A core run may be any depth interval of concern. Only natural fractures are considered for determining the length of core pieces. Mechanical breaks formed during or after coring do not count against the length determination. The length of recovered core pieces is measured along the core axis, between fracture midpoints. RQD (ASTM D6032, Deere & Deere, 1988, 1989) is defined as the total length of core pieces at least four inches long recovered from a core run divided by the total length of the core run, times 100 percent. A core run may be any depth interval of concern. Only natural fractures are considered for determining the length of core pieces. Mechanical breaks formed during or after coring do not count against the length determination. The length of recovered core pieces should be measured along the core axis, between fracture midpoints. Core pieces that are highly to severely weathered, very weak, or contain numerous pores should not count toward RQD. Bottom of Boring at 25.0 ft. Boring drilled with drilling fluid. Water level readings in boring may not represent groundwater conditions in formation. Boring backfilled with bentonite upon completion. CH 1071.4 1069.0 1066.5 1046.5 0.1 2.5 5.0 25.0 S-01, SPT 4+4+5 REC=12", 67% S-02, SPT 7+25+50/4" REC=12", 75% S-03, SPT 50/2" REC=0", 0% Run 1, CORE Run = 5.0 ft REC=43", 72% RQD=5.5", 9% Run 2, CORE Run = 5.0 ft REC=60", 100% RQD=37", 62% Run 3, CORE Run = 5.0 ft REC=56", 93% RQD=25", 42% Run 4, CORE Run = 5.0 ft REC=53", 88% RQD=53", 88% Bottom of Boring at 25.0 ft. Boring drilled with drilling fluid. Water level readings in boring may not represent groundwater conditions in formation. Boring backfilled with bentonite upon completion. 0.0 - 0.1 ft: Topsoil 0.1 - 2.5 ft: FAT CLAY WITH SAND; moist, dark brown, trace gravel 2.5 - 5.0 ft: WEATHERED LIMESTONE, severely weathered, tan 5.0 - 25.0 ft: LIMESTONE, weak to strong, slightly weathered, highly fractured (2.5 - 8 in) to moderately fractured (8 in - 2 ft), light gray and tan, w/chert nodules and ferrous staining 10.0 ft: Change: moderately weathered 14.5 ft: Change: fresh to slightly weathered, light gray 18.0 ft: Change: light gray and tan, fossiliferous, w/pits, vugs, and ferrous staining LL = 72 PL = 31 MC = 31.0% 12:00 AM --- ------Not Encountered 1/19/22 (continued) Schnabel Representative:C. Patel Total Depth:25.0 ft Equipment:CME-45 (Truck) Ground Surface Elevation:1072± (ft) Contractor:Austin GeoLogic Austin, Texas Contractor Foreman:Jeff Dates Started: 1/19/22 Finished: 1/19/22 Location: See Location Plan Method:Air Rotary, Conventional NWD4 Hammer Type:Auto Hammer (140 lb) Coordinates: Lat.:30.52226°Long.:-97.87221° Date Time Depth CavedCasing Water Level Observations SAMPLING DEPTH 5 10 15 20 25 REMARKS TEST BORING LOG Project: STRA TUM BCRUA Phase 1D WTP Expansion Cedar Park, Texas SYMBOL Contract Number: 22640001.000 Sheet: 1 of 1 DEPTH (ft) ELEV (ft) Boring Number: DATA B-1 MATERIAL DESCRIPTION TESTS TEST BORING LOG BCRUA PH.1D.GPJ SCHNABEL DATA TEMPLATE 2008_07_06.GDT 4/12/22 Bottom of Boring at 25.0 ft. Boring drilled with drilling fluid. Water level readings in boring may not represent groundwater conditions in formation. Boring backfilled with bentonite upon completion. CH 1072.4 1068.5 1067.5 1047.5 0.1 4.0 5.0 25.0 S-01, SPT 7+12+15 REC=10", 56% S-02, SPT 4+11+11 REC=15", 83% S-03, SPT 50/3" REC=3", 100% Run 1, CORE Run = 5.0 ft REC=48", 80% RQD=15", 25% Run 2, CORE Run = 5.0 ft REC=40", 67% RQD=13.5", 23% Run 3, CORE Run = 5.0 ft REC=60", 100% RQD=28", 47% Run 4, CORE Run = 5.0 ft REC=60", 100% RQD=43", 72% Bottom of Boring at 25.0 ft. Boring drilled with drilling fluid. Water level readings in boring may not represent groundwater conditions in formation. Boring backfilled with bentonite upon completion. 0.0 - 0.1 ft: Topsoil 0.1 - 4.0 ft: FAT CLAY WITH SAND; moist, dark grayish brown, trace gravel 4.0 - 5.0 ft: WEATHERED LIMESTONE, severely weathered, tan 5.0 - 25.0 ft: LIMESTONE, medium strong to strong, slightly weathered, highly fractured (2.5 - 8 in), light gray, w/chert nodules and ferrous staining 10.0 ft: Change: slightly weathered to moderately weathered, light gray to tan 15.0 ft: Change: fresh to slightly weathered, gray 18.0 ft: Change: slightly weathered to moderately weathered, light gray, fossiliferous, w/pits, vugs, and ferrous staining LL = 70 PL = 29 MC = 24.3% 12:00 AM --- ------Not Encountered 1/19/22 (continued) Schnabel Representative:C. Patel Total Depth:25.0 ft Equipment:CME-45 (Truck) Ground Surface Elevation:1073± (ft) Contractor:Austin GeoLogic Austin, Texas Contractor Foreman:Jeff Dates Started: 1/19/22 Finished: 1/19/22 Location: See Location Plan Method:Air Rotary, Conventional NWD4 Hammer Type:Auto Hammer (140 lb) Coordinates: Lat.:30.52207°Long.:-97.87198° Date Time Depth CavedCasing Water Level Observations SAMPLING DEPTH 5 10 15 20 25 REMARKS TEST BORING LOG Project: STRA TUM BCRUA Phase 1D WTP Expansion Cedar Park, Texas SYMBOL Contract Number: 22640001.000 Sheet: 1 of 1 DEPTH (ft) ELEV (ft) Boring Number: DATA B-2 MATERIAL DESCRIPTION TESTS TEST BORING LOG BCRUA PH.1D.GPJ SCHNABEL DATA TEMPLATE 2008_07_06.GDT 4/12/22 BCRUA—Phase 1D WTP Expansion I Section 00300—Proposal form PROPOSAL FORM (Reissued by AD-02) 1.0 General Conditions 1.1 This Request for Proposal ("RFP") shall be available for viewing and download on the CIVCAST website (www.CIVCASTusa.com) or for viewing only at the City of Round Rock City Hall, 221 E. Main St., Round Rock, Texas 78664,from 8:00 a.m. until 5:00 p.m.,Monday through Friday,and available to interested individuals and entities("Proposers")from the Date Issued until the Due Date and Time. 1.1.1 Proposers are expected to examine all documents that make up this RFP. Proposers shall promptly notify the Owner of any omission, ambiguity, inconsistency, or error that they may discover upon examination of the RFP.The Owner assumes no responsibility for errors or misrepresentations that result from the use of incomplete proposals. 1.2 All responses to this RFP("Proposals")shall be submitted on the attached response forms of this RFP.Proposals must be received by the Brushy Creek Regional Utility Authority (Owner) at or before 2:00 PM local time on February 28, 2023. Each Proposal must be properly identified with the subject title and date and time due. Proposals shall be submitted in written, hard-copy format, and delivered in a sealed envelope via mail, courier service,or hand delivery to: Brushy Creek Regional Utility Authority Attn: Karen Bondy,General Manager 221 E. Main St. Round Rock,TX 78664 FAXED OR E-MAILED PROPOSALS AND/OR LATE SUBMISSIONS WILL NOT BE ACCEPTED. 1.3 All Proposals shall be addressed as shown below: Request for Proposal on: BCRUA Phase 1D Water Treatment Plant Expansion Due Date and Time: February 28,2023,at 2:00 PM local time READ THIS RFP FULLY AND CAREFULLY. PROPOSALS SHALL BE COMPLETE UPON SUBMISSION,INCLUDING ALL FORMS AND ATTACHMENTS REQUIRED HEREIN. FAILURE TO STRICTLY COMPLY WITH THESE STATED TERMS OF SUBMISSION MAY RESULT IN REJECTION OF THE PROPOSAL. 1.4 During the pendency of this RFP,Proposer shall not contact any Owner staff except those designated herein this RFP or subsequent addendums or correspondence. Any questions or concerns should be submitted via the CIVCAST website after the Advertisement and at least five(5)business days prior to the Due Date(on or before February 21,2023). 1.5 PRE-PROPOSAL Conference: A mandatory Pre-Proposal conference will be conducted at 2:00 p.m. on February 7,2023, at the BCRUA WTP Main Conference Room,located at, 1906 Hur Industrial Blvd,Cedar Park,TX 78613. All interested parties planning to submit a Proposal are encouraged to attend this conference. 1.6 Receipt of an addendum to a Proposal must be acknowledged by signing and returning the addendum with the Proposal. Addenda information will be posted on the CIVCAST website as specified in Section 1.1. 1.7 All information required of the proposer,unless otherwise specified, must be completed on the forms provided by the Owner. Failure to manually sign the Proposer Qualifications (Section 00400) will disqualify Proposer. Persons signing the Proposal shall have the authority to sign the Proposal on Proposer's behalf and shall be an officer or person authorized to bind the entity they represent to this proposal. 1.8 Proposer shall submit a Proposal that is in strict conformance with the Contract Documents as modified by Addenda. Proposed deviations from the terms,conditions,specifications,or performance requirements of this RFP shall be listed on the Deviation Form (Article 6.0 of this RFP) upon submission of your Proposal. Proposed Issued for Bid(Reissued by AD-02) Page 1 of 15 BCRLJA—Phase 1D WTP Expansion Section 00300—Proposal Form 9.0 Conflicts of Interest The Texas Ethics Commission adopted the attached Conflict of Interest Questionnaire(Form CIQ) pursuant to Texas Local Government Code Chapter 176,as amended. For questions about these forms,please see the Texas Ethics Commission at: https://www.ethics.state.tx.us/forms/CIQ.Pdf Proposer shall answer each question in the attached Form Coq in relation to the following individuals and submit a completed form with its Proposal: Local Government Office_r Title Anne Duffy Board Member Matthew Baker Board Member' Jason Anderson Board Member Na'Cole Thompson Board Member Rene Flores Board Member Mel Kirkland Board Member Karen Bondy General Manager Steve Sheets Attorney Kenneth Wheeler Oversight Committee Michael Thane Oversight Committee Dan Grimsbo Oversight Committee 10.0 Disclosure of Interested Parties Prior to entering into a contract that is over one million dollars in value,the Proposer must submit a"Certificate of Interested Parties"Form,in accordance with Texas Government Code Section 2252.908,as amended.Within 30 days of receipt of the form,the Owner must submit a copy to the Texas Ethics Commission.The Certificate of Interested Parties form is attached. Issued for Bid(Reissued by AD-02) Page 14 of 15 Revised 11/30/2015Form provided by Texas Ethics Commission www.ethics.state.tx.us CONFLICT OF INTEREST QUESTIONNAIRE For vendor doing business with local governmental entity A complete copy of Chapter 176 of the Local Government Code may be found at http://www.statutes.legis.state.tx.us/ Docs/LG/htm/LG.176.htm. For easy reference, below are some of the sections cited on this form. Local Government Code § 176.001(1-a): "Business relationship" means a connection between two or more parties based on commercial activity of one of the parties. The term does not include a connection based on: (A) a transaction that is subject to rate or fee regulation by a federal, state, or local governmental entity or an agency of a federal, state, or local governmental entity; (B) a transaction conducted at a price and subject to terms available to the public; or (C) a purchase or lease of goods or services from a person that is chartered by a state or federal agency and that is subject to regular examination by, and reporting to, that agency. Local Government Code § 176.003(a)(2)(A) and (B): (a) A local government officer shall file a conflicts disclosure statement with respect to a vendor if: *** (2) the vendor: (A) has an employment or other business relationship with the local government officer or a family member of the officer that results in the officer or family member receiving taxable income, other than investment income, that exceeds $2,500 during the 12-month period preceding the date that the officer becomes aware that (i) a contract between the local governmental entity and vendor has been executed; or (ii) the local governmental entity is considering entering into a contract with the vendor; (B) has given to the local government officer or a family member of the officer one or more gifts that have an aggregate value of more than $100 in the 12-month period preceding the date the officer becomes aware that: (i) a contract between the local governmental entity and vendor has been executed; or (ii) the local governmental entity is considering entering into a contract with the vendor. Local Government Code § 176.006(a) and (a-1) (a) A vendor shall file a completed conflict of interest questionnaire if the vendor has a business relationship with a local governmental entity and: (1) has an employment or other business relationship with a local government officer of that local governmental entity, or a family member of the officer, described by Section 176.003(a)(2)(A); (2) has given a local government officer of that local governmental entity, or a family member of the officer, one or more gifts with the aggregate value specified by Section 176.003(a)(2)(B), excluding any gift described by Section 176.003(a-1); or (3) has a family relationship with a local government officer of that local governmental entity. (a-1) The completed conflict of interest questionnaire must be filed with the appropriate records administrator not later than the seventh business day after the later of: (1) the date that the vendor: (A) begins discussions or negotiations to enter into a contract with the local governmental entity; or (B) submits to the local governmental entity an application, response to a request for proposals or bids, correspondence, or another writing related to a potential contract with the local governmental entity; or (2) the date the vendor becomes aware: (A) of an employment or other business relationship with a local government officer, or a family member of the officer, described by Subsection (a); (B) that the vendor has given one or more gifts described by Subsection (a); or (C) of a family relationship with a local government officer. TWDB-0552 Rev 11/18 Page 1 of 20 Texas Water Development Board Supplemental Contract Conditions and Instructions For Construction Services for Projects Funded through State Programs TWDB-0552 Rev 11/18 Page 2 of 20 Table of Contents I. INSTRUCTIONS TO APPLICANT .......................................................................................................... 5 1. Applicability ........................................................................................................................................... 5 2. Use of Conditions .................................................................................................................................. 5 3. Modifications to Provisions .................................................................................................................. 6 4. Good Business Practices ....................................................................................................................... 7 5. Other Requirements.............................................................................................................................. 7 6. Advertisements for Bids ....................................................................................................................... 7 7. Bid Proposal .......................................................................................................................................... 8 8. Bidding Process ..................................................................................................................................... 8 9. Release of Funds .................................................................................................................................... 8 II. INSTRUCTIONS TO BIDDERS ............................................................................................................. 10 1. Contingent Award of Contract .............................................................................................................. 10 2. U.S. Iron and Steel (Does not apply to SWIFT Projects funded prior to May 1, 2019) ....................... 10 3. Bid Guarantee ....................................................................................................................................... 10 4. Award of Contract to Nonresident Bidder ............................................................................................ 10 III. SUPPLEMENTAL CONTRACT CONDITIONS ............................................................................... 11 1. Supersession ......................................................................................................................................... 11 2. Privity of Contract ................................................................................................................................ 11 3. Definitions ............................................................................................................................................ 11 4. Laws to be Observed ............................................................................................................................ 11 5. Review by Owner and TWDB .............................................................................................................. 11 6. Performance and Payment Bonds ......................................................................................................... 12 7. Payments Schedule and Cost Breakdown ............................................................................................. 12 8. Workers’ Compensation Insurance Coverage (as applicable, consistent with Texas Labor Code § 406.096) ........................................................................................................................................................ 12 9. U.S. Iron and Steel (Does not apply to SWIFT Projects funded prior to May 1, 2019) ....................... 13 10. Prevailing Wage Rates ...................................................................................................................... 14 11. Employment of Local Labor (only applicable to projects funded by EDAP) .................................. 15 12. Payments ........................................................................................................................................... 15 13. Archaeological Discoveries and Cultural Resources ........................................................................ 17 14. Endangered Species .......................................................................................................................... 17 15. Hazardous Materials ......................................................................................................................... 18 16. Changes ............................................................................................................................................ 18 TWDB-0552 Rev 11/18 Page 3 of 20 17. Operation and Maintenance Manuals and Training .......................................................................... 19 18. As-built Dimensions and Drawings .................................................................................................. 19 19. Close-Out Procedures ....................................................................................................................... 20 IV. FORMS AND GUIDANCE LIST ........................................................................................................ 20 TWDB-0552 Rev 11/18 Page 4 of 20 Forms and Guidance: The Texas Water Development Board (TWDB) forms and guidance documents noted in this instruction document may be accessed through the TWDB’s Financial Assistance web site at: http://www.twdb.texas.gov/financial/instructions/index.asp Search by either the document number or name. TWDB-0552 Rev 11/18 Page 5 of 20 I. INSTRUCTIONS TO APPLICANT 1. Applicability These Supplemental Conditions contain provisions that are worded to comply with certain statutes and regulations which specifically relate to projects receiving state funds only. Except as noted, these supplemental conditions apply to projects funded by the following financial assistance programs: Agricultural Water Conservation Fund (AWCF) Economically Distressed Areas Program (EDAP) Rural Water Assistance Fund (RWAF) State Participation (SP) State Water Implementation Fund for Texas (SWIFT) Texas Water Development Fund II (WDF) Provisions that are applicable to the project's funding source or dollar value of the contract are so noted within these provisions. NOTES: - Per Section 17.183(c)(4), Texas Water Code (TWC), U.S. Iron and Steel requirements do not apply to SWIFT projects funded prior to May 1, 2019. - Effective September 1, 2017, TWC §17.183 eliminated the requirement for Manufactured Goods. Thus, projects approved for funding after September 1, 2013 and which are not currently under construction, will only need to meet the requirements of TWC §17.183 as amended by S.B. 1289, 85th Legislative Session, and as outlined in these Contract Conditions. - Texas Water Code § 17.183 does not apply to the Agricultural Water Conservation Fund; however, the US I&S provisions in Texas Government Code, Chapter 2252, Subchapter F may apply to certain conservation projects funded through the Agricultural Water Conservation Fund. See Attachment 1 for supplemental guidance regarding Agricultural Water Conservation Fund projects. 2. Use of Conditions The language and conditions listed under Section II: Instructions to Bidders are to be included in the instructions to bidders for construction services. The provisions listed under Section III: Supplemental Contract Conditions shall be included in their entirety with the other general and special conditions that are typically included in the construction contract documents by the design engineer. TWDB-0552 Rev 11/18 Page 6 of 20 3. Modifications to Provisions These provisions shall be included as a stand-alone section in the contract documents. The Applicant and the consulting engineer (Engineer) should carefully study these provisions before incorporating them into the construction contract documents. In particular, Water Districts and other types of districts should be aware of statutes relating to their creation and operation which may affect the application of these conditions. The TWDB Project Engineer/Reviewer should be consulted if the Applicant thinks there is a need to modify parts of these provisions. Supplemental Condition #13 (Archeological Discoveries and Cultural Resources) and #14 (Endangered Species) may be superseded or modified by project specific conditions established during the environmental review process. These documents may confer certain duties and responsibilities on the Engineer that are beyond, or short of, what the Applicant intends to delegate. The Applicant should ensure that the contractual agreement with the Engineer provides for the appropriate services. Otherwise the Applicant should revise the wording in these special conditions to agree with actually delegated functions. TWDB-0552 Rev 11/18 Page 7 of 20 4. Good Business Practices There are other contract provisions that the Applicant (Owner) and Engineer should include as a matter of good business practices. It is recommended that provisions addressing the following matters be included in the construction contract. (a) Specifying the time frame for accomplishing the construction of the project, and the consequences of not completing on time, including liquidation damages. (b) Specifying the type, dollar value, and documentation of insurance the contractor is to carry. At a minimum the contractor should carry worker’s compensation, liability and builder's risk insurance. (c) Identifying the responsibility of the contractor – Responsibility and Warranty of Work. (d) Price reduction for defective pricing of negotiated costs. (e) Differing site conditions - notice and claims regarding site conditions differing from indicated conditions. (f) Covenants against contingent fees - prohibit contingent fees for securing business. (g) Gratuities - prohibitions against offering and accepting gratuities. (h) Audit and access to records. (i) Suspension of work - conditions under which the Owner may suspend work. (j) Termination - conditions under which the Owner may terminate the contract. (k) Remedies - procedures for resolving disputes. 5. Other Requirements There may be other local government requirements and applicable Federal and State statutes and regulations that are not accommodated by these conditions. It is the Applicant's responsibility to ensure that the project and all contract provisions are consistent with the relevant statutes and regulations. 6. Advertisements for Bids State procurement statutes require advertising a contract for bids for at least two (2) consecutive weeks. By not following this requirement, the project may need to be re- advertised. The official advertisement for bids that is published in newspapers shall include certain information such as, but not limited to, the following: (a) A clear description of what is being procured. (b) How to obtain plans and specifications (P&S) and necessary forms and information. (c) The date and time by which bids are to be submitted (deadline). (d) The address where bids are to be provided. (e) This contract is contingent upon release of funds from the Texas Water Development Board (TWDB). (f) Any contract(s) awarded under this Invitation for Bids is/are subject to the United States Iron and Steel (US I&S) requirements of Texas Water Code §17.183 and/or Texas Government Code, Chapter 2252, Subchapter F, as amended by SB 1289, 85th Legislative Session, as applicable. (NOTE: does not apply to SWIFT projects funded prior to May 1, 2019). (g) Acknowledgement of any special requirements such as mandatory pre-bid conference. (h) Right to reject any and all bids. (i) General bond requirements. TWDB-0552 Rev 11/18 Page 8 of 20 Bid Proposal The Bid Proposal form should account for the following: (a) If lump sum bid, include a list of the materials used and associated costs. (b) Distinguish eligible and ineligible items. (c) Accommodate trench safety requirements with separate per unit pay item for trench excavation safety protection, Health and Safety Code Chapter 756, Subchapter C. (d) Include space for the Contractor to acknowledge receipt of each Addendum issued during the bidding process. 7. Bidding Process The Plans and Specifications (P&S) should include an explanation of how the bids will be processed. The explanation should include the following components: (a) Whether a pre-bid conference will be held, whether it is optional or mandatory, where and when it will be held. (b) Specify the criteria and process for determining responsiveness and responsibility of the bidder. (c) Specify the method of determining the successful bidder and award (e.g., award to the lowest responsive, responsible bidder, accounting for any multiple parts to bids) and accounting for non-resident bidder reciprocity requirements. (d) Allow for withdrawal of a bid due to a material mistake. (e) Identify the time frame that the bids may be held by the Applicant before awarding a contract (e.g., typically for 60 or 90 days). (f) Acknowledge right of the Applicant to reject any and all bids. 8. Release of Funds (a) Submittal of Bid Documents to TWDB Project Engineer/Reviewer to allow contingent award of contract: (1) Advertisement and affidavit of advertisement. (2) Bid tabulation. (3) All addenda submitted and approved for the contract. (4) Bid proposal of apparent low bidder (or chosen bidder, with explanation) with bid bond. (5) Site certificate (ED-101). (6) Consulting engineer’s recommendation to award letter. (7) A description of any bidding irregularities. (8) Construction inspection proposal. (9) Vendor Compliance with Reciprocity of Non-Resident Bidders Form (TWDB- 0459). TWDB-0552 Rev 11/18 Page 9 of 20 (b) Following contingent award of the contract, TWDB Project Engineer/Reviewer should receive a bound copy of the executed contract documents (including specifications). This document should include: (1) Executed agreement. (2) Contractor’s act of assurance (ED-103). (3) Contractor’s act of assurance resolution (ED-104). (4) Payment and Performance bond (must be executed on or after the date of execution of the contract). (5) Contractor’s Certificate of Insurance. (6) Sufficiency of funds letter (if the project is not 100% funded with TWDB funds). After reviewing and approving the executed bid documents, the TWDB will issue an authorization for the Applicant to issue a notice to proceed. At this time, TWDB staff can begin releasing construction funds, in accordance with program specific requirements. For any questions or proposed modifications to these conditions, please contact your TWDB Project Engineer/Reviewer. TWDB-0552 Rev 11/18 Page 10 of 20 II. INSTRUCTIONS TO BIDDERS The language and conditions listed in this section shall be included in the “Instructions to Bidders” section of the construction contract document. 1. Contingent Award of Contract This contract is contingent upon release of funds from the Texas Water Development Board. Any contract or contracts awarded under this Invitation for Bids is/are expected to be funded in part by a loan or grant from the Texas Water Development Board. Neither the state of Texas, nor any of its departments, agencies, or employees are or will be a party to this Invitation for Bids or any resulting contract. 2. U.S. Iron and Steel (Does not apply to SWIFT Projects funded prior to May 1, 2019) Any contract(s) awarded under this Invitation for Bids is/are subject to the United States Iron and Steel requirements of Texas Water Code §17.183 and/or Texas Government Code, Chapter 2252, Subchapter F, as amended by SB 1289, 85th Legislative Session. The contractor must complete the statement of understanding regarding this requirement, found in the Supplemental Contract Conditions, Item No. 9. Refer to TWDB-1105 – United States Iron and Steel (US I&S) Guidance. 3. Bid Guarantee Each bidder shall furnish a bid guarantee equivalent to five percent of the bid price (Water Code §17.183). If a bid bond is provided, the Contractor shall utilize a surety company which is authorized to do business in Texas in accordance with Surety Bonds and Related Instruments, Chapter 3503 of the Insurance Code. 4. Award of Contract to Nonresident Bidder A governmental entity may not award a governmental contract to a nonresident bidder unless the nonresident underbids the lowest bid submitted by a responsible resident bidder by an amount that is not less than the amount by which a resident bidder would be required to underbid the nonresident bidder to obtain a comparable contract in the state in which the nonresident's principal place of business is located. A non-resident bidder is a Contractor whose corporate offices or principal place of business is outside of the state of Texas (Source: Texas Government Code, Chapter 2252, Subchapter A, Nonresident Bidders, §2252.002). The bidder will complete form TWDB-0459, Vendor Compliance with Reciprocity on Non- Resident Bidders, which must be submitted with the bid. TWDB-0552 Rev 11/18 Page 11 of 20 III. SUPPLEMENTAL CONTRACT CONDITIONS 1. Supersession The Owner and the Contractor agree that the TWDB Supplemental Conditions apply to the work eligible for Texas Water Development Board assistance to be performed under this contract and these clauses supersede any conflicting provisions of this contract. 2. Privity of Contract Funding for this project is expected to be provided in part by a loan or grant from the Texas Water Development Board. Neither the state of Texas, nor any of its departments, agencies or employees is, or will be, a party to this contract or any lower tier contract. This contract is subject to applicable provisions in 31 TAC Chapter 363 in effect on the date of the assistance award for this project. 3. Definitions (a) The term “Owner” means the local entity contracting for the construction services. (b) The term "TWDB" means the Executive Administrator of the Texas Water Development Board, or other person who may be at the time acting in the capacity or authorized to perform the functions of such Executive Administrator, or the authorized representative thereof. (c) The term “Engineer” means the Owner’s authorized consulting engineer for the project. 4. Laws to be Observed In the execution of the contract, the Contractor must comply with all applicable local, state and federal laws, including but not limited to laws concerned with labor, safety, minimum wages, and the environment. The Contractor shall be familiar with and at all times shall observe and comply with all federal, state, and local laws, ordinances and regulations which in any manner affect the conduct of the work, and shall indemnify and save harmless the Owner, Texas Water Development Board, and their representatives against any claim arising from violation of any such law, ordinance or regulation by the Contractor, their Subcontractor or their employees. 5. Review by Owner and TWDB (a) The Owner, authorized representatives and agents of the Owner, and the TWDB shall, at all times have access to and be permitted to observe and review all work, materials, equipment, payrolls, personnel records, employment conditions, material invoices, and other relevant data and records pertaining to this contract, provided, however that all instructions and approval with respect to the work will be given to the Contractor only by the Owner through authorized representatives or agents. (b) Any such inspection or review by the TWDB shall not subject the state of Texas, or its representatives, to any action for damages. TWDB-0552 Rev 11/18 Page 12 of 20 6. Performance and Payment Bonds Each Contractor awarded a construction contract must furnish performance and payment bonds: (a) the performance bond shall include without limitation guarantees that work done under the contract will be completed and performed according to approved plans and specifications and in accordance with sound construction principles and practices; (b) the performance and payment bonds shall be in a penal sum of not less than 100 percent of the contract price and remain in effect for one year beyond the date of approval by the Engineer of the political subdivision; and (c) the Contractor shall utilize a surety company that is authorized to do business in Texas in accordance with Surety Bonds and Related Instruments, Chapter 3503 of the Insurance Code. 7. Payments Schedule and Cost Breakdown (a) The Contractor shall submit for approval immediately after execution of the Agreement, a carefully prepared Progress Schedule, showing the proposed dates of starting and completing each of the various sections of the work, the anticipated monthly payments to become due to the Contractor, and the accumulated percent of progress each month. (b) The following paragraph applies only to contracts awarded on a lump sum contract price: COST BREAKDOWN - The Contractor shall submit to the Owner a detailed breakdown of the estimated cost of all work to be accomplished under the contract, so arranged and itemized as to meet the approval of the Owner or funding agencies. This breakdown shall be submitted promptly after execution of the agreement and before any payment is made to the Contractor for the work performed under the contract. After approval by the Owner the unit prices established in the breakdown shall be used in estimating the amount of partial payments to be made to the Contractor. 8. Workers’ Compensation Insurance Coverage (as applicable, consistent with Texas Labor Code § 406.096) (a) The Contractor shall certify in writing that they provide workers' compensation insurance coverage for each employee of the Contractor employed on the public project. (b) Each Subcontractor on the public project shall provide such a certificate relating to coverage of the Subcontractor's employees to the general Contractor, who shall provide the Subcontractor's certificate to the governmental entity. (c) A Contractor who has a contract that requires workers' compensation insurance coverage may provide the coverage through a group plan or other method satisfactory to the governing body of the governmental entity. (d) The employment of a maintenance employee by an employer who is not engaging in building or construction as the employer's primary business does not constitute engaging in building or construction. TWDB-0552 Rev 11/18 Page 13 of 20 (e) In this section: (1) "Building or construction" includes: i. erecting or preparing to erect a structure, including a building, bridge, roadway, public utility facility, or related appurtenance; ii. remodeling, extending, repairing, or demolishing a structure; or iii. otherwise improving real property or an appurtenance to real property through similar activities. (2) "Governmental entity" means this state or a political subdivision of this state. The term includes a municipality. 9. U.S. Iron and Steel (Does not apply to SWIFT Projects funded prior to May 1, 2019) The following statement must be completed by the Contractor and made a part of the agreement between the Owner and the Contractor. The Contractor acknowledges to and for the benefit of the Applicant (“Purchaser”) and the Texas Water Development Board (“TWDB”) that it understands the goods and services under this Agreement are being funded with monies made available by the Water Development Fund, Rural Water Assistance Fund, Economically Distressed Areas, State Participation Fund and/or Agricultural Water Conservation Fund. That these funds have statutory requirements commonly known as “United States Iron and Steel” that requires all of the iron and steel products used in the project to be produced in the United States (“United States Iron and Steel Requirement”) including iron and steel products provided by the Contactor pursuant to this Agreement. The Contractor hereby represents and warrants to and for the benefit of the Purchaser and the TWDB that (a) the Contractor has reviewed and understands the United States Iron and Steel Requirement, (b) all of the iron and steel products used in the project will be and/or have been produced in the United States in a manner that complies with the United States Iron and Steel Requirement, unless a waiver of the requirement is approved, and (c) the Contractor will provide any further verified information, certification or assurance of compliance with this paragraph, or information necessary to support a waiver of the United States Iron and Steel Requirement, as may be requested by the Purchaser or the TWDB. Notwithstanding any other provision of this Agreement, any failure to comply with this paragraph by the Contractor shall permit the Purchaser to enforce this Agreement and recover as damages against the Contractor any loss, expense, or cost (including without limitation attorney’s fees) incurred by the Purchaser resulting from any such failure (including without limitation any impairment or loss of funding, whether in whole or in part, from the TWDB or any damages owed to the TWDB by the Purchaser). Neither this paragraph (nor any other provision of this Agreement necessary to give this paragraph force or effect) shall be amended or waived without the prior written consent of the TWDB. In the execution of the Contract, the Contractor shall be familiar with and at all times shall observe and comply with all applicable federal, state, and local laws, ordinances and regulations concerned with the use of iron and steel made in the United States which in any manner affect the conduct of the work, and shall indemnify and save harmless the Texas Water Development Board against any claim arising from violation of any such law, ordinance or regulation by the Contractor or by their Subcontractor or their employees. TWDB-0552 Rev 11/18 Page 14 of 20 Additional information on the United States Iron and Steel (US I&S) and its applicability to this contract can be found in the TWDB-11005 guidance. It is recommended the Owner receive and maintain files documenting the Contractor’s use of US I&S. Compliance with US I&S will be verified by the Owner through the submittal of the TWDB form TWDB-1105-A. 10. Prevailing Wage Rates This contract is subject to Government Code Chapter 2258 concerning payment of Prevailing Wage Rates. The Owner will determine what the general prevailing rates are in accordance with the statute. The applicable provisions include, but are not limited to the following: §2258.021. Right to be Paid Prevailing Wage Rates (a) A worker employed on a public work by or on behalf of the state or a political subdivision of the state shall be paid: (1) not less than the general prevailing rate of per diem wages for work of a similar character in the locality in which the work is performed; and (2) not less than the general prevailing rate of per diem wages for legal holiday and overtime work. (b) Subsection (a) does not apply to maintenance work. (c) A worker is employed on a public work for the purposes of this section if the worker is employed by a Contractor or Subcontractor in the execution of a contract for the public work with the state, a political subdivision of the state, or any officer or public body of the state or a political subdivision of the state. §2258.023. Prevailing Wage Rates to be Paid by Contractor and Subcontractor; Penalty (a) The Contractor who is awarded a contract by a public body or a Subcontractor of the Contractor shall pay not less than the rates determined under Section 2258.022 to a worker employed by it in the execution of the contract. (b) A Contractor or Subcontractor who violates this section shall pay to the state or a political subdivision of the state on whose behalf the contract is made, $60 for each worker employed for each calendar day or part of the day that the worker is paid less than the wage rates stipulated in the contract. A public body awarding a contract shall specify this penalty in the contract. (c) A Contractor or Subcontractor does not violate this section if a public body awarding a contract does not determine the prevailing wage rates and specify the rates in the contract as provided by Section 2258.022. (d) The public body shall use any money collected under this section to offset the costs incurred in the administration of this chapter. (e) A municipality is entitled to collect a penalty under this section only if the municipality has a population of more than 10,000. TWDB-0552 Rev 11/18 Page 15 of 20 §2258. 024. Records (a) A Contractor and Subcontractor shall keep a record showing: (1) the name and occupation of each worker employed by the Contractor or Subcontractor in the construction of the public work; and (2) the actual per diem wages paid to each worker. (b) The record shall be open at all reasonable hours to inspection by the officers and agents of the public body. §2258. 025. Payment Greater Than Prevailing Rate Not Prohibited This chapter does not prohibit the payment to a worker employed on a public work an amount greater than the general prevailing rate of per diem wages. 11. Employment of Local Labor (only applicable to projects funded by EDAP) The Contractor shall, to the maximum feasible extent, employ local labor for construction of the project. The Contractor and every Subcontractor undertaking to do work on the project which is, or reasonably may be done as on-site work, shall employ qualified persons who regularly reside within the political subdivision boundary of the Owner and the economically distressed area where the project is located (Texas Water Code, Section 17.183). 12. Payments (a) Progress Payments: (1) The Contractor shall prepare their requisition for progress payment as of the last day of the month and submit it, with the required number of copies, to the Engineer for review. Except as provided in paragraph (3) of this subsection, the amount of the payment due the Contractor shall be determined by adding to the total value of work completed to date, the value of materials properly stored on the site and deducting: (1) five percent (5%) minimum of the total amount, as a retainage and (2) the amount of all previous payments. The total value of work completed to date shall be based on the actual or estimated quantities of work completed and on the unit prices contained in the agreement (or cost breakdown approved pursuant to section 7b relating to lump sum bids) and adjusted by approved change orders. The value of materials properly stored on the site shall be based upon the estimated quantities of such materials and the invoice prices. Copies of all invoices shall be available for inspection by the Engineer. (2) The Contractor shall be responsible for the care and protection of all materials and work upon which payments have been made until final acceptance of such work and materials by the Owner. Such payments shall not constitute a waiver of the right of the Owner to require the fulfillment of all terms of the Contract and the delivery of all improvements embraced in this contract complete and satisfactory to the Owner in all details. TWDB-0552 Rev 11/18 Page 16 of 20 (3) This clause applies to contracts when the Owner is a District or Authority. The retainage shall be ten percent of the amount otherwise due until at least fifty percent of the work has been completed. After the project is fifty percent completed, and if the District or Authority’s Board finds that satisfactory progress is being made, then the District may authorize any of the remaining progress payments to be made in full. The District is not obligated to pay interest earned on the first 50% of work completed (Texas Water Code Sec. 49.276(d)). (4) The five percent (5%) retainage of the progress payments due to the Contractor may not be reduced until the building of the project is substantially complete and a reduction in the retainage has been authorized by the TWDB. (b) Withholding Payments. The Owner may withhold from any payment otherwise due the Contractor so much as may be necessary to protect the Owner and if so elects may also withhold any amounts due from the Contractor to any Subcontractors or material dealers, for work performed or material furnished by them. The foregoing provisions shall be construed solely for the benefit of the Owner and will not require the Owner to determine or adjust any claims or disputes between the Contractor and their Subcontractors or Material dealers, or to withhold any monies for their protection unless the Owner elects to do so. The failure or refusal of the Owner to withhold any monies from the Contractor shall in no way impair the obligations of any surety or sureties under any bond or bonds furnished under this contract. (c) Payments Subject to Submission of Certificates. Each payment to the Contractor by the Owner shall be made subject to submission by the Contractor of all written certifications required of the Contractor, their Subcontractors and other general and special conditions elsewhere in this contract. (d) Final Payment. (1) Upon satisfactory completion of the work performed under this contract, as a condition before final payment under this contract or as a termination settlement under this contract the Contractor shall execute and deliver to the Owner a release of all claims against the Owner arising under, or by virtue of, this contract, except claims which are specifically exempted by the Contractor to be set forth therein. Unless otherwise provided in this contract, by state law or otherwise expressly agreed to by the parties to this contract, final payment under this contract or settlement upon termination of this contract shall not constitute a waiver of the Owner' s claims against the Contractor or their sureties under this contract or applicable performance and payment bonds. (2) After final inspection and acceptance by the Owner of all work under the Contract, the Contractor shall prepare their requisition for final payment which shall be based upon the carefully measured or computed quantity of each item of work at the applicable unit prices stipulated in the Agreement or cost breakdown (if lump sum), as adjusted by approved change orders. The total amount of the final payment due to the Contractor under this contract shall be the amount computed as described above less all previous payments. TWDB-0552 Rev 11/18 Page 17 of 20 (3) The retainage and its interest earnings, if any, shall not be paid to the Contractor until the TWDB has authorized a reduction in, or release of, retainage on the contract work. (4) Withholding of any amount due to the Owner, under general and/or special conditions regarding "Liquidated Damages" shall be deducted from the final payment due the Contractor. 13. Archaeological Discoveries and Cultural Resources No activity which may affect properties listed or properties eligible for listing in the National Register of Historic Places or eligible for designation as a State Archeological Landmark is authorized until the Owner has complied with the provisions of the National Historic Preservation Act and the Antiquities Code of Texas. The Owner has previously coordinated with the appropriate agencies and impacts to known cultural or archeological deposits have been avoided or mitigated. However, the Contractor may encounter unanticipated cultural or archeological deposits during construction. If archeological sites or historic structures which may qualify for designation as a State Archeological Landmark according to the criteria in 13 TAC Chapter 26, or that may be eligible for listing on the National Register of Historic Places in accordance with 36 CFR Part 800, are discovered after construction operations are begun, the Contractor shall immediately cease operations in that particular area and notify the Owner, the TWDB, and the Texas Historical Commission, 1511 N. Colorado St. , P. O. Box 12276, Capitol Station, Austin, Texas 78711-2276. The Contractor shall take reasonable steps to protect and preserve the discoveries until they have been inspected by the Owner's representative and the TWDB. The Owner will promptly coordinate with the State Historic Preservation Officer and any other appropriate agencies to obtain any necessary approvals or permits to enable the work to continue. The Contractor shall not resume work in the area of the discovery until authorized to do so by the Owner. 14. Endangered Species No activity is authorized that is likely to jeopardize the continued existence of a threatened or endangered species as listed or proposed for listing under the Federal Endangered Species Act (ESA), and/or the State of Texas Parks and Wildlife Code on Endangered Species, or to destroy or adversely modify the habitat of such species. If a threatened or endangered species is encountered during construction, the Contractor shall immediately cease work in the area of the encounter and notify the Owner, who will immediately implement actions in accordance with the ESA and applicable State statutes. These actions shall include reporting the encounter to the TWDB, the U.S. Fish and Wildlife Service, and the Texas Parks and Wildlife Department, obtaining any necessary approvals or permits to enable the work to continue, or implement other mitigation actions. The Contractor shall not resume construction in the area of the encounter until authorized to do so by the Owner. TWDB-0552 Rev 11/18 Page 18 of 20 15. Hazardous Materials Materials utilized in the project shall be free of any hazardous materials, except as may be specifically provided for in the specifications. If the Contractor encounters existing material on sites owned or controlled by the Owner or in material sources that are suspected by visual observation or smell to contain hazardous materials, the Contractor shall immediately notify the Engineer and the Owner. The Owner will be responsible for the testing and removal or disposal of hazardous materials on sites owned or controlled by the Owner. The Owner may suspend the work, wholly or in part during the testing, removal or disposal of hazardous materials on sites owned or controlled by the Owner. 16. Changes *Provisions identified with an asterisk below are consistent with Local Government Code 271.060. Counties and Municipalities may modify the identified provisions, when applicable, to conform to Local Government Code 262.031 (Counties) or 252.048 (Municipalities). (a) The Owner may at any time, without notice to any surety, by written order designated or indicated to be a change order, make changes in the work within the general scope of the contract, including but not limited to changes: (1) In the specifications (including drawings and designs); (2) In the time, method or manner of performance of the work; (3) To decrease or increase the quantity of work to be performed or materials, equipment or supplies to be furnished; (b) *The total price of a contract may not be increased by a change order unless provision has been made for the payment of the added cost by the appropriation of current funds or bond funds for that purpose, by the authorization of the issuance of certificates, or by a combination of those procedures. (c) *A contract with an original contract price of $1 million or more may not be increased by more than 25 percent. If a change order for a contract, with an original contract price of less than $1 million, increases the contract amount to $1 million or more, subsequent change orders may not increase the revised contract amount by more than 25 percent. (d) *A governing body may grant authority to an official or employee responsible for purchasing or for administering a contract to approve a change order that involves an increase or decrease of $50,000 or less. (e) Changes that involve an increase in price will be supported by documentation of the cost components. For projects funded through the EDAP program, or with grant proceeds, TWDB staff may request this information to be provided in a format equivalent to the Cost and Pricing Information form (No. WRD-277). (f) Any change orders involving a change in the project requiring a relocation of project components, sizing, or process may require additional environmental approval. A map and description of the proposed changes should be sent to the TWDB Environmental TWDB-0552 Rev 11/18 Page 19 of 20 Reviewer for coordination and approval as soon as possible to avoid any delay. 17. Operation and Maintenance Manuals and Training (a) The Contractor shall obtain installation, operation, and maintenance manuals from manufacturers and suppliers for equipment furnished under the contract. The Contractor shall submit three copies of each complete manual to the Engineer within 90 days after approval of shop drawings, product data, and samples, and not later than the date of shipment of each item of equipment to the project site or storage location. (b) The Owner shall require the Engineer to promptly review each manual submitted, noting necessary corrections and revisions. If the Engineer rejects the manual, the Contractor shall correct and resubmit the manual until it is acceptable to the Engineer as being in conformance with the design concept of the project and for compliance with information given in the contract documents. Owner may assess Contractor a charge for reviews of same items in excess of three (3) times. Such procedure shall not be considered cause for delay. (c) Acceptance of manuals by Engineer does not relieve Contractor of any requirements of terms of Contract. (d) The Contractor shall provide the services of trained, qualified technicians to check final equipment installation, to assist as required in placing same in operation, and to instruct operating personnel in the proper manner of performing routine operation and maintenance of the equipment. (e) Operations and maintenance manuals specified hereinafter are in addition to any operation, maintenance, or installation instructions required by the Contractor to install, test, and start-up the equipment. (f) Each manual is to be bound in a folder and labeled to identify the contents and project to which it applies. The manual shall contain the following applicable items: (1) A listing of the manufacturer's identification, including order number, model, serial number, and location of parts and service centers. (2) A list of recommended stock of parts, including part number and quantity. (3) Complete replacement parts list. (4) Performance data and rating tables. (5) Specific instructions for installation, operation, adjustment, and maintenance. (6) Exploded view drawings for major equipment items. (7) Lubrication requirements. (8) Complete equipment wiring diagrams and control schematics with terminal identification. 18. As-built Dimensions and Drawings (a) Contractor shall make appropriate daily measurements of facilities constructed and keep accurate records of location (horizontal and vertical) of all facilities. TWDB-0552 Rev 11/18 Page 20 of 20 (b) Upon completion of each facility, the Contractor shall furnish the Owner with one set of direct prints, marked with red pencil, to show as-built dimensions and locations of all work constructed. As a minimum, the final drawings shall include the following: (1) Horizontal and vertical locations of work. (2) Changes in equipment and dimensions due to substitutions. (3) "Nameplate" data on all installed equipment. (4) Deletions, additions, and changes to scope of work. (5) Any other changes made. 19. Close-Out Procedures To close-out the contract and release final retainage, the following steps must be completed: (a) TWDB Staff must conduct a construction contract final inspection (CCFI). (b) The following submittals must be received, reviewed, and accepted by TWDB: (1) The final change order, adjustment of quantities, or a statement that all change orders have previously been submitted and there will be no more change orders; (2) The final pay request from the Contractor; (3) An affidavit by the Contractor that all bills have been paid; (4) Certification by the consulting Engineer that the work has been completed and was constructed in accordance with the approved plans and specifications and sound engineering principles and construction practices; (5) Acceptance of the project by the Owner in the form of a written resolution or other formal action; (6) Notification of the beginning date of the warranty period for the contract; and (7) Confirmation that the Owner has received as-built drawings from the Contractor. (8) Certificate of Compliance with U.S. Iron and Steel Requirements (TWDB- 1105A) (c) TWDB will issue a Certificate of Approval allowing the release of retainage. IV. FORMS AND GUIDANCE LIST The following documents, mentioned throughout this guidance are available on the TWDB website at: http://www.twdb.texas.gov/financial/instructions/index.asp Forms: The following forms must be included in the bid documents: Contractor' s Act of Assurance (ED-103) Contractor' s Act of Assurance Resolution (ED-104) Certificate of Compliance with U.S. Iron and Steel Requirements (TWDB-1105A) Site Certificate (ED-101) Vendor Compliance with Reciprocity of Non-Resident Bidders (TWDB-0459). Guidance Document: United States Iron and Steel Guidance (TWDB-1105) May10th BCRUA--Phase 10 WTP Expansion Section 00500—Agreement 1.0 THE WORK OF THIS CONTRACT Unless otherwise provided in the Contract Documents, the CONTRACTOR shall be responsible for performing or causing to be performed all Work including labor and materials, necessary to build, construct, erect and equip the Project in accordance with the Contract Documents and, at its own cost and expense, to furnish all the materials, supplies, machinery, equipment, tools, superintendence, labor, insurance, and other accessories and services necessary to complete the said construction, in accordance with the Contract Documents and for the Contract Price defined in Section 3.0 of this Agreement . The Contract Documents for this Project include this Agreement and the following documents: • Modifications • General Conditions (Section 00700) • Supplemental General Conditions (Section 00800) • Specifications bearing the title BCRUA Phase 1D Water Treatment Plant Expansion dated January 17, 2023 • Drawings bearing the title BCRUA Phase 1D Water Treatment Plant Expansion dated January 17, 2023 • Addenda 01 through 03 • Proposal Form (Section 00300) • Conflict of Interest Questionnaire (Section 00300-A) • Certificate of Interested Parties (Section 00300-B) • Statement of Proposers Experience (Section 00400) • Vendor Compliance with Reciprocity of Non-Resident Bidders (TWDB-0459) • Contractor's Act of Assurance (ED-103) • Contractor's Act of Assurance Resolution (ED-104) • Supplemental Contract Conditions and Instructions (TWDB-0552) • Notice of Award (Section 00510) • Notice to Proceed (Section 00520) • Performance Bond (Section 00610) • Payment Bond (Section 00620) • Contractor's Certificate of Insurance • All other documents referenced in the Request for Competitive Sealed Proposals for the Project In addition to the provisions set forth in other Contract Documents, including but not limited to Section 3.03 of the General Conditions,in the event that a conflict between any of the provisions within the Contract Documents exist, OWNER shall determine which provision controls. If CONTRACTOR identifies the conflict, CONTRACTOR shall notify Owner's representative of the conflict, in writing. issued for Bid Pav 2 c;f 7 BCRUA Phase 1D WTP Expansion Section 00500—Agreement The Contract Documents are forms adopted by Owner and are not subject to negotiation, modification or change unless Owner, in its sole discretion, agrees to do so. 2.0 CONTRACT TIME AND COMPLETION § 2.1 The date of commencement of the Work shall be stated in a Notice to Proceed issued by the OWNER. § 2.2 Contract Time §2.2.1 The Contract Time shall be measured from the date of commencement. §2.2.2 Time is of the essence in all phases of the Work. Additionally, time limits and periods of time stated in the Contract Documents are of the essence. It is specifically understood and agreed to by and between OWNER and CONTRACTOR that time is of the essence in the substantial and final completion of the Work, and that failure to substantially complete or finally complete the Work within the designated period,or as it may be extended, shall be construed as a breach of this Agreement. § 2.3 Substantial Completion The CONTRACTOR shall achieve Substantial Completion, as that term is defined in the Contract Documents,of the entire Work not later than 540 calendar days from the date of commencement, subject to any adjustments of this Contract Time as provided in the Contract Documents. § 2.4 Liquidated Damages The CONTRACTOR acknowledges and recognizes that the OWNER is entitled to full and beneficial occupancy and use of the completed Work following expiration of the Contract Time. The CONTRACTOR further acknowledges and agrees that, if the CONTRACTOR fails to achieve Substantial Completion of any portion of the Work within the Contract time,the OWNER will sustain actual damages as a result of such failure. OWNER and CONTRACTOR agree that the exact amount of such damages will be difficult, if not impossible, to ascertain. Therefore, the OWNER and CONTRACTOR agree that, if the CONTRACTOR should fail, or refuse to achieve Substantial Completion of the Work by the date of Substantial Completion,subject to extensions of the Contract Time granted by the OWNER,then the CONTRACTOR agrees to pay the OWNER the sum of One thousand dollars ($1,000) Issued for Bid Pate 9 cf 7 BCRUA—Phase 1D WTP Expans-on Section 00500—Agreement for each Calendar Day in which such Work is not Substantially Complete, not as penalty, but as a reasonable estimation of the damages ("Liquidated Damages") that would be suffered by OWNER as a result of delay for each and every calendar day that the CONTRACTOR shall have failed to achieve Substantial Completion of the Work as required herein. The Liquidated Damages shall be in lieu of any and all other damages which may be incurred by OWNER as a result of the failure of CONTRACTOR to achieve Substantial Completion of the Work within the Contract Time. § 2.5 Final Completion § 2.5.1 Timely Final Completion is an essential condition of this Agreement. CONTRACTOR agrees to achieve Final Completion of the Work within 60 days of the designated or extended date of Substantial Completion. § 2.5.2 Final Completion means actual completion of the Work, including any extras or Change Orders reasonably required or contemplated under the Contract Documents other than warranty work that may be required pursuant to the Contract Documents. 3.0 CONTRACT PRICE § 3.1 The OWNER shall pay the CONTRACTOR the Contract Price in current funds for the CONTRACTOR's proper and complete performance of the Work and all of CONTRACTOR's obligations under the Contract Documents. The Contract Price shall be Sixteen million eight hundred thirty six thousand one hundred dollars and no cents ($16,836,100.00), subject to additions and deductions as provided in the Contract Documents. § 3.2 The Contract Price is based upon the following alternates, if any,which are described in the Contract Documents and are hereby accepted by the OWNER: None § 3.3 Unit prices, if any: Refer to Proposal for Trench Safety issued for Bid Page 4 of 7 BCRUA—Phase 10 V,/TP Expansion Section 00500—Agreement 4.0 PAYMENT § 4.1 APPLICATIONS FOR PAYMENT Subject to any applicable provisions set forth in other Contract Documents, each Application for Payment shall be based on the most recent schedule of values ("Schedule of Values") submitted by the CONTRACTOR in accordance with the Contract Documents. The Schedule of Values shall allocate the entire Contract Price among the various portions of the Work. The Schedule of Values shall be prepared in such form and supported by such data to substantiate its accuracy as the ENGINEER and OWNER may require. The Schedule of Values, as approved by the ENGINEER or OWNER, shall be used as a basis for reviewing the CONTRACTOR'S Applications for Payment. As the Work progresses the Schedule of Values may be revised as the OWNER and ENGINEER, in their sole discretion, may deem appropriate to reflect the sequencing of the Work and the values to be assigned to each portion of the Work included in the Schedule of Values. §4.1.1 Applications for Payment shall show the percentage of completion of each portion of the Work as of the end of the period covered by the Application for Payment. Subject to the provisions of the General Conditions, the CONTRACTOR shall prepare its Application for Payment for a progress payment as of the last day of each calendar month and submit it, with the required number of copies, to the Engineer for review. The total value of work completed to date shall be based on the actual or estimated quantities of Work completed and, if applicable, on the unit prices contained in the Agreement (or approved schedule of values relating to lump sum bids)and adjusted by approved Change Orders. The value of materials properly stored on the site shall be based upon the estimated quantities of such materials and the invoice prices. Copies of all invoices shall be available for inspection by the ENGINEER. §4.1.2 Subject to other provisions of the Contract Documents, the amount of each progress payment shall be computed as follows: .1 Take that portion of the Contract Price properly allocable to completed Work as determined by multiplying the percentage completion of each portion of the Work by the share of the Contract Price allocated to that portion of the Work in the Schedule of Values, less retainage of Five percent (5.00%). Pending final determination of cost to the OWNER of changes in the Work, amounts not in dispute shall be included; .2 Add that portion of the Contract Price properly allocable to materials and equipment delivered and suitably stored at the site for subsequent incorporation in the completed construction(or, if approved in advance by the OWNER, suitably stored off the site at a location agreed upon in writing), less retainage of Five percent (5.00%); .3 Subtract the aggregate of previous payments made by the OWNER; and Issued for Bid Page 5 c 7 BCRUA—Phase 1D WTP Expansion Section 00500 Agreement .4 Subtract amounts, if any,for which the ENGINEER has withheld or nullified an Application for Payment. §4.1.3 The Contractor shall be responsible for the care and protection of all materials and Work upon which payments have been made until final acceptance of such Work and materials by the Owner. Such payments shall not constitute a waiver of the right of the Owner to require the fulfillment of all terms of the Contract Documents and the delivery of all improvements embraced in Contract Documents complete and satisfactory to the Owner in all respects. §4.1.4 Reduction or limitation of retainage, if any, shall be as follows: Reduction or limitation of retainage shall be at the OWNER's sole discretion. §4.1-5 Except with the OWNER's prior approval, the CONTRACTOR shall not make advance payments to suppliers for materials or equipment which have not been delivered and stored at the site. § 4.2 FINAL PAYMENT §4.2.1 Final payment, constituting the entire unpaid balance of the Contract Price, shall be made by the OWNER to the CONTRACTOR when: .1 the CONTRACTOR has fully performed its obligations under the Contract Documents, except for the CONTRACTOR's responsibility to correct Work as provided in the General Conditions, and to satisfy other requirements, if any, which extend beyond Final Payment; and .2 a letter of Final Acceptance has been issued by the ENGINEER and accepted by the OWNER. .3 CONTRACTOR has satisfied all of the conditions to receipt of Final Payment as set forth in the General Conditions. §4.2.2 The OWNER's final payment to the CONTRACTOR shall be made no later than 30 days after the Work has been completed and accepted by the OWNER, in writing, following the issuance of the ENGINEER's final Certificate for Payment: Issued for Bid Page 6 of 7 Karen BondyGeneral Manager BCRUA—Phase 1D WTP Expansion Section 00510—Notice of Award NOTICE OF AWARD Dated: May 2, 2023 TO: Excel Construction Services, LLC ADDRESS: 1202 Leander Drive Leander,TX 78641 PROJECT: Phase 1D Water Treatment Plant Expansion OWNER'S CONTRACT NO: N/A CONTRACT FOR: Phase 1D Water Treatment Plant Expansion You are notified that your Proposal dated February 28, 2023 for the above contract has been considered. You are apparent Successful Bidder and have been awarded a contract for building and site improvements including the following: See attached Proposal. The Contract Price of your contract is: $16,836,100.00. 1 original of the proposed Contract Documents (except drawings) accompany this Notice of Award. 1 electronic file (pdf) of the conformed construction drawings will be delivered or otherwise made available to you immediately. You must comply with the following conditions precedent within 10 calendar days of the date of this Notice of Award. 1. You must deliver to the Owner a fully executed version of the Agreement including all Contract Documents. Each of the Contract Documents must bear your original signature. 2. You must deliver with the executed Agreement the Contract Security(Bonds) as specified in the RFP, General Conditions, and Supplementary Conditions. 3. You must deliver to the Owner Certificates of Insurance with the executed Contract. Issued for B d Page i of 2 BCRUA—Phase 1D wTP Expansion Section 00510—Notice of Award Failure to comply with these conditions within the time specified will entitle Owner to consider your bid in default, to annul this Notice of Award and to declare your Proposal Security forfeited. Within 10 days after you comply with the above conditions, Owner will return to you one fully signed counterpart of the Agreement with the Contract Documents attached. BRUSHY CREEK REGIONAL UTILITY AUTHORITY (OWNER) (AUTHORIZED SIGNAT E) General Manager (TITLE) 512123 (DATE) CONCURRENCE OF AWARD (CONTRACTOR) By: �nL tm-r-',rirve- (AUTHORIZED SIGNATURE) s I$I�L (DATE) Issued for Bid 2 ' 2 BCRUA—Phase 11)WTP Expansion Section 00520—Notice to Proceed NOTICE TO PROCEED Dated: May 26 . 2023 TO: Excel Construction Services, LLC ADDRESS: 1202 Leander Drive Leander,TX 78641 PROJECT: You are notified that the Contract Times under the above contract will commence to run May 30 , 2023. By that date, you are to start performing your obligations under the Contract Documents. In accordance with the agreement, the dates of Substantial Completion and Completion and readiness for final payment are: November 20, 2024 for substantial completeness of the entire project; and January 20, 2025 for Completion and Acceptance of the entire project. Before you may start and Work at the site,the General Conditions provide that you deliver to the Owner(with copies to Engineer and other identified additional insureds) certificates of insurance which is required to be purchased and maintained in accordance with the Contract Documents. BRUSHY CREEK REGIONAL UTILITY AUTHORITY (OWNER) By: d�J (AUTHORIZED SIGNA RE) General Manner (TITLE) May 26, 2023 (DATE) Issued for Bid P{ _101 2 BCRUA—Phase 1D WTP Expansion Section 00520—Notice to Proceed CONCURRENCE OF NOTICE TO PROCEED (CONTRACTOR) By: ?A-UT-H0- ED SIGNATURE) (DATE) Issued for Bid Page 2 of 2 10thMay 10thMay General ManagerMay 10, 2023 10thMay 10thMay General ManagerMay 10, 2023 MERCHANTS�� BONDING COMPANY.. POWER OF ATTORNEY Know All Persons By These Presents,that MERCHANTS BONDING COMPANY(MUTUAL)and MERCHANTS NATIONAL BONDING,INC., both being corporations of the State of Iowa,dlb/a Merchants National Indemnity Company(in California only)(herein collectively called the "Companies")do hereby make,constitute and appoint,individually, Barbara A Shamard;Rob Bridges their true and lawful Attorney(s)in Fact. to sign its name as surety(ies) and to execute, seal and acknowledge any and all bonds, undertakings, contracts and other written instruments n the nature thereof, on behalf of the Companies in their business of guaranteeing the fidelity of persons, guaranteeing the performance of contracts and executing or guaranteeing bonds and undertakings required or permitted in any actions or proceedings allowed by law. This Power-of-Attomey is granted and is signed and sealed by facsim,le under and by authority of the following By-Laws adopted by the Board of Directors of Merchants Bonding Company (Mutual) on April 23, 2011 and amended August 14, 2015 and adopted by the Board of Directors of Merchants National Bonding,Inc,on October 16,2015. "The President, Secretary, Treasurer, or any Assistant Treasurer or any Assistant Secretary or any Vice President shall have power and authority to appo'nt Attorneys in.-Fact, and to authorize them to execute on behalf of the Company, and attach the seal of the Company thereto, bonds and undertakings,recognizances,contracts of indemnity and other writings obligatory in the nature thereof." "The signature of any authorized officer and the seal of the Company may be affixed by facsimile or electronic transmission to any Power of Attorney or Certification thereof authorizing the execution and delivery of any bond, undertaking, recognizance, or other suretyship obligations of the Company,and such signature and seal when so used shall have the same force and effect as though manually fixed." In connection with obligations in favor of the Florida Department of Transportation only, it is agreed that the power and aut hority hereby given to the Attomey-in-Fact includes any and all consents for the release of retained percentages and/or final estimates on engineering and construction contracts required by the State of Florida Department of Transportation. It is fully understood that consenting to the State of Florida Department of Transportation making payment of the final estimate to the Contractor andlor its assignee, shall not relieve this surety company of any of its obligations under its bond. In connection with obligations in favor of the Kentucky Department of Highways only,it is agreed that the power and authority hereby given to the Attorney:n-Fact cannot be modified or revoked unless prior written personal notice of such intent has been given to the Commissioner- Department of Highways of the Commonwealth of Kentucky at least thirty(30)days prior to the modification or revocation In Witness Whereof,the Companies have caused this instrument to be signed and sealed this 15th day of December 2022 ,••" •., .••"'••. MERCHANTS BONDING COMPANY(MUTUAL) ••�.�P•�IONq�e �O��1G iCQ�p MERCHANTS NATIONAL BONDING,INC. •��Gj: 4.:Z *.�D�OQIPOA��9Z�: dlbla MERCHANTS NATIONAL INDEMNITY COMPANY QZ -o- 0, .ty:Z -o- a; v 2003 ;�� y_ 1933 e: By 'a�., ted. •;� . •,�� �•.,, �,' President••••��•.....••11••• STATE OF IOWA '•. lVi .•• •• .• COUNTY OF DALLAS ss. •��""''"•' ••• ` On this 15th day of December 2022 before me appeared Lary Taylor, to me personally known, who being by me duly swom did say that he is President of MERCHANTS BONDING COMPANY (MUTUAL)and MERCHANTS NATIONAL BONDING, INC.; and that the seals affixed to the foregoing instrument are the Corporate Seals of the Companies;and that the said instrument was signed and sealed in behalf of the Companies by authority of their respective Boards of Directors. ArtiLut s Kim tee o 'r.r• Commission Number &LU z My Commission Expates pres f � Apn`14,2024 4M Notary Public (Expiration of notary's commission does not invalidate this instrument) I,William Warner,Jr.,Secretary of MERCHANTS BONDING COMPANY(MUTUAL)and MERCHANTS NATIONAL BONDING,'NC.,do hereby certify that the above and foregoing is a true and correct copy of the POWER-OF-ATTORNEY executed by said Companies,which is still in full force and effect and has not been amended or revoked. In Witness Whereof,I have hereunto set my hand and affixed the seal of the Companies on this 4th day of May ,2023 ,•�Pt% Nq�••., . '0ING CQ. :•y:•papOR,4•�O%. OjkPOA9'Oyy: -0- 0- w'• 2003 ;�� y' 1933 0:c; Secretary • ,• : gid. POA 0018 (10122) ""���' +••�•••• F MERCHANTS BONDING COMPANY,. MFRCHANTS BONDING COMPANY(MUTUAL) • MFRCIIANTS NATIONAL BONDING. INC P.O. BOX 14498 • DES MOINES. 104VA 50306-,3498 • (80W 678-81?1 • (515)243-3854 FAX Please send all notices of claim on this bond to: Merchants Bonding Company (Mutual) /Merchants National Bonding, Inc. P.O. Box 14498 Des Moines, Iowa 50306-3498 (515) 243-8171 (800) 678-8171 Physical Address: 6700 Westown Parkway, West Des Moines, Iowa 50266 SUP 0073 TX (2115) BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 1 of 72 STANDARD GENERAL CONDITIONS OF THE CONSTRUCTION CONTRACT TABLE OF CONTENTS Page ARTICLE 1 – Definitions and Terminology ....................................................................................... 5 1.01 Defined Terms ........................................................................................................................ 5 1.02 Terminology ........................................................................................................................... 7 ARTICLE 2 – Preliminary Matters .................................................................................................... 8 2.01 Delivery of Bonds and Evidence of Insurance ........................................................................ 8 2.02 Copies of Documents ............................................................................................................. 8 2.03 Before Starting Construction ................................................................................................. 9 2.04 Preconstruction Conference .................................................................................................. 9 2.05 Initial Acceptance of Schedules ............................................................................................. 9 2.06 Electronic Transmittals ......................................................................................................... 10 2.07 Designation of Authorized Representatives ........................................................................ 10 ARTICLE 3 – Documents: Intent, Requirements, Reuse ................................................................ 10 3.01 Intent .................................................................................................................................... 10 3.02 Reference Standards ............................................................................................................ 10 3.03 Reporting and Resolving Discrepancies ............................................................................... 11 3.04 Requirements of the Contract Documents .......................................................................... 12 ARTICLE 4 – Commencement and Progress of the Work ............................................................. 13 4.01 Commencement of Contract Times; Notice to Proceed ...................................................... 13 4.02 Commencement of Performance......................................................................................... 13 4.03 Reference Points .................................................................................................................. 14 4.04 Progress Schedule ................................................................................................................ 15 4.05 Delays in Contractor’s Progress ........................................................................................... 15 ARTICLE 5 – Availability of Lands; Subsurface and Physical Conditions; Hazardous Environmental Conditions ..................................................................................................................................... 17 5.01 Availability of Lands ............................................................................................................. 17 5.02 Use of Site and Other Areas ................................................................................................. 17 5.03 Subsurface and Physical Conditions ..................................................................................... 18 5.04 Differing Subsurface or Physical Conditions ........................................................................ 20 5.05 Underground Facilities ......................................................................................................... 22 5.06 Hazardous Environmental Conditions at Site ...................................................................... 23 5.07 Endangered Species ............................................................................................................. 24 BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 2 of 72 5.08 Archaeological Discoveries and Cultural Resources ............................................................ 25 5.09 Control of Water .................................................................................................................. 25 5.10 Site Preservation .................................................................................................................. 26 ARTICLE 6 – Bonds and Insurance ................................................................................................. 26 6.01 Performance, Payment, and Other Bonds ........................................................................... 26 6.02 Insurance—General Provisions ............................................................................................ 27 6.03 Workers’ Compensation Insurance Coverage ...................................................................... 27 ARTICLE 7 – Contractor’s Responsibilities .................................................................................... 27 7.01 Supervision and Superintendence ....................................................................................... 27 7.02 Labor; Working Hours .......................................................................................................... 28 7.03 Services, Materials, and Equipment ..................................................................................... 28 7.04 “Or Equals” ........................................................................................................................... 30 7.05 Substitutes ........................................................................................................................... 31 7.06 Concerning Subcontractors, Suppliers, and Others ............................................................. 32 7.07 Patent Fees and Royalties .................................................................................................... 33 7.08 Permits ................................................................................................................................. 33 7.09 Taxes .................................................................................................................................... 33 7.10 Laws and Regulations ........................................................................................................... 34 7.11 Record Documents ............................................................................................................... 35 7.12 Safety and Protection ........................................................................................................... 36 7.13 Safety Representative .......................................................................................................... 38 7.14 Hazard Communication Programs ....................................................................................... 38 7.15 Emergencies ......................................................................................................................... 38 7.16 Shop Drawings, Samples, and Other Submittals .................................................................. 38 7.17 Contractor’s General Warranty and Guarantee................................................................... 41 7.18 Indemnification .................................................................................................................... 43 7.19 Delegation of Professional Design Services ......................................................................... 43 7.20 Administrative Charges ........................................................................................................ 44 7.21 Miscellaneous Contractor Responsibilities: ......................................................................... 44 ARTICLE 8 – Other Work at the Site .............................................................................................. 45 8.01 Other Work .......................................................................................................................... 45 8.02 Coordination ........................................................................................................................ 46 8.03 Legal Relationships ............................................................................................................... 46 ARTICLE 9 – Owner’s Responsibilities ........................................................................................... 47 9.01 Communications to Contractor ............................................................................................ 47 BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 3 of 72 9.02 Replacement of Engineer ..................................................................................................... 47 9.03 Furnish Data ......................................................................................................................... 47 9.04 Pay When Due ...................................................................................................................... 47 9.05 Lands and Easements; Reports, Tests, and Drawings .......................................................... 47 9.06 Limitations on Owner’s Responsibilities .............................................................................. 47 9.07 Evidence of Financial Arrangements .................................................................................... 48 9.08 Safety Programs ................................................................................................................... 48 9.09 Video Observation................................................................................................................ 48 ARTICLE 10 – Engineer’s Status During Construction ................................................................... 48 10.01 Owner’s Representative ....................................................................................................... 48 10.02 Visits to Site .......................................................................................................................... 48 10.03 Project Representative ......................................................................................................... 48 10.04 Rejecting Defective Work ..................................................................................................... 49 10.05 Shop Drawings, Change Orders and Payments .................................................................... 49 10.06 Determinations for Unit Price Work .................................................................................... 49 10.07 Decisions on Requirements of Contract Documents and Acceptability of Work ................ 49 10.08 Limitations on Engineer’s Authority and Responsibilities .................................................... 49 10.09 Compliance with Safety Program ......................................................................................... 50 ARTICLE 11 – Amending the Contract Documents; Changes in the Work.................................... 50 11.01 Amending and Supplementing Contract Documents .......................................................... 50 11.02 Owner-Authorized Changes in the Work ............................................................................. 50 11.03 Unauthorized Changes in the Work ..................................................................................... 51 11.04 Change of Contract Price ..................................................................................................... 51 11.05 Change of Contract Time...................................................................................................... 52 11.06 Change Proposals ................................................................................................................. 52 11.07 Execution of Change Orders ................................................................................................. 53 ARTICLE 12 – Claims ...................................................................................................................... 53 12.01 Claims ................................................................................................................................... 53 ARTICLE 13 – Cost of the Work; Allowances; Unit Price Work ..................................................... 54 13.01 Cost of the Work .................................................................................................................. 54 13.02 Unit Price Work .................................................................................................................... 56 ARTICLE 14 – Tests and Inspections; Correction, Removal or Acceptance of Defective Work .... 57 14.01 Access to Work ..................................................................................................................... 57 14.02 Tests, Inspections, and Approvals ........................................................................................ 57 BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 4 of 72 14.03 Defective Work..................................................................................................................... 58 14.04 Acceptance of Defective Work ............................................................................................. 58 14.05 Uncovering Work ................................................................................................................. 59 14.06 Owner May Stop the Work .................................................................................................. 59 14.07 Owner May Correct Defective Work .................................................................................... 59 ARTICLE 15 – Payments to Contractor; Set-Offs; Completion; Correction Period ....................... 60 15.01 Progress Payments ............................................................................................................... 60 15.02 Contractor’s Warranty of Title ............................................................................................. 62 15.03 Substantial Completion ........................................................................................................ 63 15.04 Partial Use or Occupancy ..................................................................................................... 63 15.05 Final Inspection .................................................................................................................... 64 15.06 Final Payment ....................................................................................................................... 64 15.07 Waiver of Claims .................................................................................................................. 65 15.08 Correction Period ................................................................................................................. 66 ARTICLE 16 – Suspension of Work and Termination .................................................................... 66 16.01 Owner May Suspend Work .................................................................................................. 66 16.02 Owner May Terminate for Cause ......................................................................................... 67 16.03 Owner May Terminate For Convenience ............................................................................. 68 16.04 Contractor May Stop Work or Terminate ............................................................................ 68 ARTICLE 17 – Final Resolution of Disputes ................................................................................... 68 17.01 Methods and Procedures ..................................................................................................... 68 ARTICLE 18 – Miscellaneous ......................................................................................................... 69 18.01 Giving Notice ........................................................................................................................ 69 18.02 Computation of Times .......................................................................................................... 69 18.03 Cumulative Remedies .......................................................................................................... 69 18.04 Limitation of Damages ......................................................................................................... 69 18.05 No Waiver ............................................................................................................................ 70 18.06 Survival of Obligations ......................................................................................................... 70 18.07 Controlling Law .................................................................................................................... 70 18.08 Headings ............................................................................................................................... 70 18.09 Prevailing Wage Rates .......................................................................................................... 70 18.10 Right to Audit: ...................................................................................................................... 71 18.11 Prohibition Against Boycotting Israel: .................................................................................. 72 18.12 Non-Waiver of Sovereign Immunity .................................................................................... 72 BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 5 of 72 Section 00700 – General Conditions ARTICLE 1 – DEFINITIONS AND TERMINOLOGY 1.01 Defined Terms A. Wherever used in the Bidding Requirements or Contract Documents listed in the Agreement, a term printed with initial capital letters, including the term’s singular and plural forms, will have the meaning indicated in the definitions below or as defined in the Agreement and other Contract Documents. In addition to terms specifically defined, terms with initial capital letters in the Contract Documents include references to identified articles and paragraphs, and the titles of other documents or forms. 1. Addenda—Written or graphic instruments issued prior to the opening of Bids which clarify, correct, or change the Bidding Requirements or the proposed Contract Documents. 2. Agreement—The written instrument, entitled Agreement Between Owner and Contractor, executed by Owner and Contractor, that sets forth the Contract Price and Contract Time, identifies the parties, and designates the specific items that are Contract Documents. 3. Application for Payment—The form acceptable to Owner which is to be used by Contractor during the course of the Work in requesting progress or final payments and which is to be accompanied by such supporting documentation as is required by the Contract Documents, and as reasonably required by Owner and Engineer. 4. Change Order—A document which is signed by Contractor and Owner and authorizes an addition, deletion, or revision in the Work or an adjustment in the Contract Price or the Contract Time, or other revision to the Contract Documents, issued on or after the Effective Date of the Agreement. 5. Change Proposal—A written request by Contractor, duly submitted in compliance with the procedural requirements set forth in the Contract Documents, seeking an adjustment in Contract Price or Contract Time, or both. 6. Claim—A demand or assertion duly submitted in compliance with the procedural requirements set forth herein: seeking an adjustment of Contract Price or Contract Time, or both; contesting an initial decision by Engineer concerning the requirements of the Contract Documents or the acceptability of Work under the Contract Documents; contesting Engineer’s decision regarding a Change Proposal; seeking resolution of a contractual issue that Engineer has declined to address; or seeking other relief with respect to the terms of the Contract. A demand for money or services by a third party is not a Claim. 7. Constituent of Concern—Asbestos, petroleum, radioactive materials, polychlorinated biphenyls (PCBs), hazardous waste, and any substance, product, waste, or other material of any nature whatsoever that is or becomes listed, regulated, or addressed pursuant to (a) the Comprehensive Environmental Response, Compensation and Liability Act, 42 U.S.C. §§9601 et seq. (“CERCLA”); (b) the Hazardous Materials Transportation Act, 49 U.S.C. §§5501 et seq.; (c) the Resource Conservation and Recovery Act, 42 U.S.C. §§6901 et seq. (“RCRA”); (d) the Toxic Substances Control Act, 15 U.S.C. §§2601 et seq.; (e) the Clean Water Act, 33 U.S.C. §§1251 et seq.; (f) the Clean Air Act, 42 U.S.C. §§7401 et seq.; or (g) any other federal, state, or local statute, law, rule, regulation, ordinance, resolution, code, order, or decree regulating, relating to, or BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 6 of 72 Section 00700 – General Conditions imposing liability or standards of conduct concerning, any hazardous, toxic, or dangerous waste, substance, or material. 8. Effective Date of the Agreement—The date, indicated in the Agreement, on which the Agreement becomes effective. 9. Engineer –The Project Engineer retained by the Owner as identified on page 1 of the Agreement. 10. Field Order—A written order issued by Engineer which requires minor changes in the Work but does not change the Contract Price or the Contract Time. 11. Geotechnical Engineering Reports – Reports developed to support near-surface work at or contiguous to the Site and provide for information purpose only as “Technical Data”. 12. Hazardous Environmental Condition—The presence at the Site of Constituents of Concern in such quantities or circumstances that may present a danger to persons or property exposed thereto. The presence at the Site of materials that are necessary for the execution of the Work, or that are to be incorporated in the Work, and that are controlled and contained pursuant to industry practices, Laws and Regulations, and the requirements of the Contract, does not establish a Hazardous Environmental Condition. 13. Laws and Regulations; Laws or Regulations—Any and all applicable laws, statutes, rules, regulations, ordinances, codes, and orders of any and all governmental bodies, agencies, authorities, and courts having jurisdiction. 14. Milestone—A principal event in the performance of the Work that the Contract Documents require Contractor to achieve by an intermediate completion date or by a time prior to Substantial Completion of all the Work. 15. Modification—A Modification is (1) a written amendment to the Agreement signed by both parties (2) a Change Order (3) a Work Change Directive or (4) a Field Order. 16. Owner – the local entity contracting for the construction services as identified on page 1 of the Agreement. Owner may sometimes herein be referred to as “BCRUA”. 17. Project —The full scope of the Work as described in the Contract Documents. 18. Project Manual—The written documents prepared for, or made available for, procuring and constructing the Work, including but not limited to the Bidding Documents or other construction procurement documents, geotechnical and existing conditions information, the Agreement, bond forms, General Conditions, Supplemental General Conditions, and Specifications. The contents of the Project Manual may be bound in one or more volumes. 19. Resident Project Representative—The authorized representative of Engineer assigned to assist Engineer at the Site. As used herein, the term Resident Project Representative or “RPR” includes any assistants or field staff of Resident Project Representative. 20. Samples—Physical examples of materials, equipment, or workmanship that are representative of some portion of the Work and that establish the standards by which such portion of the Work will be judged. 21. Site—Lands or areas indicated in the Contract Documents as being furnished by Owner upon which the Work is to be performed, including rights-of-way and easements, and such other lands furnished by Owner which are designated for the use of Contractor. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 7 of 72 Section 00700 – General Conditions 22. Substantial Completion—The time at which the Work (or a specified part thereof) has progressed to the point where, in the opinion of Engineer and Owner, the Work (or a specified part thereof) is sufficiently complete, in accordance with the Contract Documents, so that the Work (or a specified part thereof) can be utilized for the purposes for which it is intended. The terms “Substantially Complete” and “Substantially Completed” as applied to all or part of the Work refer to Substantial Completion thereof. 23. Successful Bidder—The Bidder who’s Bid the Owner accepts, and to which the Owner makes an award of contract, subject to stated conditions. 24. Technical Data—Those items expressly identified as Technical Data in the Contract Documents, with respect to either (a) subsurface conditions at the Site, or physical conditions relating to existing surface or subsurface structures at the Site (except Underground Facilities) or (b) Hazardous Environmental Conditions at the Site. If no such express identifications of Technical Data have been made with respect to conditions at the Site, then the data contained in boring logs, recorded measurements of subsurface water levels, laboratory test results, and other factual, objective information regarding conditions at the Site that are set forth in any geotechnical or environmental report prepared for the Project and made available to Contractor are hereby defined as Technical Data with respect to conditions at the Site under Paragraphs 5.03, 5.04, and 5.06. 25. Underground Facilities—All underground pipelines, conduits, ducts, cables, wires, manholes, vaults, tanks, tunnels, or other such facilities or attachments, and any encasements containing such facilities, including but not limited to those that convey electricity, gases, steam, liquid petroleum products, telephone or other communications, fiber optic transmissions, cable television, water, wastewater, storm water, other liquids or chemicals, or traffic or other control systems. 26. Work—The entire construction or the various separately identifiable parts thereof required to be provided under the Contract Documents. Work includes and is the result of performing or providing all labor, services, and documentation necessary to produce such construction; furnishing, installing, and incorporating all materials and equipment into such construction; and may include related services such as testing, start-up, and commissioning, all as required by the Contract Documents. 27. Work Change Directive—A written directive to Contractor issued on or after the Effective Date of the Agreement, signed by Owner and recommended by Engineer, ordering an addition, deletion, or revision in the Work. 1.02 Terminology A. The words and terms discussed in the following paragraphs are not defined but, when used in the Bidding Requirements or Contract Documents, have the indicated meaning. B. Defective: 1. The word “defective,” when modifying the word “Work,” refers to Work that: a. is unsatisfactory; or b. is faulty; or c. was not performed in a good and workmanlike manner; or d. does not properly perform as required; or BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 8 of 72 Section 00700 – General Conditions e. does not conform to the Contract Documents; or f. does not meet the requirements of any applicable inspection, reference standard, test, or approval referred to in the Contract Documents; or g. has been damaged prior to Engineer’s recommendation of final payment unless responsibility for the protection thereof has been assumed by Owner, in writing, at Substantial Completion. C. Furnish, Install, Perform, Provide: 1. The word “furnish,” when used in connection with services, materials, or equipment, shall mean to supply and deliver said services, materials, or equipment to the Site (or some other specified location) so that they are ready for use or installation and in usable or operable condition. 2. The word “install,” when used in connection with services, materials, or equipment, shall mean to put into use or place in final position said services, materials, or equipment so that they are complete and ready for intended use. 3. The words “perform” or “provide,” when used in connection with services, materials, or equipment, shall mean to furnish and install said services, materials, or equipment so that they are complete and ready for intended use. 4. If the Contract Documents establish an obligation of Contractor with respect to specific services, materials, or equipment, but do not expressly use any of the four words “furnish,” “install,” “perform,” or “provide,” then Contractor shall furnish and install said services, materials, or equipment in compliance with the Contract Documents, complete and ready for intended use. D. Unless stated otherwise in the Contract Documents, words or phrases that have a well- known technical or construction industry or trade meaning are used in the Contract Documents in accordance with such recognized meaning. ARTICLE 2 – PRELIMINARY MATTERS 2.01 Delivery of Bonds and Evidence of Insurance A. Bonds: Contractor shall deliver to Owner such bonds as Contractor may be required to furnish within 10 days of the date on which Contractor signs the Agreement. Contractor shall not be permitted to commence performance until the bonds have been delivered even though the Contract Time may have commenced. B. Evidence of Contractor’s Insurance: When Contractor delivers the executed counterparts of the Agreement to Owner, Contractor shall also deliver to Owner, with copies to each named insured and additional insured (as identified in the Supplemental Conditions or elsewhere in the Contract Documents), the certificates and other evidence of insurance required to be provided by Contractor in accordance with Article 6. 2.02 Copies of Documents A. Owner shall furnish to Contractor three printed copies of the Agreement (including one fully executed counterpart of the Agreement), and one copy in electronic portable document format (PDF). Additional printed copies will be furnished upon request at the cost of reproduction. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 9 of 72 Section 00700 – General Conditions B. Owner shall maintain and safeguard at least one original printed record version of the Agreement, including Drawings and Specifications signed and sealed by Engineer and other design professionals. 2.03 Before Starting Construction A. Preliminary Schedules: Within 10 days after the Effective Date of the Agreement (or as otherwise specifically required by the Contract Documents), Contractor shall submit to the Owner and Engineer: 1. a preliminary Progress Schedule indicating the times (numbers of days or dates) for starting and completing the various stages of the Work, including any Milestones specified in the Contract Documents; 2. a preliminary Schedule of Submittals; and 3. a preliminary Schedule of Values (“Schedule of Values”) for all of the Work which includes quantities and prices of items which when added together equal the Contract Price and subdivides the Work into component parts in sufficient detail to serve as the basis for progress payments during performance of the Work. Such prices will include an appropriate amount of overhead and profit applicable to each item of Work. The preliminary Schedule of Values submitted by the Contractor shall include a reasonable estimation of the value of each item included and shall not contain disproportionate values assigned to any item or items. 2.04 Preconstruction Conference A. Before any Work at the Site is started and after the schedules described in Paragraph 2.03 A above have been submitted, a pre-construction conference attended by Owner, Contractor, Engineer, and others as appropriate will be held to establish a working understanding among the parties as to the Work and to discuss the schedules referred to in Paragraph 2.03.A, procedures for handling Shop Drawings, Samples, and other submittals, processing Applications for Payment, electronic or digital transmittals, and maintaining required records. 2.05 Initial Acceptance of Schedules A. At the pre-construction conference, the schedules submitted in accordance with Paragraph 2.03.A will be reviewed. Contractor shall have an additional 10 days to make corrections and adjustments and to complete and resubmit the schedules. No progress payment shall be made to Contractor until acceptable schedules are submitted to Engineer. 1. The final approved Progress Schedule shall provide for an orderly progression of the Work to completion within the Contract Time and must be acceptable to Owner and Engineer. 2. Contractor’s Schedule of Submittals shall provide for a workable arrangement for reviewing and processing the required submittals and must be acceptable to Owner and Engineer. The Progress Schedule shall not exceed time limits current under the Contract Documents, shall be revised at appropriate intervals as required by the conditions of the Work and Project, and shall provide for expeditious and practical execution of the Work. The Progress Schedule shall be in a detailed critical path method or other format satisfactory to the Owner and the Engineer and shall provide a graphic representation of all the significant activities and events that will occur during the performance of the Work, identify each phase of construction in occupancy and set forth dates that are BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 10 of 72 Section 00700 – General Conditions critical in insuring the timely and orderly completion of the Work in accordance with the requirements of the Contract Documents. 3. Contractor’s Schedule of Values shall provide for a reasonable allocation of the Contract Price to the component parts of the Work and shall be acceptable in form and substance to Owner and Engineer. 2.06 Electronic Transmittals A. Except as otherwise stated elsewhere in the Contract Documents, the Owner, Engineer, and Contractor shall transmit, and shall accept, Project-related correspondence, text, data, documents, drawings, information, and graphics, including but not limited to Shop Drawings, Submittals, Contractor Requests and other transmittals, in electronic media or digital format, as directed by the Engineer either directly, or through access to an Engineer provided and maintained secure Project website. B. When transmitting items in electronic media or digital format, the transmitting party makes no representations as to long term compatibility, usability, or readability of the items resulting from the recipient’s use of software application packages, operating systems, or computer hardware differing from those used in the drafting or transmittal of the items. 2.07 Designation of Authorized Representatives A. Prior to or within three (3) days of the Notice to Proceed, the Owner and Contractor shall designate, in writing, a specific individual to act as its authorized representative with respect to the services and responsibilities under the Contract Documents. Such individuals shall have the authority to transmit and receive information, render decisions relative to the Contract Documents, and otherwise act on behalf of each respective party. ARTICLE 3 – DOCUMENTS: INTENT, REQUIREMENTS, REUSE 3.01 Intent A. The Contract Documents are complementary; what is required by one is as binding as if required by all. B. It is the intent of the Contract Documents to describe a functionally complete project (or part thereof) to be constructed in accordance with the Contract Documents. C. Unless otherwise stated in the Contract Documents, if there is a discrepancy between the electronic or digital versions of the Contract Documents (including any printed copies derived from such electronic or digital versions) and the printed record version, the printed record version shall govern. D. The Contract Documents supersedes prior negotiations, representations, and agreements, whether written or oral. 3.02 Reference Standards A. Standards Specifications, Codes, Laws and Regulations 1. Reference in the Contract Documents to standard specifications, manuals, reference standards, or codes of any technical society, organization, or association, or to Laws or Regulations, whether such reference be specific or by implication, shall mean the standard specification, manual, reference standard, code, or Laws or Regulations in effect at the time of opening of Bids (or on the Effective Date of the Agreement if there BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 11 of 72 Section 00700 – General Conditions were no Bids), except as may be otherwise specifically stated in the Contract Documents. 2. No provision of any such standard specification, manual, reference standard, or code, or any instruction of a Supplier, shall be effective to change the duties or responsibilities of Owner, Contractor, or Engineer, or any of their subcontractors, consultants, agents, or employees, from those set forth in the part of the Contract Documents prepared by or for Engineer. No such provision or instruction shall be effective to assign to Owner, Engineer, or any of their officers, directors, members, partners, employees, agents, consultants, or subcontractors, any duty or authority to supervise or direct the performance of the Work or any duty or authority to undertake responsibility inconsistent with the provisions of the part of the Contract Documents prepared by or for Engineer. 3.03 Reporting and Resolving Discrepancies A. Review of Contract Document: 1. Prior to commencing the Work, the Contractor shall review the Contract Documents for the purpose of discovering any conflict, error, ambiguity or discrepancy in the Contract Documents. B. Reporting Discrepancies: 1. Contractor’s Verification of Figures and Field Measurements: Before undertaking each part of the Work, Contractor shall carefully study the Contract Documents, and check and verify pertinent figures and dimensions therein, particularly with respect to applicable field measurements. Contractor shall promptly report in writing to Engineer any conflict, error, ambiguity, or discrepancy that Contractor discovers, or has actual knowledge of, and shall not proceed with any Work affected thereby until the conflict, error, ambiguity, or discrepancy is resolved, by a clarification or interpretation by Engineer, or by an amendment or supplement to the Contract Documents issued pursuant to Paragraph 11.01. 2. Discovery of Discrepancies in Contract Documents: If, before or during the performance of the Work, Contractor discovers any conflict, error, ambiguity, or discrepancy within the Contract Documents, or between the Contract Documents and (a) any applicable Law or Regulation, (b) actual field conditions, (c) any standard specification, manual, reference standard, or code, or (d) any instruction of any Supplier, then Contractor shall promptly report it to Engineer in writing. Contractor shall not proceed with the Work affected thereby (except in an emergency as required by Paragraph 7.15) until the conflict, error, ambiguity, or discrepancy is resolved, by a clarification or interpretation by Engineer, or by an amendment or supplement to the Contract Documents issued pursuant to Paragraph 11.01. 3. Should Contractor perform the Work after discovery of such a conflict without reporting the conflict or before receipt of a clarification or interpretation by Engineer or if, using Contractor’s reasonable expertise and experience, Contractor should have reasonably discovered any conflict, error, ambiguity or discrepancy that might exist in the Contract Documents, Contractor will be solely liable for any correction or other measures that may be required to overcome the conflict or bring the Work into compliance with the Contract Documents. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 12 of 72 Section 00700 – General Conditions C. Resolving Discrepancies: 1. Except as may be otherwise specifically stated in the Contract Documents, the provisions of the part of the Contract Documents prepared by or for Engineer shall take precedence in resolving any conflict, error, ambiguity, or discrepancy between such provisions of the Contract Documents and: a. the provisions of any standard specification, manual, reference standard, or code, or the instruction of any Supplier (whether or not specifically incorporated by reference as a Contract Document); or b. the provisions of any Laws or Regulations applicable to the performance of the Work (unless such an interpretation of the provisions of the Contract Documents would result in violation of such Law or Regulation). Subject to the provisions of Section 3.03 C.1 above, any discrepancies or conflicts within each of the Contract Documents themselves or with each other shall be resolved by applying the following order of precedence to each of the Contract Documents. 1. Modifications 2. The Agreement 3. The Supplemental General Conditions. 4. The General Conditions 5. The Specifications 6. Drawings 7. Any other Contract Documents. 2. In regard to the Drawings and Specifications, figures shall govern over scaled measurements; large scale drawings shall govern over small scale drawings; descriptive writing shall govern over legends indicating material or condition; and the provision or interpretation that results in the greater quantity and/or quality of Work or material shall prevail. 3.04 Requirements of the Contract Documents A. During the performance of the Work and until final payment, Contractor shall submit to the Engineer all matters in question concerning the requirements of the Contract Documents, or relating to the acceptability of the Work under the Contract Documents, as soon as possible after such matters arise. Engineer will be the initial interpreter of the requirements of the Contract Documents. B. Engineer will, with reasonable promptness, render a written clarification, interpretation, or decision on the issue submitted, or initiate an amendment or supplement to the Contract Documents. Engineer’s written clarification, interpretation, or decision will be final and binding, unless Contractor appeals by submitting a Change Proposal. C. If a submitted matter in question concerns terms and conditions of the Contract Documents that do not involve (1) the performance or acceptability of the Work under the Contract Documents, (2) the design (as set forth in the Drawings, Specifications, or otherwise), or (3) other engineering or technical matters, then Engineer will promptly give written notice to Owner and Contractor that Engineer is unable to provide a decision or interpretation. If BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 13 of 72 Section 00700 – General Conditions Owner and Contractor are unable to agree on resolution of such a matter in question, either party may pursue resolution as provided in Article 12. ARTICLE 4 – COMMENCEMENT AND PROGRESS OF THE WORK 4.01 Commencement of Contract Times; Notice to Proceed A. The Contract Times will commence upon issuance of a Notice to Proceed by the Owner. 4.02 Commencement of Performance A. Subject to the provisions of Paragraphs 3.02 and 3.03 above, Contractor may commence performance upon receipt of the Notice to Proceed and in accordance with any terms and dates contained therein. No Work shall be done at the Site prior to such date. B. Contractor to visually record all areas of proposed construction, to depict existing surroundings of the Site prior to beginning work. Recording to be in DVD format, recorded with date, time, and locations, and two copies are to be given to the Owner. Contractor is not allowed to proceed with the work in any area until the required DVD is submitted and accepted by the Owner. No direct payment shall be allotted for visually recording the Site. Cost of visual recording is incidental to and included in the Contract Price. Visually recording shall be in accordance with 01380, except in DVD format, or as follows, if 01380 is not applicable: 1. Video and Project Photographs - Contractor shall videotape all areas of proposed construction and all areas in the limits of work to be performed, to depict existing surroundings of the Site, prior to beginning the Work. The only work that may proceed prior to the video is work that may be necessary for the video/photographs (staking, clearing with hand-tools, pruning, mowing, etc.) The video shall be narrated indicating the Station Number and/or site address being observed. When appropriate, the address of the Project should be noted on the photo and in the video. Damage to private property caused prior to the video shall be further detailed. Special attention shall be made to previously damaged driveways, sidewalks, mailboxes, landscaping, lighting, fencing, gates, and roads. The Contractor shall also videotape the gravity sanitary sewer line segments after testing is completed. 2. Tapes to be color DVD digital format, recorded with date, time, and locations, and two (2) copies to be given to the Owner. Contractor is not allowed to proceed with the Work in any area until the required DVDs are submitted and accepted by the Owner and Engineer. Cost of visually documenting of all areas of proposed construction is to be incidental to the cost of the Project unless specifically identified on the bid form. If the Owner or Engineer is not satisfied with the quality or quantity of the photographs or video, no additional amount will be paid to Contractor to provide photographs or videos acceptable to the Owner or Engineer. No additional time will be granted for delay in construction activities due to unsatisfactory photographs or video. 3. The Contractor shall keep a copy of all pre-construction photos in the Job Office (if included in Project) or in the superintendent's vehicle (if no job office is required) for the duration of the Project. C. Construction progress photographs shall be taken by the Contractor as follows: 1. The Contractor shall provide a minimum of twenty-four (24) photographs per month to depict the progress of the construction. The time and content of the photographs may BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 14 of 72 Section 00700 – General Conditions be directed by the Owner or the Engineer. Attention shall be placed on items of interest to the Project (connections to existing utilities, fittings, bends, borings, taps, etc.). Monthly progress photos will be delivered to the Engineer at the monthly progress meetings or submitted with the monthly pay application, whichever is more appropriate. Owner will not approve monthly pay applications without delivery of the monthly progress photos. 2. All photographic work shall be done by a qualified photographer acceptable to the Owner and Engineer. Three (3) prints of each photograph shall be furnished promptly to the Engineer, and each print shall have a color glossy finish mounted on a substantial backing. The overall dimensions of each mounted print shall be a minimum of 3"X5" and presented to the engineer using plastic photo sleeves included in a 3-ring binder or printed on glossy photograph paper (for digital images). The outside of the binder shall be clearly labeled on the spine to include the Project name, addresses and/or station numbers included inside, and the date range the photographs were taken. Alternately, a DVD-ROM of the photographs in JPG format can be provided, if an index of the photographs on the DVD-ROM is provided. The resolution of digital images shall not be less than 1024 X 768 pixels. 3. The film negatives (or digital files) shall be retained in the files of the photographer until the completion of the Project and then be turned over to the Owner. 4. Each photograph shall have attached to the backing or underneath the photo a label, approximately 2-1/4" wide by 1-3/4" high containing thereon in neat lettering: Contractor's name, short description of view, station number, photo number, date and time taken, address (when appropriate) and photographer's firm name. Alternately, a DVD-ROM of the photographs in JPG format can be provided, if an index of the photographs on the DVD-ROM is provided that includes the Contractor's name, short description of view, station number, photo number, date and time taken, address (when appropriate) and photographer's firm name. D. Post-construction photos shall also be taken after restoration of the construction site and repair/replacement of any private property damaged by the Contractor. Post-construction photos shall be taken every 150-200 feet of station, in both directions. Post-construction photos shall be delivered to the Engineer, in accordance with item (b), prior to application for final payment. 4.03 Reference Points A. If applicable, Owner shall provide engineering surveys, or GPS control points to establish reference points for construction which, in Engineer’s judgment, are necessary to proceed with the Work. Contractor shall be responsible for laying out the Work, shall protect and preserve the established reference points and property monuments, and shall make no changes or relocations without the prior written approval of Owner and Engineer. Contractor shall notify the Engineer, in writing, whenever any reference point or property monument is lost or destroyed or requires relocation because of necessary changes in grades or locations, and shall be responsible for the accurate replacement or relocation of such reference points or property monuments by professionally qualified personnel. B. Contractor shall note the location of all reference points and controls on a set of red-lined drawings or exhibits to be maintained at all times on the jobsite. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 15 of 72 Section 00700 – General Conditions 4.04 Progress Schedule A. Contractor shall adhere to the Progress Schedule established in accordance with Paragraph 2.05 as it may be adjusted from time to time as provided below. 1. Contractor shall submit to Engineer for Owner’s acceptance (to the extent indicated in Paragraph 2.05) proposed adjustments in the Progress Schedule that will not result in changing the Contract Time. 2. Proposed adjustments in the Progress Schedule that will change the Contract Time shall be submitted in accordance with the requirements of Article 11. B. Contractor shall carry on the Work and adhere to the Progress Schedule during all disputes or disagreements with Owner. No Work shall be delayed or postponed pending resolution of any disputes or disagreements, or during any appeal process, except as permitted by Paragraph 16.04, or as Owner and Contractor may otherwise agree in writing. C. A recurring construction status meeting shall be held at a location selected by the Owner. The recurrence schedule of this meeting shall be established at the Pre-Construction Conference. Contractor shall be responsible to provide a current Progress Schedule at each construction status meeting. 4.05 Delays in Contractor’s Progress A. If Owner, Engineer, or anyone for whom Owner is responsible, delays, disrupts, or interferes with the performance or progress of the Work and such delay, disruption or interference is indisputably proven by Contractor to adversely affect the critical path of the Progress Schedule, then Contractor shall be entitled to an equitable adjustment of the Contract Time. Contractor’s entitlement to an adjustment of the Contract Time is also conditioned on such adjustment being essential to Contractor’s ability to complete the Work within the Contract Time. B. Contractor shall not be entitled to an adjustment in Contract Time for delay, disruption, or interference caused by or within the control of Contractor. Delay, disruption, and interference attributable to and within the control of a Subcontractor or Supplier shall be deemed to be within the control of Contractor. C. If Contractor’s performance or progress is delayed, disrupted, or interfered with by unanticipated causes listed below not the fault of and beyond the control of Owner, Contractor, and those for which they are responsible and such delay, disruption or interference is indisputably proven by Contractor to adversely affect the critical path of the Progress Schedule, then Contractor shall be entitled to an equitable adjustment of the Contract Time. Contractor’s entitlement to an adjustment of the Contract Time is conditioned on such adjustment being essential to Contractor’s ability to complete the Work within the Contract Time. Such an adjustment shall be Contractor’s sole and exclusive remedy for the delays, disruption, and interference described in this paragraph. Causes of delay, disruption, or interference that may give rise to an adjustment in Contract Time under this paragraph include the following: 1. severe and unavoidable natural catastrophes such as fires, floods, epidemics, pandemics and earthquakes; 2. Unusual inclement weather; 3. acts or failures to act of utility owners (other than those performing other work at or adjacent to the Site by arrangement with the Owner, as contemplated in Article 8); BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 16 of 72 Section 00700 – General Conditions 4. acts of war or terrorism; or 5. acts of any governmental entity or courts having jurisdiction over the Project. D. Unusual Inclement Weather is defined as a rain event or other related event which occurs at the site in excess of Normal Rainfall during a particular calendar month and is of sufficient magnitude to prevent Contractor from performing units of Work critical to maintaining the Progress Schedule. “Normal Rainfall” compiled and published by the National Oceanic And Atmospheric Administration - National Centers for Environmental Information as a Summary of Monthly Normals for precipitation accumulated from 1991 to 2020 for the Austin Camp Mabry Station, TX, USW00013958, is considered a part of the calendar day contract, and is not a justification for an extension of time. Listed below are the number of days in each calendar month which constitute Normal Rainfall for such month and for which no compensatory days for rainfall events (“Rain Days”) in such months may be claimed: January 8 days February 8 days March 7 days April 7 days May 9 days June 6 days July 5 days August 5 days September 7 days October 7 days November 7 days December 7 days Rain Days in addition to the baseline rain day determination described above will be measured with the Owner’s or Owner’s Representative’s approval at the nearest operational public weather data collection facility to the Site. E. Delays, disruption, and interference to the performance or progress of the Work resulting from the existence of a differing subsurface or physical condition, an Underground Facility that was not shown or indicated by the Contract Documents, or not shown or indicated with reasonable accuracy, and those resulting from Hazardous Environmental Conditions, are governed by Article 5. F. Paragraph 8.03 governs delays, disruption, and interference to the performance or progress of the Work resulting from the performance of certain other work at or adjacent to the Site. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 17 of 72 Section 00700 – General Conditions G. Contractor shall not be entitled to an adjustment in Contract Price or Contract Time for any delay, disruption, or interference if such delay is concurrent with a delay, disruption, or interference caused by or within the control of Contractor. H. Contractor must submit any Change Proposal seeking an adjustment in Contract Time under this paragraph within 30 days of the commencement of the delaying, disrupting, or interfering event. I. Contractor expressly waives any right to an adjustment in Contract Price for any event of delay. Except as provided otherwise by applicable law, Contractor’s sole remedy for any delay shall be limited to an adjustment in Contract Time. ARTICLE 5 – AVAILABILITY OF LANDS; SUBSURFACE AND PHYSICAL CONDITIONS; HAZARDOUS ENVIRONMENTAL CONDITIONS 5.01 Availability of Lands A. Owner shall furnish the Site. Owner shall notify Contractor of any encumbrances or restrictions not of general application but specifically related to use of the Site with which Contractor must comply in performing the Work. B. Owner shall provide any easements for ingress and egress necessary for access to the Site. C. Contractor, at Contractor’s sole cost and expense, shall provide for any additional lands and access thereto that may be required for temporary construction facilities or storage of materials and equipment for which the Site and any Owner provided easements do not provide. 5.02 Use of Site and Other Areas A. Limitation on Use of Site and Other Areas: 1. Contractor shall confine construction equipment, temporary construction facilities, the storage of materials and equipment, and the operations of workers to the Site, adjacent areas that Owner or Contractor have arranged to use through construction easements or otherwise, and other adjacent areas permitted by Laws and Regulations, and shall not unreasonably encumber the Site and such other adjacent areas with construction equipment or other materials or equipment. Contractor shall assume full responsibility for (a) damage to the Site; (b) damage to any such other adjacent areas used for Contractor’s operations; (c) damage to any other adjacent land or areas; and (d) for injuries and losses sustained by the owners or occupants of any such land or areas; provided that such damage or injuries result from the performance of Contractor’s obligations under the Contract Documents or from other actions or conduct of the Contractor or those for which Contractor is responsible. 2. If a damage or injury claim is made by the owner or occupant of any land or area because of the performance of Contractor’s obligations under the Contract Documents, or because of other actions or conduct of the Contractor or those for which Contractor is responsible, Contractor shall (a) take immediate corrective or remedial action as required by Paragraph 7.12, or otherwise; (b) promptly attempt to settle the claim as to all parties through negotiations with such owner or occupant, or otherwise resolve the claim by arbitration or other dispute resolution proceeding, or at law; and (c) TO THE FULLEST EXTENT PERMITTED BY LAWS AND REGULATIONS, INDEMNIFY AND HOLD HARMLESS OWNER, ITS OFFICERS, DIRECTORS, MEMBERS, PARTNERS, EMPLOYEES, BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 18 of 72 Section 00700 – General Conditions AGENTS, AND CONSULTANTS FROM AND AGAINST ANY SUCH CLAIM, AND AGAINST ALL COSTS, LOSSES, AND DAMAGES (INCLUDING BUT NOT LIMITED TO ALL FEES AND CHARGES OF ENGINEERS, ARCHITECTS, ATTORNEYS, AND OTHER PROFESSIONALS AND ALL COURT OR ARBITRATION OR OTHER DISPUTE RESOLUTION COSTS) ARISING OUT OF OR RELATING TO ANY CLAIM OR ACTION, LEGAL OR EQUITABLE, BROUGHT BY ANY SUCH OWNER OR OCCUPANT AGAINST OWNER OR ANY OTHER PARTY INDEMNIFIED HEREUNDER TO THE EXTENT CAUSED DIRECTLY OR INDIRECTLY, IN WHOLE OR IN PART BY, OR BASED UPON, CONTRACTOR’S PERFORMANCE OF CONTRACTOR’S OBLIGATIONS UNDER THE CONTRACT DOCUMENTS, OR BECAUSE OF OTHER ACTIONS OR CONDUCT OF THE CONTRACTOR OR THOSE FOR WHICH CONTRACTOR IS RESPONSIBLE. B. Removal of Debris During Performance of the Work: During the progress of the Work the Contractor shall keep the Site and other adjacent areas free from accumulations of waste materials, rubbish, and other debris. Removal and disposal of such waste materials, rubbish, and other debris shall also conform to applicable Laws and Regulations. C. Cleaning: Prior to Substantial Completion of the Work, Contractor shall clean the Site and the Work and make it ready for utilization by Owner. At the completion of the Work, Contractor shall remove from the Site and adjacent areas all tools, appliances, construction equipment and machinery, and surplus materials and shall restore to original condition all property not designated for alteration by the Contract Documents. D. Loading of Structures: Contractor shall not load nor permit any part of any structure to be loaded in any manner that will endanger the structure, nor shall Contractor subject any part of the Work or adjacent structures or land to stresses or pressures that will endanger them. 5.03 Subsurface and Physical Conditions A. Contractor accepts the responsibility to satisfy itself as to the soil conditions and nature and type of geological formations in and through which this Project will be constructed. Such information as may be obtained from the test borings and accompanying notations shown on the plans is merely for the guidance of the Contractor and is not to be construed in any manner as a guarantee by the Owner that such conditions of sub-surface strata are infallible. B. Contractor waives any and all rights to make a claim against Owner relating to representations related to geotechnical data provided in the Contract Documents. If a Geotechnical Report (“Geotechnical Report”) is provided by the Owner, the locations of the test holes, if applicable, are shown in the Geotechnical Report. Logs of these test holes are included in the Geotechnical Report. Test holes information represents subsurface characteristics to the extent indicated and only for the point location of the test hole. Contractor shall make its own interpretation of the character and condition of the materials, which will be encountered. Contractor may, at its own expense, make additional surveys and investigations as it may deem necessary to determine conditions, which will affect performance of the Work. C. Reports and Drawings: Owner will identify to the Contractor: 1. any reports known to Owner of explorations and tests of subsurface conditions at or adjacent to the Site; and 2. any drawings known to Owner of physical conditions relating to existing surface or subsurface structures at the Site (except Underground Facilities). BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 19 of 72 Section 00700 – General Conditions D. Reliance by Contractor on Technical Data Authorized: Contractor may rely upon the general accuracy of the Technical Data contained in such reports and drawings, but such reports and drawings are not Contract Documents. Except for such reliance on Technical Data, Contractor may not rely upon or make any claim against Owner with respect to: 1. the completeness of such reports and drawings for Contractor’s purposes, including, but not limited to, any aspects of the means, methods, techniques, sequences, and procedures of construction to be employed by Contractor, and safety precautions and programs incident thereto; or 2. other data, interpretations, opinions, and information contained in such reports or shown or indicated in such drawings; or 3. any Contractor interpretation of or conclusion drawn from any Technical Data or any such other data, interpretations, opinions, or information. E. Where excavation or demolition endangers adjacent structures and utilities, the Contractor shall at its own expense carefully support and protect all such structures and/or utilities so that there will be no failure or settlement. Where it is necessary to move services, poles, guy wires, pipelines, or other obstructions, the Contractor shall notify and cooperate with the utility owner. In cases where damage to an existing structure or utility occurs, the Contractor shall restore the structure or utility to its original condition and position without compensation from the Owner. Contractor shall repair or replace all damage to street surfaces, driveways, sidewalks, curb and gutter, fences, drainage structures, or other structures, to the satisfaction of the Owner, the Engineer and the respective utility Owner or authority. Structures shall be restored to a condition equal to or better than the original condition and of a similar material and design. The costs of such repair or replacement shall be borne by the Contractor and shall be included in the Proposal. Contractor shall maintain access to all driveways at all times. Contractor shall notify residents 48 hours prior to construction adjacent to their property. The Engineer has shown the approximate location of existing piping (proposed and existing), valves, electrical conduits, fiber optic, telephone, utility poles, et al., as best as can be determined from available records. The Contractor shall verify the type, size, and location of all existing utilities in the construction area. All piping, valves, electrical conduit, etc. in the construction area shall be relocated and/or removed as necessary in a manner acceptable to the Engineer, and no additional compensation will be considered for relocating any of these items whether shown on the plans or not. F. All private property along and adjacent to the Contractor’s operation, including but not limited to lawns, yards, shrubs, trees, structures, trails, paths, livestock, fences, and mailboxes shall be adequately protected, and when damaged or removed, at Contractor’s sole cost and expense shall be repaired, replaced, renewed, or otherwise put in a condition equal to or better than that which existed before the Contractor caused the damage or removal. Contractor shall make provisions for continued mail delivery during construction. All mailboxes and fences affected by construction shall be repaired or replaced immediately. Where livestock are present, Contractor shall take all necessary precautions to assure that no construction or construction related activity will allow livestock to leave their confine. Where existing fences are being crossed, Contractor shall maintain the integrity of the fence during construction through placement of guards, temporary fences, or other adequate measures as approved by the Engineer. All construction activities, including ingress and egress shall occur within the boundaries and contract constraints of the temporary and permanent construction easements. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 20 of 72 Section 00700 – General Conditions 5.04 Differing Subsurface or Physical Conditions A. Notice by Contractor: If Contractor believes that any subsurface or physical condition that is uncovered or revealed at the Site and was not reasonably discoverable at the time Contractor submitted its bid, either: 1. is of such a nature as to establish that any Technical Data on which Contractor is entitled to rely as provided in Paragraph 5.03 is materially inaccurate; or 2. is of such a nature as to require a material change in the Drawings or Specifications; or 3. differs materially from that shown or indicated in the Contract Documents; or 4. is of an unusual nature, and differs materially from conditions ordinarily encountered and generally recognized as inherent in work of the character provided for in the Contract Documents; then Contractor, after becoming aware thereof and before further disturbing the subsurface or physical conditions or performing any Work in connection therewith (except in an emergency as required by Paragraph 7.15), shall notify Owner and Engineer in writing about such condition within three (3) business days after Contractor becomes aware of such condition. Contractor shall not further disturb such condition or perform any Work in connection therewith (except with respect to an emergency) until receipt of a written statement from Owner permitting Contractor to do so. B. Engineer’s Review: After receipt of written notice as required by the preceding paragraph, Engineer will promptly review the subsurface or physical condition in question; determine the necessity of obtaining additional exploration or testing with respect to the condition encountered, conclude whether the condition falls within any one or more of the differing site condition categories in Paragraph 5.04.A above; obtain any pertinent price and schedule information from Contractor; prepare recommendations to Owner regarding the Contractor’s resumption of Work in connection with the subsurface or physical condition in question and the need for any change in the Drawings or Specifications; and advise Owner in writing of Engineer’s findings, conclusions, and recommendations. C. Owner’s Statement to Contractor Regarding Site Condition: After receipt of Engineer’s written findings, conclusions, and recommendations, Owner shall issue a written statement to Contractor (with a copy to Engineer) regarding the subsurface or physical condition in question, addressing the resumption of Work in connection with such condition, indicating whether any change in the Drawings or Specifications will be made, and adopting or rejecting Engineer’s written findings, conclusions, and recommendations, in whole or in part. D. Possible Contract Price and Contract Time Adjustments: 1. Contractor may be entitled to an equitable adjustment in the Contract Time or Contract Price, or both, to the extent that the existence of a differing subsurface or physical condition, or any related delay, disruption, or interference, causes an increase or decrease in Contractor’s time required for performance of the Work; subject, however, to the following: a. such condition must fall within any one or more of the categories described in Paragraph 5.04.A; b. the materially different condition encountered must be the direct and proximate cause of Contractor’s increased cost of or time for performing the Work; BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 21 of 72 Section 00700 – General Conditions c. Contractor’s entitlement to an adjustment of the Contract Time is conditioned on such adjustment being essential to Contractor’s ability to complete the Work within the Contract Time and adversely impacts the critical path as shown in the Progress Schedule. d. Contractor provides such documentation, testing or other evidence to support the applicability of subparagraphs a. through c. above to Owner’s and Engineer’s reasonable satisfaction. 2. Contractor shall not be entitled to any adjustment in the Contract Time or Contract Price with respect to a subsurface or physical condition if: a. Contractor knew or reasonably should have known of the existence of such condition at the time Contractor submitted its Bid or entered into the Agreement with Owner for the Project; or b. the existence of such condition reasonably could have been discovered or revealed as a result of any examination, investigation, exploration, test, or study of the Site and contiguous areas expressly required by the Bidding Requirements or Contract Documents to be conducted by or for Contractor prior to Contractor’s making such commitment; or c. Contractor failed to timely give the written notice as required by Paragraph 5.04.A. Contractor agrees that the failure to give such notice within the time described in Paragraph 5.04.A shall constitute a waiver and release of any claim that Contractor may have for an adjustment in the Contract Price or Contract Time. 3. If Owner and Contractor agree regarding Contractor’s entitlement to and the amount or extent of any adjustment in the Contract Price or Contract Time, or both, then any such adjustment shall be set forth in a Change Order. 4. Provided all of the conditions described above are satisfied and if Owner and Contractor cannot come to an agreement regarding an appropriate adjustment to the Contract Price or Contract Time, Contractor may submit a Change Proposal regarding its entitlement to or the amount or extent of any adjustment in the Contract Time and Contract Price, no later than 30 days after Owner’s issuance of the Owner’s written statement to Contractor regarding the subsurface or physical condition in question. 5. Adjustments to Contract Price or Contract Time, or both, are the sole and exclusive remedies of the Contractor for differing site condition claims, and the Contractor shall not be entitled to, and hereby waives, any claims for lost profits, extended home office overhead, and all other consequential damages and/or expenses. 6. If the Contractor’s actions disturb the site such that the Owner or Engineer cannot adequately and fully investigate the alleged differing site condition, the Contractor waives its right to receive any adjustments to Contract Price or Contract Time as a result of the differing site condition. 7. Contractor shall be responsible for any and all costs and damages incurred by the Owner resulting from the Contractor’s failure to provide appropriate and timely written notice as required by Paragraph 5.04.A. 8. No request by the Contractor for an adjustment to Contract Price for differing site conditions shall be allowed if made after final payment under the Agreement. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 22 of 72 Section 00700 – General Conditions 5.05 Underground Facilities A. Contractor’s Responsibilities: The information and data shown or indicated in the Contract Documents with respect to existing Underground Facilities at or adjacent to the Site is based on information and data furnished to Owner or Engineer by the owners of such Underground Facilities, including Owner, or by others. Unless it is otherwise expressly provided in the Contract Documents: 1. Owner and Engineer do not warrant or guarantee the accuracy or completeness of any such information or data provided by others; and 2. the cost of all of the following will be included in the Contract Price, and Contractor shall have full responsibility for: a. reviewing and checking all information and data regarding existing Underground Facilities at the Site; b. locating all Underground Facilities shown or indicated in the Contract Documents as being at the Site; c. coordination of the Work with the owners (including Owner) of such Underground Facilities, during construction; and d. the safety and protection of all existing Underground Facilities at the Site, and repairing any damage thereto resulting from the Work. B. Notice by Contractor: If Contractor believes that an Underground Facility that is uncovered or revealed at the Site was not shown or indicated in the Contract Documents, or was not shown or indicated with reasonable accuracy, then Contractor, promptly after becoming aware thereof and before further disturbing conditions affected thereby or performing any Work in connection therewith (except in an emergency as required by Paragraph 7.15), shall identify the owner of such Underground Facility and, within three (3) business days after Contractor becomes aware of such condition, give written notice to that owner and to Owner and Engineer. C. Engineer’s Review: Engineer will promptly review the Underground Facility and conclude whether such Underground Facility was not shown or indicated in the Contract Documents, or was not shown or indicated with reasonable accuracy; obtain any pertinent price and schedule information from Contractor; prepare recommendations to Owner regarding the Contractor’s resumption of Work in connection with the Underground Facility in question; determine the extent, if any, to which a change is required in the Drawings or Specifications to reflect and document the consequences of the existence or location of the Underground Facility; and advise Owner in writing of Engineer’s findings, conclusions, and recommendations. During such time, Contractor shall be responsible for the safety and protection of such Underground Facility. D. Owner’s Statement to Contractor Regarding Underground Facility: After receipt of Engineer’s written findings, conclusions, and recommendations, Owner shall issue a written statement to Contractor (with a copy to Engineer) regarding the Underground Facility in question, addressing the resumption of Work in connection with such Underground Facility, indicating whether any change in the Drawings or Specifications will be made, and adopting or rejecting Engineer’s written findings, conclusions, and recommendations in whole or in part. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 23 of 72 Section 00700 – General Conditions E. Possible Contract Price and Time Adjustments: 1. Contractor may be entitled to an equitable adjustment in the Contract Time or Contract Price, or both, to the extent that any existing Underground Facility at the Site that was not shown or indicated in the Contract Documents, or was not shown or indicated with reasonable accuracy, or any related delay, disruption, or interference, causes an increase or decrease in Contractor’s time required for performance of the Work; subject, however, to the following: a. Contractor did not know of and could not reasonably have been expected to be aware of or to have anticipated the existence or actual location of the Underground Facility in question; b. Contractor’s entitlement to an adjustment of the Contract Time is conditioned on such adjustment being essential to Contractor’s ability to complete the Work within the Contract Times; and c. Contractor timely gave the notice required in Paragraph 5.05.B. 2. If Owner and Contractor agree regarding Contractor’s entitlement to and the amount or extent of any adjustment in the Contract Time or Contract Price, or both, then any such adjustment shall be set forth in a Change Order. 3. If Owner and Contractor cannot agree on Contractor’s entitlement to or the amount or extent of any adjustment in the Contract Time or Contract Price, or both, Contractor may submit a Change Proposal regarding its entitlement to or the amount or extent of any adjustment in the Contract Time no later than 30 days after Owner’s issuance of the Owner’s written statement to Contractor regarding the Underground Facility in question. 5.06 Hazardous Environmental Conditions at Site A. Contractor shall not be responsible for removing or remediating any Hazardous Environmental Condition encountered, uncovered, or revealed at the Site unless such removal or remediation is expressly identified in the Contract Documents to be within the scope of the Work. B. Contractor shall be responsible for controlling, containing, and duly removing all Constituents of Concern brought to the Site by Contractor, Subcontractors, Suppliers, or anyone else for whom Contractor is responsible, and for any associated costs; and for the costs of removing and remediating any Hazardous Environmental Condition created by the presence of any such Constituents of Concern. C. If Contractor encounters, uncovers, or reveals a Hazardous Environmental Condition whose removal or remediation is not expressly identified in the Contract Documents as being within the scope of the Work, or if Contractor or anyone for whom Contractor is responsible creates a Hazardous Environmental Condition, then Contractor shall immediately: (1) secure or otherwise isolate such condition; (2) stop all Work in connection with such condition and in any area affected thereby (except in an emergency as required by Paragraph 7.15); and (3) notify Owner and Engineer in writing within twenty-four (24) hours of the discovery of such condition. Owner shall promptly consult with Engineer concerning the necessity for Owner to retain a qualified expert to evaluate such condition or take corrective action, if any. Promptly after consulting with Engineer, Owner shall take such actions as are necessary to permit Owner to timely obtain required permits and provide Contractor the written notice BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 24 of 72 Section 00700 – General Conditions required by Paragraph 5.06.F. If Contractor or anyone for whom Contractor is responsible created the Hazardous Environmental Condition in question, then Owner may remove and remediate the Hazardous Environmental Condition and deduct all costs incurred from the Contract balance or if the Contract balance is insufficient to cover the costs incurred, Owner may file a claim for such costs. D. Contractor shall not resume Work in connection with such Hazardous Environmental Condition or in any affected area until after Owner has obtained any required permits related thereto, and delivered written notice to Contractor either (1) specifying that such condition and any affected area is or has been rendered safe for the resumption of Work, or (2) specifying any special conditions under which such Work may be resumed safely. E. If Owner and Contractor cannot agree as to entitlement to or on the amount or extent, if any, of any adjustment in Contract Price or Contract Time, or both, as a result of such Work stoppage or such special conditions under which Work is agreed to be resumed by Contractor, then within 30 days of Owner’s written notice regarding the resumption of Work, Contractor may submit a Change Proposal, or Owner may impose a set-off. F. If after receipt of such written notice, Contractor does not agree to resume such Work based on a reasonable belief it is unsafe, or does not agree to resume such Work under such special conditions, then Owner may order the portion of the Work that is in the area affected by such condition to be deleted from the Work, following the contractual change procedures in Article 11. Owner may have such deleted portion of the Work performed by Owner’s own forces or others in accordance with Article 8. G. TO THE FULLEST EXTENT PERMITTED BY LAWS AND REGULATIONS, CONTRACTOR SHALL INDEMNIFY AND HOLD HARMLESS OWNER AND ITS OFFICERS, DIRECTORS, MEMBERS, PARTNERS, EMPLOYEES, AGENTS, AND CONSULTANTS FROM AND AGAINST ALL CLAIMS, COSTS, LOSSES, AND DAMAGES (INCLUDING BUT NOT LIMITED TO ALL FEES AND CHARGES OF ENGINEERS, ARCHITECTS, ATTORNEYS, AND OTHER PROFESSIONALS AND ALL COURT OR ARBITRATION OR OTHER DISPUTE RESOLUTION COSTS) ARISING OUT OF OR RELATING TO THE FAILURE TO CONTROL, CONTAIN, OR REMOVE A CONSTITUENT OF CONCERN BROUGHT TO THE SITE BY CONTRACTOR OR BY ANYONE FOR WHOM CONTRACTOR IS RESPONSIBLE, OR TO A HAZARDOUS ENVIRONMENTAL CONDITION CREATED BY CONTRACTOR OR BY ANYONE FOR WHOM CONTRACTOR IS RESPONSIBLE. H. The provisions of Paragraphs 5.03, 5.04, and 5.05 do not apply to the presence of Constituents of Concern or to a Hazardous Environmental Condition uncovered or revealed at the Site. I. Materials utilized in the construction of the Project shall be free of any hazardous materials, except as may be specifically provided for in the Contract Documents. 5.07 Endangered Species A. No activity is authorized that is likely to jeopardize the continued existence of a threatened or endangered species as listed or proposed for listing under the Federal Endangered Species Act (ESA), and/or the State of Texas Parks and Wildlife Code on Endangered Species, or to destroy or adversely modify the habitat of such species. B. If a threatened or endangered species is encountered during construction, the Contractor shall immediately cease work in the area of the encounter and notify the Owner who will immediately implement actions in accordance with applicable statutes. These actions shall include reporting the encounter to the Texas Water Development Board (“TWDB”), the U.S. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 25 of 72 Section 00700 – General Conditions Fish and Wildlife Service, and the Texas Parks and Wildlife Department, obtaining any necessary approvals or permits to enable the work to continue, or implement other mitigation actions. The Contractor shall not resume construction in the area of the encounter until authorized to do so by the Owner. C. Possible Contract Time Adjustment: 1. The Contractor will not be entitled to any adjustment in Contract Time due to impacts caused by the presence of endangered species if the impact is caused by the Contractor's Work, negligence or willful conduct. Contractor may be entitled to an equitable adjustment in the Contract Time to the extent that any present endangered species at the Site causes an increase or decrease in Contractor’s time required for performance of the Work; subject, however, to the following: a. Contractor did not know of and could not reasonably have been expected to be aware of or to have anticipated the presence of endangered species; b. Contractor’s entitlement to an adjustment of the Contract Time is conditioned on such adjustment being essential to Contractor’s ability to complete the Work within the Contract Times; and c. Contractor gives written notice to the Owner and Engineer as required by Paragraph 5.07.B. 2. If Owner and Contractor agree regarding Contractor’s entitlement to and the amount or extent of any adjustment in the Contract Time, then any such adjustment shall be set forth in a Change Order. 5.08 Archaeological Discoveries and Cultural Resources A. No activity which may affect properties listed or eligible for designation as a State Archeological Landmark is authorized until the Owner has complied with the provisions of the National Historic Preservation Act and the Antiquities Code of Texas. The Owner has previously coordinated with the appropriate agencies, and impacts to known cultural or archeological deposits have been avoided or mitigated. However, the Contractor may encounter unanticipated cultural or archeological deposits during construction. B. If archeological sites or historic structures which may qualify for designation as a State Archeological Landmark according to the criteria in 13 TAC Chapter 26, or that may be eligible for listing on the National Register of Historic Places in accordance with 36 CFR Part 800, are discovered after construction operations are begun, the Contractor shall immediately cease operations in that particular area and notify the Owner, the TWDB, and the Texas Historical Commission, 1511 N. Colorado St. , P. O. Box 12276, Capitol Station, Austin, Texas 78711- 2276. The Contractor shall take reasonable steps to protect TWDB-0552 Page 16 of 19 Rev 02/17 and preserve the discoveries until they have been inspected by the Owner's representative and the TWDB. The Owner will promptly coordinate with the State Historic Preservation Officer and any other appropriate agencies to obtain any necessary approvals or permits to enable the work to continue. The Contractor shall not resume work in the area of the discovery until authorized to do so by the Owner. 5.09 Control of Water A. Should the work to be performed require the draining, pumping, dewatering or routing of water for construction, testing, cleaning, or restoration purposes, it shall be the obligation of the Contractor to perform same, while maintaining any additional erosion control or BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 26 of 72 Section 00700 – General Conditions filtration systems as may be required by the Owner, City of Cedar Park, Travis County, Williamson County, Texas Department of Transportation, Texas Commission on Environmental Quality, Lower Colorado River Authority, or Engineer to assure clean water control, at no extra compensation. Dewatering a contractor cost and is subsidiary to bid items for excavation and/or pipe installation. 5.10 Site Preservation A. The Contractor shall exercise care to preserve the natural landscape within the Site and shall conduct his construction operations so as to prevent any unnecessary destruction, scarification, or defacing of the natural surroundings in the vicinity of the work. Except where clearing is required for permanent construction, trees and vegetation shall be preserved and protected from damages which may be caused by equipment and construction operations. Where unnecessary destruction or damage to trees occurs as a result of the Contractor’s operations, replacement or corrections shall be made at the Contractor’s expense as directed by the Engineer. Prevention of noise pollution shall be a responsibility of the Contractor. Garbage, trash, and material debris shall be picked up daily and deposited in a suitable receptacle provided and maintained by the Contractor. Measures shall also be implemented to prevent the escape of mud and concrete. ARTICLE 6 – BONDS AND INSURANCE 6.01 Performance, Payment, and Other Bonds A. Contractor shall furnish a performance bond and a payment bond in accordance with chapter 2253 of the Texas Government Code. The performance bond shall extend for one (1) year from the date of Final Completion. In addition to and not in lieu of the performance bond, Contractor shall furnish a Maintenance Bond in the amount of ten percent of the final construction cost throughout the Correction period (2 years from the date of Final Completion) to maintain, correct any deficiencies, and keep in good repair the Work. Contractor shall also furnish such other bonds, if any, as are required by other specific provisions of the Contract Documents. B. A bond signed by an agent or attorney-in-fact must be accompanied by a certified copy of that individual’s authority to bind the surety. The evidence of authority shall show that it is effective on the date the agent or attorney-in-fact signed the accompanying bond. C. Contractor shall obtain the required bonds in a form acceptable to Owner. The surety on the bonds must be duly licensed or authorized in the jurisdiction in which the Project is located to issue bonds in the required amounts and be acceptable to the Owner. D. If the surety on a bond furnished by Contractor is declared bankrupt or becomes insolvent, or its right to do business is terminated in Texas, or the surety ceases to meet the requirements above, then Contractor shall promptly notify Owner and Engineer and shall, within 20 days after the event giving rise to such notification, provide bonds from another surety, all of which shall comply with the requirements above. E. If Contractor has failed to obtain a required bond, Owner may exclude the Contractor from the Site and exercise Owner’s suspension and/or termination rights under Article 16. F. The performance bond shall include, without limitation, guarantees that work done under the Contract Documents will be completed and performed according to the Contract Documents and in accordance with sound construction principles and practices applicable to the performance of the Work; BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 27 of 72 Section 00700 – General Conditions G. The performance and payment bonds shall be in a penal sum of not less than 100 percent of the Contract Price and remain in effect as required by applicable laws and the requirements set forth above. H. The Contractor shall utilize a surety company that is authorized to do business in Texas in accordance with Surety Bonds and Related Instruments, Chapter 3503 of the Insurance Code. 6.02 Insurance—General Provisions A. Owner is self-insured as a Local Government Corporation formed under the laws of the State of Texas. B. Contractor shall provide all insurance required by Exhibit A to these General Conditions (“Owner’s Insurance Requirements”). 6.03 Workers’ Compensation Insurance Coverage A. The Contractor shall certify in writing that it provides workers' compensation insurance coverage for each employee of the Contractor employed on the Project. B. Each Subcontractor on the Project shall provide such a certificate relating to coverage of the Subcontractor's employees to the general Contractor, who shall provide the Subcontractor's certificate to the Owner. C. A Contractor who has a contract that requires workers' compensation insurance coverage may provide the coverage through a group plan or other method satisfactory to the Owner. D. The employment of a maintenance employee by an employer who is not engaging in building or construction as the employer's primary business does not constitute engaging in building or construction. E. In this section: 1. “Building or construction” includes: a. erecting or preparing to erect a structure, including a building, bridge, roadway, public utility facility, or related appurtenance; b. remodeling, extending, repairing, or demolishing a structure; or iii. otherwise improving real property or an appurtenance to real property through similar activities. 2. “Governmental entity” means this state or a political subdivision of this state. The term includes a municipality and the Owner. ARTICLE 7 – CONTRACTOR’S RESPONSIBILITIES 7.01 Supervision and Superintendence A. Contractor shall supervise, inspect, and direct the Work competently and efficiently, devoting such attention thereto and applying such skills and expertise as may be necessary to perform the Work in accordance with the Contract Documents. Contractor shall be solely responsible for the means, methods, techniques, sequences, and procedures of construction. B. At all times during the progress of the Work, Contractor shall assign a competent resident superintendent who shall not be replaced without written consent of Owner. Such consent shall not be unreasonably withheld. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 28 of 72 Section 00700 – General Conditions C. The Contractor will be responsible for the execution of a satisfactory and complete piece of work, in accordance with the Contract Documents. Contractor shall provide, without extra charge, all incidental items required as a part of its work even though not particularly specified or indicated. Should the Contractor object to methods or materials specified, Contractor shall notify Owner in writing and have same adjusted before proceeding with the Work. Proceeding without notice shall be construed as a waiver of any Contractor objections. D. Contractor shall verify all measurements and be responsible for the same and shall report to Owner and Engineer any errors, discrepancies or inconsistencies in the Contract Documents, and shall await instructions before proceeding with the Work. Prior to submitting its proposal, Contractor shall examine the premises and the limitations under which the Work will have to be executed, as well as any subsurface conditions. Contractor shall be deemed to have accepted and anticipated any condition that was or should have been discovered by such examination and hereby waives and releases any claim related thereto, including but not limited to a claim for an adjustment of the Contract Time or Contract Price. 7.02 Labor; Working Hours A. Contractor shall provide competent, suitably qualified personnel to survey and lay out the Work and perform construction as required by the Contract Documents. Contractor shall at all times maintain good discipline and order at the Site. B. Except as otherwise required for the safety or protection of persons or the Work or property at the Site or adjacent thereto, and except as otherwise stated in the Contract Documents, all Work at the Site shall be performed during regular working hours, Monday through Friday. Contractor may perform Work outside regular working hours or on Saturdays, Sundays, or legal holidays only with Owner’s written consent, which may be withheld at Owner’s discretion for any reason. 1. Regular working hours are defined as Monday through Friday between the hours of 7:00 A.M. and 6:00 P.M. However, construction activities within five hundred feet (500’) of a dwelling or dwelling unit that is occupied as a residence shall only be performed between the hours of 8:00 A.M. and 6:00 P.M. Requests to work other than regular working hours shall be submitted to the Owner, Owners Representative, and Engineer not less than 48 hours prior to any proposed work outside of regular working hours. 2. Contractor shall reimburse the Owner for additional engineering and/or inspection costs incurred as a result of overtime work at times other than during regular working hours stipulated in 7.02.B.1 above and for evaluating alternative material, equipment, etc. proposed by the Contractor. At Owner’s option, overtime and evaluation costs may either be invoiced directly, deducted from the Contractor’s monthly payment request, or deducted from the Contractor’s retention prior to release of Final Payment. Overtime and evaluation costs for the Owner’s personnel shall be based on the individual’s current overtime wage rate. Overtime and evaluation costs for personnel employed by the Engineer or other Owner’s representatives shall be calculated in accordance with the terms of their respective contracts with the Owner. C. Contractor shall provide and pay for labor in accordance with the prevailing wage in the locality and shall not pay less than the prevailing wage. 7.03 Services, Materials, and Equipment A. Unless otherwise specified in the Contract Documents, Contractor shall provide and assume full responsibility for all services, materials, equipment, labor, transportation, construction BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 29 of 72 Section 00700 – General Conditions equipment and machinery, tools, appliances, fuel, power, light, heat, telephone, water, sanitary facilities, temporary facilities, and all other facilities and incidentals necessary for the performance, testing, start up, and completion of the Work, whether or not such items are specifically called for in the Contract Documents. B. All materials and equipment incorporated into the Work shall be of good quality and new, except as otherwise provided in the Contract Documents. All special warranties and guarantees required by the Contract Documents shall expressly run to the benefit of Owner. If required by Owner, Contractor shall furnish satisfactory evidence (including reports of required tests) as to the source, kind, and quality of materials and equipment. The Contractor warrants to the Owner that materials and equipment used will not be defective or damaged. The Contractor shall examine all materials furnished at the time and place of delivery and shall reject all defective or damaged material. Any defective material not rejected by the Contractor and discovered prior to Final Acceptance of the work shall be replaced with non-defective material by the Contractor, and the Contractor shall furnish such additional material and supplies as may be necessary to install such replaced material. The Contractor shall remove defective materials and install the replaced material at the Contractor’s own expense, furnishing all labor and facilities necessary to meet requirements of the Contract Documents or modifications made during construction. Inspection before installation shall not relieve the Contractor from the responsibility to furnish good quality materials in place required by the provisions of these General Conditions and the other Contract Documents. The Owner will not accept delivery of materials for the Contractor; therefore, the Contractor shall be fully responsible for making its own arrangements with suppliers and shipping agencies for delivery to the proper locations. In addition, the Contractor shall be responsible for acceptance of delivery of materials and supplies by its own personnel. C. All materials and equipment shall be stored, applied, installed, connected, erected, protected, used, cleaned, and conditioned in accordance with instructions of the applicable supplier, except as otherwise may be provided in the Contract Documents. D. Excess earth shall be removed at the Contractor’s expense. Contractor shall obtain approval of the Owner if the disposal site is located inside the Owner’s jurisdictional boundaries. Material deemed unacceptable for backfill must be disposed of in accordance with all applicable local, county, state, and federal laws, rules and regulations at the Contractor’s expense. E. Contractor will pay for construction staking of all improvements under the Contract Documents. Cut sheets and/or copy of field notes shall be issued to the Engineer. The Engineer will have the authority to stop all Work and withhold approval of payment to the Contractor at any time construction stakes have been destroyed and adequate control is not in existence on the site. The decision of the Engineer and Owner is final. Halting of Work due to violation of this term shall not be considered as cause for extension of the Contract Time or an adjustment of the Contract Price. Acknowledging that property pins are used for construction staking, the Contractor shall direct his work forces to use reasonable care in protecting existing property pins. Prior to commencing excavation operations, the Contractor shall meet with the Engineer and advise the Engineer of which property pins may be disturbed. The Contractor, in its inspection of the Site prior to construction, shall satisfy itself that all property pins are in place and the pin locations are marked so as to be easily located and identified. It is further understood that all property pins destroyed during BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 30 of 72 Section 00700 – General Conditions construction will be replaced by a registered professional land surveyor at the Contractor’s expense so as to easily be located and identified, before final payment is made. F. The Contractor shall remove from the Site, including the staging and access areas, all rejected and condemned materials or work of any kind brought to or incorporated in the Project. Should the Contractor fail to do so, or to make satisfactory progress in so doing, within forty- eight (48) hours after the date a written notice from the Engineer or Owner ordering such removal, the condemned material or Work may be removed from the Project by the Owner and the cost of such removal shall be paid to Owner by Contractor or Owner may deduct such costs from the Contract Price that may be due or may become due to the Contractor under the provisions of the Contract Documents. No such rejected or condemned material shall again be offered for use by the Contractor on the Project. 7.04 “Or Equals” A. Whenever an item of material or equipment is specified or described in the Contract Documents by using the name of a proprietary item or the name of a particular Supplier, the Contract Price has been based upon Contractor furnishing such item as specified. The specification or description of such an item is intended to establish the type, function, appearance, and quality required. Unless the specification or description contains or is followed by words reading that no like, equivalent, or “or equal” item is permitted, Contractor may request that Engineer authorize the use of other items of material or equipment, or items from other proposed suppliers under the circumstances described below. 1. If Engineer, in its sole discretion, determines that an item of material or equipment proposed by Contractor is functionally equal to that named and sufficiently similar so that no change in related Work will be required, Engineer may deem it an “or equal” item. For the purposes of this paragraph, a proposed item of material or equipment will be considered functionally equal to an item so named if: a. in the exercise of reasonable judgment Engineer determines that: 1) it is at least equal in materials of construction, quality, durability, appearance, strength, and design characteristics; 2) it will reliably perform at least equally well the function and achieve the results imposed by the design concept of the completed Project as a functioning whole; 3) it has a proven record of performance and availability of responsive service; and 4) it is not objectionable to Owner. b. Contractor certifies that, if approved and incorporated into the Work: 1) there will be no increase in cost to the Owner or increase in Contract Time; and 2) it will conform substantially to the detailed requirements of the item named in the Contract Documents. B. Contractor’s Expense: Contractor shall provide all data in support of any proposed “or equal” item at Contractor’s sole expense. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 31 of 72 Section 00700 – General Conditions C. Engineer’s Evaluation and Determination: Engineer will be allowed a reasonable time to evaluate each “or-equal” request. Engineer will be the sole judge of acceptability. No “or- equal” item will be ordered, furnished, installed, or utilized until Engineer’s review is complete and Engineer determines that the proposed item is an “or-equal”, which will be evidenced by an approved Shop Drawing or other written communication. Engineer will advise Contractor in writing of any negative determination. Use of an unapproved “or-equal” item will render such Work defective and will be subject to Article 14 provisions. D. Effect of Engineer’s Determination: Neither approval nor denial of an “or-equal” request shall result in any change in Contract Price. The Engineer’s denial of an “or-equal” request shall be final and binding, and may not be reversed through an appeal under any provision of the Contract Documents. E. Treatment as a Substitution Request: If Engineer determines that an item of material or equipment proposed by Contractor does not qualify as an “or-equal” item, Contractor may request that Engineer considered the proposed item as a substitute pursuant to Paragraph 7.05. 7.05 Substitutes A. Unless the specification or description of an item of material or equipment required to be furnished under the Contract Documents contains or is followed by words reading that no substitution is permitted, Contractor may request that Engineer authorize the use of other items of material or equipment under the circumstances described below. To the extent possible such requests shall be made before commencement of related construction at the Site. 1. Contractor shall submit sufficient information as provided below to allow Engineer to determine if the item of material or equipment proposed is functionally equivalent to that named and an acceptable substitute therefor. Engineer will not accept requests for review of proposed substitute items of material or equipment from anyone other than Contractor. 2. The requirements for review by Engineer will be as set forth in Paragraph 7.05.B, as supplemented by the Specifications, and as Engineer may decide is appropriate under the circumstances. 3. Contractor shall make written application to Engineer for review of a proposed substitute item of material or equipment that Contractor seeks to furnish or use. The application: a. shall certify that the proposed substitute item will: 1) perform adequately the functions and achieve the results called for by the general design, 2) be similar in substance to that specified, and 3) be suited to the same use as that specified. b. will state: 1) the extent, if any, to which the use of the proposed substitute item will necessitate a change in Contract Time, 2) whether use of the proposed substitute item in the Work will require a change in any of the Contract Documents (or in the provisions of any other direct BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 32 of 72 Section 00700 – General Conditions contract with Owner for other work on the Project) to adapt the design to the proposed substitute item, and 3) whether incorporation or use of the proposed substitute item in connection with the Work is subject to payment of any license fee or royalty. c. will identify: 1) all variations of the proposed substitute item from that specified, and 2) available engineering, sales, maintenance, repair, and replacement services. d. shall contain an itemized estimate of all costs or credits that will result directly or indirectly from use of such substitute item, including but not limited to changes in Contract Price, shared savings, costs of redesign, and claims of other contractors affected by any resulting change. B. Engineer’s Evaluation and Determination: Engineer will be allowed a reasonable time to evaluate each substitute request, and to obtain comments and direction from Owner. Engineer will be the sole judge of acceptability. No substitute will be ordered, furnished, installed, or utilized until Engineer’s review is complete and Engineer determines that the proposed item is an acceptable substitute. Engineer’s determination will be evidenced by a Field Order or a proposed Change Order accounting for the substitution itself and all related impacts, including changes in Contract Price or Contract Time. Engineer will advise Contractor in writing of any negative determination. Use of an unapproved substitute item will render such Work defective and will be subject to Article 14 provisions. C. Special Guarantee: Owner may require Contractor to furnish, at Contractor’s expense, a special performance guarantee or other warranty bond with respect to any substitute. D. Contractor’s Expense: Contractor shall provide all data in support of any proposed substitute at Contractor’s expense. E. Effect of Engineer’s Determination: If Engineer approves the substitution request, Contractor shall execute any required documentation and proceed with the substitution. The Engineer’s denial of a substitution request shall be final and binding, and may not be reversed through an appeal under any provision of the Contract Documents. 7.06 Concerning Subcontractors, Suppliers, and Others A. Prior to entry into any binding subcontract or purchase order, Contractor shall submit to Owner the identity of the proposed Subcontractor or Supplier (unless Owner has already deemed such proposed Subcontractor or Supplier acceptable, during the bidding process or otherwise). Such proposed Subcontractor or Supplier shall be deemed acceptable to Owner unless Owner raises a substantive, reasonable objection within five days. B. No acceptance by Owner of any such Subcontractor, Supplier, or other individual or entity, shall constitute a waiver of the right of Owner to the completion of the Work in accordance with the Contract Documents. C. On a monthly basis, Contractor shall submit to Engineer a complete list of all Subcontractors and Suppliers having a direct contract with Contractor, and of all other Subcontractors and Suppliers known to Contractor at the time of submittal. D. Contractor shall be fully responsible to Owner for all acts and omissions of the Subcontractors, Suppliers, and other individuals or entities performing or furnishing any of the Work just as Contractor is responsible for Contractor’s own acts and omissions. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 33 of 72 Section 00700 – General Conditions E. Contractor shall be solely responsible for scheduling and coordinating the work of Subcontractors, Suppliers, and all other individuals or entities performing or furnishing any of the Work. F. Contractor shall restrict all Subcontractors, Suppliers, and such other individuals or entities performing or furnishing any of the Work from communicating with Engineer or Owner, except through Contractor or in case of an emergency, or as otherwise expressly allowed herein. G. The divisions and sections of the Specifications and the identifications of any Drawings shall not control Contractor in dividing the Work among Subcontractors or Suppliers or delineating the Work to be performed by any specific trade. H. All Work performed for Contractor by a Subcontractor or Supplier shall be pursuant to an appropriate contractual agreement that specifically binds the Subcontractor or Supplier to the applicable terms and conditions of the Contract Documents for the benefit of Owner. I. Owner may furnish to any Subcontractor or Supplier, to the extent practicable, information about amounts paid to Contractor on account of Work performed for Contractor by the particular Subcontractor or Supplier. 7.07 Patent Fees and Royalties A. Contractor shall pay all license fees and royalties and assume all costs incident to the use in the performance of the Work or the incorporation in the Work of any invention, design, process, product, or device which is the subject of patent rights or copyrights held by others. If a particular invention, design, process, product, or device is specified in the Contract Documents for use in the performance of the Work and if, to the actual knowledge of Owner or Engineer, its use is subject to patent rights or copyrights calling for the payment of any license fee or royalty to others, the existence of such rights shall be disclosed by Owner in the Contract Documents. B. TO THE FULLEST EXTENT PERMITTED BY LAWS AND REGULATIONS, CONTRACTOR SHALL INDEMNIFY AND HOLD HARMLESS OWNER, ITS OFFICERS, DIRECTORS, MEMBERS, PARTNERS, EMPLOYEES, AGENTS, AND CONSULTANTS OF EACH AND ANY OF THEM FROM AND AGAINST ALL CLAIMS, COSTS, LOSSES, AND DAMAGES (INCLUDING BUT NOT LIMITED TO ALL FEES AND CHARGES OF ENGINEERS, ARCHITECTS, ATTORNEYS, AND OTHER PROFESSIONALS AND ALL COURT OR ARBITRATION OR OTHER DISPUTE RESOLUTION COSTS) ARISING OUT OF OR RELATING TO ANY INFRINGEMENT OF PATENT RIGHTS OR COPYRIGHTS INCIDENT TO THE USE IN THE PERFORMANCE OF THE WORK OR RESULTING FROM THE INCORPORATION IN THE WORK OF ANY INVENTION, DESIGN, PROCESS, PRODUCT, OR DEVICE NOT SPECIFIED IN THE CONTRACT DOCUMENTS. 7.08 Permits A. Unless otherwise provided in the Contract Documents, Contractor shall pay all governmental charges, permit fees and inspection fees necessary for the prosecution of the Work which are applicable at the time of the submission of Contractor’s Bid (or when Contractor became bound under a negotiated contract). 7.09 Taxes A. The Owner enjoys tax-exempt status. To enjoy the cost-savings benefits of its tax-exempt status, the Owner will provide a Tax Exemption Certificate to the Contractor for use on the Project. The Contractor shall use that certificate to exempt any purchases made for the Work BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 34 of 72 Section 00700 – General Conditions from taxes. All savings for the tax-exempt status will be passed on to the Owner by the Contractor. The Contractor agrees to bind all Subcontractors of any tier to the obligation to present and use the Tax Exemption Certificate and pass all savings to the Owner. 7.10 Laws and Regulations A. Contractor shall give all notices required by and shall comply with all Laws and Regulations applicable to the performance of the Work. Except where otherwise expressly required by applicable Laws and Regulations, neither Owner nor Engineer shall be responsible for monitoring Contractor’s compliance with any Laws or Regulations. B. If Contractor performs any Work or takes any other action knowing, having reason to know or reasonably should have known that it is contrary to Laws or Regulations, Contractor shall bear all resulting costs and losses. However, Contractor has no responsibility or liability for determining whether the Work as described in the Contract Documents complies with applicable Laws or Regulations. C. All construction by the Contractor, or his sub-contractors, shall be in accordance with all applicable BCRUA, City of Cedar Park and State of Texas ordinances, statutes, rules, and regulations. This includes, but is not limited to, the conditions noted in the Contract Documents and any permits related to the Project. These documents are included herein by reference. The Construction Specification Standards of the Engineering Department of the City of Austin, Texas as presented in the City of Austin’s Standard Specifications for Public Works Construction, latest edition (“City of Austin Specifications”), shall apply to this Project. The City of Austin Specifications are included herein by reference. In the case of conflicts between standards or specifications between jurisdictions, the City of Austin Specifications shall govern unless otherwise directed by the Owner or Engineer. Copies of these specifications may be purchased at the City of Austin or are available for inspection at the City of Cedar Park, Public Works Department, 2401 Brushy Creek Loop, Building 1, Cedar Park, Texas, 78613 or City of Cedar Park, Engineering Department, 450 Cypress Creek Road, Building 1, Cedar Park, Texas 78613. D. In the execution of its obligations under the Contract Documents, the Contractor must comply with all applicable local, state and federal laws, including but not limited to laws concerned with labor, safety, minimum wages, and the environment. The Contractor shall be familiar with and at all times shall observe and comply with all federal, state, and local laws, ordinances and regulations which in any manner affect the conduct of the Work, and shall indemnify and save harmless the Owner and their representatives against any claim arising from violation of any such law, ordinance or regulation by the Contractor, its Subcontractors or their respective employees. E. The Contractor shall not discriminate against any worker or applicant for employment because of race, sex, color, or national origin. The Contractor shall comply with all provisions of Executive Order 11246 of September 24, 1965 and Executive Order 11375 of October 13, 1967 and the rules, regulations, and relevant orders of the Secretary of Labor. F. As a requirement under the Texas Pollutant Discharge Elimination System (TPDES) of the Texas Commission on Environmental Quality (TCEQ) , a Stormwater Pollution Prevention Plan (SWP3) shall be prepared by the Contractor for this Project. The following conditions apply to this contract: BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 35 of 72 Section 00700 – General Conditions 1. Prior to the start of construction, the Contractor and the Owner will be required to execute, forward to the TCEQ, and Contractor to pay application fee for a Notice of Intent (NOI) to be covered by a TPDES general permit. 2. Prior to the start of construction, the Contractor and all subcontractors will implement the measures of the SWP3. 3. Upon final acceptance of the Work by the Owner, the Contractor, along with the Owner, will be required to execute and forward to the TCEQ a Notice of Termination (NOT). 7.11 Record Documents A. Contractor shall maintain in a safe place at the Site one printed record copy of all Drawings, Specifications, Addenda, Change Orders, Work Change Directives, Field Orders, written interpretations and clarifications, and approved Shop Drawings. Contractor shall keep such record documents in good order and annotate them to show changes made during construction. These record documents, together with all approved Samples, will be available to Engineer for reference. Upon completion of the Work, Contractor shall deliver these record documents to Owner. Delivery of a complete set of record documents to Owner is a condition precedent to Final Completion. B. The Contractor shall prepare a daily construction diary recording as a minimum the following information concerning events at the site and submit duplication copies to the Owner’s Representative at weekly intervals. The copies are to be signed by the Project Superintendent. 1. Work Performed. 2. Approximate count of Contractor’s personnel, by classification, on the site. 3. List by classification, of all Subcontractors, personnel and any professionals on the site that day. 4. List of all equipment on the site by make and model. 5. High and low temperatures together with general weather conditions. 6. Start time and finish time of day’s work. 7. Accidents and/or unusual events. 8. Meetings and significant decisions made. 9. Stoppages, delays, shortages and/or losses. 10. Meter readings and/or similar recordings. 11. Emergencies procedures that may have been needed. 12. Orders and requests of governing authorities. 13. Change orders received and implemented. 14. Services connected and/or disconnected. 15. Installed equipment and/or system tests and/or startups and results. 16. Partial completions and/or occupancies. 17. Date of substantial completion certified. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 36 of 72 Section 00700 – General Conditions C. The Contractor shall make appropriate daily measurements of facilities constructed and keep accurate records of location (horizontal and vertical) of all facilities. D. Once per month on a recurring day determined by the Engineer, the Contractor shall furnish as-recorded drawings for the Work performed up to the end of the week preceding the day the drawings are furnished. Approval of Contractor Applications for Payment shall be contingent upon comprehensive and generally accurate as-recorded drawings. Drawings shall show as-built dimensions and locations of all work constructed. As a minimum, the final drawings shall include the following: 1. Horizontal and vertical locations of Work. 2. Changes in equipment and dimensions due to substitutions. 3. “Nameplate” data on all installed equipment. 4. Deletions, additions, and changes to scope of Work. 5. Any other changes made. 7.12 Safety and Protection A. Contractor shall be responsible for initiating, maintaining, and supervising all safety precautions and programs in connection with the Work. Contractor shall comply with all Laws and Regulations regarding safety and shall take all necessary precautions for the safety of, and shall provide the necessary protection to prevent damage, injury, or loss to: 1. all persons on the Site or who may be affected by the Work; 2. all the Work and materials and equipment to be incorporated therein, whether in storage on or off the Site; and 3. other property at the Site or adjacent thereto, including trees, shrubs, lawns, walks, pavements, roadways, structures, other work in progress, utilities, and Underground Facilities not designated for removal, relocation, or replacement in the course of construction. B. Contractor shall notify Owner; the owners of adjacent property, Underground Facilities, and other utilities; and other contractors and utility owners performing work at or adjacent to the Site, when prosecution of the Work may affect them, and shall cooperate with them in the protection, removal, relocation, and replacement of their property or work in progress. C. Contractor shall comply with the applicable requirements of Owner’s safety programs, if any. D. Contractor shall inform Owner and Engineer of the specific requirements of Contractor’s safety program with which Owner’s and Engineer’s employees and representatives must comply while at the Site. E. All damage, injury, or loss to any property referred to in Paragraph 7.12.A.2 or 7.12.A.3 caused, directly or indirectly, in whole or in part, by Contractor, any Subcontractor, Supplier, or any other individual or entity directly or indirectly employed by any of them to perform any of the Work, or anyone for whose acts any of them may be liable, shall be remedied by Contractor at its expense (except damage or loss attributable to the fault of Drawings or Specifications or to the acts or omissions of Owner or Engineer or anyone employed by any of them, or anyone for whose acts any of them may be liable, and not attributable, directly or indirectly, in whole or in part, to the fault or negligence of Contractor or any BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 37 of 72 Section 00700 – General Conditions Subcontractor, Supplier, or other individual or entity directly or indirectly employed by any of them). F. Contractor’s duties and responsibilities for safety and protection shall continue until such time as all the Work is completed and Engineer has issued a notice to Owner and Contractor in accordance with Paragraph 15.06.B that the Work is acceptable (except as otherwise expressly provided in connection with Substantial Completion). G. Contractor’s duties and responsibilities for safety and protection shall resume whenever Contractor or any Subcontractor or Supplier returns to the Site to fulfill warranty or correction obligations, or to conduct other tasks arising from the Contract Documents. H. Owner prohibits the use, possession, sale, transfer, or storage of prohibited drugs or alcohol on the Site by Contractor’s employees. This policy also applies to those employees of subcontractors who perform work for Contractor. Contractor specifically acknowledges its understanding of and familiarity with Owner’s policies, procedures, and restrictions concerning the influence, use, or presence of drugs and/or alcohol at the Project and agrees to be bound by and fully comply with the same. Further, Contractor agrees that the foregoing shall apply to its employees and those of its subcontractors and hereby agrees to ensure that all personnel engaged in the Work are aware of and familiar with Owner’s policies, procedures, and restrictions and to remove from the Project and replace any personnel Contractor believes to be in violation thereof. It is understood and agreed that Owner shall have the right to require the removal and replacement of any person or entity not adhering to such requirements. Contractor shall include the foregoing provisions in each of its subcontracts relating to the Project in order that the terms of this Article shall fully apply to such parties. I. During unfavorable weather, wet ground, or other unsuitable construction conditions, the Contractor shall confine its operations to work which will not be affected adversely thereby. No portion of the Work shall be constructed under conditions, which would affect adversely the quality or efficiency thereof, unless special means or precautions are taken by the Contractor to perform the Work in a proper and satisfactory manner. J. Water used for the mixing of concrete, testing, or any other purpose incidental to this project, will be furnished by the Contractor. The Contractor shall make the necessary arrangements for securing and transporting such water. No separate payment will be made for water used, but the cost thereof shall be included in the various items of the proposal and bid schedule. The Contractor will be required to provide and install temporary meter(s) on existing hydrant(s) at the Contractor’s expense as necessary for Contractor’s performance of work. K. All traffic control shall be in accordance with the Texas Manual of Uniform Traffic Control Devices (TMUTCD). Where the Work is carried on in or adjacent to any street, alley, or public place, the Contractor shall, at its own cost and expense, furnish and erect such barricades, fences, lights, and danger signals, shall provide such watchmen, and shall provide such other precautionary measures for the protection of persons or property and of the Work as are necessary. Where applicable, the Contractor shall notify Leander Independent School District (LISD), City of Cedar Park Field Operations, Public Works, and Emergency Services a minimum of seven (7) business days prior to any lane reduction, lane closure, or roadway closure. L. Barricades shall be painted in a color that will be visible at night. From sunset to sunrise, the Contractor shall furnish and maintain at least one light at each barricade and sufficient BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 38 of 72 Section 00700 – General Conditions number of barricades shall be erected to keep vehicles from being driven on or into any Work under construction. The Contractor shall furnish watchmen in sufficient numbers to protect the Work. M. The Contractor will be held responsible for all damage to the Work due to the failure of barricades, signs, lights, and watchmen to protect it, and whenever evidence is found of such damage, the Engineer may order the damaged portion immediately removed and replace by the Contractor at its cost and expense. The Contractor’s responsibility for the maintenance of barricades, signs, and lights, and for providing watchmen shall not cease until the project shall has been accepted by the Owner. All lanes of traffic shall be open at the end of each working day. No trenches shall remain open at the end of each working day. 7.13 Safety Representative A. Contractor shall designate a qualified and experienced safety representative at the Site whose duties and responsibilities shall be the prevention of accidents and the maintaining and supervising of safety precautions and programs. 7.14 Hazard Communication Programs A. Contractor shall be responsible for coordinating any exchange of material safety data sheets or other hazard communication information required to be made available to or exchanged between or among employers at the Site in accordance with Laws or Regulations. 7.15 Emergencies A. In emergencies affecting the safety or protection of persons or the Work or property at the Site or adjacent thereto, Contractor is obligated to act to prevent threatened damage, injury, or loss. Contractor shall give Engineer prompt written notice if Contractor believes that any significant changes in the Work or variations from the Contract Documents have been caused thereby or are required as a result thereof. If Engineer determines that a change in the Contract Documents is required because of the action taken by Contractor in response to such an emergency, a Work Change Directive or Change Order will be issued. B. In the event there is an accident involving injury to any individual on or near the Work, the Contractor shall notify Owner's Representative within twenty-four (24) hours of the event and shall be responsible for recording the location of the event and the circumstances surrounding the event through photographs, interviewing witnesses, obtaining medical reports and other documentation that describes the event. Copies of such documentation shall be provided to Owner, for the Owner's and Engineer's records, within forty-eight (48) hours of the event. Nothing in this section will relieve Contractor of its obligations and responsibilities with respect to an injury under any state and federal laws and regulations. 7.16 Shop Drawings, Samples, and Other Submittals A. Shop Drawing and Sample Submittal Requirements: 1. Before submitting a Shop Drawing or Sample, Contractor shall have: a. reviewed and coordinated the Shop Drawing or Sample with other Shop Drawings and Samples and with the requirements of the Work and the Contract Documents; b. determined and verified all field measurements, quantities, dimensions, specified performance and design criteria, installation requirements, materials, catalog numbers, and similar information with respect thereto; BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 39 of 72 Section 00700 – General Conditions c. determined and verified the suitability of all materials and equipment offered with respect to the indicated application, fabrication, shipping, handling, storage, assembly, and installation pertaining to the performance of the Work; and d. determined and verified all information relative to Contractor’s responsibilities for means, methods, techniques, sequences, and procedures of construction, and safety precautions and programs incident thereto. 2. Each submittal shall bear a stamp or specific written certification that Contractor has satisfied Contractor’s obligations under the Contract Documents with respect to Contractor’s review of that submittal, and that Contractor approves the submittal. 3. With each submittal, Contractor shall give Engineer specific written notice of any variations that the Shop Drawing or Sample may have from the requirements of the Contract Documents. This notice shall be set forth in a written communication separate from the Shop Drawings or Sample submittal; and, in addition, in the case of Shop Drawings by a specific notation made on each Shop Drawing submitted to Engineer for review and approval of each such variation. B. Submittal Procedures for Shop Drawings and Samples: Contractor shall submit Shop Drawings and Samples to Engineer for review and approval in accordance with the accepted Schedule of Submittals. Each submittal will be identified as Engineer may require. 1. Shop Drawings: a. Contractor shall submit the number of copies required in the Specifications. b. Data shown on the Shop Drawings will be complete with respect to quantities, dimensions, specified performance and design criteria, materials, and similar data to show Engineer the services, materials, and equipment Contractor proposes to provide and to enable Engineer to review the information for the limited purposes required by Paragraph 7.16.D. 2. Samples: a. Contractor shall submit the number of Samples required in the Specifications. b. Contractor shall clearly identify each Sample as to material, Supplier, pertinent data such as catalog numbers, the use for which intended and other data as Engineer may require to enable Engineer to review the submittal for the limited purposes required by Paragraph 7.16.D. 3. Where a Shop Drawing or Sample is required by the Contract Documents or the Schedule of Submittals, any related Work performed prior to Engineer’s review and approval of the pertinent submittal will be at the sole expense and responsibility of Contractor. 4. After review and approval of a Submittal, Shop Drawing or Sample by Engineer in accordance with this section, Contractor may rely on the information provided by Engineer and Work performed in accordance with any approved Shop Drawing, Submittal or Sample and the Contract Documents will be presumed to be acceptable to Owner unless an actual defect in the Work is discovered. 5. The Contractor shall be responsible for delays caused by rejection of the submittal of inadequate or incorrect shop drawings, product data or samples. The Contractor shall be responsible for seeing that only “approved” copies of shop drawings bearing the BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 40 of 72 Section 00700 – General Conditions approval of the Engineer are allowed on the Site. The Contractor shall be responsible for providing all copies of approved shop drawings necessary for the construction operation. No portion of the Work requiring submission of a shop drawing, product data or sample shall be commenced until the submittal has been approved by the Engineer. All such portions of the Work shall be in accordance with approved submittals. C. Other Submittals: Contractor shall submit other submittals to Engineer in accordance with the accepted Schedule of Submittals, and pursuant to the applicable terms of the Contract Documents. D. Operation and Maintenance Manuals and Training: These provisions apply if they are applicable and not otherwise stated in the Contract Documents. 1. The Contractor shall obtain installation, operation, and maintenance manuals from manufacturers and suppliers for equipment furnished under the Contract Documents. The Contractor shall submit three copies of each complete manual to the Engineer within 90 days after approval of shop drawings, product data, and samples, and not later than the date of shipment of each item of equipment to the project site or storage location. 2. The Owner shall require the Engineer to promptly review each manual submitted, noting necessary corrections and revisions. If the Engineer rejects the manual, the Contractor shall correct and resubmit the manual until it is acceptable to the Engineer as being in conformance with the design concept of the project and for compliance with information given in the contract documents. Owner may assess Contractor a charge for reviews of same items in excess of three (3) times. Such procedure shall not be considered cause for delay. 3. Acceptance of manuals by Engineer does not relieve Contractor of any requirements of terms of the Contract Documents. 4. The Contractor shall provide the services of trained, qualified technicians to check final equipment installation, to assist as required in placing same in operation, and to instruct operating personnel in the proper manner of performing routine operation and maintenance of the equipment. 5. Operations and maintenance manuals specified hereinafter are in addition to any operation, maintenance, or installation instructions required by the Contractor to install, test, and start-up the equipment. 6. Each manual is to be bound in a folder and labeled to identify the contents and project to which it applies. The manual shall contain the following applicable items: a. A listing of the manufacturer's identification, including order number, model, serial number, and location of parts and service centers. b. A list of recommended stock of parts, including part number and quantity. c. Complete replacement parts list. d. Performance data and rating tables. e. Specific instructions for installation, operation, adjustment, and maintenance. f. Exploded view drawings for major equipment items. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 41 of 72 Section 00700 – General Conditions g. Lubrication requirements. h. Complete equipment wiring diagrams and control schematics with terminal identification. E. Engineer’s Review: 1. Engineer will provide timely review of Shop Drawings and Samples in accordance with the Schedule of Submittals acceptable to Engineer. Engineer’s review and approval will be only to determine if the items covered by the submittals will, after installation or incorporation in the Work, conform to the information given in the Contract Documents and be compatible with the design concept of the completed Project as a functioning whole as indicated by the Contract Documents. 2. Engineer’s review and approval of a Shop Drawing or Sample shall not relieve Contractor from responsibility for any variation from the requirements of the Contract Documents unless Contractor has complied with the requirements of Paragraph 7.16.A.3 and Engineer has given written approval of each such variation by specific written notation thereof incorporated in or accompanying the Shop Drawing or Sample. Engineer will document any such approved variation from the requirements of the Contract Documents in a Field Order. 3. Engineer’s review and approval of a Shop Drawing or Sample, or of a variation from the requirements of the Contract Documents, shall not, under any circumstances, change the Contract Time or Contract Price, unless such changes are included in a Change Order. 4. Neither Engineer’s receipt, review, acceptance nor approval of a Shop Drawing, Sample, or other submittal shall result in such item becoming a Contract Document. 5. Contractor shall perform the Work in compliance with the requirements and commitments set forth in approved Shop Drawings and Samples, subject to the provisions of Paragraph 4 above. F. Resubmittal Procedures: 1. Contractor shall make corrections required by Engineer and shall return the required number of corrected copies of Shop Drawings and submit, as required, new Samples for review and approval. Contractor shall direct specific attention in writing to revisions other than the corrections called for by Engineer on previous submittals. 2. Contractor shall furnish required submittals with sufficient information and accuracy to obtain required approval of an item with no more than three submittals. Engineer will record Engineer’s time for reviewing a fourth or subsequent submittal of a Shop Drawings, sample, or other item requiring approval, and Contractor shall be responsible for Engineer’s charges to Owner for such time. Owner may impose a set-off against payments due to Contractor to secure reimbursement for such charges. 3. If Contractor requests a change of a previously approved submittal item, Contractor shall be responsible for Engineer’s charges to Owner for its review time, and Owner may impose a set-off against payments due to Contractor to secure reimbursement for such charges, unless the need for such change is beyond the control of Contractor. 7.17 Contractor’s General Warranty and Guarantee A. The Contractor warrants to the Owner that materials and equipment furnished under the Contract will be of good quality and new unless the Contract Documents require or permit BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 42 of 72 Section 00700 – General Conditions otherwise. The Contractor further warrants that the Work will be performed in a good and workmanlike manner, will conform to the requirements of the Contract Documents and will be free from defects, except for those inherent in the quality of the Work the Contract Documents require or permit. Work, materials, or equipment not conforming to these requirements shall be considered defective. If required by the Owner, the Contractor shall furnish satisfactory evidence as to the kind and quality of materials and equipment. B. In addition to Contractor’s warranty obligations set forth elsewhere in the Contract Documents, including but not limited to Paragraph 7.17 A above and subject to the provisions of Paragraph 15.08 below, the Contractor warrants and guarantees the Work for two (2) years from Final Completion (“Correction Period”), or for a longer period if expressly stated in the Contract Documents. This includes a warranty and guarantee against any and all defects. The Contractor must correct any and all defects in material and/or workmanship which may appear during such Correction Period, or any defects that occur during the Correction Period even if discovered more than two (2) years after Final Completion, by repairing (or replacing with new items or new materials, if necessary) any such defect at no cost to the Owner, within a reasonable period of time, and to the Owner's satisfaction. C. Contractor’s warranty and guarantee hereunder excludes defects or damage caused by: 1. abuse, modification, or improper maintenance or operation by persons other than Contractor, Subcontractors, Suppliers, or any other individual or entity for whom Contractor is responsible; or 2. normal wear and tear under normal usage. D. Contractor’s obligation to perform and complete the Work in accordance with the Contract Documents shall be absolute. None of the following will constitute an acceptance of Work that is not in accordance with the Contract Documents or a release of Contractor’s obligation to perform the Work in accordance with the Contract Documents: 1. observations by Engineer; 2. recommendation by Engineer or payment by Owner of any progress or final payment; 3. the issuance of a certificate of Substantial Completion by Engineer or any payment related thereto by Owner; 4. use or occupancy of the Work or any part thereof by Owner; 5. any review and approval of a Shop Drawing or Sample submittal; 6. the issuance of a notice of acceptability by Engineer; 7. any inspection, test, or approval by others; or 8. any correction of defective Work by Owner. 9. The failure of the Owner, Engineer, the Resident Project Representative or any other person or entity acting on behalf of the Owner or Engineer to observe, detect or discover any defect in the Work or any non-conformance of the Work with any requirement of the Contract Documents. Contractor hereby waives any claim or defense to any claim by the Owner that any failure by the Owner, Engineer, Resident Project Representative or any other person or entity acting on behalf of the Owner to observe, detect or discover any defect in the Work relieves or releases, in whole or in part, Contractor from any obligations or responsibility for the BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 43 of 72 Section 00700 – General Conditions correction of such defects or any other obligation of Contractor under the Contract Documents. E. Prior to the expiration of the Correction Period, the Owner reserves the right to require a re- inspection of the Work. Such inspection shall be made by duly authorized representatives of the Owner, Engineer, and Contractor, in order to determine if any defects or deficiencies exist which are due to be corrected by the Contractor. F. Manufacturer’s Warranties on installed machinery and equipment as well as subcontractor and supplier warranties and guarantees, express or implied, respecting any part of the work and any materials used therein shall be deemed obtained – and shall be enforced – by the Contractor as the agent and for the benefit of the Owner. 7.18 Indemnification TO THE FULLEST EXTENT PERMITTED BY LAW, AND IN ADDITION TO ANY OTHER OBLIGATIONS OF CONTRACTOR UNDER THE CONTRACT DOCUMENTS OR OTHERWISE, CONTRACTOR SHALL INDEMNIFY AND HOLD HARMLESS OWNER, ITS OFFICERS, DIRECTORS, MEMBERS, PARTNERS, EMPLOYEES, AGENTS, AND CONSULTANTS FROM AND AGAINST ALL CLAIMS, COSTS, LOSSES, AND DAMAGES (INCLUDING BUT NOT LIMITED TO ALL FEES AND CHARGES OF ENGINEERS, ARCHITECTS, ATTORNEYS, CONSULTANTS, EXPERTS AND OTHER PROFESSIONALS AND ALL COURT OR ARBITRATION OR OTHER DISPUTE RESOLUTION COSTS) ARISING OUT OF OR RELATING TO THE PERFORMANCE OF THE WORK, INCLUDING THE LOSS OF USE RESULTING THEREFROM, REGARDLESS OF ANY COMPARATIVE OR CONTRIBUTORY RESPONSIBILITY OF AN INDEMNITEE AND REGARDLESS OF WHETHER SUCH CLAIMS, COSTS, LOSSES, OR DAMAGES WERE CAUSED, IN WHOLE OR IN PART, BY THE NEGLIGENCE, ACTS, ERRORS OR OMISSIONS OF ANY INDEMNITEE. TO THE EXTENT THAT SUBCHAPTER C OF CHAPTER 151 OF THE TEXAS INSURANCE CODE (“CHAPTER 151”) APPLIES TO THE OWNER, IT IS THE INTENT OF THE OWNER THAT IF THE PROVISIONS OF CHAPTER 151 DO APPLY, NOTHING HEREIN SHALL IMPOSE ANY REQUIREMENTS ON CONTRACTOR THAT ARE PROHIBITED BY CHAPTER 151 AND THAT ANY OF THE PROVISIONS HEREOF THAT ARE NOT PROHIBITED BY CHAPTER 151 SHALL REMAIN IN FULL FORCE AND EFFECT. ACCORDINLY, IN THE EVENT THAT IN CONSTRUING AND INTERPRETING THE CONTRACT DOCUMENTS, A COURT OF COMPETENT JURISDICTION OR, IF APPLICABLE, AN ARBITRATOR, DETERMINES THAT CHAPTER 151 APPLIES TO THE OWNER, THEN THE COURT OR ARBITRATOR SHALL REFORM THE PROVISIONS HEREOF SO AS TO COMPLY WITH CHAPTER 151 AND SUCH REFORMATION SHALL NOT AFFECT THE VALIDITY OF ANY PROVISIONS HEREOF THAT ARE NOT PROHIBITED BY CHAPTER 151. 7.19 Delegation of Professional Design Services A. Unless otherwise provided in the Contract Documents, Contractor shall not be responsible for nor warrant the adequacy of the design, performance, criteria, or design criteria specified by Owner or Engineer in the Contract Documents, Plans, and Specifications. B. Contractor will not be required to provide professional design services unless such services are specifically required by the Contract Documents for a portion of the Work or unless such services are required to carry out Contractor’s responsibilities for construction means, BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 44 of 72 Section 00700 – General Conditions methods, techniques, sequences and procedures. Contractor shall not be required to provide professional services in violation of applicable Laws and Regulations. 1. If professional design services or certifications by a design professional related to systems, materials, or equipment are specifically required of Contractor by the Contract Documents, Owner and Engineer will specify all performance and design criteria that such services must satisfy. Contractor shall cause such services or certifications to be provided by a properly licensed professional, whose signature and seal shall appear on all drawings, calculations, specifications, certifications, and other submittals prepared by such professional. Shop Drawings and other submittals related to the Work designed or certified by such professional, if prepared by others, shall bear such professional’s written approval when submitted to Engineer. 2. Owner shall be entitled to rely upon the adequacy, accuracy, and completeness of the services, certifications, or approvals performed by such design professionals, provided Owner and Engineer have specified to Contractor all performance and design criteria that such services must satisfy. 3. Pursuant to this paragraph, Engineer’s review and approval of design calculations and design drawings will be only for the limited purpose of checking for conformance with performance and design criteria given and the design concept expressed in the Contract Documents. Engineer’s review and approval of Shop Drawings and other submittals (except design calculations and design drawings) will be only for the purpose stated in Paragraph 7.16.D.1. 7.20 Administrative Charges A. The Contractor shall also pay to the Owner administrative charges after the Substantial and then Final Completion date as follows: B. The Owner shall back charge the Contractor for any and all engineering charges and field observation charges incurred after the Substantial and then Final Completion date until acceptance of the Work by Owner. C. Back charges will be determined monthly and according to the following schedule: Description Rate Engineer or other outside services on the project Invoice Amount Owner Project Manager or Engineer $180/hr Owner Field Observer $150/hr Administrative Expenses $50/hr 7.21 Miscellaneous Contractor Responsibilities: A. It shall be the responsibility of the Contractor, prior to the initiation of construction on easements through private property, to inform the property Owner of his intent to begin construction. Before beginning construction in areas of public dedication, the Contractor shall inform the agency having jurisdiction in the area forty-eight (48) hours prior to initiation of the work. The Contractor’s attention is directed to the limits of right-of-way and easements as obtained by the Owner and as shown on the plans. The Contractor shall restrict his operations to within the limits of the right-of-way and easements. He shall be responsible for all damages to trees, crops, grasses, etc. which as a result of his operations occur outside such limits. Should the Contractor require additional right-of-way for ingress or egress, he BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 45 of 72 Section 00700 – General Conditions shall make arrangements with the owners of such property for such right-of-way at no cost to the Owner. Permits and licenses of a temporary nature necessary for the prosecution of the work shall be secured and paid for by the Contractor. B. Use of explosives shall not be permitted on this Project. C. The Contractor shall protect trees, other than Cedar less than six inches in diameter, or that are within the trench width, as directed by the Engineer. The working space noted on the plans is not intended to indicate all trees can be removed. Trees to be protected will be identified prior to construction. Unauthorized tree removal will be compensated at $100.00 per caliper inch of trunk as measured at a point four feet above the ground. D. Contractor is not required to provide a field office. Meetings involving BCRUA Staff may be held at the Owner’s Water Treatment Plant. E. Contractor shall provide sanitary facilities with hand washing stations for his employees at locations along the project route, not to exceed 1,000 linear feet in spacing. For Facility projects provide sanitary facilities with hand washing station at a ratio 1:10 workers per week. F. Contractor shall be responsible for and pay for all costs incurred to complete the Work. Because of the anticipated length of the Contract Time, Contractor, in preparing and submitting its Proposal and agreeing to the Contract Price, understood that there may be increases in the cost of labor and materials to perform the Work and Contractor has taken the possibility of such increases into consideration. Contractor further acknowledges and agrees that Contractor shall not be entitled to an adjustment in the Contract Price based upon any increases in the cost of any labor, materials or any other services necessary for Contractor to complete the Work and satisfy its obligations under the Contract Documents, regardless of the reasons for such increases. ARTICLE 8 – OTHER WORK AT THE SITE 8.01 Other Work A. In addition to and apart from the Work under the Contract Documents, the Owner may perform other work at or adjacent to the Site. Such other work may be performed by Owner’s employees, or through contracts between the Owner and third parties. Owner may also arrange to have third-party utility owners perform work on their utilities and facilities at or adjacent to the Site. B. If Owner performs other work at or adjacent to the Site, then Owner shall give Contractor written notice thereof prior to starting any such other work. If Owner has advance information regarding the start of any utility work at or adjacent to the Site, Owner shall provide such information to Contractor. C. Contractor shall afford each other contractor that performs such other work, each utility owner performing other work, and Owner proper and safe access to the Site, and provide a reasonable opportunity for the introduction and storage of materials and equipment and the execution of such other work. Contractor shall do all cutting, fitting, and patching of the Work that may be required to properly connect or otherwise make its several parts come together and properly integrate with such other work. Contractor shall not endanger any work of others by cutting, excavating, or otherwise altering such work; provided, however, that Contractor may cut or alter others' work with the written consent of Engineer and the others whose work will be affected. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 46 of 72 Section 00700 – General Conditions D. If the proper execution or results of any part of Contractor’s Work depends upon work performed by others under this Article 8, Contractor shall inspect such other work and promptly report to Engineer in writing any delays, defects, or deficiencies in such other work that render it unavailable or unsuitable for the proper execution and results of Contractor’s Work. Contractor’s failure to so report will constitute an acceptance of such other work as fit and proper for integration with Contractor’s Work except for latent defects and deficiencies in such other work. 8.02 Coordination A. If Owner intends to contract with others for the performance of other work at or adjacent to the Site, to perform other work at or adjacent to the Site with Owner’s employees, or to arrange to have utility owners perform work at or adjacent to the Site, the following will be set forth in the Supplemental General Conditions or provided to Contractor prior to the start of any such other work: 1. the identity of the individual or entity that will have authority and responsibility for coordination of the activities among the various contractors; 2. an itemization of the specific matters to be covered by such authority and responsibility; and 3. the extent of such authority and responsibilities. B. Unless otherwise provided in the Supplemental General Conditions, Owner shall have sole authority and responsibility for such coordination. 8.03 Legal Relationships A. If, in the course of performing other work at or adjacent to the Site for Owner, the Owner’s employees, any other contractor working for Owner, or any utility owner causes damage to the Work or to the property of Contractor or its Subcontractors, or delays, disrupts, interferes with, or increases the scope or cost of the performance of the Work, through actions or inaction, then Contractor may be entitled to an equitable adjustment in the Contract Price and/or Contract Time. Contractor must submit any Change Proposal seeking an equitable adjustment in the Contract Price or the Contract Time under this paragraph within 30 days of the damaging, delaying, disrupting, or interfering event. Contractor’s entitlement to an adjustment of the Contract Time is conditioned on such adjustment being essential to Contractor’s ability to complete the Work within the Contract Time and such delays, disruptions or interferences adversely affect the critical path of the Work as set forth in the most recent Progress Schedule. B. Contractor shall take reasonable and customary measures to avoid damaging, delaying, disrupting, or interfering with the work of Owner, any other contractor, or any utility owner performing other work at or adjacent to the Site. If Contractor fails to take such measures and as a result damages, delays, disrupts, or interferes with the work of any such other contractor or utility owner, then Owner may impose a set-off against payments due to Contractor. C. If Contractor damages, delays, disrupts, or interferes with the work of any other contractor, or any utility owner performing other work at or adjacent to the Site, through Contractor’s failure to take reasonable and customary measures to avoid such impacts, or if any claim arising out of Contractor’s actions, inactions, or negligence in performance of the Work at or adjacent to the Site is made by any such other contractor or utility owner against Contractor, BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 47 of 72 Section 00700 – General Conditions Owner, or Engineer, then Contractor shall (1) promptly attempt to settle the claim as to all parties through negotiations with such other contractor or utility owner, or otherwise resolve the claim by arbitration or other dispute resolution proceeding or at law, and (2) INDEMNIFY AND HOLD HARMLESS OWNER, ITS OFFICERS, DIRECTORS, MEMBERS, PARTNERS, EMPLOYEES, AGENTS, AND CONSULTANTS FROM AND AGAINST ANY SUCH CLAIMS, AND AGAINST ALL COSTS, LOSSES, AND DAMAGES (INCLUDING BUT NOT LIMITED TO ALL FEES AND CHARGES OF ENGINEERS, ARCHITECTS, ATTORNEYS, AND OTHER PROFESSIONALS AND ALL COURT OR ARBITRATION OR OTHER DISPUTE RESOLUTION COSTS) ARISING OUT OF OR RELATING TO SUCH DAMAGE, DELAY, DISRUPTION, OR INTERFERENCE. ARTICLE 9 – OWNER’S RESPONSIBILITIES 9.01 Communications to Contractor A. For all Project and performance of Work matters, Owner will issue communications to Contractor through Engineer. However, Owner may, at its discretion, issue communications related to the Project directly to Contractor. In all such direct communications, Owner will endeavor to copy Engineer. 9.02 Replacement of Engineer A. Owner may at its discretion appoint an engineer to replace Engineer. The replacement engineer’s status under the Contract Documents shall be that of the former Engineer. 9.03 Furnish Data A. Owner shall promptly furnish the data required of Owner under the Contract Documents. 9.04 Pay When Due A. Owner shall make payments to Contractor when they are due as provided in the Contract Documents. 9.05 Lands and Easements; Reports, Tests, and Drawings A. Owner’s duties with respect to providing lands and easements are set forth in Paragraph 5.01. B. Owner’s duties with respect to providing engineering surveys to establish reference points are set forth in Paragraph 4.03. 9.06 Limitations on Owner’s Responsibilities A. The Owner shall not supervise, direct, or have control or authority over, nor be responsible for, Contractor’s means, methods, techniques, sequences, or procedures of construction, or the safety precautions and programs incident thereto, or for any failure of Contractor to comply with Laws and Regulations applicable to the performance of the Work. The Owner is not responsible for the Contractor’s failure to perform or furnish the Work in accordance with the Contract Documents. The failure or omission of the Owner, Engineer, Resident Project Representative or any other person or entity acting on behalf of the Owner to observe, detect, discover, or object to or condemn any defective Work or material shall not release the Contractor from Contractor’s obligation to properly and fully perform the Work pursuant to the Contract Documents. The Owner shall not be responsible for the acts, errors or omissions of the Contractor, or any Subcontractor, Supplier or any other person or entity performing or furnishing any of the Work on behalf of the Contractor. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 48 of 72 Section 00700 – General Conditions 9.07 Evidence of Financial Arrangements A. Within Thirty (30) days after executing the Agreement, Contractor may request, and Owner shall furnish, reasonable evidence that financial arrangements have been made to satisfy Owner’s obligations under the Contract Documents. 9.08 Safety Programs A. While at the Site, Owner’s employees and representatives shall comply with the specific applicable requirements of Contractor’s safety programs of which Owner has been informed. B. Owner shall furnish copies of any applicable Owner safety programs to Contractor. 9.09 Video Observation A. The Owner or it’s Representative, at their sole discretion, can install, set up, operate and maintain video equipment on Site to monitor and observe the progression of the Work. Recording can take place without notification full time or as time-lapse. ARTICLE 10 – ENGINEER’S STATUS DURING CONSTRUCTION 10.01 Owner’s Representative A. Engineer will act as the Owner’s representative for Project administration during the construction period. Engineer shall not have the authority to bind the Owner as that authority lies with the Owner’s designated representative, but Engineer may communicate on behalf of Owner in all Project matters. 10.02 Visits to Site A. Engineer will make visits to the Site at intervals appropriate to the various stages of construction as Engineer deems necessary in order to observe as an experienced and qualified design professional the progress that has been made and the quality of the various aspects of Contractor’s executed Work. Based on information obtained during such visits and observations, Engineer, for the benefit of Owner, will determine, in general, if the Work is proceeding in accordance with the Contract Documents. Engineer’s efforts will be directed toward providing for Owner a greater degree of confidence that the completed Work will conform generally to the Contract Documents. On the basis of such visits and observations, Engineer will keep Owner informed of the progress of the Work and will endeavor to guard Owner against defective Work. B. Engineer’s visits and observations are subject to all the limitations on Engineer’s authority and responsibility set forth in Paragraph 10.08. Particularly, but without limitation, during or as a result of Engineer’s visits or observations of Contractor’s Work, Engineer will not supervise, direct, control, or have authority over or be responsible for Contractor’s means, methods, techniques, sequences, or procedures of construction, or the safety precautions and programs incident thereto, or for any failure of Contractor to comply with Laws and Regulations applicable to the performance of the Work. 10.03 Project Representative A. If Owner and Engineer have agreed that Engineer will furnish a Resident Project Representative to represent Engineer at the Site and assist Engineer in observing the progress and quality of the Work, then the authority and responsibilities of any such Resident Project Representative will be as provided in this Article 10. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 49 of 72 Section 00700 – General Conditions 10.04 Rejecting Defective Work A. Engineer has the authority to reject Work in accordance with Article 14. 10.05 Shop Drawings, Change Orders and Payments A. Engineer’s authority, and limitations thereof, as to Shop Drawings and Samples, are set forth in Paragraph 7.16. B. Engineer’s authority, and limitations thereof, as to design calculations and design drawings submitted in response to a delegation of professional design services, if any, are set forth in Paragraph 7.19. C. Engineer’s authority as to Change Orders is set forth in Article 11. D. Engineer’s authority as to Applications for Payment is set forth in Article 15. 10.06 Determinations for Unit Price Work A. Engineer will determine the actual quantities and classifications of Unit Price Work performed by Contractor as set forth in Paragraph 13.02. 10.07 Decisions on Requirements of Contract Documents and Acceptability of Work A. Engineer will render decisions regarding the requirements of the Contract Documents, and judge the acceptability of the Work, pursuant to the specific procedures set forth herein for initial interpretations, Change Proposals, and acceptance of the Work. In rendering such decisions and judgments, Engineer will not show partiality to Owner or Contractor. 10.08 Limitations on Engineer’s Authority and Responsibilities A. Engineer’s authority, responsibility and actions as Owner’s representative shall not give rise to any liability to Contractor. Contractor expressly waives any claims it has against Engineer for the performance of its responsibilities as Owner’s representative. B. Engineer will not supervise, direct, control, or have authority over or be responsible for Contractor’s means, methods, techniques, sequences, or procedures of construction, or the safety precautions and programs incident thereto. Engineer shall not be responsible for the Contractor’s failure to perform or furnish the Work in accordance with the Contract Documents. The failure or omission of the Engineer to observe, detect, discover or object to or condemn any defective Work or material shall not release the Contractor, in whole or in part, from the Contractor’s obligation to properly and fully perform the Work in accordance with the Contract Documents. C. Engineer’s review of the final Application for Payment and accompanying documentation and all maintenance and operating instructions, schedules, guarantees, bonds, certificates of inspection, tests and approvals, and other documentation required to be delivered by Paragraph 15.06.A will only be to determine generally that their content complies with the requirements of, and in the case of certificates of inspections, tests, and approvals, that the results certified indicate compliance with the Contract Documents. D. The limitations upon authority and responsibility set forth in this Paragraph 10.08 shall also apply to the Resident Project Representative, if any. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 50 of 72 Section 00700 – General Conditions 10.09 Compliance with Safety Program A. While at the Site, Engineer’s employees and representatives will comply with the specific applicable requirements of Owner’s and Contractor’s safety programs (if any) of which Engineer has been informed. ARTICLE 11 – AMENDING THE CONTRACT DOCUMENTS; CHANGES IN THE WORK 11.01 Amending and Supplementing Contract Documents A. The Contract Documents may be amended or supplemented by a Change Order, a Work Change Directive, or a Field Order. 1. Change Orders: a. A Change Order shall be used to amend or supplement the Contract Documents when the Parties agree to the amendment, supplement, modification to the scope of work, or change in the Contract Price or the Contract Time. 2. Work Change Directives: A Work Change Directive may be issued by the Owner if the Parties cannot agree on a Change Order or if: a. The parties expect that the modification ordered or documented by a Work Change Directive will be incorporated in a subsequently issued Change Order, following negotiations by the parties as to the Work Change Directive’s effect, if any, on the Contract Price and Contract Time; or, if negotiations are unsuccessful, by a determination under the terms of the Contract Documents governing adjustments, expressly including Paragraph 11.04 regarding change of Contract Price. b. Contractor must submit any Change Proposal seeking an adjustment of the Contract Price or the Contract Time, or both, no later than 30 days after the completion of the Work set out in the Work Change Directive. Owner must submit any Claim seeking an adjustment of the Contract Price or the Contract Time, or both, no later than 60 days after issuance of the Work Change Directive. c. Upon receipt of a Change Directive, Contractor shall promptly proceed with the change in the Work involved. 3. Field Orders: Owner or Engineer may authorize minor changes in the Work if the changes do not involve an adjustment in the Contract Price or the Contract Time and are compatible with the design concept of the completed Project as a functioning whole as indicated by the Contract Documents. Such changes will be accomplished by a Field Order and will be binding on Owner and on Contractor, which shall perform the Work involved promptly. If Contractor believes that a Field Order justifies an adjustment in the Contract Price or Contract Time, or both, then before proceeding with the Work at issue, Contractor shall submit a Change Proposal as provided herein. 11.02 Owner-Authorized Changes in the Work A. Without invalidating the Agreement and without notice to any surety, Owner may, at any time or from time to time, order additions, deletions, or revisions in the Work. Such changes shall be supported by Engineer’s recommendation, to the extent the change involves the design (as set forth in the Drawings, Specifications, or otherwise), or other engineering or technical matters. Such changes may be accomplished by a Change Order, if Owner and Contractor have agreed as to the effect, if any, of the changes on Contract Time or Contract BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 51 of 72 Section 00700 – General Conditions Price; or by a Work Change Directive. Upon receipt of any such document, Contractor shall promptly proceed with the Work involved; or, in the case of a deletion in the Work, promptly cease construction activities with respect to such deleted Work. Added or revised Work shall be performed under the applicable conditions of the Contract Documents. Nothing in this paragraph shall obligate Contractor to undertake work that Contractor reasonably concludes cannot be performed in a manner consistent with Contractor’s safety obligations under the Contract Documents or Laws and Regulations. B. The total Contract Price may not be increased by a Change Order unless provision has been made for the payment of the added cost by the appropriation of current funds or bond funds for that purpose, by the authorization of the issuance of certificates, or by a combination of those procedures. C. Changes that involve an increase in the Contract Price shall be supported by documentation of the cost components. 11.03 Unauthorized Changes in the Work A. Contractor shall not be entitled to an increase in the Contract Price or an extension of the Contract Time with respect to any work performed that is not required by the Contract Documents, as amended, modified, or supplemented, except in the case of an emergency as provided in Paragraph 7.15 or in the case of uncovering Work as provided in Paragraph 14.05. 11.04 Change of Contract Price A. The Contract Price may only be changed by a Change Order. Any Change Proposal for an adjustment in the Contract Price shall comply with the provisions of Paragraph 11.06. Any Claim for an adjustment of Contract Price shall comply with the provisions of Article 12. B. An adjustment in the Contract Price will be determined as follows: 1. where the Work involved is covered by unit prices contained in the Contract Documents, then by application of such unit prices to the quantities of the items involved (subject to the provisions of Paragraph 13.02); or 2. where the Work involved is not covered by unit prices contained in the Contract Documents, then by a mutually agreed lump sum (which may include an allowance for overhead and profit not necessarily in accordance with Paragraph 11.04.C.2); or 3. where the Work involved is not covered by unit prices contained in the Contract Documents and the parties do not reach mutual agreement to a lump sum, then on the basis of the Cost of the Work (determined as provided in Paragraph 13.01) plus a Contractor’s fee for overhead and profit (determined as provided in Paragraph 11.04.C). C. Contractor’s Fee: When applicable, the Contractor’s fee, which shall include overhead and profit, shall be determined as follows: 1. a mutually acceptable fixed fee; or 2. if a fixed fee is not agreed upon, then a fee based on the following percentages of the various portions of the Cost of the Work: a. for costs incurred under Paragraphs 13.01.B.1 and 13.01.B.2, the Contractor’s fee shall be 15 percent; b. for costs incurred under Paragraph 13.01.B.3, the Contractor’s fee shall be five percent; BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 52 of 72 Section 00700 – General Conditions c. where one or more tiers of subcontracts are on the basis of Cost of the Work plus a fee and no fixed fee is agreed upon, the intent of Paragraphs 11.01.C.2.a and 11.01.C.2.b is that the Contractor’s fee shall be based on: (1) a fee of 15 percent of the costs incurred under Paragraphs 13.01.A.1 and 13.01.A.2 by the Subcontractor that actually performs the Work, at whatever tier, and (2) with respect to Contractor itself and to any Subcontractors of a tier higher than that of the Subcontractor that actually performs the Work, a fee of five percent of the amount (fee plus underlying costs incurred) attributable to the next lower tier Subcontractor; provided, however, that for any such subcontracted work the maximum total fee to be paid by Owner shall be no greater than 27 percent of the costs incurred by the Subcontractor that actually performs the work; d. no fee shall be payable on the basis of costs itemized under Paragraphs 13.01.B.4, 13.01.B.5, and 13.01.C; e. the amount of credit to be allowed by Contractor to Owner for any change which results in a net decrease in cost will be the amount of the actual net decrease in cost plus a deduction in Contractor’s fee by an amount equal to five percent of such net decrease; and f. when both additions and credits are involved in any one change, the adjustment in Contractor’s fee shall be computed on the basis of the net change in accordance with Paragraphs 11.04.C.2.a through 11.04.C.2.e, inclusive. 11.05 Change of Contract Time A. The Contract Time may only be changed by a Change Order. Any Change Proposal for an adjustment in the Contract Time shall comply with the provisions of Paragraph 11.06. Any Claim for an adjustment in the Contract Time shall comply with the provisions of Article 12. B. An adjustment of the Contract Time shall be subject to the limitations set forth in Paragraph 4.05, concerning delays in Contractor’s progress. 11.06 Change Proposals A. Contractor shall submit a Change Proposal to Engineer to request an adjustment in the Contract Time or Contract Price; appeal an initial decision by Engineer concerning the requirements of the Contract Documents or relating to the acceptability of the Work under the Contract Documents; contest a set-off against payment due; or seek other relief under the Contract. The Change Proposal shall specify any proposed change in Contract Time or Contract Price, or both, or other proposed relief, and explain the reason for the proposed change, with citations to any governing or applicable provisions of the Contract Documents. 1. Procedures: Contractor shall submit each Change Proposal to Engineer promptly (but in no event later than 30 days) after the start of the event giving rise thereto, or after such initial decision. The Contractor shall submit supporting data, including the proposed change in Contract Price or Contract Time (if any), to the Engineer and Owner within 15 days after the submittal of the Change Proposal. The supporting data shall be accompanied by a written statement that the supporting data are accurate and complete, and that any requested time or price adjustment is the entire adjustment to which Contractor believes it is entitled as a result of said event. Engineer will advise Owner regarding the Change Proposal, and consider any comments or response from Owner regarding the Change Proposal. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 53 of 72 Section 00700 – General Conditions 2. Engineer’s Action: Engineer will review each Change Proposal with Owner and, within 30 days after receipt of the Contractor’s supporting data, either deny the Change Proposal in whole, approve it in whole, or deny it in part and approve it in part. Engineer’s action on a Change Proposal will not have the effect of adjusting the Contract Time or Contract Price without express written approval of Owner and a memorialization of Engineer’s Action in a Change Order. Such actions shall be in writing, with a copy provided to Owner and Contractor. If Engineer does not take action on the Change Proposal within 30 days, then either Owner or Contractor may at any time thereafter submit a letter to the other party indicating that as a result of Engineer’s inaction the Change Proposal is deemed denied, thereby commencing the time for appeal of the denial under Article 12. 3. Binding Decision: Engineer’s decision will be final and binding upon Contractor, unless Contractor appeals the decision by filing a Claim under Article 12. B. Resolution of Certain Change Proposals: If the Change Proposal does not involve the design (as set forth in the Drawings, Specifications, or otherwise), the acceptability of the Work, or other engineering or technical matters, then Engineer will notify the parties that the Engineer is unable to resolve the Change Proposal. For purposes of further resolution of such a Change Proposal, such notice shall be deemed a denial, and Contractor may choose to seek resolution under the terms of Article 12. 11.07 Execution of Change Orders A. Owner and Contractor shall execute appropriate Change Orders covering: 1. changes in the Contract Price or Contract Time which are agreed to by the parties, including any undisputed sum or amount of time for Work actually performed in accordance with a Work Change Directive; 2. changes in Contract Price resulting from an Owner set-off, unless Contractor has duly contested such set-off; 3. changes in the Work which are: (a) ordered by Owner pursuant to Paragraph 11.02, (b) required because of Owner’s acceptance of defective Work under Paragraph 14.04 or Owner’s correction of defective Work under Paragraph 14.07; and 4. changes in the Contract Price or Contract Times, or other changes, which embody the substance of any final and binding results under Paragraph 11.06, or Article 12. ARTICLE 12 – CLAIMS 12.01 Claims A. Claims Process: The following disputes between Owner and Contractor shall be submitted to the Claims process set forth in this Article: 1. Appeals by Owner or Contractor of Engineer’s decisions regarding Change Proposals; 2. Owner or Contractor demands for adjustments in the Contract Price or Contract Time, or other relief under the Contract Documents; and 3. Disputes that Engineer has been unable to address because they do not involve the design (as set forth in the Drawings, Specifications, or otherwise), the acceptability of the Work, or other engineering or technical matters. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 54 of 72 Section 00700 – General Conditions B. Submittal of Claim: Unless otherwise provided in the Contract Documents, the party submitting a Claim shall deliver it directly to the other party to the Contract promptly (but in no event later than 30 days) after the start of the event giving rise thereto; in the case of appeals regarding Change Proposals within 30 days of the decision under appeal. The responsibility to substantiate a Claim shall rest with the party making the Claim. Except for Claims submitted by the Contractor to increase the Contract Price or Contract Time as permitted in the Contract Documents, the failure of a party to timely give the notice of Claim set forth herein shall not constitute a waiver of such Claim. C. Review and Resolution: The party receiving a Claim shall review it thoroughly, giving full consideration to its merits. The two parties shall seek to resolve the Claim through the exchange of information and direct negotiations. The parties may extend the time for resolving the Claim by mutual agreement. All actions taken on a Claim shall be stated in writing and submitted to the other party, with a copy to Engineer. D. Mediation: 1. At any time after initiation of a Claim, Owner and Contractor may mutually agree to mediation of the underlying dispute. The agreement to mediate shall stay the Claim submittal and response process. 2. If Owner and Contractor agree to mediation, the mediation shall occur within 60 days after the agreement to mediate. However, the mediation may be stayed and its scope and schedule may be amended. 3. Owner and Contractor shall each pay one-half of the mediator’s fees and costs. 4. Mediation is a condition precedent to litigation before a court of competent jurisdiction or tribunal. E. Denial of Claim: If efforts to resolve a Claim are not successful, the party receiving the Claim may deny it by giving written notice of denial to the other party. F. Final and Binding Results: If the parties reach a mutual agreement regarding a Claim, whether through approval of the Claim, direct negotiations, mediation, or otherwise, that agreement should be memorialized in a Change Order if the Project is ongoing at the time of resolution and the agreement affects the Contract scope, price, or time. G. During the pendency of any claim, Contractor shall continue with all Work, including the Work in dispute, and Owner will continue to pay for properly performed Work in accordance with the payment provisions in the Contract Documents. Contractor shall not have the right to stop the Work because of Owner’s failure to pay any amount disputed by Owner. H. If the Project is not Substantially Complete during the pendency or after the denial of a claim, Contractor shall not have the right to file suit against Owner in the court of competent jurisdiction until the Work is Substantially Complete. If litigation is initiated it shall be filed in the District Courts of Williamson County, Texas. ARTICLE 13 – COST OF THE WORK; ALLOWANCES; UNIT PRICE WORK 13.01 Cost of the Work A. Purposes for Determination of Cost of the Work: The term Cost of the Work means the sum of all costs necessary for the proper performance of the Work at issue, as further defined below. The provisions of this Paragraph 13.01 are used for two distinct purposes: BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 55 of 72 Section 00700 – General Conditions 1. To determine Cost of the Work when Cost of the Work is a component of the Contract Price, under cost-plus-fee, time-and-materials, or other cost-based terms; or 2. To determine the value of a Change Order, Change Proposal, Claim, set-off, or other adjustment in Contract Price. When the value of any such adjustment is determined on the basis of Cost of the Work, Contractor is entitled only to those additional or incremental costs required because of the change in the Work or because of the event giving rise to the adjustment. B. Costs Included: Except as otherwise may be agreed to in writing by Owner, costs included in the Cost of the Work shall be in amounts no higher than those prevailing in the locality of the Project, shall not include any of the costs itemized in Paragraph 13.01.C, and shall include only the following items: 1. Payroll costs for employees in the direct employ of Contractor in the performance of the Work. Such employees shall include, without limitation, superintendents, foremen, and other personnel employed full time. Payroll costs shall include, but not be limited to, salaries and wages plus the cost of fringe benefits, which shall include social security contributions, unemployment, excise, and payroll taxes, workers’ compensation, health and retirement benefits, bonuses, sick leave, and vacation and holiday pay applicable thereto. 2. Cost of all materials and equipment furnished and incorporated in the Work, including costs of transportation and storage thereof, and Suppliers’ field services required in connection therewith. All trade discounts, rebates, and refunds and returns from sale of surplus materials and equipment shall accrue to Owner, and Contractor shall make provisions so that they may be obtained. 3. Payments made by Contractor to Subcontractors for Work performed by Subcontractors. If any subcontract provides that the Subcontractor is to be paid on the basis of Cost of the Work plus a fee, the Subcontractor’s Cost of the Work and fee shall be determined in the same manner as Contractor’s Cost of the Work and fee as provided in this Paragraph 13.01. 4. Costs of special consultants (including but not limited to engineers, architects, testing laboratories, surveyors, attorneys, and accountants) employed for services specifically related to the Work. 5. Supplemental costs including the following: a. The proportion of necessary transportation, travel, and subsistence expenses of Contractor’s employees incurred in discharge of duties connected with the Work. b. Cost, including transportation and maintenance, of all materials, supplies, equipment, machinery, appliances, office, and temporary facilities at the Site, and hand tools not owned by the workers, which are consumed in the performance of the Work, and cost, less market value, of such items used but not consumed which remain the property of Contractor. c. Rentals of all construction equipment and machinery, and the parts thereof, approved by Owner, and the costs of transportation, loading, unloading, assembly, dismantling, and removal thereof. All such costs shall be in accordance with the terms of rental agreements. The rental of any such equipment, machinery, or parts shall cease when the use thereof is no longer necessary for the Work. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 56 of 72 Section 00700 – General Conditions d. The cost of utilities, fuel, and sanitary facilities at the Site. e. The costs of premiums for all bonds and insurance that Contractor is required by the Contract Documents to purchase and maintain. C. Costs Excluded: The term Cost of the Work shall not include any of the following items: 1. Payroll costs and other compensation of Contractor’s employees, agents and other personnel not included in Paragraph 13.01.B, whether at the Site or in Contractor’s principal or branch office for general administration of the Work. The payroll costs and other compensation excluded here are to be considered administrative costs covered by the Contractor’s fee. 2. Expenses of Contractor’s principal and branch offices other than Contractor’s office at the Site. 3. Any part of Contractor’s capital expenses, including interest on Contractor’s capital employed for the Work and charges against Contractor for delinquent payments. 4. Other overhead or general expense costs of any kind and the costs of any item not specifically and expressly included in Paragraph 13.01.B. D. Contractor’s Fee: When the Work as a whole is performed on the basis of Cost of the Work, Contractor’s fee shall be determined as set forth in the Contract Documents. When the value of any Work covered by a Change Order, Change Proposal, Claim, set-off, or other adjustment in Contract Price is determined on the basis of Cost of the Work, Contractor’s fee shall be determined as set forth in Paragraph 11.04.C. E. Documentation: Whenever the Cost of the Work for any purpose is to be determined pursuant to this Article 13, Contractor will establish and maintain records thereof in accordance with generally accepted accounting practices and submit in a form acceptable to Engineer an itemized cost breakdown together with supporting data. 13.02 Unit Price Work A. Where the Contract Documents provide that all or part of the Work is to be Unit Price Work, initially the Contract Price will be deemed to include for all Unit Price Work an amount equal to the sum of the unit price for each separately identified item of Unit Price Work times the estimated quantity of each item as indicated in the Contract Documents. B. The estimated quantities of items of Unit Price Work are not guaranteed and are solely for the purpose of comparison of Bids and determining an initial Contract Price. Payments to Contractor for Unit Price Work will be based on actual quantities. C. Each unit price will be deemed to include an amount considered by Contractor to be adequate to cover Contractor’s overhead and profit for each separately identified item. D. Engineer will determine the actual quantities and classifications of Unit Price Work performed by Contractor. Engineer will review with Contractor the Engineer’s preliminary determinations on such matters before rendering a written decision thereon (by recommendation of an Application for Payment or otherwise). Engineer’s written decision thereon will be final and binding (except as modified by Engineer to reflect changed factual conditions or more accurate data) upon Owner and Contractor, subject to the provisions of the following paragraph. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 57 of 72 Section 00700 – General Conditions E. Within 30 days of Engineer’s written decision under the preceding paragraph, Contractor may submit a Change Proposal, or Owner may file a Claim, seeking an adjustment in the Contract Price if: 1. the quantity of any item of Unit Price Work performed by Contractor differs materially and significantly from the estimated quantity of such item indicated in the Contract Documents; 2. there is no corresponding adjustment with respect to any other item of Work; and 3. Contractor believes that it is entitled to an increase in Contract Price as a result of having incurred additional expense or Owner believes that Owner is entitled to a decrease in Contract Price, and the parties are unable to agree as to the amount of any such increase or decrease. ARTICLE 14 – TESTS AND INSPECTIONS; CORRECTION, REMOVAL OR ACCEPTANCE OF DEFECTIVE WORK 14.01 Access to Work A. Owner, Engineer, their consultants and other representatives and personnel of Owner, independent testing laboratories, and authorities having jurisdiction will have access to the Site and the Work at reasonable times for their observation, inspection, and testing. Contractor shall provide them proper and safe conditions for such access and advise them of Contractor’s safety procedures and programs so that they may comply therewith as applicable. 14.02 Tests, Inspections, and Approvals A. Contractor shall give Engineer timely notice of readiness of the Work (or specific parts thereof) for all required inspections and tests, and shall cooperate with inspection and testing personnel to facilitate required inspections and tests. B. Owner shall be responsible for providing the services of an independent inspection and testing lab if the Contract Documents so require. C. Contractor shall be responsible for arranging, obtaining, and paying for all inspections and tests required: 1. by the Contract Documents, unless the Contract Documents expressly allocate responsibility for a specific inspection or test to Owner; 2. to attain Owner’s and Engineer’s acceptance of materials or equipment to be incorporated in the Work; 3. by manufacturers of equipment furnished under the Contract Documents; 4. for testing, adjusting, and balancing of mechanical, electrical, and other equipment to be incorporated into the Work; and 5. for acceptance of materials, mix designs, or equipment submitted for approval prior to Contractor’s purchase thereof for incorporation in the Work. Such inspections and tests shall be performed by independent inspectors, testing laboratories, or other qualified individuals or entities acceptable to Owner. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 58 of 72 Section 00700 – General Conditions D. If the Contract Documents require the Work (or part thereof) to be approved by Owner, Engineer, or another designated individual or entity, then Contractor shall assume full responsibility for arranging and obtaining such approvals. E. If any Work (or the work of others) that is to be inspected, tested, or approved is covered by Contractor without written concurrence of Engineer, Contractor shall, if requested by Engineer, uncover such Work for observation. Such uncovering shall be at Contractor’s expense unless Contractor had given Engineer timely notice of Contractor’s intention to cover the same and Engineer had not acted with reasonable promptness in response to such notice. 14.03 Defective Work A. Contractor’s Obligation: It is Contractor’s obligation to assure that the Work is not defective. B. Engineer’s Authority: Engineer has the authority to determine whether Work is defective, and to reject defective Work. C. Notice of Defects: Prompt notice of all defective Work of which Owner or Engineer has actual knowledge will be given to Contractor. D. Correction, or Removal and Replacement: Promptly after receipt of written notice of defective Work, Contractor shall correct all such defective Work or, if Engineer has rejected the defective Work, remove it from the Project and replace it with Work that is not defective. The Owner shall have the right, in Owner’s sole discretion, to have the Engineer or other consultants specify the means and methods that will be followed to correct or address any defective Work. If the Owner specifies a means or method by which defective Work will be addressed or corrected, the Contractor shall perform the specified work necessary to address or correct the defective Work at Contractor’s sole cost and expense. E. Preservation of Warranties: When correcting defective Work, Contractor shall take no action that would void or otherwise impair Owner’s special warranty and guarantee, if any, on said Work. F. Costs and Damages: Contractor shall pay all claims, costs, losses, and damages arising out of or relating to defective Work, including but not limited to the cost of the inspection, testing, correction, removal, replacement, or reconstruction of such defective Work, and the costs of repair or replacement of work of others resulting from defective Work, including but not limited to any engineering or other consultant’s fees incurred by the Owner to investigate such defective Work and/or to determine the appropriate means or methods to address or correct such defective Work. Prior to final payment, if Owner and Contractor are unable to agree as to the measure of such claims, costs, losses, and damages resulting from defective Work, then Owner may impose a reasonable set-off against payments due under Article 15. 14.04 Acceptance of Defective Work A. If, instead of requiring correction or removal and replacement of defective Work, Owner prefers to accept it, Owner may do so. Contractor shall pay all claims, costs, losses, and damages attributable to Owner’s evaluation of and determination to accept such defective Work, including but not limited to any engineering or other consultant’s fees incurred by the Owner to investigate such defective Work and/or to determine the appropriate means or methods and work necessary to allow Owner to accept the defective Work and Contractor shall pay for all work required to be performed to allow Owner to accept the defective Work and any estimated costs, expenses and the greater of (1) the costs, expenses and damages BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 59 of 72 Section 00700 – General Conditions Owner may sustain in the future as a result of accepting the defective Work or (2) the diminution in the value of the Work resulting from Owner’s acceptance of defective Work. If any such acceptance occurs prior to final payment, the necessary revisions in the Contract Documents with respect to the Work shall be incorporated in a Change Order. If the parties are unable to agree as to the decrease in the Contract Price, then Owner may impose a reasonable set-off against payments due under Article 15. If the acceptance of defective Work occurs after final payment, Contractor shall pay to Owner the above described costs, expenses and damages incurred by Owner as a result of Owner’s acceptance of defective Work. 14.05 Uncovering Work A. Engineer has the authority to require special inspection or testing of the Work, whether or not the Work is fabricated, installed, or completed. B. If any Work is covered contrary to the written request of Engineer, then Contractor shall, if requested by Engineer, uncover such Work for Engineer’s observation, and then replace the covering, all at Contractor’s expense. C. If Engineer considers it necessary or advisable that covered Work be observed by Engineer or inspected or tested by others, then Contractor, upon Owner’s approval and Engineer’s request, shall uncover, expose, or otherwise make available for observation, inspection, or testing as Engineer may require, that portion of the Work in question, and provide all necessary labor, material, and equipment. 1. If it is found that the uncovered Work is defective, Contractor shall be responsible for all claims, costs, losses, and damages arising out of or relating to such uncovering, exposure, observation, inspection, and testing, and of satisfactory replacement or reconstruction (including but not limited to all costs of repair or replacement of work of others); and pending Contractor’s full discharge of this responsibility the Owner shall be entitled to impose a reasonable set-off against payments due under Article 15. 2. If the uncovered Work is not found to be defective, Contractor shall be allowed an increase in the Contract Price or an extension of the Contract Times, or both, directly attributable to such uncovering, exposure, observation, inspection, testing, replacement, and reconstruction. If the parties are unable to agree as to the amount or extent thereof, then Contractor may submit a Change Proposal within 30 days of the determination that the Work is not defective. 14.06 Owner May Stop the Work A. If the Work is defective, or Contractor fails to supply sufficient skilled workers or suitable materials or equipment, or fails to perform the Work in such a way that the completed Work will conform to the Contract Documents, then Owner may order Contractor to stop the Work, or any portion thereof, until the cause for such order has been eliminated. 14.07 Owner May Correct Defective Work A. If Contractor fails within a reasonable time after written notice from Engineer to correct defective Work, or to remove and replace rejected Work as required by Engineer, or if Contractor fails to perform the Work in accordance with the Contract Documents, or if Contractor fails to comply with any other provision of the Contract Documents, then Owner may, after seven days written notice to Contractor, correct or remedy any such defective Work. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 60 of 72 Section 00700 – General Conditions B. In exercising the rights and remedies under this Paragraph 14.07, Owner shall proceed expeditiously. In connection with such corrective or remedial action, Owner may exclude Contractor from all or part of the Site, take possession of all or part of the Work and suspend Contractor’s services related thereto, and incorporate in the Work all materials and equipment stored at the Site or for which Owner has paid Contractor but which are stored elsewhere. Contractor shall allow Owner, Owner’s representatives, agents and employees, Owner’s other contractors, and Engineer and Engineer’s consultants access to the Site to enable Owner to exercise the rights and remedies under this paragraph. C. All claims, costs, losses, and damages incurred or sustained by Owner in exercising the rights and remedies under this Paragraph 14.07 will be charged against Contractor as set-offs against payments due under Article 15. Such claims, costs, losses and damages will include but not be limited to all costs of repair, or replacement of work of others destroyed or damaged by correction, removal, or replacement of Contractor’s defective Work. If the payments due under Article 15 are not sufficient to cover such claims, costs, losses and damages, the Contractor shall pay the amount of such claims, costs, losses and damages to Owner upon demand by Owner. D. Contractor shall not be allowed an extension of the Contract Times because of any delay in the performance of the Work attributable to the exercise by Owner of Owner’s rights and remedies under this Paragraph 14.07. ARTICLE 15 – PAYMENTS TO CONTRACTOR; SET-OFFS; COMPLETION; CORRECTION PERIOD 15.01 Progress Payments A. Basis for Progress Payments: The Schedule of Values established as provided in Article 2 will serve as the basis for progress payments and will be incorporated into a form of Application for Payment acceptable to Owner and Engineer. Progress payments on account of Unit Price Work will be based on the number of units completed during the pay period, as determined under the provisions of Paragraph 13.02. Progress payments for cost-based Work will be based on Cost of the Work completed by Contractor during the pay period. B. Applications for Payments: 1. At least 20 days before the date established in the Agreement for each progress payment (but not more often than once a month), Contractor shall submit to Engineer for review an Application for Payment filled out and signed by Contractor covering the Work completed as of the date of the Application and accompanied by such supporting documentation as is required by the Contract Documents. If payment is requested on the basis of materials and equipment not incorporated in the Work but delivered and suitably stored at the Site or at another location agreed to in writing, the Application for Payment shall also be accompanied by a bill of sale, invoice, or other documentation warranting that Owner has received the materials and equipment free and clear of all Liens, and evidence that the materials and equipment are covered by appropriate property insurance, a warehouse bond, or other arrangements to protect Owner’s interest therein, all of which must be satisfactory to Owner. 2. Beginning with the second Application for Payment, each Application shall include an affidavit of Contractor stating that all previous progress payments received on account of the Work have been applied on account to discharge Contractor’s legitimate obligations associated with prior Applications for Payment. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 61 of 72 Section 00700 – General Conditions 3. The amount of retainage with respect to progress payments will be as stipulated in the Agreement. 4. Each payment to the Contractor by the Owner shall be made subject to submission by the Contractor of all written certifications required of the Contractor, their Subcontractors and other general and special conditions required elsewhere in the Contract Documents. C. Review of Applications: 1. Engineer will, within 10 days after receipt of each Application for Payment, including each resubmittal, either indicate in writing a recommendation of payment and present the Application to Owner, or return the Application to Contractor indicating in writing Engineer’s reasons for refusing to recommend payment. In the latter case, Contractor may make the necessary corrections and resubmit the Application. 2. Engineer’s recommendation of any payment requested in an Application for Payment will constitute a representation by Engineer to Owner, based on Engineer’s observations of the executed Work as an experienced and qualified design professional, and on Engineer’s review of the Application for Payment and the accompanying data and schedules, that to the best of Engineer’s knowledge, information and belief: a. the Work has progressed to the point indicated; b. the quality of the Work is generally in accordance with the Contract Documents; and c. the conditions precedent to Contractor’s being entitled to such payment appear to have been fulfilled in so far as it is Engineer’s responsibility to observe the Work. 3. By recommending any such payment Engineer will not thereby be deemed to have represented that: a. inspections made to check the quality or the quantity of the Work as it has been performed have been exhaustive, extended to every aspect of the Work in progress, or involved detailed inspections of the Work beyond the responsibilities specifically assigned to Engineer in the Contract; or b. there may not be other matters or issues between the parties that might entitle Contractor to be paid additionally by Owner or entitle Owner to withhold payment to Contractor. 4. Engineer will recommend reductions in payment (set-offs) necessary in Engineer’s opinion to protect Owner from loss because: a. the Work is defective, requiring correction or replacement; b. the Contract Price has been reduced by Change Orders; c. Owner has been required to correct defective Work in accordance with Paragraph 14.07, or has accepted defective Work pursuant to Paragraph 14.04; d. Owner has been required to remove or remediate a Hazardous Environmental Condition for which Contractor is responsible; or e. Engineer has actual knowledge of the occurrence of any of the events that would constitute a default by Contractor and therefore justify termination for cause under the Contract Documents. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 62 of 72 Section 00700 – General Conditions D. Reductions in Payment by Owner: 1. In addition to any reductions in payment (set-offs) recommended by Engineer, Owner is entitled to impose a set-off against payment based on any of the following: a. claims have been made against Owner on account of Contractor’s conduct in the performance or furnishing of the Work, or Owner has incurred costs, losses, or damages on account of Contractor’s conduct in the performance or furnishing of the Work; b. Contractor has failed to take reasonable and customary measures to avoid damage, delay, disruption, and interference with other work at or adjacent to the Site; c. Contractor has failed to provide and maintain required bonds or insurance; d. Owner has been required to remove or remediate a Hazardous Environmental Condition for which Contractor is responsible; e. Owner has incurred extra charges or engineering costs related to submittal reviews, evaluations of proposed substitutes, tests and inspections, or return visits to manufacturing or assembly facilities; f. the Work is defective, requiring correction or replacement; g. liquidated damages have accrued as a result of Contractor’s failure to achieve Milestones, Substantial Completion, or final completion of the Work; h. other items set forth in the Contract Documents entitling Owner to a set off against the amount recommended. 2. If Owner imposes any set-off against payment, whether based on its own knowledge or on the written recommendations of Engineer, Owner will give Contractor immediate written notice (with a copy to Engineer) stating the reasons for such action and the specific amount of the reduction, and promptly pay Contractor any amount remaining after deduction of the amount so withheld. Owner shall promptly pay Contractor the amount so withheld, or any adjustment thereto agreed to by Owner and Contractor, if Contractor remedies the reasons for such action. The reduction imposed shall be binding on Contractor unless it duly submits a Change Proposal contesting the reduction. E. Withholding Payments. The Owner may withhold from any payment otherwise due the Contractor so much as may be necessary to protect the Owner and if so elects may also withhold any amounts due from the Contractor to any Subcontractors or material dealers, for work performed or material furnished by them. The foregoing provisions shall be construed solely for the benefit of the Owner and will not require the Owner to determine or adjust any claims or disputes between the Contractor and their Subcontractors or Material dealers, or to withhold any monies for their protection unless the Owner elects to do so. The failure or refusal of the Owner to withhold any monies from the Contractor shall in no way impair the obligations of any surety or sureties under any bond or bonds furnished under the Contract Documents. 15.02 Contractor’s Warranty of Title A. Contractor warrants and guarantees that title to all Work, materials, and equipment furnished under the Contract Documents will pass to Owner free and clear of (1) all Liens and BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 63 of 72 Section 00700 – General Conditions other title defects, and (2) all patent, licensing, copyright, or royalty obligations, no later than seven days after the time of payment by Owner. 15.03 Substantial Completion A. When Contractor considers the entire Work Substantially Complete, Contractor shall notify Owner and Engineer in writing that the entire Work is Substantially Complete and request that Engineer issue a certificate of Substantial Completion. Contractor shall at the same time submit to Owner and Engineer an initial draft of punch list items to be completed or corrected before Final Payment. B. Promptly after Contractor’s notification, Owner, Contractor, and Engineer shall make an inspection of the Work to determine the status of completion. At that inspection, Owner and Engineer will review, supplement, and edit the initial punch list prepared by Contractor or prepare an additional punch list if Contractor has not yet provided a punch list. If Owner or Engineer does not consider the Work Substantially Complete, Engineer will notify Contractor in writing giving the reasons therefor. C. If Owner and Engineer consider the Work Substantially Complete, Engineer will deliver to Owner a preliminary Certificate of Substantial Completion which shall fix the date of Substantial Completion. Engineer shall attach to the certificate a punch list of items to be completed or corrected before final payment. If Owner and Engineer do not consider the Work Substantially Complete, the Engineer shall notify Contractor of such, in writing, with a specific explanation of those portions of the Work that are the basis for determining the Work is not substantially complete. D. After Substantial Completion, the Contractor shall promptly begin work on the punch list of items to be completed or corrected prior to Final Payment. In appropriate cases Contractor may submit monthly Applications for Payment for completed punch list items, following the progress payment procedures set forth above. 15.04 Partial Use or Occupancy A. Prior to Substantial Completion of all the Work, Owner may use or occupy any Substantially Completed part of the Work which has specifically been identified in the Contract Documents, or which Owner and Engineer Contractor agree constitutes a separately functioning and usable part of the Work that can be used by Owner for its intended purpose without significant interference with Contractor’s performance of the remainder of the Work, subject to the following conditions: 1. At any time Owner may notify the Contractor in writing that Owner intends to use or occupy any such part of the Work that Owner believes to be Substantially Complete. Contractor, Owner, and Engineer will follow the procedures of Paragraph 15.03 for that part of the Work. 2. At any time Contractor may notify Owner and Engineer in writing that Contractor considers any such part of the Work substantially complete and request Engineer to issue a certificate of Substantial Completion for that part of the Work. The Owner shall have no obligation, however, to accept any portion of Work as being Substantially Complete or to occupy or use any portion of the Work until all of the Work is Substantially Complete 3. Within a reasonable time after either such request, Owner, Contractor, and Engineer shall make an inspection of that part of the Work to determine its status of completion. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 64 of 72 Section 00700 – General Conditions If Owner or Engineer does not consider that part of the Work to be Substantially Complete, Engineer will notify Contractor in writing giving the reasons therefor. If Owner and Engineer consider that part of the Work to be Substantially Complete, and if Owner elects to use and occupy that part of the Work, the provisions of Paragraph 15.03 will apply with respect to certification of Substantial Completion of that part of the Work. 4. No use or occupancy or separate operation of part of the Work by Owner will relieve Contractor of its insurance obligations under these Contract Documents. B. The Owner, at the Owner's sole option, shall have the right to take possession of and use any completed or partially completed portion of the Work regardless of the time for completing the entire Work. The Owner’s exercise of such use and possession shall not be construed to mean that the Owner acknowledges that any part of the Work so possessed and used is substantially complete or that it is accepted by Owner, and the Owner’s exercise of such use and possession shall not relieve the Contractor of its responsibility to complete all Work in accordance with the Contract Documents. 15.05 Final Inspection A. Upon written notice from Contractor that the entire Work or an agreed portion thereof is complete, Engineer will promptly make a final inspection with Owner and Contractor and will notify Contractor in writing of all particulars in which this inspection reveals that the Work, or agreed portion thereof, is incomplete or defective. Contractor shall immediately take such measures as are necessary to complete such Work or remedy such deficiencies. 15.06 Final Payment A. Application for Payment: 1. After Contractor has, in the opinion of the Owner and Engineer, satisfactorily completed all corrections identified during the final inspection and has delivered, in accordance with the Contract Documents, all maintenance and operating instructions, schedules, guarantees, bonds, certificates or other evidence of insurance, certificates of inspection, annotated record documents (as provided in Paragraph 7.11), and other documents, Contractor may make application for Final Payment. 2. The Final Application for Payment shall be accompanied (except as previously delivered) by: a. all documentation called for in the Contract Documents; b. consent of the surety, if any, to Final Payment; c. satisfactory evidence that all title issues have been resolved such that title to all Work, materials, and equipment has passed to Owner free and clear of any Liens or other title defects, or will so pass upon final payment. d. a list of all disputes that Contractor believes are unsettled; and e. complete and legally effective releases or waivers (satisfactory to Owner) of all Lien rights arising out of the Work, and of Liens filed in connection with the Work. 3. In lieu of the releases or waivers of Liens specified in Paragraph 15.06.A.2 and as approved by Owner, Contractor may furnish receipts or releases in full and an affidavit of Contractor that: (a) the releases and receipts include all labor, services, material, and equipment for which a Lien could be filed; and (b) all payrolls, material and equipment BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 65 of 72 Section 00700 – General Conditions bills, and other indebtedness connected with the Work for which Owner might in any way be responsible, or which might in any way result in liens or other burdens on Owner's property, have been paid or otherwise satisfied. If any Subcontractor or Supplier fails to furnish such a release or receipt in full, Contractor may furnish a bond or other collateral satisfactory to Owner to indemnify Owner against any Lien, or Owner at its option may issue joint checks payable to Contractor and specified Subcontractors and Suppliers. 4. The retainage and its interest earnings, if any, shall not be paid to the Contractor until the all other agencies having jurisdiction over any portion of the Work has authorized a reduction in, or release of, retainage on the Work. B. Engineer’s Review of Application and Acceptance: 1. If, on the basis of Engineer’s observation of the Work during construction and final inspection, and Engineer’s review of the Final Application for Payment and accompanying documentation as required by the Contract Documents, Engineer is satisfied that the Work has been completed and Contractor’s other obligations under the Contract have been fulfilled, Engineer will, within ten days after receipt of the Final Application for Payment, indicate in writing Engineer’s recommendation of Final Payment and present the Final Application for Payment to Owner for payment. Such recommendation shall account for any set-offs against payment that are necessary to protect Owner from loss for the reasons stated above with respect to progress payments. Otherwise, Engineer will return the Final Application for Payment to Contractor, indicating in writing the reasons for refusing to recommend final payment, in which case Contractor shall make the necessary corrections and resubmit the Final Application for Payment. C. Completion of Work: The Work is complete (subject to surviving obligations) when it is ready for Final Payment as established by the Engineer’s written recommendation of Final Payment. D. Payment Becomes Due: Thirty days after the presentation to Owner of the Engineer’s recommendation regarding whether the Work is complete and the amount of the Final Payment to be made to the Contractor, the amount recommended by Engineer (less any further sum Owner is entitled to set off) will become due and shall be paid by Owner to Contractor, unless Owner disputes the recommendation of the Engineer. If Owner disputes the recommendation of the Engineer, the Owner shall provide to the Contractor a written description of the reasons why the Owner disputes the recommendation of the Engineer and Owner shall pursue a Claim against the Contractor pursuant to the dispute resolution procedures set forth in the Contract Documents. E. Contractor’s Warranty and Guarantee: Contractor’s general warranty and guarantee will begin to run upon Final Completion as approved by Owner, and following Engineer’s written recommendation. 15.07 Waiver of Claims A. The making of final payment will not constitute a waiver by Owner of Claims or rights against Contractor. Owner expressly reserves Claims and rights arising from defective Work appearing after Final Completion, from Contractor’s failure to comply with the Contract Documents or the terms of any guarantees specified therein, from outstanding Claims by Owner, or from Contractor’s continuing obligations under the Contract Documents. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 66 of 72 Section 00700 – General Conditions B. The acceptance of Final Payment by Contractor will constitute a waiver by Contractor of all Claims and rights against Owner other than those pending matters that have been duly submitted, in writing, expressly reserved, or appealed under the provisions of Article 17. 15.08 Correction Period A. If within two years after the date of Final Completion (or such longer period of time as may be prescribed by the terms of any applicable special guarantee required by the Contract Documents, or by any specific provision of the Contract Documents), any Work is in need of repair, adjustment, modification, correction, or found to be defective, or if the repair of any damages to the Site, adjacent areas that Contractor has arranged to use through construction easements or otherwise, and other adjacent areas used by Contractor as permitted by Laws and Regulations, is found to be defective, then Contractor shall promptly, without cost to Owner and in accordance with Owner’s written instructions: 1. correct the defective repairs to the Site or such other adjacent areas; 2. correct such defective Work; 3. if the defective Work has been rejected by Owner, remove it from the Project and replace it with Work that is not defective; 4. satisfactorily correct or repair or remove and replace any damage to other Work, to the work of others, or to other land or areas resulting therefrom, and 5. Perform such work specified by Owner that will allow Owner to accept defective Work. B. If Contractor does not promptly comply with the terms of Owner’s written instructions, or in an emergency where delay would cause serious risk of loss or damage, Owner may have the defective Work corrected or repaired, may have the rejected Work removed and replaced, or may have work performed to allow Owner to accept defective Work. Contractor shall pay all claims, costs, losses, and damages (including but not limited to all fees and charges of engineers, architects, attorneys, and other professionals and all court or arbitration or other dispute resolution costs) arising out of or relating to such correction or repair, removal and replacement or other work performed to allow Owner to accept defective Work (including but not limited to all costs of repair or replacement of work of others). C. In special circumstances where a particular item of equipment is placed in continuous service before Substantial Completion of all the Work, the correction period for that item may start to run from an earlier date if so provided in the Specifications. D. Where defective Work (and damage to other Work resulting therefrom) has been corrected or removed and replaced under this paragraph, the Correction Period hereunder with respect to such Work will be extended for an additional period of one year after such correction or removal and replacement has been satisfactorily completed. E. Contractor’s obligations under this paragraph are in addition to all other obligations and warranties. The provisions of this paragraph shall not be construed as a substitute for, or a waiver of, the provisions of any applicable statute of limitation or repose. ARTICLE 16 – SUSPENSION OF WORK AND TERMINATION 16.01 Owner May Suspend Work A. At any time and without cause, Owner may suspend the Work or any portion thereof by written notice to Contractor and Engineer. Such notice will fix the date on which Work will BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 67 of 72 Section 00700 – General Conditions be resumed. Contractor shall resume the Work on the date so fixed. Contractor shall be entitled to an adjustment in the Contract Price or an extension of the Contract Time, or both, directly attributable to any such suspension. Any Change Proposal seeking such adjustments shall be submitted no later than 30 days after the date fixed for resumption of Work. 16.02 Owner May Terminate for Cause A. The occurrence of any one or more of the following events will constitute a default by Contractor and justify termination of the Agreement or termination of Contractor’s right to proceed with the Work for cause: 1. Contractor’s failure to perform the Work in accordance with the Contract Documents (including, but not limited to, failure to supply sufficient skilled workers or suitable materials or equipment or failure to adhere to the Progress Schedule); 2. Failure of Contractor to perform or otherwise to comply with a material term of the Contract Documents; or 3. Contractor’s disregard of the authority of Owner or Engineer. B. If one or more of the events identified in Paragraph 16.02A occurs, then after giving Contractor ten (10) days written notice that Owner is considering a declaration that Contractor is in default and termination of the Agreement or Contractor’s right to proceed with the Work, Owner may proceed to: 1. declare Contractor to be in default, and give Contractor notice that the Agreement is terminated or Owner has terminated Contractor’s right to proceed with the Work; and 2. enforce the rights available to Owner under any applicable performance bond. C. If Owner has exercised any of the remedies described in Paragraph 16.02B above, Owner may exclude Contractor from the Site, take possession of the Work, incorporate in the Work all materials and equipment stored at the Site or for which Owner has paid Contractor but which are stored elsewhere, and complete the Work as Owner may deem expedient. If Owner chooses to complete the Work in accordance with this provision, Owner and Contractor expressly agree that Owner shall be exempt from publicly bidding the completion work pursuant to Section 252.022 of the Texas Local Government Code. D. Owner may not proceed with the remedies under Paragraph 16.02B if Contractor within seven (7) days of receipt of notice of intent to terminate begins to correct its default and proceeds diligently to cure such default. E. If Owner proceeds to complete the Work and/or correct the default, Contractor shall not be entitled to receive any further payment until the Work is completed. If the unpaid balance of the Contract Price exceeds all related claims, costs, losses, and damages (including but not limited to all fees and charges of engineers, architects, attorneys, and other professionals) sustained by Owner, such excess will be paid to Contractor. If the cost of all related claims, costs, losses, and damages exceeds such unpaid balance, Contractor shall pay the difference to Owner. F. Where Contractor’s services have been so terminated by Owner, the termination will not affect any rights or remedies of Owner against Contractor then existing or which may thereafter accrue, or any rights or remedies of Owner against Contractor or any surety under the Contract Documents and under any applicable Laws and Regulations. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 68 of 72 Section 00700 – General Conditions 16.03 Owner May Terminate For Convenience A. Upon seven days written notice to Contractor, Owner, without cause and without prejudice to any other right or remedy of Owner, may terminate the Agreement. In such case, Contractor shall be paid for: 1. completed and acceptable Work executed in accordance with the Contract Documents prior to the effective date of termination; 2. expenses sustained prior to the effective date of termination in performing services and furnishing labor, materials, or equipment as required by the Contract Documents in connection with uncompleted Work; 3. demobilization expenses; and 4. overhead and profit on unperformed work. B. Contractor shall not be paid for any economic loss arising out of or resulting from such termination, except for those costs expressly identified above. 16.04 Contractor May Stop Work or Terminate A. If, through no act or fault of Contractor, ( (1) Engineer fails to act on any Application for Payment within 30 days after it is submitted, or (2) Owner fails for 30 days to pay Contractor any sum finally determined to be due, then Contractor may, upon seven days written notice to Owner and Engineer, and provided Owner or Engineer do not remedy such suspension or failure within that time, terminate the contract and recover from Owner payment on the same terms as provided in Paragraph 16.03. B. In lieu of terminating the Contract and without prejudice to any other right or remedy, if Engineer has failed to act on an Application for Payment within 30 days after it is submitted, or Owner has failed for 30 days to pay Contractor any sum finally determined to be due, Contractor may, seven days after written notice to Owner and Engineer, stop the Work until payment is made of all such amounts due Contractor. The provisions of this paragraph are not intended to preclude Contractor from submitting a Change Proposal for an adjustment in Contract Price or Contract Time or otherwise for expenses or damage directly attributable to Contractor’s stopping the Work as permitted by this paragraph. ARTICLE 17 – FINAL RESOLUTION OF DISPUTES 17.01 Methods and Procedures A. Disputes Subject to Final Resolution: The following disputed matters are subject to final resolution under the provisions of this Article: 1. A timely appeal of an approval in part and denial in part of a Claim, or of a denial in full; and 2. Disputes between Owner and Contractor concerning the Work or obligations under the Contract Documents, and arising after Final Payment has been made. 3. Reserved claims of Owner or Contractor under the Contract Documents, including Article 12. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 69 of 72 Section 00700 – General Conditions B. Final Resolution of Disputes: 1. For any disputes subject to this Article, Owner and Contractor shall endeavor to resolve their Claims by mediation. The parties shall share the mediator’s fee and any filing fees equally. The mediation shall be held in the place where the Project is located, unless another location is mutually agreed upon. Agreements reached in mediation shall be enforceable as settlement agreements in any court having jurisdiction. Mediation is a condition precedent to litigation before a court of competent jurisdiction. 2. For any claim not resolved by mediation, the parties agree to submit such claims to the jurisdiction of the District Courts of Williamson County, Texas for final dispute resolution through litigation. ARTICLE 18 – MISCELLANEOUS 18.01 Giving Notice A. Whenever any provision of the Contract Documents requires the giving of written notice, it will be deemed to have been validly given if: 1. delivered in person, by a commercial courier service or otherwise, to the individual or to a member of the firm or to an officer of the corporation for which it is intended; 2. delivered at or sent by registered or certified mail, postage prepaid, to the last business address known to the sender of the notice; or 3. delivered by electronic means with a corresponding confirmation of delivery or read receipt. 18.02 Computation of Times A. When any period of time is referred to in the Contract Documents by days, it will be computed to exclude the first and include the last day of such period. If the last day of any such period falls on a Saturday, Sunday or a legal holiday, the computation of time will conclude on the next business day. 18.03 Cumulative Remedies A. The duties and obligations imposed by these General Conditions and the rights and remedies available hereunder to the parties hereto are in addition to, and are not to be construed in any way as a limitation of, any rights and remedies available to any or all of them which are otherwise imposed or available, by special warranty or guarantee, or by other provisions of the Contract Documents. 18.04 Limitation of Damages A. The Contractor and Owner waive claims against each other for consequential damages arising out of or relating to this Contract. This mutual waiver includes: 1. damages incurred by the Owner for rental expenses, for losses of use, income, profit, financing, business and reputation, and for loss of management or employee productivity or of the services of such persons; and 2. damages incurred by the Contractor for principal office expenses including the compensation of personnel stationed there and home office overhead, for losses of financing, bonding capacity, business and reputation, and for loss of profit except BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 70 of 72 Section 00700 – General Conditions anticipated profit arising directly from the Work and any other damages limited by applicable Laws and Regulations. B. Contractor expressly acknowledges, to the exclusion of all other damages, the total amount of money awarded in an adjudication brought against the Owner for breach of the Agreement shall be limited to the following: 1. The balance due and owed by the Owner under this Contract as it may have been amended; 2. The amount owed for approved change orders or additional work the Contractor was directed to perform by the Owner in connection with this Contract; 3. Reasonable and necessary attorney’s fees that are equitable and just; and 4. Interest as allowed by law, including interest as calculated under the Texas Government Code Chapter 2251. C. Notwithstanding any other limitation of damages set forth in this Contract, the total amount of damages awarded in an adjudication brought against the Owner arising under this Contract shall not include: 1. Consequential damages, including those waived under Paragraph 18.04.A.2; 2. Exemplary damages; 3. Damages for unabsorbed home office overhead; or 4. Damages not expressly permitted under Paragraph 18.04 D. This Section 18.04 does not limit recovery by the Owner of Liquidated Damages or actual damages for delay if Liquidated Damages are not recoverable. 18.05 No Waiver A. A party’s non-enforcement of any provision shall not constitute a waiver of that provision, nor shall it affect the enforceability of that provision or of the remainder of the Contract Documents. 18.06 Survival of Obligations A. All representations, indemnifications, warranties, and guarantees made in, required by, or given in accordance with the Contract Documents, as well as all continuing obligations indicated in the Contract Documents, will survive Final Payment, Final Completion, and Final Acceptance of the Work or termination or completion of the Agreement or termination of the services of Contractor. 18.07 Controlling Law A. The Agreement shall be governed by the laws of the State of Texas. 18.08 Headings A. Article and paragraph headings are inserted for convenience only and do not constitute substantive provisions of the Contract Documents. 18.09 Prevailing Wage Rates A. The Work subject to Government Code Chapter 2258, as amended, concerning payment of Prevailing Wage Rates. BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 71 of 72 Section 00700 – General Conditions B. Contractor shall provide and pay for labor in accordance with the prevailing wage in the locality and shall not pay less than the prevailing wage. Prevailing wage schedule as provided by the most current decision of the U.S. Department of Labor for Williamson County, Texas. C. Contractor shall pay to Owner sixty dollars ($60) for each worker employed for each calendar day or part of the day that the worker is paid less than the wage rates stipulated in this section. 18.10 Right to Audit: A. Whenever the Owner enters into any type of contractual arrangement with the Contractor, then the Contractor’s “records”, upon reasonable notice, shall be open to inspection and subject to audit and/or reproduction during normal business working hours. The Owner’s representative, or an outside representative engaged by the Owner, may perform such audits. The Contractor shall maintain all records relating to this Agreement for four (4) years from the date of Final Payment under the Agreement. B. The Owner shall have the exclusive right to examine the records of the Contractor. The term “records” as referred to herein shall include any and all information, materials and data of every kind and character, including without limitation records, books, papers, documents, contracts, schedules, commitments, arrangements, notes, daily diaries, reports, drawings, receipts, vouchers and memoranda, and any and all other agreements, sources of information and matters that may, in the Owner’s judgment, have any bearing on or pertain to any matters, rights, duties or obligations under or covered by any contract document. Such records shall include (hard copy, as well as computer-readable data if it can be made available), written policies and procedures, time sheets, payroll registers, cancelled checks, personnel file data, correspondence, general ledger entries, and any other record in the Contractor’s possession which may have a bearing on matters of interest to the Owner in connection with the Contractor’s dealings with the Owner (all of the foregoing are hereinafter referred to as “records”). In addition, the Contractor shall permit interviews of employees as well as agents, representatives, vendors, subcontractors and other third parties paid by the Contractor to the extent necessary to adequately permit evaluation and verification of the following: 1. The Contractor’s compliance with Contract Documents; 2. The Contractor’s compliance with the Owner’s business ethics policies; and 3. If necessary, the extent of the Work performed by the Contractor at the time of contract termination. C. The Contractor shall require all payees (examples of payees include subcontractors, insurance agents, material suppliers, etc.) to comply with the provisions of this Article 18.10 by securing the requirements hereof in a written agreement between the Contractor and payee. Such requirements include a flow-down right of audit provision in contracts with payees that also apply to subcontractors and sub-subcontractors, material suppliers, etc. The Contractor shall cooperate fully and shall require Related Parties and all of the Contractor’s subcontractors to cooperate fully in furnishing or in making available to the Owner from time to time whenever requested, in an expeditious manner, any and all such information, materials, and data. D. The Owner’s authorized representative or designee shall have reasonable access to the Contractor’s facilities, shall be allowed to interview all current or former employees to discuss matters pertinent to the performance of this Agreement, and shall be provided BCRUA – Phase 1D WTP Expansion Section 00700 – General Conditions Issued for Bid Page 72 of 72 Section 00700 – General Conditions adequate and appropriate work space in order to conduct audits in compliance with this Article 18.10. E. If an audit inspection or examination in accordance with this Article 18.10 discloses overpricing or overcharges of any nature by the Contractor to the Owner in excess of one- half of one percent (.5%) of the total contract billings, then the reasonable actual cost of the Owner’s audit shall be reimbursed to the Owner by the Contractor. Any adjustments and/or payments, which must be made as a result of any such audit or inspection of the Contractor’s invoices and/or records, shall be made within a reasonable amount of time (not to exceed 90 days) from presentation of the Owner’s findings to the Contractor. F. Review by Owner 1. The Owner, authorized representatives and agents of the Owner, and the TWDB shall, at all times have access to and be permitted to observe and review all work, materials, equipment, payrolls, personnel records, employment conditions, material invoices, and other relevant data and records pertaining to this contract, provided, however that all instructions and approval with respect to the work will be given to the Contractor only by the Owner through authorized representatives or agents. 18.11 Prohibition Against Boycotting Israel: A. Contractor agrees that Contractor currently does not boycott Israel, as that term is defined in Texas Government Code Section 808.001, as amended, nor will Contractor boycott Israel during the term of this Agreement. 18.12 Non-Waiver of Sovereign Immunity A. Nothing in the Contract Documents shall constitute and shall not be interpreted or construed to constitute a waiver of sovereign immunity applicable to the Owner. B. Any limitation of the sovereign immunity of the Owner shall be controlled by applicable Laws and Regulations. 1 Exhibit A. Owner’s Insurance Requirements of Contractor 1. Specific Insurance Requirements The following insurance shall be maintained in effect with limits not less than those set forth below at all times during the term of this Agreement and thereafter as required: Insurance Coverage/Limits Other Requirements Commercial General Liability (Occurrence Basis) Amounts of coverage shall be no less than: $1,000,000 Per Occurrence $2,000,000 General Aggregate $2,000,000 Products/Completed Operations Aggregate $1,000,000 Personal And Advertising Injury Designated Construction Project(s) General Aggregate Limit • Current ISO edition of CG 00 01 • Additional insured status shall be provided in favor of Owner Parties on a combination of ISO forms CG 20 10 04 13 and CG 20 37 04 13. • This coverage shall be endorsed to provide primary and non-contributing liability coverage. It is the intent of the parties to this Agreement that all insurance coverage required herein shall be primary to and will not seek contribution from any other insurance held by Owner Parties, with Owner Parties’ insurance being excess, secondary and non-contributing. • Contractor agrees to waive its rights of recovery and shall cause this insurance to be endorsed to waive all rights of subrogation in favor of Owner Parties on ISO form CG 24 04 19 or CG 24 53 12 19. • The following exclusions/limitations (or their equivalent(s), are prohibited: o Contractual Liability Limitation CG 21 39 o Amendment of Insured Contract Definition CG 24 26 o Limitation of Coverage to Designated Premises or Project, CG 21 44 o Exclusion-Damage to Work Performed by Subcontractors On Your Behalf, CG 22 94 or CG 22 95 o Exclusion-Explosion, Collapse and Underground Property Damage Hazard, CG 21 42 or CG 21 43 o Any Classification limitation o Any Completed Operations exclusion o Any endorsement modifying the Employer’s Liability exclusion or deleting the exception to it o Any endorsement modifying or deleting Explosion, Collapse or Underground coverage o Any Earth Movement (CG 40 04, CG 40 05, or CG 40 06) or Subsidence exclusion o Any Habitational or Residential 2 exclusion applicable to the Work o Any “Insured vs. Insured” exclusion except Named Insured vs. Named Insured o Any Punitive, Exemplary or Multiplied Damages exclusion o Any Earth Movement (CG 40 04, CG 40 05, or CG 40 06) or Subsidence exclusion Business Auto Liability Amount of coverage shall be no less than: $1,000,000 Per Accident (combined single limit for bodily injury and property damage) Current ISO edition of CA 00 01 Arising out of any auto (Symbol 1), including owned, hired and nonowned. Additional Insured status shall be provided to Owner Parties on ISO form CA 20 48 10 13. This insurance shall be endorsed to provide primary and non-contributory liability coverage on ISO form CA 04 49. Workers’ Compensation and Employer’s Liability Amounts of coverage shall be no less than: Statutory Limits $1,000,000 Each Accident and Disease Alternate Employer endorsement USL&H must be provided where such exposure exists. The State in which work is to be performed must listed under Item 3.A. on the Information Page Such insurance shall cover liability arising out of the Contractor’s employment of workers and anyone for whom the Contractor may be liable for workers’ compensation claims. Workers’ compensation insurance is required, and no “alternative” forms of insurance shall be permitted. Stop Gap coverage shall be provided if any work is to be performed in a monopolistic workers’ compensation state. To the extent permitting by law, Contractor agrees to waive its rights of recovery and shall cause this insurance to be endorsed to waive all rights of subrogation in favor of Owner Parties on form WC 42 03 04. Where a Professional Employer Organization (PEO) or “leased employees” are utilized, Contractor shall require its leasing company to provide Workers’ Compensation insurance for said workers and such policy shall be endorsed to provide an Alternate Employer endorsement in favor of Contractor and Owner. Where Contractor uses leased employees with Workers’ Compensation insurance provided by a PEO or employee leasing company, Contractor is strictly prohibited from subletting any of its work without the express written agreement of Owner. Excess Liability (Occurrence Basis) Amounts of coverage shall be no less than: $5,000,000 Each Occurrence $5,000,000 Annual Aggregate Such insurance shall be excess over and be no less broad than all coverages and conditions described above, including but not limited to the required additional insured status, designated construction project(s) and/or location(s) general aggregate, waiver of subrogation, notice 3 of cancellation, and prohibited exclusions or limitations, and will be primary to and not seek contribution from any other insurance (primary, umbrella, contingent or excess) maintained by Owner Parties. Drop-down coverage shall be provided for reduction and/or exhaustion of underlying aggregate limits and shall include a duty to defend any insured. Builders Risk Coverage shall be provided in an amount equal at all times to the full contract value, including change orders, and cost of debris removal for any single occurrence. Coverage shall be at least as broad as an unmodified ISO Special form, shall be provided on a completed-value basis, and shall be primary to any other insurance coverage available to the named insured parties, with that other insurance being excess, secondary and non-contributing. The policy must provide coverage for: Insureds shall include Owner, General Contractor, all Loss Payees and Mortgagees, and subcontractors of all tiers in the Work as Insureds. Such insurance shall cover: o all structure(s) under construction, including retaining walls, paved surfaces and roadways, bridges, glass, foundation(s), footings, underground pipes and wiring, excavations, grading, backfilling or filling; o all temporary structures (e.g., fencing, scaffolding, cribbing, false work, forms, site lighting, temporary utilities and buildings) o Agreed Value o Damage arising from error, omission or deficiency in construction methods, design, specifications, workmanship or materials, including collapse o Debris removal additional limit o Earthquake and Earthquake Sprinkler Leakage o Flood o Freezing o Mechanical breakdown including hot & cold testing o Ordinance or law o Pollutant clean-up and removal o Preservation of property o Theft • Deductible shall not exceed o All Risks of Direct Damage, Per Occurrence, except o Named Storm o Earthquake and Earthquake Sprinkler Leakage, Per Occurrence o Flood, Per Occurrence or excess of NFIP if in Flood Included Included $1,000,000 $5,000,000 $5,000,000 Included Included $1,000,000 $ 25,000 Included Included $10,000 2% subject to $50,000 minimum $100,000 $100,000 located at the site; o all property including materials and supplies on site for installation; o occupancy pre-completion: included without sublimit; o all property including materials and supplies at other locations but intended for use at the site; o all property including materials and supplies in transit to the site for installation by all means of transportation other than ocean transit; and o other Work at the site identified in the Agreement to which this Exhibit is attached. o No protective safeguard warranty shall be permitted. o The termination of coverage provision shall be endorsed to permit occupancy of the covered property being constructed This insurance shall be maintained in effect, unless otherwise provided for the Agreement Documents, until the earliest of: o the date on which all persons and organizations who are insureds under the policy agree that it shall be terminated; o occupancy, in whole or in part; o the date on which release of substantial completion is executed; or o the date on which the insurable interests of Contractor in the Covered Property has ceased. o A waiver of subrogation provision shall be 4 Zone A or V provided in favor of all insureds. Pollution Liability. Contractor ☒ is ☐ is not required to maintain Pollution Liability insurance meeting at least the following specifications. Amounts of coverage shall be no less than: $2,000,000 each claim / $4,000,000 annual aggregate. The policy shall be provided on an occurrence form. Coverage extensions to the General Liability insurance policy without a separate insurance agreement for Contractors Pollution Liability insurance will not fulfill this requirement. The policy must provide coverage for: a. the full scope of the named insured’s operations (ongoing and completed) as described within the scope of work for this Agreement; b. loss arising from pollutants including but not limited to fungus, bacteria, biological substances, mold, microbial matter, asbestos, lead, silica and contaminated drywall; c. third party liability for bodily injury, property damage, clean up expenses, and defense arising from the operations; d. diminution of value and Natural Resources damages; e. contractual liability; and f. claims arising from owned and non- owned disposal sites utilized in the performance of this Agreement. This insurance must name Owner Parties as an Additional Insured. Coverage shall include but not be limited to liability assumed by Contractor under the Agreement, including the tort liability of another assumed in a business contract and provide a separation of insureds clause. This insurance shall be endorsed to provide primary and non-contributing liability coverage. It is the specific intent of the parties to the Agreement that all insurance required herein shall be primary to and shall seek no contribution from all insurance (primary, umbrella, contingent or excess) maintained by Owner, with Owner’s insurance being excess, secondary and non-contributing. Contractor agrees to waive its rights of recovery and shall cause this insurance to be endorsed to waive all rights of subrogation in favor of Owner Parties. This insurance shall be endorsed to provide a 30- day notice of cancellation to Owner. If coverage is provided on a claims-made basis, coverage will at least be retroactive to the earlier date of this Agreement or the commencement of Contractor’s services relative to the work. This insurance is not permitted to include any type of exclusion or limitation of coverage applicable to claims arising from: o Insured vs. insured actions; however, exclusions for claims made between insured within the same economic family are acceptable; o impaired property that has not been physically injured; 5 o materials supplied or handled by the named insured; however, exclusions for the sale and manufacture of products are allowed. Exclusionary language pertaining to materials supplied by the insured shall be reviewed by the certificate holder for approval. o property damage to the work performed by the Contractor; o faulty workmanship as it relates to clean up costs; o punitive, exemplary or multiplied damages; o work performed by subcontractors; and o contractual liability incurred as a result of an injury to an employee of the insured. o Completed operations coverage shall be maintained for a minimum of ten (10) years after the completion of work. The extended reporting period on a claims-made based policy does not fulfill this requirement. Pollution Liability insurance policies insuring a specific job shall have completed operations coverage for at least the duration of the work plus ten (10) years. 2. General Insurance Requirements A. Definitions. For purposes of this Agreement: i. “ISO” means Insurance Services Office. ii. “Contractor” shall include subcontractors of any tier. iii. “Owner Parties” means (a) Brushy Creek Regional Utility Authority (“Owner”), (b) the Project, (c) any lender whose loan is secured by a lien against the Work, (d) their respective shareholders, members, partners, joint venturers, affiliates, subsidiaries, successors and assigns, (e) Engineer and Owner’s Representative (Walker Partners, LLC), (f) any directors, officers, employees, or agents of such persons or entities, and (g) others as required by the Construction Documents. B. Policies. i. Contractor shall maintain such General Liability, Excess Liability, Professional and Pollution insurance in identical coverage, form and amount, including required endorsements, for at least two (2) years following Date of Substantial Completion of the Work to be performed under this Agreement. Contractor shall provide written representation to Owner stating Work completion date. ii. All policies must: a. Be written through insurance companies authorized to do business in the State in which the work is to be performed and rated no less than A-: VII in the most current edition of A. M. Best’s Key Rating Guide at all times Work is to be performed. b. Provide a waiver of subrogation in favor of Owner Parties on all insurance coverage carried by Contractor, whether required herein or not. c. Contain an endorsement providing for thirty (30) days prior written notice of cancellation to Owner. d. Be provided to the Owner Parties in compliance with the requirements herein and shall contain no endorsements that restrict, limit, or exclude coverage required herein in any manner without the prior express written approval of the Owner. 6 iii. Failure of any Owner Party to demand such certificate or other evidence of full compliance with these insurance requirements or failure of any Owner Party to identify a deficiency from evidence that is provided shall not be construed as a waiver of the Contractor’s obligation to maintain such insurance. iv. Contractor shall provide to the Owner a certified copy of all insurance policies required herein within ten (10) days of any such request. Renewal policies, if necessary, shall be delivered to the Owner prior to the expiration of the previous policy. v. Commencement of Work without provision of the required certificate of insurance, evidence of insurance and/or required endorsements, or without compliance with any other provision of this Agreement, shall not constitute a waiver by any Owner Party of any rights. The Owner shall have the right, but not the obligation, of prohibiting the Contractor or any subcontractor from performing any Work until such certificate of insurance, evidence of insurance and/or required endorsements are received and approved by the Owner. C. Limits, Deductibles and Retentions i. The limits of liability may be provided by a single policy of insurance or by a combination of primary and excess policies, but in no event shall the total limits of liability available for any one occurrence or accident be less than the amount required herein. ii. No deductible or self-insured retention shall exceed $25,000 without prior written approval of the Owner, except as otherwise specified herein. All deductibles and/or retentions shall be paid by, assumed by, for the account of, and at the Contractor’s sole risk. The Contractor shall not be reimbursed for same D. Forms i. If the forms of policies, endorsements, certificates or evidence of insurance required by this Exhibit are superseded or discontinued, Owner will have the right to require other equivalent forms. ii. Any policy or endorsement form other than a form specified in this Exhibit must be approved in advance by Owner. E. Evidence of Insurance. Insurance must be evidenced as follows: i. ACORD Form 25 Certificate of Liability Insurance for liability coverages. ii. ACORD Form 28 Evidence of Commercial Property Insurance for property coverages. iii. Evidence shall be provided to Owner prior to commencing Work and prior to the expiration of any required coverage. iv. ACORD Forms specify: a. Owner as certificate holder at Owner’s mailing address; b. Insured’s name, which must match that on this Agreement; c. Insurance companies producing each coverage and the policy number and policy date of each coverage; d. Producer of the certificate with correct address and phone number and have the signature of the authorized representative of the producer; e. Additional Insured status in favor of Owner Parties; f. Amount of any deductible or self-insured retention in excess of $25,000; g. Designated Construction Project(s) General Aggregate Limit; h. Primary and non-contributory status; i. Waivers of subrogation; and j. All exclusions and limitations added by endorsement to the General Liability coverage. This can be achieved by attachment of the Schedule of Forms and Endorsements page. v. Copies of the following shall also be provided: a. General Liability Additional insured endorsement(s); b. General Liability Schedule of Forms and Endorsements page(s); and c. 30 Day Notice of Cancellation endorsement applicable to all required policies. F. Contractor Insurance Representations to Owner Parties i. It is expressly understood and agreed that the insurance coverages required herein (a) represent Owner Parties’ minimum requirements and are not to be construed to void or limit the Contractor’s indemnity obligations as contained in this Agreement nor represent in any manner a determination of the insurance coverages the Contractor should or should not maintain for its own protection; and (b) are being, or have been, obtained by the Contractor in 7 support of the Contractor’s liability and indemnity obligations under this Agreement. Irrespective of the requirements as to insurance to be carried as provided for herein, the insolvency, bankruptcy or failure of any insurance company carrying insurance of the Contractor, or the failure of any insurance company to pay claims accruing, shall not be held to affect, negate or waive any of the provisions of this Agreement. ii. Failure to obtain and maintain the required insurance shall constitute a material breach of, and default under, this Agreement. If the Contractor shall fail to remedy such breach within five (5) business days after notice by the Owner, the Contractor will be liable for any and all costs, liabilities, damages and penalties resulting to the Owner Parties from such breach, unless a written waiver of the specific insurance requirement(s) is provided to the Contractor by the Owner. In the event of any failure by the Contractor to comply with the provisions of this Agreement, the Owner may, without in any way compromising or waiving any right or remedy at law or in equity, on notice to the Contractor, purchase such insurance, at the Contractor’s expense, provided that the Owner shall have no obligation to do so and if the Owner shall do so, the Contractor shall not be relieved of or excused from the obligation to obtain and maintain such insurance amounts and coverages. iii. This Exhibit is an independent contract provision and shall survive the termination or expiration of the Construction Agreement. G. Insurance Requirements of Contractor’s Subcontractors i. Insurance similar to that required of the Contractor shall be provided by all subcontractors (or provided by the Contractor on behalf of subcontractors) to cover operations performed under any subcontract agreement. The Contractor shall be held responsible for any modification in these insurance requirements as they apply to subcontractors. The Contractor shall maintain certificates of insurance from all subcontractors containing provisions similar to those listed herein (modified to recognize that the certificate is from subcontractor) enumerating, among other things, the waivers of subrogation, additional insured status, and primary liability as required herein, and make them available to the Owner upon request. ii. The Contractor is fully responsible for loss and damage to its property on the site, including tools and equipment, and shall take necessary precautions to prevent damage to or vandalism, theft, burglary, pilferage and unexplained disappearance of property. Any insurance covering the Contractor’s or its subcontractor’s property shall be the Contractor’s and its subcontractor’s sole and complete means or recovery for any such loss. To the extent any loss is not covered by said insurance or subject to any deductible or co-insurance, the Contractor shall not be reimbursed for same. Should the Contractor or its subcontractors choose to self insure this risk, it is expressly agreed that the Contractor hereby waives, and shall cause its subcontractors to waive, any claim for damage or loss to said property in favor of the Owner Parties. H. Use of the Owners Equipment The Contractor, its agents, employees, subcontractors or suppliers shall use the Owners equipment only with express written permission of the Owners designated representative and in accordance with the Owners terms and condition for such use. If the Contractor or any of its agents, employees, subcontractors or suppliers utilize any of the Owners equipment for any purpose, including machinery, tools, scaffolding, hoists, lifts or similar items owned, leased or under the control of the Owner, the Contractor shall defend, indemnify and be liable to the Owner Parties for any and all loss or damage which may arise from such use. I. Release and Waiver The Contractor hereby releases, and shall cause its subcontractors to release, the Owner Parties from any and all claims or causes of action whatsoever which the Contractor and/or its subcontractors might otherwise now or hereafter possess resulting in or from or in any way connected with any loss covered by insurance, whether required herein or not, or which should have been covered by insurance required herein, including the deductible and/or uninsured portion thereof, maintained and/or required to be maintained by the Contractor and/or its subcontractors pursuant to this Agreement. THE FOREGOING RELEASE AND WAIVER APPLY EVEN IF THE LOSS OR DAMAGE IS CAUSED IN WHOLE OR IN PART BY THE FAULT OR NEGLIGENCE OR STRICT LIABILITY OF THE OWNER PARTIES. INSR ADDL SUBR LTR INSR WVD DATE (MM/DD/YYYY) PRODUCER CONTACT NAME: FAXPHONE (A/C, No):(A/C, No, Ext): E-MAIL ADDRESS: INSURER A : INSURED INSURER B : INSURER C : INSURER D : INSURER E : INSURER F : POLICY NUMBER POLICY EFF POLICY EXPTYPE OF INSURANCE LIMITS(MM/DD/YYYY)(MM/DD/YYYY) COMMERCIAL GENERAL LIABILITY AUTOMOBILE LIABILITY UMBRELLA LIAB EXCESS LIAB WORKERS COMPENSATION AND EMPLOYERS' LIABILITY DESCRIPTION OF OPERATIONS / LOCATIONS / VEHICLES (ACORD 101, Additional Remarks Schedule, may be attached if more space is required) AUTHORIZED REPRESENTATIVE INSURER(S) AFFORDING COVERAGE NAIC # Y / N N / A (Mandatory in NH) ANY PROPRIETOR/PARTNER/EXECUTIVE OFFICER/MEMBER EXCLUDED? EACH OCCURRENCE $ DAMAGE TO RENTED $PREMISES (Ea occurrence)CLAIMS-MADE OCCUR MED EXP (Any one person)$ PERSONAL & ADV INJURY $ GENERAL AGGREGATE $GEN'L AGGREGATE LIMIT APPLIES PER: PRODUCTS - COMP/OP AGG $ $ PRO- OTHER: LOCJECT COMBINED SINGLE LIMIT $(Ea accident) BODILY INJURY (Per person)$ANY AUTO OWNED SCHEDULED BODILY INJURY (Per accident)$AUTOS ONLY AUTOS AUTOS ONLY HIRED PROPERTY DAMAGE $AUTOS ONLY (Per accident) $ OCCUR EACH OCCURRENCE $ CLAIMS-MADE AGGREGATE $ DED RETENTION $$ PER OTH- STATUTE ER E.L. EACH ACCIDENT $ E.L. DISEASE - EA EMPLOYEE $ If yes, describe under E.L. DISEASE - POLICY LIMIT $DESCRIPTION OF OPERATIONS below POLICY NON-OWNED SHOULD ANY OF THE ABOVE DESCRIBED POLICIES BE CANCELLED BEFORE THE EXPIRATION DATE THEREOF, NOTICE WILL BE DELIVERED IN ACCORDANCE WITH THE POLICY PROVISIONS. THIS IS TO CERTIFY THAT THE POLICIES OF INSURANCE LISTED BELOW HAVE BEEN ISSUED TO THE INSURED NAMED ABOVE FOR THE POLICY PERIOD INDICATED. NOTWITHSTANDING ANY REQUIREMENT, TERM OR CONDITION OF ANY CONTRACT OR OTHER DOCUMENT WITH RESPECT TO WHICH THIS CERTIFICATE MAY BE ISSUED OR MAY PERTAIN, THE INSURANCE AFFORDED BY THE POLICIES DESCRIBED HEREIN IS SUBJECT TO ALL THE TERMS, EXCLUSIONS AND CONDITIONS OF SUCH POLICIES. LIMITS SHOWN MAY HAVE BEEN REDUCED BY PAID CLAIMS. THIS CERTIFICATE IS ISSUED AS A MATTER OF INFORMATION ONLY AND CONFERS NO RIGHTS UPON THE CERTIFICATE HOLDER. THIS CERTIFICATE DOES NOT AFFIRMATIVELY OR NEGATIVELY AMEND, EXTEND OR ALTER THE COVERAGE AFFORDED BY THE POLICIES BELOW. THIS CERTIFICATE OF INSURANCE DOES NOT CONSTITUTE A CONTRACT BETWEEN THE ISSUING INSURER(S), AUTHORIZED REPRESENTATIVE OR PRODUCER, AND THE CERTIFICATE HOLDER. IMPORTANT: If the certificate holder is an ADDITIONAL INSURED, the policy(ies) must have ADDITIONAL INSURED provisions or be endorsed. If SUBROGATION IS WAIVED, subject to the terms and conditions of the policy, certain policies may require an endorsement. A statement on this certificate does not confer any rights to the certificate holder in lieu of such endorsement(s). COVERAGES CERTIFICATE NUMBER:REVISION NUMBER: CERTIFICATE HOLDER CANCELLATION © 1988-2015 ACORD CORPORATION. All rights reserved. The ACORD name and logo are registered marks of ACORDACORD 25 (2016/03) ACORDTM CERTIFICATE OF LIABILITY INSURANCE The Cincinnati Insurance Company Texas Mutual Insurance Company Evanston Insurance Company 5/31/2023 Marsh & McLennan Agency LLC 221 West 6th St, Ste. 1400 Austin, TX 78701 512 453-0031 Laura Gregory Byno 972 770-1600 laura.gregory@MarshMMA.com Excel Construction Services, LLC P. O. Box 2260 Leander, TX 78646 10677 22945 35378 A X X X PD Ded:1,000 X EPP0065940 03/01/2023 03/01/2024 1,000,000 500,000 5,000 1,000,000 2,000,000 2,000,000 A X X X EPP0065940 03/01/2023 03/01/2024 1,000,000 A X X EPP0065940 03/01/2023 03/01/2024 5,000,000 5,000,000 B N 0001177290 03/01/2023 03/01/2024 X 1,000,000 1,000,000 1,000,000 C Pollution Liab CPLMOL117420 05/30/2023 11/20/2024 $2,000,000 - Occurrence $4,000,000 - Aggregate Project: Phase 1D Water Treatment Plant Expansion Certificate holder and its parties are included as additional insured as per written contract Forms and Endorsements Schedule: (See Attached Descriptions) Brushy Creek Regional Utility Authority 221 E Main St Round Rock, TX 78664 1 of 2 #S12846222/M12846208 EXCELCONST3Client#: 812465 SSLXG 1 of 2 #S12846222/M12846208 SAGITTA 25.3 (2016/03) DESCRIPTIONS (Continued from Page 1) General Liability: Contractors' Commercial General Liability Broadened Endorsement #GA233 0207 Commercial General Liability Coverage Form #GA101TX1008 Cancellation or Non-Renewal by Us Notification to Designated Entity #IA4087 0811 Automobile: Additional Insured by Contract #AA 4171 1105 Blanket Waiver of Subrogation - Auto #AA4172 0909 Cancellation or Non-Renewal by Us Notification to Designated Entity #IA4087 0811 Workers Compensation: Texas Waiver of Our Right to Recover from Others #WC420304B Texas Notice of Material Change Endorsement #WC420601 2 of 2 #S12846222/M12846208 DATE (MM/DD/YYYY) AGENCY PHONE (A/C, No, Ext): COMPANY E-MAIL ADDRESS: FAX (A/C, No): CODE:SUB CODE: AGENCY CUSTOMER ID #: INSURED LOAN NUMBER POLICY NUMBER EFFECTIVE DATE EXPIRATION DATE THIS REPLACES PRIOR EVIDENCE DATED: LOCATION/DESCRIPTION COVERAGE/PERILS/FORMS AMOUNT OF INSURANCE DEDUCTIBLE NAME AND ADDRESS AUTHORIZED REPRESENTATIVE CONTINUED UNTIL TERMINATED IF CHECKED ADDITIONAL INSURED LENDER'S LOSS PAYABLE MORTGAGEE LOAN # LOSS PAYEE THIS EVIDENCE OF PROPERTY INSURANCE IS ISSUED AS A MATTER OF INFORMATION ONLY AND CONFERS NO RIGHTS UPON THE ADDITIONAL INTEREST NAMED BELOW. THIS EVIDENCE DOES NOT AFFIRMATIVELY OR NEGATIVELY AMEND, EXTEND OR ALTER THE COVERAGE AFFORDED BY THE POLICIES BELOW. THIS EVIDENCE OF INSURANCE DOES NOT CONSTITUTE A CONTRACT BETWEEN THE ISSUING INSURER(S), AUTHORIZED REPRESENTATIVE OR PRODUCER, AND THE ADDITIONAL INTEREST. SHOULD ANY OF THE ABOVE DESCRIBED POLICIES BE CANCELLED BEFORE THE EXPIRATION DATE THEREOF, NOTICE WILL BE DELIVERED IN ACCORDANCE WITH THE POLICY PROVISIONS. PROPERTY INFORMATION COVERAGE INFORMATION REMARKS (Including Special Conditions) CANCELLATION ADDITIONAL INTEREST ACORD 27 (2016/03) 1 of © 1993-2015 ACORD CORPORATION. All rights reserved. The ACORD name and logo are registered marks of ACORD THE POLICIES OF INSURANCE LISTED BELOW HAVE BEEN ISSUED TO THE INSURED NAMED ABOVE FOR THE POLICY PERIOD INDICATED. NOTWITHSTANDING ANY REQUIREMENT, TERM OR CONDITION OF ANY CONTRACT OR OTHER DOCUMENT WITH RESPECT TO WHICH THIS EVIDENCE OF PROPERTY INSURANCE MAY BE ISSUED OR MAY PERTAIN, THE INSURANCE AFFORDED BY THE POLICIES DESCRIBED HEREIN IS SUBJECT TO ALL THE TERMS, EXCLUSIONS AND CONDITIONS OF SUCH POLICIES. LIMITS SHOWN MAY HAVE BEEN REDUCED BY PAID CLAIMS. PERILS INSURED BASIC BROAD SPECIAL ACORDTM EVIDENCE OF PROPERTY INSURANCE EXCELCONST3 05/31/2023 Marsh & McLennan Agency LLC 221 West 6th St, Ste. 1400 Austin, TX 78701 512 453-0031 812465 laura.gregory@MarshMMA.com Travelers Lloyds Insurance Company One Tower Square Hartford, CT 06183 Excel Construction Services, LLC P. O. Box 2260 Leander, TX 78646 QT6609824601TLC23 05/30/23 11/30/24 Location #1 Job Site Cedar Park, TX 78613 X Builder's Risk $16,836,100 $50,000 Temporary Storage $1,000,000 $50,000 Transit $500,000 $50,000 Brushy Creek Regional Utility Authority 221 E. Main St. Round Rock, TX 78664 X Owner 1 S 608765 SSLXG BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 1 of 36 SUPPLEMENTAL GENERAL CONDITIONS OF THE CONSTRUCTION CONTRACT FEDERAL REQUIREMENTS FOR AMERICAN RESCUE PLAN GRANT FUNDED RPOJECTS The Work performed under this Contract shall conform to the following Federal Requirements for a federally funded project under 2 CFR 200. Section No. Title FR-01 Breach of Contract Terms FR-02 Termination of Contract FR-03 Equal Employment Opportunity - 41 CFR Part 60-1.4(b) FR-04 Standard Federal Equal Employment Opportunity Construction Contract Specifications – 41 CFR Part 60.4.3 FR-05 Copeland Anti-Kickback Act 29 CFR Part 5 FR-06 Davis-Bacon Labor Requirements 29 CFR part 5 FR-07 Contract Work hours and Safety Standards Act Requirements FR-08 Rights to Inventions FR-9 Access to Records and Record Retention FR-10 Clean Air and Water Pollution Control FR-11 Energy Conservation Requirements FR-12 Certification Regarding Debarment, Suspension, Ineligibility, and Voluntary Exclusion FR-13 Lobbying and Influencing Procurement FR-14 Domestic Preference for Procurements FR-15 Procurement of Recovered Materials BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 2 of 36 FEDERAL REQUIREMENTS: FR-01 BREACH OF CONTRACT TERMS Any violation or breach of terms of this contract on the part of the contractor or their subcontractors may result in the suspension or termination of this contract or such other action that may be necessary to enforce the rights of the parties of this agreement. The duties and obligations imposed by the Contract Documents and the rights and remedies available thereunder shall be in addition to and not a limitation of any duties, obligations, rights and remedies otherwise imposed or available by law. BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 3 of 36 FEDERAL REQUIREMENTS: FR-02 TERMINATION OF CONTRACT 1 The City may, by written notice, terminate this contract in whole or in part at any time, either for the City's convenience or because of failure to fulfill the contract obligations. Upon receipt of such notice services shall be immediately discontinued (unless the notice directs otherwise) and all materials as may have been accumulated in performing this contract, whether completed or in progress, delivered to the City. 2 If the termination is for the convenience of the City, an equitable adjustment in the contract price shall be made, but no amount shall be allowed for anticipated profit on unperformed services. 3 If the termination is due to failure to fulfill the contractor's obligations, the City may take over the work and prosecute the same to completion by contract or otherwise. In such case, the contractor shall be liable to the City for any additional cost occasioned to the City thereby. 4 If, after notice of termination for failure to fulfill contract obligations, it is determined that the contractor had not so failed, the termination shall be deemed to have been effected for the convenience of the City. In such event, adjustment in the contract price shall be made as provided in this clause. 5 The rights and remedies of the City provided in this clause are in addition to any other rights and remedies provided by law or under this contract. BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 4 of 36 FEDERAL REQUIREMENTS: FR-03 EQUAL EMPLOYMENT OPPORTUNITY - Executive Order 11246 as amended, 41 CFR PART 60- 1.4(b) During the performance of this contract, the contractor agrees as follows: a. The contractor will not discriminate against any employee or applicant for employment because of race, color, religion, sex, or national origin. The contractor will take affirmative action to ensure that applicants are employed, and that employees are treated during employment without regard to their race, color, religion, sex, or national origin. Such action shall include, but not be limited to the following: Employment, upgrading, demotion, or transfer; recruitment or recruitment advertising; layoff or termination; rates of pay or other forms of compensation; and selection for training, including apprenticeship. The contractor agrees to post in conspicuous places, available to employees and applicants for employment, notices to be provided setting forth the provisions of this nondiscrimination clause. b. The contractor will, in all solicitations or advertisements for employees placed by or on behalf of the contractor, state that all qualified applicants will receive considerations for employment without regard to race, color, religion, sex, or national origin. c. The contractor will send to each labor union or representative of workers with which he/she has a collective bargaining agreement or other contract or understanding, a notice to be provided by the agency contracting officer, advising the labor union or workers' representatives of the contractor's commitments under Section 202 of Executive Order 11246 of September 24, 1965, and shall post copies of the notice in conspicuous places available to employees and applicants for employment. d. The contractor will comply with all provisions of Executive Order 11246 of September 24, 1965, as amended, and of the rules, regulations, and relevant orders of the Secretary of Labor. e. The contractor will furnish all information and reports required by Executive Order 11246 of September 24, 1965, and by rules, regulations, and orders of the Secretary of Labor, or pursuant thereto, and will permit access to his/her books, records, and accounts by the contracting agency and the Secretary of Labor for purposes of investigation to ascertain compliance with such rules, regulations, and orders. f. In the event of the contractor's noncompliance with the nondiscrimination clauses of this contract or with any of the such rules, regulations, or orders, this contract may be cancelled, terminated or suspended in whole or in part and the contractor may be declared ineligible for further Government contracts or federally assisted construction contracts in accordance with procedure authorized in Executive Order 11246 of September 24, 1965, and such other sanctions may be imposed and remedies invoked as provided in Executive Order 11246 of September 24, BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 5 of 36 1965, or by rule, regulation, or order of the Secretary of Labor, or as otherwise provided by law. g. The contractor will include the provisions of paragraphs (1) through (7) in every subcontract or purchase order unless exempted by rules, regulations, or orders of the Secretary of Labor issued pursuant to Section 204 of Executive Order 11246 of September 24, 1965, so that such provisions will be binding upon each subcontractor or vendor. The contractor will take such action with respect to any subcontract or purchase order as may be directed by the Secretary of Labor as a means of enforcing such provision, including sanctions for noncompliance: Provided, however, that in the event a contractor becomes involved in, or is threatened with, litigation with a subcontractor or vendor as a result of such direction by the administering agency the contractor may request the United States to enter into such litigation to protect the interests of the United States. [Sec. 202 amended by EO 11375 of Oct 13, 1967, 32 FR 14303, 3 CFR, 1966-1970 Comp., p. 684. EO 12086 of Oct5, 1978, 43 FR 46501, 3 CFR, 1978 Comp., p. 230] SEC. 203.Each contractor having a contract containing the provisions prescribed in Section 202 shall file, and shalt cause each of his subcontractors to file, Compliance Reports with the contracting agency or the Secretary of Labor as may be directed. Compliance Reports shall be filed within such times and shall contain such information as to the practices, policies, programs, and employment policies, programs, and employment statistics of the contractor and each subcontractor, and shall be in such form, as the Secretary of Labor may prescribe. Contractors or subcontractors may be required to state whether they have participated in any previous contract subject to the provisions of this Order, or any preceding similar Executive order, and in that event to submit, on behalf of themselves and their proposed subcontractors, Compliance Reports prior to or as an initial part of their bid or negotiation of a contract. Whenever the contractor or subcontractor has a collective bargaining agreement or other contract or understanding with a labor union or an agency referring workers or providing or supervising apprenticeship or training for such workers, the Compliance Report shall include such information as to such labor union's or agency's practices and policies affecting compliance as the Secretary of Labor may prescribe: Provided, That to the extent such information is within the exclusive possession of a labor union or an agency referring workers or providing or supervising apprenticeship or training and such labor union or agency shall refuse to furnish such information to the contractor, the contractor shall so certify to the Secretary of Labor as part of its Compliance Report and shall set forth what efforts he has made to obtain such information. The Secretary of Labor may direct that any contractor or subcontractor shall submit, as part of his/her Compliance Report, a statement in writing, signed by an authorized officer or agent on behalf of any labor union or any agency referring workers or providing or supervising apprenticeship or other training, with which the contractor deals, with supporting BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 6 of 36 information, to the effect that the signer's practices and policies do not discriminate on the grounds of race, color, religion, sex or national origin, and that the signer either will affirmatively cooperate in the implementation of the policy and provisions of this Order or that it consents and agrees that recruitment, employment, and the terms and conditions of employment under the proposed contract shall be in accordance with the purposes and provisions of the order. In the event that the union, or the agency shall refuse to execute such a statement, the Compliance Report shall so certify and set forth what efforts have been made to secure such a statement and such additional factual material as the Secretary of Labor may require. [Sec. 203 amended by EO 11375 of Oct. 13, 1967, 32 FR 14303, 3 CFR, 1966-1970 Comp., p. 684; EO 12086 of Oct. 5, 1978, 43 FR 46501, 3 CFR, 1978 Comp., p.230] BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 7 of 36 FEDERAL REQUIREMENTS: FR-04 STANDARD FEDERAL EQUAL EMPLOYMENT OPPORTUNITY CONSTRUCTION CONTRACT SPECIFICATIONS - 41 CFR Part 60.4.3 1. As used in these specifications: a. "Covered area" means the geographical area described in the solicitation from which this contract resulted; b. "Director" means Director, Office of Federal Contract Compliance Programs (OFCCP), U.S. Department of Labor, or any person to whom the Director delegates authority; c. "Employer identification number" means the Federal social security number used on the Employer's Quarterly Federal Tax Return, U.S. Treasury Department Form 941; d. "Minority" includes: (i) Black (all) persons having origins in any of the Black African racial groups not of Hispanic origin); (ii) Hispanic (all persons of Mexican, Puerto Rican, Cuban, Central or South American, or other Spanish culture or origin regardless of race); (iii) Asian and Pacific Islander (all persons having origins in any of the original peoples of the Far East, Southeast Asia, the Indian Subcontinent, or the Pacific Islands); and (iv) American Indian or Alaskan native (all persons having origins in any of the original peoples of North America and maintaining identifiable tribal affiliations through membership and participation or community identification). 2. Whenever the contractor, or any subcontractor at any tier, subcontracts a portion of the work involving any construction trade, it shall physically include in each subcontract in excess of $10,000 the provisions of these specifications and the Notice which contains the applicable goals for minority and female participation and which is set forth in the solicitations from which this contract resulted. 3. If the contractor is participating (pursuant to 41 CFR 60-4.5) in a Hometown Plan approved by the U.S. Department of Labor in the covered area either individually or through an association, its affirmative action obligations on all work in the Plan area (including goals and timetables) shall be in accordance with that Plan for those trades which have unions participating in the Plan. Contractors shall be able to demonstrate their participation in and compliance with the provisions of any such Hometown Plan. Each contractor or subcontractor participating in an approved plan is individually required to comply with its obligations under the EEO clause and to make a good faith effort to achieve each goal under the BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 8 of 36 Plan in each trade in which it has employees. The overall good faith performance by other contractors or subcontractors toward a goal in an approved Plan does not excuse any covered contractor's or subcontractor's failure to take good faith efforts to achieve the Plan goals and timetables. 4. The contractor shall implement the specific affirmative action standards provided in paragraphs 18.7a through 18.7p of these specifications. The goals set forth in the solicitation from which this contract resulted are expressed as percentages of the total hours of employment and training of minority and female utilization the contractor should reasonably be able to achieve in each construction trade in which it has employees in the covered area. Covered construction contractors performing construction work in a geographical area where they do not have a Federal or federally assisted construction contract shall apply the minority and female goals established for the geographical area where the work is being performed. Goals are published periodically in the Federal Register in notice form, and such notices may be obtained from any Office of Federal Contract Compliance Programs office or from Federal procurement contracting officers. The contractor is expected to make substantially uniform progress in meeting its goals in each craft during the period specified. 5. Neither the provisions of any collective bargaining agreement nor the failure by a union with whom the contractor has a collective bargaining agreement to refer either minorities or women shall excuse the contractor's obligations under these specifications, Executive Order 11246 or the regulations promulgated pursuant thereto. 6. In order for the non-working training hours of apprentices and trainees to be counted in meeting the goals, such apprentices and trainees shall be employed by the contractor during the training period and the contractor shall have made a commitment to employ the apprentices and trainees at the completion of their training, subject to the availability of employment opportunities. Trainees shall be trained pursuant to training programs approved by the U.S. Department of Labor. 7. The contractor shall take specific affirmative actions to ensure equal employment opportunity. The evaluation of the contractor's compliance with these specifications shall be based upon its effort to achieve maximum results from its actions. The contractor shall document these efforts fully and shall implement affirmative action steps at least as extensive as the following: a. Ensure and maintain a working environment free of harassment, intimidation, and coercion at all sites, and in all facilities at which the contractor's employees are assigned to work. The contractor, where possible, will assign two or more women to each construction project. The contractor shall specifically ensure that all foremen, superintendents, and other onsite supervisory personnel are aware of and carry out the contractor's obligation to maintain such a working environment, with specific attention to minority or female individuals working at such sites or in such facilities. BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 9 of 36 b. Establish and maintain a current list of minority and female recruitment sources, provide written notification to minority and female recruitment sources and to community organizations when the contractor or its unions have employment opportunities available, and maintain a record of the organizations' responses. c. Maintain a current file of the names, addresses, and telephone numbers of each minority and female off-the-street applicant and minority or female referral from a union, a recruitment source, or community organization and of what action was taken with respect to each such individual. If such individual was sent to the union hiring hall for referral and was not referred back to the contractor by the union or, if referred, not employed by the contractor, this shall be documented in the file with the reason therefore along with whatever additional actions the contractor may have taken. d. Provide immediate written notification to the Director when the union or unions with which the contractor has a collective bargaining agreement has not referred to the contractor a minority person or female sent by the contractor, or when the contractor has other information that the union referral process has impeded the contractor's efforts to meet its obligations. e. Develop on-the-job training opportunities and/or participate in training programs for the area which expressly include minorities and women, including upgrading programs and apprenticeship and trainee programs relevant to the contractor's employment needs, especially those programs funded or approved by the Department of Labor. The contractor shall provide notice of these programs to the sources compiled under 7b above. f. Disseminate the contractor's EEO policy by providing notice of the policy to unions and training programs and requesting their cooperation in assisting the contractor in meeting its EEO obligations; by including it in any policy manual and collective bargaining agreement; by publicizing it in the company newspaper, annual report, etc.; by specific review of the policy with all management personnel and with all minority and female employees at least once a year; and by posting the company EEO policy on bulletin boards accessible to all employees at each location where construction work is performed. g. Review, at least annually, the company's EEO policy and affirmative action obligations under these specifications with all employees having any responsibility for hiring, assignment, layoff, termination, or other employment decisions including specific review of these items with onsite supervisory personnel such a superintendents, general foremen, etc., prior to the initiation of construction work at any job site. A written record shall be made and maintained identifying the time and place of these meetings, persons attending, subject matter discussed, and disposition of the subject matter. h. Disseminate the contractor's EEO policy externally by including it in any advertising in the news media, specifically including minority and female news media, and providing written notification to and discussing the contractor's EEO policy with other contractors and subcontractors with whom the contractor does or anticipates doing business. BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 10 of 36 i. Direct its recruitment efforts, both oral and written, to minority, female, and community organizations, to schools with minority and female students; and to minority and female recruitment and training organizations serving the contractor's recruitment area and employment needs. Not later than one month prior to the date for the acceptance of applications for apprenticeship or other training by any recruitment source, the contractor shall send written notification to organizations, such as the above, describing the openings, screening procedures, and tests to be used in the selection process. j. Encourage present minority and female employees to recruit other minority persons and women and, where reasonable provide after school, summer, and vacation employment to minority and female youth both on the site and in other areas of a contractor's workforce. k. Validate all tests and other selection requirements where there is an obligation to do so under 41 CFR Part 60-3. l. Conduct, at least annually, an inventory and evaluation at least of all minority and female personnel, for promotional opportunities and encourage these employees to seek or to prepare for, through appropriate training, etc., such opportunities. m. Ensure that seniority practices, job classifications, work assignments, and other personnel practices do not have a discriminatory effect by continually monitoring all personnel and employment related activities to ensure that the EEO policy and the contractor's obligations under these specifications are being carried out. n. Ensure that all facilities and company activities are non-segregated except that separate or single user toilet and necessary changing facilities shall be provided to assure privacy between the sexes. o. Document and maintain a record of all solicitations of offers for subcontracts from minority and female construction contractors and suppliers, including circulation of solicitations to minority and female contractor associations and other business associations. p. Conduct a review, at least annually, of all supervisor's adherence to and performance under the contractor's EEO policies and affirmative action obligations. 8. Contractors are encouraged to participate in voluntary associations, which assist in fulfilling one or more of their affirmative action obligations (18.7a through 18.7p). The efforts of a contractor association, joint contractor union, contractor community, or other similar groups of which the contractor is a member and participant, may be asserted as fulfilling any one or more of its obligations under 18.7a through 18.7p of these specifications provided that the contractor actively participates in the group, makes every effort to assure that the group has a positive impact on the employment of minorities and women in the industry, ensures that the concrete benefits of the program are reflected in the contractor's minority and female workforce participation, makes a good faith effort to meet its individual goals and BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 11 of 36 timetables, and can provide access to documentation which demonstrates the effectiveness of actions taken on behalf of the contractor. The obligation to comply, however, is the contractor's and failure of such a group to fulfill an obligation shall not be a defense for the contractor's noncompliance. 9. A single goal for minorities and a separate single goal for women have been established. The contractor, however, is required to provide equal employment opportunity and to take affirmative action for all minority groups, both male and female, and all women, both minority and non-minority. Consequently, if the particular group is employed in a substantially disparate manner (for example, even though the contractor has achieved its goals for women generally,) the contractor may be in violation of the Executive Order if a specific minority group of women is underutilized. 10. The contractor shall not use the goals and timetables or affirmative action standards to discriminate against any person because of race, color, religion, sex, or national origin. 11. The contractor shall not enter into any subcontract with any person or firm debarred from Government contracts pursuant to Executive Order 11246. 12. The contractor shall carry out such sanctions and penalties for violation of these specifications and of the Equal Opportunity Clause, including suspension, termination, and cancellation of existing subcontracts as may be imposed or ordered pursuant to Executive Order 11246, as amended, and its implementing regulations, by the Office of Federal Contract Compliance Programs. Any contractor who fails to carry out such sanctions and penalties shall be in violation of these specifications and Executive Order 11246, as amended. 13. The contractor, in fulfilling its obligations under these specifications, shall implement specific affirmative action steps, at least as extensive as those standards prescribed in paragraph 18.7 of these specifications, so as to achieve maximum results from its efforts to ensure equal employment opportunity. If the contractor fails to comply with the requirements of the Executive Order, the implementing regulations, or these specifications, the Director shall proceed in accordance with 41 CFR 60-4.8. 14. The contractor shall designate a responsible official to monitor all employment related activity to ensure that the company EEO policy is being carried out, to submit reports relating to the provisions hereof as may be required by the Government, and to keep records. Records shall at least include for each employee, the name, address, telephone number, construction trade, union affiliation if any, employee identification number when assigned, social security number, race, sex, status (e.g., mechanic, apprentice, trainee, helper, or laborer), dates of changes in status, hours worked per week in the indicated trade, rate of pay, and locations at which the work was performed. Records shall be maintained in an easily understandable and retrievable form; however, to the degree that existing records satisfy this requirement, contractors shall not be required to maintain separate records. BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 12 of 36 15. Nothing herein provided shall be construed as a limitation upon the application of other laws which establish different standards of compliance or upon the application of requirements for the hiring of local or other area residents. BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 13 of 36 FEDERAL REQUIREMENTS: FR-05 COPELAND “ANTI-KICKBACK” ACT – 18 U.S.C. 874 / 40 U.S.C. 276c / 29 CFR Part 3 Compliance with Copeland Act requirements. The Contractor shall comply with all the requirements of 29 CFR Part 3 which are incorporated by reference in this contract. TITLE 18 USC 874 Sec. 874. Kickbacks from public works employees "Whoever, by force, intimidation, or threat of procuring dismissal from employment, or by any other manner whatsoever induces any person employed in the construction, prosecution, completion or repair of any public building, public work, or building or work financed in whole or in part by loans or grants from the United States, to give up any part of the compensation to which he is entitled under his contract of employment, shall be fined not more than $5,000 or imprisoned not more than five years, or both." TITLE 40, U.S.C. (as amended) Sec. 276c, Regulations governing contractors and subcontractors "The Secretary of Labor shall make reasonable regulations for contractors and subcontractors engaged in the construction, prosecution, completion or repair of public buildings, public works or buildings or works financed in whole or in part by loans or grants from the United States, including a provision that each contractor and subcontractor shall furnish weekly a statement with respect to the wages paid each employee during the preceding week. Section 1001 of Title 18 of the United States Code (Criminal Code and Criminal Procedure) shall apply to such statements." Reorganization Plan No. 14 of 1950 (15 F.R. 3176, 64 Stat. 1267, 5 U.S.C. 133z note): "In order to assure coordination of administration and consistency of enforcement of the labor standards provision of each of the [foregoing and other enumerated] Acts by the Federal agencies responsible for the administration thereof, the Secretary of Labor shall prescribe appropriate standards, regulations, and procedures, which shall be observed by these agencies, and cause to be made by the Department of Labor such investigations, with respect to compliance with and enforcement of such labor standards, as he deems desirable, ..." BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 14 of 36 FEDERAL REQUIREMENTS: FR-06 FEDERAL LABOR STANDARDS PROVISIONS (HUD 4010) DAVIS - BACON REQUIREMENTS Compliance with Davis-Bacon and Related Act Requirements: All rulings and interpretations of the Davis-Bacon and Related Acts Contained in 29 CFR Parts 1, 3 and 5 are herein incorporated by reference. For additional information regarding Labor Rates, please go to the following official website of the United States government: www.SAM.gov Applicability The Project or Program to which the construction work covered by this contract pertains is being assisted by the United States of America and the following Federal Labor Standards Provisions are included in this Contract pursuant to the provisions applicable to such Federal assistance. 1. (i) Minimum Wages All laborers and mechanics employed or working upon the site of the work will be paid unconditionally and not less often than once a week, and without subsequent deduction or rebate on any account (except such payroll deductions as are permitted by the Secretary of Labor under the Copeland Act (29 CFR Part 3)), the full amount of wages and bona fide fringe benefits (or cash equivalent thereof) due at time of payment computed at rates not less than those contained in the wage determination of the Secretary of Labor which is attached hereto and made a part hereof, regardless of any contractual relationship which may be alleged to exist between the contractor and such laborers and mechanics. Contributions made or costs reasonably anticipated for bona fide fringe benefits under Section 1(b)(2) of the Davis-Bacon Act on behalf of laborers or mechanics are considered wages paid to such laborers or mechanics, subject to the provisions of 29 CFR 5.5(a.)(1)(iv); also, regular contributions made or costs incurred for more than a weekly period (but not less often than quarterly) under plans, funds, or programs which cover the particular weekly period, are deemed to be constructively made or incurred during such weekly period. Such laborers and mechanics shall be paid the appropriate wage rate and fringe benefits on the wage determination for the classification of work actually performed, without regard to skill, except as provided in 29 CFR Part 5.5(a)(4). Laborers or mechanics performing work in more than one classification may be compensated at the rate specified for each classification for the time actually worked therein: Provided, that the employer's payroll records accurately set forth the time spent in each classification in which work is performed. The wage determination (including any additional classification and wage rates conformed under 29 BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 15 of 36 CFR 5.5(a)(1)(ii) and the Davis-Bacon poster (WH-1321) shall be posted at all times by the contractor and its subcontractors at the site of the work in a prominent and accessible place where it can easily be seen by the workers. (ii) (a) Any class of laborers or mechanics, which is not listed in the wage determination and which is to be employed under the contract shall be classified in conformance with the wage determination. HUD shall approve an additional classification and wage rate and fringe benefits therefore only when the following criteria have been met: (1) The work to be performed by the classification requested is not performed by a classification in the wage determination; and (2) The classification is utilized in the area by the construction industry; and (3) The proposed wage rate, including any bona fide fringe benefits, bears a reasonable relationship to the wage rates contained in the wage determination. (b) If the contractor and the laborers and mechanics to be employed in the classification (if known), or their representatives, and HUD or its designee agree on the classification and wage rate (including the amount designated for fringe benefits where appropriate), a report of the action taken shall be sent by HUD or its designee to the Administrator of the Wage and Hour Division, Employment Standards Administration, U.S. Department of Labor, Washington, D.C. 20210. The Administrator, or an authorized representative, will approve, modify, or disapprove every additional classification action within 30 days of receipt and so advise HUD or its designee or will notify HUD or its designee within the 30-day period that additional time is necessary. (Approved by the Office of Management and Budged under OMB control number 12150140.) (c) In the event the contractor, the laborers or mechanics to be employed in the classification or their representatives, and HUD or its designee do not agree on the proposed classification and wage rate (including the amount designated for fringe benefits where appropriate), HUD or its designee shall refer the questions, including the views of all interested parties and the recommendation of HUD or its designee, to the Administrator for determination. The Administrator, or an authorized representative, will issue a determination within 30 days of receipt and so advise HUD or its designee or will notify HUD or its designee within the 30- day period that additional time is necessary. (Approved by the Office of Management and Budged under OMB control number 12150140.) (d) The wage rate (including fringe benefits where appropriate) determined pursuant to subparagraphs (1)(ii) (b) or (c) of this paragraph, shall be paid to all workers performing work in the classification under this contract from the first day on which work is performed in the classification. (iii) Whenever the minimum wage rate prescribed in the contract for a class of laborers or mechanics includes a fringe benefit which is not expressed as an hourly rate, the contractor shall BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 16 of 36 either pay the benefit as stated in the wage determination or shall pay another bona fide fringe benefit or an hourly cash equivalent thereof. (iv) If the contractor does not make payments to a trustee or other third person, the contractor may consider as part of the wages of any laborer or mechanic the amount of any costs reasonably anticipated in providing bona fide fringe benefits under a plan or program, Provided, That the Secretary of Labor has found, upon the written request of the contractor, that the applicable standards of the Davis-Bacon Act have been met. The Secretary of Labor may require the contractor to set aside in a separate account assets for the meeting of obligations under the plan or program. (Approved by the Office of Management and Budged under OMB control number 12150140.) 2. Withholding. HUD or its designee shall upon its own action or upon written request of an authorized representative of the Department of Labor withhold or cause to be withheld from the contractor under this contract or any other Federal contract with the same prime contractor, or any other Federally-assisted contract subject to David-Bacon prevailing wage requirements, which is held by the same prime contractor, so much of the accrued payments or advances as may be considered necessary to pay laborers and mechanics, including apprentices, trainees, and helpers, employed by the contractor or any subcontractor the full amount of wages required by the contract. In the event of failure to pay any laborer or mechanic, including any apprentice, trainee, or helper, employed or working on the site of work, all or part of the wages required by the contract, the HUD or its designee may, after written notice to the contractor, sponsor, applicant, or owner, take such action as may be necessary to cause the suspension of any further payment, advance, or guarantee of funds until such violations have ceased. HUD or its designee may, after written notice to the contractor, disburse such amounts withheld for and on account of the contractor or subcontractor to the respective employees to whom they are due. The Comptroller General shall make such disbursements in the case of direct Davis-Bacon Act contracts. 3. (i) Payrolls and basic records. Payrolls and basic records relating thereto shall be maintained by the contractor during the course of the work and preserved for a period of three years thereafter for all laborers and mechanics working at the site of the work. Such records shall contain the name, address, and social security number of each such worker, his or her correct classification, hourly rates of wages paid (including rates of contributions or costs anticipated for bona fide fringe benefits or cash equivalents thereof of the types described in Section 1(b) (2) (B) of the Davis-Bacon Act), daily and weekly number of hours worked, deductions made and actual wages paid. Whenever the Secretary of Labor has found under 29 CFR 5.5(a)(1)(iv) that the wages of any laborer or mechanic include the amount of any costs reasonably anticipated in providing benefits under a plan or program described in Section 1(b)(2)(B) of the Davis-Bacon Act, the contractor shall maintain records which show that the commitment to provide such benefits is enforceable, that the plan or program is financially responsible, and that the plan or program has been communicated in writing to the laborers or mechanics affected, and records which show the costs anticipated or the actual costs incurred in providing such benefits. Contractors employing apprentices or trainees under approved programs shall maintain written evidence of the registration of apprenticeship programs and certification of trainee programs, the registration of the apprentices and trainees, and the ratios and wage rates prescribed in the applicable BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 17 of 36 programs. (Approved by the Office of Management and Budget under OMB Control Numbers 1215-0140 and 1215-0017.) (ii) (a) The contractor shall submit weekly, for each week in which any contract work is performed, a copy of all payrolls to HUD or its designee if the agency is a party to the contract, but if the agency is not such a party, the contractor will submit the payrolls to the applicant sponsor or owner, as the case may be, for transmission to HUD or its designee. The payrolls submitted shall set out accurately and completely all of the information required to be maintained under 29 CFR 5.5(a) (3) (i). This information may be submitted in any form desired. Optional Form WH-347 is available for this purpose and may be purchased from the Superintendent of Documents (Federal Stock Number 029-005-00014-1), U.S. Government Printing Office, Washington, D.C. 20402. The prime contractor is responsible for the submission of copies of payrolls by all subcontractors. (Approved by the Office of Management and Budget under OMB Control Numbers 1215-0149.) (b) Each payroll submitted shall be accompanied by a "Statement of Compliance, "signed by the contractor or subcontractor or his or her agent who pays or supervises the payment of the persons employed under the contract and shall certify the following: (1) That the payroll for the payroll period contains the information required to be maintained under CFR 5.5(a) (3) (i) above and that such information is correct and complete; (2) That each laborer and mechanic (including each helper, apprentice and trainee) employed on the contract during the payroll period has been paid the full weekly wages earned, without rebate, either directly or indirectly, and that no deductions have been made either directly or indirectly from the full wages earned, other than permissible deductions as set forth in Regulations 29 CFR Part 3; (3) That each laborer or mechanic has been paid not less than the applicable wage rates and fringe benefits or cash equivalents for the classification of work performed, as specified in the applicable wage determination incorporated into the contract. (c) The weekly submission of a properly executed certification set forth on the reverse side of Optional Form WH-347 shall satisfy the requirement for submission of the "Statement of Compliance" required by paragraph A.3.(ii)(b). (d) The falsification of any of the above certifications may subject the contractor or subcontractor to civil or criminal prosecution under Section 1001 of Title 18 and Section 231 of Title 31 of the United States Code. (iii) The contractor or subcontractor shall make the records required under paragraph A.3.(i) available for inspection, copying or transcription by authorized representatives of HUD or its designee, or the Department of Labor, and shall permit such representatives to interview employees during working hours on the job. If the contractor or subcontractor fails to submit the required records or to make them available, HUD or its designee may, after written notice to BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 18 of 36 the contractor, sponsor, applicant or owner, take such action as may be necessary to cause the suspension of any further payment, advance, or guarantee of funds. Furthermore, failure to submit the required records upon request or to make such records available may be grounds for debarment action pursuant to 29 CFR 5.12. 4. Apprentices and Trainees. (i) Apprentices. Apprentices will be permitted to work at less than the predetermined rate for the work they performed when they are employed pursuant to and individually registered in a bona fide apprenticeship program registered with the U.S. Department of Labor, Employment and Training Administration, Office of Apprenticeship Training, Employer and Labor Services or with a State Apprenticeship Agency recognized by the Office, or if a person is employed in his or her first 90 days of probationary employment as an apprentice in such an apprenticeship program, who is not individually registered in the program, but who has been certified by the Office of Apprenticeship Training, Employer and Labor Services or a State Apprenticeship Agency (where appropriate) to be eligible for probationary employment as an apprentice. The allowable ratio of apprentices to journeymen on the job site in any craft classification shall not be greater than the ratio permitted to the contractor as to the entire work force under the registered program. Any worker listed on a payroll at an apprentice wage rate, who is not registered or otherwise employed as stated above, shall be paid not less than the applicable wage rate on the wage determination for the classification of work actually performed. In addition, any apprentice performing work on the job site in excess of the ratio permitted under the registered program shall be paid not less than the applicable wage rate on the wage determination for the work actually performed. Where a contractor is performing construction on a project in a locality other than that in which its program is registered, the ratios and wage rates (expressed in percentages of the journeyman's hourly rate) specified in the contractor's or subcontractor's registered program shall be observed. Every apprentice must be paid at not less than the rate specified in the registered program for the apprentice's level of progress, expressed as a percentage of the journeymen hourly rate specified in the applicable wage determination. Apprentices shall be paid fringe benefits in accordance with the provisions of the apprenticeship program. If the apprenticeship program does not specify fringe benefits, apprentices must be paid the full amount of fringe benefits listed on the wage determination for the applicable classification. If the Administrator determines that a different practice prevails for the applicable apprentice classification, fringes shall be paid in accordance with that determination. In the event the Office of Apprenticeship Training, Employer and Labor Services, or a State Apprenticeship Agency recognized by the Office, withdraws approval of an apprenticeship program, the contractor will no longer be permitted to utilize apprentices at less than the applicable predetermined rate for the work performed until an acceptable program is approved. (ii) Trainees. Except as provided in 29 CFR 5.16, trainees will not be permitted to work at less than the predetermined rate for the work performed unless they are employed pursuant to and individually registered in a program which has received prior approval, evidenced by formal certification by the U.S. Department of Labor, Employment and Training Administration. The ratio of trainees to journeymen on the job site shall not be greater than permitted under BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 19 of 36 the plan approved by the Employment and Training Administration. Every trainee must be paid at not less than the rate specified in the approved program for the trainee's level of progress, expressed as a percentage of the journeyman hourly rate specified in the applicable wage determination. Trainees shall be paid fringe benefits in accordance with the provisions of the trainee program. If the trainee program does not mention fringe benefits, trainees shall be paid the full amount of fringe benefits listed on the wage determination unless the Administrator of the Wage and Hour Division determines that there is an apprenticeship program associated with the corresponding journeyman wage rate on the wage determination which provides for less than full fringe benefits for apprentices. Any employee listed on the payroll at a trainee rate who is not registered and participating in a training plan approved by the Employment and Training Administration shall be paid not less than the applicable wage rate on the wage determination for the classification of work actually performed. In addition, any trainee performing work on the job site in excess of the ratio permitted under the registered program shall be paid not less than the applicable wage rate on the wage determination for the work actually performed. In the event the Employment and Training Administration withdraws approval of a training program, the contractor will no longer be permitted to utilize trainees at less than the applicable predetermined rate for the work performed until an acceptable program is approved. (iii) Equal Employment Opportunity. The utilization of apprentices, trainees and journeymen under 29 CFR Part 5 shall be in conformity with the equal employment opportunity requirements of Executive Order 11246, as amended, and 29 CFR Part 30. 5. Compliance with Copeland Act Requirements. The contractor shall comply with the requirements of 29 CFR Part 3, which are incorporated by reference in this contract. 6. Subcontracts. The contractor or subcontractor shall insert in any subcontracts the clauses contained in subparagraphs 1 through 11 of this paragraph A and such other clauses as HUD or its designee may by appropriate instructions require, and a copy of the applicable prevailing wage decision, and also a clause requiring the subcontractors to include these clauses in any lower tier subcontracts. The prime contractor shall be responsible for the compliance by any subcontractor or lower tier subcontractor with all the contract clauses in this paragraph. 7. Contract termination: debarment. A breach of the contract clauses in 29 CFR 5.5 may be grounds for termination of the contract, and for debarment as a contractor and a subcontractor as provided in 29 CFR 5.12. 8. Compliance with Davis-Bacon and Related Act Requirements. All rulings and interpretations of the Davis-Bacon and Related Acts contained in 29 CFR Parts 1, 3, and 5 are herein incorporated by reference in this contract. BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 20 of 36 9. Disputes Concerning Labor Standards. Disputes arising out of the labor standards provisions of this contract shall not be subject to the general disputes clause of this contract. Such disputes shall be resolved in accordance with the procedures of the Department of Labor set forth in 29 CFR Parts 5, 6 and 7. Disputes within the meaning of this clause include disputes between the contractor (or any of its subcontractors) and HUD, the U.S. Department of Labor, or the employees or their representatives. 10. (i) Certification of Eligibility. By entering into this contract, the contractor certifies that neither it (nor he or she) nor any person or firm who has an interest in the contractor's firm is a person or firm ineligible to be awarded. Government contracts by virtue of section 3(a) of the Davis- Bacon Act or 29 CFR 5.12(a) (1) or to be awarded HUD contracts or participate in HUD programs pursuant to 24 CF Part 24. (ii) No part of this contract shall be subcontracted to any person or firm ineligible for award of a Government contract by virtue of section 3(a) of the Davis-Bacon Act or 29 CFR 5.12 (a)(1) or to be awarded HUD contracts or participate in HUD programs pursuant to 24 CFR Part 24. (iii) The penalty for making false statements is prescribed in the U.S. Criminal Code, 18 U.S. Criminal 1001. Additionally, U.S. Criminal Code Section 1 01 0, Title 18, U.S.C. 1001. Additionally, U.S. Criminal Code, Section 1 01 0, Title 18, U.S.C, “Federal Housing Administration transactions”, provides in part: “Whoever, for the purpose of ….. influencing in any way the action of such Administration….makes, utters or publishes any statement knowing the same to be false…..shall be fined not more than $5,000 or imprisoned not more than two years, or both.” 11. Complaints, Proceedings, or Testimony by Employees. No laborer or mechanic to whom the wage, salary, or other labor standards provision of this Contract are applicable shall be discharged or in any other manner discrimination against by the Contractor or any subcontractor because such employee has filed any complaint or instituted or caused to be instituted any proceeding or has testified or is about to testify in any proceeding under or relating to the labor standards applicable under this Contract to his employer. BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 21 of 36 WAGE RATES "General Decision Number: TX20230007 01/06/2023 Superseded General Decision Number: TX20220007 State: Texas Construction Types: Heavy and Highway Counties: Atascosa, Bandera, Bastrop, Bell, Bexar, Brazos, Burleson, Caldwell, Comal, Coryell, Guadalupe, Hays, Kendall, Lampasas, McLennan, Medina, Robertson, Travis, Williamson and Wilson Counties in Texas. HEAVY (excluding tunnels and dams, not to be used for work on Sewage or Water Treatment Plants or Lift / Pump Stations in Bell, Coryell, McClennon and Williamson Counties) and HIGHWAY Construction Projects Note: Contracts subject to the Davis-Bacon Act are generally required to pay at least the applicable minimum wage rate required under Executive Order 14026 or Executive Order 13658. Please note that these Executive Orders apply to covered contracts entered into by the federal government that are subject to the Davis-Bacon Act itself, but do not apply to contracts subject only to the Davis-Bacon Related Acts, including those set forth at 29 CFR 5.1(a)(2)-(60). ______________________________________________________________ |If the contract is entered |. Executive Order 14026 | |into on or after January 30, | generally applies to the | |2022, or the contract is | contract. | |renewed or extended (e.g., an |. The contractor must pay | |option is exercised) on or | all covered workers at | |after January 30, 2022: | least $16.20 per hour (or | | | the applicable wage rate | | | listed on this wage | | | determination, if it is | | | higher) for all hours | | | spent performing on the | | | contract in 2023. | |______________________________|_____________________________| |If the contract was awarded on|. Executive Order 13658 | |or between January 1, 2015 and| generally applies to the | |January 29, 2022, and the | contract. | |contract is not renewed or |. The contractor must pay all| |extended on or after January | covered workers at least | |30, 2022: | $12.15 per hour (or the | | | applicable wage rate listed| | | on this wage determination,| BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 22 of 36 | | if it is higher) for all | | | hours spent performing on | | | that contract in 2023. | |______________________________|_____________________________| The applicable Executive Order minimum wage rate will be adjusted annually. If this contract is covered by one of the Executive Orders and a classification considered necessary for performance of work on the contract does not appear on this wage determination, the contractor must still submit a conformance request. Additional information on contractor requirements and worker protections under the Executive Orders is available at http://www.dol.gov/whd/govcontracts. Modification Number Publication Date 0 01/06/2023 SUTX2011-006 08/03/2011 Rates Fringes CEMENT MASON/CONCRETE FINISHER (Paving and Structures)......................$ 12.56 ** ELECTRICIAN......................$ 26.35 FORM BUILDER/FORM SETTER Paving & Curb...............$ 12.94 ** Structures..................$ 12.87 ** LABORER Asphalt Raker...............$ 12.12 ** Flagger.....................$ 9.45 ** Laborer, Common.............$ 10.50 ** Laborer, Utility............$ 12.27 ** Pipelayer...................$ 12.79 ** Work Zone Barricade Servicer....................$ 11.85 ** PAINTER (Structures).............$ 18.34 POWER EQUIPMENT OPERATOR: Agricultural Tractor........$ 12.69 ** Asphalt Distributor.........$ 15.55 ** Asphalt Paving Machine......$ 14.36 ** Boom Truck..................$ 18.36 Broom or Sweeper............$ 11.04 ** Concrete Pavement Finishing Machine...........$ 15.48 ** Crane, Hydraulic 80 tons BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 23 of 36 or less.....................$ 18.36 Crane, Lattice Boom 80 tons or less................$ 15.87 ** Crane, Lattice Boom over 80 tons.....................$ 19.38 Crawler Tractor.............$ 15.67 ** Directional Drilling Locator.....................$ 11.67 ** Directional Drilling Operator....................$ 17.24 Excavator 50,000 lbs or Less........................$ 12.88 ** Excavator over 50,000 lbs...$ 17.71 Foundation Drill, Truck Mounted.....................$ 16.93 Front End Loader, 3 CY or Less........................$ 13.04 ** Front End Loader, Over 3 CY.$ 13.21 ** Loader/Backhoe..............$ 14.12 ** Mechanic....................$ 17.10 Milling Machine.............$ 14.18 ** Motor Grader, Fine Grade....$ 18.51 Motor Grader, Rough.........$ 14.63 ** Pavement Marking Machine....$ 19.17 Reclaimer/Pulverizer........$ 12.88 ** Roller, Asphalt.............$ 12.78 ** Roller, Other...............$ 10.50 ** Scraper.....................$ 12.27 ** Spreader Box................$ 14.04 ** Trenching Machine, Heavy....$ 18.48 Servicer.........................$ 14.51 ** Steel Worker Reinforcing.................$ 14.00 ** Structural..................$ 19.29 TRAFFIC SIGNALIZATION: Traffic Signal Installation Traffic Signal/Light Pole Worker......................$ 16.00 ** TRUCK DRIVER Lowboy-Float................$ 15.66 ** Off Road Hauler.............$ 11.88 ** Single Axle.................$ 11.79 ** Single or Tandem Axle Dump Truck.......................$ 11.68 ** Tandem Axle Tractor w/Semi Trailer.....................$ 12.81 ** WELDER...........................$ 15.97 ** ---------------------------------------------------------------- BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 24 of 36 WELDERS - Receive rate prescribed for craft performing operation to which welding is incidental. ================================================================ ** Workers in this classification may be entitled to a higher minimum wage under Executive Order 14026 ($16.20) or 13658 ($12.15). Please see the Note at the top of the wage determination for more information. Note: Executive Order (EO) 13706, Establishing Paid Sick Leave for Federal Contractors applies to all contracts subject to the Davis-Bacon Act for which the contract is awarded (and any solicitation was issued) on or after January 1, 2017. If this contract is covered by the EO, the contractor must provide employees with 1 hour of paid sick leave for every 30 hours they work, up to 56 hours of paid sick leave each year. Employees must be permitted to use paid sick leave for their own illness, injury or other health-related needs, including preventive care; to assist a family member (or person who is like family to the employee) who is ill, injured, or has other health-related needs, including preventive care; or for reasons resulting from, or to assist a family member (or person who is like family to the employee) who is a victim of, domestic violence, sexual assault, or stalking. Additional information on contractor requirements and worker protections under the EO is available at https://www.dol.gov/agencies/whd/government-contracts. Unlisted classifications needed for work not included within the scope of the classifications listed may be added after award only as provided in the labor standards contract clauses (29CFR 5.5 (a) (1) (ii)). ---------------------------------------------------------------- The body of each wage determination lists the classification and wage rates that have been found to be prevailing for the cited type(s) of construction in the area covered by the wage determination. The classifications are listed in alphabetical order of ""identifiers"" that indicate whether the particular rate is a union rate (current union negotiated rate for local), a survey rate (weighted average rate) or a union average rate (weighted union average rate). Union Rate Identifiers A four letter classification abbreviation identifier enclosed in dotted lines beginning with characters other than ""SU"" or ""UAVG"" denotes that the union classification and rate were prevailing for that classification in the survey. Example: PLUM0198-005 07/01/2014. PLUM is an abbreviation identifier of the union which prevailed in the survey for this classification, which in this example would be Plumbers. 0198 BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 25 of 36 indicates the local union number or district council number where applicable, i.e., Plumbers Local 0198. The next number, 005 in the example, is an internal number used in processing the wage determination. 07/01/2014 is the effective date of the most current negotiated rate, which in this example is July 1, 2014. Union prevailing wage rates are updated to reflect all rate changes in the collective bargaining agreement (CBA) governing this classification and rate. Survey Rate Identifiers Classifications listed under the ""SU"" identifier indicate that no one rate prevailed for this classification in the survey and the published rate is derived by computing a weighted average rate based on all the rates reported in the survey for that classification. As this weighted average rate includes all rates reported in the survey, it may include both union and non-union rates. Example: SULA2012-007 5/13/2014. SU indicates the rates are survey rates based on a weighted average calculation of rates and are not majority rates. LA indicates the State of Louisiana. 2012 is the year of survey on which these classifications and rates are based. The next number, 007 in the example, is an internal number used in producing the wage determination. 5/13/2014 indicates the survey completion date for the classifications and rates under that identifier. Survey wage rates are not updated and remain in effect until a new survey is conducted. Union Average Rate Identifiers Classification(s) listed under the UAVG identifier indicate that no single majority rate prevailed for those classifications; however, 100% of the data reported for the classifications was union data. EXAMPLE: UAVG-OH-0010 08/29/2014. UAVG indicates that the rate is a weighted union average rate. OH indicates the state. The next number, 0010 in the example, is an internal number used in producing the wage determination. 08/29/2014 indicates the survey completion date for the classifications and rates under that identifier. A UAVG rate will be updated once a year, usually in January of each year, to reflect a weighted average of the current negotiated/CBA rate of the union locals from which the rate is based. ---------------------------------------------------------------- WAGE DETERMINATION APPEALS PROCESS 1.) Has there been an initial decision in the matter? This can be: BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 26 of 36 * an existing published wage determination * a survey underlying a wage determination * a Wage and Hour Division letter setting forth a position on a wage determination matter * a conformance (additional classification and rate) ruling On survey related matters, initial contact, including requests for summaries of surveys, should be with the Wage and Hour National Office because National Office has responsibility for the Davis-Bacon survey program. If the response from this initial contact is not satisfactory, then the process described in 2.) and 3.) should be followed. With regard to any other matter not yet ripe for the formal process described here, initial contact should be with the Branch of Construction Wage Determinations. Write to: Branch of Construction Wage Determinations Wage and Hour Division U.S. Department of Labor 200 Constitution Avenue, N.W. Washington, DC 20210 2.) If the answer to the question in 1.) is yes, then an interested party (those affected by the action) can request review and reconsideration from the Wage and Hour Administrator (See 29 CFR Part 1.8 and 29 CFR Part 7). Write to: Wage and Hour Administrator U.S. Department of Labor 200 Constitution Avenue, N.W. Washington, DC 20210 The request should be accompanied by a full statement of the interested party's position and by any information (wage payment data, project description, area practice material, etc.) that the requestor considers relevant to the issue. 3.) If the decision of the Administrator is not favorable, an interested party may appeal directly to the Administrative Review Board (formerly the Wage Appeals Board). Write to: Administrative Review Board U.S. Department of Labor 200 Constitution Avenue, N.W. Washington, DC 20210 4.) All decisions by the Administrative Review Board are final. ================================================================ END OF GENERAL DECISIO" BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 27 of 36 FEDERAL REQUIREMENTS: FR-07 CONTRACT WORK HOURS AND SAFETY STANDARDS ACT REQUIREMENTS (1) Overtime requirements. No contractor or subcontractor contracting for any part of the contract work which may require or involve the employment of laborers or mechanics shall require or permit any such laborer or mechanic, in any workweek in which he or she is employed on such work to work in excess of 40 hours in such workweek unless such laborer or mechanic receives compensation at a rate not less than one and one-half times the basic rate of pay for all hours worked in excess of forty hours in such workweek. (2) Violation; Liability for Unpaid Wages; Liquidated Damages. In the event of any violation of the clause set forth in subparagraph (1) of this paragraph, the contractor and any subcontractor responsible therefor shall be liable for the unpaid wages. In addition, such contractor and subcontractor shall be liable to the United States (in the case of work done under contract for the District of Columbia or a territory, to such District or to such territory), for liquidated damages. Such liquidated damages shall be computed with respect to each individual laborer or mechanic, including watchmen and guards, employed in violation of the clause set forth in subparagraph (1) of this paragraph above, in the sum of $10 for each calendar day on which such individual was required or permitted to work in excess of the standard workweek of 40 hours without payment of the overtime wages required by the clause set forth in subparagraph (1) of this paragraph. (3) Withholding for unpaid wages and liquidated damages. HUD or its designee shall upon its own action or upon written request of an authorized representative of the Department of Labor withhold or cause to be withheld, from any monies payable on account of work performed by the contractor or subcontractor under any such contract or any other Federal contract with the same prime contractor, or any other Federally-assisted contract subject to the Contract Work Hours and Safety Standards Act, which is held by the same prime contractor, such sums as may be determined to be necessary to satisfy any liabilities of such contractor or subcontractor for unpaid wages and liquidated damages as provided in the clause set forth in paragraph (2) of this paragraph. (4) Subcontractors. The contractor or subcontractor shall insert in any subcontracts the clauses set forth in paragraphs (1) through (4) of this paragraph and also a clause requiring the subcontractor to include these clauses in any lower tier subcontracts. The prime contractor shall be responsible for compliance by any subcontractor or lower tier subcontractor with the clauses set forth in subparagraphs (1) through (4) of this paragraph. (5) Health and Safety. No laborer or mechanic shall be required to work in surroundings or under working conditions which are unsanitary, hazardous, or dangerous to his/her health and safety as determined under construction safety and health standards promulgated by the Secretary of Labor by regulation. BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 28 of 36 The Contractor shall comply with all regulations issued by the Secretary of Labor pursuant to Title 29 Part1926 and failure to comply may result in imposition of sanctions pursuant to the Contract Work Hours and Safety Standards Act, 40 USC 3701 et seq. The Contractor shall include the provisions of this paragraph in every subcontract so that such provisions will be binding on each subcontractor. The Contractor shall take such action with respect to any subcontract as the Secretary of Housing and Urban Development or the Secretary. BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 29 of 36 FEDERAL REQUIREMENTS: FR-08 RIGHTS TO INVENTIONS All rights to inventions and materials generated under this contract are subject to regulations issued by the Sponsor of the Federal grant under which this contract is executed. BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 30 of 36 FEDERAL REQUIREMENTS: FR-9 ACCESS TO RECORDS AND RECORD RETENTION The Contractor shall maintain an acceptable cost accounting system. The Contractor agrees to provide the Sponsor and the Comptroller General of the United States or any of their duly authorized representative’s access to any books, documents, papers, and records of the contractor which are directly pertinent to the specific contract for the purpose of making audit, examination, excerpts and transcriptions. The Contractor agrees to maintain all books, records and reports required under this contract for a period of not less than three years after final payment is made and all pending matters are closed. BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 31 of 36 FEDERAL REQUIREMENTS: FR-10 CLEAN AIR AND WATER POLLUTION CONTROL Contractors and subcontractors agree: a. That any facility to be used in the performance of the contract or subcontract or to benefit from the contract is not listed on the Environmental Protection Agency (EPA) List of Violating Facilities; b. To comply with all the requirements of Section 114 of the Clean Air Act, as amended, 42 U.S.C. 1857 et seq. and Section 308 of the Federal Water Pollution Control Act, as amended, 33 U.S.C. 1251 et seq. relating to inspection, monitoring, entry, reports, and information, as well as all other requirements specified in Section 114 and Section 308 of the Acts, respectively, and all other regulations and guidelines issued thereunder; c. That, as a condition for the award of this contract, the contractor or subcontractor will notify the awarding official of the receipt of any communication from the EPA indicating that a facility to be used for the performance of or benefit from the contract is under consideration to be listed on the EPA List of Violating Facilities; d. To include or cause to be included in any construction contract or subcontract which exceeds $ 100,000 the aforementioned criteria and requirements. BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 32 of 36 FEDERAL REQUIREMENTS: FR-11 ENERGY CONSERVATION REQUIREMENTS The contractor agrees to comply with mandatory standards and policies relating to energy efficiency that are contained in the state energy conservation plan issued in compliance with the Energy Policy and Conservation Act (Public Law 94-163). BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 33 of 36 FEDERAL REQUIREMENTS: FR-12 CERTIFICATION REGARDING DEBARMENT, SUSPENSION, INELIGIBILITY AND VOLUNTARY EXCLUSION The Contractor certifies, by acceptance of this contract, that neither it nor its principals is presently debarred, suspended, proposed for debarment, declared ineligible, or voluntarily excluded from participation in this transaction by any Federal department or agency. It further agrees that it will include this clause without modification in all lower tier transactions, solicitations, proposals, contracts, and subcontracts. BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 34 of 36 FEDERAL REQUIREMENTS: FR-13 LOBBYING AND INFLUENCING FEDERAL EMPLOYEES (1) No Federal appropriated funds shall be paid, by or on behalf of the contractor, to any person for influencing or attempting to influence an officer or employee of any agency, a Member of Congress, an officer or employee of Congress, or an employee of a Member of Congress in connection with the making of any Federal grant and the amendment or modification of any Federal grant. (2) If any funds other than Federal appropriated funds have been paid or will be paid to any person for influencing or attempting to influence an officer or employee of any agency, a Member of Congress, an officer or employee of Congress, or an employee of a Member of Congress in connection with any Federal grant, the contractor shall complete and submit Standard Form-LLL, “Disclosure of Lobby Activities,” in accordance with its instructions. (3) Contractor shall require that the language of this certification be included in the award documents for all subawards at all tiers (including subcontracts, subgrants, and contracts under grants, loans, and cooperative agreement) and that all subrecipients shall certify and disclose accordingly. This certification is a material representation of fact upon which reliance was placed when this transaction was made or entered into. Submission of this certification is a prerequisite for making or entering into this transaction imposed by Section 1352, Title 31, US Code. Any person who fails to file the required cert ification shall be subject to a civil penalty of not less than $10,000 and not more than $100,000 for such failure. BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 35 of 36 FEDERAL REQUIREMENTS: FR-14 DOMESTIC PREFERENCE FOR PROCUREMENTS As appropriate and to the extent consistent with law, the non -Federal entity should, to the greatest extent practicable under the award, provide a preference for the purchase, acquisition, or use of goods, products, or materials produced in the United Stat es) including but not limited to iron, aluminum, steel, cement, and other manufactured products). The requirements of this section must be included in all subawards including all contracts and purchase order or products under this award. BCRUA – Phase 1D WTP Expansion Section 00800 – Supplemental Conditions Issued for Bid Page 36 of 36 FEDERAL REQUIREMENTS: FR-15 PROCUREMENT OF RECOVERED MATERIALS A non-Federal entity that is a state agency or agency of a political subdivision of the state and its contractors must comply with section 6002 of the Solid Waste Disposal Act, as amended by the Resource Conservation and Recovery Act. The requirements of 6002 include procuring only items designed in guidelines of the EPA at 40 CFR 247 that contain the highest percentage of recovered materials practicable consistent with maintaining a satisfactory level of competition, where the purchase price of the item exceeds $10,000 or the value of the quantity acquired during the preceding fiscal year exceeded $10,000; procuring solid waste management services in a manner that maximizes energy and resource recovery; and establishing an affirmative procurement program for procurement of recovered materials identified in the EPA guidelines. BCRUA – Phase 1D WTP Expansion Addendum No. 01 T.B.P.E Registration No. 8053 Page 1 of 1 ADDENDUM No. 01 Date: January 30, 2023 Project Name: Phase 1D Water Treatment Plant Expansion This Addendum forms a part of the Contract and corrects or modifies original RFP Documents, dated January 17, 2023. Acknowledge receipt of this Addendum in space provided on Proposal Form. Failure to do so may subject Proposer to disqualification. A. Project Manual Revisions: 1. Section 00100, Advertisement for Proposals: In the 1st paragraph of page 2, delete “January 31, 2023” and replace with “February 7, 2023”. 2. Section 00300, Proposal Form: In Article 1.5 on page 1, delete “January 31, 2023” and replace with “February 7, 2023”. This addendum consists of one page. _________________________________________ Approved by ENGINEER END 01-30-2023 All Addendum revisions and attachments, if any, have been conformed into Contract Documents. BCRUA – Phase 1D WTP Expansion Addendum No. 02 T.B.P.E Registration No. 8053 Page 1 of 12 ADDENDUM No. 02 Date: February 15, 2023 Project Name: Phase 1D Water Treatment Plant Expansion This Addendum forms a part of the Contract and corrects or modifies original RFP Documents, dated January 17, 2023. Acknowledge receipt of this Addendum in space provided on Proposal Form. Failure to do so may subject Proposer to disqualification. A. Project Manual Revisions: 1. Section 00100, Advertisement for Proposals: a. In the 1st paragraph on page 1 regarding the proposal opening, delete “February 21, 2023” and replace with “February 28, 2023”. b. In the 2nd paragraph of page 2, delete “Tuesday, February 14, 2023” and replace with “Tuesday, February 21, 2023”. 2. Section 00200, Instructions to Proposers: In Article 8 on page 6, add the following to the end of the sentence: “because the TWDB funds were committed before May 1, 2019.” 3. Section 00300, Proposal Form: Replace with reissued section attached to this Addendum to revise dates. 4. Section 26 01 26, Testing of Electrical Systems: a. On page 1, list the following testing agency at the end of paragraph 1.2B. “ 5. Power Engineering Services, Inc.” 5. Section 26 05 19, Low Voltage Electrical Conductors & Cables: a. On page 1, add the following after paragraph 1.3A.1 f. “g. Multimode optical-fiber cabling.” b. On page 6, add the following after paragraph 2.4. “2.5 MULTIMODE OPTICAL-FIBER CABLE A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. 3M. 2. Belden Inc. All Addendum revisions and attachments, if any, have been conformed into Contract Documents. BCRUA – Phase 1D WTP Expansion Addendum No. 02 T.B.P.E Registration No. 8053 Page 2 of 12 3. Nexans. 4. CommScope, Inc. 5. Corning Cable Systems. B. Description: Multimode, 50/125-micrometer, 6-fiber, nonconductive, tight- buffer, optical-fiber cable; fiber category OM2. 1. Comply with ICEA S-83-596 for mechanical properties. 2. Comply with TIA-568-C.3 for performance specifications. 3. Comply with TIA-492AAAB-B for detailed specifications. 4. Listed and labeled by an NRTL acceptable to authorities having jurisdiction as complying with UL 444, UL 1651, and NFPA 70 for the following types: a. Plenum Rated, Nonconductive: Type OFN, Type OFNG, Type OFNP, or Type OFNR in metallic conduit. 5. Maximum Attenuation: 2.8 dB/km at 850 nm; 1.0 dB/km at 1300 nm. 6. Minimum Effective Modal Bandwidth: 950 MHz-km at 850 nm. C. Jacket: 1. Jacket Color: Black for 50/125-micrometer cable. 2. Cable cordage jacket, fiber, unit, and group color shall be according to TIA-598-C. 3. Imprinted with fiber count, fiber type, and aggregate length at regular intervals not to exceed 40 inches. 2.6 OPTICAL-FIBER CABLE HARDWARE A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. ADC. 2. American Technology Systems Industries, Inc. 3. Belden Inc. 4. Nexans. 5. Corning Cable Systems. B. Number of Connectors per Field: One for each fiber of cable or cables assigned to field. BCRUA – Phase 1D WTP Expansion Addendum No. 02 T.B.P.E Registration No. 8053 Page 3 of 12 C. Patch Cords: Factory-made, dual-fiber cables in 36-inch lengths. D. Cable Connecting Hardware: 1. Comply with Optical-Fiber Connector Intermate-ability Standards (FOCIS) specifications of TIA-604-2-B, TIA-604-3-B, and TIA/EIA-604-12. Comply with TIA-568-C.3. 2. Quick-connect, simplex and duplex, Type ST connectors. Insertion loss of not more than 0.75 dB. 3.Type SFF connectors may be used in termination racks, panels, and equipment packages.” c. On page 9, add the following after paragraph 3.6A. “B. Testing Agency: Engage a qualified testing agency to perform tests and inspections. 1. After installing fiber optic cable, test for compliance with requirements. a. Optical-Fiber Cable Tests: 1). Test instruments shall meet or exceed applicable requirements in TIA-568-C.0. Use only test cords and adapters that are qualified by test equipment manufacturer for channel or link test configuration. 2). Link End-to-End Attenuation Tests: a). Multimode Link Measurements: Test in one direction according to TIA/EIA-526-14-A, Method B, One Reference Jumper. b). Attenuation test results for links shall be less than that calculated according to equation in TIA-568-C.0.” 6. Section 26 29 23, Low Voltage Variable Frequency Drives: a. On page 1, add the following after paragraph 1.1D. “E. Contractor shall procure the services of Eaton to modify the existing sludge pump VFDs, two total, to place the VFDs in multipurpose application mode. In this mode, the VFDs will each be able to be controlled by the existing and new Belt Filter Press Control panels via dry contacts and 4-20mA speed reference setpoints, as well as speed and status feedback to each belt filter press control panel. Refer to design drawings for modifications needed. Provide additional expansion I/O cards, hardware and programming as needed for a fully operational VFD per the project manual and design drawings. Eaton shall provide the on-site services for startup, field tests, and troubleshooting of the sludge feed pump VFDs. ” b. On page 3, add the following after paragraph 1.3A.1.j. BCRUA – Phase 1D WTP Expansion Addendum No. 02 T.B.P.E Registration No. 8053 Page 4 of 12 “k. Submit proposed changes to sludge feed pump VFDs, including recommended programming and hardware modifications. Provide updated wiring diagram.” 7. Section 33 16 33, Prestressed Concrete Water Storage Tanks: a. On page 9, insert the following at the beginning of Paragraph 2.10A.1.: “Precast Dome:”. b. On page 9, insert new Paragraph 2.10A.2 as follows and renumber subsequent paragraph accordingly: “2. Cast-In-Place Dome: Decorative coating shall be applied to the exterior dome surfaces using two coats of a non-cementitious, high build, 100% acrylic resin polymer such as “Tammscoat Smooth” textured protective coating or “Tnemec Envirocrete 156”.” c. On page 10, Paragraph 2.11A.10. Dome Guardrails: In the 3rd sentence, delete the word “anodized”. 8. Section 40 05 00, Common Requirements for Process Piping: On pages 25 & 26, delete paragraph 3.20G, System 7: Storm Drain. Refer to Drawings for Reinforced Concrete Box (RCB) Storm Drain requirements. 9. Section 40 05 59.23, Fabricated Stainless Steel Slide Gates: Replace with reissued section attached to this addendum. 10. Section 40 05 59.33, Cast Iron Slide Gates: On page 5, in the Type of Lift Mechanism column of the Gate Schedule table in paragraph 3.4A, delete “CH” and replace with “Ped with CH” for both gates. 11. Section 40 90 01, Instrumentation: a. On page 1, replace paragraph 1.2C with the following. “C. POWER SUPPLIES: The drawings and specifications indicate the energy sources that will be provided. Any other devices or power supplies necessary to obtain proper operation of the instrument system from these energy sources shall be furnished with the instrumentation. For instruments or transmitters with 120VAC power supplies, provide 20A toggle switch with weatherproof cover. Mount the toggle switch next to instrument.” b. On page 6, add the following at the end of paragraph 2.7F. “3. Raw Water Tanks only: Provide 4” schedule 40 PVC conduit stilling well for level transducer. Strap conduit to interior access ladder with stainless steel bands. Provide vertical slots cut into still well conduit to equalize level between tank and stilling well. Conduit shall be continuous from top of ladder to one foot from the tank floor. 4. Filter 7C only: Provide 6” schedule 40 PVC conduit to use as stilling well for level transducer. Strap conduit to interior access ladder with stainless steel bands. Provide vertical slots cut into still well conduit to equalize level between filter and stilling well. Match stilling well mounting height and length to existing filters.” BCRUA – Phase 1D WTP Expansion Addendum No. 02 T.B.P.E Registration No. 8053 Page 5 of 12 c. On page 8, add the following at the end of paragraph 2.8C.3. “b. Provide 6” schedule 40 PVC stilling well with flange fitting and blind flange for level transducer. Mount stilling well to filter wall. Match stilling well mounting height and length to existing filters.” d. On page 10, delete paragraph 3.1B and the table in paragraph 3.1C. 12. Section 40 90 02, Supervisory Control and Data Acquisition (SCADA) System: a. On page 1, add the following at the end of paragraph 1.1B.7. “8. Fluorosilicic Acid Fill Station: a. Refer to design drawings for schematic and elevation. b. Refer to Section 26 29 13.01, Industrial Control Panels for panel fabrication requirements. 9. Polymer Selector Control Panel (SDF-PSP-01).” b. On page 9, add the following at the end of paragraph 2.7A. “B. Fiber optic patch panel (RWT-PLC-01, EB-PLC-01): 1. Provide compact fiber patch panel which consists of: a. Compact wall-mount connector housing, two panel minimum, ST compatible connectors, OM2 50um. b. six (6) fiber minimum. 2. Mount to enclosure backplane. 3. Terminate all fibers to patch panel. 4. Manufactured by Corning, Panduit, Tripp Lite or equal. C. Media Converter (EB-PLC-01): 1. Provide media with one 10BASE FX port with ST connector and one 10/100BaseT(X) RJ45 port. Media converter shall be din rail mounted suitable for temperatures ranging from -10C to 60C. 2. 100Base FX port shall be OM2 multimode, 50/125 um with a tx/rx distance of 5 km. Link budget shall not exceed 12 dB. 3. Power input shall be 12 to 48VDC and media converter shall include integral overload current protection. Provide a compatible power supply within cabinet. 4. Model shall be Moxa IMC-21 series or equal. D. Raw Water Tank Displays (RWT-PLC-01): BCRUA – Phase 1D WTP Expansion Addendum No. 02 T.B.P.E Registration No. 8053 Page 6 of 12 1. Single Input Display: a. Provide four (4) level displays to power raw water tank submersible transducers. Transducers are loop powered. Display provided shall have high visibility red LED 6 digit display with lettering at least 0.46” high. Displays shall be mounted to PLC enclosure door. b. Inputs: Two (2) 4-20mA input signals. c. Outputs: Two (2) 4-20mA, isolated. d. Power supply: 120VAC or 24 VDC, powered from PLC UPS. e. Enclosure: Display shall be NEMA 4X while face-mounted to PLC enclosure door and shall maintain the NEMA 4X rating of PLC enclosure. Provide sunshield for each display to prevent direct sunlight on display. f. Display shall be manufactured by Precision Digital, model PD6000 or equal. E. Ethernet Switch: 1. General: a. Mounting: Din rail or backplane mountable. b. Operating temperature: -10C to 60C. 2. RWT-PLC-01: a. 10/100BaseT(X) Ports, RJ45 Connectors: 4, minimum. b. 100BaseFX Ports, Multimode, ST Connectors: 1 pair. c. Manufactured by Moxa model EDS-308, Phoenix Contact or equal. 3. TSC-PLC-02: a. 10/100BaseT(X) Ports, RJ45 Connectors: 8, minimum. b. 100BaseFX Ports, Multimode, ST Connectors: None. c. Manufactured by Moxa model EDS-308, Phoenix Contact or equal.” c. On page 13, add the following at the end of paragraph 2.12. “B. Polymer Selector Control Panel (SDF-PSP-01): 1. It is the intent of this panel description to provide a general overview of the operation of the polymer selector control panel. The Contractor is responsible for providing the necessary relays and wiring to ensure the existing and proposed belt filter press controls and polymer system controls operate as a complete and operable system. BCRUA – Phase 1D WTP Expansion Addendum No. 02 T.B.P.E Registration No. 8053 Page 7 of 12 2. The existing belt filter press control panel has the capability to monitor and control the two existing polymer systems. A second belt filter press control panel will be added under this contract and will have the same capabilities as the existing belt filter press control panel. 3. The existing belt filter press control panel as-builts can be made available upon request by the Contractor. 4. General panel requirements: a. Panel shall be powered by a 120VAC power supply from a nearby lighting panel. b. Panel shall be NEMA 4X 304 stainless steel. The panel door shall swing horizontally and be held closed with mechanical spring-loaded fasteners. c. Refer to Section 26 29 13.01, Industrial Control Panels for panel materials and fabrication requirements. d. Provide all necessary conduit and wiring to interconnect existing conduits between belt filter press control panel and polymer panels. e. Wiring and relay configuration of polymer selector panel will prevent back feed of voltage between belt filter press control panels regardless of selector switch position. 5. The polymer selector panel shall have the following included with panel: a. Indicators: 1) Power On (White). b. Selector Switches: 1) Polymer System 1 - 3 Position (Belt Filter Press 1/None/ Belt Filter Press 2). 2) Polymer System 2 - 3 Position (Belt Filter Press 1/None/ Belt Filter Press 2). c. Discrete signals from each polymer control panel to each belt filter press control panel. The discrete signals between the control panels are currently dry contacts and will remain dry contacts after the polymer selector panel is installed. 1) Polymer system 1 running (To belt filter control panel 1). 2) Polymer system 1 fail (To belt filter control panel 1). 3) Polymer system 1 In Auto (To belt filter control panel 1). BCRUA – Phase 1D WTP Expansion Addendum No. 02 T.B.P.E Registration No. 8053 Page 8 of 12 4) Polymer system 1 running (To belt filter control panel 2). 5) Polymer system 1 fail (To belt filter control panel 2). 6) Polymer system 1 In Auto (To belt filter control panel 2). 7) Polymer system 2 running (To belt filter control panel 1). 8) Polymer system 2 fail (To belt filter control panel 1). 9) Polymer system 2 In Auto (To belt filter control panel 1). 10) Polymer system 2 running (To belt filter control panel 2). 11) Polymer system 2 fail (To belt filter control panel 2). 12) Polymer system 2 In Auto (To belt filter control panel 2). 13) Start/Stop polymer system 1 (From belt filter press control panel 1). 14) Start/Stop polymer system 2 (From belt filter press control panel 1). 15) Start/Stop polymer system 1 (From belt filter press control panel 2). 16) Start/Stop polymer system 2 (From belt filter press control panel 2). d. 4-20mA analog signals from each polymer control panel to each belt filter press control panel. 1) Polymer system 1 speed feedback (To belt filter control panel 1). 2) Polymer system 2 speed feedback (To belt filter control panel 1). 3) Polymer system 1 speed setpoint (From belt filter control panel 2). 4) Polymer system 2 speed setpoint (From belt filter control panel 2). e. Polymer system discrete and analog feedback signals will be split via control relays and analog splitters for continuous feedback to each belt filter press control panel. f. When the polymer system selector switch is assigned to one of the two belt filter press control panels, the discrete start/stop command and the 4-20mA analog speed setpoint signal will be available only to BCRUA – Phase 1D WTP Expansion Addendum No. 02 T.B.P.E Registration No. 8053 Page 9 of 12 that polymer system. Only one belt filter press will utilize a polymer system at a time.” 13. Section 40 90 02.01, SCADA Loop Descriptions: Replace with reissued section attached to this Addendum to revise raw water flow control. 14. Section 41 12 13, Shaftless Screw Conveyors: a. On page 4, list the following manufacturer at the end of paragraph 2.1A. “5. Jim Myers & Sons, Inc. (JMS)." b. On page 4, paragraph 2.3A.1, delete “12-inches” and replace with “16-inches”. c. On page 4, paragraph 2.3A.2, delete “700 cubic feet per hour” and replace with “350 cubic feet per hour”. d. On page 4, add the following at the end of paragraph 2.3A.4: “Incline angle of SDF-SSC- 005 shall not exceed 30 degrees.” e. On page 4, paragraph 2.3A.6.a, delete “3 HP maximum” and replace with “5 HP maximum for SDF-SSC-003 and 004; 10 HP maximum for SDF-SSC-005”. 15. Section 46 43 11, Chain and Flight Sludge Collection Equipment: a. On page 7, delete the first sentence of paragraph 2.5A.1 and replace with: “The collector chain shall be completely non-metallic, manufactured of fiberglass composite material, corresponding to HS730.” b. On page 7, paragraph 2.5A.3, delete “3,000 pounds, minimum” and replace with “4,500 pounds, minimum”. 16. Section 46 71 13, Circular Gravity Thickener Equipment: a. On page 6, in the first sentence of paragraph 2.3D.1, delete “18,000 ft-lbs” and replace with “17,000 ft-lbs”. b. On page 7, delete the last sentence of paragraph 2.3D.6. c. On page 8, add “or NEMA 4x cast aluminum” at the end of the 2nd to last sentence in paragraph 2.3D.11. d. On page 9, insert “Access bridge and drive platform” at the beginning of the 6th sentence of paragraph 2.3E. 17. Section 46 76 21, Belt Filter Press: a. On page 15, replace paragraph 2.7A.1 with the following paragraph. “1. Provide main and local control panels to control the belt filter press and auxiliary equipment. Main control panel shall have starters and VFDs for belt drive, hydraulic pump, booster pump and any other belt filter press drive mechanism or valves. Sludge BCRUA – Phase 1D WTP Expansion Addendum No. 02 T.B.P.E Registration No. 8053 Page 10 of 12 feed pumps, polymer pumps/systems, and conveyors shall be powered by external starters and VFDs. Local control panel shall have interfaces to view and modify sludge feed pump speed, polymer feed pump speed and belt drive speed, and view sludge feed rate.” b. On page 15, replace paragraph 2.7A.2 with the following paragraph. “2. PLC with operator interface terminal (OIT) installed in main panel with the ability to connect to WTP SCADA. Communication protocol shall be Ethernet IP. PLC shall be ControlLogix. OIT shall be Panelview Plus or equal by Allen Bradley.” c. On page 15, replace paragraph 2.7A.4 with the following paragraph. “4. Single-point 480VAC, 3 Phase, 60A power connection and grounding lug. a. All necessary power conditioning shall be furnished inside the panel for proper equipment operation.” B. Drawing Revisions: 1. Sheet G-1, Drawing Index: Replace with reissued sheet attached to this Addendum. Sheets added by this addendum have been added to the Index. 2. Sheet C-1, Overall Site Plan & Dimensional Control: Replace with reissued sheet attached to this Addendum. Updates to the Coordinate Table for the sidewalk and tank outlet structure. 3. Sheet C-2, Existing Soil Borings Plan: Replace with reissued sheet attached to this Addendum. Culverts from CL Drawings updated to align with Addendum changes. 4. Sheet CL-1, Treatment Structure, Grading Plan: Replace with reissued sheet attached to this Addendum. Sidewalk callouts by lift station updated. 5. Sheet CL-3, Raw Water Head Tanks, Overflow Discharge, Grading Plan 1: Replace with reissued sheet attached to this Addendum. 6. Sheet CL-4, Raw Water Head Tanks, Overflow Discharge, Grading Plan 2: Replace with reissued sheet attached to this Addendum. 7. Sheet CL-5, Raw Water Head Tanks, Overflow Discharge, Modifications to Culv #12 and Culv #7, Plan and Profile: Add new drawing sheet attached to this Addendum. 8. Sheet CL-6, Raw Water Head Tanks, Overflow Discharge, Channel 1 – Overflow Structure to Culv #12, Plan and Profile: Add new drawing sheet attached to this Addendum. 9. Sheet CL-7, Raw Water Head Tanks, Overflow Discharge, Channel 2 – Culv #12 to Culv #7, Plan and Profile: Add new drawing sheet attached to this Addendum. 10. Sheet CL-8, Raw Water Head Tanks, Overflow Discharge, Channel 3 – Culv #7 to End, Plan and Profile: Add new drawing sheet attached to this Addendum. BCRUA – Phase 1D WTP Expansion Addendum No. 02 T.B.P.E Registration No. 8053 Page 11 of 12 11. Sheet CL-9, Raw Water Head Tanks, Overflow Discharge, Channel Cross Sections: Add new drawing sheet attached to this Addendum. 12. Sheet CM-1, Site Layout, GC Laydown Area & Env Control Plan 1: Replace with reissued sheet attached to this Addendum. Culverts from CL Drawings updated to align with Addendum changes. 13. Sheet CM-3, Raw Water Head Tanks Site Layout, Construction and Environmental Control Plan: Add the following sentence to the end of General Note 2: “ANY TEMPORARY OR PERMANENT MODIFICATIONS TO THE OVERHEAD ELECTRIC DEEMED NECESSARY FOR TANK CONSTRUCTION SHALL BE COORDINATED WITH PEC AND ALL RESULTING COSTS SHALL BE PAID FOR BY THE CONTRACTOR.” 14. Sheet CP-1, Overall Yard Piping Plan: Replace with reissued sheet attached to this Addendum. Culverts from CL Drawings updated to align with Addendum changes. 15. Sheet CP-2, Yard Piping Plan 1: Replace with reissued sheet attached to this Addendum. Culverts from CL Drawings updated to align with Addendum changes. 16. Sheet CZ-6, Standard Civil Details 6: Replace with reissued sheet attached to this Addendum. TxDOT Detail SETP-CD Sheet 1 of 2 replaced with TxDOT Detail PW. 17. Sheet CZ-7, Standard Civil Details 7: Replace with reissued sheet attached to this Addendum. TxDOT Detail SETP-CD Sheet 2 of 2 replaced with TxDOT Detail SCP-4 and Detail SCP-MD. 18. Sheet CZ-8, Standard Civil Details 8: Replace with reissued sheet attached to this Addendum. Details for civil work added. 19. Sheet MA-6, Raw Water Pipe Gallery and Rapid Mix Sections: In Section 2, delete the callout to Detail “A/MZ-10” and replace with “C/MZ-10”. 20. Sheet MA-7, Flocculator Sections & Detail: In Section 1, delete the callout to Detail “A/MZ-10” and replace with “E/MZ-10 OVERHUNG OPERATOR (TYP)”. 21. Sheet MA-9, Sedimentation Basin Sections: In Section 2, delete the leader text “SELF- CONTAINED SLIDE GATE” and replace with “NON-SELF-CONTAINED SLIDE GATE WITH WALL MOUNTED PEDESTAL OPERATOR”. 22. Sheet MP-1 Raw Water Head Tanks, Plan: Replace with reissued sheet attached to this Addendum. 23. Sheet MP-3, Raw Water Head Tank Sections: In Section 2, delete the scale 1/4” = 1’-0” and replace with “NTS” (Not to Scale). 24. Sheet MP-4 Raw Water Head Tanks, Details 1: Replace with reissued sheet attached to this Addendum. 25. Sheet MP-5, Raw Water Head Tanks Details 2: In Detail E, Note 1, delete “75,000 GPM” and replace with “106 MGD”. BCRUA – Phase 1D WTP Expansion Addendum No. 02 T.B.P.E Registration No. 8053 Page 12 of 12 26. Sheet MP-6, Raw Water Head Tanks Details 3: In Detail E, Note 3, delete “75,000 GPM” and replace with “106 MGD”. 27. Sheet MP-7, Raw Water Head Tanks, Overflow Structure: Replace with reissued sheet attached to this Addendum. 28. Sheet EH-3, Sludge Dewatering Facility Partial Power & Instrumentation Plan II: Replace screw conveyor tag SDF-SSC-005 control station conduit tag no. “C-SDF-SCC5-1” with “C-SDF-SSC5-1”. 29. Sheet EP-1, Raw Water Head Tanks Power & Instrumentation Plan: Replace section callout “21/EZ-6" with “12/EZ-6". 30. Sheet EY-7, Electrical Conduit Schedule 1: Replace with reissued sheet attached to this Addendum. 31. Sheet EY-8, Electrical Conduit Schedule 2: Replace with reissued sheet attached to this Addendum. 32. Sheet EY-9, Electrical Conduit Schedule 3: Replace with reissued sheet attached to this Addendum. This addendum consists of 80 page(s)/sheet(s), including attachments. _________________________________________ Approved by ENGINEER END 02-15-2023 BCRUA – Phase 1D WTP Expansion Addendum No. 03 T.B.P.E Registration No. 8053 Page 1 of 3 ADDENDUM No. 03 Date: February 23, 2023 Project Name: Phase 1D Water Treatment Plant Expansion This Addendum forms a part of the Contract and corrects or modifies original RFP Documents, dated January 17, 2023. Acknowledge receipt of this Addendum in space provided on Proposal Form. Failure to do so may subject Proposer to disqualification. A. Project Manual Revisions: 1. Section 01 50 00, Temporary Facilities and Controls: On page 9, delete paragraph 1.18C and renumber the following paragraph accordingly. 2. Section 40 90 02, Supervisory Control and Data Acquisition (SCADA) System: a. On page 5, replace paragraphs 2.1 and 2.2 with the following: “2.1 FILTER REMOTE I/O A. Filter console 7 shall include at a minimum the following: 1. Existing filter console to remain. Contractor shall provide the enclosure back plane. 2. GFCI Convenience receptacle. 3. LED light. 4. Coax Cable T-Tap. 5. Operator Interface Terminal – Allen-Bradley PanelView Plus 7 10”. 6. Relay output module – Allen-Bradley 1756-OW16I. 7. Analog Input Module – Allen Bradley 1756-IF6I. 8. Analog Output Module – Allen Bradley 1756-OF6CI. 9. Relay input module – Allen Bradley 1756-IA16I. 10. ControlNet Bridge Module - Allen Bradley 1756-CN2. 11. PLC Chassis, 10 slot – Allen Bradley 1756-A10. 12. Redundant Power Supplies and module (Sola SDN2.5-20RED). 13. Surge Suppressor – Control Concepts IC+107 or approved equal. All Addendum revisions and attachments, if any, have been conformed into Contract Documents. BCRUA – Phase 1D WTP Expansion Addendum No. 03 T.B.P.E Registration No. 8053 Page 2 of 3 14. Ground Bar. 15. Furnish all the necessary cables, face plates, connectors, modems, transceivers, repeaters, modules, splice kits, etc. required for a complete and operational Remote I/O data highway. 2.2 PLC Cabinets (RWT-PLC-01, SDF-PLC-01, TSC-PLC-01 and TSC-PLC-02) A. Contractor shall provide hardware as required to match existing components: 1. Relay output module – Allen-Bradley 1756-OW16I. 2. Analog Input Module – Allen Bradley 1756-IF6I. 3. Analog Output Module – Allen Bradley 1756-OF6CI. 4. Relay input module – Allen Bradley 1756-IA16I. 5. PLC Chassis, 10 slot – Allen Bradley 1756-A10. 6. Redundant Power Supplies and module (Sola SDN2.5-20RED). 7. Surge Suppressor – Control Concepts IC+107 or approved equal. 8. Ground Bar. 9. Furnish all the necessary cables, face plates, connectors, modems, transceivers, repeaters, modules, splice kits, etc. required for a complete and operational Remote I/O data highway. 10 RWT-PLC-02 Only: CPU - Control Logix 1756-L71. 11. TSC-PLC-02a only: CPU - ControlLogix 1756-L73 with 1756-RM2 redundancy module. 12. RWT-PLC-01 Only: UPS sized for 15 minutes of runtime.” 3. Section 46 76 21, Belt Filter Press: a. On page 20, add the following after paragraph 2.8.F.6.a. “b. The Local control panel manual adjustments available shall be made using 1/16 DIN or greater industrial controllers located on local control panel door. Provide four controllers in local control panel, one for each adjustment parameter listed. Controllers shall include 4-20mA input and 4-20mA output signals for communicating with the BFP PLC. Controllers shall be Redlion PXU or equal. c. The local control panel shall include the following mounted to the door: E-Stop mushroom head pushbutton, sludge speed mode and sludge flow mode indicator lights, and Local/Remote selector switch. d. Manual control of individual equipment shall be executed at the BFP control panel OIT and local control panel controllers.” BCRUA – Phase 1D WTP Expansion Addendum No. 03 T.B.P.E Registration No. 8053 Page 3 of 3 B. Drawing Revisions: 1. Sheet MH-5, Sludge Dewatering Facility Sections: Replace with reissued sheet attached to this Addendum to clarify inclined conveyor Section 1. 2. Sheet MP-6, Raw Water Head Tanks Details 3: In Note 3 of the Manway Ladder Detail D, delete “FLUTED” and replace with “KNURLED”. 3. Sheet E-5, Site Plan – B: Change the graphic scale from 1”=20’ to 1”=40’. 4. Sheet EH-3, Sludge Dewatering Facility Partial Power & Instrumentation Plan II: Replace with reissued sheet attached to this Addendum to modify drawing scale. 5. Sheet EY-17, Electrical Schematics 8: Replace with reissued sheet attached to this Addendum to delete level relay panel schematic and to add a polymer selector panel schematic. 6. Sheet I-1, Process System Architecture: Replace with reissued sheet attached to this Addendum to clarify the system integrators scope of work. This addendum consists of 7 page(s)/sheet(s), including attachments. _________________________________________ Approved by ENGINEER END 02-23-2023 SPECIFICATIONS – DIVISION 1 SECTIONS 01 10 00 – 01 91 00 PHASE 1D - WATER TREATMENT PLANT EXPANSION BCRUA – Phase 1D WTP Expansion Issued for Bid Summary of Work and Operational Requirements 01 10 00 - 1 SECTION 01 10 00 – SUMMARY OF WORK AND OPERATIONAL REQUIREMENTS PART 1 GENERAL 1.1 SUMMARY A. Section includes: 1. Contract description. 2. Work by Owner or other related Work. 3. Owner furnished products. 4. Contractor's use of site and premises. 5. Work sequence. 6. Operational requirements. 7. Owner occupancy. 8. Permits. 9. Specification conventions. 10. Reference specifications and standards. 1.2 SUBMITTALS A. See Section 01 33 00 – Submittal Procedures for general requirements. B. Shop Drawings: 1. Submit a construction plan as specified herein. 2. Submit a Maintenance of Plant Operations (MOPO) plan as specified herein. 1.3 CONTRACT DESCRIPTION A. Work includes furnishing of labor, materials, equipment and services for construction of an expansion to the existing Brushy Creek Regional Utility Authority (BCRUA) Water Treatment Plant (WTP) from a current rated capacity of 32.5 million gallons per day (MGD) to a proposed capacity of 42 MGD. The Base Proposal for the nominal 10 MGD expansion includes construction of new facilities, as well as modifications and improvements to existing facilities as generally described below. 1. Construction of two nominal 0.5 million gallon (MG) prestressed concrete raw water head tanks with associated appurtenances, piping and valves. 2. Construction of a new pretreatment train consisting of six flocculation basins with vertical shaft flocculators and one rectangular sedimentation basin with sludge collectors. The proposed pretreatment train will be structurally connected to the existing Central Treatment Structure. 3. Installation of one dual media, gravity filter with underdrains and wash water troughs, which will be installed in an existing filter cell in the Central Treatment Structure, and associated piping. 4. Improvements to the fluorosilicic acid feed system, including installation of one 6,000 gallon bulk storage tank, two peristaltic transfer pumps, one 250 gallon day tank, and related appurtenances in the existing Chemical Feed Area within the Central Treatment Structure. 5. Installation of one 12,150 gallon sodium hypochlorite bulk storage tank and related appurtenances in the existing Disinfection Facility. BCRUA – Phase 1D WTP Expansion Issued for Bid Summary of Work and Operational Requirements 01 10 00 - 2 6. Installation of a submersible chemical induction unit in the existing Disinfection Basin. 7. Construction of one 60-foot diameter gravity sludge thickener with associated appurtenances, piping, and valves. 8. Installation of one 2 meter, two-belt, extended gravity belt filter press with three screw conveyors and other related components in the existing Sludge Dewatering Facility. 9. Related civil, structural, electrical, instrumentation and other items necessary for a complete, operational project. B. The project includes Base Proposal items, including Allowances. Reference Section 01 21 00 for detailed descriptions of all Proposal Items. C. Construct the Work in accordance with the Proposal Items listed on the Proposal Form (Section 00300), as generally described below. 1. Bonds, Mobilization, and Start-up. 2. Trench Safety. 3. Construction of all other Work. 4. Allowance for Commissioning and Startup. 1.4 WORK BY OWNER OR OTHER RELATED WORK A. The existing WTP is currently in operation and deliveries, maintenance, etc. regularly occur. If any Owner awarded contracts interfere with each other due to work being performed at the same time or at the same site, Owner will determine the sequence of work for all contracts according to the Work Sequence and Contractor's Use of Site and Premises Articles in this Section. B. Contractor shall coordinate Work with utilities of Owner, and public or private agencies. C. Construction of the BCRUA Phase 2 Raw Water Delivery System will occur at the same time as the WTP expansion under a separate OWNER contract. The Phase 2 project is primarily located on Lake Travis and construction will not impact the WTP site. However, Contractor coordination may be required for shutdowns and start-up as specified and detailed in the contract documents. D. Construction of the BCRUA 6.0 Million Gallon (MG) Clearwell project will occur at the same time as the WTP expansion under a separate OWNER contract. The Clearwell project will be primarily located on the northwest corner of the WTP site and will not directly impact work areas in the Phase 1D expansion. However, Contractor coordination will likely be required for adjacent work activities, deliveries, shutdowns, and start-up as specified and detailed in the contract documents. 1.5 OWNER-FURNISHED PRODUCTS A. Owner's Responsibilities: 1. Arrange for and deliver Owner reviewed Shop Drawings, Product Data, and Samples to Contractor. 2. Upon delivery, inspect products jointly with Contractor. 3. Arrange for manufacturers' warranties, inspections, and service. B. Contractor's Responsibilities: BCRUA – Phase 1D WTP Expansion Issued for Bid Summary of Work and Operational Requirements 01 10 00 - 3 1. Review Owner reviewed Shop Drawings, Product Data, and Samples. 2. Receive and unload products at Site; inspect for completeness or damage jointly with Owner. 3. Furnish, handle, store, install, and finish products. 4. Repair or replace items damaged after receipt. 1.6 CONTRACTOR'S USE OF SITE AND PREMISES A. Owner will occupy the premises during the entire period of construction for the conduct of normal operations. Contractor shall coordinate with Owner in all construction operations to minimize conflicts and shutdowns and to facilitate continuous Owner usage. B. Construction Operations: Limited to areas indicated on Drawings. C. Time Restrictions for Performing Work: Reference General Conditions Article 7. D. Construction Plan: Before start of construction, submit a construction plan regarding access to Work and use of site for acceptance by Owner. After acceptance of plan, construction operations shall comply with accepted plan unless deviations are accepted by Owner in writing. 1.7 WORK SEQUENCE A. Construct Work in phases during construction period. Coordinate construction schedule and operations with Engineer. B. Sequence of Construction Plan: Before start of construction, submit construction plan regarding phasing of construction and new Work for acceptance by Owner. The proposed work sequence shall be submitted to the Engineer with the Construction Progress Schedule (see Section 01 32 16). After acceptance of plan, construction sequence shall comply with accepted plan unless deviations are accepted by Owner in writing. C. The Contractor shall organize and plan the construction activities to assure the safety and reliability of and to minimize the interruption to the WTP and all other related utilities. D. Contractor shall provide temporary facilities and make temporary modifications as necessary to keep the existing facilities in operation during the construction period. E. Contractor shall be solely responsible for all means and methods of construction. This general sequence is not intended as a scope of work and does not cover all Work required under the Contract. Neither Engineer nor Owner assumes responsibility regarding construction work by listing this general sequence of construction. Any potential conflicts or other issues related to this sequence shall be brought to the attention of Engineer and Owner during the pre- construction meeting. F. Except as specified otherwise herein, schedule work to ensure continuous operation of the WTP and related necessary facilities. Notify Owner by advance written or verbal warning at least 30 days prior to any Work requiring temporary interruption to facility operations. Notify Owner again at least 48 hours prior to commencing such Work. Owner may require Contractor BCRUA – Phase 1D WTP Expansion Issued for Bid Summary of Work and Operational Requirements 01 10 00 - 4 to delay work requiring facility disruption if the disruption would, in the Owner’s opinion, cause an unacceptable shortage of water production. G. Connections to existing facilities which are in service shall be thoroughly planned in advance, and all required equipment, materials and labor shall be on hand at the time of the connection. Work shall proceed continuously (24-hour a day basis), if necessary, to complete connections in the minimum time. Operations of existing valves or appurtenances on existing utilities, when required, shall be by or under the direct supervision of the OWNER. H. Verify the location of all conflicting utilities and components prior to construction to minimize disruptions to existing facility operations. Contractor is responsible for buried utilities in the field. Any discrepancies with the Drawings found in the field shall be brought immediately to the attention of the Owner’s Representative and Engineer. I. Any existing utilities, fencing, structures, etc. that are damaged or removed as a result of construction work shall be repaired to like new condition or replaced by the Contractor at no cost to the Owner. 1.8 OPERATIONAL REQUIREMENTS A. The existing WTP is in operation. Construction operations shall be scheduled to allow the Owner uninterrupted operation of necessary existing facilities, except as specified herein. Contractor shall coordinate connections with existing facilities to ensure timely completion of interfaced items. B. At no time shall Contractor or its employees modify operation of existing facilities or start construction modifications without prior approval from the Owner, except in an emergency to prevent or minimize damage. C. Contractor shall submit a Maintenance of Plant Operations (MOPO) plan to the Engineer a minimum of 30 days prior to any scheduled WTP shutdown for any activity that will interrupt existing operations. The MOPO plan shall include the following: 1. Schedule and detailed sequence of work to be completed, including estimated durations for activities. 2. Detailed contingency plan. 3. List of staff, materials, and labor required to complete the activity. 4. Prerequisite steps required to complete work. 5. Contractor contact list. D. Except as specified otherwise herein, the WTP shall be able to produce and distribute finished water on a continuous basis during construction. Construction activities shall be coordinated with WTP operations, and planned and scheduled to minimize construction impacts on operations, as well as maintain plant capacity. WTP production varies seasonally and is expected to average approximately 20-25 MGD in “summer” months (May through September) and 10-12 MGD in “winter” months (November through February) during this project. The existing WTP has a rated finished water capacity of 32.5 MGD and customer demand may necessitate production at this rate during the project. Where modifications or connections to existing facilities and piping are made, planning and coordination will be necessary to allow construction activities to proceed without unacceptable impacts to WTP operations. The Contractor shall be responsible for planning and coordinating work, and for BCRUA – Phase 1D WTP Expansion Issued for Bid Summary of Work and Operational Requirements 01 10 00 - 5 implementation of any temporary facilities required during construction. Selected construction activities, and operational requirements and shutdowns associated with such activities, are listed in the following subparagraphs. The Contractor shall provide a minimum 30-day notice to the Owner prior to any scheduled WTP shutdown. The list below is not intended to include all construction activities that may impact facility operational requirements. 1. Spring 2023: a. Existing Sedimentation Basin 3C shall be dewatered during excavation and subgrade preparation for proposed Sedimentation Basin 4C. The existing basin may be taken out of service for a maximum of four weeks (28 calendar days) to perform this work. The shutdown shall occur during low demand months and the related work shall be completed before June 16, 2023. The existing basin shall be returned to service after installation of subgrade structural fill is accepted by Owner. 1) The OWNER shall be responsible for dewatering and refilling the existing sedimentation basin. Time required for Owner to dewater/fill basins is not included in Contractor’s allowable shutdown period. 2. Process Integration: a. Expansion of the WTP will require multiple connections to existing process units, piping, and utilities. Some process connections will require temporary shutdowns to portions of the WTP, including, but not limited to installation of the following: 1) Proposed Rapid Mix gates. 2) Proposed valves and piping associated with Filter 7C. 3) Proposed backwash Flow Control Valve. b. Shutdowns required for process integration shall be limited to a maximum of 8 hours each. Shutdowns on consecutive days may only occur if approved by the Owner. The Contractor shall make good faith effort to complete necessary process integration work during low demand winter months. 1) If the WTP is operating when a process integration shutdown is required, the shutdown may need to be scheduled during low water demand periods (i.e., overnight or early morning) to prevent disruption of public water supply. 2) The OWNER shall be responsible for dewatering and refilling adjacent existing process units as needed. Time required for Owner to dewater/fill basins is not included in Contractor’s allowable shutdown period. c. Shutdowns for process integration shall not be made until proposed improvements to be integrated are substantially complete and ready for full-scale operation, or unless the proposed improvements can be isolated (i.e., valved off) from existing process units after connection is made. d. The OWNER shall be responsible for taking affected existing treatment units out of service for process integration shutdowns and subsequently returning them to service after the shutdown is complete. e. The Owner reserves the right to cancel, postpone or terminate scheduled process integration shutdowns if WTP operation is determined necessary or if the shutdown is not completed within the allotted timeframe. 3. Structural Integration: a. Completion of Sedimentation Basin 4C will require removal of existing knockout walls in the Flocculated and Settled Water channels, which will require shutdown of existing Flocculators 05 and 06 and Sedimentation Basin 3C, as well as dewatering of the associated channels. The knockout walls shall not be removed until the proposed Flocculators and Sedimentation Basin are ready to treat water, unless the Contractor provides temporary isolation between basins that can be removed without BCRUA – Phase 1D WTP Expansion Issued for Bid Summary of Work and Operational Requirements 01 10 00 - 6 impacting WTP operation. The shutdown for removal of both knockout walls shall be limited to a maximum of 8 hours. 1) The OWNER shall be responsible for dewatering and refilling adjacent existing channels and process units as needed. Time required for Owner to dewater/fill channels and basins is not included in Contractor’s allowable shutdown period. 4. Electrical Integration: a. Electrical work related to proposed expansion of the WTP may require temporary power outages to specific areas of the plant. Temporary outages to specific areas of the WTP shall be planned and scheduled such that power is not disrupted for more than two hours, and shall be scheduled only at times approved by the Owner. The Contractor shall make good faith effort to schedule temporary power outages during periods when the WTP is shut down for other work as described above. b. Reference Section 26 05 00 for expected electrical outages related to this project. 5. Where possible, the Contractor should combine shutdowns from multiple areas to minimize overall impacts to the WTP. 1.9 OWNER OCCUPANCY A. Owner will occupy site during entire period of construction. B. Cooperate with Owner to minimize conflict and to facilitate Owner's operations. C. Schedule the Work to accommodate Owner occupancy. 1.10 PERMITS A. Furnish all necessary permits for construction of the Work. Reference General Conditions Article 7.08. 1.11 SPECIFICATION CONVENTIONS A. These Specifications are written in imperative mood and streamlined form. This imperative language is directed to Contractor unless specifically noted otherwise. The words "shall be" are included by inference where a colon (:) is used within sentences or phrases. 1.12 REFERENCE SPECIFICATIONS AND STANDARDS A. Materials which are specified by reference to Federal Specifications; ASTM, ASME, ANSI or AWWA specifications; Federal Standards; or other standard specifications must comply with latest editions, revisions, amendments or supplements in effect on date proposals are received. Requirements in reference specifications and standards are considered minimum acceptable quality for all equipment, material and work. In instances where capacities, size or other feature of equipment, devices or materials exceed these minimums, meet listed or shown capacities. BCRUA – Phase 1D WTP Expansion Issued for Bid Summary of Work and Operational Requirements 01 10 00 - 7 PART 2 PRODUCTS - Not Used PART 3 EXECUTION - Not Used END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Price and Payment Procedures 01 20 00 - 1 SECTION 01 20 00 - PRICE AND PAYMENT PROCEDURES PART 1 GENERAL 1.1 SECTION INCLUDES A. Allowances. B. Schedule of Values. C. Application for Payment. D. Change procedures. E. Nonconformance assessment and nonpayment for rejected products. F. Unit prices & measurement. G. Partial payment for stored materials and equipment H. Alternates. I. Mobilization, traffic handling, and incidentals 1.2 ALLOWANCES A. Consult with Engineer in selection of products or services. Obtain proposals from Suppliers and Installers and offer recommendations. B. Allowances are stipulated amounts listed in the Proposal Form for anticipated materials, equipment, services, or for use upon Owner’s instruction as contingency. In addition to this Section, refer to General Conditions, as may be modified by the Supplemental Conditions; and individual Specification Sections for Contractor’s costs to be covered by allowances, and Contractor’s costs, including overhead and profit, to be included elsewhere in the Contract Price. C. For each allowance, submit to Engineer a Change Order proposal to adjust Contract Price for difference between specified allowance amount and actual cost. Prepare Change Order proposal in accordance with the General Conditions and Supplemental Conditions, except that payment within limit of a cash allowance shall exclude cost of bond and insurance premiums. D. Submit invoices to show actual cost and quantity of permits, materials, or equipment furnished and used in fulfilling each allowance. E. Submit, with application for payment, invoice showing date of purchase, from whom the purchase was made, the date of delivery of the product or service, and the price, including delivery to the site and applicable taxes. F. Contractor's costs for products, delivery, installation, labor, insurance, payroll, taxes, bonding, equipment rental, overhead, and profit will be included in Change Orders authorizing expenditure of funds from the contingency allowance. G. Funds will be drawn from contingency allowances only by Change Order. H. At closeout of Contract, funds remaining in contingency allowances will be credited to Owner by Change Order. BCRUA - Phase 1D WTP Expansion Issued for Bid Price and Payment Procedures 01 20 00 - 2 1.3 SCHEDULE OF VALUES A. Submit schedule of Values on either EJCDC Form C-620 or on Contractor’s standard form to be approved by the Engineer. B. Submit Schedule of Values before starting construction as specified in Section 00700 – General Conditions. C. Format: Use Table of Contents of this Project Manual. Identify each line item with number and title of major Specification Section. D. Include within each line item, direct proportional amount of Contractor's overhead and profit. E. Revise schedule to list approved Change Orders with each Application for Payment. F. Upon request of Engineer, provide documentation to support the accuracy of the Schedule of Values. G. An unbalanced or front-end loaded schedule will not be acceptable. H. Schedule of Values shall be acceptable to Engineer prior to submission of the first Application for Payment. I. The summation of the Schedule of Values shall represent all Work under the Contract and shall equal the Contract Price. J. Unit Price Work: Reflect unit price quantity and price breakdown from conformed Proposal Form. K. Lump Sum Work: 1. Reflect in conformed Proposal Forms, specified allowances, alternates, and equipment selected by Owner, as applicable. 2. List bonds and insurance premiums, preliminary and detailed progress schedule preparation, equipment testing, facility startup, and contract closeout separately. 3. Break down by Division 2 through 49 with appropriate subdivision of each Specification. 1.4 APPLICATION FOR PAYMENT A. Attach a Summary Form with each detailed Application for Payment for each schedule and include Request for Payment of Materials and Equipment on Hand as applicable. Execute certification by authorized officer of Contractor. B. Submit three copies of each Application for Payment on EJCDC C-620 - Contractor's Application for Payment or a Contractor’s electronic media driven form as approved by the Engineer. C. Content and Format: Use accepted Schedule of Values for each schedule or portion of lump sum Work, the unit price breakdown for the Work to be paid on a unit priced basis, a listing of Owner-selected equipment, if applicable, and allowances as appropriate for listing items in Application for Payment. BCRUA - Phase 1D WTP Expansion Issued for Bid Price and Payment Procedures 01 20 00 - 3 D. Include separate line item for each Change Order and Work Change Directive executed prior to date of submission. Provide further breakdown of such as requested by Engineer. E. Submit revised and current construction progress schedule as specified in Section 01 32 16 - Construction Progress Schedule with each Application for Payment. F. Payment Period: Submit at intervals stipulated in the Agreement. G. Submit pay applications with transmittal letter as specified in Section 01 33 00 – Submittal Procedures. H. Substantiating Data: When Engineer requires substantiating information, submit data justifying dollar amounts in question. Include the following with Application for Payment: 1. Partial release of liens from major Subcontractors and vendors. 2. Record Documents as specified in Section 01 70 00 – Execution and Closeout Requirements, for review by Owner, which will be returned to Contractor. 3. Supporting documentation as specified in Section 00700 – General Conditions for materials and equipment not incorporated in the Work but suitably stored at the Site or another location. 1.5 CHANGE PROCEDURES A. Submittals: Submit name of individual who is authorized to receive change documents and is responsible for informing others in Contractor’s employment or Subcontractors of changes to the Work. B. Carefully study and compare Contract Documents before proceeding with fabrication and installation of Work. Promptly advise Engineer of any error, inconsistency, omission, or apparent discrepancy. C. Engineer will advise of minor changes in the Work not involving adjustment to Contract Sum/Price or Contract Time by issuing supplemental instructions on EJCDC C-942 – Field Order. D. Engineer may issue Change Proposal Request including a detailed description of proposed change with supplementary or revised Drawings and Specifications, a change in Contract Time for executing the change and with the period of time during which the requested price will be considered valid. Contractor will prepare and submit estimate within 10 calendar days. E. Contractor may propose changes by submitting a Change Proposal Request for change to Engineer, describing proposed change and its full effect on the Work. Include a statement describing reason for the change and the effect on Contract Sum/Price and Contract Time with full documentation and a statement describing effect on the Work by separate or other Contractors. Document requested substitutions according to Section 01 25 00 – Substitution Procedures. F. Stipulated Sum/Price Change Order: Based on Change Proposal Request and Contractor's fixed price quotation or Contractor's request for Change Order as recommended by Engineer and approved by Owner. BCRUA - Phase 1D WTP Expansion Issued for Bid Price and Payment Procedures 01 20 00 - 4 G. Unit Price Change Order: For Contract unit prices and quantities, the Change Order will be executed on a fixed unit price basis. For unit costs or quantities of units of that which are not predetermined, execute Work under Work Directive Change. Changes in Contract Price or Contract Time will be computed as specified for Time and Material Change Order. H. Work Directive Change: Engineer may issue directive, on EJCDC C-940 - Work Change Directive signed by Owner, instructing Contractor to proceed with change in the Work, for subsequent inclusion in a Change Order. Document will describe changes in the Work and designate method of determining any change in Contract Sum/Price or Contract Time. Promptly execute change. I. Document each quotation for change in Project Cost or Time with sufficient data to allow evaluation of quotation. J. Change Order Forms: EJCDC C-941 - Change Order or as approved by Engineer. K. Execution of Change Orders: Engineer will issue Change Orders for signatures of parties as provided in the General Conditions of the Contract. L. Correlation of Contractor Submittals: 1. Promptly revise Schedule of Values and Application for Payment forms to record each authorized Change Order as separate line item and adjust Contract Sum/Price. 2. Promptly revise Progress Schedules to reflect change in Contract Time, revise sub- schedules to adjust times for other items of Work affected by the change, and resubmit. 3. Promptly enter changes in Record Documents. 1.6 NONCONFORMANCE ASSESSMENT AND NONPAYMENT FOR REJECTED PRODUCTS A. Replace the Work, or portions of the Work, not conforming to specified requirements. Reference Section 00700 – General Conditions for additional requirements for defective Work. B. If, in the opinion of Engineer, it is not practical to remove and replace the Work, Engineer will direct appropriate remedy or adjust payment. 1. When the defective Work is deemed to remain, the unit price will be adjusted to new price at discretion of Engineer and Owner. C. Individual Specification Sections may modify these options or may identify specific formula or percentage sum/price reduction. D. Authority of Engineer and Owner to assess defects and identify payment adjustments is final. E. Nonpayment for Rejected Products: Payment will not be made for rejected products for any of the following reasons: 1. Products wasted or disposed of in a manner that is not acceptable under the Contract Documents. 2. Rejected loads of material, including material rejected after it has been placed by reason of failure of Contractor to conform to provisions of Contract Documents. 3. Products determined as unacceptable before or after placement. 4. Products not completely unloaded from transporting vehicle. BCRUA - Phase 1D WTP Expansion Issued for Bid Price and Payment Procedures 01 20 00 - 5 5. Products placed beyond lines and levels of the required Work. 6. Products remaining on hand after completion of the Work. 7. Loading, hauling, and disposing of rejected products. 1.7 UNIT PRICES AND MEASUREMENT A. Authority: Measurement methods are described in individual Specification Sections. B. Measurement methods delineated in individual Specification Sections complement criteria of this Section. In event of conflict, requirements of individual Specification Section govern. C. Take measurements and compute quantities. Engineer will verify measurements and quantities. D. Unit Quantities: Quantities and measurements indicated on Proposal Form are for Contract purposes only. Actual quantities provided shall determine payment. 1. When actual Work requires more or fewer quantities than those quantities indicated, provide required quantities at contracted unit sum/prices. 2. When actual Work requires 25 percent or greater change in quantity than those quantities indicated, Owner or Contractor may claim a Contract Price adjustment. E. Payment Includes: Full compensation for required labor, products, tools, equipment, plant and facilities, transportation, services and incidentals; erection, application, or installation of item of the Work; overhead and profit. F. Final payment for Work governed by unit prices will be made on basis of actual measurements and quantities accepted by Engineer multiplied by unit price for Work incorporated in or made necessary by the Work. A final Change Order will be executed to adjust the contract amount accordingly. G. Measurement of Quantities: 1. Weighing, measuring, and metering devices used to measure quantity of material for Work shall be suitable for purpose intended and conform to tolerances and specifications as specified in National Institute of Standards and Technology, Handbook 44. 2. Measurement by Volume: Measured by cubic dimension using mean length, width, and height or thickness. 3. Measurement by Area: Measured horizontally by square dimension using mean length and width or radius. 4. Linear Measurement: Measured horizontally by linear dimension, at item centerline or mean chord. 5. Stipulated Sum/Price Measurement: Items measured by weight, volume, area, or linear means or combination, as appropriate, as completed item or unit of the Work. 6. Whenever pay quantities of material are determined by weight, material shall be weighed on scaled furnished by Contractor and certified accurate by state agency responsible. Weight or load slip shall be obtained from weigher and delivered to Owner’s representative at point of delivery of material. 7. If material is shipped by rail, car weights will be accepted provided that actual weight of material only will be paid for and not minimum car weight used for assessing freight tariff, and provided further that car weights will not be acceptable for material to be passed through mixing plants. BCRUA - Phase 1D WTP Expansion Issued for Bid Price and Payment Procedures 01 20 00 - 6 8. Vehicles used to haul material being paid for by weight shall be weighed empty daily and at such additional times as required by Engineer. Each vehicle shall bear a plainly legible identification mark. 9. Materials that are specified for measurement by the cubic yard measured in the vehicle shall be hauled in vehicles of such type and size that actual contents may be readily and accurately determined. Unless all vehicles are of uniform capacity, each vehicle must bear a plainly legible identification mark indicating its water level capacity. Vehicles shall be loaded to at least their water level capacity. Loads hauled in vehicles not meeting above requirements or loads of a quantity less than the capacity of the vehicle, measured after being level off as above provided, will be subject to rejection, and no compensation will be allowed for such material. 10. Where measurement of quantities depends on elevation of existing ground, elevations obtained during construction will be compared with those shown on Drawings. Variations of 1 foot or less will be ignored, and profiles shown on Drawings will be used for determining quantities. 11. Units of measure shown on Schedule of Values shall be as follows, unless specified otherwise. Item Method of Measurement AC Acre – Field Measure by Engineer CY Cubic Yard – Field Measure by Engineer within limits specified or shown CY-VM Cubic Yard – Measured in Vehicle by Volume EA Each – Field Count by Engineer GAL Gallon – Field Measure by Engineer HR Hour LB Pound(s) – Weight Measure by Scale LF Linear Foot – Field Measured by Engineer MFBM Thousand Foot Board Measure – Delivery Invoice SF Square Foot SY Square Yard TON Ton – Weight Measure by Scale (2,000 pounds) BCRUA - Phase 1D WTP Expansion Issued for Bid Price and Payment Procedures 01 20 00 - 7 12. Measurement of Linear Items: Where payment will be made based on linear quantities and on parameters other than length, those parameters shall be as follows: Item Measurement Parameters Trench Safety System Depth of Trench: 0 to 4 feet; 4 to 10 feet; over 10 feet in 2-foot increments. The depth of trench will be measured at intervals of 25 feet along the centerline of the trench. The depth of each measuring point will be the depth from existing at grade surface to bottom of pipe base, 6 inches below pipe invert and will used for computing the depth of trench for a distance of 25 feet ahead of the point of measurement. The depth figures indicated in Schedule of Values are inclusive to nearest 0.1 foot; that is, a trench depth measured as 11.9 feet will be paid for at the unit price for excavation 10 to 12 feet deep. A trench depth measured as 12 feet will be paid for at the unit price excavation 12 to 14 feet deep. Unclassified Trench Excavation Depth of Trench: Same as Trench Safety System above. Trench Backfill and Compaction Depth of Trench: Same as Unclassified Trench Excavation above. 1.8 PARTIAL PAYMENT FOR STORED MATERIALS AND EQUIPMENT A. Partial Payment: Partial payments will be made for materials and equipment delivered or stored when Shop Drawings and preliminary operation and maintenance data is acceptable to Engineer. B. Final Payment: Will be made only for products incorporated in Work; remaining products, for which partial payments have been made, shall revert to Contractor unless otherwise agreed, and partial payments made for those items will be deducted from final payment. 1.9 ALTERNATES A. Alternates quoted on Proposal Form will be reviewed and accepted or rejected at Owner's option. Accepted Alternates will be identified in Owner-Contractor Agreement. 1.10 MOBILIZATION, TRAFFIC HANDLING, AND INCIDENTALS A. As specified in Section 01 21 00. PART 2 PRODUCTS - Not Used PART 3 EXECUTION - Not Used END OF SECTION BCRUA – Phase 1D WTP Expansion Issued for Bid Proposal Items: Scope of Work 01 21 00 - 1 SECTION 01 21 00 – PROPOSAL ITEMS: SCOPE OF WORK PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. A description of the work included with each Proposal Item. 2. Basis of Measurement for each Proposal Item. B. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Division 01 – General Requirements. 1.2 DEFINITIONS A. Base Proposal Items refers to those Proposal items that will be included in the contract without exception. B. Allowance refers to those items for which the cost of materials or services is established and identified on the Proposal Form. Allowances are included in the Base Proposal. 1. See Section 01 20 00 for Allowance requirements. C. Alternate Proposal Items refers to those Proposal Items that will be included in the contract at the Owner’s discretion during the period of the contract, except as noted herein. A Proposal for an Alternate Proposal Item is the amount stated in the Proposal Form and identified below, if an Alternate Proposal Item is accepted. It is expressly understood that the Owner reserves the right to accept or reject any or all Alternates and may select Alternates regardless of order in the Proposal Form. If any Alternates are accepted, they will be added to the Total Base Proposal. Includes Additive Alternate Proposal Items. D. Cost refers to the total cost to the Owner for the work described, including all direct and indirect costs borne by the Contractor in conjunction with the work described, plus Contractor’s overhead and profit associated with the work described. 1. In the case of Allowances, Cost refers to the direct cost to the Contractor of the materials or services described and shall be equal to the stated Allowance. Cost shall exclude indirect costs borne by the Contractor and Contractor overhead and profit. 1.3 BASE PROPOSAL ITEMS A. Proposal Item 1: Bonds, Mobilization, and Start-up. 1. Work Included: Provision of acceptable Contract Documents, bonds, insurance, and placement in field and transportation of Contractor’s equipment to the project site. Mobilization and start-up will be paid 50 percent upon submission of the first pay application. The remaining 50 percent will be paid on a performance basis over the following applications. 2. Measurement: Lump Sum. Shall not exceed 5 percent of total Proposal price. BCRUA – Phase 1D WTP Expansion Issued for Bid Proposal Items: Scope of Work 01 21 00 - 2 B. Proposal Item 2: Trench Safety. 1. Work Included: Design, furnish, install, maintain and remove trench safety systems as required for all proposed pipeline trenches greater than 5 feet deep, including trench safety plan as specified in Section 31 23 15. 2. Measurement: Linear Feet. C. Proposal Item 3: Construction of all Work as specified and detailed, excluding Work included in other Proposal Items. 1. Work Included: Cost of all Work described in Section 01 10 00 and not specifically included under other Proposal Items. 2. Measurement: Lump Sum. D. Proposal Item 4: Allowance for Commissioning and Start-up. 1. Work Included: Cost of commissioning and start-up for the Water Treatment Plant as specified in Section 01 91 00 – Facility Commissioning. 2. Measurement: Lump Sum. 1.4 ADDITIVE ALTERNATE PROPOSAL ITEMS – Not used. 1.5 REFERENCES – Not used. 1.6 QUALITY ASSURANCE – Not used. PART 2 PRODUCTS – Not used. PART 3 EXECUTION – Not used. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Substitution Procedures 01 25 00 - 1 SECTION 01 25 00 - SUBSTITUTION PROCEDURES PART 1 GENERAL 1.1 SECTION INCLUDES A. Quality assurance. B. Product options. C. Product substitution procedures. D. Installer substitution procedures. 1.2 QUALITY ASSURANCE A. Contract is based on products and standards established in Contract Documents without consideration of proposed substitutions. B. Products specified define standard of quality, type, function, dimension, appearance, and performance required. C. Substitution Proposals: Permitted for specified products except where specified otherwise. Do not substitute products unless substitution has been accepted and approved in writing by Owner. 1.3 PRODUCT OPTIONS A. See Section 01 60 00 - Product Requirements. 1.4 PRODUCT SUBSTITUTION PROCEDURES A. Substitutions may be considered when a product becomes unavailable through no fault of Contractor. B. Document each request with complete data, substantiating compliance of proposed substitution with Contract Documents, including: 1. Manufacturer's name and address, product, trade name, model, or catalog number, performance and test data, and reference standards. 2. Itemized point-by-point comparison of proposed substitution with specified product, listing variations in quality, performance, and other pertinent characteristics. 3. Reference to Article and Paragraph numbers in Specification Section. 4. Cost data comparing proposed substitution with specified product and amount of net change to Contract Sum. 5. Schedule data describing changes in construction schedule. 6. Product experience including location of history of past projects utilizing product and name and telephone number of persons associated with reference projects. 7. Changes required in other Work. 8. Availability of maintenance service and source of replacement parts as applicable. 9. Certified test data to show compliance with performance characteristics specified. 10. Samples when applicable or requested. 11. Other information as necessary to assist Architect/Engineer's evaluation. BCRUA - Phase 1D WTP Expansion Issued for Bid Substitution Procedures 01 25 00 - 2 C. A request constitutes a representation that Proposer or Contractor: 1. Has investigated proposed product and determined that it meets or exceeds quality level of specified product. 2. Will provide same warranty for substitution as for specified product. 3. Will coordinate installation and make changes to other Work that may be required for the Work to be complete with no additional cost to Owner. 4. Waives claims for additional costs or time extension that may subsequently become apparent. 5. Will coordinate installation of the accepted substitute, making such changes as may be required for the Work to be complete in all respects. 6. Will reimburse Owner and Engineer for review or redesign services associated with reapproval by authorities having jurisdiction. D. Substitutions will not be considered when they are indicated or implied on Shop Drawing or Product Data submittals without separate written request or when acceptance will require revision to Contract Documents. E. Substitution Submittal Procedure: 1. Submit requests for substitutions in writing in accordance with the requirements of this specification section. 2. Submit electronic files of Request for Substitution for consideration. Limit each request to one proposed substitution. 3. Submit Shop Drawings, Product Data, and certified test results attesting to proposed product equivalence. Burden of proof is on Proposer or Contractor. 4. Architect/Engineer will notify Contractor in writing of decision to accept or reject request. 5. Provisions of General Conditions will apply in the event the substitution is approved and results in a change of Contract Sum or schedule. 6. Substitution will be rejected if, in the Engineer’s opinion, acceptance will require substantial revision of the original design or the substitution will not adequately perform the intended function. 1.5 INSTALLER SUBSTITUTION PROCEDURES A. Document each request with: 1. Installer's qualifications. 2. Installer's experience in work similar to that specified. 3. Other information as necessary to assist Architect/Engineer's evaluation. B. Substitution Submittal Procedure: 1. Submit electronic files of Request for Substitution for consideration. Limit each request to one proposed substitution. 2. Engineer will notify Contractor in writing of decision to accept or reject request. BCRUA - Phase 1D WTP Expansion Issued for Bid Substitution Procedures 01 25 00 - 3 PART 2 PRODUCTS - Not Used PART 3 EXECUTION - Not Used END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Administrative Requirements 01 30 00 - 1 SECTION 01 30 00 - ADMINISTRATIVE REQUIREMENTS PART 1 GENERAL 1.1 SECTION INCLUDES A. Coordination and Project conditions. B. Preconstruction meeting. C. Site mobilization meeting. D. Progress meetings. E. Preinstallation meetings. F. Closeout meeting. G. Alteration procedures. 1.2 COORDINATION AND PROJECT CONDITIONS A. Coordinate scheduling, submittals, and Work of various Sections of Project Manual to ensure efficient and orderly sequence of installation of interdependent construction elements, with provisions for accommodating items installed later. B. Verify that utility requirements and characteristics of operating equipment are compatible with building utilities. Coordinate Work of various Sections having interdependent responsibilities for installing, connecting to, and placing operating equipment in service. C. Coordinate space requirements, supports, and installation of mechanical and electrical Work indicated diagrammatically on Drawings. Follow routing shown for pipes, ducts, and conduit as closely as practical; place runs parallel with lines of building. Use spaces efficiently to maximize accessibility for other installations, for maintenance, and for repairs. D. Coordinate interruptions of all utilities and services. All work shall be in accordance with the requirements of the applicable utility company or agency involved. E. In finished areas except as otherwise indicated, conceal pipes, ducts, and wiring within construction. Coordinate locations of fixtures and outlets with finish elements. F. Coordinate completion and clean-up of Work of separate Sections in preparation for Substantial Completion and for portions of Work designated for Owner's partial occupancy. G. After Owner's occupancy of premises, coordinate access to Site for correction of defective Work and Work not complying with Contract Documents, to minimize disruption of Owner's activities. 1.3 PRECONSTRUCTION MEETING A. Engineer will schedule and preside over meeting after the Agreement has been executed and all bonds and insurance are in affect for the project and before any Work is started. B. The preconstruction meeting will be held at a location selected by the Engineer. BCRUA - Phase 1D WTP Expansion Issued for Bid Administrative Requirements 01 30 00 - 2 C. Attendance Required: Engineer, Owner, Owner’s Resident Project Representative (RPR), Contractor, and major Subcontractors. D. Minimum Agenda: 1. Execution of Owner-Contractor Agreement. 2. Submission of executed bonds and insurance certificates. 3. Distribution of Contract Documents. 4. Lines of communication and chain of command. 5. Submission of list of Subcontractors, list of products, schedule of values, and Progress Schedule. 6. Security and housekeeping procedures. 7. Application for payment procedures including date for monthly submission of the Application for payment. 8. Designation of personnel representing parties in Contract and Engineer. 9. Procedures and processing of requests for interpretations, field decisions, submittals, substitutions, Applications for Payments, change proposal requests, Change Orders, and Contract closeout procedures. 10. Project Safety. 11. Permits. 12. Scheduling activities of Contractor including sequencing of critical path Work. 13. Procedures of testing. 14. Procedures for maintaining record documents. 15. Requirements for start-up of equipment. 16. Inspection and acceptance of equipment put into service during construction period. 1.4 PROGRESS MEETINGS A. Schedule and administer meetings throughout progress of the Work at monthly intervals, or at intervals agreed upon by Engineer and Contractor. B. Engineer will make arrangements for meetings, prepare agenda with copies for participants, and preside over meetings. C. Attendance Required: Contractor’s project manager and superintendent, major Subcontractors and suppliers, Owner, Owner’s RPR, and Engineer, as appropriate to agenda topics for each meeting. D. Minimum Agenda: 1. Review minutes of previous meetings. 2. Review of Work progress. 3. Field observations, problems, and decisions. 4. Identification of problems impeding planned progress. 5. Review of submittal schedule and status of submittals. 6. Review of off-site fabrication and delivery schedules. 7. Maintenance of Progress Schedule. 8. Corrective measures to regain projected schedules. 9. Planned progress during succeeding work period. 10. Coordination of projected progress. 11. Maintenance of quality and work standards. 12. Effect of proposed changes on Progress Schedule and coordination. BCRUA - Phase 1D WTP Expansion Issued for Bid Administrative Requirements 01 30 00 - 3 13. Review of progress payments. 14. Other business relating to Work. E. Section 01 91 00 – Facility Commissioning contains requirements for Commissioning Meetings. 1.5 PRE-INSTALLATION MEETINGS A. When required in individual Specification Sections, convene preinstallation meetings at Project Site before starting Work of specific Section. B. Require attendance of parties directly affecting, or affected by, Work of specific Section. C. Notify Engineer seven days in advance of meeting date. D. Prepare agenda and preside over meeting: 1. Review conditions of installation, preparation, and installation procedures. 2. Review coordination with related Work. 1.6 CLOSEOUT MEETING A. Schedule Project closeout meeting with sufficient time to prepare for requesting Substantial Completion. Preside over meeting and be responsible for minutes. B. Attendance Required: Contractor, Engineer, Owner, Owner’s RPR, and others appropriate to agenda. C. Notify Engineer ten days in advance of meeting date. D. Minimum Agenda: 1. Start-up of facilities and systems. 2. Operations and maintenance manuals. 3. Testing, adjusting, and balancing. 4. System demonstration and observation. 5. Operation and maintenance instructions for Owner's personnel. 6. Contractor's inspection of Work. 7. Contractor's preparation of an initial "punch list." 8. Procedure to request Engineer inspection to determine date of Substantial Completion. 9. Completion time for correcting deficiencies. 10. Inspections by authorities having jurisdiction. 11. Certificate of Occupancy and transfer of insurance responsibilities. 12. Partial release of retainage. 13. Final cleaning. 14. Preparation for final inspection. 15. Closeout Submittals: a. Project record documents. b. Operating and maintenance documents. c. Operating and maintenance materials. d. Affidavits. 16. Final Application for Payment. BCRUA - Phase 1D WTP Expansion Issued for Bid Administrative Requirements 01 30 00 - 4 17. Contractor's demobilization of site. 18. Maintenance. 19. Asset management and warranty information. 20. Spare parts. PART 2 PRODUCTS - Not Used PART 3 EXECUTION 3.1 ALTERATION PROCEDURES A. Entire facility will be occupied for normal operations during progress of construction. Cooperate with Owner in scheduling operations to minimize conflict and to permit continuous usage. 1. Perform Work not to interfere with operations of occupied areas. 2. Keep utility and service outages to a minimum and perform only after written approval of Owner. a. See section 01 10 00 – Summary of Work and Operational Requirements. 3. Clean Owner-occupied areas daily. Clean spillage, overspray, and heavy collection of dust in Owner-occupied areas immediately. B. Materials: As specified in product Sections; match existing products with new products for patching and extending Work. C. Employ original and/or skilled and experienced installer to perform alteration and renovation Work. D. Cut, move, or remove items as necessary for access to alterations and renovation Work. Replace and restore at completion. Comply with Section 01 70 00 - Execution and Closeout Requirements E. Remove unsuitable material not marked for salvage, including rotted wood, corroded metals, and deteriorated masonry and concrete. Replace materials as specified for finished Work. F. Remove debris and abandoned items from area and from concealed spaces. G. Prepare surface and remove surface finishes to permit installation of new Work and finishes. H. Close openings in exterior surfaces to protect existing Work from weather and extremes of temperature and humidity. I. Remove, cut, and patch Work to minimize damage and to permit restoring products and finishes to original or specified condition. J. Refinish existing visible surfaces to remain in renovated rooms and spaces, to specified condition for each material, with neat transition to adjacent finishes. BCRUA - Phase 1D WTP Expansion Issued for Bid Administrative Requirements 01 30 00 - 5 K. Where new Work abuts or aligns with existing Work, provide smooth and even transition. Patch Work to match existing adjacent Work in texture and appearance. L. When finished surfaces are cut so that smooth transition with new Work is not possible, terminate existing surface along straight line at natural line of division and submit recommendation to Engineer for review. M. Where change of plane of 1/4 inch or more occurs, submit recommendation for providing smooth transition to Engineer for review. N. Patch or replace portions of existing surfaces that are damaged, lifted, discolored, or showing other imperfections. O. Finish surfaces as specified in individual product Sections. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Construction Progress Schedule 01 32 16 - 1 SECTION 01 32 16 - CONSTRUCTION PROGRESS SCHEDULE PART 1 GENERAL 1.1 SECTION INCLUDES A. Submittals. B. Quality assurance. C. Network analysis schedules. D. Bar chart schedules. E. Review and evaluation. F. Updating schedules. G. Distribution. 1.2 SUBMITTALS A. Submit proposed preliminary bar chart schedule within 10 days after effective date of the Owner-Contractor Agreement, Preliminary schedule shall define planned operations for first 60 days of Work, with general outline for remainder of Work. B. Participate in review of preliminary bar chart schedule jointly with Engineer. C. Within 20 days after joint review of proposed preliminary bar chart schedule, submit draft of proposed complete Critical Path Method (CPM) network diagram for review. Include written certification that major Subcontractors have reviewed and accepted proposed schedule. D. Participate in review of complete network diagram jointly with Engineer. E. Within 10 days after joint review of complete network diagram, submit updated and complete network analysis consisting of network diagrams and mathematical analyses. F. Submit updated network schedules with each Application for Payment. G. Submit PDF electronic file and raw data file of project schedule in Microsoft Project format. H. Submit network schedules under transmittal letter form specified in Section 01 33 00- Submittal Procedures. I. Schedule Updates: 1. Overall percent complete, projected and actual. 2. Completion progress by listed activity and sub-activity, to within five working days prior to submittal. 3. Changes in Work scope and activities modified since submittal. 4. Delays in submittals or resubmittals, deliveries, or Work. 5. Adjusted or modified sequences of Work. 6. Other identifiable changes. 7. Revised projections of progress and completion. J. Narrative Progress Report: 1. Submit with each monthly submission of Progress Schedule. BCRUA - Phase 1D WTP Expansion Issued for Bid Construction Progress Schedule 01 32 16 - 2 2. Summary of Work completed during the past period between reports. 3. Work planned during the next period. 4. Explanation of differences between summary of Work completed and Work planned in previously submitted report. 5. Current and anticipated delaying factors and estimated impact on other activities and completion milestones. 6. Corrective action taken or proposed. K. Provide bar chart type schedule at each construction progress meeting, which details schedule for upcoming month. L. Provide Commissioning Schedule specified in Section 01 91 00 – Facility Commissioning. 1.3 QUALITY ASSURANCE A. Scheduler: Contractor's personnel specializing in CPM scheduling with two years' minimum experience in scheduling construction work of complexity comparable to the Project and having use of computer facilities capable of delivering detailed graphic printout within 48 hours of request. B. Contractor’s Administrative Personnel: two years' minimum experience in using and monitoring CPM schedules on comparable Projects. 1.4 NETWORK ANALYSIS SCHEDULES A. Prepare network analysis diagrams and supporting mathematical analyses using CPM. The schedule requirement herein is the minimum required. Contactor may prepare a more sophisticated schedule if it will aid in execution and timely completion of Work. B. Format: 1. Listings: Reading from left to right, in ascending order for each activity. Identify each activity with applicable Specification Section number. 2. Diagram Sheet Size: 22 inches high x 34 inches wide. 3. Scale and Spacing: To allow for notations and revisions. 4. Use Microsoft Project latest version or equivalent scheduling software. 5. Critical path shall be clearly shown on the schedule. C. Illustrate order and interdependence of activities and sequence of Work; how start of given activity depends on completion of preceding activities, and how completion of activity may restrain start of subsequent activities. D. Illustrate complete sequence of construction by activity, identifying Work of separate stages. Indicate dates for submittals, including dates for Owner-furnished items, and return of submittals; dates for procurement and delivery of critical products; proposed dates for facility shutdowns, and dates for installation and provision for testing. Include legend for symbols and abbreviations used. E. Mathematical Analysis: Tabulate each activity of detailed network diagrams using calendar dates, and identify for each activity: 1. Preceding and following event numbers. BCRUA - Phase 1D WTP Expansion Issued for Bid Construction Progress Schedule 01 32 16 - 3 2. Activity description. 3. Estimated duration of activity, in maximum 30-day intervals. Status of critical activities. 4. Earliest start date. 5. Earliest finish date. 6. Actual start date. 7. Actual finish date. 8. Latest start date. 9. Latest finish date. 10. Total and free float; accrue float time to Owner and to Owner's benefit. 11. Monetary value of activity, keyed to Schedule of Values. 12. Percentage of activity completed. 13. Responsibility. F. Analysis Program: Capable of compiling monetary value of completed and partially completed activities, of accepting revised completion dates, and of recomputing of scheduled dates and float. G. Required Sorts: List activities in sorts or groups: 1. By preceding Work item or event number from lowest to highest. 2. By longest float, then in order of early start. 3. By responsibility in order of earliest possible start date. 4. In order of latest allowable start dates. 5. In order of latest allowable finish dates. 6. Contractor's periodic payment request sorted by Schedule of Values list. 7. List of basic input data-generating report. 8. List of activities on critical path. H. Prepare sub-schedules for each stage of Work identified in Section 01 10 00. I. Coordinate contents with Schedule of Values in Section 01 33 00 – Submittal Procedures. 1.5 BAR CHART SCHEDULES A. Format: Bar chart Schedule, to include at least: 1. Identification and listing in chronological order of those activities reasonably required to complete the Work, including: a. Subcontract Work. b. Major equipment design, fabrication, factory testing, and delivery dates including required lead times. c. Move-in and other preliminary activities. d. Equipment and equipment system test and startup activities. e. Project closeout and cleanup. f. Work sequences, constraints, and milestones. 2. Listings identified by Specification Section number. 3. Identification of the following: a. Horizontal time frame by year, month, and week. b. Duration, early start, and completion for each activity and sub-activity. c. Critical activities and Project float. d. Sub-schedules to further define critical portions of Work. BCRUA - Phase 1D WTP Expansion Issued for Bid Construction Progress Schedule 01 32 16 - 4 1.6 REVIEW AND EVALUATION A. Participate in joint review and evaluation of schedules with Engineer at each submittal. B. Evaluate Project status to determine Work behind schedule and Work ahead of schedule. C. After review, revise schedules incorporating results of review, and resubmit within 10 days. D. Contractor shall submit a written statement as to how Contractor intends to correct nonperformance and return to the acceptable construction schedule if Contractor fails to accomplish work according to the schedule. Contractor may require increased work forces, extra equipment, extra shifts or other action as necessary. Actions taken by Contractor to complete Work within Contract Times (or Milestones) will not be justification for adjustment to Contract Sum or Contract Times. 1.7 UPDATING SCHEDULES A. Maintain schedules to record actual start and finish dates of completed activities. B. Indicate progress of each activity to date of revision, with projected completion date of each activity. Update schedules to depict current status of Work. C. Identify activities modified since previous submittal, major changes in Work, and other identifiable changes. D. Upon approval of a Change Order, include the change in the next schedule submittal. E. Indicate changes required to maintain Date of Substantial Completion. F. Submit sorts as required to support recommended changes. G. Prepare narrative report to define problem areas, anticipated delays, and impact on schedule. Report corrective action taken or proposed and its effect including effects of changes on schedules of separate Contractors. 1.8 DISTRIBUTION A. Following joint review, distribute copies of updated schedules to Subcontractors, suppliers, Engineer, Owner, and other concerned parties. B. Instruct recipients to promptly report, in writing, problems anticipated by projections shown in schedules. PART 2 PRODUCTS - Not Used PART 3 EXECUTION - Not Used END OF SECTION BCRUA – Phase 1D WTP Expansion Issued for Bid Submittal Procedures 01 33 00 - 1 SECTION 01 33 00 - SUBMITTAL PROCEDURES PART 1 GENERAL 1.1 SECTION INCLUDES A. Submittal procedures. B. Construction progress schedules. C. Proposed product list. D. Product data. E. Use of electronic CAD files of Project Drawings. F. Shop Drawings. G. Samples. H. Design data. I. Test reports. J. Certificates. K. Manufacturer's instructions. L. Manufacturer's field reports. M. Erection Drawings. N. Contractor review. O. Engineer review. 1.2 SUBMITTAL PROCEDURES A. Submittals shall be directly from the Contractor. Submittals from others (i.e., suppliers or subcontractors) shall not be accepted. B. Transmit each submittal on an Engineer accepted form. C. Sequentially number transmittal forms. Mark revised submittals with original number followed by a “.” and sequential numeric suffix. 1. Example resubmittal for shop drawing: SD-001.1. D. Identify Project, Contractor, subcontractor and supplier; pertinent drawing and detail number, and specification section number, appropriate to submittal. BCRUA – Phase 1D WTP Expansion Issued for Bid Submittal Procedures 01 33 00 - 2 E. Apply Contractor's stamp, signed or initialed certifying that review, approval, verification of products required, field dimensions, adjacent construction Work, and coordination of information is in accordance with requirements of the Work and Contract Documents. F. Schedule submittals to expedite Project, and deliver to Engineer at business address. Coordinate submission of related items. G. For each submittal for review, allow 15 days excluding delivery time to and from Contractor. H. Identify variations from Contract Documents and product or system limitations which may be detrimental to successful performance of completed Work. I. Allow space on submittals for Contractor and Engineer review stamps. J. When revised for resubmission, identify changes made since previous submission. K. Distribute copies of reviewed submittals as appropriate. Instruct parties to promptly report inability to comply with requirements. L. Submittals not requested will not be recognized or processed. M. Incomplete Submittals: Engineer will not review. Complete submittals for each item are required. Delays resulting from incomplete submittals are not the responsibility of Engineer. 1.3 CONSTRUCTION PROGRESS SCHEDULES A. Comply with Section 01 32 16 - Construction Progress Schedule 1.4 PROPOSED PRODUCT LIST A. Within 15 days after date of Notice to Proceed, submit list of major products proposed for use, with name of manufacturer, trade name, and model number of each product. B. For products specified only by reference standards, indicate manufacturer, trade name, model or catalog designation, and reference standards. 1.5 PRODUCT DATA A. Product Data: Action Submittal: Submit to Engineer for review for assessing conformance with information given and design concept expressed in Contract Documents. B. Submit electronic submittals to Engineer via email as PDF electronic files. C. Identify applicable products, models, options, and other data. Supplement manufacturers' standard data to provide information specific to this Project. D. Indicate product utility and electrical characteristics, utility connection requirements, and location of utility outlets for service for functional equipment and appliances. BCRUA – Phase 1D WTP Expansion Issued for Bid Submittal Procedures 01 33 00 - 3 E. After review, distribute according to "Submittal Procedures" Article and for record documents described in Section 01 70 00 - Execution and Closeout Requirements. 1.6 ELECTRONIC CAD FILES OF PROJECT DRAWINGS A. Electronic CAD Files of Project Drawings: May only be used to expedite production of Shop Drawings for the Project. Use for other Projects or purposes is not allowed. B. Electronic CAD Files of Project Drawings: Distributed only under the following conditions: 1. Use of files is solely at receiver's risk. Engineer does not warrant accuracy of files. Receiving files in electronic form does not relieve receiver of responsibilities for measurements, dimensions, and quantities set forth in Contract Documents. In the event of ambiguity, discrepancy, or conflict between information on electronic media and that in Contract Documents, notify Engineer of discrepancy and use information in hard-copy Drawings and Specifications. 2. CAD files do not necessarily represent the latest Contract Documents, existing conditions, and as-built conditions. Receiver is responsible for determining and complying with these conditions and for incorporating addenda and modifications. 3. User is responsible for removing information not normally provided on Shop Drawings and removing references to Contract Documents. Shop Drawings submitted with information associated with other trades or with references to Contract Documents will not be reviewed and will be immediately returned. 4. Receiver shall not hold Engineer responsible for data or file clean-up required to make files usable, nor for error or malfunction in translation, interpretation, or use of this electronic information. 5. Receiver shall understand that even though Engineer has computer virus scanning software to detect presence of computer viruses, there is no guarantee that computer viruses are not present in files or in electronic media. 6. Receiver shall not hold Engineer responsible for such viruses or their consequences, and shall hold Engineer harmless against costs, losses, or damage caused by presence of computer virus in files or media. 1.7 SHOP DRAWINGS A. Shop Drawings: Action Submittal: Submit to Engineer for assessing conformance with information given and design concept expressed in Contract Documents. Submit information as specified in individual specifications including but not limited to the following: 1. Details, sizes, and dimensions. 2. Identification of equipment, product, and material use. 3. Clear identification of the exact item, model or materials to be provided. 4. Demonstrate compliance with specified standards. 5. Indication of deviations from the Contract Documents and justify said deviation in detail in a separate letter. 6. Custom prepared data such as fabrication and erection/installation (working) drawings 7. Scheduled information. 8. Setting diagrams. 9. Actual shopwork manufacturing instructions. 10. Custom templates. 11. Special wiring diagrams. BCRUA – Phase 1D WTP Expansion Issued for Bid Submittal Procedures 01 33 00 - 4 12. Coordination drawings. 13. Individual system or equipment inspection and test reports including performance curves and certifications. 14. Identify and Indicate: a. Applicable Contract Drawing and Detail number, products, units and assemblies, and system or equipment identification or tag numbers. b. Equipment and Component Title: Identical to title shown on Drawings. c. Critical field dimensions and relationships to other critical features of Work. Note dimensions established by field measurement. d. Project-specific information drawn accurately to scale. 15. Manufacturer’s standard schematic drawings and diagrams as follows: a. Modify to delete information that is not applicable to the Work. b. Supplement standard information to provide information specifically applicable to the Work. 16. Details including relation of the various parts to the main members and lines of the structure and field measurements when correct fabrication of the Work depends upon such measurements. B. Separate and submit shop drawings by individual Specification Section, work item, pipe system, etc. Do not submit multiple, unrelated items in the same shop drawing. C. Indicate special utility and electrical characteristics, utility connection requirements, and location of utility outlets for service for functional equipment and appliances. D. When required by individual Specification Sections, provide Shop Drawings signed and sealed by a professional Engineer responsible for designing components shown on Shop Drawings. 1. Include signed and sealed calculations to support design. 2. Submit Shop Drawings and calculations in form suitable for submission to and approval by authorities having jurisdiction. 3. Make revisions and provide additional information when required by authorities having jurisdiction. E. Submit electronic Shop Drawings to Engineer as PDF electronic files. F. After review, distribute according to "Submittal Procedures" Article and for record documents described in Section 01 70 00 - Execution and Closeout Requirements. 1.8 SAMPLES A. Samples: Action Submittal: Submit to Engineer for assessing conformance with information given and design concept expressed in Contract Documents. B. Samples for Selection as Specified in Product Sections: 1. Submit to Engineer for aesthetic, color, and finish selection. 2. Submit Samples of finishes, textures, and patterns for Engineer selection. C. Submit Samples to illustrate functional and aesthetic characteristics of products, with integral parts and attachment devices. Coordinate Sample submittals for interfacing work. BCRUA – Phase 1D WTP Expansion Issued for Bid Submittal Procedures 01 33 00 - 5 D. Include identification on each Sample, with full Project information. E. Submit number of Samples specified in individual Specification Sections; Engineer will retain one Sample. F. Reviewed Samples that may be used in the Work are indicated in individual Specification Sections. G. Samples will not be used for testing purposes unless specifically stated in Specification Section. H. After review, produce copies and distribute according to "Submittal Procedures" Article and for record documents described in Section 01 70 00 - Execution and Closeout Requirements. 1.9 DESIGN DATA A. Submit to Engineer’s knowledge as contract administrator or for Owner. B. Submit to Engineer for information for limited purpose of assessing conformance with information given and design concept expressed in Contract Documents. 1.10 TEST REPORTS A. Informational Submittal: Submit reports for Engineer’s knowledge as Contract administrator or for Owner. B. Submit test reports to Engineer for information for assessing conformance with information given and design concept expressed in Contract Documents. 1.11 CERTIFICATES A. Informational Submittal: When specified in Technical Specifications, submit certification by manufacturer, installation/application Subcontractor, or Contractor to Engineer, in quantities specified for Product Data. B. Manufacturer’s Certificate of Compliance: 1. When specified, a Manufacturer’s Certificate of Compliance, a copy of which is attached to this section, shall be completed in full, signed by the entity supplying the product, material, or service, and submitted prior to shipment of product or material or the execution of the services. 2. Indicate material or product conforms to or exceeds specified requirements. Submit supporting reference data, affidavits, and certifications as appropriate. 3. Certificates may be recent or previous test results on material or product but must be acceptable to Engineer. C. Manufacturer’s Certificate of Proper Installation: 1. When specified, a Manufacturer’s Certificate of Proper Installation form, a copy of which is attached to this section, shall be completed and signed by the equipment manufacturer’s representative. BCRUA – Phase 1D WTP Expansion Issued for Bid Submittal Procedures 01 33 00 - 6 2. Such form shall certify that the signing party is a duly authorized representative of the manufacturer, is empowered by the manufacturer to inspect, approve, and operate their equipment and is authorized to make recommendations required to assure that the equipment is complete and operational. D. Manufacturer’s Certificate of Completion of Field Services: 1. When specified, a Manufacturer’s Certificate of Completion of Field Services form, a copy of which is attached to this section, shall be completed and signed by the equipment manufacturer’s representative. 2. Such form shall certify that the signing party is a duly authorized representative of the manufacturer, is empowered by the manufacturer to inspect, approve, and operate their equipment and is authorized to make recommendations required to assure that the equipment furnished by the manufacturer is complete and operational. 1.12 MANUFACTURER'S INSTRUCTIONS A. Informational Submittal: When specified in Technical Specifications, submit manufacturer's installation instructions to Engineer for informational purposes. B. Submit printed instructions for delivery, storage, assembly, installation, startup, adjusting, and finishing, to Engineer for delivery to Owner in quantities specified for Product Data. C. Indicate special procedures, perimeter conditions requiring special attention, and special environmental criteria required for application or installation. 1.13 MANUFACTURER'S FIELD REPORTS A. Informational Submittal: Submit reports for Engineer's knowledge as Contract administrator or for Owner. B. Submit report in duplicate within three days of observation to Engineer for information. C. Submit reports for information for limited purposes of assessing conformance with information given and design concept expressed in Contract Documents. 1.14 ERECTION DRAWINGS A. Informational Submittal: Submit Drawings for Engineer's benefit as Contract administrator or for Owner. B. Submit Drawings to Engineer for information assessing conformance with information given and design concept expressed in Contract Documents. C. Data indicating inappropriate or unacceptable Work may be subject to action by Engineer or Owner. BCRUA – Phase 1D WTP Expansion Issued for Bid Submittal Procedures 01 33 00 - 7 1.15 CONTRACTOR REVIEW A. Review for compliance with Contract Documents and approve submittals before transmitting to Engineer. B. Contractor: Responsible for: 1. Determination and verification of materials including manufacturer's catalog numbers. 2. Determination and verification of field measurements and field construction criteria. 3. Checking and coordinating information in submittal with requirements of Work and of Contract Documents. 4. Determination of accuracy and completeness of dimensions and quantities. 5. Confirmation and coordination of dimensions and field conditions at Site. 6. Construction means, techniques, sequences, and procedures. 7. Safety precautions. 8. Coordination and performance of Work of all trades. C. Stamp, sign or initial, and date each submittal to certify compliance with requirements of Contract Documents. D. Do not fabricate products or begin Work for which submittals are required until approved submittals have been received from Engineer. 1.16 ENGINEER REVIEW A. Engineer will review each submittal and return with one of the following Status/Action responses for shop drawings: 1. Status: a. “Approved” authorizes Contractor to proceed with the work provided it complies with the requirements of the Contract Documents. b. “Approved as Noted” authorizes Contractor to proceed with the work provided it complies with notations or corrections on the submittal and the requirements of the Contract Documents. c. “Not Approved” does not allow the work to proceed and requires revision and resubmittal according to the notations or corrections. d. “Cancelled or Void” does not allow the work to proceed and cancels the submittal. e. “Returned without Review” is for submittals required for informational or record purposes where Engineer’s review is not required. 2. Action: a. “Revise and Resubmit” triggers resubmittal from Contractor. b. “Additional Information Required” triggers resubmittal from Contractor. c. “No Action Required”. d. “Cancelled or Void”. e. “Final Distribution” finalizes the submittal. B. Do not make "mass submittals" to Engineer. "Mass submittals" are defined as six or more submittals or items in one day or 15 or more submittals or items in one week. If "mass submittals" are received, Engineer's review time stated above will be extended as necessary to perform proper review. Engineer will review "mass submittals" based on priority determined by Engineer after consultation with Owner. BCRUA – Phase 1D WTP Expansion Issued for Bid Submittal Procedures 01 33 00 - 8 C. Informational submittals and other similar data are for Engineer's information, do not require Engineer's responsive action, and will not be reviewed or returned with comment. D. Submittals made by Contractor that are not required by Contract Documents may be returned without action. E. Submittal approval does not authorize changes to Contract requirements unless accompanied by Change Order, Field Order, or Work Change Directive. PART 2 PRODUCTS - Not Used PART 3 EXECUTION 3.1 SUPPLEMENTS A. The supplements listed below, following “End of Section”, are part of this Specification. 1. Form: Manufacturer’s Certificate of Compliance. 2. Form: Manufacturer’s Certificate of Proper Installation. 3. Form: Manufacturer’s Certificate of Completion of Field Services. B. Reference Section 01 91 00 – Facility Commissioning for additional information on the Certificate of Proper Installation and Manufacturer’s Certificate of Completion of Field Services. END OF SECTION BCRUA – Phase 1D WTP Expansion Issued for Bid Submittal Procedures 01 33 00 - 9 MANUFACTURER’S CERTIFICATE OF COMPLIANCE OWNER: PROJECT NAME: PROJECT NO: PRODUCT, MATERIAL, OR SERVICE SUBMITTED: Comments: I hereby certify that the above-referenced product, material, or service called for by the contract for the named project will be furnished in accordance with all applicable requirements. I further certify that the product, material, or service are of the quality specified and conform in all respects with the contract requirements, and are in the quantity shown. Date of Execution: , 20 Manufacturer: Manufacturer’s Authorized Representative (print): (Authorized Signature) 01 33 00 SUPPLEMENT - 01 BCRUA – Phase 1D WTP Expansion Issued for Bid Submittal Procedures 01 33 00 - 10 MANUFACTURER’S CERTIFICATE OF PROPER INSTALLATION OWNER EQPT SERIAL NO: EQPT TAG NO: EQPT/SYSTEM: PROJECT NO: SPEC. SECTION: I hereby certify that the above-referenced equipment/system has been: (Check Applicable) Installed, inspected, adjusted, aligned, calibrated, and lubricated in accordance with Manufacturer’s recommendations. Installed with proper internal clearances and clearances to adjacent equipment and structures. Installed free of any stresses imposed by connecting pipes or anchor bolts. Installed in a manner than will not void the warranty. Installed in a manner that is ready to be operated by others. Installed in a manner that will reliability perform the function for which it is installed. Suitable for satisfactory full-time operation under full load conditions. Electrical and mechanical connections meet quality and safety standards. All applicable safety equipment has been properly installed. Functional tests. System has been performance tested and meets or exceeds specified performance requirements. (When complete system of one manufacturer) Note: Attach any performance test documentation from manufacturer. Comments: I, the undersigned Manufacturer’s Representative, hereby certify that I am (i) a duly authorized representative of the manufacturer, (ii) empowered by the manufacturer to inspect, approve, and operate equipment and (iii) authorized to make recommendations required to assure that the equipment furnished by the manufacturer is complete and operational, except as may be otherwise indicated herein. I further certify that all information contained herein is true and accurate. BCRUA – Phase 1D WTP Expansion Issued for Bid Submittal Procedures 01 33 00 - 11 Date: , 20 Manufacturer: By Manufacturer’s Authorized Representative: (Authorized Signature) I, the undersigned Contractor, hereby certify that I am a duly authorized representative of the Contractor and certify that all information contained herein is true and accurate. Date: , 20 Contractor: By Contractor’s Authorized Representative: (Authorized Signature) 01 33 00 SUPPLEMENT - 02 BCRUA Phase 1D WTP Expansion Issued for Bid Submittal Procedures 01 33 00 - 12 MANUFACTURER’S CERTIFICATE OF COMPLETION OF FIELD SERVICES OWNER EQPT SERIAL NO: I hereby certify that the above-referenced equipment/system: (Check Applicable) Operates within the allowable limits for vibration (if applicable). Controls, protective devices, instrumentation, and control panels furnished as part of the equipment package are properly installed, calibrated, and functioning. Control logic for startup, shutdown, sequencing, interlocks, and emergency shutdown has been tested and is properly functioning. Is installed in accordance with the manufacturer’s recommendation and Contract Documents. Operates in conformance with the design, Contract Documents, and manufacturer’s requirements and is ready to be placed in service for normal operation. Field services have been fully completed as required by the Contract Documents, including all required field adjustments or calibrations, training, and performance testing (excluding any field services required to be provided following Substantial Completion). I, the undersigned Manufacturer’s Representative, hereby certify that I am (i) a duly authorized representative of the manufacturer, (ii) empowered by the manufacturer to inspect, approve, and operate equipment and (iii) authorized to make recommendations required to assure that the equipment furnished by the manufacturer is complete and operational, except as may be otherwise indicated herein. I further certify that all information contained herein is true and accurate. Date: , 20___ Manufacturer: (Authorized Signature) I, the undersigned Contractor, hereby certify that I am a duly authorized representative of the Contractor and certify that all information contained herein is true and accurate. Date: , 20 Contractor’s Authorized Representative: (Authorized Signature) 01 33 00 SUPPLEMENT - 03 EQPT TAG NO: EQPT/SYSTEM: PROJECT NO: SPEC. SECTION: Manufacturer’s Authorized Representative: Contractor: BCRUA - Phase 1D WTP Expansion Issued for Bid Quality Requirements 01 40 00 - 1 SECTION 01 40 00 - QUALITY REQUIREMENTS PART 1 GENERAL 1.1 SECTION INCLUDES A. Quality control. B. Tolerances. C. References. D. Labeling. E. Testing and inspection services. F. Contractor’s responsibilities. G. Manufacturers' field services. 1.2 QUALITY CONTROL A. Monitor quality control over suppliers, manufacturers, products, services, Site conditions, and workmanship, to produce Work of specified quality. B. Comply with manufacturers' instructions, including each step in sequence. C. When manufacturers' instructions conflict with Contract Documents, request clarification from Engineer before proceeding. D. Products, materials, and equipment may be subject to inspection by Engineer and Owner at place of manufacture or fabrication. Such inspections shall not relieve Contractor of complying with requirements of Contract Documents. E. Supervise performance of Work in such manner and by such means to ensure that Work, whether completed or in progress, will not be subjected to harmful, dangerous, damaging, or otherwise deleterious exposure during construction period. 1.3 TOLERANCES A. Monitor fabrication and installation tolerance control of products to produce acceptable Work. Do not permit tolerances to accumulate. B. Comply with manufacturers' recommended tolerances and tolerance requirements in reference standards. When such tolerances conflict with Contract Documents, request clarification from Engineer before proceeding. C. Adjust products to appropriate dimensions; position before securing products in place. 1.4 REFERENCES A. For products or workmanship specified by association, trade, or other consensus standards, comply with requirements of standard except when more rigid requirements are specified or are required by applicable codes. BCRUA - Phase 1D WTP Expansion Issued for Bid Quality Requirements 01 40 00 - 2 B. Conform to reference standard by date of issue current as of date for receiving Bids except where specific date is established by code. C. Obtain copies of standards and maintain on Site when required by product Specification Sections. D. When requirements of indicated reference standards conflict with Contract Documents, request clarification from Engineer before proceeding. E. Neither contractual relationships, duties, or responsibilities of parties in Contract nor those of Engineer shall be altered from Contract Documents by mention or inference in reference documents. 1.5 LABELING A. Attach label from agency approved by authorities having jurisdiction for products, assemblies, and systems required to be labeled by applicable code. B. Label Information: Include manufacturer's or fabricator's identification, approved agency identification, and the following information, as applicable, on each label: 1. Model number. 2. Serial number. 3. Performance characteristics. C. Manufacturer's Nameplates, Trademarks, Logos, and Other Identifying Marks on Products: Not allowed on surfaces exposed to view in public areas, interior or exterior. 1.6 TESTING AND INSPECTION SERVICES A. Owner will employ and pay for specified services of an independent firm to perform testing and inspection. B. Independent testing firm will perform tests, inspections, and other services specified in individual Specification Sections and as required by Engineer. In the event of a conflict in the Contract Documents concerning sampling and testing frequency, the more stringent standard shall be enforced, unless otherwise approved by the Engineer. 1. Laboratory: Authorized to operate in State of Texas. 2. Laboratory Staff: Maintain full-time Professional Engineer on staff to review services. 3. Testing Equipment: Calibrated at reasonable intervals with devices of an accuracy traceable to National Bureau of Standards or accepted values of natural physical constants. C. Testing, inspections, and source quality control may occur on or off Project Site. Perform off- Site testing as required by Engineer or Owner. D. Reports shall be submitted by independent firm to Engineer, Contractor, and authorities having jurisdiction, in duplicate, indicating observations and results of tests and compliance or non-compliance with Contract Documents. 1. Submit final report indicating correction of Work previously reported as non-compliant. BCRUA - Phase 1D WTP Expansion Issued for Bid Quality Requirements 01 40 00 - 3 E. Cooperate with independent testing firm; furnish samples of materials, design mix, equipment, tools, storage, safe access, and assistance by incidental labor as requested. 1. Notify Engineer and independent testing firm 48 hours before expected time for operations requiring services. 2. Make arrangements with independent testing firm and pay for additional Samples and tests required for Contractor's use. F. Testing and employment of testing agency or laboratory shall not relieve Contractor of obligation to perform Work according to requirements of Contract Documents. G. Retesting or re-inspection required because of nonconformance with specified or indicated requirements shall be performed by same independent testing firm on instructions from Engineer. Payment for retesting or re-inspection will be charged to Contractor by deducting testing charges from Contract Price. H. Independent Testing Firm Responsibilities: 1. Test Samples of mixes submitted by Contractor. 2. Provide qualified personnel at Site. Cooperate with Engineer and Contractor in performance of services. 3. Perform indicated sampling and testing of products according to specified standards. 4. Ascertain compliance of materials and mixes with requirements of Contract Documents. 5. Promptly notify Engineer and Contractor of observed irregularities or nonconformance of Work or products. 6. Perform additional tests required by Engineer. 7. Attend preconstruction meetings and progress meetings. I. Material Testing Reports: After each test, Independent Testing Firm shall promptly submit two copies of testing reports to Engineer, Contractor, and other entities as directed, indicating observations and results of tests and compliance or noncompliance with Contract Documents. At a minimum, include the following information in testing reports: 1. Date issued. 2. Project title and number. 3. Name of inspector/testing technician. 4. Date and time of sampling or inspection. 5. Identification of product and Specification Section. 6. Location in Project. 7. Type of inspection or test. 8. Date of test. 9. Results of tests. 10. Compliance or noncompliance with Contract Documents. 11. Special observations, if any. Submit final report indicating correction of Work previously reported as noncompliant. Log all test results in an electronic spreadsheet for each test procedure and provide updated versions to Engineer at agreed upon time interval. J. Limits on Independent Testing Firm Authority: 1. Independent Testing Firm may not release, revoke, alter, or enlarge on requirements of Contract Documents. 2. Independent Testing Firm may not approve or accept any portion of the Work. BCRUA - Phase 1D WTP Expansion Issued for Bid Quality Requirements 01 40 00 - 4 3. Independent Testing Firm may not assume duties of Contractor. 4. Independent Testing Firm has no authority to stop the Work. 1.7 CONTRACTOR’S RESPONSIBILITIES A. Correct, remove, or replace defective work per Section 00700 – General Conditions. 1.8 MANUFACTURER'S FIELD SERVICES A. When specified in individual Specification Sections, require material or product suppliers or manufacturers to provide qualified staff personnel to observe Site conditions, conditions of surfaces and installation, quality of workmanship, startup of equipment, testing, adjusting, and balancing of equipment as applicable, and to initiate instructions when necessary. B. Submit qualifications of observer to Engineer 30 days in advance of required observations. Observer is subject to approval of Engineer. C. Report observations and Site decisions or instructions given to applicators or installers that are supplemental or contrary to manufacturer's written instructions. D. Refer to Section 01 33 00 - Submittal Procedures, "Manufacturer's Field Reports" Article. PART 2 PRODUCTS - Not Used PART 3 EXECUTION - Not Used END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid IBC Special Inspections 01 40 01 - 1 SECTION 01 40 01 - IBC SPECIAL INSPECTIONS PART 1 GENERAL 1.1 OVERVIEW A. The purpose of this Section is to provide the Owner and the Contractor with an understanding of what constitutes special inspections as defined by the International Building Code (IBC), Chapter 17, “Special Inspections and Tests,” the Contractor’s requirements per IBC and role in enabling the Owner to perform the inspections, and provide the Owner with a Statement of Special Inspection specific to this Project’s Special Inspection requirements. 1. IBC Special Inspections are not a substitute for other quality control testing required elsewhere in the contract documents. 2. IBC Special Inspections may not be performed by the Contractor, unless the Contractor and Owner are the same entity. 1.2 CONTRACTOR RESPONSIBILITIES A. Enable the Owner and Owner’s Agent to conduct the required IBC Special Inspections as outlined below in “Special Inspection Activities by the Owner.” 1. Set up pre-construction meeting and coordinate with Owner and Owner’s Agent, prior to beginning construction, regarding the specific inspection needs and requirements that will be performed as part of these Special Inspections. 2. Provide complete access to the Site and make Contract Documents available on-site. a. Provide and pay for all means necessary to enable inspection access at each location requiring inspection. This includes, but is not limited to, ladders, scaffolding, trench boxes/shielding, fall protection, adequate lighting, adequate ventilation, and designated area(s) for storing inspector equipment and test samples. 1) All required access shall be conducted and constructed in accordance with OSHA. b. Protect Special Inspection test specimens of products and construction materials at the Site in accordance with recognized test procedures. c. Provide materials needed to perform sampling or field tests. 3. Notify the Owner and Owner’s Agent a minimum of 48 hours in advance of when construction activities requiring testing will be performed or when construction activities will limit and/or prevent inspector(s) from observing construction work already performed. a. Provide adequate notice before proceeding with Work that would interfere with sampling, testing, or other required verification. b. Notify the Owner and Owner’s Agent prior to the time that testing is required. Lead time is to be adequate to allow arrangements to be made for testing. c. Do not proceed with any Work until testing services have been performed and results of tests indicate that the Work is acceptable. d. Notify the Owner and Owner’s Agent when schedules change. Be in communication with the Owner as soon as a delay is expected. 4. Provide adequate quantities of representative product to be tested to the laboratory at the designated location. B. Contractor shall submit the following submittals in accordance with Section 01 33 00 “Submittal Procedures” and shall include: BCRUA - Phase 1D WTP Expansion Issued for Bid IBC Special Inspections 01 40 01 - 2 1. A written schedule that establishes the approximate major and/or critical inspection milestones. Submit this schedule as Record Data. Any alterations to the schedule shall be resubmitted under the original Record Data tracking number with revision designation. 2. Maintain a log of times and dates when notification is given for an inspection, delay, re- inspection, etc. and who was notified. Submit this log at the end of the job under the next consecutive revision designation as mentioned above. C. Special Inspection quality assurance activities are for the purpose of monitoring the results of the Contractor’s Work to see that it is in compliance with the requirements of the Contract Documents. D. Special Inspection testing requirements mentioned in this Section do not release the Contractor from providing Contractor required testing specified elsewhere in the Contract Documents. 1. Contractor shall provide all testing documentation required in the Contract Documents based solely on Contractor paid testing, which shall be independent of Owner providing testing and testing documentation. 2. As specified in Section 01 40 00, “Quality Requirements,” provide and pay for any additional testing performed by the Contractor or by the Owner as a result of failed Special Inspection tests. E. Special Inspection activities or non-performance of Special Inspection activities: 1. Do not relieve the Contractor of its responsibility to perform Work and furnish materials and products and constructed Work conforming to the requirements of the Contract Documents. 2. Do not relieve the Contractor of its responsibility for providing adequate quality control measures. 3. Do not relieve the Contractor of its responsibility for damage to or loss of the material, product or Work before Owner’s acceptance. 4. Do not constitute or imply Owner’s acceptance. 5. Do not affect the continuing rights of the Owner after Owner’s acceptance of the completed Work. F. All materials and products are subject to Owner’s quality assurance observations or testing at any time during preparation or use. Material or products which have been tested or observed or approved by Owner at a supply source or staging area may be re-observed or re-tested by Owner before or during or after incorporation into the Work, and rejected if they do not comply with the Contract Documents. 1.3 OWNER RESPONSIBILITIES – SPECIAL INSPECTION ACTIVITIES A. According to the 2015 IBC Chapter 17, “Special Inspections and Tests,” adopted by the City of Cedar Park, the Owner or the Owner’s authorized agent shall employ a registered design professional to act as the Registered Design Professional In Responsible Charge (RDPIRC). Additionally, the Owner or the Owner’s authorized agent shall employee one or more approved agencies to perform inspections and tests during construction on the types of work listed in the Statement of Special Inspection. B. The Owner or the Owner’s authorized agent shall perform the following: 1. Permit: As required by the Building Official for permit issuance, submit the Statement of Special Inspection located in Attachment A. BCRUA - Phase 1D WTP Expansion Issued for Bid IBC Special Inspections 01 40 01 - 3 2. Preconstruction: Prior to the start of construction submit to the Building Official names and qualifications of each individual inspector scheduled to perform these inspections. Minimum requirements for inspectors shall be as indicated in the Statement of Special Inspection. 3. Inspections: The RDPIRC shall forward a copy of all inspection and test reports to the Building Official. a. Discrepancies shall be brought to the immediate attention of the Contractor and Owner. PART 2 PRODUCTS (NOT USED) PART 3 EXECUTION 3.1 CONTRACTOR NOTIFICATION LOG A. Contractor Notification Log: Maintain a record of inspector notifications. At a minimum, the log should include the following: 1. Date applicable inspector(s) was notified of required inspection or testing. 2. Inspector(s) conducting inspection or test. 3. Date applicable construction work in was completed. B. Maintain log at Project Site. Post changes and revisions as they occur. Provide access to notification log for reference during normal working hours. 3.2 CONTRACTOR REPAIR AND PROTECTION A. General: On completion of inspections and tests, repair damaged construction and restore substrates and finishes. 1. Provide materials and comply with installation requirements specified in other Specification Sections or matching existing substrates and finishes. Restore patched areas and extend restoration in adjoining areas with durable seams that are invisible as possible. B. Protect construction exposed by or for special inspection activities. C. Repair and protection are Contractor’s responsibility, regardless of the assignment of responsibility for the Special Inspection activities. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid IBC Special Inspections 01 40 01 - 4 ATTACHMENT A STATEMENT OF SPECIAL INSPECTIONS This Statement of Special Inspections has been prepared in accordance with International Building Code 2015 Chapter 17 by the Engineer of Record for the following: Project: Project Name: Location: Owner: Structural Engineer of Record: Peter A. Bartels Registered Design Professional In Responsible Charge: Inspectors and their qualifications shall be submitted, by the Owner or Owner’s authorized agent prior to the start of construction, to the Building Official for approval. Abbreviations Inspectors ACI: An American Concrete Institute certified technician, certified in the applicable construction type. AWS-CWI: An American Welding Society/American Institute of Steel Construction certified welding inspector. AWS/AISC-SSI: An American Welding Society certified structural steel inspector. EIT: An Engineer-In-Training, a graduate engineer who has passed the Fundamentals of Engineering exam, and is under the direct supervision of a PE. NICET: A National Institute for Certification in Engineering Technologies certified technician, certified in the applicable construction type. PE: A licensed professional engineer and/or a structural engineer (SE) competent in the area of construction being inspected. Specifications ACI 318: American Concrete Institute Building Code Requirements for Structural Concrete. AISC 360: American Institute of Steel Construction, Specification for Structural Steel Buildings. ASTM: American Society of Testing and Materials. AWS: American Welding Society RCSC: RCSC Specification for Structural Joints Using ASTM A325 or A490 Bolts. Common Words C: Continuous observation of specified construction activity. P: Periodic observation of specified construction activity. CFSF: Cold formed steel framing. CD: Contract Documents and/or Shop Drawings (if item is performance specified). Special Inspectors minimum qualifications are listed below for each area of competency. BCRUA - Phase 1D WTP Expansion Issued for Bid IBC Special Inspections 01 40 01 - 5 Special Inspector Qualifications Applicable IBC Section Minimum Inspector Qualifications Remarks 1705.3 Concrete Construction ACI or NICET, PE, or EIT AWS-CWI All welds shall be inspected by an AWS-CWI. 1705.3 Post-Installed Concrete Anchors PE or ACI Professional engineer performing inspection shall have knowledge of post-installed anchor installation requirements and experience in the design and specifying post-installed anchors. 1705.6 Soils ACI, NICET, PE, or EIT BCRUA - Phase 1D WTP Expansion Issued for Bid IBC Special Inspections 01 40 01 - 6 Concrete Construction The inspection requirements for this type of construction include cast-in-place concrete. Verification and Inspection Frequency Remarks C P Formwork - X Verify formwork for shape, location and dimensions of the concrete member being formed are in conformance with CD. Reinforcing steel material and type - X Verify size of bars and/or stressing strands, ASTM standard, and grade are in conformance with CD. Reinforcing steel position - X Verify quantity and spacing of bars and/or stressing strands, concrete clear cover on all sides. Verify lap splice type, location, and size. Verify no welding of reinforcing except where specifically noted. Cast-in-Place anchors - X Verify size, type, position, and embedment prior to concrete placement. Verify position after concrete placement. Cast-in-Place anchors X - Verify placement and consolidation of concrete around anchors. Mix design - X Verify batch plant tickets’ mix number matches approved mix design for each mix design and application. Fresh concrete samples X - At the same time fresh concrete is sampled to fabricate specimens for strength tests, perform slump and air content tests, and determine the temperature of the concrete. Sample per ASTM C31, C143, C231 (or C173), C1064. Refer to Specification Section 03 33 00. Placement technique X - At the time of concrete or shotcrete placement, verify that proper application techniques are being implemented per the CD and ACI 301. Curing technique - X Verify that approved means of curing and extreme weather protection are implemented in accordance with the CD. Shore removal - X Verify in-situ concrete strength prior to stressing. Refer to CD requirements. BCRUA - Phase 1D WTP Expansion Issued for Bid IBC Special Inspections 01 40 01 - 7 Post-Installed Concrete Anchors The inspection requirements for this type of construction include adhesive and expansion type anchors installed in hardened concrete and masonry construction. For each construction personnel, anchor type, diameter, and embedment the inspection of initial anchors placed shall be continuous based on the requirements below. With the exception of anchors that are upwardly inclined, continuously load in tension, after initial anchor placement inspections have been performed, then inspector may perform quality assurance on a periodic basis. Any change in personnel or anchor type shall require an initial continuous inspection as indicated here. Verification and Inspection Frequency Remarks C P Inspection tasks prior to anchor hole drilling - X Verify all personnel are qualified to install anchors. Installation of adhesive anchors horizontally or upwardly inclined shall be performed by personnel certified by an acceptable program. - X Verify contractor has manufacturer’s printed installation instructions (MPII) on site and available for reference by construction personnel. - X If manufacturer does not have a representative on site, then special inspector shall review MPII with contractor personnel prior to beginning construction. - X Verify edge distance limitations indicated in CD’s and existing reinforcing locations compared to proposed anchor hole locations. - X Verify drill bit diameter matches MPII for anchor diameter indicated in CD’s. Special inspector does not need to be present during actual drilling of holes. Inspection tasks after drilling prior to anchor placement - X Verify every hole diameter is in accordance with MPII and verify embedment is in accordance with CD’s and hole depth is in accordance with MPII (hole depth may need to exceed embedment depth, refer to MPII). - X Verify cleaning operations are in accordance with CD’s and MPII. - X Verify anchor type, material, diameter, and length. - X Where adhesive anchors are specified: verify adhesive type is per CD’s, adhesive expiration date, and adhesive dispensing equipment is per MPII. - X Verify that for horizontal and upwardly inclined adhesive anchors have all MPII required installation items (e.g. piston-plug) Inspection tasks during anchor placement - X Verify that all anchors are installed in accordance with MPII. BCRUA - Phase 1D WTP Expansion Issued for Bid IBC Special Inspections 01 40 01 - 8 Soils The inspection requirements for this type of construction include structural fill and compacted fill and slabs-on-grade. Verification and Inspection Frequency Remarks C P Subgrade for shallow footings - X Verify that materials below shallow foundations are adequate to achieve the design bearing capacity, excavations are extended to the proper depth, and have reached the proper material. Backfill materials - X Perform classification and testing of compacted fill materials. Test per ASTM D422, D1140, and D698 as required to verify fill materials are in accordance with the CD. Subgrade preparation - X Verify the use of proper subgrade preparation per the CD, including but not limited to proof rolling and scarifying. Compaction X - Verify proper fill materials, densities, and lift thicknesses during placement and compaction of fill is in accordance with the CD. Test density of each lift per ASTM D698. END OF ATTACHMENT A BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-03) Temporary Facilities and Controls 01 50 00 - 1 SECTION 01 50 00 - TEMPORARY FACILITIES AND CONTROLS (Revised by AD-03) PART 1 GENERAL 1.1 SECTION INCLUDES A. Temporary Utilities 1. Temporary electricity 2. Temporary lighting for construction purposes 3. Temporary heating 4. Temporary ventilation 5. Temporary water service 6. Temporary sanitary facilities B. Construction Facilities 1. Field offices and sheds 2. Vehicular access 3. Parking 4. Progress cleaning and waste removal 5. Project identification 6. Traffic regulation 7. Fire-prevention facilities C. Temporary Controls 1. Barriers 2. Enclosures and fencing 3. Security 4. Water control 5. Dust control 6. Erosion and sediment control 7. Noise control 8. Pest and rodent control 9. Pollution control D. Removal of utilities, facilities, and controls 1.2 REFERENCES A. ASTM International: 1. ASTM E 84 - Standard Test Method for Surface Burning Characteristics of Building Materials. 2. ASTM E 90 - Standard Test Method for Laboratory Measurement of Airborne Sound Transmission Loss of Building Partitions and Elements. 3. ASTM E 119 - Standard Test Methods for Fire Tests of Building Construction and Materials. 1.3 TEMPORARY ELECTRICITY A. Provide and pay for power service required from utility source as needed for construction operation. B. Provide temporary electric feeder from electrical service at location as directed by Engineer. Do not disrupt Owner's use of service. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-03) Temporary Facilities and Controls 01 50 00 - 2 C. Provide electric power and all electric power costs for Contractor’s field offices, as required. D. Complement existing power service capacity and characteristics as required for construction operations. E. Provide power outlets with branch wiring and distribution boxes located as required for construction operations. Provide suitable, flexible power cords as required for portable construction tools and equipment. F. Provide main service disconnect and overcurrent protection at feeder switch at source distribution equipment. G. Permanent convenience receptacles may be used during construction. H. Provide distribution equipment, wiring, and outlets for single-phase branch circuits for power and lighting. 1. Provide 20-ampere duplex outlets, single-phase circuits for power. 2. Provide 20-ampere, single-phase branch circuits for lighting. 1.4 TEMPORARY LIGHTING FOR CONSTRUCTION PURPOSES A. Provide and maintain lighting for construction operations to meet applicable safety requirements to allow erection, application, or installation of materials and equipment, and observation or inspection of the Work. B. Provide branch wiring from power source to distribution boxes with lighting conductors, pigtails, lamps, and the like, for specified lighting levels. C. Maintain lighting and provide routine repairs. D. Permanent lighting may be used during construction. 1.5 TEMPORARY HEATING A. Where available, existing heating systems in Owner facilities may be used during construction. B. Before operating permanent equipment for temporary heating purposes, verify installation is approved for operation, equipment is lubricated, and filters are in place. Provide and pay for operation, maintenance, and regular replacement of filters and worn or consumed parts. Replace filters at Substantial Completion. C. Maintain minimum ambient temperature of 50 degrees F in indoor areas where construction is in progress unless indicated otherwise in individual product Sections. 1.6 TEMPORARY VENTILATION A. Ventilate enclosed areas to achieve curing of materials, to dissipate humidity, and to prevent accumulation of dust, fumes, vapors, or gases. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-03) Temporary Facilities and Controls 01 50 00 - 3 B. Where available, existing ventilation equipment in Owner facilities may be used during construction. Extend and supplement equipment with temporary fan units as required to maintain clean air for construction operations. C. Pay costs of installation, maintenance, operation, removal, and fuel consumed. 1.7 TEMPORARY WATER SERVICE A. Provide and pay for suitable quality water service as needed to maintain specified conditions for construction operations. Extend branch piping with outlets located so that water is available by hoses with threaded connections. Provide temporary pipe insulation and heat tape to prevent freezing. B. Owner will provide water for testing. If initial tests fail, water for retesting shall be paid for by Contractor at Owner’s current, applicable water rates. 1.8 TEMPORARY SANITARY FACILITIES A. Provide and maintain required facilities and enclosures. Existing facility use is not permitted. Provide facilities at time of Project mobilization. B. At end of construction, return existing facilities used for construction operations to same or better condition as original condition. 1.9 FIELD OFFICES AND SHEDS A. Do not use existing facilities for field offices or for storage, unless approved by Owner. B. Contractor’s Field Office: Weathertight, with lighting, electrical outlets, heating, cooling and ventilating equipment, and equipped with sturdy furniture including drawing display table. C. Provide space for Project meetings, with table and chairs to accommodate six persons. D. Locate field offices and sheds in areas indicated on Drawings and a minimum distance of 30 feet from existing and new structures. E. Do not use permanent facilities for field offices or for storage. F. Construction: Portable or mobile buildings, or buildings constructed with floors raised aboveground, securely fixed to foundations with steps and landings at entrance doors. 1. Construction: Structurally sound, secure, weathertight enclosures for office and storage spaces. Maintain during progress of Work; remove enclosures when no longer needed. 2. Thermal Resistance of Floors, Walls, and Ceilings: Compatible with occupancy and storage requirements. 3. Exterior Materials: Weather-resistant, finished in one color acceptable to Engineer. 4. Interior Materials in Field Offices: Sheet-type materials for walls and ceilings, prefinished or painted; resilient floors and bases. 5. Interior Materials in Storage Sheds: As required to provide specified conditions for storage of products. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-03) Temporary Facilities and Controls 01 50 00 - 4 G. Environmental Control: 1. Heating, Cooling, and Ventilating for Offices: Automatic equipment to maintain comfort conditions. 2. Storage Spaces: Heating and ventilating as needed to maintain products according to Contract Documents; lighting for maintenance and inspection of products. H. Storage Areas and Sheds: Size to storage requirements for products of individual Sections, allowing for access and orderly provision for maintenance and inspection of products to suit requirements in Section 01 60 00 - Product Requirements. I. Preparation: Fill and grade Sites for temporary structures sloped for drainage away from buildings. J. Installation: 1. Install field office spaces ready for occupancy 15 days after date established by Owner- Contractor Agreement. 2. Level, block, tie down, provide access stairways and relocate when necessary and approved. 3. Employee Residential Occupancy: Not allowed on Owner's property. K. Maintenance and Cleaning: 1. Weekly janitorial services for field offices; periodic cleaning and maintenance for sheds and storage areas. 2. Maintain walks free of mud, water, snow, and the like. L. Removal: At completion of Work remove buildings, foundations, utility services, and debris. Restore areas to same or better condition as original condition. 1.10 VEHICULAR ACCESS A. Construct temporary all-weather access roads from public thoroughfares to serve construction area, of width and load-bearing capacity to accommodate unimpeded traffic for construction purposes. B. Construct temporary bridges and culverts to span low areas and allow unimpeded drainage. C. Extend and relocate vehicular access as Work progress requires and provide detours as necessary for unimpeded traffic flow. D. Location as approved by Engineer. E. Provide unimpeded access for emergency vehicles. Maintain 20 foot-wide driveways with turning space between and around combustible materials. F. Provide and maintain access to fire hydrants and control valves free of obstructions. G. Provide means of removing mud from vehicle wheels before entering streets. H. Use designated existing on-Site roads for construction traffic. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-03) Temporary Facilities and Controls 01 50 00 - 5 1.11 PARKING A. Construct temporary gravel surface parking areas to accommodate construction personnel. B. Location as indicated on Drawings or approved by Engineer. C. Contractor to provide and maintain suitable parking areas for the use of all construction workers and others performing Work or furnishing services in connection with the Project to avoid any need for parking personal vehicles where they may interfere with public traffic, Owner’s operations, or construction activities. D. If Site space is not adequate, Contractor shall provide additional off-Site parking at no cost to Owner. E. Use of existing on-Site streets and driveways used for construction traffic is not permitted, unless approved by Owner. Tracked vehicles are not allowed on paved areas. F. Use of designated areas of existing parking facilities used by construction personnel is not permitted. G. Do not allow heavy vehicles or construction equipment in parking areas. H. Do not allow vehicle parking on existing pavement. I. Designate one parking space for Engineer and Owner. J. Permanent Pavements and Parking Facilities: 1. Before Substantial Completion, bases for permanent roads and parking areas may be used for construction traffic. 2. Avoid traffic loading beyond paving design capacity. Tracked vehicles are not allowed. 3. Use of permanent parking structures is not permitted. K. Maintenance: 1. Maintain traffic and parking areas in sound condition free of excavated material, construction equipment, products, mud, snow, ice, and the like. 2. Maintain existing and permanent paved areas used for construction; promptly repair breaks, potholes, low areas, standing water, and other deficiencies, to maintain paving and drainage in original condition. L. Removal, Repair: 1. Remove temporary materials and construction before Substantial Completion. 2. Remove underground Work and compacted materials to depth of 2 feet; fill and grade Site as indicated. 3. Repair existing facilities damaged by use, to original condition. M. Mud from Site vehicles: Provide means of removing mud from vehicle wheels before entering streets. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-03) Temporary Facilities and Controls 01 50 00 - 6 1.12 PROGRESS CLEANING AND WASTE REMOVAL A. Maintain areas free of waste materials, debris, and rubbish. Maintain Site in clean and orderly condition. B. Remove debris and rubbish from pipe chases, plenums, attics, crawl spaces, and other closed or remote spaces, before enclosing spaces. C. Broom and vacuum clean interior areas before starting surface finishing, and continue cleaning to eliminate dust. D. Collect and remove waste materials, debris, and rubbish from Site periodically and dispose of off-Site. E. Open free-fall chutes are not permitted. Terminate closed chutes into appropriate containers with lids. F. Comply with all applicable local, state, and federal requirements regarding excess and waste material, including methods of handling and disposal. G. At least weekly, brush sweep entry drive, roadways, and other streets affected by the Work and where adjacent to the Work. 1.13 PROJECT IDENTIFICATION A. Project Identification Sign: 1. One painted sign, 32-sq ft area, bottom 4 feet aboveground. 2. Content: a. Project number, title, logo, and name of Owner. b. Names and titles of authorities. c. Names and titles of Engineer and Consultants. d. Name of Prime Contractor. e. Texas Water Development Board logo and text, as required. 3. Graphic Design, Colors, and Style of Lettering: Designated by Engineer. B. Project Informational Signs: 1. Painted informational signs of same colors and lettering as Project identification sign or standard products; size lettering for legibility at 100-foot distance. 2. Provide sign at each field office and storage shed and provide directional signs to direct traffic into and within Site. Relocate as Work progress requires. 3. No other signs are allowed without Owner's permission except those required by law. C. Design sign and structure to withstand 70-mph wind velocity. D. Sign Painter: Experienced as professional sign painter for minimum of three years. E. Finishes, Painting: Adequate to withstand weathering, fading, and chipping for duration of construction. F. Show content, layout, lettering, color, foundation, structure, sizes, and grades of members. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-03) Temporary Facilities and Controls 01 50 00 - 7 G. Sign Materials: 1. Structure and Framing: New wood, structurally adequate. 2. Sign Surfaces: Exterior grade plywood with medium-density overlay, minimum of 3/4 inches thick, standard large sizes to minimize joints. 3. Rough Hardware: Galvanized. 4. Paint and Primers: Exterior quality, two coats; sign background of color as selected. 5. Lettering: Exterior quality paint, contrasting colors as selected. H. Installation: 1. Install Project identification sign within 15 days after date established by Notice to Proceed. 2. Erect at designated location. 3. Erect supports and framing on secure foundation, rigidly braced and framed to resist wind loadings. 4. Install sign surface plumb and level, with butt joints. Anchor securely. 5. Paint exposed surfaces of sign, supports, and framing. I. Maintenance: Maintain clean signs and supports; repair deterioration and damage. J. Removal: Remove signs, framing, supports, and foundations at completion of Project and restore area. 1.14 TRAFFIC REGULATION A. Comply with Laws and Regulations regarding closing or restricting use of public streets or highways. No public or private road shall be closed, except by written permission of proper authority. Ensure the least possible obstruction to traffic and normal commercial pursuits. B. Conduct the Work to interfere as little as possible with public travel, whether vehicular or pedestrian. C. Whenever it is necessary to cross, close, or obstruct roads, driveways, and walks, whether public or private, provide and maintain suitable and safe bridges, detours, or other temporary expedients for accommodation of public and private travel. D. Signs, Signals, and Devices: 1. Post-Mounted and Wall-Mounted Traffic Control and Informational Signs: As approved by authorities having jurisdiction. 2. Traffic Control Signals: As approved by local jurisdictions. 3. Traffic Cones, Drums, Flares, and Lights: As approved by authorities having jurisdiction. 4. Flag Person Equipment: As required by authorities having jurisdiction. E. Flag Persons: Provide trained and equipped flag persons to regulate traffic when construction operations or traffic encroach on public traffic lanes. F. Flares and Lights: Use flares and lights during hours of low visibility to delineate traffic lanes and to guide traffic. G. Haul Routes: BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-03) Temporary Facilities and Controls 01 50 00 - 8 1. Consult with authorities having jurisdiction and establish public thoroughfares to be used for haul routes and Site access. 2. Confine construction traffic to designated haul routes. 3. Provide traffic control at critical areas of haul routes to regulate traffic and to minimize interference with public traffic. H. Traffic Signs and Signals: 1. Provide signs at approaches to Site and on Site, at crossroads, detours, parking areas, and elsewhere as needed to direct construction and affected public traffic. 2. Provide, operate, and maintain traffic control signals to direct and maintain orderly flow of traffic in areas under Contractor's control and areas affected by Contractor's operations. 3. Relocate signs and signals as Work progresses, to maintain effective traffic control. I. Removal: 1. Remove equipment and devices when no longer required. 2. Repair damage caused by installation. 3. Remove post settings to depth of 2 feet. 1.15 FIRE-PREVENTION FACILITIES A. Prohibit smoking within buildings under construction and demolition. Designate area on Site where smoking is permitted. Provide approved ashtrays in designated smoking areas. B. Establish fire watch for cutting, welding, and other hazardous operations capable of starting fires. Maintain fire watch before, during, and after hazardous operations until threat of fire does not exist. C. Portable Fire Extinguishers: NFPA 10; 10-pound capacity, 4A-60B: C UL rating. 1. Provide one fire extinguisher at each facility. 2. Provide minimum of one fire extinguisher in every construction trailer and storage shed. 3. Provide minimum of one fire extinguisher on roof during roofing operations using heat- producing equipment. 1.16 BARRIERS A. Provide barriers to prevent unauthorized entry to construction areas, to allow for Owner's use of Site, and to protect existing facilities and adjacent properties from damage from construction operations and demolition. B. Provide barricades and covered walkways required by authorities having jurisdiction for public rights-of-way. C. Tree and Plant Protection: Preserve and protect existing trees and plants designated to remain. 1. Protect areas within drip lines from traffic, parking, storage, dumping, chemically injurious materials and liquids, ponding, and continuous running water. 2. Provide 4-foot-high barriers around drip line, with access for maintenance. 3. Replace trees and plants damaged by construction operations. D. Protect non-owned vehicular traffic, stored materials, Site, and structures from damage. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-03) Temporary Facilities and Controls 01 50 00 - 9 1.17 ENCLOSURES AND FENCING A. Provide fencing as necessary for protection of existing facilities and to maintain controlled access to the Site. Maintain fence throughout construction period. B. Construction: Commercial-grade chain-link fence. C. Provide 8-foot-high fence around Contractor field office and parking area, and construction Site as required; equip with vehicular and pedestrian gates with locks. D. Provide orange plastic construction netting around open excavations. E. Exterior Enclosures: 1. Provide temporary weathertight closure of exterior openings to accommodate acceptable working conditions and protection for products, to allow for temporary heating and maintenance of required ambient temperatures identified in individual Specification Sections, and to prevent entry of unauthorized persons. Provide access doors with self- closing hardware and locks. 2. Provide temporary roofing as necessary. 3. Provide environmental control systems that meet recommendations of manufacturers of equipment and materials stored. 1.18 SECURITY A. Security Program: 1. Contractor is responsible for protecting the Work premises from theft, vandalism, and unauthorized entry. 2. Initiate program at Project mobilization. 3. Maintain program throughout construction period until directed by Engineer. 4. No claim is to be made against Owner by reason of any act of an employee or trespasser. Contractor to make good all damage to Owner property resulting from Contractor failure or provide suitable security measures. 5. Security program to be at least equal to those provided by Owner to protect existing facilities during normal operation and shall include additional security fencing, surveillance, barricades, lighting, and other measures as required to protect the Site. 6. Submit a security program to Engineer for review if requested. B. Entry Control: 1. Restrict entrance of persons and vehicles to Project Site. 2. Allow entrance only to authorized persons with proper identification. 3. Maintain log of workers and visitors and make available to Owner on request. 4. Coordinate access of Owner's personnel to Site in coordination with Owner's security forces. C. Personnel Identification: 5. Provide identification badge for each person authorized to enter premises. 6. Badge to Include: Personal photograph, name, and employer. 7. Maintain list of accredited persons and submit copy to Owner on request. 8. Require return of badges at expiration of employment on the Work. (AD-03) BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-03) Temporary Facilities and Controls 01 50 00 - 10 C. Restrictions: 1. Do not allow cameras on Site or photographs taken except by written approval of Owner or as specified. 2. Do no work on Saturdays or Sundays without approval of Owner. 1.19 WATER CONTROL A. Grade Site to drain. Maintain excavations free of water. Provide, operate, and maintain necessary pumping equipment. B. Protect Site from puddles or running water. Provide water barriers as required to protect Site from soil erosion. 1.20 DUST CONTROL A. Execute Work by methods that minimize raising dust from construction operations. B. Provide positive means to prevent airborne dust from dispersing into atmosphere. 1.21 EROSION AND SEDIMENT CONTROL A. Refer to Section 31 25 12 – Storm Water Pollution Prevention. B. Plan and execute construction by methods to control surface drainage from cuts and fills from borrow and waste disposal areas. Prevent erosion and sedimentation. C. Minimize surface area of bare soil exposed at one time. D. Provide temporary measures including berms, dikes, drains, and other devices to prevent water flow. E. Construct fill and waste areas by selective placement to avoid erosive surface silts and clays. F. Periodically inspect earthwork to detect evidence of erosion and sedimentation. Promptly apply corrective measures. 1.22 NOISE CONTROL A. Provide methods, means, and facilities to minimize noise produced by construction operations. B. Conduct construction operations during regular working hours except as approved by Engineer. 1.23 PEST AND RODENT CONTROL A. Provide methods, means, and facilities to prevent pests and insects from damaging the Work. B. Provide methods, means, and facilities to prevent rodents from accessing or invading premises. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-03) Temporary Facilities and Controls 01 50 00 - 11 1.24 POLLUTION CONTROL A. Provide methods, means, and facilities to prevent contamination of soil, water, and atmosphere from discharge of noxious, toxic substances and pollutants produced by construction operations. B. Comply with pollution and environmental control requirements of authorities having jurisdiction. C. Control dust caused by the work and comply with pollution control regulations of governing authorities. Sprinkling or similar methods will be permitted to control dust. Use of petroleum products or chlorides is prohibited. Sprinkling must be repeated as needed to keep the disturbed area damp. Dust control shall be performed as the work proceeds whenever a potential for dust nuisance or hazard occurs. D. Burning is not allowed on this project. E. Blasting is not allowed on this project. 1.25 REMOVAL OF UTILITIES, FACILITIES, AND CONTROLS A. Remove temporary utilities, equipment, facilities, and materials before Final Application for Payment inspection. B. Remove underground installations to minimum depth of 2 feet. Grade Site as indicated on Drawings. C. Clean and repair damage caused by installation or use of temporary Work. D. Restore existing and permanent facilities used during construction to original condition. Restore permanent facilities used during construction to specified condition. PART 2 PRODUCTS - Not Used PART 3 EXECUTION - Not Used END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Product Requirements 01 60 00 - 1 SECTION 01 60 00 - PRODUCT REQUIREMENTS PART 1 GENERAL 1.1 SECTION INCLUDES A. Products. B. Product delivery requirements. C. Product storage and handling requirements. D. Product options. E. Equipment electrical characteristics and components. 1.2 PRODUCTS A. Specified products define standard of quality, type, function, dimension, appearance, and performance required. B. Furnish products of qualified manufacturers that are suitable for intended use. Furnish products of each type by single manufacturer unless specified otherwise. Confirm that manufacturer's production capacity can provide sufficient product, on time, to meet Project requirements. C. Domestic Products: Except where specified otherwise, domestic products are not required for this Project. Domestic products are interpreted to mean products mined, manufactured, fabricated, or produced in United States or its territories. D. Do not use materials and equipment removed from existing premises except as specifically permitted by Contract Documents. E. Furnish interchangeable components from same manufacturer for components being replaced. 1.3 PRODUCT DELIVERY REQUIREMENTS A. When practical, factory assemble products. Mark or tag separate parts and assemblies to facilitate field assembly. Cover machined and unpainted parts that may be damaged by the elements with strippable protective coating. B. Transport and handle products according to manufacturer's instructions. C. Schedule delivery of products or equipment as required to allow timely installation and to avoid prolonged storage. D. Deliver products in undamaged condition, in manufacturer’s original container or packaging, with identifying labels intact and legible. Include on label, date of manufacture and shelf life, where applicable. E. Promptly inspect shipments to ensure products comply with requirements, quantities are correct, and products are undamaged. BCRUA - Phase 1D WTP Expansion Issued for Bid Product Requirements 01 60 00 - 2 F. Provide equipment and personnel to handle products; use methods to prevent soiling, disfigurement, or damage. G. Remove damaged products from Site and expedite delivery of identical new undamaged products, and remedy incomplete or lost products to provide that specified, so as not to delay progress of the Work. 1.4 PRODUCT STORAGE AND HANDLING REQUIREMENTS A. Store, rotate, maintain, and protect products according to manufacturer's instructions. Manufacturer’s instructions for material requiring special handling, storage, or protection shall be provided prior to delivery of material. B. Store in approved storage yards or sheds provided in accordance with Section 01 50 00 - Temporary Facilities and Controls. Provide manufacturer’s recommended maintenance during storage, installation, and until products are accepted for use by Owner. C. Store and protect products according to manufacturer's instructions. D. Store products with seals and labels intact and legible. E. Store sensitive products in weathertight, climate-controlled enclosures in an environment suitable to product. F. For exterior storage of fabricated products, place products on sloped supports aboveground. G. Cover products subject to deterioration with impervious sheet covering. Provide ventilation to prevent condensation and degradation of products. H. Store loose granular materials on solid flat surfaces in well-drained area. Prevent mixing with foreign matter. I. Provide equipment and personnel to store products; use methods to prevent soiling, disfigurement, or damage. J. Arrange storage of products to permit access for inspection. Periodically inspect to verify products are undamaged and are maintained in acceptable condition. K. Keep running account of products in storage to facilitate inspection and to estimate progress payments for products delivered, but not installed in the Work. 1.5 PRODUCT OPTIONS A. Products Specified by Reference Standards or by Description Only: Products complying with specified reference standards or description. B. Products Specified by Naming One or More Manufacturers: Products of one of manufacturers named and complying with Specifications; no options or substitutions allowed. BCRUA - Phase 1D WTP Expansion Issued for Bid Product Requirements 01 60 00 - 3 C. Products Specified by Naming One or More Manufacturers with Provision for Substitutions: Submit Request for Substitution for any manufacturer not named according to Section 01 25 00 - Substitution Procedures. PART 2 PRODUCTS 2.1 EQUIPMENT ELECTRICAL CHARACTERISTICS AND COMPONENTS A. Wiring Terminations: Furnish terminal lugs to match branch circuit conductor quantities, sizes, and materials indicated. Include lugs for terminal box. B. Cord and Plug: Furnish minimum 6-foot long cord and plug including grounding connector for connection to electric wiring system. Cord of longer length may be specified in individual Specification Sections. PART 3 EXECUTION - Not Used END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Common Requirements for Equipment 01 61 03 - 1 SECTION 01 61 03 – COMMON REQUIREMENTS FOR EQUIPMENT PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: Common requirements for equipment. B. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Division 01 – General Requirements. 3. Section 03 30 00 – Cast-In-Place Concrete. 4. Section 09 96 00 – High-Performance Coatings. 5. Section 10 14 00 – Identification for Process Piping and Equipment. 6. Section 40 05 00 – Common Requirements for Process Piping. 7. Section 40 90 01 – Instrumentation. 1.2 QUALITY ASSURANCE A. Reference Standards: 1. American Bearing Manufacturers Association (ABMA). 2. American Gear Manufacturers Association (AGMA). 3. ASTM International (ASTM): a. E1934, Standard Guide for Examining Electrical and Mechanical Equipment with Infrared Thermography. b. F593, Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs. 4. Hydraulic Institute (HI): a. 9.6.4, Centrifugal and Vertical Pumps for Vibration Measurements and Allowable Valves. 5. International Electrotechnical Commission (IEC). 6. Institute of Electrical and Electronics Engineers, Inc. (IEEE). 7. International Organization for Standardization (ISO): a. 1940, Mechanical Vibration - Balance Quality Requirements for Rotors in a Constant (Rigid) State - Part 1: Specification and Verification of Balance Tolerances. 8. National Electrical Manufacturers Association (NEMA): a. 250, Enclosures for Electrical Equipment (1000 Volts Maximum). b. ICS 6, Enclosures for Industrial Control and System. c. MG 1, Motors and Generators. 9. International Electrical Testing Association (NETA): a. ATS, Acceptance Testing Specification for Electrical Power Distribution Equipment and Systems. 10. National Fire Protection Association (NFPA): a. 70, National Electrical Code (NEC): 1) Article 430, Motors, Motor Circuits, and Controllers. 11. National Institute for Certification in Engineering Technologies (NICET). 12. National Institute of Standards and Technology (NIST). 13. Occupational Safety and Health Administration (OSHA): a. 29 CFR 1910, Occupational Safety and Health Standards, referred to herein as OSHA Standards. BCRUA - Phase 1D WTP Expansion Issued for Bid Common Requirements for Equipment 01 61 03 - 2 14. Underwriters Laboratories, Inc. (UL). a. 508, Standard for Safety Industrial Control Equipment. b. 508A, Standard for Safety Industrial Control Panels. 15. Vibration Institute. B. Miscellaneous: 1. A single manufacturer of a "product" shall be selected and utilized uniformly throughout Project even if: a. More than one (1) manufacturer is listed for a given "product" in Specifications. b. No manufacturer is listed. 2. Equipment, electrical assemblies, related electrical wiring, instrumentation, controls, and system components shall fully comply with specific NEC requirements related to area classification and to NEMA 250 and NEMA ICS 6 designations shown on Electrical Power Drawings and/or defined in the Electrical specifications. 3. Variable speed equipment applications: The VFD manufacturer and driven equipment manufacturer shall have joint responsibility for coordination of the equipment and VFD system and verify their compatibility. 1.3 DEFINITIONS A. Product: Manufactured materials and equipment. B. Major Equipment Supports - Supports for Equipment: 1. Located on or suspended from elevated slabs with supported equipment weighing 2000 LBS or greater, or; 2. Located on or suspended from roofs with supported equipment weighing 500 LBS or greater, or; 3. Located on slab-on-grade or earth with supported equipment weighing 5000 LBS or more. C. Equipment: 1. One (1) or more assemblies capable of performing a complete function. 2. Mechanical, electrical, instrumentation or other devices requiring an electrical, pneumatic, electronic or hydraulic connection. 3. Not limited to items specifically referenced in "Equipment" articles within individual Specifications. D. Installer or Applicator: 1. Installer or applicator is the person installing or applying the product in the field at the Project site. 2. Installer and applicator are synonymous. 1.4 SUBMITTALS A. See Section 01 33 00 – Submittal Procedures for general requirements. B. Shop Drawings: 1. General for all equipment: a. Data sheets that include manufacturer's name and complete product model number. 1) Clearly identify all optional accessories that are included. BCRUA - Phase 1D WTP Expansion Issued for Bid Common Requirements for Equipment 01 61 03 - 3 b. Acknowledgement that products submitted comply with the requirements of the standards referenced. c. Manufacturer's delivery, storage, handling, and installation instructions. d. Equipment identification utilizing tagging system and name utilized in Drawings. e. Equipment installation details: 1) Location of anchorage. 2) Type, size, and materials of construction of anchorage. 3) Anchorage setting templates. 4) Manufacturer's installation instructions. f. Equipment area classification rating. g. Shipping and operating weight. h. Equipment physical characteristics: 1) Dimensions (both horizontal and vertical). 2) Materials of construction and construction details. i. Equipment factory primer and paint data. j. Manufacturer's recommended spare parts list. k. Equipment lining and coatings. l. Equipment utility requirements including air, natural gas, electricity, and water. m. Ladders and platforms provided with equipment: 1) Certification that all components comply fully with OSHA requirements. 2) Full details of construction/fabrication. 3) Scaled plan and sections showing relationship to equipment. 2. Mechanical and process equipment: a. Operating characteristics: 1) Technical information including applicable performance curves showing specified equipment capacity, rangeability, and efficiencies. 2) Brake horsepower requirements. 3) Copies of equipment data plates. b. Piping and duct connection size, type and location. c. Equipment bearing life certification. d. Equipment foundation data: 1) Equipment center of gravity. 2) Criteria for designing vibration, special or unbalanced forces resulting from equipment operation. 3. Electric motors: a. Motor manufacturer and model number. b. Complete motor nameplate data. c. Weight. d. NEMA design type. e. Enclosure type. f. Frame size. g. Winding insulation class and temperature rise. h. Starts per hour. i. Performance data (unless specified otherwise): 1) Guaranteed minimum efficiencies at 100 percent, 75 percent, and 50 percent of full load 2) Guaranteed minimum power factor at 100 percent, 75 percent, and 50 percent of full load. 3) Locked rotor and full load current at rated terminal voltage and minimum permissible or specified terminal voltage. BCRUA - Phase 1D WTP Expansion Issued for Bid Common Requirements for Equipment 01 61 03 - 4 4) Starting, full load, and breakdown torque at rated terminal voltage and minimum permissible or specified terminal voltage. j. Bearing data and lubrication system. k. Thermal protection system including recommended alarm and trip settings for winding and bearing RTDs. l. Fabrication and/or layout drawings: 1) Dimensioned outlined drawing. 2) Connection diagrams including accessories (strip heaters, thermal protection, etc.). m. Certifications: 1) When utilized with a reduced voltage starter, certify that motor and driven equipment are compatible. 2) When utilized with a variable frequency controller, certify motor is inverter duty and the controller and motor are compatible. a) Include minimum speed at which the motor may be operated for the driven machinery. n. Electrical gear: 1) Unless specified in a narrow-scope Specification Section, provide the following: a) Equipment ratings: Voltage, continuous current, kVa, watts, short circuit with stand, etc., as applicable. 2) Control panels: a) Panel construction. b) Point-to-point ladder diagrams. c) Scaled panel face and subpanel layout. d) Technical product data on panel components. e) Panel and subpanel dimensions and weights. f) Panel access openings. g) Nameplate schedule. h) Panel anchorage. 4. Systems schematics and data: a. Provide system schematics where required in system specifications. 1) Acknowledge all system components being supplied as part of the system. 2) Utilize equipment, instrument and valving tag numbers defined in the Contract Documents for all components. 3) Provide technical data for each system component showing compliance with the Contract Document requirements. 4) For piping components, identify all utility connections, vents and drains which will be included as part of the system. 5) For factory painted equipment, provide paint submittals in accordance with Section 09 96 00 - High-Performance Coatings. C. Contract Closeout Information: 1. Operation and Maintenance Data: a. See Section 01 70 00 – Execution and Closeout Requirements. D. Informational Submittals: 1. Certification that equipment has been installed properly, has been initially started up, has been calibrated and/or adjusted as required, and is ready for operation. a. Reference Certificate of Proper Installation form attached to Section 01 33 00 – Submittal Procedures. BCRUA - Phase 1D WTP Expansion Issued for Bid Common Requirements for Equipment 01 61 03 - 5 2. Certification for major equipment supports that equipment foundation design loads shown on the Drawings or specified have been compared to actual loads exhibited by equipment provided for this Project and that said design loadings are equal to or greater than the loads produced by the equipment provided. 3. Field noise testing reports, if such testing is specified in narrow-scope Specification Sections. 4. Notification, at least four (4) weeks in advance or as specified elsewhere, that motor testing will be conducted at the factory. 5. Certification from equipment manufacturer that all manufacturer-supplied control panels that interface in any way with other controls or panels have been submitted to and coordinated with the supplier/installer of those interfacing systems. 6. Motor test reports. 7. Certification prior to Project closeout that electrical panel drawings for manufacturer- supplied control panels truly represent panel wiring including any field-made modifications. 8. Certification that driven equipment and VFDs are compatible. 1.5 EXISTING CONDITIONS A. Service Conditions: 1. Ambient Air Temperature (ºF): a. Minimum: 6. b. Average: 69. c. Maximum: 111. 2. Wind Speed (mph): a. Minimum Average Daily: 0.2. b. Mean Average Daily: 8. c. Maximum Average Daily: 20. 3. Raw Water Temperature (ºF): a. Minimum: 50. b. Average: 72. c. Maximum: 90. PART 2 - PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. The following manufacturers are acceptable: 1. Motors (Unless noted otherwise in narrow-scope Specification Sections): a. Baldor. b. General Electric. c. Marathon Electric. d. Reliance Electric. e. Siemens. f. Teco-Westinghouse. g. U.S. Motors. h. WEG. 2. VFDs: See Section 26 29 23 – Low Voltage Variable Frequency Drives. BCRUA - Phase 1D WTP Expansion Issued for Bid Common Requirements for Equipment 01 61 03 - 6 B. Submit request for substitution in accordance with Section 01 25 00. 2.2 MANUFACTURED UNITS A. Low Voltage Electric Motors: 1. Where used in conjunction with adjustable speed AC or DC drives, provide motors that are fully compatible with the speed controllers. 2. Design for frequent starting duty equivalent to duty service required by driven equipment. 3. Design for full voltage starting. 4. Design bearing life based upon actual operating load conditions imposed by driven equipment. 5. Size for altitude of Project. 6. Furnish with stainless steel nameplates which include all data required by NEC Article 430. 7. Use of manufacturer's standard motor will be permitted on integrally constructed motor driven equipment specified by model number in which a redesign of the complete unit would be required to provide a motor with features specified. 8. AC electric motors less than 1/3 HP: a. Single phase, 60 Hz, designed for the supply voltage shown on the Drawings. b. Permanently lubricated sealed bearings conforming to ABMA standards. c. Built-in manual reset thermal protector or integrally mounted manual motor starter with thermal overload element with stainless steel enclosure. 9. AC electric motors 1/3 to 1 HP: a. Single or 3 PH, 60 Hz, designed for the supply voltage shown on the Drawings. b. Permanently lubricated sealed bearings conforming to ABMA standards. 1) For single phase motors, provide built-in manual reset thermal protector or integrally mounted manual motor starter with thermal overload element. 10. AC electric motors 1-1/2 to 10 HP: a. Single or 3 PH, 60 Hz, designed for the supply voltage shown on the Drawings. b. Permanently lubricated sealed bearings conforming to ABMA standards. c. For vertical motors provide 15-year, average-life thrust bearings conforming to ABMA standards. 11. AC electric motors greater than 10 HP: a. Single or 3 PH, 60 Hz, designed for the supply voltage shown on the Drawings. b. Oil or grease lubricated antifriction bearings conforming to ABMA standards. 1) Design bearing life for 90 percent survival rating at 50,000 HRS of operation for motors up to and including 100 HP. c. For vertical motors provide 15-year, average-life thrust bearings conforming to ABMA standards. d. Thermal protection: 1) For motors 50 HP and above controlled from a variable frequency drive and for all other motors 100 HP and above, provide integral thermal detectors with normally closed contacts that will open on over-temperature or resistance type temperature detector (RTD) complete with monitor and alarm panel having a normally closed contact that will open on over-temperature. a) Two (2) thermal sensing devices per phase in each phase hot-spot location. 12. Severe duty motor to have the following minimum features: a. All cast iron construction. b. Gasketed conduit box. c. Epoxy finish for corrosion protection. BCRUA - Phase 1D WTP Expansion Issued for Bid Common Requirements for Equipment 01 61 03 - 7 d. Hydroscopic varnish on windings for corrosion protection. e. Drain plug and breather. B. Low Voltage NEMA Design Squirrel Cage Induction Motors: 1. Provide motors designed and applied in compliance with NEMA and IEEE for the specific duty imposed by the driven equipment. 2. Motors to meet NEMA MG 1 (NEMA Premium) efficiencies. 3. Do not provide motors having a locked rotor kVA per HP exceeding the NEMA standard for the assigned NEMA code letter. 4. For use on variable frequency type adjustable speed drives, provide: a. Induction motors that are in compliance with NEMA MG 1, Part 31. b. Nameplate identification meeting NEMA MG 1 Part 31 requirements. c. Insulated drive end bearing on all motors. d. Insulated non-drive end bearings, at a minimum, on all motors with horizontal shaft 100 HP and larger. e. An insulated bearing carrier on the non-drive end for vertical shaft motors 100 HP and larger. f. Shaft grounding ring on all motors: 1) Factory installed, maintenance free, circumferential, bearing protection ring with conductive microfiber shaft contacting material. 2) Electro Static Technology AEGIS SGR Bearing Protection Ring or approved equal. 5. Design motor insulation in accordance with NEMA standards for Class F insulation with Class B temperature rise above a 40 Deg C ambient. 6. Design motors for continuous duty. 7. Size motors having a 1.0 service factor so that nameplate HP is a minimum of 15 percent greater than the maximum HP requirements of the driven equipment over its entire operating range. a. As an alternative, furnish motors with a 1.15 service factor and size so that nameplate HP is at least equal to the maximum HP requirements of the driven equipment over its entire operating range. 8. Motor enclosure and winding insulation application: a. The following shall apply unless modified by narrow-scope Specification Sections: MOTOR LOCATION MOTOR ENCLOSURE / WINDING INSULATION Unclassified Indoor Areas TEFC, Standard Insulation Wet indoor Areas TEFC, Standard Insulation Wet outdoor Areas TEFC, Extra Dip and Bake for Moisture Corrosive Areas TEFC, Severe/ Chemical Duty Class I, Division 1 Areas Explosion Proof, Approved for Class I Division 1 Locations Class II, Division 1 Areas Explosion Proof, Approved for Class II Division 1 Locations Class I or Class II, Division 2 Areas Explosion Proof, Approved for Division 1 Locations or TEFC with maximum external frame temperature compatible with the gas or dust in the area, Extra Dip and Bake for moisture NOTE: Provide TENV motors in the smaller horsepower ratings where TEFC is not available. BCRUA - Phase 1D WTP Expansion Issued for Bid Common Requirements for Equipment 01 61 03 - 8 9. Provide oversize conduit box complete with clamp type grounding terminals inside the conduit box. C. V-Belt Drive: 1. Provide each V-belt drive with sliding base or other suitable tension adjustment. 2. Provide V-belt drives with a service factor of at least 1.6 at maximum speed. 3. Provide static proof belts. D. VFDs: See Section 26 29 23 - Low Voltage Variable Frequency Drives. 2.3 ACCESSORIES A. Guards: 1. Provide each piece of equipment having exposed moving parts with full length, easily removable guards, meeting OSHA requirements. 2. Interior applications: a. Construct from expanded galvanized steel rolled to conform to shaft or coupling surface. b. Utilize non-flattened type 16 GA galvanized steel with nominal 1/2 IN spacing. c. Connect to equipment frame with hot-dip galvanized bolts and wing nuts. 3. Exterior applications: a. Construct from 16 GA stainless steel or aluminum. b. Construct to preclude entrance of rain, snow, or moisture. c. Roll to conform to shaft or coupling surface. d. Connect to equipment frame with stainless steel bolts and wing nuts. B. Anchorage: 1. Cast-in-place anchorage: a. Provide ASTM F593, Type 316 stainless steel anchorage for all equipment. b. Configuration and number of anchor bolts shall be per manufacturer's recommendations. c. Provide two (2) nuts for each bolt. 2. Post-installed anchors: a. Reference Drawing S-1. C. Data Plate: 1. Attach a stainless-steel data plate to each piece of rotary or reciprocating equipment. 2. Permanently stamp information on data plate including manufacturer's name, equipment operating parameters, serial number, and speed. D. Gages: 1. Provide gages in accordance with Sections 40 05 06 – Couplings, Adapters, and Specials for Process Piping and 40 90 01 - Instrumentation. 2. Provide at the following locations: a. At locations identified on Drawings. 3. Utilize tapping sleeves or saddles where indicated on Drawings for mounting per Section 40 05 06 - Couplings, Adapters, and Specials for Process Piping. E. Lifting Eye Bolts or Lugs: 1. Provide on all equipment 50 LBS or greater. BCRUA - Phase 1D WTP Expansion Issued for Bid Common Requirements for Equipment 01 61 03 - 9 2. Provide on other equipment or products as specified in the narrow-scope Specification Sections. F. Platforms and Ladders: 1. Design and fabricate in accordance with OSHA Standards. 2. Fabricate components from aluminum. 3. Provide platform surface: Non-skid checkered plate, unless specified in narrow-scope Specification Sections. 2.4 FABRICATION A. Design, fabricate, and assemble equipment in accordance with modern engineering and shop practices. B. Manufacture individual parts to standard sizes and gages so that repair parts, furnished at any time, can be installed in field. C. Furnish like parts of duplicate units to be interchangeable. D. Ensure that equipment has not been in service at any time prior to delivery, except as required by tests. E. Furnish equipment which requires periodic internal inspection or adjustment with access panels which will not require disassembly of guards, dismantling of piping or equipment or similar major efforts. 1. Quick opening but sound, securable access ports or windows shall be provided for inspection of chains, belts, or similar items. F. Provide common, lipped base plate mounting for equipment and equipment motor where said mounting is a manufacturer's standard option. 1. Provide drain connection for 3/4 IN PVC tubing. G. Machine the mounting feet of rotating equipment. H. Fabricate equipment which will be subject to Corrosive Environment in such a way as to avoid back-to-back placement of surfaces that cannot be properly prepared and painted. 1. When such back-to-back fabrication cannot be avoided, provide continuous welds to seal such surfaces from contact with corrosive environment. 2. Where continuous welds are not practical, after painting seal the back-to-back surfaces from the environment in accordance with Section 07 92 00 – Joint Sealants. I. Critical Speed: 1. All rotating parts accurately machined and in as near perfect rotational balance as practicable. 2. Excessive vibration is sufficient cause for equipment rejection. 3. Ratio of all rotative speeds to critical speed of a unit or components: Greater than 1.2. J. Control Panels Engineered and Provided with the Equipment by the Manufacturer: 1. Manufacturer’s standard design for components and control logic unless specific requirements are specified in the narrow-scope equipment Specification Section. BCRUA - Phase 1D WTP Expansion Issued for Bid Common Requirements for Equipment 01 61 03 - 10 2. NEMA or IEC rated components are acceptable, whichever is used in the manufacturer’s standard engineered design, unless specific requirements are required in the narrow-scope equipment Specification Section. 3. Affix entire assembly with a UL 508A label "Listed Enclosed Industrial Control Panel" prior to delivery. a. Control panels without an affixed UL 508A label shall be rejected. 2.5 SHOP OR FACTORY PAINT FINISHES A. Electrical Equipment: 1. Provide factory-applied paint coating system(s) for all electrical equipment components except those specified in Section 09 96 00 to receive field painting. a. Field painted equipment: See Section 09 96 00 for factory applied primer/field paint compatibility requirements. B. Field paint other equipment in accordance with Section 09 96 00 – High-Performance Coatings. 1. See Section 09 96 00 for factory applied primer/field paint compatibility requirements. 2.6 SOURCE QUALITY CONTROL A. Motor Tests: 1. Test motors in accordance with NEMA and IEEE standards. 2. Provide routine tests for all motors in accordance with applicable NEMA standards. 3. The Owner reserves the right to select and have tested, either routine or complete, any motor included in the project. a. The Owner will pay all costs, including shipping and handling, for all motors successfully passing the tests unless other payment provisions are specified in the individual Specification Sections. b. The Contractor shall pay all costs, including shipping and handling, for all motors failing the tests. c. If two (2) successive motors of the same manufacturer fail testing, the Owner has the right to reject all motors from that manufacturer. PART 3 - EXECUTION 3.1 INSTALLATION A. Install equipment as shown on Drawings and in accordance with manufacturer's directions. B. Utilize templates for anchorage placement for slab-mounted equipment. C. For equipment having drainage requirements such as seal water, provide 3/4 IN PVC or clear plastic tubing from equipment base to nearest floor or equipment drain. 1. Route clear of major traffic areas and as approved by Engineer. D. Do not construct foundations until major equipment supports are approved. E. Extend all non-accessible grease fittings using stainless steel tubing to a location which allows easy access of fittings from closest operating floor level. BCRUA - Phase 1D WTP Expansion Issued for Bid Common Requirements for Equipment 01 61 03 - 11 F. Equipment Base: 1. Construct level in both directions. 2. Take particular care at anchor bolt locations so these areas are flat and level. G. Machine Base: 1. Mount machine base of rotating equipment on equipment base. a. Level in both directions, using a machinist level, according to machined surfaces on base. 2. Level machine base on equipment base and align couplings between driver and driven unit using steel blocks and shims. a. Size blocks and shims to provide solid support at each mounting bolt location. 1) Provide area size of blocks and shims approximately 1-1/2 times area support surface at each mounting bolt point. b. Provide blocks and shims at each mounting bolt. 1) Furnish blocks and shims that are square shape with "U" cut out to allow blocks and shims to be centered on mounting bolts. c. After all leveling and alignment has been completed and before grouting, tighten mounting bolts to proper torque value. H. Rotating equipment Couplings: 1. Align in the annular and parallel positions. a. For equipment rotating at 1200 rpm or less, align both annular and parallel within 0.001 IN tolerance for couplings 4 IN size and smaller. b. Couplings larger than 4 IN size: Increase tolerance 0.0005 IN per inches of coupling diameter, i.e., allow 6 IN coupling 0.002 IN tolerance, and allow a 10 IN coupling 0.004 IN tolerance. c. For equipment rotating at speeds greater than 1200 rpm allow both annular and parallel positions within a tolerance rate of 0.00025 IN per inch coupling diameter. 2. If equipment is delivered as a mounted unit from factory, verify factory alignment on site after installation and realigned if necessary. 3. Check surfaces for runout before attempting to trim or align units. I. Grouting: 1. After machine base has been shimmed, leveled onto equipment base, couplings aligned and mounting bolts tightened to correct torque value, place a dam or formwork around base to contain grouting between equipment base and equipment support pad. a. Extend dam or formwork to cover leveling shims and blocks. b. Do not use nuts below the machine base to level the unit. 2. Saturate top of roughened concrete subbase with water before grouting. a. Add grout until entire space under machine base is filled to the top of the base underside. b. Puddle grout by working a stiff wire through the grout and vent holes to work grout in place and release any entrained air in the grout or base cavity. 3. When the grout has sufficiently hardened, remove dam or formwork and finish the exposed grout surface to fine, smooth surface. a. Cover exposed grout surfaces with wet burlap and keep covering sufficiently wet to prevent too rapid evaporation of water from the grout. b. When the grout has fully hardened (after a minimum of seven (7) days) tighten all anchor bolts to engage equipment base to grout, shims, and equipment support pad. c. Recheck driver-driven unit for proper alignment. BCRUA - Phase 1D WTP Expansion Issued for Bid Common Requirements for Equipment 01 61 03 - 12 3.2 INSTALLATION CHECKS A. For all equipment specifically required in detailed Specifications, secure services of experienced, competent, and authorized representative(s) of equipment manufacturer to visit site of work and inspect, check, adjust and approve equipment installation. 1. In each case, representative(s) shall be present during placement and start-up of equipment and as often as necessary to resolve any operational issues which may arise. B. Secure from equipment manufacturer's representative(s) a written report certifying that equipment: 1. Has been properly installed and lubricated. 2. Is in accurate alignment. 3. Is free from any undue stress imposed by connecting piping or anchor bolts. 4. Has been operated under full load conditions and that it operated satisfactorily. a. Secure and deliver a field written report to Owner immediately prior to leaving jobsite. C. Reference Section 01 33 00 – Submittal Procedures and Section 01 91 00 – Facility Commissioning for Certificate of Compliance and Certificate of Proper Installation. D. No separate payment shall be made for installation checks. 1. All or any time expended during installation check does not qualify as Operation and Maintenance training or instruction time when specified. 3.3 IDENTIFICATION OF EQUIPMENT AND HAZARD WARNING SIGNS A. Identify equipment and install hazard warning signs in accordance with Section 10 14 00 – Identification for Process Piping and Equipment. 3.4 FIELD PAINTING AND PROTECTIVE COATINGS A. For required field painting and protective coatings, comply with Section 09 96 00 - High- Performance Coatings. 3.5 WIRING CONNECTIONS AND TERMINATION A. Clean wires before installing lugs and connectors. B. Coat connection with oxidation eliminating compound for aluminum wire. C. Terminate motor circuit conductors with copper lugs bolted to motor leads. D. Tape stripped ends of conductors and associated connectors with electrical tape. 1. Wrapping thickness shall be 150 percent of the conductor insulation thickness. E. Connections to carry full ampacity of conductors without temperature rise. F. Terminate spare conductors with electrical tape. BCRUA - Phase 1D WTP Expansion Issued for Bid Common Requirements for Equipment 01 61 03 - 13 3.6 FIELD QUALITY CONTROL A. General: 1. Furnish equipment manufacturer’s field quality control services and testing as specified in the individual equipment Specification Sections. 2. Execute start-up requirements in accordance with Section 01 70 00 – Execution and Closeout Requirements and Section 01 91 00 – Facility Commissioning. 3. Perform and report on all tests required by the equipment manufacturer’s Operation and Maintenance Manual. 4. Provide testing of electrical equipment and connections in accordance with the Electrical specifications. B. Other Testing: 1. Perform tests and inspections not specifically listed but required to assure equipment is safe to energize and operate. 2. Subbase that supports the equipment base and that is made in the form of a cast iron or steel structure that has supporting beams, legs, and cross members that are cast, welded, or bolted shall be tested for a natural frequency of vibration after equipment is mounted. a. The ratio of the natural frequency of the structure to the frequency of the disturbing force shall not be between 0.5 and 1.5. 3.7 DEMONSTRATION A. Demonstrate equipment in accordance with Section 01 70 00 – Execution and Closeout Requirements and Section 01 91 00 – Facility Commissioning. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Execution and Closeout Requirements 01 70 00 - 1 SECTION 01 70 00 - EXECUTION AND CLOSEOUT REQUIREMENTS PART 1 GENERAL 1.1 SECTION INCLUDES A. Field engineering. B. Closeout procedures. C. Starting of systems. D. Demonstration and instructions. E. Minimum start up requirements. F. Project record documents. G. Operation and maintenance data. H. Manual for materials and finishes. I. Manual for equipment and systems. J. Spare parts and maintenance products. K. Product warranties and product bonds. L. Maintenance service. M. Examination. N. Preparation. O. Execution. P. Cutting and patching. Q. Protecting installed construction. R. Final cleaning. 1.2 FIELD ENGINEERING A. Engineer will locate and Contractor shall protect survey control and reference points. Promptly notify Engineer of discrepancies discovered. B. Control datum for survey is established by Owner-provided survey indicated on Drawings. C. Retain professional land surveyor or civil engineer registered in state of Texas who shall perform or supervise engineering surveying necessary for additional construction staking and layout. D. Contractor shall verify setbacks and easements; confirm Drawing dimensions and elevations. E. Protect survey control points prior to starting Site Work; preserve permanent reference points during construction. F. Promptly report to Engineer loss or destruction of reference point or relocation required because of changes in grades or other reasons. G. Contractor shall retain Engineer to replace dislocated survey control points based on original survey control. BCRUA - Phase 1D WTP Expansion Issued for Bid Execution and Closeout Requirements 01 70 00 - 2 1.3 CLOSEOUT PROCEDURES A. Prerequisites to Substantial Completion: Complete following items before requesting Certification of Substantial Completion, either for entire Work or for portions of Work: 1. Submit approved maintenance manuals, Project record documents, digital images of construction photographs, and other similar final record data in compliance with this Section. 2. Complete facility startup, testing, adjusting, balancing of systems and equipment, demonstrations, and instructions to Owner's operating and maintenance personnel as specified in the Contract Documents. 3. Submit asset management information documentation per Section 01 91 00 – Facility Commissioning. 4. Conduct inspection to establish basis for request that Work is substantially complete. Create comprehensive list (initial punch list) indicating items to be completed or corrected, value of incomplete or nonconforming Work, reason for being incomplete, and date of anticipated completion for each item. Include copy of list with request for Certificate of Substantial Completion. 5. Obtain and submit releases enabling Owner's full, unrestricted use of Project and access to services and utilities. Include certificate of occupancy, operating certificates, and similar releases from authorities having jurisdiction and utility companies. 6. Install all grating, stairs, guardrails, and other required safety devices. 7. Assemble and place as-built control panel and loop drawings in all cabinets. 8. Install all identification for process piping, equipment, and systems per Section 10 14 00 – Identification for Process Piping and Equipment, Section 23 05 53 – Identification for HVAC, and Section 26 05 53 – Identification for Electrical Systems. 9. Deliver tools, spare parts, extra stocks of material, and similar physical items to Owner. 10. Make final change-over of locks and transmit keys directly to Owner. Advise Owner's personnel of change-over in security provisions. 11. Discontinue or change over and remove temporary facilities and services from Project Site, along with construction tools, mockups, and similar elements. 12. Perform final cleaning according to this Section. B. Prerequisites for Final Completion: Complete following items before requesting final acceptance and final payment. 1. When Contractor considers Work to be complete, submit written certification that: a. Contract Documents have been reviewed. b. Work has been examined for compliance with Contract Documents. c. Work has been completed according to Contract Documents. d. Work is completed and ready for final inspection. 2. Submittals: Submit following: a. Final punch list indicating all items have been completed or corrected. b. Final payment request with final releases and supporting documentation not previously submitted and accepted. Include certificates of insurance for products and completed operations where required. c. Specified warranties, workmanship/maintenance bonds, maintenance agreements, and other similar documents. d. Accounting statement for final changes to Contract Sum. e. Contractor's affidavit of payment of debts and claims on Contractor's Affidavit of Payment of Debts and Claims. f. Contractor affidavit of release of liens on Contractor's Affidavit of Release of Liens. BCRUA - Phase 1D WTP Expansion Issued for Bid Execution and Closeout Requirements 01 70 00 - 3 g. Consent of surety to final payment on Consent of Surety to Final Payment Form. 3. Perform final cleaning for Contractor-soiled areas according to this Section. 1.4 STARTING OF SYSTEMS A. Coordinate schedule for startup of various equipment and systems. Reference Section 01 91 00 – Facility Commissioning. B. Verify that each piece of equipment or system has been checked for proper lubrication, drive rotation, belt tension, control sequence, and for conditions which may cause damage. C. Verify that tests, meter readings, and electrical characteristics agree with those required by equipment or system manufacturer. D. Verify that wiring and support components for equipment are complete and tested. E. Execute startup under supervision of manufacturer's representative or Contractors' personnel according to manufacturer's instructions, in accordance with the requirements of Section 01 91 00 – Facility Commissioning, and the individual Specification Sections. F. When specified in individual Specification Sections, require manufacturer to provide authorized representative who will be present at Site to inspect, check, and approve equipment or system installation prior to startup and will supervise placing equipment or system in operation. G. Submit a written report according to Section 01 33 00 - Submittal Procedures and Section 01 91 00 – Facility Commissioning that equipment or system has been properly installed and is functioning correctly. 1.5 DEMONSTRATION AND INSTRUCTIONS A. Demonstrate operation and maintenance of products to Owner's personnel including training and start-up prior to date of Substantial Completion. B. Demonstrate Project equipment and instruct in classroom environment located at the BCRUA WTP. Instruction shall be provided by qualified manufacturer's representative who is knowledgeable about the equipment and Project. C. For equipment or systems requiring seasonal operation, perform demonstration for other season within six months. D. Use operation and maintenance manuals as basis for instruction. Review contents of manual with Owner's personnel in detail to explain all aspects of operation and maintenance. E. Demonstrate startup, operation, control, adjustment, troubleshooting, servicing, maintenance, and shutdown of each item of equipment at agreed time, at equipment location. F. Prepare and insert additional data in operations and maintenance manuals when need for additional data becomes apparent during instruction and prior to date of Substantial Completion. BCRUA - Phase 1D WTP Expansion Issued for Bid Execution and Closeout Requirements 01 70 00 - 4 G. Equipment and systems requiring training are specified in individual Specification Sections. H. Required instruction time for each item of equipment and system is specified in individual Specification Sections. I. The manufacturer's instructor shall present at least one "hands-on" demonstration of common preventative and corrective maintenance repairs so that all operation and maintenance personnel have the opportunity to witness the demonstration. The manufacturer shall provide the tools and equipment to conduct the demonstrations and prepare and submit video recordings of the demonstrations for future reference. J. In any “hands-on” training situation where Owner’s operation or maintenance personnel participate in disassembly or assembly of equipment components, the manufacturer shall be responsible for such disassembly or assembly and shall provide written certification of proper equipment operation to the Engineer after reassembly of all equipment. K. Demonstration Period: 1. Demonstrate the functional integrity of the mechanical, electrical, and control interfaces of the respective equipment and components comprising the facility as evidence of Substantial Completion. 2. Duration of Demonstration Period: Minimum 30 consecutive days. 3. Timing of Demonstration Period: a. Complete Functional Demonstration Test (FDT) specified in Section 40 90 02 – Supervisory Control and Data Acquisition (SCADA) System. b. Following successful completion of FDT, Demonstration Period shall begin in conjunction with 30-Day Acceptance Test specified in Section 40 90 02 – Supervisory Control and Data Acquisition (SCADA) System. 4. Demonstration Period must be successfully completed prior to Substantial Completion. 5. If, during the Demonstration Period, the aggregate amount of time used for repair, alteration, or unscheduled adjustments to any equipment or systems that renders the affected equipment or system inoperative exceeds 5 percent of the Demonstration Period, the demonstration of functional integrity will be deemed to have failed. a. In the event of failure, a new Demonstration Period will recommence after correction of the cause of failure. b. The new Demonstration Period shall have the same requirements and duration as the Demonstration Period previously conducted. 6. Conduct the demonstration of functional integrity under full operational conditions. 7. Owner will provide operations personnel during Demonstration Period. a. Owner’s personnel will be available to operate the system and provide process decisions affecting plant performance. b. Contractor shall assist with operation of the system under authority of Owner’s operations personnel and provide preventative/corrective maintenance of equipment until successful completion of the Demonstration Period. 8. Owner reserves the right to simulate operational variables, equipment failures, routine maintenance scenarios, etc., to verify the functional integrity of automatic and manual backup systems and alternate operating modes. 9. Time of beginning and ending any Demonstration Period shall be agreed upon by Contractor, Owner, and Engineer in advance of initiating Demonstration Period. BCRUA - Phase 1D WTP Expansion Issued for Bid Execution and Closeout Requirements 01 70 00 - 5 10. Throughout the Demonstration Period, provide knowledgeable personnel to answer Owner’s questions, provide final field instruction on select systems and to respond to any system problems or failures which may occur. 11. Provide all labor, supervision, utilities, chemicals, maintenance, equipment, vehicles, or any other item necessary to operate and demonstrate all systems being demonstrated. 1.6 MINIMUM START UP REQUIREMENTS A. Bearings and Shafting. 1. Inspect for cleanliness, clean and remove foreign materials if bearings and shafting run rough or noisy. 2. Lubricate as necessary, in accordance with manufacturer’s recommendations. B. Drives. 1. Adjust tension in V-belt drives and adjust vari-pitch sheaves and drives for proper equipment speed. 2. Adjust drives for alignment of sheaves and V-belts. 3. Clean and remove foreign materials before starting operation. C. Motors. 1. Check each motor for comparison to amperage nameplate value. 2. Correct conditions which produce excessive current flow, and which exist due to equipment malfunction. D. Pumps. 1. Check glands and seals for cleanliness and adjustment before running pumps. 2. Inspect shaft sleeves for scoring. 3. Inspect mechanical faces, chambers, and seal rings, and replace if defective. 4. Verify that piping system is free of dirt, debris and scale before circulating liquid through the pump. E. Valves. 1. Inspect hand and automatic control valves, clean bonnets and stems. 2. Tighten packing glands to assure no leakage but permit valve stems to operate without galling. 3. Replace packing in valves to retain maximum adjustment after system is judged complete. 4. Replace packing on any valve which continues to leak. 5. Remove and repair bonnets which leak. 6. Coat packing gland threads and valve stems with a surface preparation of “Moly-Cote” or “Mallow-Pro”, after cleaning. F. Verify that control valve seats are free from foreign material and are properly positioned for intended use. G. Tighten all pipe joints after system has been placed in operation. Replace gaskets which show any sign of leakage after tightening. H. Inspect all joints for leakage. 1. Promptly remake each joint which appears to be faulty, do not wait for rust to form. BCRUA - Phase 1D WTP Expansion Issued for Bid Execution and Closeout Requirements 01 70 00 - 6 2. Clean threads on both parts, apply compound and remake joints. I. After system has been placed in operation, clean strainers, dirt pockets, orifices, valve seats and headers in fluid system, to assure freedom from foreign materials. J. Open traps and air vents where used, remove operating elements. Clean thoroughly, replace internal parts, and put back into operation. K. Remove rust, scale and foreign material from equipment and renew defaced surfaces. L. Set and calibrate equipment and instrumentation, including all electrical and control systems per Section 40 90 01 – Instrumentation. Field calibration is acceptable for any equipment and instrumentation if within 12 months of factory calibration with a calibration certificate or sticker. Calibration shall be completed using instrumentation calibrated by NIST traceable certified calibration facility and have a calibration sticker dated within 12 months of the use date. M. All instrumentation shall be within calibration per Section 40 90 01 at Substantial Completion. Any instrumentation not within calibration shall be re-calibrated or replaced with calibrated instrumentation prior to Substantial Completion. N. Inspect fan wheels for clearance and balance. Provide factory-authorized personnel for adjustment when needed. O. Check each electrical control and power circuit to assure that operation complies with specifications and requirements to provide desired performance. P. Replace items which are defaced, broken, or which read incorrectly. Q. Repair damaged insulation. R. Vent gasses trapped in any part of systems. Verify that liquids are drained from all parts of gas or air systems. S. Provide reports to Engineer indicating observations and results of tests and indicating compliance or non-compliance with requirements of Contract Documents. 1.7 PROJECT RECORD DOCUMENTS A. Maintain on Site one complete paper copy set of the following record documents; record actual revisions to the Work in accordance with General Conditions 00700: 1. Drawings. 2. Specifications. 3. Addenda. 4. Change Orders and other modifications to the Contract. 5. Reviewed Shop Drawings, product data, and Samples. 6. Manufacturer's instruction for assembly, installation, and adjusting. B. Ensure entries are complete and accurate, enabling future reference by Engineer and Owner. BCRUA - Phase 1D WTP Expansion Issued for Bid Execution and Closeout Requirements 01 70 00 - 7 1. Thoroughly coordinate changes within the Record Documents, making adequate and proper entries on each page of Specifications and each sheet of Drawings and other Documents where such entry is required to show the change properly. 2. Accuracy of records shall be such that future search for items shown in the Contract Documents may rely reasonably on information obtained from the approved Project Record Documents. 3. To facilitate accuracy of records, make entries within 24 hours after receipt of information that the change has occurred. 4. Provide factual information regarding all aspects of the Work, both concealed and visible, to enable future modification of the Work to proceed without lengthy and expensive site measurement, investigation and examination. 5. Data indicating inappropriate or unacceptable Work may be subject to action by Engineer or Owner. C. Store record documents separate from documents used for construction. D. Record information concurrent with construction progress, not less than weekly. E. Specifications: Legibly mark and record, at each product Section, description of actual products installed, including the following: 1. Manufacturer's name and product model and number. 2. Product substitutions or alternates used. 3. Changes made by Addenda and modifications. F. Record Drawings and Shop Drawings: Legibly mark each item to record actual construction as follows: 1. Include Contract modifications such as Addenda, supplementary instructions, change directives, field orders, minor changes in the Work, and change orders. 2. Include locations of concealed elements of the Work. 3. Identify depth of buried utility lines and provide dimensions showing distances from permanent facility components that are parallel to utilities. 4. Dimension ends, corners, and junctions of buried utilities to permanent facility components using triangulation. 5. Identify and locate existing buried or concealed items encountered during Project. 6. Measured depths of foundations in relation to vertical datum. 7. Measured horizontal and vertical locations of underground utilities and appurtenances, referenced to permanent surface improvements. 8. Measured locations of internal utilities and appurtenances concealed in construction, referenced to visible and accessible features of the Work. 9. Field changes of dimension and detail. 10. Details not on original Drawings. G. Submit marked-up paper copy documents to Engineer with claim for final Application for Payment. H. Submit PDF electronic files of marked-up documents to Engineer with claim for final Application for Payment. BCRUA - Phase 1D WTP Expansion Issued for Bid Execution and Closeout Requirements 01 70 00 - 8 1.8 OPERATION AND MAINTENANCE DATA A. Submit preliminary data electronically as a PDF within 60 days after approval of corresponding shop drawing(s). Files to be fully functional, searchable, and viewable in the most recent version of Adobe Acrobat and Bluebeam. B. After all preliminary data have been found to be acceptable to Engineer and owner, submit updated PDF and provide two hard copy sets of data bound in 8-1/2 x 11-inch text pages, three D side ring binders with durable plastic covers. Include bookmarks in PDF to match manual table of contents. C. Prepare binder cover with printed title "OPERATION AND MAINTENANCE INSTRUCTIONS," title of Project, and subject matter of binder when multiple binders are required. Include cover information on spine of binder. D. Internally subdivide binder contents with permanent page dividers, logically organized as described below; with tab titling clearly printed under reinforced laminated plastic tabs. Provide heavy duty plastic sheet lifters in front and back of binder. E. Drawings: Provide with reinforced punched binder tab. Bind in with text; fold larger drawings to size of text pages. F. Contents: Prepare table of contents for each volume, with each product or system description identified, typed on white paper, in three parts as follows: 1. Part 1: Directory, listing names, addresses, and telephone numbers of Engineer, Contractor, Subcontractors, and major equipment suppliers and equipment supplier’s project number. 2. Part 2: Operation and maintenance instructions, arranged by system and subdivided by Specification Section. For each category, identify names, addresses, and telephone numbers of Subcontractors and suppliers. Include the following: a. Significant design criteria. b. List of equipment. c. Parts list for each component. d. Operating instructions. e. Maintenance instructions for equipment and systems. f. Maintenance instructions for special finishes, including recommended cleaning methods and materials, and special precautions identifying detrimental agents. g. Safety precautions to be taken when operating and maintaining or working near equipment. 3. Part 3: Project documents and certificates, including the following: a. Shop Drawings and product data. b. Air and water balance reports. c. Specified certificates and service agreements. d. Originals of warranties and bonds. 1.9 MANUAL FOR MATERIALS AND FINISHES A. Submit electronic preliminary draft or proposed formats and outlines of contents before start of Work. Engineer will review draft and return with comments. BCRUA - Phase 1D WTP Expansion Issued for Bid Execution and Closeout Requirements 01 70 00 - 9 B. For equipment or component parts of equipment put into service during construction and operated by Owner, submit documents within ten days after acceptance. C. Submit completed volumes at least 15 days prior to request for Substantial Completion. Draft will be reviewed and returned with Engineer comments. Revise content of document sets as required prior to final submission. D. Submit two sets of revised final volumes within ten days after final inspection. 1. Provide one electronic final volume in searchable PDF. Include bookmarks in PDF to match manual table of contents. E. Products, Applied Materials, and Finishes: Include product data, with catalog number, size, composition, and color and texture designations. Include information for re-ordering custom- manufactured products. F. Instructions for Care and Maintenance: Include manufacturer's recommendations for cleaning agents and methods, precautions against detrimental agents and methods, and recommended schedule for cleaning and maintenance. G. Moisture Protection and Weather Exposed Products: Include product data listing applicable reference standards, chemical composition, and details of installation. Include recommendations for inspections, maintenance, and repair. H. Additional Requirements: As specified in individual product Specification Sections. I. Include listing in table of contents for design data, with tabbed fly sheet and space for insertion of data. 1.10 MANUAL FOR EQUIPMENT AND SYSTEMS A. Submit preliminary draft or proposed formats and outlines of contents before start of Work. Engineer will review draft and return with comments. B. For equipment, or component parts of equipment put into service during construction and operated by Owner, submit documents within ten days after acceptance. C. Submit completed volumes at least 30 days prior to request for Substantial Completion. Draft will be reviewed and returned with Engineer comments. Revise content of document sets as required prior to final submission. D. Submit two sets of revised final volumes within ten days after final inspection. 1. Provide one electronic final volume in PDF. Include bookmarks in PDF to match manual table of contents. E. Each Item of Equipment and Each System: Include description of unit or system and component parts. Identify function, normal operating characteristics, and limiting conditions. Include performance curves, with engineering data and tests, and complete nomenclature and model number of replaceable parts. BCRUA - Phase 1D WTP Expansion Issued for Bid Execution and Closeout Requirements 01 70 00 - 10 F. Panelboard Circuit Directories: Provide electrical service characteristics, controls, and communications; typed. G. Include color-coded wiring diagrams as installed. H. Operating Procedures: Include startup, break-in, and routine normal operating instructions and sequences. Include regulation, control, stopping, shutdown, and emergency instructions. Include summer, winter, and special operating instructions. I. Maintenance Requirements: Include routine procedures and guide for preventative maintenance and troubleshooting; disassembly, repair, and reassembly instructions; and alignment, adjusting, balancing, and checking instructions. J. Include servicing and lubrication schedule and list of lubricants required. K. Include manufacturer's printed operation and maintenance instructions. L. Include sequence of operation by controls manufacturer. M. Include original manufacturer's parts list, illustrations, assembly drawings, and diagrams required for maintenance. N. Include configuration information. O. Include control diagrams by controls manufacturer as installed. P. Include Contractor's coordination drawings with color-coded piping diagrams as installed. Q. Include charts of valve tag numbers, with location and function of each valve, keyed to flow and control diagrams. R. Include list of original manufacturer's spare parts, current prices, and recommended quantities to be maintained in storage. S. Include field test reports and test and balancing reports as specified in Section 01 40 00 - Quality Requirements and individual Specification Sections. T. Additional Requirements: As specified in individual product Specification Sections. U. Include listing in table of contents for design data with tabbed dividers and space for insertion of data. 1.11 SPARE PARTS AND MAINTENANCE PRODUCTS A. Furnish spare parts, maintenance, and extra products in quantities specified in individual Specification Sections. Store and maintain all components in accordance with the manufacturer's recommendations until they have been transferred to the Owner. B. Spare parts may be transferred on an individual Specification Section basis or for the entire Project after commissioning and startup and successful completion of the Demonstration BCRUA - Phase 1D WTP Expansion Issued for Bid Execution and Closeout Requirements 01 70 00 - 11 Period. Once spare parts have been transferred to the Owner, they shall not be transferred back to the Contractor and shall not be available for use by the Contractor to address deficiencies or warranty items. C. Assemble and deliver all spare parts to Project Site and place in location as directed by Owner. D. Develop and utilize a Chain of Custody form to document the transfer of all spare parts and extra products. 1. At a minimum, the Chain of Custody form shall include the description, manufacturer, model number, and quantity of all parts being transferred, as well as the Project name, Specification Section, date of transfer, and the printed name and signature of the Contractor and Owner’s representatives responsible for transferring/receiving the spare parts. 2. An executed copy of each Chain of Custody form shall be provided to the Owner within 24 hours of transfer and retained by the Contractor until the completion of the Project. 3. Any parts transferred to the Owner without an accompanying Chain of Custody form documenting the transfer shall be replaced by the Contractor at no additional cost. 1.12 PRODUCT WARRANTIES A. Reference General Conditions 7.17 for Contractor’s general warranty and guarantee. B. Obtain warranties executed in duplicate by responsible Subcontractors, suppliers, and manufacturers within ten days after completion of applicable item of Work. C. Execute and assemble transferable warranty documents from Subcontractors, suppliers, and manufacturers. D. Verify documents are in proper form, contain full information, and are notarized. E. Co-execute submittals when required. F. Include table of contents and assemble all warranties in three D side ring binder with durable plastic cover. Provide electronic PDF submittal as well. G. Submit prior to final Application for Payment. H. Time of Submittals: 1. For equipment or component parts of equipment put into service during construction with Owner's permission, submit documents within ten days after acceptance. 2. Make other submittals within ten days after date of Substantial Completion, prior to final Application for Payment. 3. For items of Work for which acceptance is delayed beyond Substantial Completion, submit within ten days after acceptance, listing date of acceptance as beginning of warranty or bond period. BCRUA - Phase 1D WTP Expansion Issued for Bid Execution and Closeout Requirements 01 70 00 - 12 1.13 MAINTENANCE SERVICE A. Unless specified otherwise, furnish service and maintenance of components indicated in Specification Sections for two years from date of Final Completion as specified in General Conditions 7.17.B. B. Contractor shall coordinate to have these services provided by the manufacturer’s representative with Contractor support as required. C. Examine system components at frequency consistent with reliable operation. Clean, adjust, and lubricate as required. D. Include systematic examination, adjustment, and lubrication of components. Repair or replace parts whenever required. Use parts produced by manufacturer of original component. E. Do not assign or transfer maintenance service to agent or Subcontractor without prior written consent of Owner. PART 2 PRODUCTS - Not Used PART 3 EXECUTION 3.1 EXAMINATION A. Verify that existing Site conditions and substrate surfaces are acceptable for subsequent Work. Beginning new Work means acceptance of existing conditions. B. Verify that existing substrate is capable of structural support or attachment of new Work being applied or attached. C. Examine and verify specific conditions described in individual Specification Sections. D. Verify that utility services are available with correct characteristics and in correct locations. 3.2 PREPARATION A. Clean substrate surfaces prior to applying next material or substance according to manufacturer's instructions. B. Seal cracks or openings of substrate prior to applying next material or substance. C. Apply manufacturer-required or -recommended substrate primer, sealer, or conditioner prior to applying new material or substance in contact or bond. BCRUA - Phase 1D WTP Expansion Issued for Bid Execution and Closeout Requirements 01 70 00 - 13 3.3 EXECUTION A. Comply with manufacturer's installation instructions, performing each step in sequence. Maintain one set of manufacturer's installation instructions at Project Site during installation and until completion of construction. B. When manufacturer's installation instructions conflict with Contract Documents, request clarification from Engineer before proceeding. C. Verify that field measurements are as indicated on approved Shop Drawings or as instructed by manufacturer. D. Secure products in place with positive anchorage devices designed and sized to withstand stresses, vibration, physical distortion, or disfigurement. 1. Secure Work true to line and level and within specified tolerances, or if not specified, industry-recognized tolerances. 2. Physically separate products in place, provide electrical insulation, or provide protective coatings to prevent galvanic action or corrosion between dissimilar metals. 3. Exposed Joints: Provide uniform joint width and arrange to obtain best visual effect. Refer questionable visual-effect choices to Engineer for final decision. E. Allow for expansion of materials and building and structural movement. F. Climatic Conditions and Project Status: Install each unit of Work under conditions to ensure best possible results in coordination with entire Project. 1. Isolate each unit of Work from incompatible Work as necessary to prevent deterioration. 2. Coordination enclosure of Work with required inspections and test to minimize necessity of uncovering Work for those purposes. G. Mounting Heights: Where not indicated, mount individual units of Work at industry recognized standard mounting heights for particular application indicated. 1. Refer questionable mounting heights choices to Engineer for final decision. 2. Elements Identified as Accessible to Handicapped: Comply with applicable codes and regulations. H. Adjust operating products and equipment to ensure smooth and unhindered operation. I. Clean and perform maintenance on installed Work as frequently as necessary through remainder of construction period. Lubricate operable components as recommended by manufacturer. 3.4 CUTTING AND PATCHING A. Employ skilled and experienced installers to perform cutting and patching. B. Submit written request in advance of cutting or altering elements affecting: 1. Structural integrity of element. 2. Integrity of weather-exposed or moisture-resistant elements. 3. Efficiency, maintenance, or safety of element. 4. Visual qualities of sight-exposed elements. BCRUA - Phase 1D WTP Expansion Issued for Bid Execution and Closeout Requirements 01 70 00 - 14 5. Work of Owner or separate contractor. C. Execute cutting, fitting, and patching including excavation and fill to complete Work and to: 1. Fit the several parts together, to integrate with other Work. 2. Uncover Work to install or correct ill-timed Work. 3. Remove and replace defective and nonconforming Work. 4. Remove samples of installed Work for testing. 5. Provide openings in elements of Work for penetrations of mechanical and electrical Work. D. Execute Work by methods to avoid damage to other Work and to provide proper surfaces to receive patching and finishing. E. Cut masonry and concrete materials using masonry saw or core drill. F. Restore Work with new products according to requirements of Contract Documents. G. Fit Work tight to pipes, sleeves, ducts, conduits, and other penetrations through surfaces. H. Maintain integrity of wall, ceiling, or floor construction; completely seal voids. I. Refinish surfaces to match adjacent finishes. For continuous surfaces, refinish to nearest intersection; for assembly, refinish entire unit. J. Identify hazardous substances or conditions exposed during the Work to Engineer for decision or remedy. 3.5 PROTECTING INSTALLED CONSTRUCTION A. Protect installed Work and provide special protection where specified in individual Specification Sections. B. Provide temporary and removable protection for installed products. Control activity in immediate Work area to prevent damage. C. Provide protective coverings at walls, projections, jambs, sills, and soffits of openings. D. Use durable sheet materials to protect finished floors, stairs, and other surfaces from traffic, dirt, wear, damage, or movement of heavy objects. E. Prohibit traffic or storage upon waterproofed or roofed surfaces. When traffic or activity is necessary, obtain recommendations for protection from waterproofing or roofing material manufacturer. F. Prohibit traffic from landscaped areas. 3.6 FINAL CLEANING A. Execute final cleaning prior to final Project assessment. BCRUA - Phase 1D WTP Expansion Issued for Bid Execution and Closeout Requirements 01 70 00 - 15 B. Clean interior and exterior glass and surfaces exposed to view; remove temporary labels, stains, and foreign substances; polish transparent and glossy surfaces; and vacuum carpeted and soft surfaces. C. Clean debris from roofs, gutters, downspouts, and drainage systems. D. Clean Site; sweep paved areas, rake clean landscaped surfaces. E. Remove waste and surplus materials, rubbish, and construction facilities from Site. F. Clean interior of all electrical cabinets and gear of dust, debris, and wire clippings. G. Clean equipment and fixtures to sanitary condition with appropriate cleaning materials. H. Install new filters of operating equipment. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Openings and Penetration in Construction 01 73 20 - 1 SECTION 01 73 20 - OPENINGS AND PENETRATIONS IN CONSTRUCTION PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. Methods of installing and sealing openings and penetrations in construction. B. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Division 01 – General Requirements. 3. Section 07 92 00 – Joint Sealants. 4. Section 09 96 00 – High-Performance Coatings. 5. Section 40 05 06 – Couplings, Adapters, and Specials for Process Piping. 1.2 QUALITY ASSURANCE A. Reference Standards: 1. American Concrete Institute (ACI): a. 318, Building Code Requirements for Structural Concrete. 2. ASTM International (ASTM): a. A36, Standard Specification for Carbon Structural Steel. b. A53, Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless. c. A269, Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service. d. A312, Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes. e. A351, Standard Specification for Castings, Austenitic, for Pressure-Containing Parts. f. A554, Standard Specification for Welded Stainless Steel Mechanical Tubing. g. A653, Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc- Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process. h. A666, Standard Specification for Annealed or Cold-Worked Austenitic Stainless Steel Sheet, Strip, Plate, and Flat Bar. i. A995, Castings, Austenitic-Ferritic (Duplex) Stainless Steel, for Pressure- Containing Parts. 3. National Fire Protection Association (NFPA): a. 70, National Electrical Code (NEC): 1) Article 501, Class 1 Locations. b. 90A, Standard for Installation of Air Conditioning and Ventilating Systems. c. Sheet Metal and Air Conditioning Contractors' National Association (SMACNA). 1.3 DEFINITIONS A. Corrosive Areas: For the purpose of this specification section, the following areas are defined as corrosive: 1. Chemical Storage and Feed Areas. BCRUA - Phase 1D WTP Expansion Issued for Bid Openings and Penetration in Construction 01 73 20 - 2 B. Hazardous Areas: Areas shown in the Contract Documents as having Class I or Class II area classifications. C. Washdown Areas: Areas having floor drains or hose bibbs. 1.4 SUBMITTALS A. Shop Drawings: 1. See Specification Section 01 33 00 – Submittal Procedures for requirements. 2. For each structure, provide dimensioned or scaled (minimum 1/8 IN = 1 FT) plan view drawings containing the following information: a. Vertical and horizontal location of all required openings and penetrations. b. Size of all openings and penetrations. c. Opening type. d. Seal type. 3. Manufacturer's installation instructions for standard manufactured products. 1.5 EXISTING CONDITIONS A. For purposes of this Project, intermittent water table levels are as indicated in the report attached to Section 00220 – Geotechnical Data. PART 2 PRODUCTS 2.1 MATERIALS A. Pipe Sleeves: 1. Areas listed as Corrosive Areas in PART 1: a. Stainless steel, Type 316L. b. Penetrations 24 IN DIA or less: ASTM A269, ASTM A312 or ASTM A554, Schedule 40. c. Penetrations larger than 24 IN DIA: ASTM A666, Minimum 1/4 IN thickness. 2. All other Areas, unless noted otherwise: a. Steel, Hot-dipped galvanized after fabrication, meeting requirements of ASTM A153/A153M. Electroplated zinc or cadmium plating is unacceptable. b. Penetrations 24 IN DIA or less: ASTM A53, Schedule 40. c. Penetrations larger than 24 IN DIA: ASTM A36, Minimum 1/4 IN thickness. B. Backing Rod and Sealant: See Specification Section 07 92 00 – Joint Sealants. C. Modular Mechanical Seals: 1. Acceptable manufacturers: a. Link-Seal. 2. Type: Interconnected synthetic rubber links shaped and sized to continuously fill annular space between pipe and wall sleeve opening. 3. Fabrication: a. Pressure plates shall be reinforced nylon polymer. b. Assemble interconnected rubber links with Type 316 stainless steel bolts, nuts and washers. 4. Size: According to manufacturer’s instructions for size of pipes shown on Drawings to provide a watertight seal between pipe and wall sleeve opening and to withstand a hydrostatic head of 40 feet of water. D. Sheet Metal Sleeves: BCRUA - Phase 1D WTP Expansion Issued for Bid Openings and Penetration in Construction 01 73 20 - 3 1. Areas listed as Corrosive Areas in PART 1: Stainless steel: ASTM A240, Type 316L. 2. All other areas, unless noted otherwise: Galvanized steel: ASTM A653, G90. 3. Minimum 12 GA. E. Commercial Wall Castings: 1. Ductile iron, ASTM A536. 2. For corrosive areas either side of penetration: Stainless Steel, ASTM A352 or A995. 3. As noted on Drawings. 4. Grade equal to connecting piping system. PART 3 EXECUTION 3.1 FABRICATION A. Provide waterstop plate/anchor flange for piping, ducts, castings and sleeves cast-in-place in concrete. 1. For fabricated units, weld plate to sleeve, pipe, or ductwork. 2. For commercial castings, cast water stop/anchor with wall pipe. 3. Plate is to be same thickness as sleeve, pipe, casting or ductwork. 4. For fabricated units, diameter of plate or flange to be 4 IN larger than outside diameter of sleeve, pipe or ductwork. 5. For commercial castings, waterstop/anchor size to be manufacturer standard. 6. Provide continuous around entire circumference of sleeve, pipe, or ductwork. B. Factory or shop-coat painted components in accordance with Specification Section 09 96 00 – High-Performance Coatings. 3.2 INSTALLATION AND APPLICATION A. Seal openings and penetrations in non-fire-resistance-rated construction in accordance with Specification Section 07 92 00 – Joint Sealants. B. Obtain prior acceptance from Engineer when any opening larger than 100 SQ IN must be made in newly completed construction. C. Perform HVAC penetrations in accordance with NFPA 90A. D. Perform electrical penetrations in accordance with NFPA 70, Article 501. E. Install sleeves and castings in accordance with ACI 318. F. When mechanical or electrical work cannot be installed as structure is being erected, provide and arrange for building-in of boxes, sleeves, insets, fixtures or devices necessary to permit installation later. 1. Lay out chases, holes or other openings that must be provided in masonry, concrete, or other work. G. Where pipes, conduits or ducts pass through floors in washdown areas, install sleeves with top 3 IN above finish floors. 1. In non-washdown areas, install sleeves with ends flush with finished surfaces. H. Size sleeves and blockouts that will receive sealant such that free area to receive sealant is minimized to maintain seal integrity. I. For insulated piping and ducts, size sleeves and blockouts large enough to accommodate full thickness of insulation. BCRUA - Phase 1D WTP Expansion Issued for Bid Openings and Penetration in Construction 01 73 20 - 4 J. Where pipes, conduits or ducts pass through grating, provide banding at the entire perimeter of the opening. K. Where pipes, conduits or ducts are removed where passing through grating: 1. Metal grating: Provide banding at perimeter and cover opening with 1/4 IN plate of the same material of the grating. 2. FRP grating: Provide full depth cover meeting same loading requirement as existing material or replace grating section. L. Do not cut into or core drill any beams, joists, or columns. M. Do not install sleeves in beams, joists, or columns. N. Do not install recesses in beams, joists, columns, or slabs. O. Field Cutting and Coring (Only allowed where specifically indicated on Drawings or otherwise approved by Engineer): 1. Saw or core drill with non-impact type equipment. 2. Mark opening and drill small 3/4 IN or less holes through structure following opening outline. 3. Sawcut opening outline on both surfaces. a. Knock out within saw cuts using impact type equipment. b. Do not chip or spall face of surface to remain intact. c. Do not allow any overcut with saw kerf. P. Precast-Prestressed Concrete Construction: 1. Do not cut openings or core drill vertically or horizontally through stems of members. 2. Do not locate or install sleeves or recess sleeves vertically or horizontally through or in stems of members. 3. Cast openings and sleeves into flanges of units. 4. Cast openings larger than 6 IN in diameter or 6 IN maximum dimension in units at time of manufacture. 5. Cast openings smaller than 6 IN in diameter or 6 IN maximum dimensions in flanges of units at time of manufacture or field cut. Q. Where alterations are necessary or where new and old work join, restore adjacent surfaces to their condition existing prior to start of work. R. For interior wall applications where backer rod and sealant are specified, provide backer rod and sealant at each side of wall. S. Use full depth expanding foam sealant for seal applications where single or multiple pipes, conduits, etc., pass through a single sleeve. T. Do not make duct or conduit penetrations below high water levels when entering or leaving tankage, wet wells, or other water holding structures. U. Modular Mechanical Seals: 1. Utilize one (1) seal for concrete thickness less than 8 IN and two (2) seals for concrete 8 IN thick or greater. 2. Utilize two (2) seals for piping 16 IN diameter and larger if concrete thickness permits. 3. Install seals such that bolt heads are located on the most accessible side of the penetration. V. Backer Rod and Sealant: 1. Install in accordance with Specification Section 07 92 00 – Joint Sealants. BCRUA - Phase 1D WTP Expansion Issued for Bid Openings and Penetration in Construction 01 73 20 - 5 2. Provide backer rod and sealant for modular mechanical seal applications, unless noted otherwise. a. Apply on top side of slab penetrations and on interior, dry side wall penetrations. 3.3 SCHEDULES A. General Schedule of Penetrations through Floors, Roofs, Foundation Base Slabs, Foundation Walls, Foundation Footings, Partitions and Walls for Ductwork, Piping, and Conduit: 1. Provide the following opening and penetration types, unless noted otherwise: a. Type A - Block out 2 IN larger than outside dimensions of duct, pipe, or conduits. b. Type B - Saw cut or line-drill opening. Place new concrete with integrally cast sheet metal or pipe sleeve. c. Type C - Fabricated sheet metal sleeve or pipe sleeve cast-in-place. Provide pipe sleeve with water ring for wet and/or washdown areas. d. Type D - Commercial type casting or fabrication. e. Type E – Saw cut or line drill opening. Place new concrete with integrally cast pipe, duct or conduit spools. f. Type F - Integrally cast pipe, duct or conduit. g. Type G - Saw cut or line drill. Remove area 1 IN larger than outside dimension of pipe, duct or conduit. h. Type H - Core drill. i. Type I - Block out area. At later date, place new concrete with integrally cast sheet metal or pipe sleeve. j. Type J- Grating Banding for any field cut openings. 2. Unless noted otherwise, provide seals of material and method described as follows. a. Category 1 - Modular Mechanical Seal. b. Category 2 - Roof curb and flashing according to SMACNA specifications unless otherwise noted on Drawings. c. Category 3 - 12 GA sheet metal drip sleeve set in bed of silicon sealant with backing rod and sealant used in sleeve annulus. d. Category 4 - Backer rod and sealant. e. Category 5 - Full depth compressible sealant with escutcheons on both sides of opening. f. Category 6 - Full depth compressible sealant and flanges on both sides of opening. Flanges constructed of same material as duct, fastened to duct and minimum 1/2 IN larger than opening. g. Category 7 - Full depth compressible sealant and finish sealant or full depth expanding foam sealant depending on application. h. Category 8- Banding for all grating openings and banding and cover plate of similar materials for abandoned openings. 3. Furnish openings and sealing materials through new floors, roofs, grating, partitions, and walls in accordance with Schedule A, Openings and Penetrations for New Construction, or as specifically detailed on the Drawings. 4. Furnish openings and sealing materials through existing floors, roofs, grating, partitions, and walls in accordance with Schedule B, Openings and Penetrations for Existing Construction, or as specifically detailed on the Drawings. BCRUA - Phase 1D WTP Expansion Issued for Bid Openings and Penetration in Construction 01 73 20 - 6 SCHEDULE A. OPENINGS AND PENETRATIONS SCHEDULE FOR NEW CONSTRUCTION DUCTS PIPING CONDUIT APPLICATIONS OPENING TYPE SEAL CATEGORY OPENING TYPE SEAL CATEGORY OPENING TYPE SEAL CATEGORY Through floors with bottom side a hazardous location C F I 7 Not Req 7 D F I (1) Not Req Not Req 7 C F 7 Not Req Through floors on grade above water table C F I 4 Not Req 4 C F I (1) 7 Not Req 7 C F I (1) 4 Not Req 7 Through slab on grade below water table F Not Req F Not Req F Not Req Through floors in washdown areas C I 4 4 C H (2) I (1) 4 3 4 F H (2) I (1) Not Req 3 7 Through walls where one side is a hazardous area C F I 7 Not Req 7 D F I (1) Not Req Not Req 7 C F 7 Not Req Through exterior wall below grade above water table C F I 7 Not Req 7 C D F I (1) 1 Not Req Not Req 1 F I (1) Not Req 7 Through wall from tankage or wet well (above high water level) to dry area C F I 7 Not Req 7 C D F H (2) 1 Not Req Not Req 1 C F H (2) I (1) 7 Not Req 7 7 Through wall from tankage or wet well (below high water level) to dry area F Not Req F Not Req F Not Req Through exterior wall above grade A B C 6 6 6 A B D H (2) 5 5 Not Req 5 C H (2) 5 4 Roof penetrations A 2 A 2 A 2 Through interior walls and slabs not covered by the above applications A C 4 4 A C 4 4 A C F 4 4 Not Req (1) Multiple piping 3 IN and smaller or multiple conduits. (2) Single pipe 3 IN and smaller or single conduit. (3) Single pipe or conduit larger than 3 IN. BCRUA - Phase 1D WTP Expansion Issued for Bid Openings and Penetration in Construction 01 73 20 - 7 SCHEDULE B. OPENINGS AND PENETRATIONS SCHEDULE FOR EXISTING CONSTRUCTION DUCTS PIPING CONDUIT APPLICATIONS OPENING TYPE SEAL CATEGORY OPENING TYPE SEAL CATEGORY OPENING TYPE SEAL CATEGORY Through floors with bottom side a hazardous location B E 7 Not Req B (1) E (3) H (2) 7 Not Req 7 B (1) E (3) H (2) 7 Not Req 7 Through floors on grade above water table B 7 B 7 B 7 Through slab on grade below water table E Not Req E Not Req E Not Req Through floors in washdown areas G 3 G H (2) 3 3 G H (2) 3 3 Through walls where one side is a hazardous area B E 7 Not Req B (1) B (3) E H (2) 7 1 Not Req 7 B (1) (3) E H (2) 7 Not Req 7 Through exterior wall below grade above water table B 7 B (1) B (3) H (2) 7 1 7 B (1) (3) H (2) 7 7 Through wall from tankage or wet well (above high water level) to dry area B E 7 Not Req B E H 1 Not Req 1 B (1) (3) E H (2) 7 Not Req 7 Through wall from tankage or wet well (below high water level) to dry area E Not Req E Not Req E Not Req Through exterior wall above grade G 6 G (1) (3) H (2) 5 5 G (1) (3) H (2) 5 7 Roof penetrations G 2 G (1) (3) H (2) 2 2 G 2 Through interior walls and slabs not covered by the above applications G 4 G (1) (3) H (2) 4 4 G (1) (3) H (2) 4 4 Grating openings and penetrations J 8 J 8 J 8 (1) Multiple piping 3 IN and smaller or multiple conduits. (2) Single pipe 3 IN and smaller or single conduit. (3) Single pipe or conduit larger than 3 IN. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Demolition, Cutting, and Patching 01 73 29 - 1 SECTION 01 73 29 – DEMOLITION, CUTTING, AND PATCHING PART 1 GENERAL 1.1 SUMMARY A. Section Includes: Demolition, cutting, and patching of existing construction as required to accommodate proposed work. Protection and removal of items identified to be saved or reused. 1.2 REFERENCE STANDARDS A. The following is a list of standards which may be referenced in this Section: 1. Air-Conditioning, Heating, and Refrigeration Institute (AHRI): Guideline K, Containers for Recovered Non-flammable Fluorocarbon Refrigerants. 2. American National Standards Institute (ANSI): A10.6, Safety Requirements for Demolition Operations. 3. Occupational Safety and Health Administration (OSHA), U.S. Code of Federal Regulations (CFR) Title 29 Part 1926—Occupational Safety and Health Regulations for Construction. 4. Environmental Protection Agency (EPA), U.S. Code of Federal Regulations (CFR), Title 40: a. Part 61—National Emission Standards for Hazardous Air Pollutants. b. Part 82—Protection of Stratospheric Ozone. c. Part 273—Standards for Universal Waste Management. 1.3 DEFINITIONS A. ACM: Asbestos-containing material. B. Demolition: Dismantling, razing, destroying, or wrecking of any fixed building or structure or any part thereof. C. Modify: Provide all necessary material and labor to modify an existing item to the condition indicated or specified. D. Relocate: Remove, protect, clean, and reinstall equipment, including electrical, instrumentation, and all ancillary components required to make the equipment fully functional, to the new location identified on the Drawings. E. Renovation: Altering a facility or one or more facility components in any way. F. Salvage/Salvageable: Remove and deliver, to the specified location(s), the equipment, building materials, or other items so identified to be saved from destruction, damage, or waste; such property to remain that of Owner. Unless otherwise specified, title to items identified for demolition shall revert to Contractor. G. Universal Waste Lamp: In accordance with 40 CFR 273, the bulb or tube portion of an electric lighting device, examples of which include, but are not limited to, fluorescent, BCRUA - Phase 1D WTP Expansion Issued for Bid Demolition, Cutting, and Patching 01 73 29 - 2 high-intensity discharge, neon, mercury vapor, high- pressure sodium, and metal halide lamps. H. Universal Waste Thermostat: A temperature control device that contains metallic mercury in an ampule attached to a bimetal sensing element, and mercury-containing ampules that have been removed from these temperature control devices in compliance with the requirements of 40 CFR 273. 1.4 SUBMITTALS A. See Section 01 33 00 – Submittal Procedures for general requirements. B. Informational Submittals: 1. Submit proposed Demolition/Renovation Plan, in accordance with requirements specified herein, for acceptance before such Work is started. 2. Submit copies of any notifications, authorizations and permits required to perform the Work. 3. Submit a shipping receipt or bill of lading for all containers of ACM shipped. 4. Submit a shipping receipt or bill of lading for all universal waste shipped. 1.5 REGULATORY AND SAFETY REQUIREMENTS A. When applicable, demolition Work shall be accomplished in strict accordance with 29 CFR 1926-Subpart T. B. Comply with federal, state, and local hauling and disposal regulations. In addition to the requirements of the General Conditions, Contractor’s safety requirements shall conform to ANSI A10.6. C. Furnish timely notification of this project to applicable federal, state, regional, and local authorities in accordance with 40 CFR 61-Subpart M. 1.6 DEMOLITION/RENOVATION PLAN A. Demolition/Renovation Plan shall provide for safe conduct of the Work and shall include: 1. Detailed description of methods and equipment to be used for each operation. 2. The Contractor’s planned sequence of operations, including coordination with other work in progress. 3. Procedures for removal and disposition of materials and equipment specified to be salvaged. 4. Disconnection schedule of utility services. 5. Storage plans for materials on site. 6. Identification of items to be salvaged, as directed by Owner. B. Include statements affirming Contractor inspection of the existing roof deck, floors, walls, and framing members, and their suitability to perform as a safe working platform or, if inspection reveals a safety hazard to workers, state provisions for securing the safety of the workers throughout the performance of the Work. BCRUA - Phase 1D WTP Expansion Issued for Bid Demolition, Cutting, and Patching 01 73 29 - 3 1.7 SEQUENCING AND SCHEDULING A. The Work of this Specification shall not commence until Contractor’s Demolition/Renovation Plan has been approved by Engineer. B. Include the Work of this Specification in the progress schedule, as specified in Section 01 32 16 – Construction Progress Schedule. C. Areas in which the Work is to be accomplished will be indicated in the drawings and in accordance with the sequence of work specified in Section 01 10 00 – Summary of Work and Operational Requirements. 1.8 USE OF EXPLOSIVES A. Use of explosives is not permitted. 1.9 ENVIRONMENTAL PROTECTION A. In accordance with applicable laws and regulations. PART 2 PRODUCTS (NOT USED) PART 3 EXECUTION 3.1 EXISTING FACILITIES TO BE DEMOLISHED OR RENOVATED A. Remove existing work indicated to be removed, or as necessary for installation of new work. 1. Neatly cut and remove materials, and prepare all openings to receive new work. 2. Remove masonry or concrete in small sections. B. Facilities: 1. Buildings and adjacent designated areas scheduled for complete demolition are as shown. 2. Portions of buildings and other areas scheduled for selective demolition, partial demolition, and renovation Work are as shown. C. Structures: 1. Existing above-grade structures indicated shall be removed to grade. 2. Core drill concrete slabs and other concrete improvements scheduled to remain in place below ground, or break holes at the structure’s lowest point to allow water to freely migrate through. 3. Sidewalks, curbs, gutters and street light bases shall be removed as indicated. D. Substructure: 1. Extract conflicting existing substructures when in conflict with proposed new construction. E. Utilities and Related Equipment: 1. Notify Owner or appropriate utilities to turn off affected services at least 48 hours BCRUA - Phase 1D WTP Expansion Issued for Bid Demolition, Cutting, and Patching 01 73 29 - 4 before starting demolition or renovation activities. 2. Remove existing utilities as indicated and terminate in a manner conforming to the nationally recognized code covering the specific utility and approved by Engineer. 3. When utility lines are encountered that are not indicated on the Drawings, notify Owner prior to further work in that area. 4. Remove meters and related equipment and deliver to a location as determined by the Owner. 5. Excavate and remove utility lines serving buildings to be demolished to 3 feet beyond the outside perimeter of the demolition. 6. Provide a permanent leak-proof closure for water and gas lines. 7. Plug sewer lines with concrete to a minimum plug length of 2 feet to prevent groundwater infiltration. F. Paving and Slabs: 1. Remove concrete and asphaltic concrete paving and slabs as indicated to a depth of 8 inches below existing adjacent grade. 2. Provide neat saw cuts at limits of pavement removal as indicated. G. Concrete: 1. Where indicated, remove existing concrete and finish remaining surfaces as specified. 2. Saw concrete along straight lines. Make each cut in walls perpendicular to the face and in alignment with the cut in the opposite face. Break out the remainder of the concrete provided that the broken area is concealed in the finished Work, and the remaining concrete is sound. At locations where the broken face cannot be concealed, grind smooth or saw cut entirely through the concrete. Where new concrete adjoins existing, the new Work shall abut or tie into the existing construction as indicated. 3. Protect remaining concrete from damage. 4. Make openings by sawing through the existing concrete. 5. Break out concrete after initial saw cuts in the event concrete thickness prevents cutting through. 6. Make openings by drilling holes around perimeter of opening and then chipping out the concrete where sawing is not possible. Holes shall be sufficient in number to prevent damage to remaining concrete. 7. Oversize required openings in existing concrete 1 inch on all sides and build back to required opening size by means of nonshrink grout epoxy bonded to the existing concrete. 8. Where oversized openings cannot be made, remove the concrete to the required opening size and cut back exposed reinforcing 1 inch from face of concrete and fill resulting holes with nonshrink grout. 9. Reinforcing steel that is cut and exposed: a. Remove to a depth of 2 inches. b. Fill void with epoxy patch. H. Removal of Existing Anchor Bolts or Other Protruding Elements: 1. Remove all protruding elements. 2. Remove to a depth of 1/4 inch from finished surface. 3. Fill void with epoxy patch. I. Patching: 1. Where removals leave holes and damaged surfaces exposed in the finished Work, patch and repair to match adjacent finished surfaces as to texture and finish. BCRUA - Phase 1D WTP Expansion Issued for Bid Demolition, Cutting, and Patching 01 73 29 - 5 2. Where new Work is to be applied to existing surfaces, perform removals and patching in a manner to produce surfaces suitable for receiving new Work. 3. Patching shall be as specified and indicated, and shall include: a. Fill holes and depressions left as a result of removals in existing masonry and concrete walls with an approved patching material, applied in accordance with the manufacturer’s printed instructions. J. Ceilings: 1. Patch acoustic lay-in ceiling where partitions have been removed. The transition between the different ceiling heights shall be completed by continuing the higher ceiling level over to the first runner on the lower ceiling and closing the vertical opening with a painted sheet metal strip. K. Air-Conditioning Equipment: 1. Remove air-conditioning equipment without releasing chlorofluorocarbon refrigerants to the atmosphere in accordance with the Clean Air Act Amendment of 1990. 2. Recover all refrigerants prior to removing air-conditioning equipment and dispose of properly. L. Cylinders and Canisters: Remove all fire suppression system cylinders and canisters and dispose of properly. M. Door Locksets: Remove all locksets from all doors indicated to be removed and disposed of. Turn locksets over to Owner immediately after their removal. N. Electrical: 1. Cut off concealed or embedded conduit, boxes, or other materials a minimum of 3/4 inch below final finished surface. 2. When removing designated equipment, conduit and wiring may require rework to maintain service to other equipment. 3. Rework existing circuits or provide temporary circuits as necessary during renovation to maintain service to existing lighting and equipment not scheduled to be renovated. Existing equipment and circuiting shown are based upon limited field surveys. Verify existing conditions, make all necessary adjustments, and record the Work on the Record Drawings. This shall include, but is not limited to, swapping and other adjustments to branch circuits and relocation of branch circuit breakers within panelboards as required to accomplish the finished work. 4. Reuse of existing luminaires, devices, conduits, boxes, or equipment will be permitted only where specifically indicated. 5. Raceways and cabling not scheduled for reuse. 6. Inaccessibly Concealed: Cut off and abandon in place. 7. Exposed or Concealed Above Accessible Ceilings: Remove. 8. Raceways and Cabling Scheduled for Future Use: Cap/seal and tag. 9. Relocating Equipment: Extend existing wiring or run new wiring from the source. 10. Where the existing raceway is concealed, the outlet box shall be cleaned, and a blank cover plate installed. 11. Where the concealed raceway is uncovered remove raceway (or extended to new location if appropriate). BCRUA - Phase 1D WTP Expansion Issued for Bid Demolition, Cutting, and Patching 01 73 29 - 6 12. Provide new typewritten panelboard circuit directory cards. O. Universal Waste Lamps and Thermostats: Manage, contain, package, and label in strict accordance with 40 CFR 273. 3.2 PROTECTION A. Building Occupancy: Refer to Section 01 10 00 – Summary of Work and Operational Requirements for specific requirements related to concurrent occupancy of existing facilities. B. Dust and Debris Control: 1. Prevent the spread of dust and debris to occupied portions of the building and avoid the creation of a nuisance or hazard in the surrounding area. Do not use water if it results in hazardous or objectionable conditions such as, but not limited to, ice, flooding, or pollution. 2. Vacuum and dust the Work area daily. 3. Sweep pavements as often as necessary to control the spread of debris that may result in foreign object damage potential to vehicular traffic. C. Traffic Control Signs: Where pedestrian and driver safety is endangered around removal Work, use traffic barricades with flashing lights. D. Existing Work: 1. Survey the site and examine the Drawings and Specifications to determine the extent of the Work before beginning any demolition or renovation. 2. Take necessary precautions to avoid damage to existing items scheduled to remain in place, to be reused, or to remain the property of Owner; any Contractor-damaged items shall be repaired or replaced as directed by Engineer. 3. Provide temporary weather protection during interval between removal of existing exterior surfaces and installation of new to ensure that no water leakage or damage occurs to structure or interior areas of existing building. 4. Ensure that structural elements are not overloaded as a result of or during performance of the Work. Responsibility for additional structural elements or increasing the strength of existing structural elements as may be required as a result of any Work performed under this Contract shall be that of the Contractor. Repairs, reinforcement, or structural replacement must have Engineer acceptance. 5. Do not overload pavements to remain. E. Weather Protection: For portions of the building scheduled to remain, protect building interior, materials, and equipment from weather at all times. Where removal of existing roofing is necessary to accomplish the Work, have materials and workmen ready to provide adequate and temporary covering of exposed areas to ensure effectiveness and to prevent loss. F. Facilities: 1. Protect electrical and mechanical services and utilities. Where removal of existing utilities and pavement is specified or indicated, provide approved barricades, temporary covering of exposed areas, and temporary services or connections for electrical and BCRUA - Phase 1D WTP Expansion Issued for Bid Demolition, Cutting, and Patching 01 73 29 - 7 mechanical utilities. 2. Floors, roofs, walls, columns, pilasters, and other structural elements that are designed and constructed to stand without lateral support or shoring, and are determined by Contractor to be in stable condition, shall remain standing without additional bracing, shoring, or lateral support until demolished, unless directed otherwise by the Engineer. 3. Protect all facility elements not scheduled for demolition. 4. Provide interior shoring, bracing, or support to prevent movement, settlement, or collapse of structure or element to be demolished and adjacent facilities. G. Protection of Personnel: 1. During demolition, continuously evaluate the condition of the structure being demolished and take immediate action to protect all personnel working in and around the demolition site. 2. Provide temporary barricades and other forms of protection to protect Owner’s personnel and the general public from injury due to demolition Work. 3. Provide protective measures as required to provide free and safe passage of Owner’s personnel and the general public to occupied portions of the structure. 3.3 BURNING A. The use of burning at the Site for the disposal of refuse and debris will not be permitted. 3.4 RELOCATIONS A. Perform the removal and reinstallation of relocated items as indicated with workmen skilled in the trades involved. Clean all items to be relocated prior to reinstallation, to the satisfaction of Engineer. Repair items to be relocated which are damaged or replace damaged items with new undamaged items as approved by Engineer. 3.5 BACKFILL A. Do not use demolition debris as backfill material. B. Fill excavations, open basements and other hazardous openings to existing ground level or foundation level of new construction in accordance with Sections 31 05 13 – Topsoil and 31 23 23 – Fill. 3.6 TITLE TO MATERIALS A. Owner shall have first right of refusal for all items removed. B. Except for Owner-selected salvaged equipment and materials, all items designated to be removed shall become the property of Contractor: 3.7 DISPOSITION OF MATERIAL A. Do not remove equipment and materials without acceptance of Contractor’s Demolition/Renovation Plan by Engineer. BCRUA - Phase 1D WTP Expansion Issued for Bid Demolition, Cutting, and Patching 01 73 29 - 8 B. Salvage equipment and material to the maximum extent possible. C. Remove salvaged items selected by Owner as the property of Owner in a manner to prevent damage, and pack or crate to protect the items from damage while in storage. Properly identify containers as to contents. D. Repair or replace, at the discretion of Engineer, items damaged during removal or storage. E. Deliver salvaged items that are selected by Owner as the property of Owner to a storage site as directed on the Site. F. Owner will not be responsible for the condition or loss of, or damage to, property scheduled to become Contractor’s property after Engineer’s authorization to begin demolition. Materials and equipment shall not be viewed by prospective purchasers or sold on the site. 3.8 REUSE OF MATERIALS AND EQUIPMENT A. Remove and store materials and equipment selected by Owner to be reused or relocated to prevent damage. Reinstall as the Work progresses. B. Properly store and maintain equipment and materials in same condition as when removed. C. Store equipment and material designated to be reused in a location designated by Owner. D. Equipment and material designated to be reused shall be cleaned, serviced and checked for proper operability before being put back into service. E. Engineer will determine condition of equipment and materials prior to removal. F. Salvaged items shall be delivered to Owner free from excess process material and pressure washed, if possible, without damaging the item. 3.9 UNSALVAGEABLE MATERIAL A. Concrete, masonry, and other noncombustible material, except concrete permitted to remain in place, shall be disposed of off-site in accordance with applicable permits and regulations. B. Combustible material shall be disposed of off the Site. C. Universal Waste Lamps and Thermostats: Dispose of in strict accordance with 40 CFR 273. D. Sludge or biosolids or items containing or covered with biosolids, sludge or other process material shall be disposed of in compliance with applicable regulations for disposal of wastewater biosolids and sludge material. BCRUA - Phase 1D WTP Expansion Issued for Bid Demolition, Cutting, and Patching 01 73 29 - 9 3.10 CLEANUP A. Debris and rubbish shall be removed from basement and similar excavations. Debris and rubbish shall be removed and transported in a manner that prevents spillage on streets or adjacent areas. Local regulations regarding hauling and disposal shall apply. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Facility Commissioning 01 91 00 - 1 SECTION 01 91 00 – FACILITY COMMISSIONING PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. References. 2. Definitions. 3. Commissioning description. 4. Submittals. 5. Closeout submittals. 6. Quality assurance. 7. Qualifications. 8. Commissioning services. 9. Commissioning responsibilities. 10. Commissioning meetings. 11. Commissioning reports. 12. Sequencing. 13. Scheduling. 14. Maintenance materials. 15. Test equipment. 16. Examination. 17. Implementation of verification checklists, startup forms, and functional and performance testing procedures. 18. Function and performance test methods. 19. Deficiencies and test acceptances. 20. Demonstration and training. B. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Section 01 10 00 – Summary of Work and Operational Requirements. 3. Section 01 33 00 – Submittal Procedures. 4. Section 01 70 00 – Execution and Closeout Requirements. 5. Section 23 05 93 – Testing, Adjusting, and Balancing for HVAC. 6. Section 40 90 02 – Supervisory Control and Data Acquisition (SCADA) System. 1.2 REFERENCES A. Associated Air Balance Council (AABC): 1. AABC Commissioning Guideline. B. American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE): 1. ASHRAE Guideline 1 - The HVAC Commissioning Process. C. National Environmental Balancing Bureau (NEBB): 1. NEBB - Procedural Standards for Building Systems Commissioning. BCRUA - Phase 1D WTP Expansion Issued for Bid Facility Commissioning 01 91 00 - 2 1.3 DEFINITIONS A. Commissioning Authority (CA): Contractor’s Commissioning Specialist (CCS) assigned to Project and employed by Contractor. Commissioning Authority and Contractor’s Commissioning Specialist are synonymous. B. Contractor: General construction firm contracted with Owner to construct Project. C. Engineer: Consulting engineering firm retained by Owner to perform Project design and construction administration services. The term Engineer includes any individuals directly employed by or subcontracted with engineering firm. D. Owner: Entity contracting for construction services. E. Resident Project Representative (RPR): Authorized representative of Engineer assigned to assist Engineer at Project site. The term RPR includes any assistants or field staff of Resident Project Representative. 1.4 COMMISSIONING DESCRIPTION A. Commissioning: Systematic process of ensuring systems perform interactively according to design intent and Owner's operational needs. Commissioning process encompasses and coordinates system documentation, equipment startup, control system calibration, functional and performance testing and training, and verification of actual performance. B. Commissioning Intent: 1. Verify equipment and systems are installed, fully functional, and controlled according to manufacturer's instructions, industry accepted minimum standards, and Contract Documents. 2. Verify equipment and systems receive adequate operational checkout by Contractor. 3. Verify and document proper performance of equipment and systems. 4. Verify complete operation and maintenance documentation is delivered to Owner. 5. Verify Owner's operating and maintenance personnel are adequately trained. C. Equipment and Systems to be Commissioned, including but not limited to: 1. HVAC equipment and systems. 2. Electrical equipment and systems. 3. Raw water head tanks. 4. Modulating valves. 5. Water control gates. 6. Process control and instrumentation systems. 7. Chemical storage, metering and diffusion systems. 8. Vertical shaft flocculators. 9. Rotating pipe skimmer. 10. Chain and flight sludge collection equipment. 11. Filter systems. 12. Circular gravity thickener equipment. 13. Belt filter press system. 14. Shaftless screw conveyors. D. Commissioning does not relieve Contractor of responsibility to provide finished and fully functioning Project. E. Commissioning Process Overview and General Order of Commissioning Tasks: BCRUA - Phase 1D WTP Expansion Issued for Bid Facility Commissioning 01 91 00 - 3 1. Planning Phase: a. Commissioning begins with initial commissioning meeting. b. Conduct progress commissioning meetings throughout construction to plan, scope, coordinate, and schedule future activities and to resolve problems. c. Equipment documentation is submitted to Engineer during normal submittals with detailed startup procedures. d. Engineer, assisted by manufacturers, suppliers, and the Contractor, develops Commissioning and Startup (C&SU) Plan and compiles verification checklists, provided and completed by manufacturers, suppliers, and the Contractor during the commissioning, startup, and demonstration process. 1) The C&SU plan will be developed by Engineer at least 180 days prior to proposed test dates. e. Engineer develops specific equipment and system functional and performance test procedures. Manufacturers, suppliers, and the Contractor review, approve, coordinate, manage, and conduct procedures. 1) Functional and performance test procedures will be developed by Engineer at 120 days prior to test dates. Contractor shall have 30 days to review test procedures and provide feedback to Engineer. 2. Commissioning Phase: a. In general, checkout and performance verification proceeds from simple to complex, that is, from component level to equipment to systems and intersystem levels, with verification checklists being completed before functional and performance testing. b. Contractor executes and documents verification checklists and performs verification checks and startup with assistance from equipment and system installers. Engineer verifies that checklists and startup were completed according to accepted plans. c. Contractor executes functional and performance test procedures with support from equipment and system installers and documents the results. Engineer verifies that functional and performance tests and any other procedures were completed according to accepted procedures. d. Items of noncompliance in material, installation, calibration, configuration, or setup are corrected at Contractor's expense, and system is retested. e. Engineer reviews operation and maintenance documentation for completeness. f. Engineer reviews training procedures provided by equipment and system installers. Contractor coordinates training schedules with Engineer acceptance and executes training. Engineer verifies training was completed. g. Deferred testing is conducted as specified. 3. Startup and Demonstration Phase: a. Contractor returns interim conditions used to facilitate testing to normal operating conditions and simulated signals are reset to live values in preparation for Startup. b. The following equipment is started up in a logical sequence: 1) Electrical equipment ancillary systems. 2) Raw water head tanks. 3) Vertical shaft flocculators. 4) Chain and flight sludge collection equipment. 5) Filter system (filter underdrain, filter media, and wash water troughs). 6) Chemical storage, metering and diffusion systems. 7) Circular gravity thickener equipment. 8) Belt filter press system, including, shaftless screw conveyors. 9) HVAC equipment. BCRUA - Phase 1D WTP Expansion Issued for Bid Facility Commissioning 01 91 00 - 4 c. Contractor operates the entire system with Owner’s assistance for 100 hours to complete the Functional Demonstration Test as specified in Section 40 90 02 – Supervisory Control and Data Acquisition (SCADA) System. d. Owner operates the entire system with Contractor’s assistance for 30 consecutive days to complete the Demonstration Period as specified in Section 01 70 00 – Execution and Closeout Requirements and simultaneous Acceptance Test as specified in Section 40 90 02 – Supervisory Control and Data Acquisition (SCADA) System. Owner will provide operations personnel for operation of the system during this period. 4. Commissioning is completed before Substantial Completion. 1.5 SUBMITTALS A. Furnish submittals to Engineer for acceptance according to procedures specified in Section 01 33 00 - Submittal Procedures. B. Qualification Data: Submit the following prior to the Initial Commissioning Meeting: 1. Name of Contractor’s Commissioning Specialist assigned to Project and assuming role as Commissioning Authority. 2. Resume for Contractor’s Commissioning Specialist, including firm name, address, email, telephone number, credentials, education, work experience, etc. a. Reference Paragraph 1.8 - Qualifications. 3. Detailed description of three commissioning projects of similar size and complexity, completed by Commissioning Specialist assigned to Project within past five years. Include names, telephone numbers, and emails of Owner's and Engineer’s project manager. 4. The Commissioning Authority shall be approved a minimum of 30 days prior to the Engineer scheduling the Initial Commissioning Meeting identified in paragraph 1.11.C, below. C. Furnish preliminary operation and maintenance data manuals to Engineer according to Section 01 70 00 – Execution and Closeout Requirements for each piece of equipment or system indicated to be commissioned. 1. Submit required preliminary manuals within timeframe specified in Section 01 70 00. 2. Preliminary manuals must be accepted prior to beginning commissioning and/or training activities for each piece of equipment or system. 3. In addition to items specified in Section 01 70 00 and individual Specification Sections, operation and maintenance manuals shall include the following: a. Supplemental procedures and checklists prepared by equipment and system installers to accommodate Project conditions. b. Sensor and actuator calibration procedures. c. Factory test reports. D. Furnish a Certificate of Proper Installation (COPI) at the completion of installation of each individual piece of equipment prior to beginning commissioning. Contractor shall sign COPI along with the manufacturer’s authorized representative. Contractor and manufacturer shall certify that: 1. Equipment has been properly installed, adjusted, aligned, calibrated, and lubricated. 2. Equipment has been installed with proper internal clearances and clearances to adjacent equipment and structures. 3. Equipment is free of any stresses imposed by connecting piping or anchor bolts. 4. Equipment as installed shall not void the warranty. 5. Equipment as installed is ready to be operated by others. 6. Equipment as installed will reliably perform the function for which it is installed. BCRUA - Phase 1D WTP Expansion Issued for Bid Facility Commissioning 01 91 00 - 5 7. Equipment is suitable for satisfactory full-time operation under full load conditions. E. Furnish a Certificate of Completion of Field Services at the completion of commissioning of each individual piece of equipment. Contractor shall sign Certificate of Completion of Field Services along with the manufacturer’s authorized representative. Contractor and manufacturer shall certify that: 1. Equipment operates within the allowable limits for vibration. 2. Controls, protective devices, instrumentation, and control panels furnished as part of the equipment package are properly installed, calibrated, and functioning. 3. Control logic for startup, shutdown, sequencing, interlocks, and emergency shutdown has been tested and is properly functioning. 4. Equipment is installed in accordance with the manufacturer’s recommendation and Contract Documents. 5. Equipment has been tested and is functioning as intended. F. Furnish field service reports documenting a complete list of activities completed during all site visits. Include the following: 1. Completed field checkout sheets. G. Furnish completed verification checklists, startup plans, and functional and performance test procedures to Engineer for acceptance with all fields completed and signed. Include all applicable field notes and supporting documentation. H. Submit written Training Plans to Engineer for acceptance prior to scheduling and conducting training, including the following: 1. Equipment number(s) and specification section number included in training session. 2. Intended audience. 3. Location of training. 4. Objectives. 5. Subjects covered. 6. Duration of training on each subject. 7. Instructor for each subject and instructor’s qualifications/resume. 8. Instructional methods to be used, including what portion of training will be completed in a classroom or in the field and what portion of training will be observation-only or hands- on. 9. Training materials (if separate from O&M manual). 1.6 CLOSEOUT SUBMITTALS A. Section 01 70 00 – Execution and Closeout Requirements contains requirements for closeout procedures. B. Engineer will review and accept submittals for conformance to Contract Documents as related to the commissioning process to aid in the development of functional and performance testing procedures and to verify compliance with equipment Specifications. C. Operation and Maintenance Data: Submit final operation and maintenance manuals as specified in individual equipment and system Specifications. In addition to items specified in Section 01 70 00 – Execution and Closeout Requirements, include the following in final manuals: 1. Completed Certificate of Proper Installation (COPI). 2. Completed Certificate of Completion of Field Services. 3. Field service reports. BCRUA - Phase 1D WTP Expansion Issued for Bid Facility Commissioning 01 91 00 - 6 4. Completed (as-tested) verification checklists, startup plans, and functional and performance testing procedures. 5. Detailed description of any corrections or deficiencies observed during commissioning and record of where deficiency or correction is documented. 6. Detailed description of any deviations in the accepted equipment or system from the requirements as per the Contract Documentations and where deviation acceptance is documented. 7. All data collected during commissioning. 8. Accepted training plan and training documentation. 9. Recommendations for improvement to equipment or operations, future actions, and commissioning process changes. 10. Brief description of verification method used as well as observations and conclusions from testing for each commissioned piece of equipment and system. D. Training Submittals: 1. Completed sign-in sheet (provided by Contractor) for all training sessions, including the date, time, location, equipment included, and a list of all attendees. 2. Training videos as required per Paragraph 3.5. 1.7 QUALITY ASSURANCE A. Perform Work according to specified standards and guidelines. B. Perform Work according to State of Texas regulations. C. Maintain one copy of each document on Site. 1.8 QUALIFICATIONS A. Commissioning Authority: Individual employed by Contractor specializing in performing Work of this Section. 1. Minimum of five years of documented experience performing commissioning and startup of similar municipal water and/or wastewater projects. 2. Experienced in operation and troubleshooting of conventional water treatment process systems (i.e., chemical feed, flocculation, sedimentation, filtration, sludge thickening and dewatering systems), HVAC, electrical, and instrumentation and control systems. 3. Knowledgeable in testing and balancing of HVAC systems. 4. Experienced in monitoring and analyzing system operation using control system trending or standalone data-logging equipment. 5. Excellent verbal and written communication skills, highly organized, and able to work with both management and installers. B. Instructor: Instructors providing training on specified equipment and/or systems. 1. Instructors must have knowledge of the theory of operation and practical experience with the equipment or system. 2. Instructors must be proficient and experienced in conducting training of the type required and must have successfully conducted similar training courses. 3. Submit each instructor’s résumé and specific details of instructor’s operating, maintenance, and training experience relative to the specific equipment for which instructor will provide training to demonstrate their qualifications. Provide services of replacement instructor with acceptable qualifications if Engineer does not accept qualifications of proposed instructor. BCRUA - Phase 1D WTP Expansion Issued for Bid Facility Commissioning 01 91 00 - 7 1.9 COMMISSIONING SERVICES A. Contractor shall employ and pay for services of a Commissioning Authority acceptable to Owner to perform specified commissioning. Commissioning Authority shall be employed and dedicated to the Project prior to the Initial Commissioning Meeting identified in Paragraph 1.11 below. Commissioning Authority shall be an independent member of the Contractor’s team and shall not assume another significant role on the Contractor’s team, such as Project Manager or Superintendent. Once approved, the Commissioning Authority shall not be removed or re- assigned to another project without written approval from the Owner. Commissioning Authority shall support the project as necessary for the Contractor to complete their responsibilities in line with the Project schedule. Commissioning Authority shall be on site while commissioning activities are being completed. 1.10 COMMISSIONING RESPONSIBILITIES A. Responsibilities indicated for Owner, Engineer, and Commissioning Authority are provided only to clarify commissioning process. B. Engineer Responsibilities: 1. Perform Site observation of each system immediately before system startup. 2. Furnish design narratives and sequence documentation requested by Commissioning Authority. 3. Clarify operation and control of commissioned equipment when Specifications, control drawings, or equipment documentation is not sufficient. 4. Coordinate resolution of design issues affecting system performance identified during commissioning. 5. Coordinate resolution of system deficiencies identified during commissioning, according to Contract Documents. 6. Prepare and submit final design intent documentation reflecting installed conditions for inclusion in operation and maintenance manuals. 7. Provide: a. Verification checklists and startup plans for pieces of equipment to be commissioned. b. Functional and performance test procedure forms for equipment. 8. Review all commissioning related submittals from Contractor for acceptance, including: a. Operation and maintenance manuals. b. Completed verification checklists for major pieces of equipment. c. System startup reports. d. Completed functional and performance test procedures and forms. e. All other startup documentation specified herein. 9. Witness tests for commissioning of equipment and systems. 10. Review equipment warranties to ensure Owner's responsibilities are defined. 11. Return to Site minimum of three months before expiration of overall Project warranty period. a. Review with Owner's personnel the current equipment and system operation and condition of outstanding issues related to original and seasonal commissioning. b. Interview Owner's personnel to identify problems or concerns regarding equipment and system operation. c. Make suggestions for improvements and for recording changes in operation and maintenance manuals. d. Identify deficiencies covered by warranty or original construction contract. BCRUA - Phase 1D WTP Expansion Issued for Bid Facility Commissioning 01 91 00 - 8 e. Assist Owner's personnel to develop reports, documents, and requests for services to remedy outstanding problems. 12. Recommend Owner acceptance of the commissioning Work when Engineer deems it to be complete. 13. Accept requests for deferred or seasonal testing activities that could not be completed during commissioning. Witness testing and review results submitted by the Contractor. Inspect and document deficiencies noted for resolution. C. Contractor Responsibilities: 1. Basic Contractor Responsibilities: a. Communicate requirements for commissioning submittal data, operation and maintenance data, commissioning tasks, and training to each supplier and subcontractor for equipment and systems indicated to be commissioned. b. Facilitate coordination of commissioning Work by Commissioning Authority. c. Attend commissioning meetings. d. Cooperate with Engineer and provide access to the Work and to manufacturers' facilities. e. Require manufacturers to review commissioning test procedures for equipment installed or provided by manufacturer. f. Furnish test equipment to complete equipment and system tests, including any proprietary or non-proprietary equipment. g. Furnish qualified personnel to assist in completing commissioning. h. Furnish manufacturers’ qualified field representatives as specified in individual Specification Sections to assist in completing commissioning. i. Ensure equipment and system installers execute commissioning responsibilities according to verification checklists, startup plans, and functional and performance test procedures provided by the Engineer, Contract Documents, and Progress Schedule. j. Prepare and submit operation and maintenance manuals in accordance with Section 01 70 00 - Execution and Closeout Requirements. Update original sequences of operation reflecting actual installation and commissioning. k. Ensure equipment and system installers execute any seasonal and/or deferred commissioning and testing prior to completion of the Project’s warranty period. l. Ensure equipment and system installers correct deficiencies and make necessary adjustments to operation and maintenance manuals and record documents for issues identified during testing. 2. Basic Commissioning Authority Responsibilities: a. Coordinate and direct commissioning Work. b. Coordinate execution of commissioning plans. c. Schedule commissioning Work with Engineer for inclusion in Progress Schedule and develop and update Commissioning Schedule as per Paragraph 1.14. d. Attend and actively participate in commissioning meetings. e. Provide commissioning submittals required to perform commissioning tasks. f. Complete verification tests, checklists, and startup plans. g. Execute functional and performance test procedures in cooperation with equipment and system installers. h. Attend selected Project progress meetings and all pre-installation meetings. Review corresponding meeting minutes. Resolve potential conflicts with commissioning activities. i. Inspect equipment and system installations for completeness prior to manufacturer’s installation inspections. BCRUA - Phase 1D WTP Expansion Issued for Bid Facility Commissioning 01 91 00 - 9 j. Document that equipment and systems are installed and perform according to design intent and Contract Documents. k. Notify Engineer of deficiencies. l. Coordinate Owner's personnel training and videography in accordance with Paragraph 3.5 – Demonstration and Testing. m. Coordinate and supervise all required testing and any re-testing required to confirm deficiency corrections are complete. n. Oversee and approve content and adequacy of Owner's personnel training. o. Review operation and maintenance manuals. p. Compile commissioning record and testing data for inclusion in final operation and maintenance manuals. 3. Detailed Commissioning Authority Responsibilities: a. Execute and document testing, cleaning, and flushing of each system. Include documentation in operation and maintenance manuals. b. Execute functional and performance testing of control systems and prepare them for operations. c. Create functional and performance trend logs and monitor data to verify equipment and system performance. d. Coordinate, witness, and assist as necessary to complete all functional and performance tests performed by equipment and system installers. 1) Coordinate retesting until satisfactory performance is achieved. 2) Perform actual functional and performance testing on equipment as specified in individual Specification Sections. e. Maintain deficiency and resolution log and separate testing record. Submit progress reports and test results with recommended and completed actions to Engineer. f. Review documentation from factory performance tests that Commissioning Authority does not oversee. Determine what additional testing and documentation is required to comply with Contract Documents and assist Contractor in developing a complete Factory Performance Test submittal. g. Prepare preventative maintenance plans, detailed operating plans, and record documents as specified. h. Assist the Contractor as necessary in the assembly, completion, and submission of asset management documentation. Each respective Owner will provide a template for the information they will require to be collected. 4. Commissioning Authority may not: a. Release, revoke, alter, or enlarge on requirements of Contract Documents. b. Approve or accept any portion of the Work. c. Assume duties of equipment and system installers or Engineer. d. Stop the Work. D. Owner Responsibilities: 1. Arrange for Owner's personnel to attend commissioning activities and training sessions according to commissioning plan. 2. Accept commissioning Work completion. 3. Provide operations personnel during Demonstration Period to assist in operation of the system and provide process decisions affecting plant performance. 1.11 COMMISSIONING MEETINGS A. Section 01 30 00 - Administrative Requirements contains requirements for progress meetings. BCRUA - Phase 1D WTP Expansion Issued for Bid Facility Commissioning 01 91 00 - 10 B. Engineer will arrange meetings, prepare agendas with copies for participants, and preside at meetings. C. Initial Commissioning Meeting: 1. Engineer will schedule meeting within 120 days after start of construction of the first process mechanical structure or system. 2. Attendance Required: Commissioning Authority, Owner, Engineer, Contractor, Subcontractors, SCADA Integrator, and HVAC testing, adjusting, and balancing firm. Require attendance by installers of the following equipment and systems indicated to be commissioned, including, but not limited to: a. HVAC equipment and systems. b. Electrical equipment and systems, including Variable-Frequency Motor Controllers. c. Chemical metering and diffusion systems. d. Vertical shaft flocculators. e. Chain and flight sludge collection equipment. f. Filter system (filter underdrain, filter media, and wash water troughs). g. Circular gravity thickener equipment. h. Belt filter press system, including shaftless screw conveyors. 3. Agenda: a. Designation of personnel representing parties for commissioning activities. b. Review commissioning process and responsibilities. c. Review commissioning plan development procedures. d. Review required commissioning submittals. e. Review Contractor’s initial commissioning schedule. D. Commissioning Progress Meetings: 1. Engineer will schedule meetings as required throughout progress of the Work. a. Beginning three months before commissioning and startup activities, meetings will be scheduled at maximum monthly intervals. b. During commissioning and startup activities, meetings will be scheduled at maximum bi-monthly intervals, or weekly as required. 2. Attendance Required: Engineer, Contractor, Commissioning Authority, and any subcontractors, vendors, suppliers, or manufacturers necessary to support the topics being discussed. 3. Agenda: a. Coordination of commissioning activities. b. Commissioning deficiency resolution. c. Review of the Contractor’s commissioning schedule as defined in Paragraph 1.14. d. Planning for future commissioning activities. E. Engineer will record meeting minutes and distribute copies within three days after meeting to participants and those affected by decisions made. 1.12 COMMISSIONING REPORTS A. Commissioning Authority Reports: Submit monthly reports to Engineer. Include the following. 1. Progress reports. 2. Scheduling changes. 3. Reports of specific commissioning activities. 4. Testing progress. 5. Deficiencies and deficiency resolution reports. BCRUA - Phase 1D WTP Expansion Issued for Bid Facility Commissioning 01 91 00 - 11 B. Completed “As-Tested” Verification Checklists and Startup Forms. C. Completed “As-Tested” Functional and Performance Test Procedures: 1. Completed Engineer-provided functional and performance test procedures, including all additional documentation called for in the procedures. 1.13 SEQUENCING A. Section 01 10 00 - Summary of Work contains requirements for sequencing. B. Sequence Work to complete commissioning, functional and performance testing, demonstration, and Owner's personnel training before Substantial Completion. Complete the following for each piece of equipment and system indicated to be commissioned to achieve functional completion: 1. Complete and sign startup and verification checklist documentation. 2. Complete functional and performance testing. 3. Complete training of Owner personnel. 4. Submit final operation and maintenance data manuals. 5. Submit final accepted test and balance report for HVAC systems. 6. Correct identified deficiencies or obtain acceptance by Owner to exclude deficiencies from functional completion. C. For equipment or systems requiring seasonal operation, perform commissioning for other season within six months of Substantial Completion. D. For equipment or systems where commissioning is delayed by Owner occupancy requirements or unforeseen conditions, perform commissioning as specified for seasonal operation equipment. 1.14 SCHEDULING A. Section 01 32 16 - Construction Progress Schedule contains requirements for scheduling. B. Schedule Work to allow adequate time for commissioning activities. C. Identify commissioning milestones, activities, and durations on a separate Commissioning Schedule. 1. Identify the following for each piece of equipment and system including: a. Operation and maintenance manual submittal (preliminary and final). b. Training plan submittal. c. Spare parts turnover. d. Asset management spreadsheet turnover. e. Supplier site visits related to commissioning, including inspecting equipment installation to issue Certificate of Proper Installation, overseeing functional and performance testing, providing training, and other site visits as required. f. Verification check and startup. g. Functional and performance test. h. Demonstration and training sessions. i. Commissioning completion. 2. Identify SCADA system testing as required per Section 40 90 02 – Supervisory Control and Data Acquisition (SCADA) System. 3. Identify the Demonstration Period as required per Section 01 70 00 – Execution and Closeout Requirements. BCRUA - Phase 1D WTP Expansion Issued for Bid Facility Commissioning 01 91 00 - 12 4. The initial schedule shall be presented at the first Commissioning Progress Meeting. The schedule shall be updated by the Contractor for each subsequent Commissioning Progress Meeting. 1.15 MAINTENANCE MATERIALS A. Section 01 70 00 - Execution and Closeout Requirements contains requirements for maintenance materials. B. Furnish one set of manufacturer's proprietary test equipment, tools, and instruments required to complete commissioning. 1. Deliver test equipment to Owner after completion of functional and performance test. Obtain signed receipt. PART 2 - PRODUCTS 2.1 TEST EQUIPMENT A. Testing Equipment: Calibrated within last year; of sufficient quality and accuracy to test and measure system performance within the following tolerances unless otherwise specified for individual equipment or systems. 1. Temperature Sensors and Digital Thermometers: 0.5 degrees F accuracy and plus or minus 0.1 degrees F resolution. 2. Pressure Sensors: Accuracy of plus or minus 2.0 percent of measured value range. 3. Flow Sensors: Accuracy of plus or minus 0.5 percent of measured value range B. Recalibrate test equipment according to manufacturer's recommended intervals and when dropped or damaged. 1. Affix calibration tags to test equipment or furnish calibration certificates upon request. C. Equipment Furnished by Contractor and Remaining Property of Contractor: 1. Standard testing equipment required to perform verification check and startup and required functional and performance testing. 2. Data-logging equipment and software. 3. Two-way radios for personnel performing commissioning. PART 3 - EXECUTION 3.1 EXAMINATION A. Verify equipment and systems are installed according to individual Specification Sections. B. Verify utility and power connections are complete and services operational. 3.2 IMPLEMENTATION OF VERIFICATION CHECKLISTS, STARTUP FORMS, AND FUNCTIONAL AND PERFORMANCE TESTING PROCEDURES A. Notify Engineer and Owner and schedule all commissioning and startup activities with each party required to participate a minimum of four weeks in advance. Confirm schedule with Engineer and Owner two weeks prior to activities being conducted. B. Allow Engineer and Owner to witness testing activities. BCRUA - Phase 1D WTP Expansion Issued for Bid Facility Commissioning 01 91 00 - 13 1. At their discretion, Engineer will witness procedures for equipment to be commissioned. For multiple units, Engineer will witness procedures on 50 percent, but not less than one of each type of unit. a. Equipment and systems include those identified in subsection 1.4.C. 2. Owner shall have the option to witness all testing. C. Verification Check, Startup, and Functional and Performance Test Procedures: 1. Perform verification check, startup, and functional and performance testing, and any other verification checks or tests required by equipment and component manufacturers. 2. Complete entire form or procedure for each piece of equipment or system indicated to be commissioned. 3. Complete each form or procedure in sequence performed by party assigned to each task. 4. Record completion of each task. Indicate results of task where required and record any anomalies or deviations observed in the field. Sign and date plan by individual performing task. 5. Identify items not completed successfully. 6. Sign and date plan indicating completion of entire checklist, plan, or procedure. 7. Submit executed plan to Engineer within two days of completion. D. Notify Engineer of completion of verification check and startup activities and submit verification check and startup reports for acceptance. E. Deficiencies and Acceptances: 1. Engineer will review completed reports and procedures and issue deficiency report or acceptance. 2. Correct deficiencies and resubmit updated form with statement indicating corrections made for Engineer acceptance. 3. Repeat process until all reports and procedures are accepted. 4. Costs for incomplete commissioning items that later cause deficiencies or delays may be charged to party responsible for incomplete item. F. Complete the following before performing functional and performance tests: 1. Verification check and startup. 2. Receive acceptance of completed Verification and Startup Reports from Engineer and Owner. G. Commissioning Authority will witness and document results of functional and performance tests. H. Conduct functional and performance tests as specified herein and in individual Specification Sections. I. Demonstrate that each piece of equipment and system is operating according to documented design intent and Contract Documents. 1. Conduct testing proceeding from components, to subsystems, to systems. 2. Bring equipment and systems to condition capable full dynamic operation. 3. Verify full functionality of control systems, including all modes of operation, alarms, and interlocks. 4. Verify performance of individual components and systems. 5. Verify function and performance of interactions between systems. 6. Identify and correct all areas of deficient performance. BCRUA - Phase 1D WTP Expansion Issued for Bid Facility Commissioning 01 91 00 - 14 J. Operate each piece of equipment and system through each specified mode of operation including seasonal, occupied, unoccupied, warmup, cool-down, partial load, full load, and other conditions specified in individual Specification Sections. 1. Verify each sequence in sequences of operation. 2. Test for proper responses to power failure, freezing, overheating, low oil pressure, no flow, equipment failure, etc., as identified in the control narratives and strategies, and other abnormal conditions. 3.3 FUNCTIONAL AND PERFORMANCE TEST METHODS A. Simulated Conditions: Simulating testing conditions may be conducted to check functionality but will not relieve the Contractor from proving overall functionality and performance under actual operating conditions before final acceptance of any equipment or system will be given. Engineer must accept all simulated testing conditions. B. Overwritten Values: Overwriting sensor values to simulate conditions may only be used if acceptable to the Engineer. C. Simulated Signals: When a transducer or transmitter does not include internal functionality to simulate an analog output, using a signal generator to create simulated signals to test and calibrate transducers automatic controls is generally recommended instead of using sensors as signal generators with simulated conditions or overwritten values. D. Altering Setpoints: Rather than overwriting sensor values, and when simulating conditions is difficult, altering setpoints to test a specific sequence is acceptable. Reset setpoint after completing test. E. Indirect Indicators: Using indirect indicators for responses or performance is permitted only after visually and directly verifying and documenting indirect readings through control system representing actual conditions and responses over tested parameter range. F. Perform each function and test under conditions simulating actual conditions as close as is practically possible. 1. Provide materials, temporary system modifications, and other items or steps necessary to produce flows, pressures, temperatures, and other responses to execute test according to specified conditions. 2. At completion of test, return modified equipment and systems to pretest condition. 3.4 DEFICIENCIES AND TEST ACCEPTANCES A. Deficiencies: 1. Contractor shall record and report deficiencies to the Owner and Engineer. 2. Minor deficiencies may be corrected during tests at the Engineer's discretion. Deficiency and resolution will be documented on procedure form. 3. Failure of the Commissioning Authority to attend a scheduled commissioning activity will be considered a deficiency. 4. When a deficiency is identified, Engineer will discuss issue with Commissioning Authority. a. When party executing test accepts responsibility to correct deficiency: 1) Commissioning Authority documents deficiency and submits deficiency report to responsible party believed to be responsible for deficiency. 2) Commissioning Authority receives and documents responsible party's response. BCRUA - Phase 1D WTP Expansion Issued for Bid Facility Commissioning 01 91 00 - 15 3) Responsible party corrects deficiency, signs statement of correction on deficiency form certifying equipment is ready for retesting and submits form to Commissioning Authority. 4) Commissioning Authority submits completed deficiency form to Engineer. 5) Commissioning Authority reschedules test, and test is repeated until satisfactory performance is achieved. b. When responsible party disputes deficiency or responsibility for deficiency: 1) Commissioning Authority documents response from the alleged responsible party. 2) Commissioning Authority submits deficiency report with the alleged responsible party’s response to Engineer, party executing test, and party believed to be responsible for deficiency. 3) Contractor and Commissioning Authority negotiate resolution with all parties involved to provide equipment, components, and systems in accordance with the Contract Documents. 4) Commissioning Authority documents resolution process. 5) When resolution is decided, appropriate party corrects deficiency, signs statement of correction on deficiency form certifying equipment is ready for retesting and submits form to Commissioning Authority. 6) Commissioning Authority submits completed deficiency form to Engineer. 7) Commissioning Authority reschedules test, and test is repeated until satisfactory performance is achieved. B. Retesting Costs: 1. When deficiency is discovered requiring rescheduling or retesting: a. Owner may deduct cost incurred from witnessing retesting efforts from final payment due to Contractor. C. Provide written report to Engineer before each scheduled commissioning meeting concerning status of each deficiency. Include explanations of disagreements with resolution proposals for each discrepancy. 1. Engineer will retain original deficiency forms until end of Project. D. Manufacturing Defects: Unless required otherwise in individual Specification Sections, when ten percent but not less than three identical pieces of equipment or equipment with only small size or capacity differences fail to perform to Contract Document requirements due to manufacturing defects, all identical units may be considered defective by Owner. 1. Within one week of notice from Owner, examine all other identical units and record findings. Submit findings to Owner within two weeks of original notice. 2. Within two weeks of original notification, provide signed and dated written explanation of problem, cause of defect, and proposed solutions meeting Contract Document requirements. Include equipment submittals supporting solution. 3. Owner will determine whether replacement or repair of all identical units is required. 4. Install two examples of proposed solution. Owner will test installations for up to one week before deciding if solution is acceptable. 5. Upon acceptance, replace or repair all identical items at Contractor's expense. Extend warranty accordingly if original equipment warranty had begun. 6. Complete repairs or replacements with reasonable speed beginning within one week from when parts can be obtained. E. Test Acceptance: Commissioning Authority notes each satisfactorily demonstrated function on functional and performance test forms. BCRUA - Phase 1D WTP Expansion Issued for Bid Facility Commissioning 01 91 00 - 16 1. Commissioning Authority submits completed standard forms to Engineer. 2. Engineer recommends acceptance of each test to Owner. 3. Owner gives final acceptance for each test, as required. 3.5 DEMONSTRATION AND TRAINING A. Section 01 70 00 - Execution and Closeout Requirements contains requirements for demonstration and training. B. Demonstrate equipment and systems and train Owner's personnel as specified in individual equipment and system Specifications. 1. Engineer will interview Owner's personnel to determine special needs and areas where training will be most valuable. 2. Owner and Engineer will determine type and extent of training for each commissioned piece of equipment and system. a. Training duration is specified in individual Specification Sections. 3. Commissioning Authority will communicate and coordinate training requirements to equipment and system installers and manufacturers with training responsibilities. 4. Training shall include both classroom and field instruction. C. Owner’s personnel will complete a post-training evaluation form to assess the value of the training provided by the Contractor. Post-training evaluation forms will be collected directly by the Engineer or Owner following the completion of a training session. 1. Engineer will make recommendation to Owner regarding acceptance of training based on the feedback received from the post-training evaluation forms. 2. Should training be deemed unacceptable by the Engineer’s review of the evaluation forms, Contractor shall be required to repeat the respective training at no additional cost to the Owner. An updated Training Plan shall be submitted and accepted prior to scheduling the repeat training sessions detailing what changes to the training session will be made to ensure the new training will be satisfactory. D. Scheduling Requirements for Training: 1. A minimum of four (4) weeks’ notice is required to schedule any training session. Training sessions may only be scheduled once the preliminary operation and maintenance data manual and Training Plan have been accepted for the respective system. Confirm dates with Owner two (2) weeks prior to training being conducted. 2. Training shall be scheduled to occur concurrently with the implementation of the Functional and Performance Test Procedures, such that the equipment has been authorized for full use and may be operated during the training. 3. Individual training sessions shall not exceed four (4) hours in duration. Should more than four (4) hours of training be required, training shall be split into multiple sessions. 4. A minimum of two (2) redundant training sessions will be required for some sessions to accommodate the Owner’s shift schedules. Overlapping training sessions are not acceptable. 5. Redundant training sessions will be required for the following equipment: a. 26 29 23 - Low Voltage Variable Frequency Drives and 46 41 34 - Vertical Shaft Flocculators – two (2) training sessions total. b. 40 90 02 - Supervisory Control and Data Acquisition (SCADA) System – two (2) redundant training sessions total. c. 46 76 21 - Belt Filter Press and 41 12 13 - Shaftless Screw Conveyors – two (2) training sessions total. BCRUA - Phase 1D WTP Expansion Issued for Bid Facility Commissioning 01 91 00 - 17 d. 46 33 44 - Peristaltic Metering Pumps and 46 33 73 - Liquid Chemical Diffusers – two (2) training sessions total. e. 46 43 11 - Chain and Flight Sludge Collection Equipment – two (2) training sessions total. f. 46 61 01 - Filter underdrain System – two (2) training sessions total. g. 46 71 13 - Circular Gravity Thickener Equipment – two (2) training sessions total. 6. Site-Specific Training Requirements: a. Redundant training sessions shall be scheduled on alternating weeks to accommodate shift schedules. b. Training shall be scheduled and completed between 8 am and 5 pm on business days. E. For primary equipment training: 1. Require SCADA Integrator to provide short discussion of equipment control as part of training session. F. Contractor shall provide professional videography services, including post-production editing, recording of both classroom and field portions of training, and documenting Q&A sessions, for each training session. 1. Where redundant sessions are provided for a single piece of equipment, only one session needs to be recorded. 2. Post-production editing shall include removal of all non-essential audio and video and shall separate classroom and field portions of the training into individual chapters. Provide a sample video for acceptance prior to producing and submitting project training videos. 3. Should a recording be unacceptable to the Owner due to poor sound quality, image quality, etc., training shall be repeated and re-recorded until a suitable recording is provided at no additional expense to the Owner. 4. Final delivery method of the recordings (on DVD or submitted electronically, preferred file type, etc.) shall be as requested by Owner. END OF SECTION SPECIFICATIONS – TECHNICAL SECTIONS 03 11 00 – 46 76 21 PHASE 1D - WATER TREATMENT PLANT EXPANSION BCRUA – Phase 1D WTP Expansion Issued for Bid Concrete Forming 03 11 00 - 1 SECTION 03 11 00 - CONCRETE FORMING PART 1 GENERAL 1.1 WORK INCLUDED A. Furnish material and labor to form, tie, brace and support wet concrete, reinforcing steel and embedded items until the concrete has developed sufficient strength to remove forms. 1.2 QUALITY ASSURANCE A. Design Criteria: Forms shall be designed for the pressure exerted by a liquid weighing 150 pounds per cubic foot. The rate of placing the concrete, the temperature of the concrete, and all other pertinent factors shall be taken into consideration when determining the depth of the equivalent liquid. An additional design live load of 50 pounds per square foot shall be used on horizontal surfaces. B. Alignment Control: 1. True alignment of walls and other vertical surfaces having straight lines or rectangular shapes shall be controlled and checked by the following procedures: a. Forming shall be arranged with provisions for adjusting the horizontal alignment of a form, after the form has been filled with concrete to grade, using wedges, turn buckles, or other adjustment methods. Establish a transit line or other reference so that adjustments can be made to an established line while the concrete in the top of the form is still plastic. b. Adjusting facilities shall be at intervals which permit adjustments to a straight line. Concrete shall not be placed until adequate adjusting facilities are in place. C. Tolerances: Construct formwork so concrete members and structures are of size, shape, alignment, elevation, and position indicated, within tolerance limits of ACI 117. 1.3 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Document Management” and shall include: 1. Record Data. a. Manufacturers’ literature for specified products. 1.4 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: 1. American Concrete Institute (ACI) Specifications: ACI 117 Specifications for Tolerances for Concrete Construction and Materials ACI 301 Specifications for Structural Concrete ACI 318 Building Code Requirements for Structural Concrete 2. American Institute of Steel Construction (AISC) Publication: a. AISC Manual of Steel Construction. 3. American Iron and Steel Institute (AISI) Publication: BCRUA – Phase 1D WTP Expansion Issued for Bid Concrete Forming 03 11 00 - 2 a. AISI Cold Formed Steel Design Manual. 4. American Plywood Association (APA) Standards: a. APA Design/Construction Guide: Concrete Forming. 1.5 DELIVERY AND STORAGE A. Lumber for forms shall be stacked neatly on platforms raised above ground. 1.6 JOB CONDITIONS A. The Contractor shall notify the Engineer upon completion of various portions of the work required for placing concrete so that compliance with the plans and specifications may be monitored. The Engineer will authorize the Contractor to proceed with the placement after this has been completed and corrections, if required, have been made. B. In hot weather, both sides of the face forms may be required to be treated with oil to prevent warping and to secure tight joints. PART 2 PRODUCTS 2.1 MATERIALS A. Lumber: Properly seasoned and of good quality; free from loose or unsound knots, knot holes, twists, shakes, decay, splits, and other imperfections which would affect its strength or impair the finished surface of the concrete. 1. Refer to Section 03 30 00 “Cast-In-Place Concrete” for finish requirements. B. Form Oil: Light, clear oil; shall not discolor or injuriously affect the concrete surface, subsequent coatings, or delay or impair curing operations. 2.2 FABRICATIONS A. Lumber: Lumber for facing or sheathing shall be surfaced on at least one side and two edges, and sized to uniform thickness. Lumber of nominal 1-inch thickness or plywood of 3/4-inch thickness shall be permitted for general use on structures, if backed by a sufficient number of studs and wales. B. Special Form Lumber: 1. Molding for chamfer strips or other uses shall be made of redwood, cypress, or pine materials of a grade that will not split when nailed, and which can be maintained to a true line without warping. The form shall be mill cut and dressed on all faces. Fillet forms at sharp corners, both inside and outside and at edges, with triangular chamfer strips at all non-contiguous edges exposed to view. Thoroughly oil chamfer strips before installation on forms. C. Forms: 1. Forms shall be built mortar tight and of material sufficient in strength to prevent bulging between supports. 2. Reused forms or form lumber shall be maintained clean and in good condition as to accuracy, shape, strength, rigidity, tightness, and smoothness of surface. BCRUA – Phase 1D WTP Expansion Issued for Bid Concrete Forming 03 11 00 - 3 3. All forms shall be so constructed as to permit removal without damage to the concrete. Exercise special care in framing forms for copings, offsets, railing and ornamental work, so that there will be no damage to the concrete when the forms are removed. D. Forms for Cylindrical Columns, Pedestals, and Supports: Metal, glass-fiber-reinforced plastic, paper, or fiber tubes that will produce surfaces with gradual or abrupt irregularities not exceeding specified formwork surface class. Provide units with sufficient wall thickness to resist plastic concrete loads without detrimental deformation. E. Metal Forms: 1. The specifications for “Forms” regarding design, mortar tightness, filleted corners, beveled projections, bracing, alignment, removal, re use, oiling, and wetting shall apply equally to metal forms. 2. The metal used for forms shall be of such thickness that the forms will remain true to shape. Bolt and rivet heads on the facing sides shall be countersunk. Clamps, pins, or other connecting devices shall be designed to hold the forms rigidly together and to allow removal without injury to the concrete. 3. Metal forms which do not present a smooth surface or line up properly shall not be used. Exercise special care to keep metal free from rust, grease, or other foreign material that discolors the concrete. F. Form Ties: 1. Metal form ties shall be used to hold forms in place and to provide easy metal removal. The use of wire for ties shall not be permitted. 2. Leave no metal or other material within 1-1/2 inches of the surface, when removing form tie assemblies which are used inside the forms to hold the forms in correct alignment. The assembly shall provide cone-shaped depressions in the concrete surface at least 1 inch in diameter and 1-1/2 inches deep to allow filling and patching. Such devices, when removed, shall leave a smooth depression in the concrete surface without undue injury to the surface from chipping or spalling. 3. Burning off rods, bolts, or ties shall not be permitted. 4. Metal ties shall be held in place by devices attached to wales. Each device shall be capable of developing the strength of the tie. 5. Metal and wooden spreaders which are separate from the forms shall be wired to top of form and shall be entirely removed as the concrete is placed. 6. In the construction of basement or water bearing walls, the portion of a single rod tie that is to remain in the concrete shall be provided with a tightly fitted washer at midpoint to control seepage. Multi-rod ties do not require washers. The use of form ties which are tapered or encased in paper or other material to allow the removal of complete tie, and which leave a hole through the concrete structure, shall not be permitted. G. Falsework: 1. Falsework shall be designed and constructed so that no excessive settlement or deformation occurs. Falsework shall provide necessary rigidity. 2. Timber used in falsework centering shall be sound, in good condition and free from defects which impair its strength. 3. Steel members shall be of adequate strength and shape for the intended purpose. 4. Timber piling used in falsework may be of any wood species which satisfactorily withstands driving and which adequately supports the superimposed load. 5. When sills or timber grillages are used to support falsework columns, unless founded on solid rock, shale or other hard materials, place them in excavated pits. Backfill to prevent BCRUA – Phase 1D WTP Expansion Issued for Bid Concrete Forming 03 11 00 - 4 the softening of the supporting material from form drip or from rains that may occur during the construction process. Sills or grillages shall be of ample size to support the superimposed load without settlement. 6. Falsework not founded on a satisfactory spread footing shall be supported on piling, which shall be driven to a bearing capacity to support the superimposed load without settlement. PART 3 EXECUTION 3.1 PREPARATION A. Before placing concrete, ensure that embedded items are correctly, firmly and securely fastened into place. Embedded items shall be thoroughly clean and free of oil and other foreign material. Anchor bolts shall be set to the correct location, alignment and elevation by the use of suitable anchor bolt templates. 3.2 INSTALLATION A. Pre-Placement: 1. During the elapsed time between building the forms and placing the concrete, maintain the forms to eliminate warping and shrinking. 2. Limit concrete surface irregularities, designated by ACI 347R as abrupt or gradual, as follows: a. For concrete surfaces exposed to view: Class A, 1/8 inch. b. For concrete surfaces to receive a rubbed finish: Class A, 1/8 inch. c. For concrete surfaces to receive plaster, stucco or wainscoting: Class B, 1/4 inch. d. For concrete surfaces not exposed to view: Class D, 1 inch. 3. Construct forms tight enough to prevent loss of concrete mortar. 4. Fabricate forms for easy removal without hammering or prying against concrete surfaces. Provide crush or wrecking plates where stripping may damage cast concrete surfaces. Provide top forms for inclined surfaces steeper than 1.5 horizontal to 1 vertical. Kerf wood inserts for forming keyways, reglets, recesses, and the like, for easy removal. 5. Do not use rust-stained steel form-facing material. 6. Set edge forms, bulkheads, and intermediate screed strips for slabs to achieve required elevations and slopes in finished concrete surfaces. Provide and secure units to support screed strips; use strike-off templates or compacting-type screeds. 7. Treat the facing of forms with suitable form oil before concrete is placed. Apply oil before the reinforcement is placed. Wet form surfaces which will come in contact with the concrete immediately before the concrete is placed. 8. At the time of placing concrete, the forms shall be clean and entirely free from all chips, dirt, sawdust, and other extraneous matter at the time. Forms for slab, beam and girder construction shall not have tie wire cuttings, nails or any other matter which would mar the appearance of the finished construction. Clean forms and keep them free of foreign matter during concrete placement. B. Where aluminum anchors, aluminum shapes, or aluminum electrical conduits are embedded in concrete, paint aluminum contact surfaces with zinc rich primer. Allow the paint to thoroughly dry before placing the aluminum in contact with the concrete. C. Placement: BCRUA – Phase 1D WTP Expansion Issued for Bid Concrete Forming 03 11 00 - 5 1. Set and maintain forms to the lines designated, until the concrete is sufficiently hardened to permit form removal. If, at any stage of the work, the forms show signs of bulging or sagging, immediately remove that portion of the concrete causing this condition. If necessary, reset the forms and securely brace against further movement. 2. Provide adequate cleanout openings where access to the bottom of the forms is not otherwise readily attainable. 3. Chamfer exterior corners and edges of permanently exposed concrete. 4. Form openings, chases, offsets, sinkages, keyways, reglets, blocking, screeds, and bulkheads required in the Work. Determine sizes and locations from trades providing such items. 5. Coat contact surfaces of forms with form-release agent, according to manufacturer’s written instructions, before placing reinforcement.Carefully and accurately place and support reinforcement in concrete structures. D. Removal: Remove forms so that the underlying concrete surface is not marred or damaged in any way. Forms shall not be removed until the concrete has attained sufficient strength to safely carry the dead load, but in no case less than the number of curing days set forth in the following table: Forms Curing Days Forms for concrete of minor structural load carrying importance 1 day Forms for walls, columns, sides of drilled shafts, massive structural components and other members not resisting a bending moment during curing 1 day Forms and falsework under slabs, beams and girders where deflections due to dead load moment may exist (for spans < or = 10 feet) 7 days Forms and falsework under slabs, beams and girders where deflections due to dead load moment may exist (for spans > 10 feet and < or = 20 feet) 14 days Forms and falsework under slabs, beams and girders where deflections due to dead load moment may exist (for spans > 20 feet) 21 days E. Reuse: 1. Clean and repair surfaces of forms to be reused in the Work. Split, frayed, delaminated, or otherwise damaged form-facing material will not be acceptable for exposed surfaces. Apply new form-release agent. 2. When forms are reused, clean surfaces, remove fins and laitance, and tighten to close joints. Align and secure joints to avoid offsets. Do not use patched forms for exposed concrete surfaces unless approved by Owner’s Representative. END OF SECTION BCRUA – Phase 1D WTP Expansion Issued for Bid Reinforcing Steel 03 21 00 - 1 SECTION 03 21 00 - REINFORCING STEEL PART 1 GENERAL 1.1 WORK INCLUDED A. Furnish labor and reinforcing materials required to cut, bend, tie, splice, place and support the reinforcement in the material grades, sizes, quantities, and locations specified. 1.2 QUALITY ASSURANCE A. Tolerances: 1. Reinforcing shall be placed where specified, with the following maximum tolerances, plus or minus: a. Concrete Cover: 1/4 inch. b. Reinforcing Bar Spacing: 1/4 inch in 12 inches. 1.3 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Document Management” and shall include: 1. Shop Drawings: a. Reinforcing bar layout drawing with bar lists clearly marked and referenced to the Drawings. Include: 1) Material, grade, bar schedules, stirrup spacing, bent bar diagrams, arrangement, and supports of concrete reinforcing. 2) Additional reinforcing required for openings through concrete structures. 2. Record Data: Manufacturers’ literature for specified products. 3. Certified Test Reports: a. Certification of steel quality, size, grade, and manufacturer’s origin. 1.4 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: 1. ASTM International (ASTM) Standards: ASTM A1064 Standard Specification for Carbon-Steel Wire and Welded Wire Reinforcement, Plain and Deformed, for Concrete ASTM A615 Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement 2. American Concrete Institute (ACI) Publications: ACI 301 Specification for Structural Concrete ACI SP-66 ACI Detailing Manual ACI 318 Building Code Requirements for Structural Concrete 3. Concrete Reinforcing Steel Institute (CRSI) Publications: CRSI Manual of Standard Practice BCRUA – Phase 1D WTP Expansion Issued for Bid Reinforcing Steel 03 21 00 - 2 1.5 DELIVERY AND STORAGE A. Store reinforcement above the surface of the ground upon platform skids or other supports. Protect from mechanical and chemical injury and surface deterioration caused by exposure to conditions producing rust. When placed in the Work, reinforcement shall be free from dirt, scale, dust, paint, oil and other foreign material. Tag and store reinforcement for ease of correlation with Shop Drawings. 1.6 JOB CONDITIONS A. Proposed deviations from reinforcing indicated on the Drawings or Specifications shall be approved in writing by the Engineer prior to fabrication. B. Lap lengths shall be of the length shown on the Drawings or noted in lap and embedment table and shall be in compliance with ACI 318. C. Specified cover for reinforcing shall be maintained throughout construction. Bars shall be cut to lengths necessary to allow for proper clearances. Cover of concrete shall be measured from face of forms to outside face of reinforcement. D. Stirrups shall be hooked. PART 2 PRODUCTS 2.1 MATERIALS A. Steel Reinforcing Bars: Billet-Steel bars for concrete reinforcement conforming to ASTM A615; Grade 60, deformed, with minimum yield strength of 60,000 psi. Steel reinforcing bars shall be produced in the United States of America. B. Welded Wire Reinforcement: Cold-drawn steel wire conforming to ASTM A1064; flat sheets fabricated in accordance with ASTM A1064. C. Joint Dowel Bars: Plain-steel bars, ASTM A615/A615M, Grade 60. Cut bars true to length with ends square and free of burrs. D. Epoxy-Coated Joint Dowel Bars: ASTM A775/A775M; with ASTM A615/A615M, Grade 60, plain-steel bars. E. Supports (Chairs): Bar supports shall be of the proper type for the intended use. 1. Exposed Surface: CRSI Class 1 – Maximum Protection – uniform high-density polyethylene (plastic) or fiberglass reinforced plastic (FRP). Plastic protected wire bar supports are not allowed. 2. Unexposed Surface: CRSI Class 3 – No Protection. F. Spacers: Precast mortar blocks with a 28-day compressive strength that is greater than the specified concrete strength in which the blocks are being placed. Additionally: 1. Cure a minimum of 4 days. BCRUA – Phase 1D WTP Expansion Issued for Bid Reinforcing Steel 03 21 00 - 3 2. Blocks shall be in the form of a frustum positioned such that its size increases away from the formed surface. The surface placed adjacent to the forms shall not exceed 2-1/2 x 2- 1/2 inches or 3 inches in diameter. 3. Blocks shall be accurately cast to the thickness required and the surface to be placed adjacent to the forms shall be a true plane free of surface imperfections. 4. Wires ties for securing reinforcement shall be embedded in the block. G. Mechanical Splices: 1. Mechanical splices shall develop at least 125 percent of the reinforcement yield strength. 2. Threaded coupler shall utilize a metal coupling sleeve with internal threads. H. Zinc Repair Material: ASTM A780, zinc-based solder, paint containing zinc dust, or sprayed zinc. PART 3 EXECUTION 3.1 FABRICATION A. Reinforcing bars shall be bent cold by machine to shapes indicated on the Drawings; true to shapes indicated; irregularities in bending shall be cause for rejection. Unless otherwise noted, all hook and bend details and tolerances shall conform to the requirements of ACI SP- 66 and ACI 318. 1. Fabricate reinforcement to provide lapped connections, bends and transitions in reinforcement as required for continuity of the typical reinforcement specified on the Drawings. 2. Unless otherwise detailed, intersecting wall and/or beam reinforcement shall extend to the far face and terminate in a standard hook. Reinforcement at the outside face of corners shall be continuous or provide lap splices at each side of the corner. 3.2 PREPARATION A. Clean reinforcement of loose rust and mill scale, earth, ice, and other foreign materials. B. Accurately position, support, and secure reinforcement against displacement. Locate and support reinforcement with bar supports to maintain minimum concrete cover. Do not tack weld crossing reinforcement. 3.3 INSTALLATION A. General: Place the reinforcement carefully and accurately in the concrete structures. Rigidly tie and support the reinforcement. Welding of any type of reinforcement shall not be permitted. B. Splices: 1. Splice reinforcement only as indicated on the Drawings or as approved by the Engineer prior to fabrication. Splices shall preferably occur at points of minimum stress. 2. Lap Splice: Lengths shall be as indicated on the Drawings. Rigidly wire the bars at all splices. Overlap sheets of wire fabric sufficiently to maintain a uniform strength and securely fasten. BCRUA – Phase 1D WTP Expansion Issued for Bid Reinforcing Steel 03 21 00 - 4 3. Mechanical Splice: Threaded coupler, installed in accordance with the manufacturer’s instructions and recommendations. The splice device shall develop at least 125 percent of the specified yield strength of the reinforcement. C. Placement: 1. Place reinforcement, as indicated on the Drawings with the specified tolerances. Hold securely in place during the placing of the concrete. The minimum clear distance between bars shall be per ACI 318 unless noted otherwise. Always pass vertical stirrups around the main tension members and securely attach thereto. Wire reinforcing together at a sufficient number of intersections to produce a sound, sturdy mat or cage of reinforcement that will maintain the reinforcement in correct positions when the concrete is placed. 2. Hold the reinforcing steel in concrete slabs firmly in place with wire supports or “chairs.” Sizing and spacing of the chairs shall be sufficient to properly support the steel, and shall be in accordance with CRSI Publications “Manual of Standard Practice in.” 3. Space the reinforcing steel in concrete walls the proper distance from the face of the forms, as indicated on the Drawings: a. For wall surfaces exposed to view, use chairs. b. For wall surfaces not exposed to view, use chairs or precast mortar blocks. 4. Where reinforcing conflicts with location of anchor bolts, inserts, etc., submit prompt notifications so that revisions can be made before concrete is placed. No cutting of reinforcing shall be permitted without the prior approval of the Engineer. 5. Welded wire shall be fabricated flat sheets, in longest practical lengths. Lap joints one mesh. Do not locate end laps over beams of continuous structures or midway between supporting beams. Offset end laps of adjacent widths to prevent continuous lap. Fasten ends and sides of welded wire fabric at 48 inches O.C. with tie wire. 6. Reinforcing shall extend through construction joints. 7. Do not cut or puncture vapor retarder. Repair damage and reseal vapor retarder before placing concrete. 3.4 FIELD QUALITY CONTROL A. Concrete shall not be placed until the Engineer has observed the final placing of the reinforcing steel and has given permission to place concrete. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 1 SECTION 03 30 00 CAST-IN-PLACE CONCRETE PART 1 GENERAL 1.1 SUMMARY A. Furnish labor, materials, mixing and transporting equipment and incidentals necessary to proportion, mix, transport, place, consolidate, finish, and cure concrete in the structure. 1.2 DEFINITIONS A. Cementitious Materials: Portland cement alone or in combination with one or more of the following: blended hydraulic cement, fly ash and silica fume; subject to compliance with requirements. 1.3 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Shop Drawings: a. Mix Design: For each mix design, provide documentation using field test data or trial mixture data in accordance with ACI 301, which includes average strength documentation using either field strength test data or trial mixtures. b. Submit a schedule to the Owner’s representative which shows the sequence of concrete placements. c. Submit watertightness testing procedures and test result reports. 1) Testing procedures shall be written and shall include drawings to describe locations and configurations of testing apparatuses. 2) Test result reports shall be written and shall include drawings as required for clarity. Refer to ACI 350.1 for test report requirements. 3) Repair procedures if required due to failed test or retest. 2. Certified Test Reports: a. Materials used in the mix design, and which will be used during production of concrete for the Project. b. Water: Verification that all potable mix water and curing water sources do not exceed the non-potable water limits listed in ASTM C1602 Table 2. c. Aggregate, conforming to ASTM C33, including the test reports for soundness and abrasion resistance. d. Aggregate: 1) Verification that aggregate is not “potentially reactive” per ASTM C1260. 2) Or a cement chemical analysis indicating that the total alkali content is acceptable per Paragraph 2.02.A. 3) When mix water exceeds 50 percent of the chloride limit indicated in ASTM C1602 Table 2, then test all aggregate sources for chlorides in accordance with ASTM C1524. e. 7-day and 28-day compressive strength tests results. f. If the sum total of chlorides in mix water and aggregates exceeds 80 percent of the specified limit for hardened concrete, then prior to use of concrete, test mix design to verify acceptable chloride ion concentrations in accordance with ASTM C1218. BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 2 g. Shrinkage Test Results: Submit for each concrete mix to be used on a structure for which a specified shrinkage limit is given. 3. Record Data: a. Manufacturer’s literature on specified materials. b. Documentation indicating conformance with ASTM C94 requirements. 1) Concrete delivery tickets in accordance ASTM C94. c. Documentation of supplier's National Ready Mixed Concrete Association certification. 1.4 QUALITY ASSURANCE A. Installer Qualifications: An experienced installer who has completed concrete work similar in material, design, and extent to that indicated for this Project and whose work has resulted in construction with a record of successful in-service performance. B. Manufacturer Qualifications: 1. A firm experienced in manufacturing ready-mixed concrete products complying with ASTM C94 requirements for production facilities and equipment. 2. Manufacturer must be certified according to the National Ready Mixed Concrete Association’s Certification of Ready Mixed Concrete Production Facilities. C. Testing Agency Qualifications: 1. An independent testing agency, acceptable to authorities having jurisdiction and the Engineer, qualified according to ASTM C1077 and ASTM E329 to conduct the testing indicated. 2. Personnel conducting field tests shall be qualified as ACI Concrete Field Testing Technician, Grade 1, according to ACI CP-1 or an equivalent certification program. D. Source Limitations: Obtain each type or class of cementitious material of the same brand from the same manufacturer’s plant, each aggregate from one source, and each admixture from the same manufacturer. E. Watertightness Testing: Confirm watertightness of all liquid containing structures in accordance with the latest edition of ACI 350.1 for hydrostatic tightness test for open containment structures, except as modified by this specification. 1. Evaporation allowance shall be determined using a standard circular pan procedure established by the US Weather Bureau to measure evaporation rate. 2. Calculate evaporation allowance by multiplying the evaporation rate in gallons per 24- hours per square foot of surface area by the open surface area of the water in the structure. 3. Part 2 Quantitative Criteria: 0.050% of volume per day. 4. Water Supply: Provide plant water for initial test and as required for any retest. a. Coordinate delivery of water with Owner. 5. Test Fill Height: When testing for watertightness, fill structure with water to max the maximum water surface hydraulic grade line indicated on the Drawings. 6. No specified interior or exterior coatings shall be applied to the structure prior to testing. Concrete surface coatings may only be applied after successful completion of all testing requirements, approval of testing results, and acceptable substrate conditions. 7. No backfill shall be placed around the structure prior to testing. All exterior surfaces shall be exposed and accessible for observation and completion of testing requirements. Backfill may only be placed after successful completion of all testing requirements and approval of the testing results. BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 3 1.5 DELIVERY, STORAGE, AND HANDLING A. Deliver cement in bulk or bags which are plainly marked with the brand and manufacturer’s name. Immediately upon receipt, store cement in a dry, weather-tight, and properly ventilated structure which excludes moisture. Storage facilities shall permit easy access for inspection and identification. Cement not stored in accordance with the requirements shall not be used. B. Sufficient cement shall be in storage to complete placement of concrete started. In order that cement may not become unduly aged after delivery, maintain records of delivery dates. Use cement which has been stored at the Site for 60 days or more before using cement of lesser age. No cement shall be used which is lumped, caked, stored more than 90 days, or whose temperature exceeds 170 F. 1.6 STANDARDS A. Mixing, sampling, placing, curing, testing of concrete, and the materials used, shall be in compliance with the latest revisions of the following standards, unless otherwise noted in the Contract Documents. The Contractor shall maintain one copy of each of the applicable standards at the construction field office. 1. ASTM International (ASTM) Standards: ASTM Standards ASTM C31 Standard Practice for of Making and Curing Concrete Test Specimens in the Field ASTM C33 Standard Specification for Concrete Aggregates ASTM C39 Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens ASTM C42 Standard Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete ASTM C94 Standard Specification of Ready Mixed Concrete ASTM C109 Standard Test Method for Compressive Strength of Hydraulic Cement Mortars ASTM C125 Standard Terminology Relating to Concrete and Concrete Aggregates ASTM C138 Standard Test Method for Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete ASTM C143 Standard Test Method for Slump of Hydraulic Cement Concrete ASTM C150 Standard Specification for Portland Cement ASTM C171 Standard Specification for Sheet Materials for Curing Concrete ASTM C172 Standard Practice for Sampling Freshly Mixed Concrete ASTM C173 Standard Test Method for Air Content of Freshly Mixed Concrete by the Volumetric Method ASTM C191 Standard Test Method for Time of Setting of Hydraulic Cement by Vicat Needle ASTM C192 Standard Practice for Making and Curing Concrete Test Specimens in the Laboratory ASTM C231 Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method ASTM C260 Standard Specification for Air-Entraining Admixtures for Concrete BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 4 ASTM Standards ASTM C290 Standard Specification for Elastomeric Joint Sealants ASTM C309 Standard Specification for Liquid Membrane Forming Compounds for Curing Concrete ASTM C494 Standard Specification for Chemical Admixtures for Concrete ASTM C579 Standard Test Methods for Compressive Strength of Chemical Resistant Mortars, Grouts, Monolithic Surfacings, and Polymer Concretes ASTM C580 Standard Test Method for Flexural Strength and Modulus of Elasticity of Chemical Resistant Mortars, Grouts, Monolithic Surfacings, and Polymer Concretes ASTM C595 Standard Specification for Blended Hydraulic Cements ASTM C618 Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete ASTM C827 Standard Test Method for Change in Height at Early Stages of Cylindrical Specimens of Cementitious Mixtures ASTM C845 Standard Specification for Expansive Hydraulic Cement ASTM C881 Standard Specification for Epoxy Resin Base Bonding Systems for Concrete ASTM C1116 Standard Specification for Fiber-Reinforced Concrete ASTM C1218 Standard Test Method for Water-Soluble Chloride in Mortar and Concrete ASTM C1240 Standard Specification for Silica Fume used in Cementitious Mixtures ASTM C1260 Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar-Bar Method) ASTM C1602 Standard Specification for Mixing Water Used in the Production of Hydraulic Cement Concrete ASTM D1751 Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types) ASTM D1752 Standard Specification for Preformed Sponge Rubber Cork and Recycled PVC Expansion Joint Fillers for Concrete Paving and Structural Construction ASTM D2240 Standard Test Method for Rubber Property Durometer Hardness ASTM E96 Standard Test Methods for Water Vapor Transmission of Materials 2. American Concrete Institute (ACI) Standards: ACI Standards ACI 211.1 Standard Practice for Selecting Proportions for Normal, Heavy-weight, and Mass Concrete ACI 301 Specification for Structural Concrete ACI 305.1 Specification for Hot Weather Concreting ACI 306.1 Standard Specification for Cold Weather Concreting ACI 308.1 Specification for Curing Concrete BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 5 ACI Standards ACI 350 Code Requirements for Environmental Engineering Concrete Structures 3. Concrete Plant Manufacturers Bureau (CPMB) Standards: a. Concrete Plant Standards. PART 2 PRODUCTS 2.1 MANUFACTURERS A. In other Part 2 articles where titles below introduce lists, the following requirements apply to product selection: 1. Available Products: Subject to compliance with requirements, products that may be incorporated into the Work include, but are not limited to, products specified. 2. Products: Subject to compliance with requirements, provide one of the products specified. 3. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, manufacturers specified. 4. Manufacturers: Subject to compliance with requirements, provide products by one of the manufacturers specified. 2.2 CONCRETE MATERIALS A. Cementitious Material; General: If the fine and/or coarse aggregates test “Potentially Reactive”, in accordance with ASTM C1260, then a low alkali cementitious material shall be used. A low alkali cementitious material shall be such that, the Sodium Oxide Equivalent (Na2Oeq) shall not exceed 0.6 percent of the total cementitious material content. B. Cement; Type: 1. Type II or I/II Portland cement, conforming to ASTM C150; used for all concrete, unless noted otherwise. If Portland cement is unavailable, the provide ASTM C595, Type IL cement. C. Supplementary Cementitious Materials (SCM): 1. Fly Ash/Pozzolans: Conforming to ASTM C618, Class F fly ash; used in all classes of concrete. If fly ash is unavailable, then provide a straight cement mix. D. Coarse Aggregate: 1. Crushed stone or gravel conforming to ASTM C33, in the gradation size specified. a. Class: Moderate weathering region, but not less than 3M. b. Aggregate shall have a coefficient of thermal expansion (CoTE) of 4.5 microstrain per degree Fahrenheit. 2. For gradation size number 467, a maximum aggregate size of 1-1/2 inches is: Sieve Size Percent Retained Percent Passing 2” 0 100 1-1/2” 0-5 95-100 3/4” 30-65 35-70 3/8” 70-90 10-30 BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 6 Sieve Size Percent Retained Percent Passing No. 4 95-100 0-5 3. For gradation size number 57, the maximum aggregate size of 1 inch is: Sieve Size Percent Retained Percent Passing 1-1/2” 0 100 1” 0-5 95-100 1/2” 40-75 25-60 No. 4 90-100 0-10 No. 8 95-100 0-5 4. For gradation size number 67, the maximum aggregate size of 3/4 inch is: Sieve Size Percent Retained Percent Passing 1” 0 100 3/4” 0-10 90-100 3/8” 45-80 20-55 No. 4 90-100 10-10 No. 8 90-100 0-5 5. For gradation size number 8, the maximum aggregate size of 3/8 inch is: Sieve Size Percent Retained Percent Passing 1” 0 100 3/8” 0-15 85-100 No. 4 70-90 10-30 No. 8 90-100 0-10 No. 16 95-100 0-5 E. Fine Aggregate: 1. Washed and screened natural sands or sands manufactured by crushing stones; conforming to ASTM C33. The gradation in ASTM C33 for air entrained concrete is: Sieve Size Percent Retained Percent Passing 3/8” 0 100 #4 0-5 95-100 #8 0-20 80-100 #16 15-50 50-85 #30 40-75 25-60 #50 70-90 10-30 2. Fine aggregate shall have not more than 45 percent retained between any two consecutive sieves. Its fineness modulus, as defined in ASTM C125, shall be not less than 2.3 nor more than 3.1. BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 7 F. Water: Potable and complying with ASTM C1602 and ASTM C1602 Table 2. 2.3 ADMIXTURES A. Measure and dose admixtures in accordance with manufacturer’s recommendations. B. Air Entraining Admixture: Conforming to ASTM C260. C. Water Reducing Admixtures: Conforming to ASTM C494; Types A or D. D. Set Retarding Admixtures: Conforming to ASTM C494; Types B and D. E. Water Reducing Admixtures, High Range (HRWR): High Range Water Reducer shall comply with ASTM C494, Type F or G. HRWR shall be added to the concrete mix at the concrete batch plant. HRWR may not be added at placement site except to redose a batch and only after approval of the HRWR manufacturer. The high range water reducing admixture shall be able to maintain the plasticity range without significant loss of slump or rise in concrete temperature for 2 hours. Other admixtures may only be used with the HRWR if approved by the HRWR manufacturer. A representative of the HRWR manufacturer shall be present during any large placement, placement of slabs, or during times of unusual circumstance which may require changes to the product formulation. 1. Manufacturers: a. GCP Applied Technologies. b. Master Builders Solutions US LLC. c. Sika Corporation. 2.4 WATERSTOPS A. Flexible PVC Waterstops: CE CRD-C 572, for embedding in concrete to prevent passage of fluids through joints. Factory fabricate corners, intersections, and directional changes. Unless indicated otherwise, provide the following configurations. 1. Construction Joints: a. Profile: Ribbed without center bulb. b. Width: 6 inches. c. Minimum thickness: 3/8 inch. 2. Expansion Joint: a. Profile: Ribbed with center bulb. b. Width: 9 inches. c. Minimum thickness: 3/8 inch. 3. Manufacturers: a. Sika Greenstreak and Sika Westec Barrier Technologies. b. Approved equal. All waterstops used shall be compatible with existing waterstops. B. Self-Expanding Strip Waterstops (Hydrophilic): Self-expanding strip waterstops shall be used only where specifically indicated. Manufactured rectangular or trapezoidal strip, sodium bentonite or other hydrophilic material for adhesive bonding to concrete. 1. Products: a. Adeka Ultra Seal; Mitsubishi International Corporation. 1) Lower expansion pressure hydrophilic waterstop: KBA-1510 FP. 2) Rated for 25ft of head pressure. b. Approved equal. BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 8 2.5 CURING MATERIALS A. Absorbent Material: AASHTO M182, Class 2, burlap cloth made from jute or kenaf, weighing approximately 9 oz. per sq. yd. dry. B. Sheet Curing Material: Conforming to ASTM C171. 1. Waterproof paper. 2. Polyethylene film. 3. White burlap - polyethylene film. C. Membrane Curing Compounds: Membrane curing compound conforming to ASTM C309; applied according to the manufacturer’s recommendations. USDA or NSF 61 approved, clear, waterborne, membrane-forming curing compound: ASTM C309, Type 1, Class B, 18 to 22 percent solids. D. Finishing Aid: Spraying material designed to form a monomolecular film on fresh concrete that reduces the rate of evaporation of surface moisture prior to finishing. This material is not a curing compound. Concrete must be cured as specified. 1. MasterKure ER 50; Master Builders Solutions US LLC. 2. Approved equal. 2.6 RELATED MATERIALS A. Expansion and Isolation Joint Filler: 1. Water retaining structures: ASTM D1752, Type I or II. 2. Non-water retaining structures: ASTM D1751; or ASTM D1752, Type I or II. 3. Thickness as indicated on the Drawings. B. Expansion and Isolation Joint Sealant: 1. Water retaining structures: Not applicable. Provide cap seal specified. 2. Non-water retaining structures: ASTM C920, Type S or M, Grade P or NS as applicable, Class 50, Use T, UV resistance. 3. Backing material for sealant shall be a rod of diameter and composition recommended by the sealant manufacturer. C. Bonding Agent: Water-based epoxy modified, with integral corrosion inhibitor. Install according to the manufacturer’s recommendations. 1. Sika Armatec 110 EpoCem; Sika Corporation. 2. MasterEmaco P 124; Master Builders Solutions US LLC. 3. Approved equal. D. Non-Shrink Grout: 1. General: Non-shrink grout for grouting of pump, motor, and equipment baseplates or bedplates, column baseplates, other miscellaneous baseplates, piping block outs and other uses of grout. Grout shall meet the following requirements, as verified by independent laboratory tests: a. No shrinkage from the time of placement, or expansion after set, under ASTM C827 and CRD C621 83 (Corps of Engineers). When non-shrink grouts are tested under CRD C621 83, the grout shall be tested in a fluid state. A fluid state shall be defined as flowing through a flow cone at a rate of 20 seconds, plus or minus 5 seconds. b. An initial set time of not less than 45 minutes under ASTM C191. 2. Non-Shrink Non-Metallic Grout: Pre-mixed, non-staining, non-shrink grout; minimum 28-day compressive strength of 5000 psi. BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 9 a. Do not use for vibrating equipment. b. Products: 1) MasterFlow 100; Master Builders Solutions US LLC. 2) Five Star Grout; Five Star Products, Inc. 3) SikaGrout 212; Sika Corporation. 3. Non-Shrink Epoxy Structural Grouts: Furnished in two components from the factory and mixed on the Site; conforming to ASTM C579, ASTM C580, and ASTM C827; chemical resistant, water resistant and a minimum 7-day compressive strength of 12,000 psi. a. Use for vibrating equipment. b. Products: 1) Sikadur 42, Grout-Pak; Sika Corporation. 2) Five Star HP Epoxy Grout; Five Star Products, Inc. 3) MasterFlow 648; Master Builders Solutions US LLC. E. Normal Shrinkage Grout: 1 part cement as specified, to 3 parts of clean, ASTM C33 fine aggregate; proportioning on a volumetric basis; used for non-structural applications for grouting areas as shown on the Drawings which do not require non-shrink grout. F. Zinc Rich Primer: Aluminum surfaces which contact or are embedded in concrete shall be coated with zinc rich primer. Primer shall be: 1. Tneme-Zinc; Tnemec Company, Inc. 2. MasterProtect P 8100AP; Master Builders Solutions US LLC. 3. Approved equal. 2.7 REPAIR MATERIALS A. Structural Concrete Repair Material: Low-shrink, non-slump, non-metallic, quick setting patching mortar; as approved by the manufacturer for each application and applied accordance with the manufacturer’s recommendations. 1. Products: a. Five Star Structural Concrete; Five Star Products, Inc. b. SikaTop 123; Sika Corporation. c. SikaTop 122; Sika Corporation. d. MasterEmaco N 425; Master Builders Solutions US LLC. e. Approved equal. 2.8 CONCRETE MIXTURES A. Design Criteria: 1. Provide a mix design for each concrete application indicated. This may necessitate multiple mix designs for each class of concrete depending on HRWR, entrained air, and other requirements. 2. All Concrete shall be normal weight concrete composed of Portland cement, fine aggregate, coarse aggregate, admixtures, and water, as specified. 3. ACI 211.1 shall be the basis for selecting the proportions for concrete made with aggregates of normal and high density and of workability suitable for usual cast in place structures. 4. The workability of any mix shall be as required for the specific placing conditions and the method of placement. The concrete shall have the ability to be worked readily into corners and around reinforcing steel without the segregation of materials or the collection of free water on the surface. Compliance with specified slump limitations shall not necessarily designate a satisfactory mix. BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 10 5. In no case shall the amount of coarse material produce harshness in placing or honeycombing in the structure, when forms are removed. The maximum amount of coarse aggregate (dry loose volume) per cubic foot of finished concrete shall not exceed 0.82 cubic feet. 6. In calculating water-cement ratio: The water content shall include the amount of water batched or to be added later, plus the free water in the aggregate, and minus the water content at SSD conditions. 7. No allowance shall be made for the evaporation of water after batching. If additional water is required to obtain the desired slump, a compensating amount of cement shall also be added. In no case shall the maximum water cement ratio exceed the specified maximum or that of the approved mix design. 8. Air Entrainment: Provide the percent air entrainment in each concrete mix design as recommended by ACI 350: a. Exposure Class: EF1, unless otherwise specified/restricted: 1) Do not provide air-entrainment and entrapped air shall not exceed 3 percent for the following applications: a) Interior slabs. b) Slabs on composite metal decks. 9. Maximum water-soluble chloride ion content in concrete, by percent weight of concrete, shall not exceed ACI 350 Exposure Class EC1. 10. When job conditions dictate, water-reducing and set-controlling admixtures may be used. Only specified admixtures shall be used. Admixtures shall be batched at the batch plant. 11. High Range Water Reducer (HRWR): Provide HRWR in mix designs for the following specified applications: a. Drilled shafts, footings, walls, columns, and beams. b. Interior of building curbs which are not cast monolithically with slabs. c. Precast concrete. d. Exception: Do not provide HRWR in slabs and pavement (a water reducer is permitted provided performance requirements are met). 12. If fly ash is to be used in place of cement, no more than 25 percent of the cement may be replaced. 13. Concrete shall be capable of developing two-thirds of the required 28-day compressive strength in 7 days. 14. Shrinkage Limits: All concrete used in the following structures shall have a shrinkage limit of 0.04 percent at 28 days in accordance with ASTM C157. B. Concrete Classifications: Class Min. 28-Day Compressive Strength (psi) Max. Size Aggregate (inches) Max. Water: Cementitious Materials Ratio Slump +/- 1 (inches) Min. Sacks of Cement Per Cubic Yard ** A 4000 1.5 Size No. 467 0.45 3 (8*) 5.75 B 3000 1.5 Size No. 467 0.47 3 5.75 C 4000 1.0 Size No. 57 0.45 4 (8*) 5.75 D 5000 0.75 Size No. 67 0.47 4 6.00 BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 11 Class Min. 28-Day Compressive Strength (psi) Max. Size Aggregate (inches) Max. Water: Cementitious Materials Ratio Slump +/- 1 (inches) Min. Sacks of Cement Per Cubic Yard ** E 1500 1.5 Size No. 467 0.70 4 4.00 F 4000 0.375 Size No. 8 0.47 3 6.50 * Slump shown is with HRWR ** Provide one additional sack of cement per cubic yard if concrete must be deposited in standing water. C. Concrete Usage: Class Usage Class A Use Footings, slabs, walls, beams, and other unless noted otherwise Class B Use Pavement, gutters, sidewalks Class C Use Walls with thickness less than 10-inches Class D Use Not used Class E Use Cradling, blocking, mud slab, lean concrete backfill Class F Use Not used D. Required Average Compressive Strength: 1. All concrete is required to have an average compressive strength greater than the specified strength. The required average compressive strength shall be established according to the requirements of ACI 301. 2. Standard Deviation: Calculate a standard deviation and establish the required average compressive strength (fcr’) in accordance with ACI 301. If field test records are not available, select the required average strength from ACI 301. E. Documentation of Required Average Compressive Strength: 1. Documentation indicating the proposed concrete proportions will produce an average compressive strength equal to or greater than fcr’. Documentation shall consist of field strength records or trial mixture. 2. Field Strength Test Records: Document field strength test records according to ACI 301, which is partially restated here: a. If field test data are available and represent a single group of at least 10 consecutive strength tests for one mixture, using the same materials, under the same conditions, and encompassing a period of not less than 45 days, verify that the average of the field test results equals or exceeds fcr’. b. If the field test data represent two groups of strength tests for two mixtures, plot the average strength of each group versus the water-cementitious materials ratio of the corresponding mixture proportions and interpolate between them to establish the required mixture proportions for fcr’. 3. Trial Mixtures: a. Establish trial mixture proportions according to ACI 301, which is partially restated here: BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 12 1) Make at least three trial mixtures complying with performance and design requirements. Each trial mixture shall have a different cementitious material content. Select water-cementitious materials ratios that will produce a range of compressive strengths encompassing fcr’. 2) Submit a plot of a curve showing the relationship between water-cementitious materials ratio and compressive strength. 3) Establish mixture proportions so that the maximum water-cementitious materials ratio is not exceeded when the slump is at the maximum specified. a) Trial mixtures shall be designed, sampled, and tested by an independent testing laboratory, retained and paid by the Contractor and approved by the Owner. b) Provide 7-day and 28-day strengths test results. 4. Revisions to concrete mixtures: a. When less than 15 compressive strength tests results for a given class of concrete are available from the current Project: 1) If any of the following criteria are met, take immediate steps to increase average compressive strength of the concrete. a) A 7-day compressive strength test result multiplied by 1.5 falls below the required 28-day compressive strength. b) A 28-day compressive strength test result is deemed not satisfactory. b. When at least 15 compressive strength test results for a given class of concrete become available from the current Project: 1) Calculate the actual average compressive strength, standard deviation and required average compressive strength using the previous 15 consecutive strength tests. Submit results in graphical form with each 28-day test result for that class of concrete. 2) If any of the following criteria are met, take immediate steps to increase average compressive strength of the concrete. a) A 7-day compressive strength test result multiplied by the average job-to- date ratio of 7-day to 28-day compressive strength falls below the required 28-day compressive strength. b) A 28-day compressive strength test result is deemed not satisfactory. c) The average compressive strength falls below the required average compressive strength. c. When revisions to the mix design are required, notify the Engineer in writing of the corrective actions taken. 2.9 OFF-SITE BATCH PLANT A. Batch plants shall be an established concrete batching facility meeting the requirements of the Concrete Plant Standards of the Concrete Plant Manufacturers Bureau. 2.10 CONCRETE MIXING A. Mixers may be stationary, truck, or paving mixers of approved design. They shall be capable of combining the materials into a uniform mixture and of discharging without mixture segregation. Stationary and paving mixers shall be provided with an acceptable device to lock the discharge mechanism until the required mixing time has elapsed. The mixers or mixing plant shall include a device for automatically counting the total number of batches of concrete mixed. The mixers shall be operated at the drum or mixing blade speed designated by the manufacturer on the name plate. BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 13 B. The mixing time for stationary mixers shall be based upon the mixer’s ability to produce uniform concrete throughout the batch and from batch to batch. For guidance purposes, the manufacturer’s recommendations, or 1 minute for 1 cubic yard plus 1/4 minute for each additional cubic yard may be used. Final mixing time shall be based on mixer performance. Mixers shall not be charged in excess of the capacity specified by the manufacturer. C. When a stationary mixer is used for partial mixing of the concrete (shrink mixed), the stationary mixing time may be reduced to the minimum necessary to intermingle the ingredients (about 30 seconds). D. When a truck mixer is used, either for complete mixing (transit-mixed) or to finish the partial mixing in a stationary mixer and in the absence of uniformity test data, each batch of concrete shall be mixed not less than 70 nor more than 100 revolutions of the drum, at the rate of rotation designated by the manufacturer of the equipment as mixing speed. If the batch is at least 1/2 cubic yard less than the rated capacity, in the absence of uniformity test data, the number of revolutions at mixing speed may be reduced to no less than 50. Additional mixing shall be performed at the speed designated by the manufacturer of the equipment as agitating speed. When necessary for proper control of the concrete, mixing of transit-mixed concrete shall not be permitted until the truck mixer is at the Site of the concrete placement. Truck mixers shall be equipped with accurate revolution counters. E. Paving mixers may be either single compartment drum or multiple compartment drum type. A sled or box of suitable size shall be attached to the mixer under the bucket to catch any concrete spillage that may occur when the mixer is discharging concrete into the bucket. Multiple compartment drum paving mixers shall be properly synchronized. The mixing time shall be determined by time required to transfer the concrete between compartments of the drum. F. Vehicles used in transporting materials from the batching plant to the paving mixers shall have bodies or compartments of adequate capacity to carry the materials and to deliver each batch, separated and intact, to the mixer. Cement shall be transported from the batching plant to the mixers in separate compartments which are equipped with windproof and rain proof covers. PART 3 EXECUTION 3.1 PREPARATION A. Notify the Owner’s representative upon completion of various portions of the work required for placing concrete, so that inspection may be made as early as possible. Keep the Owner’s representative informed of the anticipated concrete placing schedules. B. All items, including lines and grades, forms, waterstops, reinforcing, inserts, piping, electrical, plumbing and the Contractor’s concreting materials and equipment shall be in compliance with the Contract Documents before proceeding. C. Do not place any concrete until formwork and the placing reinforcement in that unit is complete. Place no concrete before the completion of all adjacent operations which might prove detrimental to the concrete. D. Brilliantly light the Site so that all operations are plainly visible when concrete mixing, placing, and finishing, continues after daylight. Whenever possible, concrete finishing shall be completed in daylight hours. E. When placing concrete, the forms shall be clean and entirely free from all chips, dirt, sawdust and other extraneous matter. Forms for slab, beam and girder construction shall not have tie wire cuttings, nails, or any other matter which would mar the appearance of the finished construction. Clean forms and keep them free of any foreign matter during concrete placing. BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 14 F. The concrete shall be mixed in quantities required for immediate use. Any concrete which is not in place within the time limits specified shall not be used. Concrete shall not be re- tempered. G. Concrete shall not be placed if impending weather conditions would impair the quality of the finished Work. H. Unless otherwise provided, the following requirements shall govern the time sequence on which construction operations shall be carried. 1. Forms for walls or columns shall not be erected on concrete footings until the concrete in the footing has cured for at least 2 curing days. Concrete may be placed in a wall or column as soon as the forms and reinforcing steel placements are approved. 2. Steel beams or forms and falsework for superstructures shall not be erected on ground- supported concrete substructures until the substructure concrete has cured for at least 4 curing days. 3. Falsework required for superstructures shall not be erected until the substructure has cured for 4 curing days, and shall not be removed until allowed for by Section 03 11 00 “Concrete Forming.” 3.2 EMBEDDED ITEMS A. Where aluminum anchors, aluminum shapes, or aluminum electrical conduits are embedded in concrete, paint aluminum contact surfaces with zinc rich primer. Allow the paint to thoroughly dry before placing the aluminum in contact with the concrete. B. Paint steel or other ferrous metal to be mounted on or placed in contact with dry/cured concrete, and coat in accordance with Section 09 96 00.01 “High-Performance Coatings” prior to installation. 3.3 JOINTS A. Expansion Joints and Devices: 1. Workmanship: Exercise careful workmanship in joint construction to separate the concrete sections by an open joint or by the joint materials, and make the joints true to the outline indicated. 2. Expansion Joints: Construct expansion joints and devices to provide expansion and contraction. Construct joints which are to be left open or filled with poured joint material with forms which are adaptable for loosening or early removal. In order to avoid jamming by the expansion action of the concrete and the consequent likelihood of injuring adjacent concrete, remove or loosen these forms as soon as possible after the concrete has initially set. Make provisions for loosening the forms to permit free concrete expansion without requiring full removal. 3. Armored Joints: Carefully construct armored joints to avoid defective anchorage of the steel and porous or honeycombed concrete adjacent to same. Anchor pre-molded materials to the concrete on one side of the joint with approved adhesive. Anchor so that the material does not fall out of the joint. B. Construction Joints: 1. Construction joints are formed by placing plastic concrete in direct contact with concrete which has attained its initial set. When concrete is specified as monolithic, the term shall be interpreted as the manner and sequence of concrete placement so that construction joints do not occur. BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 15 2. Additional horizontal and vertical construction joints, when submitted and approved by the Engineer, may have an impact on reinforcing details. Revise reinforcing details to reflect additional joints. 3. Unless otherwise provided, construction joints shall be square and normal to the forms. Provide bulkheads in the forms for all joints except horizontal joints. 4. Clean horizontal construction joints for receiving the succeeding lift using air water cutting. The surface shall be exposed sound, clean aggregate with a 1/4 inch amplitude. After cutting, wash the surface until there is no trace of cloudiness in the wash water. 5. In areas where air water cutting cannot be satisfactorily accomplished, or in areas where it is undesirable to disturb the surface of the concrete before it has hardened, prepare the surface for receiving the next lift by wet sand blasting to immediately remove all laitance and unsound concrete prior to placing of the next lift. Thoroughly wash the surface of the concrete after sand blasting to remove all loose material. 6. Provide construction joints with concrete keyways, reinforcing steel dowels, and waterstops where indicated on the Drawings. The method of forming keys in keyed joints shall permit the easy removal of forms without chipping, breaking, or damaging the concrete. 7. Construction joint layout unless otherwise indicated on the Drawings: a. Maximum horizontal spacing of construction joints shall be 45 feet. b. Maximum vertical spacing of construction joints shall be 15 feet. C. Hardened Concrete: Where new concrete or grout is to be placed in contact with existing or recently hardened concrete, texture the existing or recently hardened surface by chipping or other means so that an irregular surface having a height variance of not less than 1/4 inch is created. The existing or recently hardened concrete shall then be coated with a bonding agent and new concrete or grout placed. 3.4 WATERSTOPS A. PVC Waterstops: Install in construction joints as indicated to form a continuous diaphragm. Install in longest lengths practicable. Support and protect exposed waterstops during progress of Work. 1. At formed surfaces, a split form shall be used. The split form shall have a tight fit which prevents misalignment and concrete leakage. 2. The embedded flange of the waterstop must be secured prior to concrete placement. The flange shall be secured at 12 inches on-center by factory installed hog rings or grommets at the outermost rib. Never place nails or screws through the body of the waterstop. 3. All fittings and changes in direction shall be factory fabricated. Only straight butt splices shall be made in the field. Field splices shall be according to the manufacturer’s written instructions and as follows: a. Cut adjoining ends square to form matching edges. b. Uniformly melt the ends at 380 F using a thermostatically controlled, Teflon coated splicing iron. c. When a 1/8-inch diameter melt bead develops on each waterstop end, remove the splicing iron and firmly press the two ends together in proper alignment. Hold until the material has fused and cooled. Allow the splice to cool naturally; do not quench. B. Self-Expanding Strip Waterstops: 1. Install in construction joints and at other locations indicated, according to manufacturer’s written instructions, bonding or mechanically fastening and firmly pressing into place. BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 16 a. Waterstop shall be bonded to the substrate using a continuous bead of swelling sealant or adhesive as recommended by the manufacturer. 1) ADEKA Ultra Seal P-201. 2) Approved equal. 2. Install in longest lengths practicable. 3. Protect from moisture, oil, dirt, and sunlight prior to the placement of concrete. Coordinate with manufacturer for additional requirements. 3.5 CONCRETE PLACEMENT A. Cold Weather: 1. If air temperature has fallen to, or is expected to fall below 40 F during the protection period (a minimum of 48 hours but not less than that required by ACI 306.1), then cold weather concreting shall be performed in accordance with ACI 306.1. 2. In cases where the temperature drops below 40 F after the concreting operations have been started, sufficient canvas and framework or other type of housing shall be furnished to enclose and protect the structure, in accordance with the requirements of ACI 306.1. Sufficient heating apparatus to provide heat shall be supplied, and heating source and protection from combustion gas shall be in accordance with ACI 306.1. The concrete shall be protected when placed under all weather conditions. Should concrete placed under such conditions prove unsatisfactory, remove and replace the concrete at no cost to the Owner. 3. When the air temperature is above 30 F: a. The minimum concrete temperature at the time of mixing shall be 60 F unless other requirements of ACI 306.1 are met, which may allow for a lower mix temperature. b. The minimum concrete temperature at the time of placement and during the protection period shall be 55 F unless other requirements of ACI 306.1 are met, which may allow for a lower temperature. 4. The means used to heat a concrete mix shall be in accordance with ACI 306.1. 5. Salts, chemicals, or other foreign materials shall not be mixed with the concrete to preventing freezing. Calcium chloride is not permitted. B. Hot Weather: 1. Hot weather is defined as any combination of high air temperature, low relative humidity, and wind velocity that impairs the quality of the concrete. Hot weather concreting shall be in accordance with ACI 305.1. Concrete shall be placed in the forms without the addition of any more water than that required by the design (slump). No excess water shall be added on the concrete surface for finishing. Control of initial set of the concrete and extending the time for finishing operations may be accomplished with the use of approved water reducing and set retarding admixture, as specified. 2. Maximum time intervals between the addition of mixing water and/or cement to the batch, and the placing of concrete in the forms shall not exceed the following (excluding HRWR admixture use): Concrete Temperature Maximum Time from Water Batch to Placement Non-Agitated Concrete Up to 80 F 30 Minutes Over 80 F 15 Minutes Agitated Concrete BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 17 Concrete Temperature Maximum Time from Water Batch to Placement Up to 75 F 90 Minutes 75 F to 89 F 60 Minutes a. The use of an approved set-retarding admixture will permit the extension of the above time maximums by 30 minutes, for agitated concrete only. b. The use of an approved high range water reducing (HRWR) or hydration-controlling admixture will allow placement time extensions as determined by the manufacturer. 3. The maximum temperature of fresh concrete at time of discharge shall not exceed 95 F. The temperatures of the mixing water shall be reduced by the use of chilled water or ice. 4. The maximum temperature of fresh concrete with high range water reducing admixture shall not exceed 100 F at time of discharge. 5. Under extreme heat, wind, or humidity conditions, concreting operations may be suspended if the quality of the concrete being placed is not acceptable. C. Handling and Transporting: 1. Delivery tickets shall be required for each batch and shall be in accordance with ASTM C94. Each delivery ticket must show plainly the amount of water, in gallons that can be added to the mixer truck at the Site without exceeding the maximum water cement ratio approved for that mix design. Amount of water added must be in proportion to contents of truck. 2. Arrange and use chutes, troughs, or pipes as aids in placing concrete so that the ingredients of the concrete are not segregated. They shall be steel or steel lined. When steep slopes are necessary, equip the chutes with baffles or make in short lengths that reverse the direction of movement. Extend open troughs and chutes, if necessary, inside the forms or through holes left in the forms. Terminate the ends of these chutes in vertical downspouts. 3. Keep chutes, troughs, and pipes clean and free from coatings of hardened concrete by thoroughly flushing with water before and after placement. Discharge water used for flushing away from the concrete in place. 4. Use pumping equipment that has sufficient capacity so that: a. Discharge of pump concrete does not result in segregation. b. Modification of accepted concrete mixture is not required. 5. Carting or wheeling concrete batches on completed concrete floor slab shall not be permitted until the slab has aged at least 4 curing days. Unless pneumatic tired carts are used, wheel the carts on timber planking so that the loads and impact are distributed over the slab. Curing operations shall not be interrupted for the purpose of wheeling concrete over finished slabs. D. Depositing: 1. The method and manner of placing shall prevent segregation or separation of the aggregate or the displacement of the reinforcement. Use drop chutes or tremies as necessary. 2. Free Fall: Concrete shall not be allowed to free fall more than 10 feet when HRWR admixture is used or 5 feet without the use of HRWR. Free falling concrete shall avoid striking reinforcing during placement. Placement of concrete for heights exceeding the free fall limit shall be placed using a tremie. a. Concrete shall not be allowed to free fall through water. 3. Prevent the splattering of forms and reinforcing bars if the splattered concrete will dry or harden before incorporation into the mass. BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 18 4. Fill each part of the forms by directly depositing concrete as near its final position as possible. Work the concrete under and around the reinforcement bars. Depositing large quantities at one point in the forms, then running or working it along the forms shall not be permitted. a. Place required sections in one continuous operation to avoid additional cold joints. Each layer shall be fluid and concrete shall not have taken initial set when a new layer is placed upon it. Not more than 1 hour shall elapse between the placing of successive concrete layers in any portion of the structures included in continuous placement. 5. Place in continuous horizontal layers with a depth of from 1 to 3 feet. If excessive bleeding causes water to form on the surface of the concrete in tall forms, revise mix design to reduce the bleeding. 6. In tall walls, place the concrete to a point about 1 foot below the top of the wall and allow to settle for 1 hour. Resume and complete concreting before set occurs. 7. For slopes greater than 2 percent, start concrete placement at low end and proceed upslope. 8. After the concrete has taken initial set, the forms shall not be jarred. No force or load shall be placed upon projecting reinforcement. E. Consolidating: 1. Compact each layer of concrete and flush the mortar to the surface of the forms by continuous-working mechanical vibrators. Apply the vibrator to the concrete immediately after deposit. Move vibrator throughout the layer of the newly placed concrete, several inches into the plastic layer below. Thoroughly work the concrete around the reinforcement, embedded fixtures and into the corners and angles of the forms until it is well-compacted. 2. Mechanical vibrators shall not be operated so that they penetrate or disturb previously placed layers which are partially set or hardened. They shall not be used to aid the flow of concrete laterally. The vibration shall be of sufficient duration to completely compact and embed reinforcement and fixtures, but not to an extent causing segregation. 3. Keep vibrators constantly moving in the concrete and apply vertically at points uniformly spaced, not farther apart than the radius over which the vibrator is visibly effective. The vibrator shall not be held in one location longer than required to produce a liquified appearance on the surface. 4. When submerged in concrete, internal vibrators shall maintain a frequency of not less than 6000 impulses per minute for heads with diameters greater than 5 inches and 10,000 impulses for smaller vibrator heads. The vibration intensity (amplitude) shall be sufficient to produce satisfactory consolidation. a. Vibrator head shall be sufficiently small to allow placement between reinforcing steel. b. Provide at least one standby vibrator. c. Check vibrators intended for regular service or standby service prior to concreting operations. F. Placement in Water: 1. Deposit concrete in water only when dry conditions cannot be obtained. The forms, cofferdams, or caissons shall be sufficiently tight to prevent any water flowing through the space where concrete is to be deposited. Pumping of water shall not be permitted while the concrete is being placed, nor until it has set for at least 36 hours. 2. Carefully place the concrete using a tremie, closed bottom dumping bucket, or another approved method which does not permit the concrete to fall through the water without BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 19 protection. The concrete shall not be disturbed after being deposited. Regulate depositing to maintain horizontal surfaces. 3. When a tremie is used, it shall consist of a tube constructed in sections having water-tight connections. The means of supporting the tremie shall permit the movement of the discharge end over the entire top surface of the work, and shall allow the tremie to be rapidly lowered to retard the flow. The number of times it is necessary to shift the location of the tremie shall be held to a minimum for any continuous placement of concrete. During the placing of concrete, keep the tremie tube full to the bottom of the hopper. When a batch is dumped into the hopper, slightly raise the tremie, but not out of the concrete at the bottom, until the batch discharges to the level of the bottom of the hopper. Stop the flow by lowering the tremie. Continue placing operations until the work is completed. 4. When concrete is placed by means of the bottom dump bucket, the bucket shall have a capacity of not less than 1/2 cubic yard. Lower the bucket gradually and carefully until it rests upon the concrete already placed. Raise it very slowly during the discharge travel to maintain still water at the point of discharge and to avoid agitating the mixture. 5. Use a sump or other approved method to channel displaced fluid and concrete away from the shaft excavation. Recover slurry and dispose of it as approved. Do not discharge displaced fluids into or in close proximity to streams or other bodies of water. G. Placement in Slabs: 1. Allow concrete in columns, walls and deep beams or girders to stand for at least 1 hour to permit full settlement from consolidation, before concrete is placed for slabs they are to support. Haunches are considered as part of the slab and shall be placed integrally with them. 2. When monolithic slabs are placed in strips, the widths of the strips, unless otherwise specified or indicated, shall insure that concrete in any one strip is not allowed to lie in place for more than 1 hour before the adjacent strips are placed. 3. Immediately before placing concrete, thoroughly dampen the subgrade to receive concrete to prevent moisture absorption from the concrete. 4. As soon as concrete placing is complete for a slab section of sufficient width to permit finishing operations, level the concrete, strike off, tamp and screed. The screed shall be of a design adaptable to the use intended, shall have provision for vertical adjustment and shall be sufficiently rigid to hold true to shape during use. 5. The initial strike off shall leave the concrete surface at an elevation slightly above grade so that, when consolidation and finishing operations are completed, the surface of the slab is at grade elevation. 6. Continue tamping and screeding operations until the concrete is properly consolidated and free of surface voids. Bring the surface to a smooth, true alignment using longitudinal screeding, floating, belting, and/or other methods. 7. When used, templates shall be of a design which permits early removal so satisfactory finishing at and adjacent to the template is achieved. 8. While the concrete is still plastic, straighten the surface as required to achieve specified flatness requirements. Remove high spots and fill depressions with fresh concrete and re- float. Continue to check during the final finishing operation, until the surface is true to grade and free of depressions, high spots, voids, or rough spots. 9. Where floor drains are shown in slabs and sloping the slab is not indicated, slope slab to drain on a grade of 1/16 inch per foot. The thickness of slab at floor drain shall be the thickness of slab as indicated on the Drawings. BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 20 H. Placement in Foundations: Place concrete in deep foundations so that segregation of the aggregates or displacement of the reinforcement is avoided. Provide suitable chutes or vertical pipes. When footings can be placed in dry foundation pits without the use of cofferdams or caissons, forms may be omitted and the entire excavation filled with concrete to the elevation of the top of footing. The placing of concrete bases above mud slab is permitted after the forms are free from water and the seal course cleaned. Execute necessary pumping or bailing during concreting from a suitable sump located outside the forms. I. Equipment Bases and Foundations: Provide machine and equipment bases and foundations as shown on the Drawings. Set anchor bolts for machines and equipment at correct elevations, complying with diagrams or templates of manufacturer furnishing machines and equipment. 3.6 FINISHING FORMED SURFACES A. Forms for walls, columns, and sides of beams and girders shall be removed as specified in Section 03 11 00 “Concrete Forming.” Patch, repair, finish, and clean concrete after form removal. Finish concrete not more than 7 days after form removal. Cure concrete as finishing progresses. B. Air voids, for all types of finishes, are defects and shall be removed by rubbing or patching. C. Finish Schedule: Type of Finish Location No Finish Surfaces which are not visible from the inside or outside of the completed structure, are more than 12” below finish grade, and where a coating/membrane/drainage board will not be installed Rough Finish Sludge thickener foundation slab. Smooth Finish Surfaces exposed to view, areas below to a point 12” below grade, and where a coating/membrane/drainage board will be installed. Smooth Rubbed Finish Not used D. No Finish: Patch tie holes. Repair defects larger than 1-1/2 inches in diameter or 1/2 inch in deep. Remove projections larger than 1 inch. E. Rough Finish: Patch tie holes. Repair defects larger than 3/4 inches wide or 1/2 inch in depth. Remove projections larger than 1/4 inch. F. Smooth Finish: The form facing material shall produce a smooth, uniform texture on the concrete. Patch tie holes. Repair defects larger than 3/4 inch wide or 1/4 inch deep. Remove projections flush with the adjacent surface. 3.7 FINISHING FLOORS AND SLABS A. General: Screed, restraighten, and finish concrete surfaces. Do not wet concrete surfaces. B. Finish slabs, platforms, and steps monolithically and apply as indicated on the Drawings and the following schedule of finishes: Type of Finish Location Rough Finish Tank floors that receive grout topping and slabs which receive additional concrete toppings. Float Finish Top of walls, vault top slabs not subject to pedestrian foot traffic. BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 21 Type of Finish Location Trowel Finish Interior slab surfaces exposed to view or to be covered with resilient flooring, carpet, and ceramic or quarry tile set over a cleavage membrane, paint, or another thin film-finish coating system. Broom Finish Exterior concrete platforms, steps, and ramps. 1. Rough Finish: Provide a rough surface by screeding only without further finish. 2. Float Finish: Finish surfaces using a float to a true, even plane with no coarse aggregate visible. In the initial floating, while the concrete is plastic, use sufficient pressure on the float to bring excess moisture to the surface for removal. Apply a final “light float” finish to the surface as the concrete hardens. The surface shall have a uniform granular texture and shall meet the straightness requirements. 3. Trowel Finish: a. After applying float finish, apply first trowel finish and consolidate concrete by hand or power-driven trowel. Continue troweling passes and re-straighten until surface is free of trowel marks and uniform in texture and appearance. Grind smooth any surface defects that would telegraph through applied coatings or floor coverings. b. Finish and measure surface so gap at any point between concrete surface and an unleveled freestanding 10-foot long straightedge, resting on two high spots and placed anywhere on the surface, does not exceed the following: 1) 3/16 inch. 4. Broom Finish: Immediately after float finishing, slightly roughen trafficked surface by brooming with fiber-bristle broom perpendicular to main traffic route. Coordinate required final finish with the Engineer before application. C. Give sidewalks a brush finish, unless noted otherwise. Score sidewalks at a spacing equal to the width of the walk and edge on each side using a tool with a radius of approximately 1/4 inch. D. Finishing in Hot, Dry Weather: During periods of high temperature and/or low humidity, take extreme care in finishing the slabs to eliminate initial shrinkage cracks. Following the initial set of concrete, but while the concrete is still “green” continue to finish as required to remove shrinkage cracks which may occur. In hot, dry weather, keep a cement finisher on the job following normal finishing operations for a sufficient length of time to insure the removal of initial shrinkage cracks. 3.8 GROUT FINISHED SLUDGE THICKENER FLOORS A. Grout shall be normal shrinkage grout, as specified. B. Prior to the application of grout, operate the sweep mechanism for monitoring: 1. Accurately determine the elevation of a reference point near the end of each arm and monitor that elevation at every 45-degree rotation for two full rotations of the mechanism. The following measurements shall be recorded and if either of the stated criteria is not met, seek guidance from the Engineer prior to grout installation. Elevations shall be measured with respect to the theoretical surface of the earth and not with respect to the basin floor. a. Reference point elevations shall not vary from one side of the basin to the other more than 1/2 of an inch (+/- 1/4-inch). b. The reference elevations shall not vary more than one-quarter of an inch (+/- 1/8 inch) for any given reference point on the arms at any given rotation angle when compared between rotations. BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 22 2. Monitor the gap between the base of the arms to the top of the structural slab to verify that the minimum required thickness of grout can be achieved in all locations with appropriate clearance for squeegee adjustment. 3. All weight shall be on the arms, including corner sweeps, when verifying gaps. 4. Adjust the arms as necessary to achieve the minimum specified thickness of grout. Notify the Owner and Engineer if the arms are not adjustable and minimum grout thickness cannot be achieved. 5. Verify that the corresponding leading and trailing edges of adjacent blades match in elevations for a seamless transition between blades. The elevations of the corresponding leading and trailing edges shall be as compared either by rotating the mechanism and measuring vertically with respect to a common point on the basin floor or by keeping the mechanism stationary and measuring with respect to the theoretical surface of the earth. C. Screeds shall consist of wood planking of proper dimension and length with the bottom edge beveled such that not more than half of an inch width is in contact with the grout surface. Attach a light gauge metal (sheet) formed and nailed to the wood with butt joints to the bottom of wood screeds. The sheet metal shall serve as a trowel and prevents the splintering and fraying of the timbers. Firmly attach screeds to the bottom of the truss arms to prevent dislocation in the screeding operations. D. Prior to the application of grout, thoroughly clean floors of all foreign matter and wet down. With the floor in a saturated surface dry condition and just prior to grouting, sprinkle lightly with cement to improve the bond between the grout and tank bottoms. Block grout from entering any sludge hopper, drain line, etc. Apply grout over the floor surface of the tanks. Grouting shall be according to the Specifications, the recommendations of the equipment manufacturer and the grout manufacturer. E. Execute grouting by power operation of the equipment in the tank (i.e., by motor turning the mechanism, not by hand turning of the arms). Make final adjustments to truss arms of the equipment and attach a screed to the bottom of both arms for sweeping in the grout. All weight shall be on the arms, including corner sweeps, while placing the grout. F. Start grouting at the walls of the tanks and spiral inward toward the center. Perform grouting in a workmanlike manner. Excess grout should not be allowed to accumulate in front of the screed and cause the screed to float on top of the grout. G. Verify the profile of the finish floor by measuring from the arm with screeds removed and not contact between the arm and the floor. The finish grout surface shall vary no more than a range of half of an inch (+/- 1/4 inch) for any concentric circle in the finished floor. 3.9 MISCELLANEOUS CONCRETE ITEMS A. Normal Shrinkage Grouting: 1. Prior to grout application, thoroughly clean the surface of all foreign matter. Roughen concrete surface to CSP 4 and wet as required for a saturated surface dry condition (SSD). Set forms in place; tight and securely anchored to prevent the loss of grout. 2. The necessary materials and tools shall be on hand before starting grouting operations. 3. After preparing surface and immediately prior to grouting, provide scrub coat of grout material. Do not allow scrub coat to dry prior to placing grout. 4. After mixing, quickly and continuously place the grout to avoid overworking, segregation and breaking down of the initial set. Mix and place the grout where indicated on the Drawings. Cure grout using wet curing method for concrete. Grout shall receive a trowel finish, unless otherwise noted. B. Non-Shrink Grout: BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 23 1. Obtain field technical assistance from the grout manufacturer, as required, to ensure that grout mixing and installation comply with the manufacturer’s recommendations and procedures. 2. Roughen concrete surface as required by the manufacturer, but not less than CSP 4. Saturate the surface to achieve an SSD condition. Baseplates shall be free of oil, grease, laitance and other foreign substances. a. Epoxy Grout: Surface shall be dry as recommended by the manufacturer. 3. Place grout according to the manufacturer’s directions so that spaces and cavities below the bottom of the baseplates are completely filled. Provide forms where structural components of the baseplates do not confine the grout. Trowel finish the non-shrink grout where the edge of the grout is exposed to view and after the grout has reached its initial set. Cut off the exposed edges of the grout at a 45-degree angle to the baseplate, bedplate, member, or piece of equipment. 4. Wet cure a minimum of 3 days, but not less than that recommended by the manufacturer. a. Epoxy Grout: Dry curing is acceptable if recommended by the manufacturer. 5. Use epoxy non-shrink grout under all machinery, pumps, equipment, and where chemicals are present that would abate cementitious non-shrink grouts. 3.10 CONCRETE CURING AND PROTECTION A. General: Begin curing of concrete immediately after completion of finishing activities for unformed concrete and immediately after removal of forms from formed concrete. Apply curing method without staining, marring, or damaging concrete surfaces. Where pedestrian traffic is unavoidable, provide suitable walkways to protect the curing material and the concrete surface from damage. Unless a particular curing method is specified, select the appropriate curing method from the curing options indicated. B. Length of Curing Period: 1. Curing Day: A day on which the ambient temperature is above 50 deg. F for at least 18 hours. 2. Curing Period: 7 consecutive curing days. 3. Extended Curing Period: When curing day requirements are not met, then extend the curing period by one day for each day not in compliance. Extend curing up a maximum total of 14 consecutive days. C. Wet Curing with Absorbent Material: 1. Cover concrete surfaces with absorbent material and hold it in contact with concrete surface. Provide a minimum 8-inch lap of adjacent material section edges. 2. Apply water to absorbent material and saturate. Maintain saturated condition for curing period – do not allow absorbent material to dry. 3. Do not use wet curing if curing water will be subject to freezing during the curing period. D. Sheet Curing: Cover concrete surfaces with sheets and hold in contact with concrete surface. Apply in accordance with manufacturer recommendations, which includes placement, patching holes, and tape joints per manufacturer recommendations. E. Membrane Curing: 1. Cover the surface of the concrete with a continuous, uniform film. Application shall be in accordance with manufacturer recommendations. Prevent overspray as necessary to meet project requirements. 2. Do not allow foot traffic on surface in accordance with manufacturer recommendations. 3. Repair film if damaged within the curing period. 4. Unless preapproved, do not use membrane curing on surfaces that: BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 24 a. Receive concrete topping, terrazzo, paint, floor hardener, or other finish. b. Are specified to have a rubbed finish. F. Protection: During and after curing period, protect concrete surfaces from damage, marring, or staining by construction activities. 3.11 JOINT FILLING A. Prepare, clean, and install joint filler according to manufacturer’s written instructions. B. Remove dirt, debris, saw cuttings, curing compounds, and sealers from joints; leave contact faces of joint clean and dry. 3.12 CONCRETE SURFACE REPAIRS A. Defective Concrete: Repair and patch defective areas when approved by Engineer. Remove and replace concrete that cannot be repaired and patched to Engineer’s approval. B. After the tie rods are broken back or removed, thoroughly clean the holes to remove grease and loose particles. Patch holes with structural concrete repair material or non-shrink grout. After the holes are completely filled, strike off flush excess mortar and finish the surface to render the filled hole inconspicuous. C. Repairing Formed Surfaces: Surface defects include color and texture irregularities, cracks, spalls, air bubbles, honeycombs, rock pockets, fins and other projections on the surface, and stains and other discolorations that cannot be removed by cleaning. 1. If the surface of the concrete is bulged, uneven, or shows honeycombing or form marks, which in the Engineer’s opinion cannot be repaired satisfactorily, remove and replace the entire section. 2. Patch honeycomb and minor defects in all concrete surfaces with structural concrete repair material. Cut back each defective area with a pneumatic chipping tool as deep as the defect extends, but in no case less than 1/2 inch. Prepare the existing concrete and apply repair material according to the manufacturer’s recommendations. Finish the surface of the patches to match finish on surrounding concrete. 3. Immediately after form removal, cut out honeycombs, rock pockets, and voids to expose solid concrete but not less than 1-inch in depth. Make edges of cuts perpendicular to concrete surface. Clean, dampen with water, and brush-coat holes and voids with bonding agent. Fill and compact with repair material before bonding agent has dried. D. Repairing Unformed Surfaces: Test unformed surfaces, such as floors and slabs, for finish and verify surface tolerances specified for each surface. Correct low and high areas. Test surfaces sloped to drain for trueness of slope and smoothness; use a sloped template. 1. Repair finished surfaces containing defects. Surface defects include spalls, pop outs, honeycombs, rock pockets, crazing and cracks in excess of 0.01-inch wide or that penetrate to reinforcement or completely through unreinforced sections regardless of width, and other objectionable conditions. 2. After concrete has cured at least 14 days, correct high areas by grinding. 3. Correct localized low areas during or immediately after completing surface finishing operations by cutting out low areas and replacing with patching mortar. Finish repaired areas to blend into adjacent concrete. 4. Correct other low areas scheduled to remain exposed with a repair topping. Cut out low areas to ensure a minimum repair topping depth of 1/2 inch to match adjacent floor elevations. Prepare, mix, and apply repair topping and primer according to BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 25 manufacturer’s written instructions to produce a smooth, uniform, plane, and level surface. 5. Repair defective areas, except random cracks and single holes 1 inch or less in diameter, by cutting out and replacing with fresh concrete. Remove defective areas with clean, square cuts and expose steel reinforcement with at least 3/4-inch clearance all around. Dampen concrete surfaces in contact with patching concrete and apply bonding agent. Mix patching concrete of same materials and mix as original concrete except without coarse aggregate. Place, compact, and finish to blend with adjacent finished concrete. Cure in same manner as adjacent concrete. 6. Repair random cracks and single holes 1 inch or less in diameter with patching mortar. Groove top of cracks and cut out holes to sound concrete and clean off dust, dirt, and loose particles. Dampen cleaned concrete surfaces and apply bonding agent. Place patching mortar before bonding agent has dried. Compact patching mortar and finish to match adjacent concrete. Keep patched area continuously moist for at least 72 hours. E. Perform structural repairs of concrete, subject to Engineer’s approval, using epoxy adhesive and patching mortar. F. Repair materials and installation not specified above may be used, subject to Engineer’s approval. 3.13 FIELD QUALITY CONTROL A. Testing: 1. General: a. Tests shall be required throughout the Work to monitor the quality of concrete. Samples shall be taken in accordance with ASTM C172. b. Engineer may waive these requirements on concrete placements of 10 cubic yards or less. However, evidence shall be furnished showing a design mix which meets the Specifications. c. Unless noted otherwise, testing of the materials, ready mix, transit mix, or central plant concrete will be by an independent testing agency. The Owner will select and pay for this service. A summary of all tests performed will be available. No concrete shall be placed without a representative present at either the plant or at the Site. d. Unless the Owner’s laboratory is on the Site, provide housing for the curing and storage of test specimens and equipment. 2. Slump Test: Slump tests, in accordance with ASTM C143, shall be used to indicate the workability and consistency of the concrete mix from batch to batch. Generally, a slump test shall be made at the start of operations each day, at regular intervals throughout a working day, and at any time when the appearance of the concrete suggests a change in uniformity. 3. Air Content Test: Tests for the concrete’s air content shall be made in accordance with ASTM C231 or ASTM C173, at the point of delivery of concrete, prior to placing in forms. The test shall be made frequently to monitor a proper air content uniform from batch to batch. 4. Temperature Test: Test for the concrete’s temperature in accordance with ASTM C1064 and as follows: the temperature of the concrete to be placed shall be taken with a thermometer immediately before placement, with the point of measurement being in the chute or bucket. Temperature test shall be performed for each truck. Record temperatures on batch ticket. 5. Compression Test: BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 26 a. Compression test specimens shall be 6-by-12-inch concrete cylinders made and cured in accordance with ASTM C31. If the maximum aggregate size is no larger than 1 inch, 4-by-8-inch concrete cylinders are acceptable. No fewer than two 6-by- 12-inch or three 4-by-8-inch specimens shall be made for each test Sample. Samples shall be taken at a minimum of every 50 cubic yards of concrete for each class placed. At least one set of test specimens per day shall be made for each class of concrete used that day. Specimens shall be cured under laboratory conditions specified in ASTM C31. Additional concrete cylinders may be required for curing on the job under actual job curing conditions. These Samples could be required when: 1) There is a possibility of the air temperature surrounding the concrete falling below 40 F, or rising above 90 F. 2) The curing procedure may need to be improved and/or lengthened. 3) It is necessary to determine when the structure may be put into service. b. Compression strength tests shall be made on the laboratory-cured and job-cured concrete cylinders at 7 and 28 days, in accordance with ASTM C39. The value of each test result shall be the average compressive strength of all of the cylinders in the test Sample. All cylinders within a test Sample shall be taken at the same time from the same batch of concrete. For the 28-day cylinders, the strength level shall be satisfactory if the averages of all sets of three consecutive strength test results exceed the required design compressive strength, and no individual strength test result falls below the required compressive strength by more than 500 psi. 6. Failure to Meet Requirements: a. Should the 7-day strengths shown by the test specimens fall below the required values, additional curing shall be performed on those portions of the structures represented by the test specimens at the Contractor’s expense. Test cores shall be obtained and tested in accordance with ASTM C42. If additional curing does not give the strength required, the Owner reserves the right to require strengthening, replacement of those substandard portions of the structure, or additional testing, at the Contractor’s expense. b. Upon receipt of the Contractor’s written request, substandard concrete work may be reexamined in place by nondestructive testing methods or core Samples, in accordance with ACI 301. The services of an independent testing laboratory shall be retained and all expenses paid without compensation from the Owner. Laboratory results shall be evaluated by the Engineer, who shall make the final decision on acceptability of the concrete in question. Core Sample holes shall be repaired. B. The Owner may withhold payment for any section of concrete which does not meet the requirements of the Specifications. Withheld payment shall be based upon the unit prices established for concrete and reinforcing steel. Payment shall be withheld until the unacceptable concrete has been refinished, removed and replaced or otherwise brought into conformance with the Specifications. C. PVC Waterstops: Waterstops shall be observed by the Owner’s representative prior to concrete placement. Unacceptable splicing defects include: 1. Misalignment of center bulb, ribs, and end bulbs greater than 1/16 inch. 2. Bond failure at joint deeper than 1/16 inch. 3. Misalignment which reduces waterstop cross-section more than 15 percent. 4. Bubble or visible porosity in the weld. 5. Visible signs of splice separation when a cooled splice is bent by hand at a sharp angle. 6. Charred or burnt material. BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 27 END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 28 Concrete Mix Design Project Name: FNI Project Number: Project Location: Owner: General Contractor: Mix Number / Class: A. Mix Design: Cement = lb/yd³ Fly Ash = lb/yd³ Other Cementitious Material: _______________________ = lb/yd³ Fine Aggregate = lb/yd³ Coarse Aggregate = lb/yd³ Water = lb/yd³ Water Reducing Admixture = oz/yd³ High Range Water Reducer = oz/yd³ Air Entraining Admixture = oz/yd³ Other Admixture: _______________________ = oz/yd³ Slump = inches Gross Weight = lb/yd³ Air Content = percent Water/Cement Ratio = B. Materials: Source ASTM Type Remarks Cement Fly Ash Other Cementitious Material: _______________________ Fine Aggregate Coarse Aggregate Water Water Reducer High Range Water Reducer Air Entraining Other Admixture: _______________________ BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 29 C. Determination of Average Strength Required (fcr’): 1. Test Records Available: A. Summary of Test Records (Provide Supporting Documentation): Test Group No. No. of Consecutive Tests Specified Strength (psi) Standard Deviation (psi) Average Standard Deviation: B. Standard Deviation Modification Factor (ACI 30 1, Table 4.2.3.3.a): ____. C. Standard Deviation Used: ____. D. Average Compressive Strength Required: ____. 2. Test Records Not Available: A. Average Compressive Strength Required (ACI 30 1, Table 4.2.3.3.b, if required): ____. D. Documentation of Required Average Compressive Strength (Check One): 1. Field Strength: a. Field Strength Test Records (ACI 30 1, Table 4.2.3.3.a): ____. *Complete Attachment A. 2. Trial Mixtures: a. Trial Mixtures (ACI 301, Table 4.2.3.3.b, if required): ____. *Complete Attachment B. I, certify that the above information is correct and all gradations, cement certifications, and test results are located at our place of business for review by the Engineer. Name: Date: Title: Company: Address: BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 30 Attachment A Documentation of Required Average Strength – Field Strength Records (ACI 301, 4.2.3.4.a) A. Summary of Test Records (Provide Supporting Documentation): Test Record No. No. of Tests in Record Duration of Record (days) Water- Cementitious Materials Ratio Average Strength (psi) B. Interpolation used? ________. 1. Provide an interpolation calculation or plot of strength versus proportions. C. Submit the following data for each mix: 1. Brand, type, and amount of cement. 2. Brand, type, and amount of each admixture. 3. Source of each material used. 4. Amount of water. 5. Proportions of each aggregate material per cubic yard. 6. Gross weight per cubic yard. 7. Measured slump. 8. Measured air content. 9. Results of consecutive strength tests. END OF ATTACHEMENT A BCRUA - Phase 1D WTP Expansion Issued for Bid Cast-In-Place Concrete 03 30 00 - 31 Attachment B Documentation of Required Average Strength – Trial Mixtures (ACI 301, 4.2.3.4.b) A. Summary of Test Record(s): Trial Mix No. 7-Day Tests 28-Day Tests Water- Cementitious Materials Ratio Slump (in) Air Content (percent) Temperature (F) No. of Test Cylinder s Strength (psi) No. of Test Cylinders Strength (psi) B. Maximum water-cementitious materials ratio ________. 1. Provide an interpolation calculation or plot of strength versus water-cementitious materials ratio. C. Submit the following data for each mix: 1. Brand, type, and amount of cement. 2. Brand, type, and amount of each admixture. 3. Amount of water used in trial mixes. 4. Proportions of each aggregate material per cubic yard. 5. Gross weight per cubic yard. 6. Measured slump. 7. Measured air content. 8. Compressive strength developed at 7 days and 28 days, from not less than three test cylinders cast for each 7-day and 28-day test. END OF ATTACHMENT B BCRUA - Phase 1D WTP Expansion Issued for Bid Metal Fabrications 05 50 00 - 1 SECTION 05 50 00 - METAL FABRICATIONS PART 1 GENERAL 1.1 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.2 ACTION SUBMITTALS A. Product Data: For the following: 1. Fasteners 2. Grating 3. Miscellaneous framing B. Shop Drawings: Show fabrication and installation details for metal fabrications. 1. Include plans, elevations, sections, and details of metal fabrications and their connections. Show anchorage and accessory items. 1.3 INFORMATIONAL SUBMITTALS A. Mill Certificates: Signed by manufacturers of stainless-steel certifying that products furnished comply with requirements. B. Welding certificates. C. Paint Compatibility Certificates: From manufacturers of topcoats applied over shop primers certifying that shop primers are compatible with topcoats. 1.4 QUALITY ASSURANCE A. Welding Qualifications: Qualify procedures and personnel according to AWS D1.1, “Structural Welding Code - Steel.” B. Welding Qualifications: Qualify procedures and personnel according to the following: 1. AWS D1.1, “Structural Welding Code - Steel.” 2. AWS D1.2, “Structural Welding Code - Aluminum.” 3. AWS D1.6, “Structural Welding Code - Stainless Steel.” C. Fabricator Qualifications: A qualified fabricator with a record of successfully performed projects of comparable size and complexity during the previous 5 years and who participates in one of the following certification programs: 1. AISC Certification Quality Management Systems Program: Certified Building Fabricator (BU). 2. International Accreditation Service: AC172, Accreditation Criteria for Fabricator Inspection Programs for Structural Steel. BCRUA - Phase 1D WTP Expansion Issued for Bid Metal Fabrications 05 50 00 - 2 1.5 PROJECT CONDITIONS A. Field Measurements: Verify actual locations of walls and other construction contiguous with metal fabrications by field measurements before fabrication. 1.6 COORDINATION A. Coordinate selection of shop primers with topcoats to be applied over them. Comply with paint and coating manufacturers’ written recommendations to ensure that shop primers and topcoats are compatible with one another. B. Coordinate installation of anchorages and steel weld plates and angles for casting into concrete. Furnish setting drawings, templates, and directions for installing anchorages, including sleeves, concrete inserts, anchor bolts, and items with integral anchors, that are to be embedded in concrete or masonry. Deliver such items to Project site in time for installation. PART 2 PRODUCTS 2.1 METALS, GENERAL A. Metal Surfaces, General: Provide materials with smooth, flat surfaces unless otherwise indicated. For metal fabrications exposed to view in the completed Work, provide materials without seam marks, roller marks, rolled trade names, or blemishes. 2.2 METALS AND MATERIALS A. As indicated on Drawings. 2.3 FABRICATION, GENERAL A. Shop Assembly: Preassemble items in the shop to greatest extent possible. Disassemble units only as necessary for shipping and handling limitations. Use connections that maintain structural value of joined pieces. Clearly mark units for reassembly and coordinated installation. B. Cut, drill, and punch metals cleanly and accurately. Remove burrs and ease edges to a radius of approximately 1/32 inch (1 mm) unless otherwise indicated. Remove sharp or rough areas on exposed surfaces. C. Form bent-metal corners to smallest radius possible without causing grain separation or otherwise impairing work. D. Form exposed work with accurate angles and surfaces and straight edges. E. Weld corners and seams continuously to comply with the following: 1. Use materials and methods that minimize distortion and develop strength and corrosion resistance of base metals. 2. Obtain fusion without undercut or overlap. 3. Remove welding flux immediately. 4. At exposed connections, finish exposed welds and surfaces smooth and blended so no roughness shows after finishing. BCRUA - Phase 1D WTP Expansion Issued for Bid Metal Fabrications 05 50 00 - 3 F. Form exposed connections with hairline joints, flush and smooth, using concealed fasteners or welds where possible. Where exposed fasteners are required, use Phillips flat-head (countersunk) fasteners unless otherwise indicated. Locate joints where least conspicuous. G. Fabricate seams and other connections that will be exposed to weather in a manner to exclude water. Provide weep holes where water may accumulate. H. Cut, reinforce, drill, and tap metal fabrications as indicated to receive finish hardware, screws, and similar items. I. Provide for anchorage of type indicated; coordinate with supporting structure. Space anchoring devices to secure metal fabrications rigidly in place and to support indicated loads. 1. Where units are indicated to be cast into concrete or built into masonry, equip with integrally welded steel strap anchors, 1/8 by 1-1/2 inches (3.2 by 38 mm), with a minimum 6-inch (150-mm) embedment and 2-inch (50-mm) hook, not less than 8 inches (200 mm) from ends and corners of units and 24 inches (600 mm) o.c., unless otherwise indicated. 2.4 FINISHES, GENERAL A. Comply with NAAMM’s “Metal Finishes Manual for Architectural and Metal Products” for recommendations for applying and designating finishes. B. Finish metal fabrications after assembly. C. Finish exposed surfaces to remove tool and die marks and stretch lines, and to blend into surrounding surface. 2.5 STEEL AND IRON FINISHES A. Galvanizing: Hot-dip galvanize to comply with ASTM A153 for steel and iron hardware and with ASTM A123 for other steel and iron products. 1. Do not quench or apply post galvanizing treatments that might interfere with paint adhesion. 2.6 STAINLESS-STEEL FINISHES A. Remove tool and die marks and stretch lines or blend into finish. B. Grind and polish surfaces to produce uniform, directionally textured, polished finish indicated, free of cross scratches. Run grain with long dimension of each piece. C. When polishing is completed, passivate and rinse surfaces. Remove embedded foreign matter and leave surfaces chemically clean. 2.7 ALUMINUM FINISHES A. Finish designations prefixed by AA comply with the system established by the Aluminum Association for designating aluminum finishes. B. As-Fabricated Finish: AA-M10 (Mechanical Finish: as fabricated, unspecified). BCRUA - Phase 1D WTP Expansion Issued for Bid Metal Fabrications 05 50 00 - 4 2.8 MISCELLANEOUS MATERIALS A. Anti-Seize Lubricant: Loctite LB 8023 Marine Grade Anti-Seize, or approved equal. PART 3 EXECUTION 3.1 INSTALLATION, GENERAL A. Cutting, Fitting, and Placement: Perform cutting, drilling, and fitting required for installing metal fabrications. Set metal fabrications accurately in location, alignment, and elevation; with edges and surfaces level, plumb, true, and free of rack; and measured from established lines and levels. B. Fit exposed connections accurately together to form hairline joints. Weld connections that are not to be left as exposed joints but cannot be shop welded because of shipping size limitations. Do not weld, cut, or abrade surfaces of exterior units that have been hot-dip galvanized after fabrication and are for bolted or screwed field connections. C. Field Welding: Comply with the following requirements: 1. Use materials and methods that minimize distortion and develop strength and corrosion resistance of base metals. 2. Obtain fusion without undercut or overlap. 3. Remove welding flux immediately. 4. At exposed connections, finish exposed welds and surfaces smooth and blended so no roughness shows after finishing and contour of welded surface matches that of adjacent surface. D. Fastening to In-Place Construction: Provide anchorage devices and fasteners where metal fabrications are required to be fastened to in-place construction. Provide threaded fasteners for use with concrete and masonry inserts, toggle bolts, through bolts, lag screws, wood screws, and other connectors. E. Provide temporary bracing or anchors in formwork for items that are to be built into concrete, masonry, or similar construction. F. Corrosion Protection: Coat concealed surfaces of aluminum that will come into contact with grout, concrete, masonry, wood, or dissimilar metals with the following: 1. Cast Aluminum: Heavy coat of bituminous paint. 2. Extruded Aluminum: Two coats of clear lacquer. G. Stainless Steel Bolt Installation: Install stainless steel nuts and bolts with anti-seize lubricant. 3.2 FIELD QUALITY CONTROL A. Testing Agency: Owner will engage a qualified independent testing and inspecting agency to inspect field welds and high-strength bolted connections. B. Bolted Connections: Field-bolted connections will be tested and inspected according to RCSC's “Specification for Structural Joints Using ASTM A325 or A490 Bolts.” BCRUA - Phase 1D WTP Expansion Issued for Bid Metal Fabrications 05 50 00 - 5 C. Welded Connections: Field welds will be 100 percent visually inspected according to AWS D1.1. D. Correct deficiencies in Work that test reports and inspections indicate does not comply with the Contract Documents. 1. Corrective measures shall be taken when welding is unsatisfactory or indicates inferior workmanship. Chip and grind if the removal of part of the weld or a portion of the base metal is required. Where deposition of additional weld material is necessary, the sides of the area to be welded shall have no less than one to one (1:1) slope to allow room for depositing new material. Correct defective or unsound welds by the removal and replacement of the entire weld using the following procedures: a. Excessive Convexity: Reduce to size by removal of excess weld metal by grinding. b. Shrinkage Cracks, Cracks in Base Metal, Craters and Excessive Porosity: Remove defective portions of base and weld material down to sound metal, and deposit additional sound material. c. Undercutting, Undersize, and Excessive Concavity: Clean and deposit additional weld metal. d. Overlapping and Incomplete Fusion: Remove and replace the defective portion of the weld. e. Slag Inclusion: Remove those parts of the welds containing slag. Fill with sound weld metal. f. Removal of Adjacent Base Metal during Welding: Clean and form full size by depositing weld material. 2. Remove cracked welds throughout their length. 3. Where work performed subsequently to the making of the deficient weld has rendered the weld inaccessible, or has caused new conditions which make connection of the deficiency dangerous or ineffectual, restore the original conditions by removing welds or members, or both before making the necessary corrections. Another option is to compensate for the deficiency with additional work according to the revised design, approved by the Engineer. 4. Cut apart and reweld improperly fitted and misaligned parts. 5. Straighten members distorted by heat of welding using mechanical means or by carefully supervised application of a limited amount of localized heat. Heated areas shall not exceed 1200 degrees Fahrenheit as measured by Tempilsticks. Parts to be heated for straightening shall be free from external stress forces, except when mechanical means are used in conjunction with heat application. 6. If faulty welding or its removal for rewelding damages the base metal so that, in the Engineer's judgment, it is not in accordance with the intent of the Contract Documents, remove and replace the damaged material and compensate for the deficiency in a manner acceptable to the Engineer. 7. Maximum space between pieces or members for fillet welds shall be 1/16 inch. Only effective portion shall be considered in measuring fillet welds. 3.3 ADJUSTING AND CLEANING A. Galvanized Surfaces: Clean field welds, bolted connections, and abraded areas and repair galvanizing to comply with ASTM A780 and shall closely match original galvanized steel finish. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Metal Railings 05 52 00 - 1 SECTION 05 52 00 - METAL RAILINGS PART 1 GENERAL 1.1 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install guardrails, handrails, stair railing, toeguards and ancillary fasteners and components, and to tie-in to existing guardrail systems as required to provide a continuous fall protection system. 1.2 QUALITY ASSURANCE A. Acceptable Manufacturers: 1. Aluminum handrails by the following manufacturers that comply with these specifications will be acceptable: a. Thompson Fabrication Company. b. Approved equal. B. Design Criteria: Guardrails and handrails shall conform to OSHA requirements and shall be designed to resist a concentrated load of 200 pounds applied to the top rail at any point and in any direction. Deflections resulting from such stresses shall not be permanent. Reinforcing dowels may be required to meet these requirements. C. Style: Handrails and guardrails shall be multi-rail. The number of rails shall be two, or as required by local codes or OSHA requirements. Railings not accessible to the public shall be designed so that a clear spacing between horizontal rails shall not exceed 21”. Railings accessible to the public shall be designed so that the clear spacing between horizontal rails shall not exceed 4 inches. D. Tolerances: The railing system shall be installed to the following tolerances: Maximum variation from plumb 1/4” Maximum offset from alignment 1/4” 1.3 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Manufacturer’s product data sheets and specifications. 2. Certification of compliance with local, state, or Federal codes, and OSHA requirements. 3. Shop drawings indicating railing layout, methods of assembly, attachments, anchorage types, and expansion joints. 4. List as necessary. 1.4 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: 1. American Society of Testing and Materials (ASTM) Standards: ASTM B26 Specification for Aluminum-Alloy Sand Castings BCRUA - Phase 1D WTP Expansion Issued for Bid Metal Railings 05 52 00 - 2 ASTM B43 Specification for of Seamless Red Brass Pipe, Standard Sizes ASTM B210 Specification for Aluminum and Aluminum-Alloy Drawn Seamless Tubes ASTM B221 Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes ASTM B241 Specification for Aluminum and Aluminum-Alloy Seamless Pipe and Seamless Extruded Tube ASTM E894 Test Method for Anchorage of Permanent Metal Railing Systems and Rails for Buildings ASTM E985 Specifications for Permanent Metal Railing Systems and Rails for Buildings 2. American National Standards Institute (ANSI) Standards: ANSI A21.1 Safety Requirements for Floor and Wall Openings, Railings, and Toe Boards ANSI A58.1 Minimum Design Loads in Buildings and Other Structures ANSI A117.1 Specifications for Making Building and Structures Accessible to and Usable by Physically Handicapped 3. American Welding Society (AWS) Code: AWS Code for Welding in Building Construction 4. Aluminum Association (AA) Publications: ABH-21 Aluminum Brazing Handbook ADS-1 Aluminum Standards and Data DAF-45 Designation System for Architectural Finishes SAA-46 Standards for Anodized Architectural Aluminum 5. Occupational Safety and Health Administration (OSHA) Standards: OSHA 29 CFR 1910 Occupational Safety and Health Standards 6. International Code Council (ICC): IBC 2012 International Building Code 7. National Association of Architectural Metal Manufacturers (NAAMM): NAAMM Metal Finishes Manual NAAMM Pipe Railing Manual NAAMM Stair Manual BCRUA - Phase 1D WTP Expansion Issued for Bid Metal Railings 05 52 00 - 3 1.5 DELIVERY AND STORAGE A. Wrap aluminum surfaces in protective paper or plastic when shipped. Leave protective coverings in place until near completion of the project and then remove along with the adhesive. 1.6 JOB CONDITIONS A. The Contractor shall be responsible for taking complete field measurements of all areas scheduled for guardrails or handrails to assure a proper fit to field conditions. B. Provide any concrete inserts required for railing anchorage. C. Aluminum surfaces in contact with concrete or grout shall be protected with a coat of bituminous paint or mylar isolators. D. Provide handrails at both sides of stairs. Where sides of stairs consist of a solid wall, a single handrail may be provided along with handrail brackets to anchor handrail to wall surface. Handrails at wall surfaces shall have curved railings which return to the wall. E. Top handrail shall extend continuously over posts, rather than attaching to sides of posts. Provide splices in horizontal railings complete with splice reinforcing inserts. Provide expansion joints at 30-foot maximum intervals or as recommended by the manufacturer, whichever is the lesser. Provide expansion fitting which is anchored to one railing and is free to move at the opposite railing. 1.7 OPTIONS A. The Contractor may use a mechanically fastened or welded aluminum pipe system. PART 2 PRODUCTS 2.1 MATERIALS A. Aluminum Pipe Posts and Railing: Extruded seamless aluminum pipe alloy 6063-T52 or T6 B. Aluminum Cast Fittings: High strength, aluminum alloy 214. Fittings shall include wall returns, socket floor flanges, post sleeves, splice connectors, expansion joint connectors, handrail brackets, welding fittings, post caps and end caps. C. Toe Boards: Extruded aluminum alloy 6063-T52, conforming to ASTM B221 and ANSI A21.1, having a special, slightly curved shape, and brackets which anchor to posts, approximately 4 inches high. D. Mechanical Fasteners: Furnish mechanical fasteners as recommended by the manufacturer. Type 316 stainless steel E. Factory Bends and Special Railings: Furnish factory bend at railings, including stair turns and other special shapes required by the conditions. Perform no bending in the field. Shapes requiring more than one piece shall be shop welded with welds ground smooth and not visible when erected. F. Structural Adhesive: An approved epoxy adhesive, as recommended by the railing manufacturer, such as 3M “Scotch-Weld”, or approved equal. G. Post Setting Epoxy: Silicone Specialties “E-Bond #165”, Sika Corp. “Sikadur Hi-mod”, or approved equal. H. Steel Anchors: Anchors and other appurtenances shall conform to 316 Stainless Steel. I. Safety Chain: 13-link-per-foot wrought aluminum chain with 1/4-inch stainless steel eyebolt and harness snap. BCRUA - Phase 1D WTP Expansion Issued for Bid Metal Railings 05 52 00 - 4 2.2 MANUFACTURED PRODUCTS A. Finish: Finish for exposed aluminum handrails shall be NAAMM satin finish (188-220) or MIO-C22-A-41 grit with clear alumilite finish. 2.3 ALUMINUM MECHANICAL RAILING SYSTEM A. Railings shall be a complete, pre-engineered, mechanically fastened railing system, including all fittings and hardware fabricated by one manufacturer, and consisting of all components and accessories necessary for a complete system. Components shall be shipped with aluminum surfaces plastic wrapped. B. Mechanical fasteners shall be designed with connectors which anchor to posts and which are locked into position with threaded tubular rivets and stainless steel machine screws. Each fitting shall have adhesive applied to the fitting before the tubing is mated to the connector. C. Furnish all components necessary to assemble the railing system, including floor flanges, connector sleeves, end caps, post caps, socket type wall returns, elbows, radius fittings, and wall brackets. Cap all open ends of the pipe. Return all handrails to the wall. Provide floor flanges at posts and handrail brackets for wall mounted handrails. D. Ends shall be cut square and free of burrs. Rivet holes shall be drilled in such a manner that rivet holes seat properly to the surface of the rail. Provide water drainage weep holes at all posts grouted into concrete and otherwise installed in a manner to collect water. 2.4 TOE BOARDS A. Toe boards shall be extruded aluminum having a slightly curved shape or otherwise designed with offset flanges to provide stiffness. Toe boards shall have an integral extruded bracket on backside which locks into an aluminum clamp at each vertical post. Bracket and clamp will not be a rigid connection, but will allow toe board to slide in clamp for expansion and contraction. Provide prefabricated corners. 2.5 GATES AND OPENINGS A. Opening in guardrails shall be protected by means of a self-closing gate with automatic latching device. Where noted on drawings, opening may be protected by a non-corrosive chain across the opening, attached to an eye-bolt on one end and having a spring activated harness clip on the other which fastens to an eye-bolt in the opposite post. B. Regardless of type of railing system used, gates shall be fabricated with all welded joints. Gates shall have two heavy duty self-closing hinges per leaf. Where two leafs occur, provide a keeper on one leaf which secures the gate to concrete floor. PART 3 EXECUTION 3.1 PREPARATION A. Install sleeves and anchor plates in concrete as it is placed. BCRUA - Phase 1D WTP Expansion Issued for Bid Metal Railings 05 52 00 - 5 3.2 INSTALLATION A. Post spacing shall not exceed maximum spacing required by local or state codes, or OSHA requirements, or 8-foot centers; whichever is least. Handrail posts at stairs shall be spaced as required to produce uniform spacing between posts. B. Assemble and erect aluminum railing systems in strict adherence with the manufacturer’s printed instructions. Install posts plumb and true to line. Provide anchors, plates, angles and necessary fasteners to secure components into position. Top rails shall be continuous without interruption the entire length of handrails, in accordance with OSHA 1910.23 requirements. C. Provide extensions at both ends of the stair terminals, in accordance with OSHA requirements. Extend wall mounted handrails a minimum of 12 inches beyond the end of the stair. Handrails at stairs shall have a height of 2 feet-10 inches. Guardrail heights shall be 3 feet-6 inches. Make smooth radius transitions between the stair rails and guardrails. Transitions from horizontal rails to sloping rails and terminations at ends of railing shall have rounded corners. D. Install toe boards between posts at locations indicated on the plans or required by OSHA. Toe boards shall be shipped in 24-foot lengths and cut to fit in the field. Provide clamp at each past which locks in to groove on backside of toe board. Attachment shall allow the metal to expand and contract. Splices shall occur only at vertical posts. E. Provide splices and expansion joints, each having an internal splice connector. Install expansion joints according to the manufacturer’s recommendations. Expansion joints shall be free to move on one side and shall not exceed intervals of 30 feet on straight runs. F. Apply one coat of bituminous paint with a minimum thickness of 10 mils dry film thickness at railing components in contact with concrete or dissimilar materials. G. Provide a 3/16-inch stainless steel safety chain attached to an eye-bolt at the vertical post, where indicated on the plans. Provide a spring loaded clip at the opposite end. H. Provide 3/16-inch diameter weep holes located 1/4 to 3/4 inch above the grout line at exterior posts set in concrete. I. Assemble steel pipe handrails to culvert headwalls in the field by welding completely around the pipe. 3.3 CLEAN AND ADJUST A. Remove any protective covering from handrails and remove all adhesive. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Joint Sealants 07 92 00 - 1 SECTION 07 92 00 - JOINT SEALANTS PART 1 GENERAL 1.1 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.2 SUMMARY A. Section Includes: 1. Polysulfide joint sealants. 1.3 ACTION SUBMITTALS A. Product Data: For each joint-sealant product. B. Samples for Initial Selection: Manufacturer’s color charts consisting of strips of cured sealants showing the full range of colors available for each product exposed to view. C. Samples for Verification: For each kind and color of joint sealant required, provide Samples with joint sealants in 1-inch- wide joints formed between two 6-inch- long strips of material matching the appearance of exposed surfaces adjacent to joint sealants. 1. Include backing material. D. Joint-Sealant Schedule: Include the following information: 1. Joint-sealant application, joint location, and designation. 2. Joint-sealant manufacturer and product name. 3. Joint-sealant formulation. 4. Joint-sealant color. 5. Manufacturer recommended backing material. 1.4 QUALITY ASSURANCE A. Installer Qualifications: An authorized representative who is trained and approved by manufacturer. 1.5 FIELD CONDITIONS A. Do not proceed with installation of joint sealants under the following conditions: 1. When ambient and substrate temperature conditions are outside limits permitted by joint- sealant manufacturer or are below 40 deg F. 2. When joint substrates are wet. 3. Where joint widths are less than those allowed by joint-sealant manufacturer for applications indicated. 4. Where contaminants capable of interfering with adhesion have not yet been removed from joint substrates. BCRUA - Phase 1D WTP Expansion Issued for Bid Joint Sealants 07 92 00 - 2 1.6 WARRANTY A. Special Manufacturer’s Warranty: Manufacturer agrees to furnish joint sealants to repair or replace those joint sealants that do not comply with performance and other requirements specified in this Section within specified warranty period. 1. Warranty Period: 5 years from date of Substantial Completion. PART 2 PRODUCTS 2.1 JOINT SEALANTS, GENERAL A. Compatibility: Provide joint sealants, backings, and other related materials that are compatible with one another and with joint substrates under conditions of service and application, as demonstrated by joint-sealant manufacturer, based on testing and field experience. B. Colors of Exposed Joint Sealants: Coordinate with existing construction and closely match existing sealant color. 2.2 POLYSULFIDE JOINT SEALANTS A. Polysulfide, M, NS, 25, T, NT: Multicomponent, nonsag, plus 25 percent and minus 25 percent movement capability, polysulfide joint sealant; ASTM C920, Type M, Grade NS, Class 25. 1. Synthacalk GC2+ by Pecora Corporation. Use with recommended primer. 2. Approved equal. 2.3 JOINT-SEALANT BACKING A. Sealant Backing Material, General: Nonstaining; compatible with joint substrates, sealants, primers, and other joint fillers; and approved for applications indicated by sealant manufacturer based on field experience and laboratory testing. B. Cylindrical Sealant Backings: ASTM C1330, Type C (closed-cell material with a surface skin), as approved in writing by joint-sealant manufacturer for joint application indicated, and of size and density to control sealant depth and otherwise contribute to producing optimum sealant performance. C. Bond-Breaker Tape: Polyethylene tape or other plastic tape recommended by sealant manufacturer for preventing sealant from adhering to rigid, inflexible joint-filler materials or joint surfaces at back of joint. Provide self-adhesive tape where applicable. 2.4 MISCELLANEOUS MATERIALS A. Primer: Material recommended by joint-sealant manufacturer where required for adhesion of sealant to joint substrates indicated. B. Cleaners for Nonporous Surfaces: Chemical cleaners acceptable to manufacturers of sealants and sealant backing materials, free of oily residues or other substances capable of staining or harming joint substrates and adjacent nonporous surfaces in any way, and formulated to promote optimum adhesion of sealants to joint substrates. C. Masking Tape: Nonstaining, nonabsorbent material compatible with joint sealants and surfaces adjacent to joints. BCRUA - Phase 1D WTP Expansion Issued for Bid Joint Sealants 07 92 00 - 3 PART 3 EXECUTION 3.1 EXAMINATION A. Examine joints indicated to receive joint sealants, with Installer present, for compliance with requirements for joint configuration, installation tolerances, and other conditions affecting performance of the Work. B. Proceed with installation only after unsatisfactory conditions have been corrected. 3.2 PREPARATION A. Surface Cleaning of Joints: Clean out joints immediately before installing joint sealants to comply with joint-sealant manufacturer’s written instructions and the following requirements: 1. Remove all foreign material from joint substrates that could interfere with adhesion of joint sealant, including dust, paints (except for permanent, protective coatings tested and approved for sealant adhesion and compatibility by sealant manufacturer), old joint sealants, oil, grease, waterproofing, water repellents, water, surface dirt, and frost. 2. Clean porous joint substrate surfaces by brushing, grinding, mechanical abrading, or a combination of these methods to produce a clean, sound substrate capable of developing optimum bond with joint sealants. Remove loose particles remaining after cleaning operations above by vacuuming or blowing out joints with oil-free compressed air. Porous joint substrates include the following: a. Concrete. 3. Remove laitance and form-release agents from concrete. B. Joint Priming: Prime joint substrates where recommended by joint-sealant manufacturer. Apply primer to comply with joint-sealant manufacturer’s written instructions. Confine primers to areas of joint-sealant bond; do not allow spillage or migration onto adjoining surfaces. C. Masking Tape: Use masking tape where required to prevent contact of sealant or primer with adjoining surfaces that otherwise would be permanently stained or damaged by such contact or by cleaning methods required to remove sealant smears. Remove tape immediately after tooling without disturbing joint seal. 3.3 INSTALLATION OF JOINT SEALANTS A. General: Comply with joint-sealant manufacturer’s written installation instructions for products and applications indicated, unless more stringent requirements apply. B. Sealant Installation Standard: Comply with recommendations in ASTM C1193 for use of joint sealants as applicable to materials, applications, and conditions indicated. C. Install sealant backings of kind indicated to support sealants during application and at position required to produce cross-sectional shapes and depths of installed sealants relative to joint widths that allow optimum sealant movement capability. 1. Do not leave gaps between ends of sealant backings. 2. Do not stretch, twist, puncture, or tear sealant backings. 3. Remove absorbent sealant backings that have become wet before sealant application, and replace them with dry materials. D. Install bond-breaker tape behind sealants where sealant backings are not used between sealants and backs of joints. E. Install sealants using proven techniques that comply with the following and at the same time backings are installed: BCRUA - Phase 1D WTP Expansion Issued for Bid Joint Sealants 07 92 00 - 4 1. Place sealants so they directly contact and fully wet joint substrates. 2. Completely fill recesses in each joint configuration. 3. Produce uniform, cross-sectional shapes and depths relative to joint widths that allow optimum sealant movement capability. F. Tooling of Nonsag Sealants: Immediately after sealant application and before skinning or curing begins, tool sealants according to requirements specified in subparagraphs below to form smooth, uniform beads of configuration indicated; to eliminate air pockets; and to ensure contact and adhesion of sealant with sides of joint. 1. Remove excess sealant from surfaces adjacent to joints. 2. Use tooling agents that are approved in writing by sealant manufacturer and that do not discolor sealants or adjacent surfaces. 3. Coordinate joint profile shown with sealant manufacturer’s recommendations. 3.4 CLEANING A. Clean off excess sealant or sealant smears adjacent to joints as the Work progresses by methods and with cleaning materials approved in writing by manufacturers of joint sealants and of products in which joints occur. 3.5 PROTECTION A. Protect joint sealants during and after curing period from contact with contaminating substances and from damage resulting from construction operations or other causes so sealants are without deterioration or damage at time of Substantial Completion. If, despite such protection, damage or deterioration occurs, cut out, remove, and repair damaged or deteriorated joint sealants immediately so installations with repaired areas are indistinguishable from original work. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid High-Performance Coatings 09 96 00 - 1 SECTION 09 96 00 – HIGH-PERFORMANCE COATINGS PART 1 - GENERAL 1.1 SUMMARY A. Section includes high-performance coatings, other coating system components, and minimum surface preparation requirements. 1.2 REFERENCE STANDARDS A. Without limiting the general aspects of other requirements of these specifications, all surface preparation, coating and painting of interior and exterior surfaces shall conform to the applicable requirements of the Steel Structures Painting Council (SSPC), ASTM, NACE, NSF, current Local and Federal Health Standards, and the coating/paint manufacturer's printed instructions. 1.3 SUBMITTALS A. See Section 01 33 00 – Submittal Procedures for general requirements. B. Submittals Package: Submit product data and quality control submittals specified below at the same time as one package. C. Product Data: For each coating system, include manufacturer's name, brand name of product, manufacturer's identifying number (if applicable), color, formula analysis and percent by weight, flash point, surface preparation instructions, reducing and application instructions, coverage rates, and for products other than primers, the manufacturer's recommended primer. 1. Furnish color selection chart. Color selection for various components and work will be made through the Engineer following approval of the Submittals Package. D. Qualifications: Submit applicator experience qualifications as specified herein. Product data will not be reviewed until applicator experience qualifications have been submitted and approved. 1.4 QUALITY ASSURANCE A. Quality assurance procedures and practices shall be utilized to monitor all phases of surface preparation, application and inspection throughout the duration of the project. Procedures or practices not specifically defined herein may be utilized provided they meet recognized and accepted professional standards and are approved by the Engineer. B. Provide materials for each system type from a single manufacturer. C. Coating manufacturer's authorized representative shall provide written statement attesting that applicator has been instructed on proper preparation, mixing and application procedures for coatings specified. D. Applicators shall have minimum of 10 years of experience in application of similar products on similar projects. Provide references for minimum of three (3) different projects completed in last BCRUA - Phase 1D WTP Expansion Issued for Bid High-Performance Coatings 09 96 00 - 2 five (5) years with similar scope of work. Include name and address of project, size of project in value (painting) and contact person. E. Deviation from specified mil thickness or product type is not allowed without written approval of Engineer. F. Materials shall not be thinned unless approved, in writing, by coating manufacturer's authorized representative. 1.5 DELIVERY, STORAGE, AND HANDLING A. Deliver materials to the Site in original, new and sealed containers bearing the manufacturer's label. 1. Coating and paint materials shall not be used until the Owner’s Representative has inspected the contents and obtained data from information on container label. 2. Materials exceeding storage life recommended by the manufacturer shall be rejected. B. Store coatings in well-ventilated area and protect them from weather and excessive temperatures. 1. Flammable coatings must be stored in conformance with State and Federal safety codes for flammable coating and paint materials. 2. Coatings shall be protected from freezing at all times. C. Keep storage areas clean and restricted to coating and paint materials and related equipment. 1.6 PROJECT CONDITIONS A. Comply fully with the manufacturer's recommendations as to environmental conditions under which the coating and coating systems can be applied. B. Provide temporary heating, illumination, shade and/or dehumidification as required to bring area within acceptable limits. 1. Provide temporary dehumidification equipment properly sized to maintain humidity levels required by coating manufacturer. Provide clean heat with heat exchanger type equipment sufficient in size to maintain temperature on a 24 HR basis. Vent exhaust gases to exterior environment. No exhaust gases shall be allowed to vent into the space being coated or any adjacent space. 2. Keep mechanical ventilation in operation at all times while coating operations are being conducted and for a sufficient time thereafter to exhaust vapors from drying coatings. Ventilation shall reduce the concentration of air contaminants to a degree that a hazard does not exist. 3. Whenever required by the Engineer, provide additional illumination and necessary supports to cover all areas to be inspected. The level of illumination for inspection purposes shall be determined by the Engineer. C. Provide temporary partitions as required to protect adjacent mechanical equipment and other facilities from abrasive blasting particles, coatings overspray, and to contain coating vapors. D. Do not apply coatings in snow, rain, fog or mist. BCRUA - Phase 1D WTP Expansion Issued for Bid High-Performance Coatings 09 96 00 - 3 1.7 SAFETY AND HEALTH REQUIREMENTS A. Provide and require use of personnel protective equipment for persons working in the project Site, in accordance with requirements set forth by applicable regulatory agencies, the coating manufacturer's printed instructions, and appropriate technical bulletins and manuals. PART 2 - PRODUCTS 2.1 HIGH PERFORMANCE COATINGS MANUFACTURERS A. Tnemec Company, Inc., unless specified otherwise herein. B. Submit substitutions in accordance with Section 01 25 00 – Substitution Procedures. 2.2 MATERIALS A. Coatings listed are by Tnemec, unless noted otherwise. Products from other manufacturers may be considered provided that the product: 1. Is of the same generic resin. 2. Requires comparable surface preparation. 3. Has comparable application requirements. 4. Meets the same VOC levels or better. 5. Will withstand the atmospheric or immersion conditions of the location where it is to be applied. B. Where manufacturer’s product data sheet indicates a minimum mil thickness per coat that is greater than specified herein, mil thickness for entire coating system shall be increased proportionately. C. For unspecified materials, such as thinner, provide manufacturer's recommended products. D. High Performance Coatings: GENERIC DESCRIPTION PRODUCT Polyamide Epoxy Series 66 Hi-Build Epoxoline Zinc-Rich Urethane Series 90-97 Tneme-Zinc Zinc-Rich Urethane (NSF 61) Series 91-H 2 O Hydro-Zinc Aliphatic Acrylic Polyurethane Series 1094 Endura-Shield Epoxy Modified Cementitious Mortar Series 218 MortarClad Modified Waterborne Acrylate Series 156 Enviro-Crete Polyamidoamine Epoxy (NSF 61) Series N140 Pota-Pox Plus Modified Polyamine Epoxy (NSF 61) Series 22 Epoxoline Modified Polyamidoamine Epoxy Series 135 Chembuild BCRUA - Phase 1D WTP Expansion Issued for Bid High-Performance Coatings 09 96 00 - 4 GENERIC DESCRIPTION PRODUCT ¾ oz. Chopped Strand Mat Series 211-215 Fiberglass Mat Modified Polyamine Epoxy Series 215 Surfacing Epoxy Mortar additive Series 211-217 Slow Set Cementitious Repair Mortar Series 217 MortarCrete High zinc dust content regalvanizing paint ZRC Cold Galvanizing or Clearco High Performance Zinc Spray 2.3 COATING SYSTEMS Environment Surface Preparation Prime Coat Intermediate Coats Finish Coat Concrete, cast-in-place Potable Basin Exterior, Above Finished Grade SSPC SP-13 / NACE 6, Light Service 6.0 to 8.0 mil Series 156 Potable Basin Interior – NSF, Immersion SSPC SP-13 / NACE 6, Severe Service Min 1/8” Series 218 5.0 to 8.0 mil Series N140 20.0 to 40.0 mil Series 22 Existing block-out for Filter Washwater Trough – NSF, Immer- sion ICRI Guideline No. 310.2R-2103, CSP 4 or 5 4.0 to 6.0 mil Series N140 60 to 80 mil Series 215 2nd coat: 8.0 to 12.0 mil Series 22 2.5 to 3.0 mil Series 22 Ferrous Metals (Equipment with existing coating or factory applied coating not meeting specification; factory applied coating(s) to remain; includes pumps, motors, valves, etc.) Interior atmospheric (including corrosive en- vironment) 2.0 mil Series 135 2.5 mil Series 66 Exterior atmospheric 2.0 mil Series 135 2.0 mil Series 1094 Non Ferrous Metals, including piping Dissimilar Materials Protection 4.5 to 5.5 mil Series 66 Galvanized Metals, where finish top coat is not required Field touch-up of galva- nized surfaces ASTM A780 3.0 mil ZRC or Clearco Ductile Iron Piping Interior, non-immersion Pipe: NAPF 500-03-04 Fittings: NAPF 500-03-05 3.5 mil Series 90-97 6.0 mil Series 66 BCRUA - Phase 1D WTP Expansion Issued for Bid High-Performance Coatings 09 96 00 - 5 Environment Surface Preparation Prime Coat Intermediate Coats Finish Coat Exterior, non-immer- sion Pipe: NAPF 500-03-04 Fittings: NAPF 500-03-05 3.5 mil Series 90-97 6.0 mil Series 66 2.5 mil Series 1094 Immersion and within basins above water sur- face - NSF Pipe: NAPF 500-03-04 Fittings: NAPF 500-03-05 3.5 mil Series 91-H 2 O 6.0 mil Series N140 Steel Piping, Structural and Miscellaneous Steel Interior, non-immersion SSPC SP-6 3.5 mil Series 90-97 Stripe coat all weld seams Series 66 6.0 mil Series 66 Exterior, non-immer- sion SSPC SP-6 3.5 mil Series 90-97 Stripe coat all weld seams 2nd coat: 6.0 mil Series 66 2.5 mil Series 1094 Immersion and within basins above water sur- face - NSF SSPC SP-10 3.5 mil Series 91-H 2 O Stripe coat all weld seams Series N140 6.0 mil Series N140 2.4 COLOR IDENTIFICATION A. Color code piping in accordance with Color Schedule specified herein. PART 3 - EXECUTION 3.1 ITEMS TO BE COATED A. Cast-in-place concrete, where specified or specifically noted on Drawings. 1. Exterior of treatment basins, exposed areas above finished grade. 2. Interior components of treatment basins: a. Sedimentation Basin 4C Sludge Hopper walls. b. Block-outs for washwater troughs in Filter 7C. B. Ferrous metal piping, valves, fitting and supports. 1. Includes process piping scheduled to be insulated. C. Pumps and motors. D. Ferrous metal process equipment. E. Miscellaneous ferrous metal surfaces, where specifically noted on Drawings. F. Appurtenant surfaces attached to or adjacent to a surface indicated to be painted, such as conduit, boxes, covers and supports. BCRUA - Phase 1D WTP Expansion Issued for Bid High-Performance Coatings 09 96 00 - 6 3.2 ITEMS NOT TO BE COATED A. Concrete, except where specified or specifically noted on Drawings. B. Items with Approved Factory Finish, except items that require repair of damaged painted areas or painting of welded connections. C. Electrical equipment and conduit. D. Moving parts of mechanical and electrical units. E. Code labels, equipment identification or rating plates and similar labels, tagging and identification. F. Contact surfaces of friction-type structural connections. G. Stainless steel. H. Galvanized steel, except for field touch-up. I. Aluminum surfaces, except where in contact with concrete or dissimilar metals. J. Fiberglass. K. Plastic, including pipe. L. Interior of pipe, ducts and conduit. M. Pipe insulation and jacketing. 3.3 GENERAL PREPARATION AND PROTECTIONN A. Prepare surfaces to be painted in accordance with coating manufacturer's instructions, unless noted otherwise. B. Dust, dirt, oil, grease or any foreign matter that will affect the adhesion or durability of the coating shall be removed by washing with clean rags and an approved cleaning solvent, and wiped dry with clean rags. C. In order to prevent damage to surrounding painted areas, blast cleaning may require use of shrouding, shielding, and masking. If surrounding coatings are damaged, item shall be touched up or recoated, if necessary, at no additional cost to Owner. D. Painting equipment shall be designed for application of the materials specified and shall be maintained in proper working condition. Compressors shall have suitable traps and filters to remove water and oil from the air. Equipment shall be subject to approval by the Engineer. E. Adhere to manufacturer's recoat time requirements. F. Cover or otherwise protect finished work of other trades and surfaces not being painted concurrently or not to be painted. BCRUA - Phase 1D WTP Expansion Issued for Bid High-Performance Coatings 09 96 00 - 7 G. Prior to assembly, all surfaces made inaccessible after assembly shall be prepared as specified herein and shall receive the full paint system specified. 3.4 SURFACE PREPARATION A. Surface preparation and painting shall conform to applicable standards of the Steel Structures Painting Council (SSPC) and coating manufacturer's printed instructions. Material applied prior to approval of the surface by the Owner’s Representative shall be removed and reapplied at no expense to the Owner. B. Ferrous Metal: 1. Prepare ductile iron pipe in accordance with pipe manufacturer's recommendations and NAPF. a. All piping, pumps, valves, fittings and any other component used in the water piping system that requires preparation for painting shall be prepared in accordance with requirements for immersion service. b. Prepare all areas requiring patch painting in accordance with recommendations of manufacturer and NAPF. c. Remove bituminous coating per piping manufacturer, paint manufacturer and NAPF recommendations. 2. Complete fabrication, welding or burning before beginning surface preparation. a. Chip or grind off flux, spatter, slag or other laminations left from welding. b. Remove mill scale. c. Grind smooth rough welds and other sharp projections. 3. Solvent clean in accordance with SSPC SP 1. 4. Restore surface of field welds and adjacent areas to original surface preparation. C. Galvanized Steel and Non-ferrous Metals: 1. Solvent clean in accordance with SSPC SP 1 followed by brush-off blast clean in accordance with SSPC SP 16 to remove zinc oxide and other foreign contaminants. Provide uniform 1 mil profile surface. D. Concrete: 1. Allow new concrete to cure for minimum of 28 days. 2. Clean surfaces according to ASTM D4258. 3. Abrasive blast surfaces in accordance with ASTM D4259 and SSPC SP-13/NACE 6. E. Grout Installation for Existing Filter Washwater Trough Block-Outs using Form Boards: 1. Remove the existing coating system on top, bottom and both sides of the trough block-out, taking care to not damage existing coating system on both sides of wall. 2. Abrasive blast concrete, achieving a texture equal to or greater than ICRI Guideline No. 310.2R-2013, CSP 5. Other methods of abrading concrete may be considered by the Engineer; however, surface profile must equal or exceed that of CSP 5. 3. Abrasive blast exposed rebar per SSPC-SP10 Near White Metal Blast Cleaning. SSPC- SP11 Power Tool Cleaning may be allowed provided prepared surface meets the definition of an SSPC-SP10 cleaned surface. 4. Pre-wet concrete with potable water to a Saturated Surface Dry (SSD) condition. Pre-wet form boards. 5. Install a thin bond coat of Series 217 into the SSD concrete to ensure intimate contact. Note that full application of Series 217 must be installed prior to the bond coat drying. BCRUA - Phase 1D WTP Expansion Issued for Bid High-Performance Coatings 09 96 00 - 8 6. Blend one to three packets of Series 211-217 Slow Set additive into grout mix water. Mix water temperature shall be 70 deg F. 7. Blend Series 217 into mix water. 8. Blend 15 to 25 pounds pea gravel into Series 217 mixture. 9. Install fully blended Tnemec Series 217. F. Abrasive Blasting: 1. Schedule abrasive blasting operation so blasted surfaces will not be wet after blasting and before painting. 2. Provide compressed air for blasting that is free of water and oil. Provide accessible separators and traps. 3. Protect nameplates, valve stems, rotating equipment, motors and other items that may be damaged from blasting. 4. All abrasive-blasted ferrous metal surfaces shall be inspected immediately prior to application of paint coatings. Inspection shall be performed to determine cleanliness and profile depth of blasted surfaces and to certify that surface has been prepared in accordance with these Specifications. 5. Perform additional blasting and cleaning as required to achieve surface preparation required. a. Re-blast surfaces not meeting specification requirements. b. Prior to painting, re-blast surfaces allowed to set overnight and surfaces that show rust bloom. c. Surfaces allowed to set overnight or surfaces that show rust bloom prior to painting shall be re-inspected prior to paint application. 6. Profile depth of blasted surface: Not less than 1 mil or greater than 2 mils unless required otherwise by coating manufacturer. 7. Ensure abrasive blasting operation does not result in embedment of abrasive particles in paint film. 8. Confine blast abrasives to area being blasted. a. Provide shields of polyethylene sheeting or other such barriers to confine blast material. b. Plug pipes, holes, or openings before blasting and keep plugged until blast operation is complete and residue is removed. 9. Abrasive blasting media may be recovered, cleaned, and reused providing Contractor submits a comprehensive recovery plan to Engineer that outlines all procedures and equipment proposed in reclamation process. 10. Properly dispose of blasting material contaminated with debris from blasting operation. 3.5 APPLICATION A. Mix and apply coatings in strict accordance with the manufacturer's printed instructions for each coating. B. Provide complete coverage to mil thickness specified. Thickness specified is dry mil thickness. C. Thinning shall be permitted only as recommended by the paint manufacturer in writing and approved by the Engineer. D. Apply each coat evenly, free of brush marks, sags, runs, and with no evidence of poor workmanship. Finished surfaces shall be free from defects or blemishes. BCRUA - Phase 1D WTP Expansion Issued for Bid High-Performance Coatings 09 96 00 - 9 E. Work each application of material into corners, crevices, joints, and other difficult to work areas. F. Allow preceding coats to dry before recoating. Recoat within time limits specified by coating manufacturer. G. Back-roll surfaces if paint coatings are spray applied. When coating rough surfaces which cannot be back-rolled sufficiently, hand brush coating to work into all recesses. H. Coat all aluminum in contact with concrete and dissimilar materials. I. Temperature and weather conditions: Do not paint surfaces when surface temperature is below 50 Deg F, unless product has been formulated specifically for low temperature application and application is approved in writing by Engineer and paint manufacturer's authorized representative. Avoid painting surfaces exposed to hot sun. Do not paint on damp surfaces. J. Prime coat application: 1. Apply structural steel and miscellaneous steel prime coat in the factory. Factory applied prime coat shall meet requirements specified herein. 2. Prime all surfaces indicated to be painted, unless specified otherwise. Apply according to coating manufacturer instructions. 3. Prime ferrous metals embedded in concrete to minimum of 1 IN below exposed surfaces. 4. Apply zinc-rich primers while under continuous agitation. 5. Brush or spray bolts, welds, edges and difficult access areas with primer prior to primer application over entire surface. 6. Touch up damaged primer coats prior to applying intermediate and finish coats. K. Intermediate and finish coat application: 1. Apply according to coating manufacturer instructions. 2. Apply a preliminary stripe coat to all welded seams, welded joints, rivets, corners, bolts, crevices, etc. by roller or brush only. Dry film thicknesses (DFT) shall be as follows: a. Interior coating: 2-3 mils DFT. b. Exterior coating: 1.5-2.5 mils DFT. 3. Touch up damaged finish coats using same application method and same material specified for finish coat. L. Coating grout and adjacent concrete around Filter Washwater Troughs: 1. Following form removal and adequate grout cure, prepare surface per ICRI Guideline No. 310.2R-2103, CSP 4 or 5. Grout any cracks to a minimum of ¼-IN deep. 2. Abrade adjacent, existing coating system a minimum of 8-IN from newly placed grout to provide adequate tooth and anchor. All surfaces must be dry, clean and free of all contaminants. 3. Apply Series N140 prime coat per Coating Systems Table onto properly prepared grout and halfway over abraded existing coating system. 4. Fill all properly prepared cracks and form board anchor holes with Series 215 Surfacing Epoxy. Strike surface flush. 5. Apply Series 215 intermediate coat per Coating Systems Table to completely cover Series N140 prime coat. Leave at least 2-IN of exposed abraded coating. 6. Immediately embed Series 211-215 Fiberglass Mat into Series 215, leaving 1-IN of Series 215 around the edge un-glassed. Remove all air pockets to ensure intimate contact of fiberglass with Series 215. BCRUA - Phase 1D WTP Expansion Issued for Bid High-Performance Coatings 09 96 00 - 10 7. Immediately apply 2nd intermediate coat consisting of Series 22 per Coating Systems Table to fully saturate fiberglass, ensuring no dry spots remain. 8. Apply Series 22 finish coat per Coating Systems Table over saturated mat, exposed Series 215, and extend coating to completely cover all abraded areas. 3.6 QUALITY CONNTROL A. Allow Owner’s Representative an opportunity to observe and approve all preparation and coating work before proceeding to subsequent steps. B. Maintain Daily Records: Contractor shall record following information during application and curing periods. 1. Date, starting time, end time, and all breaks. 2. Air temperature. 3. Relative humidity. 4. Dew point. 5. Moisture content and pH level of concrete substrates prior to coating. 6. Surface temperature of substrate. 7. Provisions utilized to maintain work area within manufacturer's recommended parameters, including temporary heating, ventilation, cooling, dehumidification and provisions utilized to mitigate wind-blown dust and debris from contaminating the paint. 8. For exterior painting: Sky conditions and wind speed and direction. 9. Record environmental conditions, substrate moisture content and surface temperature information at least every 4 HRS during application. 10. Record hourly when temperatures are below 50 Deg F or above 100 Deg F. C. Contractor Performed Testing: Provide ongoing testing and inspection as follows. 1. Measurement and recording of environmental conditions. 2. Measurement and recording of substrate conditions. 3. Thickness Testing: a. Wet film thickness during application in accordance with ASTM D4414. b. Dry Film Thickness in accordance with SSPC PA 2 and ASTM D7091. D. Instrumentation: Provide as necessary to measure and record atmospheric and substrate conditions, including the following. 1. Dry Film Thickness Gauge. 2. Wet Film Thickness Gauge. 3. Sling Psychrometer. 4. Surface Temperature Gauge. 5. Anemometer. 6. Moisture Meter. 3.7 CLEANING A. Remove coating spots, oil and stains from adjacent surfaces. B. Clean, repair or refinish damage to surfaces to satisfaction of the Engineer. C. Remove all temporary materials used during coating work. BCRUA - Phase 1D WTP Expansion Issued for Bid High-Performance Coatings 09 96 00 - 11 3.8 COLOR SCHEDULE A. Pipe and Pipe Banding Schedule: 1. See Schedule: Piping and banding colors shall be approved by Owner. 2. For piping systems that are not painted, refer to Section 10 14 00 – Identification for Process Piping and Equipment for banding requirements. Abbrev. Service Material Paint Color Banding Color BWW Backwash Water STL Light Blue -- DR Drain DI Dark Gray -- DRW Decant Return Water DI Brown -- FLW Filtered Water STL Light Blue -- FLOC Fluosilicic Acid PVC -- Orange & Green LPA Low Pressure Air SST, Type 304L -- -- OVF Overflow STL Tan -- PTW Plant Water SST, Type 316L -- Blue PVC -- Blue DI Blue -- Copper -- Blue RW Raw Water STL Tan -- SHC Sodium Hypochlorite PVC -- Yellow & Red SL Sludge DI Brown -- SPL Sample SST, Type 316L -- -- PVC -- Tan STW Settled Water DI Green -- VT Vent DI Match Pipe Service -- WBW Waste Backwash Water STL Brown -- Material Abbreviations: DI – Ductile Iron, PVC – Polyvinyl Chloride, SST – Stainless Steel, STL – Steel END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Identification for Process Piping and Equipment 10 14 00 - 1 SECTION 10 14 00 - IDENTIFICATION FOR PROCESS PIPING AND EQUIPMENT PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. Tag, tape and stenciling systems for process equipment, piping, valves, pumps, and similar items, and hazard and safety signs. B. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Division 01 – General Requirements. 3. Section 09 96 00 – High-Performance Coatings. 4. Section 23 05 53 – Identification for HVAC. 5. Section 26 05 53 – Identification for Electrical Systems. 1.2 QUALITY ASSURANCE A. Reference Standards: 1. American Society of Mechanical Engineers (ASME): a. A13.1, Scheme for the Identification of Piping Systems. 2. The International Society of Automation (ISA). 3. National Electrical Manufacturers Association/American National Standards Institute (NEMA/ANSI): a. Z535.1, Safety Color Code. b. Z535.2, Environmental and Facility Safety Signs. c. Z535.3, Criteria for Safety Symbols. d. Z535.4, Product Safety Signs and Labels. 4. National Fire Protection Association (NFPA): a. 70, National Electrical Code (NEC). 5. Occupational Safety and Health Administration (OSHA): a. 29 CFR 1910.145, Specification for Accident Prevention Signs and Tags. 1.3 SUBMITTALS A. See Section 01 33 00 – Submittal Procedures for general requirements. B. Shop Drawings: 1. Product technical data including: a. Catalog information for all identification systems. b. Acknowledgement that products submitted meet requirements of standards referenced. 2. Identification register, listing all items in PART 3 of this Specification Section to be identified, type of identification system to be used, lettering, location and color. PART 2 PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. The following manufacturers are acceptable: BCRUA - Phase 1D WTP Expansion Issued for Bid Identification for Process Piping and Equipment 10 14 00 - 2 1. W.H. Brady Co. 2. Panduit. 3. Seton. 4. National Band and Tag Co. 5. Carlton Industries, Inc. B. Submit request for substitution in accordance with Section 01 25 00. 2.2 MANUFACTURED UNITS A. Type A1 - Round Metal Tags: 1. Materials: a. Aluminum or stainless steel. b. Stainless steel shall be used outdoors and in corrosive areas. 2. Size: a. Diameter: 1-1/2 IN minimum. b. Thickness: 0.035 IN (20 GA) minimum. 3. Fabrication: a. 3/16 IN minimum mounting hole. b. Legend: Stamped and filled with black coloring. 4. Color: Natural. B. Type A2 - Rectangle Metal Tags: 1. Materials: Stainless steel. 2. Size: a. 3-1/2 IN x 1-1/2 IN minimum or as indicated on Drawings. b. Thickness: 0.036 IN (20 GA) minimum. 3. Fabrication: a. 3/16 IN minimum mounting hole. b. Legend: Stamped and filled with black coloring. 4. Color: Natural. C. Type A3 - Metal Tape Tags: 1. Materials: Aluminum or stainless steel. 2. Size: a. Width 1/2 IN minimum. b. Length as required by text. 3. Fabrication: a. 3/16 IN minimum mounting hole. b. Legend: Embossed. 4. Color: Natural. D. Type B1- Square Nonmetallic Tags: 1. Materials: Fiberglass reinforced plastic. 2. Size: a. Surface: 2 x 2 IN minimum. b. Thickness: 100 mils. 3. Fabrication: a. 3/16 IN mounting hole with metal eyelet. b. Legend: Preprinted and permanently embedded and fade resistant. 4. Color: a. Background: Manufacturer standard or as specified. b. Lettering: Black. BCRUA - Phase 1D WTP Expansion Issued for Bid Identification for Process Piping and Equipment 10 14 00 - 3 E. Type B2 - Nonmetallic Signs: 1. Materials: Fiberglass reinforced or durable plastic. 2. Size: a. Surface: As required by text. b. Thickness: 60 mils minimum. 3. Fabrication: a. Rounded corners. b. Drilled holes in corners with grommets. c. Legend: Preprinted, permanently embedded and fade resistant for a 10- year minimum outdoor durability. 4. Color: a. Background: Manufacturer standard or as specified. b. Lettering: Black. 5. Standards for OSHA signs: NEMA/ANSI Z535.1, NEMA/ANSI Z535.2, NEMA/ANSI Z535.3, NEMA/ANSI Z535.4, OSHA 29 CFR 1910.145. F. Type C - Laminated Name Plates: 1. Materials: Phenolic or DR (high impact) acrylic. 2. Size: a. Surface: As required by text. b. Thickness: 1/16 IN. 3. Fabrication: a. Outdoor rated and UV resistant when installed outdoors. b. Two (2) layers laminated. c. Legend: Engraved through top lamination into bottom lamination. d. Two (2) drilled side holes, for screw mounting. 4. Color: Black top surface, white core, unless otherwise indicated. G. Type D - Self-Adhesive Tape Tags and Signs: 1. Materials: Vinyl tape or vinyl cloth. 2. Size: a. Surface: As required by text. b. Thickness: 5 mils minimum. 3. Fabrication: a. Indoor/Outdoor grade. b. Weather and UV resistant inks. c. Permanent adhesive. d. Legend: Preprinted. e. Wire markers to be self-laminating. 4. Color: White with black lettering or as specified. 5. Standards for OSHA signs: NEMA/ANSI Z535.1, NEMA/ANSI Z535.2, NEMA/ANSI Z535.3, NEMA/ANSI Z535.4, OSHA 29 CFR 1910.145. H. Type E - Heat Shrinkable Tape Tags: 1. Materials: Polyolefin. 2. Size: As required by text. 3. Fabrication: a. Legend: Preprinted. 4. Color: White background, black printing. I. Type F - Underground Warning Tape (Detectable): 1. Materials: Polyethylene with solid aluminum foil core. BCRUA - Phase 1D WTP Expansion Issued for Bid Identification for Process Piping and Equipment 10 14 00 - 4 2. Size: a. 6 IN wide (minimum). b. Thickness: 4.5 mils (minimum). 3. Fabrication: a. Legend: Preprinted and permanently embedded. b. Message continuous printed. c. Tensile strength: 1750 psi. 4. Color: As specified. J. Type G - Stenciling System: 1. Materials: a. Exterior type stenciling enamel. b. Either brushing grade or pressurized spray can form and grade. 2. Size: As required. 3. Fabrication: a. Legend: As required. 4. Color: Black or white for best contrast. 2.3 ACCESSORIES A. Fasteners: 1. Bead chain: #6 brass, aluminum or stainless steel. 2. Plastic strap: Nylon, urethane or polypropylene. 3. Screws: Self-tapping, stainless steel. 4. Adhesive, solvent activated. 2.4 MAINTENANCE MATERIALS A. Where stenciled markers are provided, clean and retain stencils after completion and include in extra stock, along with required stock of paints and applicators. PART 3 EXECUTION 3.1 GENERAL INSTALLATION A. Install identification devices at specified locations. B. All identification devices to be printed by mechanical process, hand printing is not acceptable. C. Attach tags to equipment with sufficient surface or body area with solvent activated adhesive applied to back of each tag. D. Attach tags with 1/8 IN round or flat head screws to equipment without sufficient surface or body area, or porous surfaces. 1. Where attachment with screws should not or cannot penetrate substrate, attach with plastic strap. E. Single items of equipment enclosed in a housing or compartment to be tagged on outside of housing. 1. Several items of equipment mounted in housing to be individually tagged inside the compartment. 3.2 SCHEDULES A. Process Systems: BCRUA - Phase 1D WTP Expansion Issued for Bid Identification for Process Piping and Equipment 10 14 00 - 5 1. General: a. Provide arrows and markers on exposed piping. 1) At 20 FT maximum centers along continuous lines. 2) At changes in direction (route) or obstructions. 3) At valves, risers, "T" joints, machinery or equipment. 4) Where pipes pass through floors, walls, ceilings, cladding assemblies and like obstructions provide markers on both sides. b. Position markers on both sides of pipe with arrow markers pointing in flow direction. 1) If flow is in both directions use double headed arrow markers. c. Apply tapes and stenciling in uniform manner parallel to piping. 2. Trenches with piping: a. Tag type: Type F - Underground Warning Tape b. Location: Halfway between top of piping and finished grade, or as indicated on Drawings. c. Letter height: 1-1/4 IN minimum. d. Potable water: 1) Color: Blue with black letters. 2) Legend: a) First line: “CAUTION CAUTION CAUTION” b) Second line: “BURIED WATER LINE BELOW” e. Storm drain, sanitary sewer, gray water, or non-potable water piping, except 3 IN and smaller irrigation pipe: 1) Color: Green with black letters. 2) Legend: a) First line: “CAUTION CAUTION CAUTION” b) Second line: “BURIED SEWER, DRAIN, or NONPOTABLE WATER LINE BELOW” f. Chemical feed piping (e.g., chlorine, sodium permanganate, copper sulfate, etc.): 1) Color: Yellow with black letters. 2) Legend: a) First line: “CAUTION CAUTION CAUTION” b) Second line: “BURIED CHEMICAL LINE BELOW” g. Other piping (e.g., raw water, fire protection, etc.): 1) Color: Yellow with black letters. 2) Legend: a) First line: “CAUTION CAUTION CAUTION” b) Second line: “BURIED PIPE LINE BELOW” 3. Yard valves, buried, with valve box and concrete pad: a. Tag type: Type A2 - Rectangle Metal Tags. b. Fastener: 3/16 IN x 7/8 IN plastic screw anchor with 1 IN #6 stainless steel pan head screw. c. Legend: 1) Letter height: 1/4 IN minimum. 2) Valve designation as indicated on the Drawings. 4. Exposed valves and slide gates: a. Tag type: 1) Outdoor locations: Type B1 - Square Nonmetallic Tags. BCRUA - Phase 1D WTP Expansion Issued for Bid Identification for Process Piping and Equipment 10 14 00 - 6 2) Indoor noncorrosive: a) Type A1 - Round Metal Tags. b) Type B1 - Square Nonmetallic Tags. 3) Indoor corrosive: a) Stainless steel Type A1 - Round Metal Tags. b) Type B1 - Square Nonmetallic Tags. b. Fastener: 1) Type A1: Chain of the same material. 2) Type B1: Stainless steel chain. c. Color: Per ASME A13.1 corresponding to the piping system. d. Legend: 1) Letter height: 1/4 IN minimum. 2) Valve designation as indicated on the Drawings. 5. Process equipment (e.g., pumps, pump motors, air compressors, etc.): a. Tag type: 1) Type B2 - Nonmetallic Signs. 2) Type D - Self-Adhesive Tape Tags and Signs. 3) Type G - Stenciling System. b. Fastener: 1) Self. 2) Screws. 3) Adhesive. c. Legend: 1) Letter height: 1/2 IN minimum. 2) Equipment designation as indicated on the Drawings (e.g., “Air Compressor AS-AC-00X”). 6. Piping systems: a. Tag type: 1) Outdoor locations: Type G - Stenciling System. 2) Indoor locations: a) Type D - Self-Adhesive Tape Tags and Signs. b) Type G - Stenciling System. b. Fastener: Self. c. Color: Per ASME A13.1 or as specified. d. Legend: 1) Letter height: Manufacturers standard for the pipe diameter. 2) Mark piping in accordance with ASME A13.1. 3) Use piping designation as indicated on the Drawings. 4) Arrow: Single arrow. e. Banding type: 1) Indoor and outdoor locations: Type D - Self-Adhesive Tape Tags and Signs. f. Fastener: Self. g. Color: Per ASME A13.1 or as specified. 7. Process tanks (over 1000 GAL) and basins, (e.g., chemical storage, surge tank, etc): a. Tag type: 1) Type B2 - Nonmetallic Signs. 2) Type G - Stenciling System. BCRUA - Phase 1D WTP Expansion Issued for Bid Identification for Process Piping and Equipment 10 14 00 - 7 b. Fastener: 1) Screw. 2) Self. c. Location as directed by Owner. d. Legend: 1) Letter height: 4 IN minimum. 2) Equipment designation as indicated on the Drawings. 8. Tanks (less than 1000 GAL) (e.g., chemical tanks, air receivers, etc.): a. Tag type: 1) Type D - Self-Adhesive Tape Tags and Signs. 2) Type G - Stenciling System. b. Fastener: Self. c. Legend: 1) Letter height: 2 IN minimum. 2) Equipment designation as indicated on the Drawings. 9. Equipment that starts automatically: a. Tag type: 1) Type B2 - Nonmetallic Signs. 2) Type D - Self-Adhesive Tape Tags and Signs. b. Fastener: 1) Type B2 - Screw or adhesive. 2) Type D - Self. c. Size: 5 IN x 7 IN d. Location: 1) Pumps and motors. 2) Generators. e. Legend: 1) OSHA Warning Sign. 2) Description of Warning: “THIS MACHINE STARTS AUTOMATICALLY”. B. Instrumentation Systems: 1. Instrumentation Equipment (e.g., flow control valves, primary elements, etc.): a. Tag type: 1) Outdoor locations: Type B1 - Square Nonmetallic Tags. 2) Indoor noncorrosive: a) Type A1 - Round Metal Tags. b) Type B1 - Square Nonmetallic Tags. 3) Indoor corrosive: a) Stainless steel Type A1 - Round Metal Tags. b) Type B1 - Square Nonmetallic Tags. b. Fastener: 1) Type A1: Chain of the same material. 2) Type B1: Stainless steel chain. c. Legend: 1) Letter height: 1/4 In minimum. 2) Equipment ISA designation as indicated on the Drawings. 3.3 HAZARD AND SAFETY SIGNS A. Provide Hazard and Safety Signs as specified, indicated on Drawings, and below: BCRUA - Phase 1D WTP Expansion Issued for Bid Identification for Process Piping and Equipment 10 14 00 - 8 1. Type B2. 2. Inscription as indicated on Drawings or directed by Owner. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Heating, Ventilating, and Air Conditioning 23 00 00 - 1 SECTION 23 00 00 – HEATING, VENTILATING, AND AIR CONDITIONING PART 1 GENERAL 1.1 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.2 SUMMARY A. This Section includes the following: 1. Piping materials and installation instructions common to most piping systems. 2. Transition fittings. 3. Dielectric fittings. 4. Mechanical demolition. 5. Equipment installation requirements common to equipment sections. 6. Painting and finishing. 1.3 DEFINITIONS A. Exposed, Exterior Installations: Exposed to view outdoors or subject to outdoor ambient temperatures and weather conditions. Examples include rooftop locations. B. The following are industry abbreviations for plastic materials: 1. PVC: Polyvinyl chloride plastic. 1.4 QUALITY ASSURANCE A. Electrical Characteristics for Mechanical Equipment: Equipment of higher electrical characteristics may be furnished provided such proposed equipment is approved in writing; connecting electrical services, circuit breakers, and conduit sizes are appropriately modified; and all is provided at no additional cost. If minimum energy ratings or efficiencies are specified, equipment shall comply with requirements. 1.5 DELIVERY, STORAGE, AND HANDLING A. Deliver pipes and tubes with factory-applied end caps. Maintain end caps through shipping, storage, and handling to prevent pipe end damage and to prevent entrance of dirt, debris, and moisture. B. Store plastic pipes protected from direct sunlight. Support to prevent sagging and bending. 1.6 COORDINATION A. Coordinate installation of required supporting devices and set sleeves in poured-in-place concrete and other structural components as they are constructed. BCRUA - Phase 1D WTP Expansion Issued for Bid Heating, Ventilating, and Air Conditioning 23 00 00 - 2 B. Coordinate requirements for access panels and doors for mechanical items requiring access that are concealed behind finished surfaces. Access panels and doors are specified in Division 08. PART 2 PRODUCTS 2.1 MANUFACTURERS A. In other Part 2 articles where subparagraph titles below introduce lists, the following requirements apply for product selection: 1. Manufacturers: Subject to compliance with requirements, provide products by the manufacturers specified. 2.2 PIPE, TUBE, AND FITTINGS A. Refer to individual Division 23 piping Sections for pipe, tube, and fitting materials and joining methods. B. Pipe Threads: ASME B1.20.1 for factory-threaded pipe and pipe fittings. 2.3 JOINING MATERIALS A. Refer to individual Division 23 piping Sections for special joining materials not listed below. B. Solder Filler Metals: ASTM B32, lead-free alloys. Include water-flushable flux according to ASTM B813. C. Brazing Filler Metals: AWS A5.8, BCuP Series, copper-phosphorus alloys for general-duty brazing, unless otherwise indicated; and AWS A5.8, BAg1, silver alloy for refrigerant piping, unless otherwise indicated. D. Solvent Cements for Joining Plastic Piping: 1. PVC Piping: ASTM D2564. Include primer according to ASTM F656. 2.4 DIELECTRIC FITTINGS A. Description: Combination fitting of copper alloy and ferrous materials with threaded, solder- joint, plain, or weld-neck end connections that match piping system materials. B. Insulating Material: Suitable for system fluid, pressure, and temperature. C. Dielectric Unions: Factory-fabricated, union assembly, for 250-psig (1725-kPa) minimum working pressure at 180 F (82 C). 1. Manufacturers: a. Capitol Manufacturing Co. b. Central Plastics Company. c. Epco Sales, Inc. d. Hart Industries, International, Inc. BCRUA - Phase 1D WTP Expansion Issued for Bid Heating, Ventilating, and Air Conditioning 23 00 00 - 3 e. Watts Industries, Inc.; Water Products Div. f. Zurn Industries, Inc.; Wilkins Div. D. Dielectric Couplings: Galvanized-steel coupling with inert and non-corrosive, thermoplastic lining; threaded ends; and 300-psig (2070-kPa) minimum working pressure at 225 F (107 C). 1. Manufacturers: a. Calpico, Inc. b. Lochinvar Corp. E. Dielectric Nipples: Electroplated steel nipple with inert and non-corrosive, thermoplastic lining; plain, threaded, or grooved ends; and 300-psig (2070-kPa) minimum working pressure at 225 F (107 C). 1. Manufacturers: a. Perfection Corp. b. Precision Plumbing Products, Inc. c. Sioux Chief Manufacturing Co., Inc. d. Victaulic Co. of America. PART 3 EXECUTION 3.1 MECHANICAL DEMOLITION A. Refer to Divisions 1 and 2 for general demolition requirements and procedures. B. Disconnect, demolish, and remove mechanical systems, equipment, and components indicated to be removed. 1. Piping to Be Removed: Remove portion of piping indicated to be removed and cap or plug remaining piping with same or compatible piping material. 2. Equipment to Be Removed: Disconnect and cap services and remove equipment. C. If pipe, insulation, or equipment to remain is damaged in appearance or is unserviceable, remove damaged or unserviceable portions and replace with new products of equal capacity and quality. 3.2 PIPING SYSTEMS - COMMON REQUIREMENTS A. Install piping according to the following requirements and Division 23 Sections specifying piping systems. B. Drawing plans, schematics, and diagrams indicate general location and arrangement of piping systems. Indicated locations and arrangements were used to size pipe and calculate friction loss, expansion, pump sizing, and other design considerations. Install piping as indicated unless deviations to layout are approved on Coordination Drawings. C. Install piping in concealed locations, unless otherwise indicated and except in equipment rooms and service areas. BCRUA - Phase 1D WTP Expansion Issued for Bid Heating, Ventilating, and Air Conditioning 23 00 00 - 4 D. Install piping indicated to be exposed and piping in equipment rooms and service areas at right angles or parallel to building walls. Diagonal runs are prohibited unless specifically indicated otherwise. E. Install piping to permit valve servicing. F. Install piping at indicated slopes. G. Install piping free of sags and bends. H. Install fittings for changes in direction and branch connections. I. Install piping, pipe hangers and supports to allow application of insulation. J. Select system components with pressure rating equal to or greater than system operating pressure. K. Wrap or enclose with rated materials PVC piping installed in rated spaces, including return air plenums. L. Verify final equipment locations for roughing-in. M. Refer to equipment specifications in other Sections of these Specifications for roughing-in requirements. 3.3 PIPING JOINT CONSTRUCTION A. Join pipe and fittings according to the following requirements and Division 23 Sections specifying piping systems. B. Ream ends of pipes and tubes and remove burrs. Bevel plain ends of steel pipe. C. Remove scale, slag, dirt, and debris from inside and outside of pipe and fittings before assembly. D. Soldered Joints: Apply ASTM B813, water-flushable flux, unless otherwise indicated, to tube end. Construct joints according to ASTM B828 or CDA’s “Copper Tube Handbook,” using lead-free solder alloy complying with ASTM B32. E. Brazed Joints: Construct joints according to AWS’s “Brazing Handbook,” “Pipe and Tube” Chapter, using copper-phosphorus brazing filler metal complying with AWS A5.8. F. Threaded Joints: Thread pipe with tapered pipe threads according to ASME B1.20.1. Cut threads full and clean using sharp dies. Ream threaded pipe ends to remove burrs and restore full ID. Join pipe fittings and valves as follows: 1. Apply appropriate tape or thread compound to external pipe threads unless dry seal threading is specified. 2. Damaged Threads: Do not use pipe or pipe fittings with threads that are corroded or damaged. Do not use pipe sections that have cracked or open welds. BCRUA - Phase 1D WTP Expansion Issued for Bid Heating, Ventilating, and Air Conditioning 23 00 00 - 5 G. Plastic Piping Solvent-Cement Joints: Clean and dry joining surfaces. Join pipe and fittings according to the following: 1. Comply with ASTM F402 for safe-handling practice of cleaners, primers, and solvent cements. 2. PVC Non-pressure Piping: Join according to ASTM D2855. H. Plastic Non-pressure Piping Gasketed Joints: Join according to ASTM D3212. 3.4 PIPING CONNECTIONS A. Make connections according to the following, unless otherwise indicated: 1. Install unions, in piping NPS 2 (DN 50) and smaller, adjacent to each valve and at final connection to each piece of equipment. 2. Dry Piping Systems: Install dielectric unions and flanges to connect piping materials of dissimilar metals. 3. Wet Piping Systems: Install dielectric coupling and nipple fittings to connect piping Materials of dissimilar metals. 3.5 EQUIPMENT INSTALLATION - COMMON REQUIREMENTS A. Install equipment level and plumb, parallel and perpendicular to other building systems and components in exposed interior spaces, unless otherwise indicated. B. Install mechanical equipment to facilitate service, maintenance, and repair or replacement of components. Connect equipment for ease of disconnecting, with minimum interference to other installations. Extend grease fittings to accessible locations. C. Install equipment to allow right of way for piping installed at required slope. 3.6 PAINTING A. Painting of mechanical systems, equipment, and components is specified in Division 09. B. Damage and Touchup: Repair marred and damaged factory-painted finishes with materials and procedures to match original factory finish. END OF SECTION BCRUA – Phase 1D WTP Expansion Issued for Bid Common Motor Requirements for HVAC Equipment 23 05 13 - 1 SECTION 23 05 13 - COMMON MOTOR REQUIREMENTS FOR HVAC EQUIPMENT PART 1 GENERAL 1.1 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.2 SUMMARY A. Section includes general requirements for single-phase and polyphase, general-purpose, horizontal, small and medium, squirrel-cage induction motors for use on alternating current power systems up to 600 V and installed at equipment manufacturer's factory or shipped separately by equipment manufacturer for field installation. 1.3 DEFINITIONS A. Factory-Installed Motor: A motor installed by motorized-equipment manufacturer as a component of equipment. 1.4 QUALITY ASSURANCE A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use. B. Comply with NFPA 70. 1.5 COORDINATION A. Coordinate features of motors, installed units, and accessory devices and features that comply with the following: 1. Compatible with the following: a. Magnetic controllers. b. Multispeed controllers. c. Reduced-voltage controllers. 2. Designed and labeled for use with variable frequency controllers, and suitable for use throughout speed range without overheating. 3. Matched to torque and horsepower requirements of the load. 4. Matched to ratings and characteristics of supply circuit and required control sequence. 5. Ambient and environmental conditions of installed location. BCRUA – Phase 1D WTP Expansion Issued for Bid Common Motor Requirements for HVAC Equipment 23 05 13 - 2 PART 2 PRODUCTS 2.1 GENERAL MOTOR REQUIREMENTS A. Comply with NEMA MG 1 unless otherwise indicated. B. Motor requirements apply to factory-installed motors except as follows: 1. Different ratings, performance, or characteristics for a motor are specified in another Section. 2. Manufacturer for a factory-installed motor requires ratings, performance, or characteristics, other than those specified in this Section, to meet performance specified. 2.2 MOTOR CHARACTERISTICS A. Duty: Continuous duty at ambient temperature of 105 F (40 C) and at altitude of 3300 feet (1005 m) above sea level. B. Capacity and Torque Characteristics: Sufficient to start, accelerate, and operate connected loads at designated speeds, at installed altitude and environment, with indicated operating sequence, and without exceeding nameplate ratings or considering service factor. C. Enclosure: Unless indicated otherwise, provide the following enclosure type: 1. Open Dripproof (ODP): Ventilation openings are arranged to prevent liquid drops from affecting performance when falling within a 15-degree angle from the vertical. Use: Indoors, in moderately clean environments. 2. Totally Enclosed, Fan Cooled (TEFC): A fan on the motor shaft, outside the stator housing and within a protective shroud, blows cooling air over the motor. Use: Outdoors. 2.3 POLYPHASE MOTORS A. Description: NEMA MG 1, Design B, medium induction motor. B. Efficiency: Premium efficient as defined in NEMA MG 1. C. Service factor: 1.15. D. Stator: Copper windings, unless otherwise indicated. 1. Multispeed motors shall have separate winding for each speed. E. Rotor: Random wound squirrel cage. F. Bearings: Regreasable, shielded, antifriction ball bearings suitable for radial and thrust loading. G. Temperature Rise: Match insulation rating. H. Insulation: Class F, unless otherwise indicated. I. Code Letter Designation: BCRUA – Phase 1D WTP Expansion Issued for Bid Common Motor Requirements for HVAC Equipment 23 05 13 - 3 1. Motors Smaller Than 15 HP: Manufacturer’s standard starting characteristic. 2.4 ADDITIONAL REQUIREMENTS FOR POLYPHASE MOTORS A. Motors Used with Reduced-Voltage and Multispeed Controllers: Match wiring connection requirements for controller with required motor leads. Provide terminals in motor terminal box, suited to control method. B. Motors Used with Variable Frequency Controllers: Inverter – duty rated. Ratings, characteristics, and features coordinated with and approved by controller manufacturer. 1. Windings: Copper magnet wire with moisture-resistant insulation varnish, designed and tested to resist transient spikes, high frequencies, and short time rise pulses produced by pulse-width-modulated inverters. 2. Premium-Efficient Motors: Class B temperature rise; Class F insulation. 3. Inverter-Duty Motors: Class F temperature rise; Class H insulation. 4. Thermal Protection: Comply with NEMA MG 1 requirements for thermally protected motors. 2.5 SINGLE-PHASE MOTORS A. Motors larger than 1/20 HP shall be one of the following, to suit starting torque and requirements of specific motor application: 1. Permanent-split capacitor. 2. Split-phase. 3. Capacitor start, inductor run. 4. Capacitor start, capacitor run. B. Multispeed Motors: Variable-torque, permanent-split-capacitor type. C. Bearings: Prelubricated, antifriction ball bearings or sleeve bearings suitable for radial and thrust loading. D. Motors 1/20 HP and Smaller: Shaded-pole type. E. Thermal Protection: Internal protection to automatically open power supply circuit to motor when winding temperature exceeds a safe value calibrated to temperature rating of motor insulation. Thermal-protection device shall automatically reset when motor temperature returns to normal range. PART 3 EXECUTION (NOT USED) END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Identification for HVAC Piping and Equipment 23 05 53 - 1 SECTION 23 05 53 - IDENTIFICATION FOR HVAC PART 1 GENERAL 1.1 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.2 SUMMARY A. This Section includes the following mechanical identification materials and their installation: 1. Equipment nameplates. 2. Equipment markers. 3. Equipment signs. 4. Access panel and door markers. 5. Warning tags. 1.3 SUBMITTALS A. Product Data: For each type of product indicated. PART 2 PRODUCTS 2.1 EQUIPMENT IDENTIFICATION DEVICES A. Equipment Nameplates: Metal, with data engraved or stamped, for permanent attachment on equipment. 1. Data: a. Manufacturer, product name, model number, and serial number. b. Capacity, operating and power characteristics, and essential data. c. Labels of tested compliances. 2. Location: Accessible and visible. 3. Fasteners: As required to mount on equipment. B. Equipment Markers: Engraved, color-coded laminated plastic. Include contact-type, permanent adhesive. 1. Terminology: Match schedules as closely as possible. 2. Data: a. Name and plan number. b. Equipment service. c. Design capacity. d. Other design parameters such as pressure drop, entering and leaving conditions, and speed. 3. Size: 2-1/2 by 4 inches (64 by 100 mm) for control devices, dampers, and valves; 4-1/2 by 6 inches (115 by 150 mm) for equipment. C. Equipment Signs: ASTM D709, Type I, cellulose, paper-base, phenolic-resin-laminate engraving stock; Grade ES-2, black surface, black phenolic core, with white melamine BCRUA - Phase 1D WTP Expansion Issued for Bid Identification for HVAC Piping and Equipment 23 05 53 - 2 subcore, unless otherwise indicated. Fabricate in sizes required for message. Provide holes for mechanical fastening. 1. Data: Instructions for operation of equipment and for safety procedures. 2. Engraving: Manufacturer’s standard letter style, of sizes and with terms to match equipment identification. 3. Thickness: 1/16 inch (1.6 mm) for units up to 20 sq. in. (130 sq. cm) or 8 inches (200 mm) in length, and 1/8 inch (3.2 mm) for larger units. 4. Fasteners: Self-tapping, stainless-steel screws or contact-type, permanent adhesive. D. Access Panel and Door Markers: 1/16-inch (1.6-mm) thick, engraved laminated plastic, with abbreviated terms and numbers corresponding to identification. Provide 1/8-inch (3.2-mm) center hole for attachment. 1. Fasteners: Self-tapping, stainless-steel screws or contact-type, permanent adhesive. 2.2 WARNING TAGS A. Warning Tags: Preprinted or partially preprinted, accident-prevention tags; of plasticized card stock with matte finish suitable for writing. 1. Size: Approximately 4 by 7 inches (100 by 178 mm). 2. Fasteners: Brass grommet and wire. 3. Nomenclature: Large-size primary caption such as DANGER, CAUTION, or DO NOT OPERATE. 4. Color: Yellow background with black lettering. PART 3 EXECUTION 3.1 APPLICATIONS, GENERAL A. Products specified are for applications referenced in other Division 23 Sections. If more than single-type material, device, or label is specified for listed applications, selection is Installer’s option. 3.2 EQUIPMENT IDENTIFICATION A. Install and permanently fasten equipment nameplates on each major item of mechanical equipment that does not have nameplate or has nameplate that is damaged or located where not easily visible. Locate nameplates where accessible and visible. B. Install equipment markers with permanent adhesive on or near each major item of mechanical equipment. Data required for markers may be included on signs, and markers may be omitted if both are indicated. 1. Letter Size: Minimum 1/4 inch (6.4 mm) for name of units if viewing distance is less than 24 inches (600 mm), 1/2 inch (13 mm) for viewing distances up to 72 inches (1830 mm), and proportionately larger lettering for greater viewing distances. Include secondary lettering 2/3 to 3/4 the size of principal lettering. 2. Data: Distinguish among multiple units, indicate operational requirements, indicate safety and emergency precautions, warn of hazards and improper operations, and identify units. BCRUA - Phase 1D WTP Expansion Issued for Bid Identification for HVAC Piping and Equipment 23 05 53 - 3 C. Install equipment signs with screws or permanent adhesive on or near each major item of mechanical equipment. Locate signs where accessible and visible. 1. Letter Size: Minimum 1/4 inch (6.4 mm) for name of units if viewing distance is less than 24 inches (600 mm), 1/2 inch (13 mm) for viewing distances up to 72 inches (1830 mm), and proportionately larger lettering for greater viewing distances. Include secondary lettering 2/3 to 3/4 the size of principal lettering. 2. Data: Distinguish among multiple units, indicate operational requirements, indicate safety and emergency precautions, warn of hazards and improper operations, and identify units. D. Install access panel markers with screws on equipment access panels. 3.3 WARNING-TAG INSTALLATION A. Write required message on, and attach warning tags to, equipment and other items where required. 3.4 ADJUSTING A. Relocate mechanical identification materials and devices that have become visually blocked by other work. 3.5 CLEANING A. Clean faces of mechanical identification devices and glass frames of valve schedules. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Testing, Adjusting, and Balancing for HVAC 23 05 93 - 1 SECTION 23 05 93 - TESTING, ADJUSTING, AND BALANCING FOR HVAC PART 1 GENERAL 1.1 SUMMARY A. This Section includes TAB to produce design objectives for the following: 1. Air Systems: a. Constant-volume air and single-zone variable-air-volume systems. 2. HVAC equipment quantitative-performance settings. 3. Verifying that automatic control devices are functioning properly. 4. Reporting results of activities and procedures specified in this Section. 1.2 SUBMITTALS A. Strategies and Procedures Plan: Within 30 days from Contractor’s Notice to Proceed, submit four copies of TAB strategies and step-by-step procedures as specified in Part 3 “Preparation” Article. Include a complete set of report forms intended for use on this Project. B. Certified TAB Reports: Submit two copies of reports prepared, as specified in this Section, on approved forms certified by TAB firm. C. Warranties specified in this Section. 1.3 QUALITY ASSURANCE A. TAB Firm Qualifications: Engage a TAB firm certified by AABC, NEBB, or TABB. B. Certification of TAB Reports: Certify TAB field data reports. This certification includes the following: 1. Review field data reports to validate accuracy of data and to prepare certified TAB reports. 2. Certify that TAB team complied with approved TAB plan and the procedures specified and referenced in this Specification. C. TAB Report Forms: Use standard forms from AABC’s “National Standards for Testing and Balancing Heating, Ventilating, and Air Conditioning Systems” or NEBB’s “Procedural Standards for Testing, Adjusting, and Balancing of Environmental Systems,” as applicable. 1.4 COORDINATION A. Coordinate the efforts of factory-authorized service representatives for systems and equipment, HVAC controls installers, and other mechanics to operate HVAC systems and equipment to support and assist TAB activities. BCRUA - Phase 1D WTP Expansion Issued for Bid Testing, Adjusting, and Balancing for HVAC 23 05 93 - 2 1.5 WARRANTY A. National Project Performance Guarantee: If AABC, provide a guarantee on AABC’s “National Standards for Testing and Balancing Heating, Ventilating, and Air Conditioning Systems” forms stating that AABC will assist in completing requirements of the Contract Documents if TAB firm fails to comply with the Contract Documents. Guarantee includes the following provisions: 1. The certified TAB firm has tested and balanced systems according to the Contract Documents. 2. Systems are balanced to optimum performance capabilities within design and installation limits. B. Special Guarantee: If NEBB, provide a guarantee on NEBB forms stating that NEBB will assist in completing requirements of the Contract Documents if TAB firm fails to comply with the Contract Documents. Guarantee shall include the following provisions: 1. The certified TAB firm has tested and balanced systems according to the Contract Documents. 2. Systems are balanced to optimum performance capabilities within design and installation limits. PART 2 PRODUCTS (not applicable) PART 3 EXECUTION 3.1 EXAMINATION A. Examine the Contract Documents to become familiar with Project requirements and to discover conditions in systems’ designs that may preclude proper TAB of systems and equipment. 1. Verify that balancing devices, such as economizer dampers and manual volume dampers, are required by the Contract Documents. Verify that quantities and locations of these balancing devices are accessible and appropriate for effective balancing and for efficient system and equipment operation. B. Examine approved submittal data of HVAC systems and equipment. C. Examine Project Record Documents described in Division 01. D. Examine design data, including HVAC system descriptions, statements of design assumptions for environmental conditions and systems’ output, and statements of philosophies and assumptions about HVAC system and equipment controls. E. Examine equipment performance data including fan curves. Relate performance data to Project conditions and requirements, including system effects that can create undesired or unpredicted conditions that cause reduced capacities in all or part of a system. Calculate system effect factors to reduce performance ratings of HVAC equipment when installed under conditions different from those presented when the equipment was performance tested at the factory. To calculate system effects for air systems, use tables and charts found in AMCA 201, “Fans and Systems,” Sections 7 through 10; or in SMACNA’s “HVAC Systems- BCRUA - Phase 1D WTP Expansion Issued for Bid Testing, Adjusting, and Balancing for HVAC 23 05 93 - 3 -Duct Design,” Sections 5 and 6. Compare this data with the design data and installed conditions. F. Examine system and equipment installations to verify that they are complete and that testing, cleaning, adjusting, and commissioning specified in individual Sections have been performed. G. Examine system and equipment test reports. H. Examine HVAC system and equipment installations to verify that indicated balancing devices, such as economizer dampers and manual volume dampers, are properly installed, and that their locations are accessible and appropriate for effective balancing and for efficient system and equipment operation. I. Examine systems for functional deficiencies that cannot be corrected by adjusting and balancing. J. Examine HVAC equipment to ensure that clean filters have been installed, bearings are greased, belts are aligned and tight, and equipment with functioning controls is ready for operation. K. Examine heat-transfer coils for correct piping connections and for clean and straight fins. L. Examine equipment for installation and for properly operating safety interlocks and controls. M. Examine automatic temperature system components to verify the following: 1. Dampers and other controlled devices are operated by the intended controller. 2. Dampers are in the position indicated by the controller. 3. Integrity of dampers for free and full operation and for tightness of fully closed and fully open positions. 4. Thermostats are located to avoid adverse effects of sunlight, drafts, and cold walls. 5. Sensors are located to sense only the intended conditions. 6. Sequence of operation for control modes is according to the Contract Documents. 7. Controller set points are set at indicated values. 8. Interlocked systems are operating. 9. Changeover from heating to cooling mode occurs according to indicated values. N. Report deficiencies discovered before and during performance of TAB procedures. Observe and record system reactions to changes in conditions. Record default set points if different from indicated values. 3.2 PREPARATION A. Prepare a TAB plan that includes strategies and step-by-step procedures. B. Complete system readiness checks and prepare system readiness reports. Verify the following: 1. Permanent electrical power wiring is complete. 2. Automatic temperature-control systems are operational. 3. Equipment and duct access doors are securely closed. 4. Balancing dampers are open. BCRUA - Phase 1D WTP Expansion Issued for Bid Testing, Adjusting, and Balancing for HVAC 23 05 93 - 4 5. Windows and doors can be closed so indicated conditions for system operations can be met. 3.3 GENERAL PROCEDURES FOR TESTING AND BALANCING A. Perform testing and balancing procedures on each system according to the procedures contained in AABC’s “National Standards for Testing and Balancing Heating, Ventilating, and Air Conditioning Systems” or NEBB’s “Procedural Standards for Testing, Adjusting, and Balancing of Environmental Systems,” as applicable, and this Section. B. Cut insulation, ducts, pipes, and equipment cabinets for installation of test probes to the minimum extent necessary to allow adequate performance of procedures. After testing and balancing, close probe holes and patch insulation with new materials identical to those removed. Restore vapor barrier and finish according to insulation Specifications for this Project. C. Mark equipment and balancing device settings with paint or other suitable, permanent identification material, including damper-control positions, valve position indicators, fan- speed-control levers, and similar controls and devices, to show final settings. 3.4 GENERAL PROCEDURES FOR BALANCING AIR SYSTEMS A. Prepare test reports for both fans and outlets. Obtain manufacturer’s outlet factors and recommended testing procedures. Crosscheck the summation of required outlet volumes with required fan volumes. B. Prepare schematic diagrams of systems’ “as-built” duct layouts. C. Check airflow patterns from the outside-air dampers and the return-air dampers, through the supply-fan discharge. D. Locate start-stop and disconnect switches, electrical interlocks, and motor starters. E. Verify that motor starters are equipped with properly sized thermal protection. F. Check dampers for proper position to achieve desired airflow path. G. Check for airflow blockages. H. Check condensate drains for proper connections and functioning. I. Check for proper sealing of air-handling unit components. J. Check for proper sealing of air duct system. 3.5 PROCEDURES FOR CONSTANT-VOLUME air and single-zone variable air-volumeSYSTEMS A. Adjust fans to deliver total indicated airflows within the maximum allowable fan speed listed by fan manufacturer. 1. Measure fan static pressures to determine actual static pressure as follows: a. Measure outlet static pressure as far downstream from the fan as practicable and upstream from restrictions in ducts such as elbows and transitions. BCRUA - Phase 1D WTP Expansion Issued for Bid Testing, Adjusting, and Balancing for HVAC 23 05 93 - 5 b. Measure static pressure directly at the fan outlet or through the flexible connection. c. Measure inlet static pressure of single-inlet fans in the inlet duct as near the fan as possible, upstream from flexible connection and downstream from duct restrictions. 2. Measure static pressure across each component that makes up an air-handling unit, rooftop unit, and other air-handling and -treating equipment. 3. Simulate dirty filter operation and record the point at which maintenance personnel must change filters. a. Compare design data with installed conditions to determine variations in design static pressures versus actual static pressures. Compare actual system effect factors with calculated system effect factors to identify where variations occur. Recommend corrective action to align design and actual conditions. b. Obtain approval from Owners Representative for adjustment of fan speed higher or lower than indicated speed. Make required adjustments to pulley sizes, motor sizes, and electrical connections to accommodate fan-speed changes at no additional cost. c. Do not make fan-speed adjustments that result in motor overload. Consult equipment manufacturers about fan-speed safety factors. Modulate dampers and measure fan-motor amperage to ensure that no overload will occur. Measure amperage in full cooling, full heating, economizer, and any other operating modes to determine the maximum required brake horsepower. B. Adjust volume dampers for major branch ducts to indicated airflows within specified tolerances. 1. Measure static pressure at a point downstream from the balancing damper and adjust volume dampers until the proper static pressure is achieved. 2. Measure airflow at terminal outlets and inlets and calculate the total airflow for that zone. 3. Remeasure each branch duct after all have been adjusted. Continue to adjust submain and branch ducts to indicated airflows within specified tolerances. C. Measure terminal outlets and inlets without making adjustments. 1. Measure terminal outlets using a direct-reading hood or outlet manufacturer’s written instructions and calculating factors. D. Adjust terminal outlets and inlets for each space to indicated airflows within specified tolerances of indicated values. Make adjustments using volume dampers rather than extractors and the dampers at air terminals. 1. Adjust each outlet in same room or space to within specified tolerances of indicated quantities without generating noise levels above the limitations prescribed by the Contract Documents. 2. Adjust patterns of adjustable outlets for proper distribution without drafts. 3.6 PROCEDURES FOR MOTORS A. Motors, 1/2 HP and Larger: Test at final balanced conditions and record the following data: 1. Manufacturer, model, and serial numbers. 2. Motor horsepower rating. 3. Motor rpm. 4. Efficiency rating. 5. Nameplate and measured voltage, each phase. 6. Nameplate and measured amperage, each phase. 7. Starter thermal-protection-element rating. BCRUA - Phase 1D WTP Expansion Issued for Bid Testing, Adjusting, and Balancing for HVAC 23 05 93 - 6 B. Motors Driven by Variable-Frequency Controllers: Test for proper operation at speeds varying from minimum to maximum. Test the manual bypass for the controller to prove proper operation. Record observations, including controller manufacturer, model and serial numbers, and nameplate data. 3.7 PROCEDURES FOR CONDENSING UNITS A. Verify proper rotation of fans. B. Measure entering- and leaving-air temperatures. C. Record compressor data. 3.8 PROCEDURES FOR HEAT-TRANSFER COILS A. Electric-Heating Coils: Measure the following data for each coil: 1. Nameplate data. 2. Airflow. 3. Entering- and leaving-air temperature at full load. 4. Voltage and amperage input of each phase at full load and at each incremental stage. 5. Calculated kilowatt at full load. 6. Fuse or circuit-breaker rating for overload protection. B. Refrigerant Coils: Measure the following data for each coil: 1. Dry-bulb temperature of entering and leaving air. 2. Wet-bulb temperature of entering and leaving air. 3. Airflow. 4. Air pressure drop. 5. Refrigerant suction pressure and temperature. 3.9 PROCEDURES FOR TEMPERATURE MEASUREMENTS A. During TAB, report the need for adjustment in temperature regulation within the automatic temperature-control system. B. Measure indoor wet- and dry-bulb temperatures every other hour for a period of two successive 8-hour days, in each separately controlled zone, to prove correctness of final temperature settings. Measure when the building or zone is occupied. C. Measure outside-air, wet- and dry-bulb temperatures. 3.10 TEMPERATURE-CONTROL VERIFICATION A. Verify that controllers are calibrated and commissioned. B. Check transmitter and controller locations and note conditions that would adversely affect control functions. C. Record controller settings and note variances between set points and actual measurements. D. Check the operation of limiting controllers (i.e., high- and low-temperature controllers). BCRUA - Phase 1D WTP Expansion Issued for Bid Testing, Adjusting, and Balancing for HVAC 23 05 93 - 7 E. Check free travel and proper operation of control devices such as damper operators. F. Check the sequence of operation of control devices. G. Check the interaction of electrically operated switch transducers. H. Check the interaction of interlock and lockout systems. I. Check main control supply-air pressure and observe compressor and dryer operations. J. Record voltages of power supply and controller output. Determine whether the system operates on a grounded or nongrounded power supply. K. Note operation of electric actuators using spring return for proper fail-safe operations. 3.11 TOLERANCES A. Set HVAC system airflow and water flow rates within the following tolerances: 1. Supply and Economizer Exhaust Fans: Plus 5 to plus 10 percent. 2. Air Outlets and Inlets: 0 to minus 10 percent. 3.12 FINAL REPORT A. General: Typewritten, or computer printout in letter-quality font, on standard bond paper, in three-ring binder, tabulated and divided into sections by tested and balanced systems. B. Include a certification sheet in front of binder signed and sealed by the certified testing and balancing engineer. 1. Include a list of instruments used for procedures, along with proof of calibration. C. Final Report Contents: In addition to certified field report data, include the following: 1. Fan curves. 2. Manufacturers’ test data. 3. Field test reports prepared by system and equipment installers. 4. Other information relative to equipment performance, but do not include Shop Drawings and Product Data. D. General Report Data: In addition to form titles and entries, include the following data in the final report, as applicable: 1. Title page. 2. Name and address of TAB firm. 3. Project name. 4. Project location. 5. Architect/Engineer’s name and address. 6. Engineer’s name and address. 7. Contractor’s name and address. 8. Report date. 9. Signature of TAB firm who certifies the report. 10. Table of Contents with the total number of pages defined for each section of the report. Number each page in the report. 11. Summary of contents including the following: BCRUA - Phase 1D WTP Expansion Issued for Bid Testing, Adjusting, and Balancing for HVAC 23 05 93 - 8 12. Indicated versus final performance. 13. Notable characteristics of systems. 14. Description of system operation sequence if it varies from the Contract Documents. 15. Nomenclature sheets for each item of equipment. 16. Notes to explain why certain final data in the body of reports varies from indicated values. 17. Test conditions for fans and pump performance forms including the following: 18. Settings for outside-, return-, and exhaust-air dampers. 19. Conditions of filters. 20. Cooling coil, wet- and dry-bulb conditions. 21. Fan drive settings including settings and percentage of maximum pitch diameter. 22. Inlet vane settings for variable-air-volume systems. 23. Settings for supply-air, static-pressure controller. 24. Other system operating conditions that affect performance. E. System Diagrams: Include schematic layouts of air distribution systems. Present each system with single-line diagram and include the following: 1. Quantities of outside, supply, return, and exhaust airflows. 2. Duct, outlet, and inlet sizes. 3. Balancing stations. 4. Position of balancing devices. 3.13 ADDITIONAL TESTS A. Within 90 days of completing TAB, perform additional testing and balancing to verify that balanced conditions are being maintained throughout and to correct unusual conditions. B. Seasonal Periods: If initial TAB procedures were not performed during near-peak summer and winter conditions, perform additional testing, inspecting, and adjusting during near-peak summer and winter conditions. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Condensate Piping 23 21 13 - 1 SECTION 23 21 13 - CONDENSATE PIPING PART 1 GENERAL 1.1 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.2 SUMMARY A. Section includes pipe and fitting materials and joining methods for the following: 1. Condensate-drain piping. 2. Piping supports. 1.3 SUBMITTALS A. Product Data for materials indicated. PART 2 PRODUCTS 2.1 Copper Pipe A. Drawn-Temper Copper Tubing: ASTM B88, Type L (ASTM B88M, Type B). B. Wrought-Copper Unions: ASME B16.22. 2.2 TRANSITION FITTINGS A. Plastic-to-Metal Transition Fittings: One-piece fitting with one threaded brass or copper insert and one solvent-cement-joint end of material and wall thickness to match plastic pipe material. 2.3 Roof Pipe Supports A. Support piping on roof with an engineered prefabricated system designed for installation without roof penetrations, flashing or damage to the roofing material. The system shall consist of bases, made of high density polypropylene plastics with UV Protection, structural steel frame. Electro-plated, galvanized, or stainless steel nuts, threaded rods and washers, spring nuts and bolts for spring nuts will be electro-plated. System shall be custom designed to fit insulated piping to be installed and the actual conditions of service. 1. Bases: Injection molded high density / high impact polypropylene with UV-inhibitors and anti-oxidants. 2. Pipe Supports and Hangers: Conform to MSS SP-58 and MSS SP-69 and as follows: a. Fabricate of electro-plated, galvanized, or stainless steel. b. Sizes 2-1/2 inch (63 mm) and smaller: Channels and pipe clamps. 3. Accessories: Clamps, bolts, nuts, washers, and other devices as required for a complete system. BCRUA - Phase 1D WTP Expansion Issued for Bid Condensate Piping 23 21 13 - 2 2.4 Vertical pipe supports A. Channel Support Systems: MFMA-2, factory-fabricated components for field assembly. B. Mechanical-Anchor Fasteners: Insert-type attachments with pull-out and shear capacities appropriate for supported loads and building materials where used. Do not use in lightweight concrete or concrete slabs less than 4 inches (100 mm) thick. C. Shields: Unless otherwise indicated and except as specified in piping system Specification Sections, install the following types: 1. Protection Shields (MSS Type 40): Of length recommended by manufacturer to prevent crushing insulation. D. Vertical-Piping Clamps: Unless otherwise indicated and except as specified in piping system Specification Sections, install the following types: 1. Extension Pipe or Riser Clamps (MSS Type 8): For support of pipe risers, NPS 3/4 to NPS 20 (DN20 to DN500). PART 3 EXECUTION 3.1 PIPING APPLICATIONS A. Condensate-Drain Piping, aboveground: Type M drawn-temper copper tubing, wrought- copper fittings, and soldered joints. 3.2 PIPING INSTALLATIONS A. Drawing plans, schematics, and diagrams indicate general location and arrangement of piping systems. Install piping as indicated unless deviations to layout are approved on Coordination Drawings. B. Install piping indicated to be exposed and piping in equipment rooms and service areas at right angles or parallel to building walls. Diagonal runs are prohibited unless specifically indicated otherwise. C. Install piping at indicated slopes. D. Install piping free of sags and bends. E. Install fittings for changes in direction and branch connections. F. Install piping to allow application of insulation. G. Install unions in piping, NPS 2 (DN 50) and smaller, at final connections of equipment, and elsewhere as indicated. H. Install plug cleanouts with threaded removal cap at changes in directions to facilitate cleanout. BCRUA - Phase 1D WTP Expansion Issued for Bid Condensate Piping 23 21 13 - 3 3.3 HANGERS AND SUPPORTS A. Pipe Hanger and Support Installation: Comply with MSS SP-69 and MSS SP-89. Install hangers, supports, clamps, and attachments as required to properly support piping from building structure. B. Install mechanical-anchor fasteners in concrete after concrete is placed and completely cured. Install fasteners according to manufacturer’s written instructions. C. Install hangers and supports complete with necessary inserts, bolts, rods, nuts, washers, and other accessories. D. Insulated Piping: Comply with the following: 1. Attach clamps and spacers to piping. 2. Install MSS SP-58, Type 40 protective shields on cold piping with vapor barrier. Shields shall span arc of 180 degrees. 3. Shield Dimensions for Pipe: Not less than the following: a. NPS 1/4 to NPS 3-1/2 (DN8 to DN90): 12 inches (305 mm) long and 0.048 inch (1.22 mm) thick. 3.4 PIPE JOINT CONSTRUCTION A. Ream ends of pipes and tubes and remove burrs. B. Remove scale, slag, dirt, and debris from inside and outside of pipe and fittings before assembly. C. Soldered Joints: Apply ASTM B813, water-flushable flux, unless otherwise indicated, to tube end. Construct joints according to ASTM B828 or CDA’s “Copper Tube Handbook,” using lead-free solder alloy complying with ASTM B32. D. Brazed Joints: Construct joints according to AWS’s “Brazing Handbook,” “Pipe and Tube” Chapter, using copper-phosphorus brazing filler metal complying with AWS A5.8/A5.8M. E. Threaded Joints: Thread pipe with tapered pipe threads according to ASME B1.20.1. Cut threads full and clean using sharp dies. Ream threaded pipe ends to remove burrs and restore full ID. Join pipe fittings and valves as follows: 1. Apply appropriate tape or thread compound to external pipe threads unless dry seal threading is specified. 2. Damaged Threads: Do not use pipe or pipe fittings with threads that are corroded or damaged. Do not use pipe sections that have cracked or open welds. F. Plastic Piping Solvent-Cemented Joints: Clean and dry joining surfaces. Join pipe and fittings according to the following: 1. Comply with ASTM F402 for safe-handling practice of cleaners, primers, and solvent cements. 2. PVC Nonpressure Piping: Join according to ASTM D2855. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Rooftop Air Conditioners 23 74 09 - 1 SECTION 23 74 09 - ROOFTOP AIR CONDITIONERS PART 1 GENERAL 1.1 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.2 SUMMARY A. This Section includes the following rooftop air conditioners: 1. Cooling and heating units 6 tons (21 kW) and smaller. 1.3 SUBMITTALS A. Product Data: Include manufacturer’s technical data for each model indicated, including rated capacities, dimensions, required clearances, characteristics, furnished specialties, and accessories. B. Shop Drawings: Detail equipment assemblies and indicate dimensions, weights, loads, required clearances, method of field assembly, components, and location and size of each field connection. Prepare the following by or under the supervision of a qualified professional engineer: 1. Detail mounting, securing, and flashing of roof curb to roof structure. Indicate coordinating requirements with roof membrane system. 2. Wiring Diagrams: Power, signal, and control wiring. C. Operation and Maintenance Data: Include emergency, operation, and maintenance manuals. D. Warranties: Special warranties specified in this Section. 1.4 QUALITY ASSURANCE A. Product Options: Drawings indicate size, profiles, and dimensional requirements of rooftop air conditioners and are based on the specific system indicated. Refer to Section 01 60 00 “Product Requirements.” B. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use. C. Energy-Efficiency Ratio: Equal to or greater than prescribed by ASHRAE 90.1, “Energy Efficient Design of New Buildings except Low-Rise Residential Buildings” and International Energy Conservation Code, whichever is greater.” D. ARI Compliance for Units with Capacities Less Than 135,000 BTUH (39.6 kW): Rate rooftop air-conditioner capacity according to ARI 210/240, “Unitary Air-Conditioning and Air-Source Heat Pump Equipment.” 1. Sound Power Level Ratings: Comply with ARI 270, “Sound Rating of Outdoor Unitary Equipment.” BCRUA - Phase 1D WTP Expansion Issued for Bid Rooftop Air Conditioners 23 74 09 - 2 1.5 COORDINATION A. Coordinate installation of roof curbs, equipment supports, and roof penetrations. 1.6 WARRANTY A. Special Warranty: Manufacturer’s standard form in which manufacturer agrees to replace components of rooftop air conditioners that fail in materials or workmanship within specified warranty period. 1. Warranty Period for Compressors: Manufacturer’s standard, but not less than 10 years from date of Substantial Completion. 2. Warranty Period for Heat Exchangers: Manufacturer’s standard, but not less than 10 years from date of Substantial Completion. 3. Warranty Period for Control Boards: Manufacturer’s standard, but not less than three years from date of Substantial Completion. 4. Warranty Period for Fan Motors: Manufacturer’s standard, but not less than 3 years from date of Substantial Completion. 5. Warranty Period for Electronic Thermostats: Manufacturer’s standard, but not less than 3 years from date of Substantial Completion. 1.7 EXTRA MATERIALS A. Furnish extra materials described below that match products installed and that are packaged with protective covering for storage and identified with labels describing contents. 1. Filters: One set of filters for each unit. PART 2 PRODUCTS 2.1 MANUFACTURERS A. In other Part 2 articles where subparagraph titles below introduce lists, the following requirements apply for product selection: 1. Manufacturers: Subject to compliance with requirements, provide products by the manufacturers specified. 2.2 ROOFTOP AIR CONDITIONERS 6 TONS (21 kW) AND SMALLER A. Manufacturers: 1. Trane 2. Carrier 3. Lennox 4. York 5. Johnson Controls 6. Daikin B. Description: Factory assembled and tested; designed for exterior installation; consisting of compressor, indoor and outside refrigerant coils, indoor fan and outside coil fan, refrigeration and temperature controls, filters, and dampers. BCRUA - Phase 1D WTP Expansion Issued for Bid Rooftop Air Conditioners 23 74 09 - 3 C. Casing: Galvanized-steel construction with enamel paint finish, removable panels or access doors with neoprene gaskets for inspection and access to internal parts, minimum 1/2-inch (13-mm) thick thermal insulation, knockouts for electrical and piping connections, exterior condensate drain connection, and lifting lugs. D. Indoor Fan: Forward curved, centrifugal,directly driven by single-speed motor. E. Outside Coil Fan: Propeller type, directly driven by motor. F. Refrigerant Coils: Aluminum-plate fin and seamless copper tube in steel casing with equalizing-type vertical distributor. G. Compressor: Hermetic scroll compressor with integral vibration isolators, internal overcurrent and overtemperature protection, internal pressure relief, and crankcase heater. H. Refrigeration System: 1. Compressor. 2. Outside coil and fan. 3. Indoor coil and fan. 4. Expansion valve with replaceable thermostatic element. 5. Refrigerant dryer. 6. High-pressure switch. 7. Low-pressure switch. 8. Thermostat for coil freeze-up protection during low-ambient temperature operation or loss of air. 9. Brass service valves installed in discharge and liquid lines. 10. Charge of refrigerant. I. Filters: 2-inch (50-mm) thick, fiberglass, pleated, throwaway filters in filter rack. J. Electric Heat: Helix-wound, nickel-chrome, electric-resistance elements, factory wired for single-point wiring connection; with time delay for element staging, and overcurrent and overheat protective devices. K. Economizer: Return- and outside-air dampers with neoprene seals, outside-air filter, and hood. L. Damper Motor: Fully modulating spring return with adjustable minimum position. M. Control: Electronic-control system uses outside-air enthalpy to adjust mixing dampers. N. Relief Damper: Gravity actuated with bird screen and hood. O. Power Connection: Provide for single connection of power to unit and control-circuit transformer with built-in circuit breaker. Coordinate with electrical on existing disconnect switch location. P. Unit Controls: Solid-state control board and components contain at least the following features: 1. Indoor fan on/off delay. 2. Default control to ensure proper operation after power interruption. BCRUA - Phase 1D WTP Expansion Issued for Bid Rooftop Air Conditioners 23 74 09 - 4 3. Service relay output. 4. Unit diagnostics and diagnostic code storage. 5. Field-adjustable control parameters. 6. Defrost control. 7. Dehumidification control with dehumidistat. 8. Economizer control. 9. Electric heat staging. 10. Low-ambient control, allowing operation down to 0 F (minus 18 C). 11. Minimum run time. 12. Night setback mode. 13. Return-air temperature limit. 14. Smoke alarm with smoke detector installed in return air. 15. Low-refrigerant pressure control. 16. Digital display of outside temperature, supply-air temperature, return-air temperature, economizer damper position, indoor-air quality, and control parameters. Q. Thermostat: Programmable, electronic; with heating setback and cooling setup with 7-day programming; and the following: 1. Touch sensitive keyboard. 2. Automatic switching. 3. Degrees F readout. 4. LED indicators. 5. Hour/day programming. 6. Manual override capability. 7. Time and operational mode readout. 8. Status indicator. 9. Battery backup. 10. Subbase with manual system switch (on-heat-auto-cool) and fan switch (auto-on). 11. Fan-proving switch to lock out unit if fan fails. 12. Dirty-filter switch. R. Optional Accessories: 1. Service Outlets: Two, 115-V, ground-fault, circuit-interrupter type. 2. Condensate drain trap. 3. Dirty-filter switch. 4. Hail guards of steel, painted to match casing. 5. Power exhaust fan. 6. Roof curb: Provide factory furnished standard roof curb. 2.3 MOTORS A. General requirements for motors are specified in Section 23 05 13 “Common Motor Requirements for HVAC.” B. Motor Sizes: Minimum size as indicated; if not indicated, large enough so driven load will not require motor to operate in service factor range above 1.0. C. Controllers, electrical devices, and wiring are specified in Division 26 Sections. BCRUA - Phase 1D WTP Expansion Issued for Bid Rooftop Air Conditioners 23 74 09 - 5 PART 3 EXECUTION 3.1 INSTALLATION A. Install units level and plumb, maintaining manufacturer’s recommended clearances. B. Install and secure rooftop air conditioners on existing roof curbs. 3.2 CONNECTIONS A. Piping installation requirements are specified in other Division 23 Sections. Drawings indicate general arrangement of piping, fittings, and specialties. B. Install piping adjacent to machine to allow service and maintenance. C. Electrical System Connections: Comply with applicable requirements in Division 26 Sections for power wiring, switches, and motor controls. D. Ground equipment according to Division 26. E. Tighten electrical connectors and terminals according to manufacturer’s published torque- tightening values. If manufacturer’s torque values are not indicated, use those specified in UL 486A and UL 486B. 3.3 FIELD QUALITY CONTROL A. Perform the following field quality-control tests and inspections and prepare test reports: 1. After installing rooftop air conditioners and after electrical circuitry has been energized, test units for compliance with requirements. 2. Inspect for and remove shipping bolts, blocks, and tie-down straps. 3. Operational Test: After electrical circuitry has been energized, start units to confirm proper motor rotation and unit operation. 4. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment. B. Remove malfunctioning units, replace with new units, and retest as specified above. 3.4 ADJUSTING A. Adjust initial temperature and humidity set points. B. Set field-adjustable switches and circuit-breaker trip ranges as indicated. C. Occupancy Adjustments: When requested within 12 months of date of Substantial Completion, provide on-site assistance in adjusting system to suit actual occupied conditions. Provide up to two visits to site outside normal occupancy hours for this purpose, without additional cost. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Testing of Electrical Systems 26 01 26 - 1 SECTION 26 01 26 - TESTING OF ELECTRICAL SYSTEMS (Revised by AD-02) PART 1 GENERAL 1.1 WORK INCLUDED A. Furnish labor, material, equipment and incidentals of an independent testing agency. Testing shall be inclusive of all low voltage equipment including conductors for the BCRUA Phase 1D Water Treatment Plant Expansion. Testing shall include all relay protective schemes and operation of the low voltage equipment. 1.2 QUALITY ASSURANCE A. Independent testing agency shall follow all tests and recommendations in NETA Acceptance Testing Specification for all equipment provided. B. Acceptable Testing Agencies: 1. National Field Services 2. Real Power Technologies 3. Shermco Industries 4. No others shall be accepted 5. Power Engineering Services, Inc. (AD-02) 1.3 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include: 1. ELECTRICAL QUALIFICATIONS & LIST OF TEST SUBMITTAL a. 60 days prior to any testing taking place, Contractor shall submit to the Owner/Engineer the name of the testing agency; a list of all tests to be conducted shall also be submitted at this same time. No testing shall take place until this has been submitted and approved by the Engineer. 2. ELECTRICAL TESTING PLAN a. A minimum of two (4) weeks before testing is to take place, Contractor shall submit a detailed testing plan of the different configurations to be tested for the Owner’s and Engineer’s approval. 3. ELECTRICAL TESTING REPORT a. A written report shall be submitted by the testing agency performing installation checks, operation and testing of low voltage equipment. This report shall certify that 1) The equipment has been properly installed, 2) Is in accurate alignment, and 3) Meets the acceptance testing specifications of NETA and the equipment manufacturer. 4) Provide a detailed list of all tests that were performed and the test results as part of the Electrical Testing Report. 5) Provide a detailed list of megger results for low voltage cables. List should include circuit tag as shown on the contract documents, voltage, phase and cycle identification, phase-to-phase result for each combination of phases, phase to neutral result for each combination of phase and phase-to-ground BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Testing of Electrical Systems 26 01 26 - 2 result for each combination of phases. List should also include persons witnessing and performing tests. 6) Infrared test results shall include the following for each item tested: a) A description of the equipment tested b) The load (in amps) and operating conditions at which the equipment was running and other testing conditions that may affect the IR results. c) A thermal image alongside a standard photograph. An image shall be included for each thermal image taken for the project. d) Where issues are identified by a thermal image, provide a photograph with annotation indicating where problems are detected. e) A description of any problems detected f) Information on the camera listing model number, processor type, date of last calibration, resolution, etc. b. Electrical Testing Report shall be submitted to the ENGINEER for approval at least 4 weeks before start-up and training and no later than one week after testing has been conducted. 1.4 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: 1. American National Standards Institute (ANSI) 2. American Standards for Testing and Materials (ASTM) 3. Institute of Electrical and Electronic Engineers (IEEE) 4. National Electrical Manufacturers Association (NEMA) 5. International Electrical Testing Association (NETA) 1.5 RELATED SPECIFICATIONS A. All testing referenced in the following Specifications shall be submitted under this section: 1. 26 05 19, “Low Voltage Electrical Conductors & Cables” 2. 26 05 26, “Grounding & Bonding for Electrical Systems” 3. 26 05 33, “Raceways and boxes for Electrical Systems” 4. 26 22 13, “Low Voltage Distribution Transformers” 5. 26 24 19, “Low Voltage Motor Control Centers (MCCs)” PART 2 26 27 26 “Wiring Devices” PRODUCTS [NOT USED] PART 3 EXECUTION 3.1 GENERAL A. Perform all testing identified in the latest edition of NETA Standard for Accepting Testing Specifications. B. All testing shall be witnessed by the Owner’s Representative. Types of equipment required to be tested by these specifications shall include but not be limited to the following: 1. The following tests shall be conducted by the testing agency: a. Cables BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Testing of Electrical Systems 26 01 26 - 3 1) Low Voltage Cables. a) Perform all tests as specified in Section 26 05 19, “Low Voltage Electrical Conductors & Cables” b) Insulation - resistance test c) Perform resistance measurements through all connections with a low resistance ohmmeter. d) Perform a thermographic survey of all connections under load conditions. e) Perform Continuity test to insure correct cable connection. f) Perform all tests as specified in NETA Acceptance Testing Specifications. b. Grounding. 1) Test grounding system at the Plant. C. All testing shall be in accordance with the manufacturer’s recommendations for energization and start-up of the equipment. D. Testing shall include a complete functionality testing of electrical equipment under all the different operating parameters identified by the OWNER and ENGINEER. E. Ground Resistance Test 1. Visual and Mechanical Inspection. a. Verify ground system complies with Contract Documents and NFPA 70 Article 250, "Grounding and Bonding." b. Inspect physical and mechanical condition. Grounding system electrical and mechanical connections shall be free of corrosion. c. Inspect bolted electrical connections for high resistance using one of the following two methods: 1) Use a low-resistance ohmmeter to compare bolted connection resistance values to values of similar connections. Investigate values that deviate from those of similar bolted connections by more than 50 percent of the lowest value. 2) Verify tightness of accessible bolted electrical connections by calibrated torque- wrench method according to manufacturer's published data or NETA ATS, Table 100.12. Bolt-torque levels shall be according to manufacturer's published data. In the absence of manufacturer's published data, use NETA ATS, Table 100.12. d. Inspect anchorage. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Common Work Results for Electrical 26 05 00 - 1 SECTION 26 05 00 - COMMON WORK RESULTS FOR ELECTRICAL PART 1 GENERAL 1.1 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary for complete and operational electrical systems, as specified herein. B. This Section, as well as Division 1, concerns all other Sections in Division 26 shall be considered a part of each of those Sections as if written in their entirety. C. CONTRACTOR shall be responsible to coordinate labor and materials required to install and test equipment supplied throughout this contract. D. Temporary utilities: 1. CONTRACTOR may need to include generator power for outages, depending on the CONTRACTORS’ means and methods of connecting to existing power equipment. 2. CONTRACTOR shall provide electrical testing and inspection services for temporary connections to existing equipment. 3. Fusing for temporary equipment shall be coordinated with upstream devices to assure the fuses will terminate before interrupting electrical service to plant process equipment. E. Electrical outages must be coordinated with Owner. 1. Known electrical outages include: a. Electrical Building RWT Power Connection b. Flocculator Power & Control Connections c. Sedimentation Power & Control Connections d. Sludge Vault Actuator Power & Control Connections e. Chemical Feed System Power & Control Connections f. Dewatering Facility Belt Filter Press, Sludge Pumps, and Sludge Thickener Motor Control Center Power and Control Connections. 2. Shut down sequencing shall be coordinated by the CONTRACTOR and if a generator is required to power equipment to maintain service, CONTRACTOR shall be responsible to provide the generator, fuel, and conductors required to keep the plant operational. 1.2 QUALITY ASSURANCE A. ELECTRICAL CONTRACTORS' QUALIFICATIONS 1. Use adequate numbers of skilled workmen, trained and experienced in their crafts, and who are familiar with the specifications and methods of performing the work in this Division. A licensed Journeyman shall be on site at all times when electrical work is being performed. Electrical work shall be performed under the direct supervision of a Master Electrician who holds a valid license in the State of Texas. The CONTRACTOR shall provide a monthly report to the OWNER/ENGINEER for review stating that the BCRUA - Phase 1D WTP Expansion Issued for Bid Common Work Results for Electrical 26 05 00 - 2 Master Electrician has been to the job site and thoroughly reviewed the work. The report shall be signed by the Master Electrician and include the data and time the Master Electrician was on site. 2. CONTRACTORs company must have 10 year’s experience with performing electrical work within water treatment plants. B. WORKMANSHIP 1. Work shall be performed in accordance with quality, commercial practices. The appearance of finished work shall be of equal importance with its operation. Materials and equipment shall be installed based upon the actual dimensions and conditions at the project site. Locations for materials or equipment requiring an exact fit shall be field measured. 1.3 SUBMITTALS A. Submittals are in accordance with Section 01 33 00, Submittal Procedures and shall include: 1. Submittals shall be submitted separated by specification section. Combined submittals will not be reviewed. 2. Incomplete submittals will not be reviewed and will be marked NOT APPROVED, revise and resubmit. 3. Resubmittals shall be marked with a red strike through for the items removed from the submittal and clouded with the items added to the submittal. Submittals shall be marked to track changes between resubmittals. 4. Component catalog number and manufacturing data sheet, indicating pertinent data and identifying each component by the item number and nomenclature as specified. 5. Component drawings showing dimensions, mounting, and external connection details in AutoCAD format. 6. Operation and maintenance manuals shall contain the shop drawings, submittals, spare part lists, schematics, project specific final wiring diagrams with any changes made during start-up and maintenance procedures. 7. Unless other additional information is required by the detailed equipment specifications, the following information must be included for motors: a. Motor identification number and nomenclature b. Make and motor type c. Brake horsepower of the motor d. Locked rotor current at full load e. Motor efficiency at full load (3-phase motors only) f. Starting torque g. Method of insulating and impregnating motor coils (3-phase only) h. Speed of the motor at full torque i. Full load current j. Service factor k. Motor temperature rise measured by resistance over 40 degrees C ambient BCRUA - Phase 1D WTP Expansion Issued for Bid Common Work Results for Electrical 26 05 00 - 3 B. Delays during submittals due to CONTRACTOR not following the format mentioned above shall not be the fault of the OWNER or ENGINEER. C. The CONTRACTOR shall provide a monthly report to the OWNER/ENGINEER for review stating that the Master Electrician has been to the job site and thoroughly reviewed the work. The report must be signed by the Master Electrician and include the date and time the Master Electrician was on site. D. The CONTRACTOR shall: 1. Prepare, and keep up-to-date, the Record Drawings and detailed construction drawings. 2. Document the exact locations of each of these differences, sizes and details of the Construction Work as executed, with cross-references to and other requirements on the Record Drawings. a. Record Drawings shall include the location of all pull boxes, junction boxes, concrete pull boxes, manholes and hand holes that were provided under this contract and those existing boxes that were modified under this contract (by either the addition or removal of cable or conduit. 1) The CONTRACTOR shall include on the drawings a label next to each pull box, junction box, concrete pull box, manhole or handhole to reflect the nameplate label installed (existing or new) at each enclosure. 3. Keep the Record Drawings on the Work Site. 4. Upon completion of the Work, or at such other time as may be determined by the ENGINEER, submit the Record Drawings and copies to the OWNER’s Representative in accordance with the OWNER’s Requirements. 5. Underground Interference drawing showing all underground duct banks, ground rods, ground conductors, pipes, piers, vaults, manholes, pull boxes, etc. that clearly identifies the location and routing of these systems. All interferences shall be brought to the ENGINEER’s attention. a. Provide as a minimum the duct bank dimensions, burial depth and coordinates of terminations and those of any changes of direction. The GPS coordinates of duct banks shall be measured (width, depth, and burial depths prior to backfilling. 6. Provide revised drawings in AutoCAD noting any changes made to equipment during start-up. 1.4 STANDARDS A. Electrical work shall be executed in accordance with local, State and national codes, ordinances and regulations which have jurisdiction or authority over the work. If the standards and codes conflict with each other, the most stringent shall apply. The applicable provisions of the following standard shall apply as if written here in their entirety: National Electrical Manufacturer Association (NEMA) American Society for Testing and Materials (ASTM) National Fire Protection Association (NFPA) National Electrical Safety Code (NESC) Institute of Electrical and Electronic ENGINEERs (IEEE) BCRUA - Phase 1D WTP Expansion Issued for Bid Common Work Results for Electrical 26 05 00 - 4 National Electrical Code (NEC) Underwriters Laboratories (UL) American National Standards Institute (ANSI) Uniform Building Code (UBC) Occupational Safety and Health Administration (OSHA) Local utility companies Local Electrical Ordinance Rural Electrification Association (REA) Insulated Power Cable ENGINEERs Association (IPCEA) International Electrical Testing Association (NETA) National Electrical CONTRACTORs Association (NECA) Association Edison Illuminating Companies (AEIC) Texas Commission on Environmental Quality (TCEQ) Environmental Protection Agency (EPA) International Electrotechnical Commission (IEC) 1.5 DELIVERY AND STORAGE A. Follow the Manufacturer's directions for the delivery, storage and handling of equipment and materials. Tightly cover equipment and materials and protect it from dirt, water, chemical or mechanical injury and theft. Major electrical equipment shall be stored indoors, and space heaters energized where applicable. B. Equipment stored indoors for an extended period of time and that do not have space heaters shall have a 100-watt incandescent light placed in it and energized to eliminate the build-up of condensation in the equipment. Coordinate with equipment manufacturer for storage requirements. C. Damaged equipment shall not be acceptable. Upon installation, protect the materials until the work is completed and accepted by the OWNER. 1.6 JOB CONDITIONS A. Permits, licenses and inspections shall be secured and paid for by the CONTRACTOR as required by law for the completion of the work. Certificates of approval shall be secured, paid for, and delivered to the OWNER before receiving the final acceptance of the work. B. The location of materials, equipment, devices and appliances indicated are approximate and subject to revisions at the time the work is installed. Final location shall be as proposed by the CONTRACTOR and approved by the ENGINEER. C. Should project conditions require any rearrangement of work, or if equipment or accessories can be installed better than the general arrangement of work on the plans, the CONTRACTOR shall prepare and submit plans of the proposed rearrangement for the ENGINEER's review and approval. BCRUA - Phase 1D WTP Expansion Issued for Bid Common Work Results for Electrical 26 05 00 - 5 D. Motor Horsepower ratings identified are anticipated ratings. If the actual equipment is a different size, the CONTRACTOR will need to provide the appropriate wiring, conduit, over current protection, starters and accessories for a complete and working system at no cost to the OWNER. E. All enclosures for equipment unless specifically identified otherwise shall be: 1. NEMA 12 for indoor air-conditioned areas. 2. NEMA 3R 304 stainless steel enclosures for indoor ventilated areas. 3. NEMA 4X 304 stainless steel for exterior applications and all other locations. 4. NEMA 4X fiberglass for interior areas within the sodium hypochlorite tank room. F. CONTRACTOR is required to abide by the OWNERs Construction Safety and Health Program where applicable. G. Clearances indicated in the National Electrical Code must be maintained around equipment. H. Enclosures shall be installed such that enclosure doors open toward the individual requiring access. PART 2 Products 2.1 Materials A. Supplemental or alternative materials supplied and installed by the CONTRACTOR shall be approved prior to installation. Materials installed without pre-approval, through the submittals process, shall be removed from the job site and replaced at no additional cost to the OWNER. No exceptions. B. Discrepancies between the plans and specifications shall be addressed prior to bidding the project, otherwise the most expensive of the two options shall be assumed. PART 3 EXECUTION 3.1 INSTALLATION A. Maintain waterproof integrity of conduit penetrations through enclosures, the roof, exterior walls and floors. B. Install steel reinforced concrete foundations below floor mounted switchboards, panelboards, motor control centers, transformers, and other floor mounted electrical equipment. Concrete foundations shall not be less than 4" high. Neatly chamfer top edges. Concrete foundations shall be 4" wider and 4" longer than the base of the equipment being installed. Concrete shall be in accordance with Division 03 and shall be reinforced with a minimum of 6" x 6" #6 welded wire mesh. BCRUA - Phase 1D WTP Expansion Issued for Bid Common Work Results for Electrical 26 05 00 - 6 C. Route all conduits parallel to building lines, columns, or steel route conduits near to columns and roof beams. D. Submit location drawings and obtain ENGINEER approval prior to installing conduit penetrations through slabs, beams, ceiling and walls. The CONTRACTOR shall not core drill through existing beams. After the conduit has been installed, fill the annular space between the conduits with mastic. The complete installation shall be watertight and fire rating of penetrations through walls, floors and ceilings shall be maintained. 3.2 CUTTING AND PATCHING A. Provide adequate support during cutting operations to prevent any damage to the affected masonry. Where openings are cut through masonry walls, provide lintels or structural supports to protect the remaining masonry. The cutting of structural members shall not be permitted without the specific written approval of the ENGINEER. B. Where sidewalks are cut for duct banks, the CONTRACTOR shall repair sidewalk to match remaining sidewalk with 3000psi concrete and rebar. Where drawings do not indicate rebar size, the CONTRACTOR shall get clarification from ENGINEER prior to replacement. 3.3 PAINTING A. Painting shall be in accordance with Division 09. Maintain the original factory finish on material and equipment installed, unless specifically indicated on the plans or specifications. If the finish is marred in transit or during installation, re-finish to a neat, workmanlike appearance. Leave equipment and raceway systems clean and free of grease, dirt, rust, and in a suitable condition for painting. 3.4 EXCAVATION, TRENCHING, BACKFILLING AND GRADING A. Prior to any excavation or trenching, notify the OWNER’s representative, utility companies and OWNER’s facilities department. Allow sufficient time for utilities to be located prior to excavation to avoid disruption of services. Provide a minimum of 72 hours written notice to the OWNER prior to trenching or excavation. Do not proceed with trenching or excavation until authorized by the OWNER. Utilities or services which are damaged, which are identified prior to excavation or trenching, or where confirmation by utility companies has not been obtained verifying that utilities are marked, shall be worked on 24/7 until the condition is repaired to operable condition immediately, at no cost to the OWNER. B. Barricade open trenches and excavations for the entire duration of the project. Barricades for excavations shall have warning lights maintained during hours of darkness. Trenches shall be marked with warning tape, or access to trenches shall be prohibited with readily identifiable sawhorses, warning tape or other acceptable means. Barriers shall be illuminated or recognizable during hours of darkness. Barriers and tape shall be properly maintained at all times. BCRUA - Phase 1D WTP Expansion Issued for Bid Common Work Results for Electrical 26 05 00 - 7 C. Protect all adjacent work, structures and properties. Damage to adjacent work, structures or properties shall be repaired, or the cost of repair reimbursed in full. D. All construction areas shall be finally graded as indicated on the contract documents, or to the conditions of the site prior to construction. Grading shall bring the site back to the existing conditions as close as practical. Turfed areas shall be sodded, or hydro-mulched with matching turf. Landscaping shall be replaced with identical shrubbery, ground cover, or plants as existed. CONTRACTOR shall be responsible for maintaining water on new turf and landscaping until established. If new turf and landscaping is impractical due to weather conditions, CONTRACTOR shall provide satisfactory arrangements to have turf and landscaping furnished and installed at the earliest opportunity thereafter. Provide a 90-day warranty on new turf and landscaping. E. Determine if irrigation systems exist prior to trenching and excavation. Obtain record or as- built drawings and locate control wiring and pressure main branches and devices. Determine by actual operation that systems are functional and repair or replace damaged systems to their original condition prior to beginning construction. F. In cases where high voltage duct banks may exist, CONTRACTOR shall employ safe drilling/excavating techniques such as vacuum excavation, etc. 3.5 LOCKING OF ELECTRICAL FACILITIES A. Install locks immediately upon the installation of the electrical facility. Provide padlocks for exterior electrical facilities subject to unauthorized entry. Furnish the OWNER with two (2) keys per lock up to a quantity of 10 keys. Furnish locks to match the OWNER's locking system. 3.6 CLEAN AND ADJUST A. Remove shipping labels, dirt, paint, grease, and stains from equipment. Remove debris as it accumulates. Upon completion of work, clean electrical equipment and the entire electrical installation. END OF SECTION BCRUA- Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Electrical Conductors & Cables 26 05 19-1 SECTION 26 05 19 - LOW VOLTAGE ELECTRICAL CONDUCTORS & CABLES (Revised by AD- 02) PART 1 GENERAL 1.1 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install and test 600 volt wires and cables. Electrical work shall be in accordance with Section 26 05 00, “Common Work Results for Electrical”. B. Work shall include building wire, cable, wiring connections and terminations, and modular wiring systems. 1.2 QUALITY ASSURANCE: TESTING A. Megger test circuits for continuity and ground. Verify phasing at connection points. Torque test conductor connections and terminations to the Manufacturer's recommended values. Megger tests shall be performed by a testing company with a minimum of 10 years’ experience. All low voltage cables shall be verified by use of telephone communications. 1.3 SUBMITTAL PROCEDURES A. Submittal Procedures shall be in accordance with Section 01 30 00, “Submittal Procedures” and shall include: 1. Shop Drawings: a. Low voltage wire b. VFC cable c. Ground wire d. Shielded cable e. Unshielded cable f. Terminations and Connections g. Multimode optical-fiber cabling. (AD-02) 1.4 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: ICEA S-19-81/NEMA WC-3 Rubber-Insulated Wire and Cable for the Transmission and Distribution of Electrical Energy ICEA S-61-402/NEMA WC-5 Thermoplastic-Insulated Wire and Cable for the Transmission and Distribution of Electrical Energy NFPA 70 National Electrical Code ANSI/TIA/EIA 606A Standard for Telecommunications Infrastructure UL 83 Thermoplastic Insulated Wires and Cables UL 1063 Machine Tool Wires and Cables ASTM B3 Soft or Annealed Copper Wires ASTM B8 Concentric-Lay-Stranded Copper Conductors, Hard, Medium, Hard, Soft BCRUA- Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Electrical Conductors & Cables 26 05 19-2 1.5 DELIVERY AND STORAGE A. Deliver cable and wire to the project site in the original packages. Conductors with damaged insulation or exposed nylon jacketing shall not be permitted. B. Where cut lengths are specified, mark reel footage accordingly. Each reel shall contain one continuous length of cable. C. Check for reels not completely restrained, reels with interlocking flanges or broken flanges, damaged reel covering or any other indication of damage. Provide impact protection by wood lagging or suitable barrier across the traverse of the reel. D. Do not drop reels from any height. E. Unload reels using a sling and spreader bar. Roll reels in the direction of the arrows shown on the reel and on surfaces free of obstructions that could damage the wire and cable. F. Store cable on a solid, well drained location. Cover cable reels with plastic sheeting or tarpaulin. Do not lay reels flat. G. Provide moisture protection by using manufacturer’s standard procedure or heat shrinkable self-healing end caps applied to both ends of cable. Do not remove end caps until cables are ready to be terminated. PART 2 PRODUCTS 2.1 Conductors and Cables A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. Alpha Wire Company 2. Belden Inc 3. Encore Wire Corporation 4. General Cable Technologies Corporation 5. Southwire Company 6. Okonite 7. Houston Wire & Cable B. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application. C. Conductor and Cable Marking: Comply with wire and cable marking according to UL’s “Wire and Cable Marking and Application Guide.” D. Comply with UL 1227, UL 1685, and NFPA 70 Type TC-ER cable used in VFC circuits. E. Conductors: Tinned Copper, complying with NEMA WC70/ICEA S-950-658. 1. Conductor Insulation: Conductor with thermoset insulation rated at 600 volts. Wire shall be water tank tested and approved as machine tool wire, in accordance with National BCRUA- Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Electrical Conductors & Cables 26 05 19-3 Machine Tool Builders Association. Comply with NEMA WC/ICEA S-95-658 for Type XHHW-2. 2. Multiconductor cables: Type TC; Multi-conductor cable specifically approved for the installation of cable trays, in accordance with NEC Article 336. Each cable shall be insulated with XHHW-2 type insulation rated at 600V. The individual conductors shall be twisted together and jacketed with a PVC outer covering. Cables shall be 600V in accordance with NEC-725 and IEEE 383 and shall be suitable for wet location. 3. Power conductors used in cable trays shall be listed TC. F. VFD Cable: Type TC-ER with oversized crosslinked polyethylene (XLPE) insulation, spiral- wrapped foil plus 85 percent coverage braided shields and insulated full-size ground wire, and sunlight- and oil-resistant outer PVC jacket. multi-conductor cable specifically approved for the installation of cable trays, in accordance with NEC Article 340. Cable shall be IEEE and UL Flame Resistant compliant. Each cable shall be approved for use in wet or dry locations at 90 degrees Celsius. The individual conductors shall be twisted together and jacketed with a PVC outer covering containing a U.L. label and necessary identification, including the Manufacturer, the number of conductors, size, conductors, sun-resistance, and other pertinent information. 2.2 Connector and Splices A. Manufacturers: Subject to compliance with requirements, provide products by the following: 1. 3M Electrical Products. 2. Ideal Industries, Inc. 3. IlSCO. 4. O-Z/Gedney; a brand of Emerson Industrial Automation. 5. AFC Cable Systems, Inc. 6. Hubbel Power Systems, Inc. 7. Thomas & Betts Corporation, A Member of the ABB Group. 8. Tyco Electronics Corp. B. Description: Factory-fabricated connectors and splices of size, ampacity rating, material, type, and class for application and service indicated; listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application. C. Connectors, compression, copper, 600 Volt: The appropriate hole sizes and spacing which are in accordance with NEMA standards; two (2) holes in the tongue for use on conductor sizes 250 kcmil or larger; not required for connections to the circuit breakers in the lighting and/or receptacle panels. All compression connectors shall be long-barrel type, no exceptions. D. 600Volt Plastic Tape: Minnesota Mining & Manufacturing Company No. 35. 1. Wirenuts: Silicone-based pre-filled spring wire connecting devices with plastic covering; UL listed for damp and wet locations. Wirenut shall meet requirements of UL 486D for Sealed Wire Connector Systems. Wirenut shall be spring insulated, properly sized and resistant to vibration may be used for No.12 through No.10 solid gauge conductor for lighting and branch circuits only. E. Mechanical Set Screw Connector: Consisting of an aluminum body which has openings on opposite ends for insertion of the conductors. Conductors inserted into these holes shall each be clamped by two set screws. Connectors shall be suitable for use with copper conductors. BCRUA- Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Electrical Conductors & Cables 26 05 19-4 F. Rubber Tape: Scotch 2210. G. Vinyl Tape: Scotch 88. H. Arc Proofing Tape: 3M “Scotch 77 Fire and Electric Arc Proofing Tape”. Fireproofing shall be done with a half-lapped layer of arc proofing tape, anchored at each end with a double wrap of 3M “Scotch 69 Glass Cloth Electrical Tape”. I. Insulating Resin: Scotch 3576, 3577, or 3578. J. Power Distribution Blocks: Rated for 600 VAC and termination of copper conductors. Individual poles shall be constructed of tin plated aluminum and mounted on an insulating base. 2.3 CONTROL CONDUCTORS A. UTP CABLE 1. Manufacturers: subject to compliance with requirements, provide products by one of the following: a. 3M b. ADC. c. Alpha Wire Company. d. AMP NETCONNECT; a Tyco Electronics brand; a TE Connectivity Ltd. Company. e. Belden CDT Networking Division/NORDX. f. Berk-Tek; A Nexans company. g. CommScope, Inc. h. Draka USA. i. General Cable Products; Honeywell International, Inc. j. KRONE Incorporated. k. Mohawk; a division of Belden Networking, Inc. l. Nexsans. m. Siemon. 2. Description: 100-ohm, four-pair UTP. a. Comply with ICEA S-90-661 for mechanical properties of Category 5e cables. b. Comply with ICEA S-102-700 for mechanical properties of Category 6 cables. c. Comply with TIA-568-C.1 for performance specifications. d. Comply with TIA-568-C.2, Category 5e. B. UTP CABLE HARDWARE 1. Manufacturers: Subject to compliance with requirements, provide products by one of the following: a. ADC. b. American Technology Systems Industries, Inc. c. Belden CDT Networking Division/NORDX. d. Belden Inc. e. Corning Cable Systems. f. Dynacom Corporation. g. Hubbell Incorporated; Wiring-Kellems. h. Hubbell Premise Wiring. i. KRONE Incorporated. j. Leviton Manufacturing Co., Inc. BCRUA- Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Electrical Conductors & Cables 26 05 19-5 k. Molex Premise Networks. l. Panduit Corp. m. Siemon Co. 2. General Requirements for Cable Connecting Hardware: Comply with TIA/EIA-568-C.2, IDC type, with modules designed for punch-down caps or tools. Cables shall be terminated with connecting hardware of same category or higher. 2.4 TWIN-AXIAL DATA HIGHWAY CABLE 1. Standard Cable: NFPA 70, Type CM. a. Paired, No. 22 AWG, stranded tinned-copper conductors. b. Polypropylene insulation. c. Individual aluminum foil-polyester tape shielded pairs with 100 percent shield coverage. d. PVC jacket. e. Pairs are cabled on common axis with No. 24 AWG, stranded (7X32) tinned-copper drain wire. f. Flame-Rated Cable: NFPA 70, Type CMP. 2. Plenum-Rated Cable: NFPA 70, Type CMP. a. Paired, No. 22 AWG, stranded tinned-copper conductors. b. Plastic insulation. c. Individual aluminum foil-polyester tape shielded pairs with 100 percent shield coverage. d. Plastic jacket. e. Pairs are cabled on common axis with No. 24 AWG, stranded (7X32) tinned copper drain wire. f. Flame Resistance: Comply with NFPA 262. B. LOW-VOLTAGE CONTROL CABLE 1. Paired cable: NFPA 70, Type CMG. a. Individually and overall shielded One pair, twisted, No. 18 AWG, stranded tinned- copper conductors with 0.021” extruded PVC; 0.004" nylon insulation twisted into pairs, stranded into a core and enclosed by a non-hygroscopic core tape, 100% coverage, helically wound, aluminum foil shield, and drain wire. Pairs shall be black/red or black/white numbered. Cables shall be 600 volts in accordance with NEC-725 and IEEE 383 and shall be suitable for wet location. b. Unshielded. c. Extruded PVC jacket minimum 0050. d. Flame Resistance: Comply with UL 1685. C. CONTROL-CIRCUIT CONDUCTORS 1. Manufacturers: Subject to compliance with requirements, provide products by one of the following: a. General Cable; General Cable Corporation. b. Southwire Company. c. Alpha. d. Okonite. e. Belden. f. Houston Wire and Cable. 2. General a. Wire and Cables installed in cable trays shall be rated (TC) as such. BCRUA- Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Electrical Conductors & Cables 26 05 19-6 b. Wires and cables shall be soft-drawn, annealed copper with a conductivity of not less than that of 98% pure copper, UL83 and UL1063 listed, rated 600 volts and certified for continuous operation at maximum conductor temperature of 90 Celsius in dry locations and in wet locations. c. Control, signal and instrumentation circuits and as specifically indicated on the plans the minimum conductor permitted is #14. 3. SINGLE CONDUCTOR CABLES: Conductor with thermoplastic insulation rated at 600 volts and insulated with type XHHW-2 insulation. Wire shall be water tank tested and approved as machine tool wire, in accordance with National Machine Tool Builders Association. 4. Class 1 Control Circuits: Stranded copper, Type XHHW-2, in raceway, complying with UL 83. 5. Class 2 Control Circuits: Stranded copper, Type XHHW-2, in raceway, power-limited tray cable, in cable tray, complying with UL 83. 6. Class 3 Remote-Control and Signal Circuits: Stranded copper, Type XHHW-2, in raceway and power-limited tray cable, in cable tray Type TW or Type TF, in raceway, complying with UL 83 2.5 MULTIMODE OPTICAL-FIBER CABLE A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. 3M. 2. Belden Inc. 3. Nexans. 4. CommScope, Inc. 5. Corning Cable Systems. B. Description: Multimode, 50/125-micrometer, 6-fiber, nonconductive, tight-buffer, optical- fiber cable; fiber category OM2. 1. Comply with ICEA S-83-596 for mechanical properties. 2. Comply with TIA-568-C.3 for performance specifications. 3. Comply with TIA-492AAAB-B for detailed specifications. 4. Listed and labeled by an NRTL acceptable to authorities having jurisdiction as complying with UL 444, UL 1651, and NFPA 70 for the following types: a. Plenum Rated, Nonconductive: Type OFN, Type OFNG, Type OFNP, or Type OFNR in metallic conduit. 5. Maximum Attenuation: 2.8 dB/km at 850 nm; 1.0 dB/km at 1300 nm. 6. Minimum Effective Modal Bandwidth: 950 MHz-km at 850 nm C. Jacket: 1. Jacket Color: Black for 50/125-micrometer cable. 2. Cable cordage jacket, fiber, unit, and group color shall be according to TIA-598-C. 3. Imprinted with fiber count, fiber type, and aggregate length at regular intervals not to exceed 40 inches. 2.6 OPTICAL-FIBER CABLE HARDWARE A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. ADC. BCRUA- Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Electrical Conductors & Cables 26 05 19-7 2. American Technology Systems Industries, Inc. 3. Belden Inc. 4. Nexans. 5. Corning Cable Systems. B. Number of Connectors per Field: One for each fiber of cable or cables assigned to field. C. Patch Cords: Factory-made, dual-fiber cables in 36-inch lengths. D. Cable Connecting Hardware: 1. Comply with Optical-Fiber Connector Intermate-ability Standards (FOCIS) specifications of TIA-604-2-B, TIA-604-3-B, and TIA/EIA-604-12. Comply with TIA-568- C.3. 2. Quick-connect, simplex and duplex, Type ST connectors. Insertion loss of not more than 0.75 dB. 3. Type SFF connectors may be used in termination racks, panels, and equipment packages. (AD-02) PART 3 EXECUTION 3.1 INSTALLATION A. Completely swab raceway system before installing conductors. Do not use cleaning agents and lubricants which have a deleterious effect on the conductors or their insulation. B. Install raceway first as a complete system without conductors. Do not install pull wires and conductors until the raceway system is in place in accordance with the NEC and these specifications. Exception: Only flexible connections to motors shall be permitted to be installed after the installation of the remainder of the raceway system. The installation of these conductors shall be limited to exposure to damage for a maximum of one (1) week prior to installing flexible connection and making final terminations. Any conductors exposed to damage (i.e. not installed in raceway) longer than one (1) week shall be subject to rejection by the Owner and/or Engineer. If rejected, the cables shall be removed, discarded, at the CONTRACTORS expense. C. Do not exceed cable manufacturer’s recommendations for maximum pulling tensions and minimum bending radii. Where pulling compound is used, use only UL listed compound compatible with the cable outer jacket and with the raceway involved. D. Use pulling means, including fish tape, cable, rope, and basket-weave wire/cable grips, that will not damage cables or raceways. E. WIRE MARKING: Wire marking shall be in accordance with the National Electrical Code Article 310 and shall be printed on the wire insulation at 2 foot intervals. The printing method used shall be permanent and the color shall sharply contrast with the jacket color. F. Wire marking shall include the U.L. label and necessary identification, including the Manufacturer, the number of conductors, size, conductor insulation type, sun-resistance, and other pertinent information. BCRUA- Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Electrical Conductors & Cables 26 05 19-8 G. Wires and cables shall be soft-drawn, annealed copper with a conductivity of not less than that of 98% pure copper, UL83 and UL1063 listed, rated 600 volts and certified for continuous operation at maximum conductor temperature of 90 Celsius in dry locations and in wet locations H. Conductors #8 or larger shall be stranded and #14 AWG conductors shall be stranded. Utilize single conductors unless noted otherwise on the plans. I. Except for control, signal and instrumentation circuits and as specifically indicated on the plans the minimum conductor size permitted is #12. J. Installed unapproved wire shall be removed and replaced at the Contractor’s expense. K. Grouping conductors together into one conduit shall not be allowed where the plans indicate the conductors to be placed in separate conduits. Each home run shown on the plans shall be in its own conduit. L. Neatly train wiring inside boxes, equipment and panelboards. Pull conductors into a raceway at the same time and use U.L. listed, wire pulling lubricant for pulling No. 4 AWG and larger wire. M. Except for hand-pulled conductors into raceways, all wire and cable installation shall be installed with tension-monitoring equipment. Where conductors are found to have been installed without tension-monitoring, the conductors and cables shall be immediately removed from the raceways, permanently identified as rejected material, and removed from the jobsite. New conductors and cables shall be reinstalled, tagged and raceways resealed, all at the Contractor’s expense. N. All wire and cable installed in cable trays shall be UL Listed as Type TC, for cable tray use. O. Where single conductors and cables in manholes, hand holes, vaults, cable trays, and other indicated locations are not wrapped together by some other means such as arc and fireproofing tapes, bundle throughout their exposed length all conductors entering from each conduit with nylon, self-locking, releasable, cable ties placed at intervals not exceeding 4 inches on center. P. Properly support cables in accordance with the NEC and manufacturer’s recommendations in all raceways. Provide strain relief as required. Q. Arrange wiring in cabinets and panels neatly cut to proper length, remove surplus wire, and bundle and secure in an acceptable manner. Identify all circuits entering motor control centers or other control cabinets in accordance with the conductor identification system specified herein and in specification Section 26 05 53, “Identification For Electrical Systems.” R. Cap spare conductors and conductors not terminated, with the UL listed end caps. S. Where conductors pass through holes or over edges in sheet metal, remove all burrs, chamfer all edges, and install bushings and protective strips of insulating material to protect the conductors. T. For conductors that will be connected by others, provide at least 6 feet spare conductors in free standing panels and at least 2 feet spare in other assemblies. Provide additional spare BCRUA- Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Electrical Conductors & Cables 26 05 19-9 conductor in any particular assembly where it is obvious that more conductor length will be needed to reach the termination point. U. Each circuit shall include a dedicated ground wire. Sharing grounds or neutrals is not allowed. 3.2 CONDUCTORS AND CABLES A. CONDUCTOR INSULATION AND MULTICONDUCTOR CABLE APPLICATIONS AND WIRING METHODS 1. Feeders Concealed in Concrete, below Slabs-on-Grade, and Underground: Type XHHW- 2, single conductors in raceway 2. Feeders in Cable Tray: Type XHHW-2, single conductors larger than No. 1/0 AWG. 3. Branch Circuits Concealed in Concrete, below Slabs-on-Grade, and Underground: Type XHHW-2, single conductors in raceway. 4. Branch Circuits in Cable Tray: Type XHHW-2, single conductors larger than No. 1/0 AWG; Type TC multiconductor cable for No. 1/0 or smaller. 5. VFC Output Circuits: Type TC-ER cable. B. GROUND WIRE: Ground wire shall be Class B stranded tin-plated conductor without insulation in all cases where a single ground wire is indicated to be installed in a conduit with no other conductors in the conduit, or where the ground wire is directly buried in earth or concrete. In all other cases, insulate ground wire with green insulator as specified for low voltage wire. 3.3 SPLICES A. Power Conductors: Splice in junction boxes or at outlets only for lighting and receptacle branch circuits. Splices for all other circuits shall be disallowed. All splices are subject to the Engineer’s approval. Obtain approval from Engineer before installing any splices. 1. For existing installations, splices of 120V circuits shall use silicone filled twist-on wire nuts. 2. For splices of existing 480V circuits, the Contractor shall terminate conductors using power distribution blocks mounted in a termination box. B. No splicing of conductors shall be performed in any below ground structure. C. Condulet type fittings shall not contain splices. Under no condition shall conductors of a different color be spliced together. D. For No. 10 and smaller, connect conductors with a silicone filled twist-on spring wirenut. If a splice or tap is between final grade and 3' above the final grade, fill the spring connectors with an electrical insulating resin so that the resin encapsulates conductor and spring materials. Conductor splices and taps inside MCCs, switchboards, VFDs, panels, etc. shall be on the terminal strips or power distribution blocks. E. For pre-approved splice locations, No. 8 and larger, connect conductors with a split bolt type of connector or a mechanical, set screw type connector. Wrap splices and taps with a single half-lapped layer or rubber tape followed by successive layers of vinyl tape until a vinyl tape layer thickness of twice the original conductor insulation thickness is achieved. If splice or tap is below 3' above the finished grade, the tape or splice shall have a final outer coating or insulating resin. BCRUA- Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Electrical Conductors & Cables 26 05 19-10 3.4 TERMINATIONS A. Conductors terminated on a screw termination shall have a crimp on type spade connector applied on the wire end, Panduit PanTerm or approved equal. B. Furnish and install power distribution blocks as required for tapping conductors at their load connection point with conductors of smaller size. Install power distribution blocks with the number of poles and sizes needed for connecting the phase, neutral, and ground conductors. C. Tighten all screws and terminal bolts using torque type wrenches and/or drivers to tighten to the inch-pound requirements of the NEC and UL. D. Use crimp connectors on all stranded conductors. E. Soldered mechanical joints insulated with tape will not be acceptable. F. SINGLE CONDUCTORS: Sufficient wire shall be left at outlets to make connections to equipment without straining. Light switches and receptacles shall be connected with pig-tails and crimp-on connectors. 3.5 GROUNDING A. Conduits and other raceway shall contain an equipment grounding conductor whether the raceway is metallic or not. Conduits, motors, cabinets, outlets, and other equipment shall be properly grounded in accordance with National Electrical Code requirements. Where ground wire is exposed to mechanical damage, install wire in rigid aluminum conduit. Make connections to equipment with solderless connections. All connections to ground rods shall be of the fused type utilizing an exothermic welding process. B. Ground metallic material, including but not limited to metallic raceway, metallic boxes and metallic enclosures. Where metallic material is not connected by raceway to a solid ground, connect the metallic material to the largest equipment grounding conductor, which it houses. Clean the metal surface under the grounding lug to bright metal. Grounding connections to motors shall be to the grounding stud, which shall be threaded into the stationary frame; Use Burndy KC Servit, or approved equal. The ground wire shall not be lugged to a mounting bolt. C. Ground wire shall be uninsulated tin plated copper sized as shown on the plans in all cases where a single ground wire is indicated to be installed in a conduit with no other conductors in the conduit, or where the ground wire is directly buried in earth or concrete. In all other cases, insulate ground wire with green insulation as specified for low voltage wire. Provide and size bonding conductors in accordance with the National Electrical Code. D. Provide a bare uninsulated ground wire to run the entire length of all cable trays. The contractor shall bond to each section and to every enclosure served by conductors routed through the cable tray system 3.6 TESTING A. Testing: All testing required shall be per Specification Section 26 01 26, “Testing of Electrical Systems”. B. Testing Agency: Engage a qualified testing agency to perform tests and inspections. BCRUA- Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Electrical Conductors & Cables 26 05 19-11 1. After installing fiber optic cable, test for compliance with requirements. a. Optical-Fiber Cable Tests: 1) Test instruments shall meet or exceed applicable requirements in TIA-568- C.0. Use only test cords and adapters that are qualified by test equipment manufacturer for channel or link test configuration. 2) Link End-to-End Attenuation Tests: a) Multimode Link Measurements: Test in one direction according to TIA/EIA-526-14-A, Method B, One Reference Jumper. b) Attenuation test results for links shall be less than that calculated according to equation in TIA-568-C.0. (AD-02) END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Grounding & Bonding for Electrical Systems 26 05 26 - 1 SECTION 26 05 26 - GROUNDING & BONDING FOR ELECTRICAL SYSTEMS PART 1 GENERAL 1.1 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install a complete grounding system in strict accordance with Article 250 of the National Electrical Code (NEC) as shown on the drawings or as specified herein. Electrical work shall be in accordance with Section 26 05 00, “Common Work Results for Electrical”. B. Contractor will be required to locate grounding at the Treatment Structure Central (TSC), connect to, and extend ground ring around the filters, rapid mix, and sedimentation basins (including sludge box). The completion of the ground ring will include ground rods and coordination with the proposed lightning protection system being added onto the existing lightning protection system which exists on the operations building only. C. Contractor will be required to provide grounding rings around each raw water head tanks (total 2). The completion of the ground ring will include ground rods and coordination with the proposed lightning protection system being added. 1.2 SUBMITTALS A. Submittal shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include: 1. Grounding materials, equipment and processes. 2. Product Data: For each type of product supplied. 3. Field quality-control grounding test reports. 1.3 QUALITY ASSURANCE A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use. B. Comply with UL 467 for grounding and bonding materials and equipment. 1.4 JOB CONDITIONS A. Measure the ground grid resistance with the earth test megger and install additional ground rods and conductors as required until the resistance to the ground conforms to National Electrical Code requirements. Ground resistance measurement shall not exceed 5 ohms. Add ground rods as required to bring resistance to 5 ohms and connect to grounding system. PART 2 PRODUCTS 2.1 MATERIALS A. GROUND RODS: Copper-clad steel at all locations, having a diameter of 3/4" and a minimum length of 10'. BCRUA - Phase 1D WTP Expansion Issued for Bid Grounding & Bonding for Electrical Systems 26 05 26 - 2 B. GROUND CABLES: Stranded, bare tinned copper of 98% conductivity and as specified in Section 26 05 19, “Low Voltage Electrical Conductors & Cables”. C. CONDUIT GROUND FITTINGS: Fittings for bonding ground cable to the conduit shall be FCI Burndy Corp., type NE or Thomas & Betts No. 3951 series. D. GROUND ROD BOXES: Precast Box with cast iron lid. Lid shall read “ground rod” on lid. Brooks Precast Model. “3-RT” or approved equal. Ground rod boxes located in driveway areas shall have an AASHTO HS-20 rating. E. EXOTHERMIC WELDING PROCESS: CADWELD MATERIALS – as manufactured by ERICO products or approved equal. F. GROUND PAD: Flat plate all copper alloy ERICO CADWELD B164-2Q or equal. Ground pad shall be installed in concrete foundations or pad for connections to motors and transformers. Ground pad shall be exothermic weld connection for connection to ground cable. 2.2 CONNECTORS A. Listed and labeled by a Nationally Recognized Testing Laboratory (NRTL) acceptable to authorities having jurisdiction for applications in which used and for specific types, sizes, and combinations of conductors and other items connected. B. Bolted Connectors for Conductors and Pipes: Copper or copper alloy, bolted pressure-type, with at least two bolts. C. Welded Connectors: Exothermic-welding kits of types recommended by kit manufacturer for materials being joined and installation conditions. D. Bus-Bar Connectors: Mechanical type, cast silicon bronze, solderless compression-type wire terminals, and long-barrel, two-bolt connection to ground bus bar. 2.3 MISCELLANEOUS A. CONDUIT GROUND FITTINGS: Fittings for bonding ground cable to the conduit shall be FCI Burndy Corp., type NE or Thomas & Betts No. 3951 series. B. GROUND ROD BOXES: Precast Box with cast iron lid. Lid shall read “ground rod”. H-10 rated boxes shall be Brooks Precast Model “3-RT” or approved equal. Ground rod boxes located in driveway areas shall have an AASHO HS-20 rating by ALT Fabrication Item #3114 or approved equal. C. EXOTHERMIC WELDING PROCESS: CADWELD MATERIALS – as manufactured by ERICO products or approved equal. 2.4 PROCESSES A. All grounding system connections to building steel and ground rods shall be exothermically welded including all cable connections, and cable steel terminations. The use of mechanical type connections is not acceptable. BCRUA - Phase 1D WTP Expansion Issued for Bid Grounding & Bonding for Electrical Systems 26 05 26 - 3 B. Any concealed connection (buried, encased in concrete or otherwise sealed) shall be done only with exothermic welds. C. All materials involved must be from the same sources to insure compatibility. Connections made from this process shall meet the requirements of IEEE Standards 80 and 837 and as listed in MIL 419 and other standards, National Electrical Code, etc. 2.5 GROUNDING SYSTEM A. Provide a complete grounding system that includes all connections and the testing of ground rods, ground cables, ground buses, conduits, fittings, anchor supports, thermite process materials and equipment and other materials required for a complete installation. Grounding system shall be installed and sized in accordance with the National Electrical Code. PART 3 EXECUTION 3.1 INSTALLATION A. Conductor Terminations and Connections: 1. Pipe and Equipment Grounding Conductor Terminations: Bolted/clamp type connectors. 2. Underground Connections or any concealed location: Exothermically welded connectors, 3. Connections to Ground Rods at Test Wells: Exothermically welded connectors. 4. Connections to Structural Steel: Exothermically welded connectors. 5. Connections to equipment: NEMA ground pads and insulated jumpers. 6. Connection to Ground Pad: Exothermic. 7. The use of “pig tails” for connections to ground loops or equipment shall not be allowed. B. Ground electrical work in accordance with NEC Article 250 and local codes. C. Install ground cables in conduits above grade or directly buried in earth to a depth of not less than 18” to 24" below grade. Installation to provide sufficient mechanical protection so as not to break ground cables or connections. If ground cables are exposed, run in conduits for added protection. D. Install ground cables continuously between connections. Splices shall not be permitted, except where indicated on the plans. Where ground cables pass through floor slabs, buildings, etc., and when not in metallic enclosures, provide a sleeve of approved, non-metallic materials. E. Install a green-colored, equipment grounding conductor in raceways. Size conductors in accordance with NEC Article 250. F. Where ground wire is directly buried in earth or concealed in concrete, structures or duct banks use standard bare copper cable, in all other cases install a green-colored insulation, equipment grounding conductor in accordance with Section 26 05 19, “Low Voltage Electrical Conductors & Cables.” Size conductors in accordance with NEC Article 250. Provide grounding conductors as required per the NEC. For larger conductors where green insulation is not available, provide green indicating tape per the National Electrical Code. BCRUA - Phase 1D WTP Expansion Issued for Bid Grounding & Bonding for Electrical Systems 26 05 26 - 4 G. Metal conduits stubbed up into motor control center or other electrical equipment shall be terminated with insulated grounding bushings and connected to the equipment ground bus. Size the grounding wire in accordance with applicable sections of the National Electrical Code. Provide grounding and bonding jumpers as required per the NEC and sized in accordance with the NEC. H. Provide exothermic weld connection for extension to existing stub-up ground conductors. I. Bonding Straps and Jumpers: Install in locations accessible for inspection and maintenance, except where routed through short lengths of conduit. 1. Provide grounding and bonding jumpers as required per the NEC. 2. Bonding to Structure: Bond straps directly to basic structure, taking care not to penetrate any adjacent parts. 3. Bonding to Equipment Mounted on Vibration Isolation Hangers and Supports: Install so vibration is not transmitted to rigidly mounted equipment. Bolt-on or crimp-on connections in lieu of exothermic welds, shall only be used upon Owner/Engineer’s approval in writing on a case by case basis. 4. Use exothermic-welded connectors for outdoor locations, but if a disconnect type connection is required; use a bolt on crimp type lug. J. Liquid tight flexible metal conduit in sizes 1-1/2” or larger shall have bonding jumpers. Bonding jumpers shall be external, run in parallel (not spiraled) and fastened with plastic tie wraps. Bonding jumpers shall be insulated copper conductors. CONTRACTOR shall provide bonding jumpers sized in accordance with the National Electrical Code. K. All equipment enclosures, motor and transformer frames, conduit systems, cable armor, exposed structural steel and all other equipment and materials required by the NEC to be grounded, shall be grounded and bonded in accordance with the NEC. Provide grounding and bonding jumpers as required per the NEC and sized in accordance with the NEC. L. Ground transformer neutrals to the nearest available grounding electrode with a conductor sized in accordance with NEC Article 250. M. Where exothermic bonding is used, molds shall be of the appropriate size for the wire and rod used. All bonds shall remain exposed for inspection of the OWNER’s Representative. N. Ground rod shall be installed such that the top of the ground rod is 6” below grade and enclosed by a ground rod box. O. At each convenience outlet, install a grounding clip attached to the outlet box and leave a sufficient length of #12 wire with green-colored insulation to connect to the grounding terminal at the receptacle. 3.2 INSPECTION A. Inspect the grounding and bonding system conductors and connections for tightness and proper installation. B. Use Biddle Direct Reading Earth Resistance Tester or equivalent to measure resistance to ground of the system. Perform testing in accordance with the test instrument manufacturer’s recommendation using the fall of potential method. BCRUA - Phase 1D WTP Expansion Issued for Bid Grounding & Bonding for Electrical Systems 26 05 26 - 5 C. All test equipment provided under this section shall be approved by the ENGINEER. D. Resistance to ground testing shall be performed during dry season. Submit test results in the form of a graph showing the number of points measured (12 minimum) and the numerical resistance to ground. E. Testing shall be performed before energizing the distribution system. F. A separate test shall be conducted for each building or system. G. Notify the ENGINEER immediately if the resistance to ground for any building or system is greater than five ohms. Provide additional ground rods and conductors as required to bring the resistance to five ohms. H. Submit reports of all tests to the Owner/Engineer. 3.3 TESTING A. Testing shall be done in accordance with 26 01 26, “Testing of Electrical Systems”. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Hangers & Supports for Electrical Systems 26 05 29 - 1 SECTION 26 05 29 - HANGERS AND SUPPORTS FOR ELECTRICAL SYSTEMS PART 1 GENERAL 1.1 WORK INCLUDED A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. B. This Section includes the following: 1. Hangers and supports for electrical equipment and systems. 2. Construction requirements for concrete bases. 1.2 PERFORMANCE REQUIREMENTS A. Design supports for multiple raceways capable of supporting combined weight of supported systems and its contents. B. Design equipment supports capable of supporting combined operating weight of supported equipment and connected systems and components. 1.3 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include Record Data. 1. Hangers. 2. Steel slotted support systems. 3. Trapeze hangers. 4. Clamps. 5. Brackets. B. Provide calculations for load limits for all trapeze-type supports, support assemblies and field fabricated support systems. 1.4 QUALITY ASSURANCE A. Welding: Qualify procedures and personnel according to AWS D1.1/D1.1M, "Structural Welding Code - Steel." B. Comply with NFPA 70. 1.5 COORDINATION A. Coordinate size and location of concrete bases. Cast anchor-bolt inserts into bases. Concrete, reinforcement, and formwork requirements are specified in Division 03. BCRUA - Phase 1D WTP Expansion Issued for Bid Hangers & Supports for Electrical Systems 26 05 29 - 2 PART 2 PRODUCTS 2.1 SUPPORT, ANCHORAGE, AND ATTACHMENT COMPONENTS A. Steel Slotted Support Systems: Comply with MFMA-4, factory-fabricated components for field assembly. 1. Manufacturers: Subject to compliance with requirements, provide products by one of the following: a. Allied Tube & Conduit. b. Cooper B-Line, Inc.; a division of Cooper Industries. c. ERICO International Corporation. d. GS Metals Corp. e. Thomas & Betts Corporation. f. Unistrut; Tyco International, Ltd. g. Wesanco, Inc. 2. Channel Dimensions: Selected for applicable load criteria. 3. Slotted channel shall be 316 stainless steel. B. Raceway and Cable Supports: As described in NECA 1 and NECA 101. C. Conduit and Cable Support Devices: 316 stainless steel hangers, clamps, straps and associated fittings, designed for types and sizes of raceway or cable to be supported. D. Structural Steel for Fabricated Supports and Restraints: ASTM A 36/A 36M, steel plates, shapes, and bars; 316 stainless steel. E. Mounting, Anchoring, and Attachment Components: Items for fastening electrical items or their supports to building surfaces include the following: 1. Mechanical-Expansion Anchors: Insert-wedge-type, 316 stainless steel, for use in hardened portland cement concrete with tension, shear, and pullout capacities appropriate for supported loads and building materials in which used. a. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1) Cooper B-Line, Inc.; a division of Cooper Industries. 2) Empire Tool and Manufacturing Co., Inc. 3) Hilti Inc. 4) ITW Ramset/Red Head; a division of Illinois Tool Works, Inc. 5) MKT Fastening, LLC. 2. Concrete Inserts: Stainless Steel, slotted support system units similar to MSS Type 18; complying with MFMA-4 or MSS SP-58. 3. Clamps for Attachment to Steel Structural Elements: MSS SP-58, type suitable for attached structural element. 4. Through Bolts: 316 Stainless Steel, Structural type, hex head, and high strength. Comply with ASTM A 325. 5. Toggle Bolts: 316 Stainless steel springhead type. 6. Hanger Rods: Threaded 316 stainless steel. 7. Washers: 316 Stainless steel. BCRUA - Phase 1D WTP Expansion Issued for Bid Hangers & Supports for Electrical Systems 26 05 29 - 3 PART 3 EXECUTION 3.1 APPLICATION A. Comply with NECA 1 and NECA 101 for application of hangers and supports for electrical equipment and systems except if requirements in this Section are stricter. B. Maximum Support Spacing and Minimum Hanger Rod Size for Raceway: Space supports for RIGID METAL CONDUIT as required by NFPA 70. Minimum rod size shall be 3/8 inch in diameter. C. Multiple Raceways or Cables: Install trapeze-type supports fabricated with stainless steel slotted support system, sized so capacity can be increased by at least 25 percent in future without exceeding specified design load limits. 1. Secure raceways and cables to these supports with single-bolt conduit clamps using spring friction action for retention in support channel. 3.2 SUPPORT INSTALLATION A. Comply with NECA 1 and NECA 101 for installation requirements except as specified in this Article. B. Raceway Support Methods: In addition to methods described in NECA 1, RIGID METAL CONDUIT may be supported by openings through structure members, as permitted in NFPA 70. C. Strength of Support Assemblies: Where not indicated, select sizes of components so strength will be adequate to carry present and future static loads within specified loading limits. Minimum static design load used for strength determination shall be weight of supported components plus 200 lb. D. Mounting and Anchorage of Surface-Mounted Equipment and Components: Anchor and fasten electrical items and their supports to building structural elements by the following methods unless otherwise indicated by code: 1. To Wood: Fasten with lag screws or through bolts. 2. To New Concrete: Bolt to concrete inserts. 3. To Masonry: Approved toggle-type bolts on hollow masonry units and expansion anchor fasteners on solid masonry units. 4. To Existing Concrete: Expansion anchor fasteners. 5. To Steel: Beam clamps (MSS Type 19, 21, 23, 25, or 27) complying with MSS SP-69. 6. To Light Steel: Sheet metal screws. 7. Items Mounted on Hollow Walls and Nonstructural Building Surfaces: Mount cabinets, panelboards, disconnect switches, control enclosures, pull and junction boxes, transformers, and other devices on slotted-channel racks attached to substrate. E. Drill holes for expansion anchors in concrete at locations and to depths that avoid reinforcing bars. BCRUA - Phase 1D WTP Expansion Issued for Bid Hangers & Supports for Electrical Systems 26 05 29 - 4 3.3 CONCRETE BASES A. Construct concrete bases of dimensions indicated but not less than 4 inches larger in both directions than supported unit, and so anchors will be a minimum of 10 bolt diameters from edge of the base. B. Use 3000-psi, 28-day compressive-strength concrete. C. Anchor equipment to concrete base. 1. Place and secure anchorage devices. Use supported equipment manufacturer's setting drawings, templates, diagrams, instructions, and directions furnished with items to be embedded. 2. Install anchor bolts to elevations required for proper attachment to supported equipment. 3. Install anchor bolts according to anchor-bolt manufacturer's written instructions. D. All floor mounted equipment shall have a 4” thick housekeeping pad on top of concrete foundations or floor for interior equipment. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Raceways and Boxes for Electrical Systems 26 05 33- 1 SECTION 26 05 33 - RACEWAYS AND BOXES FOR ELECTRICAL SYSTEMS PART 1 - GENERAL 1.1 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install a complete conduit system for each type of electrical system. Electrical work shall be in accordance with Div. 26 ELECTRICAL specifications. B. The CONTRACTOR shall be responsible for sizing all pull boxes and junction boxes per the National Electrical Code (NEC) Article 314 and all other relevant sections of the NEC. 1.2 SUMMARY A. Section Includes: 1. Metal conduits, tubing, and fittings. 2. Nonmetal conduits, tubing, and fittings. 3. Metal wireways and auxiliary gutters. 4. Surface raceways. 5. Boxes, enclosures, and cabinets. 1.3 DEFINITIONS A. ARC: Aluminum rigid conduit. B. GRC: Galvanized rigid steel conduit. C. IMC: Intermediate metal conduit. 1.4 SUBMITTALS A. Product Data: For surface raceways, wireways and fittings, hinged-cover enclosures, and cabinets. B. Shop Drawings: For custom enclosures and cabinets. Include plans, elevations, sections, and attachment details. PART 2 - PRODUCTS 2.1 METAL CONDUITS, TUBING, AND FITTINGS A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. AFC Cable Systems; a part of Atkore International. 2. Allied Tube & Conduit; a part of Atkore International. 3. Anamet Electrical, Inc. 4. Electri-Flex Company. 5. FSR Inc. 6. O-Z/Gedney; a brand of Emerson Industrial Automation. BCRUA - Phase 1D WTP Expansion Issued for Bid Raceways and Boxes for Electrical Systems 26 05 33- 2 7. Picoma Industries, Inc. 8. Republic Conduit. 9. Robroy Industries. 10. Southwire Company. 11. Thomas & Betts Corporation, A Member of the ABB Group. 12. Western Tube and Conduit Corporation. 13. Wheatland Tube Company. B. Listing and Labeling: Metal conduits, tubing, and fittings shall be listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application. C. GRC: Comply with ANSI C80.1 and UL 6. D. ARC: Comply with ANSI C80.5 and UL 6A. E. IMC: Comply with ANSI C80.6 and UL 1242. F. PVC-Coated Steel Conduit: PVC-coated rigid steel conduit. 1. Comply with NEMA RN 1. 2. Coating Thickness: 0.040 inch, minimum. G. EMT: Comply with ANSI C80.3 and UL 797. H. FMC: Comply with UL 1; zinc-coated steel. I. LFMC: Flexible steel conduit with PVC jacket and complying with UL 360. J. Fittings for Metal Conduit: Comply with NEMA FB 1 and UL 514B. 1. Fittings for EMT: a. Material: Steel. b. Type: compression. 2. Fittings for Rigid Aluminum: a. Material: Aluminum 1) Type: Form 7 3. Fittings for PVC Coated Rigid Aluminum: 1) Material: PVC Coated Cast Aluminum. 2) Type: Form 7 3) Coating for Fitting for PVC-Coated Conduit: Minimum Thickness of 0.040 inch, with overlapping sleeves protecting threaded joints. 4. Expansion Fittings: PVC or steel to match conduit type, complying with UL 651, rated for environmental conditions where installed, and including flexible external bonding jumper. K. Joint Compound for IMC, GRC, or ARC: Approved, as defined in NFPA 70, by authorities having jurisdiction for use in conduit assemblies, and compounded for use to lubricate and protect threaded conduit joints from corrosion and to enhance their conductivity. 1. Aluminum Conduit: Penetrox A-13 or approved equal. a. UL Listed b. Compatible with insulating materials such as rubber, or polyethylene. c. Rated for all voltages BCRUA - Phase 1D WTP Expansion Issued for Bid Raceways and Boxes for Electrical Systems 26 05 33- 3 L. Insulated Grounding Bushings: Threaded bushings, O-Z Type ABLG with lay-in means of grounding conduit. M. Sealing Compound: 1. Chico SpeedSeal, hydra-Seal S-60 or approved equal. 2.2 NONMETALLIC CONDUITS, TUBING, AND FITTINGS A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. AFC Cable Systems; a part of Atkore International. 2. Anamet Electrical, Inc 3. Arnco Corporation. 4. CANTEX INC. 5. CertainTeed Corporation. 6. Condux International, Inc. 7. Electri-Flex Company. 8. Kraloy. 9. Lamson & Sessions. 10. Niedax Inc. 11. RACO; Hubbell. 12. Thomas & Betts Corporation, A Member of the ABB Group. B. Listing and Labeling: Nonmetallic conduits, tubing, and fittings shall be listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application. C. ENT: Comply with NEMA TC 13 and UL 1653. D. Fittings for RNC: Comply with NEMA TC 3; match to conduit or tubing type and material. 2.3 METAL WIREWAYS AND AUXILIARY GUTTERS A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. B-line, an Eaton business. 2. Hoffman; a brand of Pentair Equipment Protection. 3. MonoSystems, Inc. 4. Square D. B. Description: Sheet metal, complying with UL 870 and NEMA 250, Type 4X unless otherwise indicated, and sized according to NFPA 70. 1. Metal wireways installed outdoors shall be listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application. C. Fittings and Accessories: Include covers, couplings, offsets, elbows, expansion joints, adapters, hold-down straps, end caps, and other fittings to match and mate with wireways as required for complete system. D. Wireway Covers: Hinged type unless otherwise indicated. BCRUA - Phase 1D WTP Expansion Issued for Bid Raceways and Boxes for Electrical Systems 26 05 33- 4 E. Finish: Manufacturer's standard enamel finish. 2.4 BOXES, ENCLOSURES, AND CABINETS A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. Adalet. 2. Crouse-Hinds, an Eaton business. 3. EGS/Appleton Electric. 4. Erickson Electrical Equipment Company. 5. FSR Inc. 6. Hoffman; a brand of Pentair Equipment Protection. 7. Hubbell Incorporated. 8. Kraloy. 9. Milbank Manufacturing Co. 10. MonoSystems, Inc. 11. Oldcastle Enclosure Solutions. 12. O-Z/Gedney; a brand of Emerson Industrial Automation. 13. RACO; Hubbell. 14. Robroy Industries. 15. Spring City Electrical Manufacturing Company. 16. Stahlin Non-Metallic Enclosures. 17. Thomas & Betts Corporation, A Member of the ABB Group. 18. Wiremold / Legrand. B. Outlet boxes for PVC Coated Rigid Aluminum 1. Material: PVC Coated Cast Copper free aluminum: 2. Type: FS 3. Coating for Fittings for PVC-Coated Outlet box: Minimum thickness of 0.040 inch, with overlapping sleeves protecting threaded joints C. Outlet boxes for Rigid Aluminum 1. Material: Cast Copper free Aluminum 2. Type: FS D. General Requirements for Boxes, Enclosures, and Cabinets: Boxes, enclosures, and cabinets installed in wet locations shall be listed for use in wet locations. E. Sheet Metal Outlet and Device Boxes: Comply with NEMA OS 1 and UL 514A. F. Cast-Metal Outlet and Device Boxes: Comply with NEMA FB 1, aluminum, Type FD, with gasketed cover. G. Small Sheet Metal Pull and Junction Boxes: NEMA OS 1. H. Cast-Metal Access, Pull, and Junction Boxes: Comply with NEMA FB 1 and UL 1773, cast aluminum with gasketed cover. I. Box extensions used to accommodate new building finishes shall be of same material as recessed box. BCRUA - Phase 1D WTP Expansion Issued for Bid Raceways and Boxes for Electrical Systems 26 05 33- 5 J. Device Box Dimensions: 4 inches square by 2-1/8 inches deep or 4 inches by 2-1/8 inches by 2-1/8 inches deep. K. Gangable boxes are allowed. L. Hinged-Cover Enclosures: Comply with UL 50 and NEMA 250, Type 4 with continuous- hinge cover with flush latch unless otherwise indicated. 1. Metal Enclosures: Steel, finished inside and out with manufacturer's standard enamel. 2. Interior Panels: Steel; all sides finished with manufacturer's standard enamel. M. Cabinets: 1. NEMA 250, Type 12 galvanized-steel box with removable interior panel and removable front, finished inside and out with manufacturer's standard enamel. 2. Hinged door in front cover with flush latch and concealed hinge. 3. Key latch to match panelboards. 4. Metal barriers to separate wiring of different systems and voltage. 5. Accessory feet where required for freestanding equipment. 6. Nonmetallic cabinets shall be listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application. PART 3 - EXECUTION 3.1 RACEWAY APPLICATION A. Outdoors: Apply raceway products as specified below unless otherwise indicated: 1. Exposed Conduit: Rigid Aluminum. 2. Concealed Conduit, Aboveground: PVC-coated aluminum conduit. 3. Underground Conduit: RNC, Type EPC-40-PVC, direct buried or concrete encased as indicated on plans. 4. Connection to Vibrating Equipment (Including Transformers and Hydraulic, Pneumatic, Electric Solenoid, or Motor-Driven Equipment): LFMC. 5. Boxes and Enclosures, Aboveground: NEMA 250, Type 4X 304 Stainless Steel. B. Indoors: Apply raceway products as specified below unless otherwise indicated: 1. Exposed, Not Subject to Physical Damage: Rigid aluminum conduit. 2. Exposed and Subject to Physical Damage: Rigid aluminum conduit. Raceway locations include the following: a. Corridors used for traffic of mechanized carts, forklifts, and pallet-handling units. b. Mechanical rooms. c. Exterior exposed conditions. 3. Concealed in Ceilings and Interior Walls and Partitions: EMT. 4. Connection to Vibrating Equipment (Including Transformers and Hydraulic, Pneumatic, Electric Solenoid, or Motor-Driven Equipment): FMC, except use LFMC in damp or wet locations. 5. Damp or Wet Locations: PVC-coated aluminum conduit. 6. Boxes and Enclosures: NEMA 250, Type 4X 304 Stainless Steel. C. Minimum Raceway Size: 3/4-inch trade size. D. Raceway Fittings: Compatible with raceways and suitable for use and location. BCRUA - Phase 1D WTP Expansion Issued for Bid Raceways and Boxes for Electrical Systems 26 05 33- 6 1. Rigid and Intermediate Steel Conduit: Use threaded rigid steel conduit fittings unless otherwise indicated. Comply with NEMA FB 2.10. 2. PVC Externally Coated, Rigid Steel Conduits: Use only fittings listed for use with this type of conduit. Patch and seal all joints, nicks, and scrapes in PVC coating after installing conduits and fittings. Use sealant recommended by fitting manufacturer and apply in thickness and number of coats recommended by manufacturer. 3. EMT: Use compression, steel fittings. Comply with NEMA FB 2.10. 4. Flexible Conduit: Use only fittings listed for use with flexible conduit. Comply with NEMA FB 2.20. E. Do not install aluminum conduits, boxes, or fittings in contact with concrete or earth. 3.2 INSTALLATION A. Comply with NECA 1 and NECA 101 for installation requirements except where requirements on Drawings or in this article are stricter. Comply with NECA 102 for aluminum conduits. Comply with NFPA 70 limitations for types of raceways allowed in specific occupancies and number of floors. B. Keep raceways at least 6 inches away from parallel runs of flues and steam or hot-water pipes. Install horizontal raceway runs above water and steam piping. C. Complete raceway installation before starting conductor installation. D. Size conduits as required by the National Electrical Code for the number and sizes of wires to be drawn into the conduit. Conduit less than ¾” shall not be used unless specified otherwise. No conduit less than 2” shall be allowed to be installed in duct banks even if exposed section of raceway is a smaller trade size. E. Aluminum conduit, straps, and struts shall not be in direct contact with concrete. Provide a neoprene washer between the two materials. F. Comply with requirements in Section 26 05 29 "Hangers and Supports for Electrical Systems" for hangers and supports. G. Install a pulling string in empty (spare) conduit, except sleeves and nipples, and leave for future pulling as applicable. H. Junction boxes shall have terminal strips/distribution blocks for splicing conductors where approved by the ENGINEER or as shown/specified on the plans. Terminal strips shall be manufactured by Allen-Bradley, Phoenix Contact or approved equal. No top entry in junction boxes with a terminal strip. I. Arrange stub-ups so curved portions of bends are not visible above finished slab. J. Use watertight hubs to fasten conduit to metal boxes, etc. in wet or damp locations per the National Electrical Code. K. Conduit penetrations in the top of any enclosure or junction box is strictly prohibited in all areas except dry NEMA 1 areas. Any enclosure top penetrated will be rejected and shall be removed and replaced at the Contractor’s expense. BCRUA - Phase 1D WTP Expansion Issued for Bid Raceways and Boxes for Electrical Systems 26 05 33- 7 L. Install no more than the equivalent of three 90-degree bends in any conduit run except for control wiring conduits, for which fewer bends are allowed. Support within 12 inches of changes in direction. M. Conceal conduit and EMT within finished walls, ceilings, and floors unless otherwise indicated. Install conduits parallel or perpendicular to building lines. N. Support conduit within 12 inches of enclosures to which attached. O. Raceways Embedded in Slabs: 1. Run conduit larger than 1-inch trade size, parallel or at right angles to main reinforcement. Where at right angles to reinforcement, place conduit close to slab support. Secure raceways to reinforcement at maximum 10-footintervals. 2. Arrange raceways to cross building expansion joints at right angles with expansion fittings. 3. Arrange raceways to keep a minimum of 2 inches of concrete cover in all directions. 4. Do not embed threadless fittings in concrete unless specifically approved by Architect for each specific location. 5. Change from ENT to GRC before rising above floor. P. Stub-ups to Above Recessed Ceilings: 1. Use EMT, IMC, or RMC for raceways. 2. Use a conduit bushing or insulated fitting to terminate stub-ups not terminated in hubs or in an enclosure. Q. Threaded Conduit Joints, Exposed to Wet, Damp, Corrosive, or Outdoor Conditions: Apply listed compound to threads of raceway and fittings before making up joints. Follow compound manufacturer's written instructions. R. Coat field-cut threads on PVC-coated raceway with a corrosion-preventing conductive compound prior to assembly. S. Terminate threaded conduits into threaded hubs on outside of boxes or cabinets. T. Install raceways square to the enclosure. U. Cut conduit perpendicular to the length. For conduits 2-inch trade size and larger, use roll cutter or a guide to make cut straight and perpendicular to the length. V. Install pull wires in empty raceways. Use polypropylene or monofilament plastic line with not less than 200-lb tensile strength. Leave at least 12 inches of slack at each end of pull wire. Cap underground raceways designated as spare above grade alongside raceways in use. W. Install raceway sealing fittings at accessible locations according to NFPA 70 and fill them with listed sealing compound. For concealed raceways, install each fitting in a flush steel box with a blank cover plate having a finish similar to that of adjacent plates or surfaces. Install raceway sealing fittings according to NFPA 70. X. Install devices to seal raceway interiors at accessible locations. Locate seals so no fittings or boxes are between the seal and the following changes of environments. Seal the interior of all raceways at the following points: BCRUA - Phase 1D WTP Expansion Issued for Bid Raceways and Boxes for Electrical Systems 26 05 33- 8 1. Where conduits pass from warm to cold locations, such as boundaries of refrigerated spaces. 2. Where an underground service raceway enters a building or structure. 3. Where otherwise required by NFPA 70. Y. Comply with manufacturer's written instructions for solvent welding RNC and fittings. Z. Expansion-Joint Fittings: 1. Install in each run of aboveground RMC and EMT conduit that is located where environmental temperature change may exceed 100 deg F and that has straight-run length that exceeds 100 feet. 2. Install fitting(s) that provide expansion and contraction for at least 0.00041 inch per foot of length of straight run per deg F of temperature change for PVC conduits. Install fitting(s) that provide expansion and contraction for at least 0.000078 inch per foot of length of straight run per deg F of temperature change for metal conduits. 3. Install expansion fittings at all locations where conduits cross building or structure expansion joints. 4. Install each expansion-joint fitting with position, mounting, and piston setting selected according to manufacturer's written instructions for conditions at specific location at time of installation. Install conduit supports to allow for expansion movement. AA. Flexible Conduit Connections: Comply with NEMA RV 3. Use a maximum of 72 inches of flexible conduit for equipment subject to vibration, noise transmission, or movement; and for transformers and motors. 1. Use LFMC in damp or wet locations subject to severe physical damage. 2. Use LFMC or LFNC in damp or wet locations not subject to severe physical damage. BB. Mount boxes at heights indicated on Drawings. If mounting heights of boxes are not individually indicated, give priority to ADA requirements. Install boxes with height measured to center of box unless otherwise indicated. CC. Recessed Boxes in Masonry Walls: Saw-cut opening for box in center of cell of masonry block, and install box flush with surface of wall. Prepare block surfaces to provide a flat surface for a raintight connection between box and cover plate or supported equipment and box. DD. Horizontally separate boxes mounted on opposite sides of walls so they are not in the same vertical channel. EE. Locate boxes so that cover or plate will not span different building finishes. FF. Fasten junction and pull boxes to or support from building structure. Do not support boxes by conduits. 3.3 PROTECTION A. Protect coatings, finishes, and cabinets from damage and deterioration. 1. Repair damage to galvanized finishes with zinc-rich paint recommended by manufacturer. 2. Repair damage to PVC coatings or paint finishes with matching touchup coating recommended by manufacturer. BCRUA - Phase 1D WTP Expansion Issued for Bid Raceways and Boxes for Electrical Systems 26 05 33- 9 3.4 TERMINATIONS A. Use threaded hubs for termination of conduits. Threaded hubs shall include a grounding lay in lug. B. Locknut termination of conduits shall not be used on this project. C. Conduit terminations shall not penetrate the top of NEMA 4X and NEMA 3R enclosures. Enclosures with top penetrations shall be removed and replaced with conduits re-routed for side or bottom penetration at contractor’s expense. If conductors have been installed and are too short to accommodate the re-routed conduit, then they shall be removed and replaced at the Contractor’s expense. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Identification for Electrical Systems 26 05 53 - 1 SECTION 26 05 53 - IDENTIFICATION FOR ELECTRICAL SYSTEMS PART 1 GENERAL 1.1 WORK INCLUDED A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. 1.2 SUMMARY A. Section Includes: 1. Identification for raceways. 2. Identification of power and control cables. 3. Identification for conductors. 4. Underground-line warning tape. 5. Warning labels and signs. 6. Instruction signs. 7. Equipment identification labels. 8. Miscellaneous identification products. 1.3 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include: 1. Identification Schedule: For each piece of electrical equipment and electrical system components to be an index of nomenclature for electrical equipment and system components used in identification signs and labels. Use same designations indicated on Drawings. 2. Shop drawings: a. Product Data to include cut sheets for each electrical identification product to be used on the project. Provide example of labeling for Owner/Engineer approval prior to beginning any work. 1.4 QUALITY ASSURANCE 1. Comply with ANSI A13.1. 2. Comply with NFPA 70. 3. Comply with 29 CFR 1910.144 and 29 CFR 1910.145. 4. Comply with ANSI Z535.4 for safety signs and labels. 5. Adhesive-attached labeling materials, including label stocks, laminating adhesives, and inks used by label printers, are not acceptable. PART 2 PRODUCTS 2.1 POWER AND CONTROL CABLE IDENTIFICATION MATERIALS A. All markings to labels, schedules, tags or nameplates shall be machine printed only. BCRUA - Phase 1D WTP Expansion Issued for Bid Identification for Electrical Systems 26 05 53 - 2 B. Circuits shall be tagged at terminations (both ends), in pull boxes, cabinets, and enclosures as follows: 1. Tags relying on adhesives or tape-on markers are not acceptable, unless noted otherwise. 2. Hand written tags are not acceptable. 3. Provide conductor tags for conductors No. 10 AWG and below with legible permanent sleeve of yellow or white PVC with machine printed black marking, Raychem TMS sleeves or approved equal. 4. Provide tags for cables and for conductors No. 8 AWG and larger consisting of permanent nylon marker plates with legible designations hot stamped on the plate. Attach these marker plates to conductors and cables with stainless steel wire wraps. Tags shall be Raychem TMS-CM cable markers or approved equal. 5. Tags shall be imprinted with panelboard and panelboard position number (e.g. LA3-23) for conductors fed from panelboards. Other conductors shall have tags imprinted with the MCC which feeds the conductors (e.g. MCC 1). 6. Switch legs shall have the designation described above on their tags, plus an “S” suffix. Travelers shall have the designation described above on their tags, plus a “T” suffix. 7. Where more than one neutral is present with a group of conductors, a tag shall be applied to each neutral indicating which phase conductors are served by each neutral (e.g. HA-2, 4, 6). 2.2 CONDUCTOR IDENTIFICATION MATERIALS A. Color-Coding Conductor Tape: Colored, self-adhesive vinyl tape not less than 3 mils thick by 1 to 2 inches wide. 2.3 UNDERGROUND-LINE WARNING TAPE A. Tape: 1. Recommended by manufacturer for the method of installation and suitable to identify and locate underground electrical and communications lines. 2. Printing on tape shall be permanent and shall not be damaged by burial operations. 3. Tape material and ink shall be chemically inert, and not subject to degrading when exposed to acids, alkalis, and other destructive substances commonly found in soils. B. Color and Printing: 1. Comply with ANSI Z535.1 through ANSI Z535.5. 2. Inscriptions for Red-Colored Tapes: ELECTRIC LINE 2.4 WARNING LABELS AND SIGNS A. Comply with NFPA 70 and 29 CFR 1910.145. B. Self-Adhesive Warning Labels: Factory-printed, multicolor, pressure-sensitive adhesive labels, configured for display on front cover, door, or other access to equipment unless otherwise indicated. C. Baked-Enamel Warning Signs: 1. Preprinted aluminum signs, punched or drilled for fasteners, with colors, legend, and size required for application. 2. 1/4-inch grommets in corners for mounting. 3. Nominal size, 7 by 10 inches. BCRUA - Phase 1D WTP Expansion Issued for Bid Identification for Electrical Systems 26 05 53 - 3 D. Warning label and sign shall include, but are not limited to, the following legends: 1. Multiple Power Source Warning: "DANGER - ELECTRICAL SHOCK HAZARD - EQUIPMENT HAS MULTIPLE POWER SOURCES." 2. Workspace Clearance Warning: "WARNING - OSHA REGULATION - AREA IN FRONT OF ELECTRICAL EQUIPMENT MUST BE KEPT CLEAR FOR 36 INCHES." 2.5 EQUIPMENT IDENTIFICATION LABELS A. Engraved, Laminated Acrylic or Melamine Label: Punched or drilled for screw mounting. Attach plates to equipment with stainless steel screws. Provide an O-ring for screws on NEMA 4X enclosures, O-rings shall maintain the integrity and NEMA 4X rating for enclosures. B. NAMEPLATES: 1. For indoor applications with Air Conditioning: Plastic, black 1" letters on white background, on the front of each door on the switchgear; identifying the compartment contents for each compartment. 2. All other applications: Plastic, black 1" letters on white background, on the front of each door on the switchgear; identifying the compartment contents for each compartment. 3. Attach nameplates with a stainless steel screw and nut at each end of the nameplate. Adhesive backed nameplates shall not be installed. 4. Label that includes tag designation shown on Drawings for the transformer, switchgear, panelboards or other electrical equipment. 2.6 CONDUIT IDENTIFICATION PLATE A. Marker plates shall be 316 stainless steel, heavy cross section, 3.5”X 0.75” as manufactured by Panduit, MMP350H-C316. B. Marker/Tag shall be embossed with manufacturers embossing tool. C. Marker/Tag shall be affixed to the conduit termination using two 316 stainless steel band, Panduit MLT6S-CP316. PART 3 EXECUTION 3.1 INSTALLATION A. Verify identity of each item before installing identification products. B. Location: Install identification materials and devices at locations for most convenient viewing without interference with operation and maintenance of equipment. C. Apply identification devices to surfaces that require finish after completing finish work. D. Self-Adhesive Identification Products: Clean surfaces before application, using materials and methods recommended by manufacturer of identification device. E. Attach signs and plastic labels that are not self-adhesive type with stainless steel mechanical fasteners appropriate to the location and substrate. BCRUA - Phase 1D WTP Expansion Issued for Bid Identification for Electrical Systems 26 05 53 - 4 F. Underground-Line Warning Tape: During backfilling of trenches install continuous underground-line warning tape directly above line at 6 to 8 inches below finished grade. Use multiple tapes where width of multiple lines installed in a common trench or concrete envelope exceeds 16 inches overall. G. Painted Identification: Comply with requirements in Division 09 painting Sections for surface preparation and paint application. 3.2 IDENTIFICATION SCHEDULE A. Power-Circuit Conductor Identification, 600 V or Less: For conductors in vaults, pull and junction boxes, and handholes, use color-coding conductor tape to identify the phase. 1. Color-Coding for Phase Identification. Use colors listed below for ungrounded service, feeder, and branch-circuit conductors. a. Color shall be field applied for sizes larger than No. 8 AWG b. Colors for 120/240V Circuits: 1) Phase A: Black 2) Phase B: Red 3) Neutral: White 4) Equipment Grounding Conductor: Green c. Colors for 208/120-V or 240V/120V, 3-phase Circuits: 1) Phase A: Black. 2) Phase B: Red. 3) Phase C: Blue. 4) Neutral: White 5) Equipment Grounding Conductor: Green d. Colors for 480/277-V Circuits: 1) Phase A: Brown. 2) Phase B: Orange. 3) Phase C: Yellow. 4) Neutral: Grey/White 5) Equipment Grounding Conductor: Green 2. Field-Applied, Color-Coding Conductor Tape: Apply in half-lapped turns for a minimum distance of 6 inches from terminal points and in boxes where splices or taps are made. Apply last two turns of tape with no tension to prevent possible unwinding. Locate bands to avoid obscuring factory cable markings. B. Locations of Underground Lines: Identify with underground-line warning tape for power, lighting, communication, and control wiring and optical fiber cable. 1. Identifying line shall be continuous along the entire underground route. C. Warning Labels for Indoor Cabinets, Boxes, and Enclosures for Power and Lighting: Self- adhesive warning labels 1. Comply with 29 CFR 1910.145. 2. Identify system voltage with black letters on an orange background. 3. Apply to exterior of door, cover, or other access. 4. For equipment with multiple power or control sources, apply to door or cover of equipment including, but not limited to, the following: a. Power transfer switches. b. Controls with external control power connections. BCRUA - Phase 1D WTP Expansion Issued for Bid Identification for Electrical Systems 26 05 53 - 5 D. Operating Instruction Signs: Install instruction signs to facilitate proper operation and maintenance of electrical systems and items to which they connect. Install instruction signs with approved legend where instructions are needed for system or equipment operation. E. Conduit/Raceway Identification Plates/Tags: 1. A conduit identification tag shall be installed on all power, control, instrumentation and communications conduits at the end of each run and at the conduit ends of intermediate junction and pull boxes, handholes, etc. Tags shall also be applied to exposed conduits 24” above grade before transitioning below grade. Where conduit does not allow for a tag 24” before transitioning to below grade, a tag shall be placed as far from the transition as possible. 2. Conduit tags shall be installed before conductors are pulled into the conduits. 3. The conduit identification tags shall identify the cable numbers as shown on the plans with the “to” and “from” information. 4. Provide an example to Owner/Engineer as a formal submittal for approval prior to the installation. 5. Attach conduit identification plate with stainless steel tie wraps. F. Equipment Identification Labels: On each unit of equipment, install unique designation label that is consistent with wiring diagrams, schedules, and the Operation and Maintenance Manual. Apply labels to disconnect switches and protection equipment, central or master units, control panels, control stations, terminal cabinets, and racks of each system. Systems include power, lighting, control, communication, signal, monitoring, and alarm systems unless equipment is provided with its own identification. 1. Labeling Instructions: a. Indoor Equipment: stainless steel screws and nuts, engraved and laminated nameplates. Unless otherwise indicated, provide a single line of text with 1/2-inch high letters on 1-1/2-inch high label; where two lines of text are required, use labels 2 inches high. b. Outdoor Equipment: Engraved, laminated acrylic or melamine label c. Elevated Components: Increase sizes of labels and letters to those appropriate for viewing from the floor. d. Fasten labels with appropriate mechanical fasteners and gaskets that do not change the NEMA or NRTL rating of the enclosure and void the U.L. listing of the enclosure. 2. Equipment to Be Labeled: a. Panelboards: Typewritten directory of circuits in the location provided by panelboard manufacturer. Panelboard identification shall be laminated acrylic or melamine label and placed in a clear plastic sleeve. Provide an updated typewritten directory for existing panelboards where loads were added or removed under this contract. b. Enclosures and electrical cabinets. c. Starters. d. Transformers: Label that includes tag designation shown on Drawings for the transformer, feeder, and panelboards or equipment supplied by the secondary. e. Motor-control centers. f. Enclosed switches. g. Enclosed circuit breakers. h. Enclosed controllers. i. Push-button stations. j. Contactors. BCRUA - Phase 1D WTP Expansion Issued for Bid Identification for Electrical Systems 26 05 53 - 6 k. Monitoring and control equipment. l. Conduits m. Variable Frequency Drives n. Pull boxes, junction boxes, concrete pull boxes, hand holes. END OF SECTION BCRUA – Phase 1D WTP Expansion Issued for Bid Power System Study 26 05 73 - 1 SECTION 26 05 73 – POWER SYSTEM STUDY PART 1 GENERAL 1.1 DESCRIPTION A. General: This section specifies that the CONTRACTOR prepare a short circuit and protective device coordination study, an arc flash hazard analysis for the BCRUA Phase 1D WTP Expansion. 1. The study shall include electrical gear added as part of this contract (complete one-line indicated on the contract drawings) including information from the utility company down to the 120V panels fed from the electrical buildings. The one-line is shown on the plans. Contractor will be responsible to gather all device settings as they are in the field. 2. The short circuit and protective device coordination study shall provide an evaluation of the electrical power system and the model numbers and settings of the protective devices and metering or motor monitoring devices for setting by the CONTRACTOR. The Study shall include settings for all motor protective relays and electric system monitoring devices. B. Scope: 1. The Contractor is responsible for providing all pertinent information necessary for the successful completion of the Short Circuit and Protective Device Coordination Study, and Arc Flash Analysis. All cable and raceway data, data for new, future and existing motors, data from all new motor control center components, panelboards, and separately mounted fuses, starters or circuit breakers shall be obtained by the Contractor. Obtain all existing or new protective device information to include all present settings. The Contractor shall obtain any needed data or information from Contract Documents, various suppliers, the Electric Utility and from conducting his own field investigations. The data obtained shall be organized and submitted to the Engineer to show that all the necessary data gathering work has been done. 2. Calculations shall utilize actual X/R and three phase short circuit values obtained by the contractor from the Electric Utility. 3. Provide a complete short circuit study. Include three phase and phase-to-ground calculations. Provide an equipment interrupting or withstand evaluation based on the actual equipment and model numbers provided on this project. Generic devices are not acceptable. Normal system operating method, alternate operation, and operations that could result in maximum fault conditions shall be thoroughly addressed in the study. The study shall assume all motors operating at rated voltage with the exception that motors identified as “standby” shall not be included. Electrical equipment bus impedance shall be assumed zero. Short circuit momentary duties and interrupting duties shall be calculated on the basis of maximum available fault current at the electrical equipment busses. The Study shall be performed using actual available short circuit currents available and system impedances as obtained from the Electric Utility. An assumption of infinite bus for the purposes of the Study is not acceptable. Study shall use actual motor X/R and lubtransient reactance data obtained from equipment suppliers. 4. A protective device coordination study shall be performed to determine appropriate protective device settings. The study shall include all electrical equipment provided under this contract and any up-stream equipment that has an impact on the coordination study due to added equipment as part of the expansion. Include all medium and low voltage switchgear, distribution switchboards, motor control center, and panelboards main circuit breakers. Complete the short circuit study down to the main breaker or main lugs on all BCRUA – Phase 1D WTP Expansion Issued for Bid Power System Study 26 05 73 - 2 panelboards. Panelboard branch circuit devices need not be considered. The phase over current and ground-fault protection shall be included as well as settings for all other adjustable protective devices. All motor monitoring protective devices and protective or monitoring devices that are a part of a supplier’s equipment (such as soft starters or variable frequency drives) shall be in included. Provide Time-Current Curves on 11X17 log-log paper. Do not put more than one branch of protective devices on any one coordination curve. Include a one-line diagram and the names of each protective device in the branch. Use the names designated in the Contract Documents. 5. Provide arc flash hazard analysis in accordance with the applicable NFPA, ANSI, and IEEE standards. 6. The studies shall be performed, sealed and signed by a Registered Professional Engineer licensed in the state of Texas. 7. Any problem areas or inadequacies in the equipment shall be promptly brought to the Engineer's attention. 8. Use industry standard short circuit software, SKM CAPTOR and DAPPER or an equal approved by the Engineer. 1.2 REFERENCES A. This Section contains references to the following documents. They are a part of this Section as specified and modified. In case of conflict between the requirements of this Section and those of the listed documents, the requirements of this Section shall prevail. Reference Title IEEE 141 Recommended Practice for Electric Power Distribution for Industrial Plants IEEE 242 Recommended Practice for Protection and Coordination of Industrial and Commercial Power Systems NFPA 70E Handbook for Electrical Safety in the Workplace IEEE 1584 IEEE Guide for Performing Arc-Flash Hazard Calculations NEC National Electrical Code 1.3 SCHEDULE A. The approved reports shall be completed and a copy sent to the electrical distribution equipment manufacturer 45 days before the equipment is shipped to the Work site. The report shall be provided to the Engineer NO LATER THAN 90 days before the equipment is shipped to the Work site. SHIPMENT AND DELIVERY OF EQUIPMENT WILL NOT BE ACCEPTED AT THE JOBSITE UNTIL THE STUDY HAS BEEN COMPLETED, SUBMITTED AND APPROVED BY THE ENGINEER. 1.4 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, Submittal Procedures and shall include: 1. Short Circuit and Protective Device Coordination Study. Provide a color hard copy study report bound in a 3-ring binder. Time current curves shall be on 11x17 log-log type paper. The Contractor can provide time current curves on 8 ½ x 11 log-log type paper as a supplement but not as a replacement. 2. Arc Flash Hazard Analysis a. Provide a copy of project specific Arc Flash labels for each panelboard, switchboard, VFD’s, disconnect, Motor Control Center, etc. BCRUA – Phase 1D WTP Expansion Issued for Bid Power System Study 26 05 73 - 3 b. Provide a 11x17 copy of the one-line diagram color-coded to show the incident ranges & clothing classifications at each bus. Provide a table indicating the color coding used for each incident range & clothing classification. The following is a recommended color coding for the following Hazard/Risk Category numbers: 1) Green to indicate a Category 0 2) Blue to indicate a Category 1 3) Brown to indicate a Category 2 4) Yellow to indicate a Category 3 5) Orange to indicate a Category 4 6) Red to indicate Above a Category 4 B. Two Software copies of actual project data files burned in on a CD. The Contractor shall provide an electronic copy on a CD-ROM of all files used to develop the electrical system model in the power system analysis program and all files for the written study analysis and summary data tables. This shall include any library files used for circuit breakers, fuses, etc. for the power system analysis. PART 2 PRODUCTS 2.1 REPORTS A. The product shall be a certified report summarizing the short circuit and coordination study and conclusions or recommendations that may affect the integrity of the electric power distribution system. As a minimum, the report shall include the following: 1. The equipment manufacturer's information used to prepare the study. 2. Assumptions made during the study. 3. Provide a One-Line diagram showing the short circuit calculations listing short circuit levels at each bus. Provide the same data in tabular from. Use the same names to designate the various pieces of equipment as employed in the Contract Documents. 4. Coordination study time-current curves (11x17 log-log type) including the instrument trans-former ratios, model numbers of the protective devices, and the protective device settings associated with each breaker. Organize the curves as specified here in. Place no more than one branch on a single drawing. Ground fault time current curves shall be on a separate sheet. 5. Comparison of short circuit duties of each bus to the interrupting capacity of the equipment that is protecting that bus. 6. All data that was used as input to the report. This data shall include cable impedance, conduit type, source impedance, equipment ratings, motor X/R and subtransient reactance data, etc. 7. Six (6) bound copies of the completed short circuit and protective device coordination study and the arc flash analysis, shall be submitted to the Engineer for approval. PART 3 - EXECUTION 3.1 GENERAL A. Provide a short-circuit and protective device coordination study and arc flash hazard analysis on the electrical power distribution system, as specified. The studies shall be performed in accordance with IEEE Standards 141 and 242, IEEE 1584, ANSI, and the NEC and shall utilize the ANSI method of short circuit analysis in accordance with ANSI C37.010. The BCRUA – Phase 1D WTP Expansion Issued for Bid Power System Study 26 05 73 - 4 studies shall be performed using actual equipment data for all equipment. The coordination studies shall use the data from the manufacturer of protective devices. 3.2 QUALIFICATIONS A. The studies shall be performed by the by an electrical manufacturer/consultant service/electrical testing agency who is regularly engaged in power system studies. A Licensed Professional Engineer with proficiency in electrical power engineering shall conduct the studies and shall seal and sign the studies. The Professional Engineer shall be licensed to practice engineering in the State of Texas. A study submitted without a Professional Engineer’s seal will not be reviewed and returned Not Approved, Revise & Resubmit. 3.3 SHORT CIRCUIT STUDY A. The CONTRACTOR shall be responsible for obtaining and verifying all data needed to perform the study. B. As a minimum, each short circuit study shall include the following: 1. One-Line Diagram: a. Location and function of each protective device in the system, such as protective devices, direct-acting trips, fuses, etc. b. Type designation, current rating, range or adjustment, manufacturer's style and catalog number for all protective devices. c. Power and voltage ratings, impedance, primary and secondary connections of all transformers. Use the ratings (ie. Impedence, X/R, etc.) of the actual transformers being provided where available. d. Type, manufacturer, and ratio of all instrument transformers energizing each protective device. e. Nameplate ratings of all new and existing motors and generators with their subtransient reactances. Transient reactances of synchronous motors and generators and synchronous reactances of all generators. Obtain data on the actual equipment being provided. Generic or average data numbers are not acceptable. f. Sources of short circuit currents such as utility ties, generators, synchronous motors, and induction motors. Provide short circuit studies using each source of power separately. The study shall determine if there is sufficient short circuit current to adequately cause interruption of a protective device using the weaker power source (typically local generation), and shall determine if the equipment can safely interrupt the fault if the greater power source is connected. Additional short circuit calculations shall include emergency as well as normal switching conditions as well as normal and emergency power sources described here in. g. All significant circuit elements such as transformers, cables, breakers, fuses, reactors, etc shall be included. h. The time-current setting of existing adjustable protective devices and direct-acting trips, if applicable. 2. Impedance Diagram: a. Available MVA or impedance from the utility company. b. Local generated capacity impedance. c. Bus impedance. d. Transformer and/or reactor impedances. e. Cable impedances. f. Equipment impedances. BCRUA – Phase 1D WTP Expansion Issued for Bid Power System Study 26 05 73 - 5 g. System voltages. h. Grounding scheme (resistance grounding, solid grounding, or no grounding). i. Motor contribution assuming the new and future motors as shown on the plans all running at the same time. 3. Calculations: a. Determine the paths and situations where short circuit currents are the greatest. Assume bolted faults and calculate the 3-phase and line-to-ground short circuits of each case. b. Calculate the maximum and minimum fault currents. c. A discussion section evaluating the adequacy or inadequacy of the equipment method of calculation and formulas used such that all calculations can be verified manually by the Engineer, with recommendations as required for improvements to the system. d. Any inadequacies shall be called to the attention of the Engineer and recommendation made for improvements. e. Six (6) bound copies of the completed short circuit study shall be submitted to the Engineer. 3.4 PROTECTIVE DEVICE COORDINATION STUDY A. As a minimum, the coordination study for the power distribution system shall include the following on 5-cycle, log-log graph paper: 1. The time-current coordination analysis shall be performed with aid of a digital computer. a. Time-current curves for each device shall be positioned to provide for maximum selectivity to minimize system disturbances during fault clearing, but still maintain a low incident energy level. Where selectivity cannot be achieved, the Engineer shall be notified as to the cause. 2. Time-current curves for each device shall be positioned to provide for maximum selectivity to minimize system disturbances during fault clearing. Where selectivity cannot be achieved, the Engineer shall be notified as to the cause. 3. Time-current curves and points for cable and equipment damage. 4. Circuit interrupting device operating and interrupting times. 5. Indicate maximum fault values on the graph. 6. Sketch of bus and breaker arrangement. 7. Six (6) bound copies of the completed protective device coordination study shall be submitted to the Engineer. 3.5 ARC FLASH HAZARD ANALYSIS A. The study shall be performed in accordance with the NEC and all applicable OSHA, ANSI, and IEEE standards. B. The contractor shall adjust all adjustable time-current devices such that the trip settings lower the arc flash exposure and minimizing the clearing time. However, the contractor shall adjust the time-current devices to avoid nuisance tripping. C. The contractor shall utilize fault current values from the short circuit analysis to determine the Incident energy, limited approach boundary, restricted approach boundary, prohibited approach boundary and appropriate PPE required. BCRUA – Phase 1D WTP Expansion Issued for Bid Power System Study 26 05 73 - 6 D. The contractor shall provide project specific arc-flash labeling. The arc-flash labeling shall be placed on the outside of the cover of the panelboard, switchboard, distribution panel, VFD, and all electrical panels, etc. such that it can be read without opening the electrical equipment. Mount arc-flash labels a maximum of 6’-6” AFF, include the housekeeping pad in the mounting height. The contractor shall provide arc-flash labeling on all existing panelboards, switchboards, distribution panel, etc. where breakers are added or work is performed in or on the electrical equipment. E. Arc Flash Labels shall be chemical resistant, UV resistant, water resistant, scratch resistant, and made of 3.0 mil vinyl tape as manufactured by DuraLabel, Brady or approved equal. The lettering shall be performed by thermal transfer print. 1. Arc Flash labels and label lettering shall be sized large enough to be legible at a distance outside the hazard area. 2. Arc Flash Labels shall be placed on the door(s) of the room if the hazard area reaches or extends beyond the electrical room door(s). 3. The arc flash label shall include a DANGER header when the incident energy is above 40cal/cm2, and a WARNING header for all other incident energy levels. F. To ensure a safe workplace, and that the labeling meets NEC, OSHA, IEEE, ANSI and NFPA requirements, use specialized arc flash software to calculate protection boundaries. These protection boundaries shall include the Flash Protection Boundary, Limited Approach Boundary, Restricted Approach Boundary and the Prohibited Approach Boundary. G. The arc-flash analysis shall be based on calculated fault from the Short Circuit Study at each respective bus. The arc-flash software program shall be used to calculate the available arcing fault at each bus in the system, the resultant flash protection boundary based on the applicable protective device operating times and the associated incident energy that workers may be exposed to at the specified working distances. H. The report shall include the following information: Arc-flash evaluation table, arc-flash and shock hazard label definitions, arc-flash evaluation information, arc-flash and shock hazard labels and definitions of terms used in the arc-flash hazard analysis. I. Six (6) bound copies of the completed arc-flash hazard analysis shall be submitted to the Engineer’s Representative. J. Arc Flash labels shall be similar to the following example: BCRUA – Phase 1D WTP Expansion Issued for Bid Power System Study 26 05 73 - 7 END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Low Voltage Transformers 26 22 00 - 1 SECTION 26 22 00 LOW VOLTAGE TRANSFORMERS PART 1 GENERAL 1.1 WORK INCLUDED A.Provide transformers as required by the Drawings and Specifications. 1.2 SUBMITTALS A. Product Data: For each type of product indicated. B. Shop Drawings: 1. Project specific transformer and mini power center cutsheets indicating: a. KVA. b. Taps c. Transformer impedance. d. Construction materials. e. Efficiency. f. Panelboard configuration g. Circuit breaker sizes h. Weight C. O&M 1.3 INFORMATIONAL SUBMITTALS A. Field quality-control reports. 1.4 QUALITY ASSURANCE A. Source Limitations: Obtain each transformer type through one source from a single manufacturer. B. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for in-tended use. C. Comply with IEEE C57.12.91, "Test Code for Dry-Type Distribution and Power Transformers." 1.5 DELIVERY, STORAGE AND HANDLING A. Temporary Heating: Apply temporary heat according to manufacturer's written instructions within the enclosure of each ventilated-type unit, throughout periods during which equipment is not energized and when transformer is not in a space that is continuously under normal control of temperature and humidity. B. COORDINATION 1. Coordinate size and location of concrete bases with actual transformer provided. Cast anchor-bolt inserts into bases. Concrete, reinforcement, and formwork requirements are specified in Division 03. BCRUA - Phase 1D WTP Expansion Issued for Bid Low Voltage Transformers 26 22 00 - 2 PART 2 PRODUCTS 2.1 MINI-POWER CENTER A. Enclosure Type: NEMA 250, Type 3R, 304 stainless steel or painted steel. Refer to Section 3.02 Installation Schedule. B. Factory -assembled and -tested for 60 Hz service. C. Cores: Grain-oriented, non-aging silicon steel. D. Coils: Continuous windings without splices except for taps. 1. Internal Coil Connections: Brazed or pressure type. 2. Coil Material: Copper E. Insulation Class: 180 degree C, UL-component-recognized with a maximum of 115 deg C rise above 40 deg C ambient temperature. F. Low-Sound-Level Requirements: Minimum of 3 dBA less than NEMA ST 20 standard sound levels when factory tested according to IEEE c57.12.91. G. Fungus Proofing: Permanent fungicidal treatment for coil and core. H. Configuration: Copper windings with bolt-on loadcenter chassis. I. Include grounding/bonding bar in compliance with NEC 450.10(A). J. Primary Main Circuit Breaker: 42,000 interrupting capacity (Symmetrical Amperes) minimum. Size main circuit breaker according to panel schedules and one-line diagrams. UL 489 listed main circuit breaker. K. Secondary Main Circuit Breaker: 18,000 interrupting capacity (Symmetrical Amperes) minimum. Size main circuit breaker according to panel schedules and one-line diagrams. UL 489 listed main circuit breaker. L. Branch Circuit Breakers: Provide 24 HACR rated bolt-on circuit breakers for all branch circuits according to panel schedules and one-line diagrams. Comply with UL489. M. Busbar: Tin-plated copper. N. Neutral and Equipment Grounding Buses: Provide separate buses for neutral and equipment grounding conductors. O. System Bonding Jumper: Sized according to NEC Table 250.102(C)(1). P. Surge Suppression Device: NEMA 250, Type 4X, 304 stainless steel enclosure, externally mounted, 50kA rating, circuit breaker connected, UL 1449 listed. Q. Acceptable Manufacturers: 1. Eaton 2. Square D; by Schneider Electric. BCRUA - Phase 1D WTP Expansion Issued for Bid Low Voltage Transformers 26 22 00 - 3 2.2 IDENTIFICATION DEVICES A. Nameplates: Engraved, laminated-plastic or metal nameplate for each distribution transformer, mounted with corrosion-resistant screws. Nameplates and label products are specified in Division 26 Section "Identification for Electrical Systems." 2.3 SOURCE QUALITY CONTROL A. Test and inspect transformers according to IEEE C57.12.91. B. Factory Sound-Level Tests: Conduct sound-level tests on equipment for this Project. PART 3 EXECUTION 3.1 EXAMINATION A. Examine conditions for compliance with enclosure- and ambient-temperature requirements for each transformer. B. Verify that field measurements are as needed to maintain working clearances required by NFPA 70 and manufacturer's written instructions. C. Examine walls, floors, roofs, and concrete bases for suitable mounting conditions where transformers will be installed. D. Verify that ground connections are in place and requirements in Division 26 Section "Grounding and Bonding for Electrical Systems" have been met. Maximum ground resistance shall be 5 ohms at location of transformer. E. Proceed with installation only after unsatisfactory conditions have been corrected. 3.2 INSTALLATION SCHEDULE A. RAW WATER HEAD TANKS: NEMA 3R, 304 STAINLESS STEEL B. CONNECTIONS 1. Ground equipment according to Division 26 Section "Grounding and Bonding for Electrical Systems." Connect wiring according to Division 26 Section "Low-Voltage Electrical Power Conductors and Cables." 3.3 FIELD QUALITY CONTROL A. Testing Agency: Engage a qualified testing agency to perform tests and inspections. 1. After installing transformers, conductors and cables and before electrical circuitry has been energized, test transformers provided for compliance with requirements. 2. Perform each of the following visual and electrical tests: a. Test connections at transformer. b. Inspect physical and mechanical condition. c. Inspect anchorage, alignment, grounding, and clearances. d. Verify that the unit is clean. BCRUA - Phase 1D WTP Expansion Issued for Bid Low Voltage Transformers 26 22 00 - 4 e. Inspect bolted electrical connections for high resistance using one of the two following methods: 1) Use a low-resistance ohmmeter. Compare bolted connection resistance values to values of similar connections. Investigate values that deviate from those of similar bolted connections by more than 50 percent of the lowest value. 2) Verify tightness of accessible bolted electrical connections by calibrated torque- wrench method in accordance with manufacturer's published data or NETA ATS Table 100.12. Bolt-torque levels shall be in accordance with manufacturer's published data. In the absence of manufacturer's published data, use NETA ATS Table 100.12. f. Verify that operation and sequencing of interlocking systems is as described in the Specifications and shown on the Drawings. 3. Infrared Scanning: Two months after Substantial Completion, perform an infrared scan of transformer connections. a. Use an infrared-scanning device designed to measure temperature or detect significant deviations from normal values. Provide documentation of device calibration. b. Prepare a certified report identifying transformer checked and describing results of scanning. Include notation of deficiencies detected, remedial action taken, and scanning observations after remedial action. B. CLEANING 1. Vacuum dirt and debris; do not use compressed air to assist in cleaning. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Low Voltage Motor Control Centers 26 24 19-1 SECTION 26 24 19 - LOW VOLTAGE MOTOR CONTROL CENTERS PART 1 GENERAL 1.1 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to modify an existing 480-volt Cutler-Hammer (EATON) Motor Control Center (MCC). The motor control center will have a new section bus spliced to the existing MCC section on the right side of the lineup. B. C. Existing MCC is a Cutler-Hammer Freedom Series 2100 MCC, Order Number: MUX0004070 IT.07-HUC, P.O. Number 4200062102. D. E. Electrical work shall be in accordance with Section 26 05 00, “Common Work Results for Electrical.” F. Unless indicated in this Section, see design drawings for horizontal bus ratings, interpreting rating, enclosure NEMA rating, feeder and branch circuit connections, elevation and footprint. 1.2 QUALITY ASSURANCE – ACCEPTABLE MANUFACTURERS A. Products shall comply with the specifications and shall be by the following Cutler-Hammer (EATON). No others approved. 1. The manufacturer shall provide the services of factory field engineers for start-up, field tests, and troubleshooting. The manufacturer field services shall include a minimum of the following: Supervision of storage and installation 1 day Start up 1 day Field Tests/start-up 1 day Troubleshooting/start-up 1 day Owner Training 1 day 1.3 1. These times do not include travel time and include a minimum of 8 working hours per day. 1.4 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include shop drawings with the following minimum information: 1. Complete rating 2. Short circuit withstand rating of lowest rated device 3. Overall outline dimensions including the space available for conduit 4. Conduit entry and exit points clearly showing dimensions of entry and exit points. Provide a detailed bottom view showing how conduits penetrate the bottom of the MCC. Coordinate with the Electrical Contractor on this prior to submitting information to the Engineer. 5. Circuit schedule indicating the circuit number BCRUA - Phase 1D WTP Expansion Issued for Bid Low Voltage Motor Control Centers 26 24 19-2 6. Equipment assembly. Indicate dimensions, shipping section dimensions weights, foundation requirements, require clearances, location and size of each field connection, and mounting and installation instructions. 7. Device description 8. One-line diagram 9. Product Data Sheets for Circuit Breakers 10. Shop Drawings 11. Wiring Diagram: Detail wiring for transfer controls and differentiate between manufacturer-installed and field-installed customer wiring. Show both power and control wiring. Show terminal strip information identifying all customer field terminations. 12. Bill of Material 13. Nameplate Schedule 14. Provide a drawing of the front view elevation with designation of equipment and devices on doors, and clearly indicating the maximum mount heights of devices on doors. 15. Include descriptive documentation of optional barriers specified for electrical insulation and isolation. 16. Include time-current coordination curves for each type and rating of overcurrent protective device included in MCC; include selectable ranges for each type of overcurrent protective device. B. OPERATION AND MAINTENANCE DATA: 1. Project consists of modifying existing MCC. Information in O&M shall be tailored for supplemental information. 2. Operation and maintenance manuals shall contain the shop drawings, submittals, spare parts lists, schematics, and maintenance procedures. 3. Include all features and operating sequences, both automatic and manual. List all factory setting relay and provide relay-setting and calibration instructions, including software, where applicable. 4. Manuals shall be prepared by the Equipment Manufacturer and shall also incorporate appropriate final certified shop drawings. Manuals may be manufacturer's standard instructions but shall be supplemented as necessary to cover any special feature not included in standard material. 5. Equipment Installation Report 6. NETA Acceptance Testing Specification (ATS) field tests and inspections tests report. 1.5 STANDARDS A. The applicable provisions of the following standard shall apply as if written here in its entirety: 1. NEMA Std. PB-2 Deadfront Distribution MCCs 2. NEMA Std. AB-1 Molded Case Circuit Breakers and Molded Case Switches 3. NEMA Std. KS-1 Enclosed Switches 4. U.L. 489 Molded Circuit Breakers 5. U.L. 891 Switchboards 6. NFPA 70 National Electrical Code 1.6 DELIVERY AND STORAGE A. Store components indoors in a dry space with uniform temperature to prevent condensation. Protect from exposure to dirt, fumes, water, corrosive substances and physical damage. B. Deliver in sections or lengths that can be moved past obstructions in delivery path. BCRUA - Phase 1D WTP Expansion Issued for Bid Low Voltage Motor Control Centers 26 24 19-3 1.7 COORDINATION A. Coordinate layout and installation of components with existing construction, keeping the manufacturer’s recommendation in mind at all times. Maintain required workspace clearances and required clearances for equipment access doors and panels. B. Coordinate sizes and locations of concrete bases with actual equipment provided. Cast anchor- bolt inserts into bases. PART 2 PRODUCTS 2.1 Characteristics and Ratings A. Short-Circuit Current Rating for Each Unit: Fully rated; 65 kA. B. Control and Load Wiring: Factory installed, with bundling, lacing, and protection included. Provide flexible conductors for No. 8 AWG and smaller, for conductors across hinges, and for conductors for interconnections between shipping units. C. Short-Circuit Current Rating of MCC: Fully rated; 65 kA. D. Environmental Ratings: 1. Ambient Temperature Rating: Not less than 0 deg F (minus 18 deg C) and not exceeding 104 deg F (40 deg C), with an average value not exceeding 95 deg F (35 deg C) over a 24-hour period. 2. Ambient Storage Temperature Rating: Not less than minus 4 deg F (minus 20 deg C) and not exceeding 140 deg F (60 deg C) 3. Humidity Rating: Less than 95 percent (noncondensing). 4. Altitude Rating: Not exceeding 6600 feet (2000 m), or 3300 feet (1000 m) if MCC includes solid-state devices. E. Future Devices: Equip compartments with mounting brackets, supports, bus connections, and appurtenances at full rating of unit. F. Bus-Bar Insulation: Factory-applied, flame-retardant, tape wrapping of individual bus bars or flame-retardant, spray-applied insulation. Minimum insulation temperature rating of 105 deg C. G. The maximum dimensions for the provided motor control center sections shall be coordinated with the conduit stub-up locations in the electrical room. 2.2 Manufacturers: Obtain all motor control center components through a single source from Cutler- Hammer (EATON). Devices shall be compatible with existing MCC. 2.3 Products A. Starters: FVNR B. Control Power Transformer: 1. Control Circuits: 120-V AC; obtained from integral CPT, with primary and secondary fuses, with CPT of sufficient capacity to operate all integral devices and remotely located pilot, indicating, and control devices. a. CPT Spare Capacity: *VA C. Phase-Failure Relays: Solid-state sensing circuit with isolated output contacts for hard-wired connections. Provide adjustable undervoltage, overvoltage, and time-delay settings in order to prevent against overloads and phase unbalance. BCRUA - Phase 1D WTP Expansion Issued for Bid Low Voltage Motor Control Centers 26 24 19-4 D. INDICATING LIGHTS, SWITCHES, PUSHBUTTONS: Heavy duty and oil tight (30 mm); Square D Class 9001 or approved equal. Pilot lights shall be push to test (Cluster LED type) and shall be Square D SK or approved equal. E. Nameplates and Labels 1. Equipment nameplates and designations shall be 2 in. by 5 in. minimum, not less than 1/16 in. thick, engraved laminated plastic fastened with stainless steel screws. Nameplates shall be 1 in. white lettering on black background and shall indicate equipment designations as shown on the drawings. 2. Provide legend plates or 1 in. by 3 in. engraved nameplates with ¼ in. lettering for identification of all pilot devices and meters. Legend nameplates shall be secured with stainless steel screws. 3. Provide permanent warning signs similar to the following: a. “DANGER – HIGH VOLTAGE – KEEP OUT” on all enclosure doors. b. “WARNING – HAZARD OF ELECTRIC SHOCK – DISCONNECT POWER BEFORE OPENING OR WORKING ON THIS UNIT” 4. Provide arc flash labeling in accordance with the National Electrical Code Article 110.16 and per the Arc Flash Hazard Analysis (performed by others). See Specification 16055 for more information. 2.4 Functional Features A. Description: Modular arrangement of main units, controller units, control devices, feeder-tap units, instruments, metering, auxiliary devices, and other items mounted in vertical sections of MCC. B. Feeder-Tap Units: Through 225-A rating shall have drawout mountings with connectors that automatically line up and connect with vertical-section buses while being racked into their normal, energized positions. C. Future Units: Compartments fully bused and equipped with guide rails or equivalent, ready for insertion of drawout units. D. Spare Units: Installed in compartments indicated "spare." 2.5 Motor Control Center Construction A. Structures 1. Structures shall be NEMA Type 1. 2. Structures shall be totally enclosed, dead-front, freestanding assemblies. Structures shall be capable of being bolted together to form a single assembly. 3. The overall height and depth of the new MCC sections shall match the existing MCC structure. 4. All unused spaces shall be covered by either hinged or hanged blank doors and a blank label shall be provided. 5. Section Alignment a. Main sections shall be completely front and rear aligned. Staggered arrangements are not acceptable. b. Feeder and branch circuit sections shall be completely front and rear aligned. Staggered arrangements are not acceptable. 6. The MCC shall be deadfront construction and require front access only. 7. Each MCC enclosure shall have an open bottom and individually removable top plate for installation and termination of conduit. BCRUA - Phase 1D WTP Expansion Issued for Bid Low Voltage Motor Control Centers 26 24 19-5 8. The MCC enclosure shall be painted on all exterior surfaces. The paint finish shall be ANSI 61 light gray, applied by electro-deposition process over an iron phosephate pre- treatment. B. Wireways 1. Structures shall contain a minimum 9 inches high horizontal wireway at the top of each section and a minimum 6 inches in high horizontal wireway at the bottom of each section. These wireways shall run the full length of MCC to allow room for power and control cable to connect between units in different sections. 2. A full-depth vertical wireway shall be provided in each MCC section that accepts modular drawout units. The vertical wireway shall connect with both the top and bottom horizontal wireway 3. Access to the wireways shall not require opening control unit doors. 4. A steel barrier for communication cabling and I/O wiring shall be provided in each vertical wireway to provide separation from motor cables. C. Bussing 1. All bussing and connectors shall be tin-plate copper and the main horizontal bus shall be of the amperage schedule on the plans and shall extend the full length of the MCC. Provision shall be provided for splicing additional sections onto either end of the MCC. 2. Bus bars shall be mounted on supports of high impact, non-tracking, insulation material which is braced to withstand mechanical forces exerted during 65,000 amp RMS symmetrical short circuit conditions. 3. Secure a tin-plated ground bus to each vertical section of the structure and extend it the entire length of the MCC. 4. Bus arrangement shall be A-B-C type, left-to-right, top-to-bottom and front-to-rear. The MCC, cables and bus connections shall be entirely accessible from the front, unless specifically indicated otherwise. 5. Furnish group-mounted, quick-make, quick-break, protective devices with bar connection straps, with a device line and load connections accessible from the front. Where “spaces” are scheduled, furnish an entire bus, excluding device connecting straps. Provide full height wiring gutter covers. 2.6 Feeder-Taps Units A. MCCB: Comply with UL 489, with interrupting capacity to meet available fault currents. 1. Thermal-Magnetic Circuit Breakers: Inverse time-current element for low-level overloads, and instantaneous magnetic trip element for short circuits. Adjustable magnetic trip setting for circuit-breaker frame sizes 250 A and larger. 2. Adjustable Instantaneous-Trip Circuit Breakers: Magnetic trip element with front- mounted, field-adjustable trip setting. 3. Electronic trip circuit breakers with rms sensing; field-replaceable rating plug or field- replicable electronic trip; and the following field-adjustable settings: a. Instantaneous trip b. Long- and short-time pickup levels c. Long- and short-time time adjustments d. Ground-fault pickup level, time delay, and I2t response 4. MCCB Features and Accessories: a. Standard frame sizes, trip ratings, and number of poles. b. Lugs: Mechanical style, suitable for number, size, trip ratings, and conductor material. BCRUA - Phase 1D WTP Expansion Issued for Bid Low Voltage Motor Control Centers 26 24 19-6 c. Undervoltage Trip: Set to operate at 35 to 75 percent of rated voltage without intentional time delay. 2.7 MCC Control Power A. Control Circuits: 120-V ac, supplied through secondary disconnecting devices from CPT. B. Control Power Fuses: Primary and secondary fuses for current-limiting and overload protection of transformer and fuses for protection of control circuits. C. Control Wiring: Factory installed, with bundling, lacing, and protection included. Provide flexible conductors for No. 8 AWG and smaller, for conductors across hinges, and for conductors for interconnections between shipping units. 2.8 Auxiliary Devices A. Accessory Set: Include tools and miscellaneous items required for overcurrent protective device test, inspection, maintenance, and operation. B. Indicating Lights, Switches, Pushbuttons: 1. Heavy duty and oil tight (30 mm); Square D Class 9001 or approved equal. Pilot lights shall be push to test (Cluster LED type) and shall be Square D SK or approved equal. C. Terminal Blocks: 1. When Type B wiring is specified, starter units shall be provided with unit control terminal blocks. 2. Terminal blocks shall be the pull-apart type with a minimum rating of 250 volts and 10 A. All current carrying parts shall be tin-plated. Terminals shall be accessible from inside the unit when the unit door is opened. Terminal blocks shall be DIN rail-mounted with the stationary portion of the block secured to the unit bottom plate. The stationary portion shall be used for factory connections and shall remain attached to the unit when removed. The terminals used for field connections shall face forward so they can be wired without removing the unit or any of its components 2.9 Motor Shock Protection Relay A. Current Transformers: Capable of carrying continuously its rated primary amperes under conditions of accidental open secondary circuit without damage to the primary insulation. Burden capacity shall be adequate to supply the connect relays, meters, and accessories. B. Motor Shock Protection Relay: The purpose of the motor shock protection relay is to prevent locked rotor current. Provide equal or approved to HMA Flow & Industrial TSBSS shock relay. Coordinate with the conveyor manufacturer on the current setting range and specific motor shock protection relay. The relay must meet the requirements below: a. UL listed product with AC100 to 340V, 60hz control power supply voltage. b. Start time of 0.2-10s. c. Shock time of 0.2-5s. d. Two-phase CT system or three-phase CT system. 2.10 Power Distribution and Power Devices A. Three Phase Monitor (Phase Failure) Relays: tube style base with pin style terminals, silver nickel contacts, 10A/B300 contact rating, SPDT Form C contact, LED indicators for relay energized (normal state) and relay de-energized (fault state), fixed or adjustable power up BCRUA - Phase 1D WTP Expansion Issued for Bid Low Voltage Motor Control Centers 26 24 19-7 delay, and automatic reset with adjustable restart time delay. The following conditions shall be monitored, with adjustable ranges as indicated: 1. Phase Loss & Reversal, Fixed at 1 second 2. Undervoltage/Overvoltage (Drop-out @+/- 10%, Pick-up @+/- 7%), 1-25 seconds 3. Voltage Unbalance (Drop-out @ 2%-8%), 1-25 seconds 4. All 120V control panels serving three phase motors shall be supplied with a three-phase monitor relay. All MCC buckets with three-phase relay shall monitor the incoming three phase power supply serving motor(s) fed from control panel and shall open the motor(s) control circuit(s) when a monitored condition is measured out of adjustable relay setpoints. 5. Manufactured by Diversified Electronics SLU-0200, Littlefuse 201A-AU Series, or Macromatic PMP575. PART 3 EXECUTION 3.1 Protection A. Provide temporary heating to maintain temperature according to manufacturer’s written instructions. 3.2 INSTALLATION A. Terminate feeder conduits only in the MCC section containing the lugs or device to which they are to be connected. 3.3 Field Quality Control A. Prepare for acceptance test as follows: 1. Test insulation resistance, using a Megger, for each component, connecting supply, feeder and control circuit for one minute each, at minimum test voltage of 1000VDC; minimum acceptance value of insulation resistance is one mega-ohm. 2. Test continuity of each circuit. B. Engage a qualified testing and inspection agency to perform the following field tests and inspections and prepare tests report: 1. Perform each electrical test and visual and mechanical inspection in NETA Acceptance Testing Specification (ATS). Certify compliance with test parameters. 2. Correct malfunctioning units on-site, where possible, and retest to demonstrate compliance; otherwise, replace with new units and retest. 3. Perform infrared scan tests and inspections and prepare report. C. Inspect completed installation for physical damage, proper alignment, anchorage, and grounding. D. Check tightness of accessible bolted bus joints using calibrated torque wrench per manufacturer's recommended torque values. E. Test ground fault systems on service entrance main breakers per the National Electrical Code. Document all test and furnish to Engineer as formal submittal. F. There is no training desired for this equipment. BCRUA - Phase 1D WTP Expansion Issued for Bid Low Voltage Motor Control Centers 26 24 19-8 3.4 Cleaning A. On completion of installation, inspect interior and exterior of MCCs. Remove paint splatters and any other debris. Vacuum dirt and debris; do not use compressed air to assist in cleaning. Repair exposed surfaces to match original finish. B. Touch up scratched or marred surfaces to match original finish. 3.5 SPARE PARTS A. The following spare parts of the type and size furnished shall be provided: 1. One of each type of power and control fuse rated 600V or less. 2. One spare relay and timer of each type. 3.6 WARRANTY A. Manufacturer shall warrant equipment to be free of defects in materials and workmanship for two (2) years from date of final completion. 3.7 ADJUSTING A. Adjust moving parts and operable components to function smoothly and lubricate as recommended by manufacturer. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Wiring Devices 26 27 26- 1 SECTION 26 27 26 - WIRING DEVICES PART 1 GENERAL 1.1 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install wiring devices. Electrical work shall be in accordance with Section 26 05 00, “Common Work Results for Electrical”. 1.2 QUALITY ASSURANCE - ACCEPTABLE MANUFACTURERS A. Source Limitations: Obtain each type of wiring device and associated wall plate through one source from a single manufacturer. Insofar as they are available, obtain all wiring devices and associated wall plates from a single manufacturer and one source. B. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use. C. Comply with NFPA 70. 1.3 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures” and shall include: 1. Shop Drawings for Wiring Devices: Cut sheets of all devices indicating model being provided, NEMA configuration, rating, color, etc. 2. Operation and Maintenance Manuals 1.4 STANDARDS A. The applicable provisions of the following standard shall apply as if written here in its entirety: 1. NEMA WD-1 General Color Requirements for Wiring Devices 2. NEMA WD-6 Wiring Devices – Dimensional Requirements 3. UL 943 Ground-Fault Circuit-Interrupters 4. NFPA 70 National Electrical Code PART 2 PRODUCTS 2.1 MANUFACTURED PRODUCTS A. Products shall comply with the specifications and shall be by the following Manufacturers: 1. Hubell 2. Leviton 3. Pass & Seymour B. WALL SWITCHES: 1. For general use BCRUA - Phase 1D WTP Expansion Issued for Bid Wiring Devices 26 27 26- 2 2. Totally enclosed industrial grade type. 3. Duty: Heavy-Duty specification grade, 4. Rated for 120/277 VAC and 20 amps. 5. Side and external screw-pressure-plate back wire with #14-#10 AWG copper or Copper- clad wiring. 6. Grounding terminal shall be screw-pressure plate back wire. C. MOTOR RATED SWITCHES: HP rated switches approved for motor control or disconnect service when controlling or disconnecting motor loads in excess of 1/4 HP; 20 amp switches for loads exceeding 10 amps. D. WEATHERPROOF SWITCHES: Fitted with a single switch as specified, and weatherproof cover with spring door cover; gray in color for all areas. E. RECEPTACLES: For general use shall be U.L. approved, specification grade heavy duty duplex grounding type 20 ampere 125 volt heavy duty phosphor bronze contacts. Terminal screws shall be large head, deep slotted #8-32 brass, backed out, color coded for polarity identification, and shall accept up to 10 AWG wire. Side wiring shall not be allowed. 1. GROUND FAULT CIRCUIT INTERRUPTING, INDOOR: GFCI receptacle shall include visible indication of ground fault condition. Feed-through feature shall not be used. Install GFCI device at each location indicated. GFCI circuit breaker shall not be permitted. 2. WEATHER RESISTANT RECEPTACLES: Weather resistant receptacles shall be listed as weather resistant type in accordance with the National Electrical Code. 3. WEATHERPROOF RECEPTACLES: a. Weatherproof receptacles shall be specification grade, 20 ampere, 125 volt and shall be listed as weather resistant type in accordance with the National Electrical Code and shall include a weatherproof device cover. 1) Weatherproof Duplex Receptacle: Provide GFCI duplex receptacle with weatherproof cover. 2) Weatherproof Single Receptacle: Provide a cast box fitted with a single receptacle and threaded cap with a weatherproof cover. b. Weatherproof device covers shall have a NEMA 3R rating while receptacle is in use Heavy Duty rating with die cast metal construction as manufactured by Taymac Corporation, Tempe, Arizona or Thomas & Betts F. SWITCH AND RECEPTACLE COVER PLATES: The cover plate shall be type 302 high nickel stainless steel (18/8) for all areas except in administration or office environments. Screws for device cover plate shall be stainless steel. Provide telephone cover plates which are the same as above, except with a single bushed pole for the telephone cable. PART 3 EXECUTION 3.1 INSTALLATION A. Disconnect power to 120V power supplied instrumentation: 1. Each 120V instrument shall include a weather proof light switch to disconnect power to that device without interrupting power to other equipment. The drawings do not indicated locations of these switches. Contractor is required to provide. 2. Each instrument with cord and plug shall not require a light switch. BCRUA - Phase 1D WTP Expansion Issued for Bid Wiring Devices 26 27 26- 3 B. GFCI circuit receptacles are required at each GFCI receptacle location identified on the drawings. One GFCI circuit shall not protect down stream receptacles. Provide deep outlet boxes at each GFCI receptacle. C. Comply with NECA 1, including the mounting heights listed in that standard, unless otherwise noted. D. Coordination with Other Trades: 1. Take steps to ensure that devices and their boxes are protected. Do not place wall finish materials over device boxes and do not cut holes for boxes with routers that are guided by riding against outside of the boxes. 2. Keep outlet boxes free of plaster, drywall joint compound, mortar, cement, concrete, dust, paint, and other material that may contaminate the raceway system, conductors, and cables. 3. Install device boxes in brick or block walls so that the cover plate does not cross a joint unless the joint is troweled flush with the face of the wall. 4. Install wiring devices after all wall preparation, including painting, is complete. E. Conductors: 1. Do not strip insulation from conductors until just before they are spliced or terminated on devices. 2. Strip insulation evenly around the conductor using tools designed for the purpose. Avoid scoring or nicking of solid wire or cutting strands from stranded wire. 3. The length of free conductors at outlets for devices shall meet provisions of NFPA 70, Article 300, without pigtails. F. Existing Conductors: 1. Cut back and pigtail, or replace all damaged conductors. 2. Straighten conductors that remain and remove corrosion and foreign matter. G. Pigtailing conductors is required. Outlet boxes shall be oversized to allow pigtailing. All wiring devices shall be wired using pigtails. H. Terminate stranded wire with crimp on connectors. I. Install receptacles and switches only in electrical boxes which are clean, free from excess building materials, dirt and debris. J. Switches installed at one (1) location shall be ganged together under one (1) cover plate. K. Sharing of neutrals is not allowed. L. Through on wiring at receptacles is not allowed. 3.2 FIELD QUALITY CONTROL A. Test wiring devices to ensure electrical continuity of grounding. Energize the circuit to demonstrate compliance with the requirements. B. Tests for Convenience Receptacles: 1. Line Voltage: Acceptable range is 108 to 132 V. BCRUA - Phase 1D WTP Expansion Issued for Bid Wiring Devices 26 27 26- 4 2. Percent Voltage Drop under 15-A Load: A value of 6 percent or higher is not acceptable. 3. Ground Impedance: Values of up to 2 ohms are acceptable. 4. GFCI Trip: Test for tripping values specified in UL 1436 and UL 943. 5. Using the test plug, verify that the device and its outlet box are securely mounted. 6. The tests shall be diagnostic, indicating damaged conductors, high resistance at the circuit breaker, poor connections, inadequate fault current path, defective devices, or similar problems. Correct circuit conditions, remove malfunctioning units and replace with new ones, and retest as specified above. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Enclosed Switches and Circuit Breakers 26 28 16 - 1 SECTION 26 28 16 - ENCLOSED SWITCHES AND CIRCUIT BREAKERS PART 1 GENERAL 1.1 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install disconnects. Electrical work shall be in accordance with Div. 26 specifications. B. Drawings and general provisions of the Contract, including General and Supplementary Conditions and other Division 01 Specification Sections, apply to this Section. 1.2 SUMMARY A. Section Includes: 1. Fusible switches. 2. Nonfusible switches. 3. Enclosures. 1.3 DEFINITIONS A. NC: Normally closed. B. NO: Normally open. C. SPST: Single pole, single throw. D. SPDT: Single pole, double throw. 1.4 SUBMITTALS A. Product Data: For each type of enclosed switch, accessory, and component indicated. Include nameplate ratings, dimensioned elevations, sections, weights, and manufacturers' technical data on features, performance, electrical characteristics, ratings, accessories, and finishes. 1. Enclosure types and details for types other than NEMA 250, Type 1. 2. Current and voltage ratings. 3. Short-circuit current ratings. 4. Detail features, characteristics, ratings, and factory settings of individual overcurrent protective devices, accessories, and auxiliary components. 5. Include time-current coordination curves (average melt) for each type and rating of overcurrent protective device; include selectable ranges for each type of overcurrent protective device. Provide in PDF and SKM PTW32 or ETAP electronic format. B. Field quality-control reports. C. Operation and Maintenance Data: For enclosed switches to include in emergency, operation, and maintenance manuals. 1. In addition to items specified in Section 017823 "Operation and Maintenance Data," include the following: a. Manufacturer's written instructions for testing and adjusting enclosed switches. BCRUA - Phase 1D WTP Expansion Issued for Bid Enclosed Switches and Circuit Breakers 26 28 16 - 2 b. Time-current coordination curves (average melt) for each type and rating of overcurrent protective device; include selectable ranges for each type of overcurrent protective device. Provide in PDF and SKM PTW32 or ETAP electronic format. D. Spares: Furnish extra materials that match products installed and that are packaged with protective covering for storage and identified with labels describing contents. 1. Fuses: Equal to 10 percent of quantity installed for each size and type, but no fewer than three of each size and type. 2. Fuse Pullers: Two for each size and type. 1.5 FIELD CONDITIONS A. Environmental Limitations: Rate equipment for continuous operation under the following conditions unless otherwise indicated: 1. Ambient Temperature: Not less than minus 22 deg F and not exceeding 140 deg F. 2. Altitude: Not exceeding 6600 feet. 1.6 WARRANTY A. Manufacturer's Warranty: Manufacturer and Installer agree to repair or replace components that fail in materials or workmanship within specified warranty period. 1. Warranty Period: The Contractor warrants and guarantees for two (2) years from Final Completion, or for a longer period if expressly stated in the Contract Documents, the Work. PART 2 PRODUCTS 2.1 GENERAL REQUIREMENTS A. Source Limitations: Obtain enclosed switches, overcurrent protective devices, components, and accessories, within same product category, from single manufacturer. B. Product Selection for Restricted Space: Drawings indicate maximum dimensions for enclosed switches, including clearances between enclosures, and adjacent surfaces and other items. Comply with indicated maximum dimensions. C. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, by an NRTL, and marked for intended location and application. D. Comply with NFPA 70. 2.2 FUSIBLE SWITCHES A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. ABB Inc. 2. Eaton. 3. General Electric Company. 4. Square D; by Schneider Electric. BCRUA - Phase 1D WTP Expansion Issued for Bid Enclosed Switches and Circuit Breakers 26 28 16 - 3 B. Type HD, Heavy Duty: 1. Single throw. 2. Three pole. 3. 600-V ac. 4. 200 A and smaller. 5. UL 98 and NEMA KS 1, horsepower rated, with clips or bolt pads to accommodate indicated fuses. 6. Lockable handle with capability to accept three padlocks and interlocked with cover in closed position. C. Accessories: 1. Equipment Ground Kit: Internally mounted and labeled for copper and aluminum ground conductors. 2. Neutral Kit: Internally mounted; insulated, capable of being grounded and bonded; labeled for copper and aluminum neutral conductors. 3. Class R Fuse Kit: Provides rejection of other fuse types when Class R fuses are specified. 4. Auxiliary Contact Kit: Two NO/NC (Form "C") auxiliary contact(s), arranged to activate before switch blades open. Contact rating - 120-V ac. See drawings for where required. 5. Hookstick Handle: Allows use of a hookstick to operate the handle. 6. Lugs: Mechanical type, suitable for number, size, and conductor material. 7. Service-Rated Switches: Labeled for use as service equipment. 2.3 NONFUSIBLE SWITCHES A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. Eaton. 2. General Electric Company. 3. SIEMENS Industry, Inc.; Energy Management Division. 4. Square D; by Schneider Electric. B. Type HD, Heavy Duty, Three Pole, Single Throw, 600-V ac, 1200 A and Smaller: UL 98 and NEMA KS 1, horsepower rated, lockable handle with capability to accept three padlocks, and interlocked with cover in closed position. C. Accessories: 1. Equipment Ground Kit: Internally mounted and labeled for copper and aluminum ground conductors. 2. Neutral Kit: Internally mounted; insulated, capable of being grounded and bonded; labeled for copper and aluminum neutral conductors. 3. Class R Fuse Kit: Provides rejection of other fuse types when Class R fuses are specified. 4. Auxiliary Contact Kit: Two NO/NC (Form "C") auxiliary contact(s), arranged to activate before switch blades open. Contact rating - 120-V ac. See drawings for where required. 5. Hookstick Handle: Allows use of a hookstick to operate the handle. 6. Lugs: Mechanical type, suitable for number, size, and conductor material. 7. Service-Rated Switches: Labeled for use as service equipment. 2.4 ENCLOSURES A. Enclosed Switches: NEMA KS 1, NEMA 250, and UL 50, to comply with environmental conditions at installed location BCRUA - Phase 1D WTP Expansion Issued for Bid Enclosed Switches and Circuit Breakers 26 28 16 - 4 B. Enclosure Finish: The enclosure shall be a brush finish on Type 304 stainless steel (NEMA 250 Type 4-4X stainless steel). C. Conduit Entry: NEMA 250 Types 4, 4X, and 12 enclosures shall contain no knockouts. D. Enclosures designated as NEMA 250 Type 4, 4X stainless steel, 12, or 12K shall have a dual cover interlock mechanism to prevent unintentional opening of the enclosure cover when the disconnect switch is ON and to prevent turning the disconnect switch ON when the enclosure cover is open. PART 3 EXECUTION 3.1 EXAMINATION A. Examine elements and surfaces to receive enclosed switches for compliance with installation tolerances and other conditions affecting performance of the Work. B. Proceed with installation only after unsatisfactory conditions have been corrected. 1. Commencement of work shall indicate Installer's acceptance of the areas and conditions as satisfactory. 3.2 PREPARATION A. Interruption of Existing Electric Service: Do not interrupt electric service to facilities occupied by Owner or others unless permitted under the following conditions and then only after arranging to provide temporary electric service according to requirements indicated: 1. Notify Construction Manager and Owner no fewer than seven days in advance of proposed interruption of electric service. 2. Indicate method of providing temporary electric service. 3. Do not proceed with interruption of electric service without Owner's written permission. 4. Comply with NFPA 70E. 3.3 ENCLOSURE ENVIRONMENTAL RATING APPLICATIONS A. Enclosed Switches: Provide enclosures at installed locations with the following environmental ratings. 1. Indoor, Dry and Clean Locations: NEMA 250, Type 4X, 304 stainless steel or NEMA 250, Type 4X, 316 stainless steel. 2. Outdoor Locations: NEMA 250, Type 4X, 304 stainless steel or NEMA 250, Type 4X, 316 stainless steel. 3.4 INSTALLATION A. Coordinate layout and installation of switches and components with equipment served and adjacent surfaces. Maintain required workspace clearances and required clearances for equipment access doors and panels. B. Install individual wall-mounted switches with tops at uniform height unless otherwise indicated. BCRUA - Phase 1D WTP Expansion Issued for Bid Enclosed Switches and Circuit Breakers 26 28 16 - 5 C. Temporary Lifting Provisions: Remove temporary lifting of eyes, channels, and brackets and temporary blocking of moving parts from enclosures and components. D. Install fuses in fusible devices. E. Comply with NFPA 70 and NECA 1. 3.5 IDENTIFICATION A. Comply with requirements in Section 26 05 53 "Identification for Electrical Systems." 1. Identify field-installed conductors, interconnecting wiring, and components; provide warning signs. 2. Label each enclosure with engraved metal or laminated-plastic nameplate. 3.6 FIELD QUALITY CONTROL A. Perform tests and inspections. B. Tests and Inspections for Switches: 1. Visual and Mechanical Inspection: a. Inspect physical and mechanical condition. b. Inspect anchorage, alignment, grounding, and clearances. c. Verify that the unit is clean. d. Verify blade alignment, blade penetration, travel stops, and mechanical operation. e. Verify that fuse sizes and types match the Specifications and Drawings. f. Verify that each fuse has adequate mechanical support and contact integrity. g. Verify that operation and sequencing of interlocking systems is as described in the Specifications and shown on the Drawings. h. Verify correct phase barrier installation. i. Verify lubrication of moving current-carrying parts and moving and sliding surfaces. 2. Electrical Tests: a. Measure contact resistance across each switchblade fuseholder. Drop values shall not exceed the high level of the manufacturer's published data. If manufacturer's published data are not available, investigate values that deviate from adjacent poles or similar switches by more than 50 percent of the lowest value. b. Perform insulation-resistance tests for one minute on each pole, phase-to-phase and phase-to-ground with switch closed, and across each open pole. Apply voltage in accordance with manufacturer's published data. In the absence of manufacturer's published data, use Table 100.1 from the NETA ATS. Investigate values of insulation resistance less than those published in Table 100.1 or as recommended in manufacturer's published data. c. Measure fuse resistance. Investigate fuse-resistance values that deviate from each other by more than 15 percent. C. Enclosed switches will be considered defective if they do not pass tests and inspections. D. Prepare test and inspection reports. 1. Test procedures used. 2. Include identification of each enclosed switch tested and describe test results. 3. List deficiencies detected, remedial action taken, and observations after remedial action. BCRUA - Phase 1D WTP Expansion Issued for Bid Enclosed Switches and Circuit Breakers 26 28 16 - 6 3.7 ADJUSTING A. Adjust moving parts and operable components to function smoothly, and lubricate as recommended by manufacturer. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Industrial Control Panels 26 29 13 .01 - 1 SECTION 26 29 13.01 INDUSTRIAL CONTROL PANELS PART 1 GENERAL 1.1 WORK INCLUDED A. Furnish labor, materials, equipment, and incidentals necessary to install industrial control panels to measure and control process mechanical equipment as specified in process equipment specifications and control schematics within Electrical design drawings. B. Electrical work shall be in accordance with Division 26, Section 26 05 00 “Common Work Results for Electrical”, and Division 40. C. Provide UL 508A labels to all control panels under this contract. Control panels shall be fabricated by a UL 508A Industrial Control Panel (ICP) shop. D. Contractor shall be responsible for sizing all control panel enclosures to comply with minimum workspace clearance requirements in Article 110 of NFPA 70. E. Horsepower Rating: Horsepower’s as indicated on the Plans are approximate. The Contractor shall furnish properly sized motor control equipment when actual motor horsepower’s are determined. If actual motor horsepower’s differ from the Plans, the Contractor shall obtain assistance from the Engineer in determining whether hardware and wiring changes are necessary. The Contractor shall provide all components and wire of the proper size. 1.2 SUMMARY A. Section Includes: 1. General use industrial controls panels. 1.3 REFERENCES A. Abbreviations 1. SCCR: Short Circuit Current Rating 2. VFD: Variable Frequency Drive B. Definitions 1. The term "panel" refers to control panels or enclosures as shown, listed, or noted on the Contract Documents. 2. Foreign Voltages: Voltages that may be present in circuits when the panel main power is disconnected. C. Reference Standards 1. The applicable provisions of the following standards shall apply as if written here in their entity. a. Local Laws and Ordinances b. State and Federal Laws c. NEMA ICS 2 d. NFPA 70 e. NFPA 79 BCRUA - Phase 1D WTP Expansion Issued for Bid Industrial Control Panels 26 29 13 .01 - 2 f. UL 508 g. American National Standards Institute (ANSI) h. National Electrical Manufacturers Association (NEMA) i. Institute of Electrical and Electronics Engineers (IEEE) 1.4 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Document Management” and as outlined below. 1. Product Data a. Complete manufacturer cutsheets for each component used. Indicate all options selected for each component. Cross out options and accessories not being supplied with component. Submittals that are not clearly marked will be returned without review. 2. Shop Drawing a. Control panel layout and wiring diagrams. 1) Complete Bill of Material of all components associated with control panel. Provide a separate Bill of Material for each control panel. Components listed in Bill of Material must have quantities and an Item ID. 2) Submit CAD formatted panel layout drawings for each control panel specified. All components and enclosures must be scaled with dimensions included. Include at a minimum the following drawings: a) Elevations identifying all components located on the interior backplane, door-in- doors, and panel exteriors. (1) Provide Item ID next to each component. (a) Enclosure NEMA rating (b) Enclosure SCCR (c) Nameplate Schedule with descriptions and locations of all nameplates. (d) Stub-up Locations (e) Shipping splits and shipping weights (f) Ventilation Details (2) Wiring Diagrams (a) FLA of panel (b) Project specific control schematics (c) Field instrumentation (d) Power sources of all 2-wire and 4-wire field instruments (e) Terminal strip layout clearly identifying all customer and field terminations for power, control, and instrumentation. b. Heat Rise Calculations: panel heat rise calculations shall be provided for each control panel supplied with an air conditioner. Indicate that sufficient dissipation or cooling is provided to maintain interior panel temperatures within the rated operating temperatures of panel components. c. UPS Battery Calculations 3. Spare Parts List 4. Equipment Installation Report 5. Warranty Information 6. O&M Manual a. Include record drawings of final control schematic, including any changes made during startup. BCRUA - Phase 1D WTP Expansion Issued for Bid Industrial Control Panels 26 29 13 .01 - 3 1.5 SPARE PARTS A. Furnish extra materials that match products installed and that are packaged with protective covering for storage and identified with labels describing contents. 1. Fuses: Equal to 10% of quantity installed for each size and type, but not fewer than six of each size and type. 2. Indication lights: One of each type and lens color 3. Relays and tube bases: Equal to 10% of quantity installed for each size and type, but not fewer than three of each size and type. 1.6 QUALITY ASSURANCE A. Control panel manufacturer must possess a current UL508A certification and hold at least one of the following certifications: ISO-9001 certificate or CSIA Certification. 1.7 DELIVERY, STORAGE, AND HANDLING A. Temporary Heating: Apply temporary heat to maintain temperature according to manufacturer's written instructions until enclosed controllers are ready to be energized and placed into service. 1.8 SITE CONDITIONS A. Ambient Temperature: 0-40C direct sunlight B. Altitude: Not exceeding 1000 feet. C. Relative Humidity: 0% to 95% (non-condensing) PART 2 PRODUCTS 2.1 GENERAL REQUIREMENTS A. Minimum SCCR of all control panels: 10kA for 120V control panels and 42 kA for 480V unless indicated otherwise within process equipment specifications. 2.2 ENCLOSURES A. General Requirements: 1. Enclosures shall be sized to sufficiently support the mounting of all panel components to the backplane of enclosure, and to support the routing and separation of power and control voltage conductors within enclosure. 2. All components shall be mounted to stud mounted backplane on the rear of enclosure. No components shall be mounted to sides of enclosure interior. 3. Panels shall meet the NEMA classifications listed under section 3.1 Enclosure Installation Schedule. All components mounted to the exterior of enclosures shall maintain the NEMA rating of enclosure. 4. Each enclosure door shall be fitted with a thermoplastic print storage pocket. BCRUA - Phase 1D WTP Expansion Issued for Bid Industrial Control Panels 26 29 13 .01 - 4 5. Enclosures shall be fitted with factory welded grounding stud on interior of enclosure door and enclosure inner side wall for bonding the two. Separate grounding studs shall be provided for each enclosure door. 6. Enclosures shall be manufactured by Hoffman by nVent, Hammond Manufacturing, Rittal, or Saginaw Control & Engineering. B. Freestanding Enclosures: Manufactured from 12-gauge sheet stainless steel, with suitable interior stiffeners, continuously welded for rigid construction, continuous piano type hinge with 3-point latching mechanism operated by padlocking handles constructed of like material as enclosure. 1. Panels 48” wide or greater shall have two doors with a removable centerpost. 2. Free standing enclosures located outdoors shall have 12-inch floor stands bolted to enclosure. 3. See enclosure installation schedule at the end of this Section for enclosure material and NEMA rating by location. C. Wall or Slotted Channel Mounted Enclosures: Manufactured from minimum 16-gauge sheet stainless steel, with integrated mounting feet, with suitable interior stiffeners, continuously welded for rigid construction, continuous piano type hinge with 3-point latching mechanism operated by padlocking handles constructed of like material as enclosure. D. Door-In-Door Enclosure Requirements: Where door-in-door enclosures are specified, provide an interior hinged sub-panel within enclosure. Sub-panel must swing a minimum 90 degrees out of enclosure, to provide access to mounted internal equipment. Stud mounted sub-panels will not be permitted in lieu of hinged type. E. Enclosure Finishing: 1. NEMA 4X stainless steel enclosures shall be finished smooth, free of all burrs, scales and imperfection, brushed smoothed, and unpainted. 2. Interior Backplanes: Painted white. F. Enclosure Conditioning 1. Panel Conditioning: Where components supplied are not rated for site ambient temperature, panel manufacturer shall provide a closed loop panel air conditioner sized to maintain the panel temperature below the lowest components rated operating temperature. a. Air conditioners shall be a closed loop type, refrigerant based system, internal component corrosive resistant coating, and a stainless-steel enclosure. Air conditioner shall maintain NEMA rating of enclosure. b. Air conditioner shall be manufacturer by Hoffman by nVent, Pentair, or ICEqube by Thermo Electric. 2. Condensation Control: A thermostat-controlled condensation strip heater and condensate drain shall be provided for all panels located outdoors or in a non-conditioned environment. Strip heater shall be sufficiently guarded to prevent accidental contact by panel components and conductors. a. Condensate Drain: ½” stainless steel vent drain threaded to conduit hub, installed on bottom of enclosure. G. Nameplates 1. Panels and exterior mounted panel components will be supplied with unique nameplates. Each device nameplate shall describe the field device (e.g. Transfer Pump 1) and the BCRUA - Phase 1D WTP Expansion Issued for Bid Industrial Control Panels 26 29 13 .01 - 5 function it serves (e.g. H/O/A). Nameplates shall be phenolic (Lamicoid), with a minimum 1” tall, engraved letters, with fixed to panel with epoxy adhesive. 2. Each component identified on the Bill of Material will have a phenolic nameplate attached to the back panel either beside or above the device. Nameplate will have the same schematic designation assigned in the drawings (e.g. RTU-01). Nameplate must be clearly visible and not blocked by wiring, wire duct, or other components. Text will be white, 1/8” high, on a black background. Nameplates will be affixed to back panel with 3M 9472 adhesive or approved equal. 2.3 POWER DISTRIBUTION AND POWER DEVICES A. General Requirements 1. All control panels shall be supplied with a single 480VAC, 3 phase, 3 wire plus ground (wye configuration) power source, unless noted otherwise. All other voltages required to operate the system served by control panel shall be derived from within panel via control power transformers and DC power supplies. 2. Provide separate branch circuit protection for each motor load, panel and motor space heaters, lights, receptacle, control circuit, etc. B. Main Overcurrent Protective Device 1. Where 120 VAC or 480 VAC circuits enter the control panel, provide an overcurrent protective device. Device shall be either a molded case circuit breaker or fuse type disconnect assembly where permitted, heavy duty, backplane mounted. Provide shaft extension for external handle mounted to front panel door to operate device without opening door. External handle shall indicate open and closed positions, must be padlock- able, chrome plated, and maintain NEMA rating of enclosure. Nonmetallic type handles will not be permitted. a. Where door-in-door is specified, disconnect assembly handle shall be mounted to inner door. 2. Device type selection criteria: Provide a molded case circuit breaker for the main overcurrent protective device unless current limiting fuses are required to meet the control panel SCCR specified. C. For control panels with a 480 VAC power feed, provide a pluggable (replaceable) type surge Protection Device (SPD): Metal oxide varistor, modular pluggable type, parallel connected, UL 1449 4th Edition, Type 2. SPD shall be DIN-rail mountable, with visual status indicator for protection status. 1. Maximum Continuous Operating Voltage (MCOV): L-N: 320V; L-L: 640V 2. Voltage Protection Rating (VPR): L-N: 1500V; L-L: 2500V 3. Nominal Discharge Current Rating (In): 20 kA 4. Provide SPD on incoming power feed after power main overcurrent protective device for each panel provided. 5. Manufactured by Mersen STP Series or Allen Bradley Bulletin 4983-DS. D. Three Phase Monitor (Phase Failure) Relays: tube style base with pin style terminals, silver nickel contacts, 10A/B300 contact rating, SPDT Form C contact, LED indicators for relay energized (normal state) and relay de-energized (fault state), fixed or adjustable power up delay, and automatic reset with adjustable restart time delay. The following conditions shall be monitored, with adjustable ranges as indicated: 1. Phase Loss & Reversal, Fixed at 1 second 2. Undervoltage/Overvoltage (Drop-out @+/- 10%, Pick-up @+/- 7%), 1-25 seconds BCRUA - Phase 1D WTP Expansion Issued for Bid Industrial Control Panels 26 29 13 .01 - 6 3. Voltage Unbalance (Drop-out @ 2%-8%), 1-25 seconds 4. All control panels serving three phase motors shall be supplied with a three-phase monitor relay. Relay shall monitor the incoming three phase power supply serving motor(s) fed from control panel and shall open the motor(s) control circuit(s) when a monitored condition is measured out of adjustable relay setpoints. 5. Manufactured by Diversified Electronics SLU-0200, Littlefuse 201A-AU Series, or Macromatic PMP575. E. Control Power Transformers (CPT): Control power transformers with factory installed primary and secondary fuse blocks for circuit protection. Ground one leg of control transformer on secondary side. CPT is permitted to installed in a separate enclosure to the side of control panel, however the NEMA rating of enclosure must be maintained. 1. Control Power Voltage: Control power shall be 120 VAC from a control transformer located in control panel. 2. Manufactured by Hammond, Acme, Square D, or Eaton. F. 120VAC Uninterruptable Power Supply (UPS) 1. Where PLC is supplied within control panel, provide a UPS to power PLC and control components. UPS shall be sized for full PLC and control component capacity for 15 minutes. UPS shall be din rail or backplane mounted and shall contain nonproprietary sealed lead acid batteries. UPS shall include a LED status display for battery online and replace battery indication. G. Motor Starter 1. Description: Across-the-line start, electrically held, three pole, for nominal system voltage of 600-V ac and less, with field replaceable contacts. a. The magnetic starter contactor shall have a maximum pick-up voltage requirement of 78% of nominal coil voltage and a maximum drop out voltage of 54% of nominal coil voltage for starter sizes 1, 2, 3 and 4, and 64% of nominal coil voltage for starter size 5. b. Minimum size contactor shall be NEMA 1. c. IEC starters are not permitted. 2. Configuration: NEMA ICS 2, Class A, full voltage, non-reversing, unless indicated otherwise. 3. Contactor Coils: Pressure-encapsulated type, rated for 120VAC, unless indicated on design drawings. Coils shall be field replaceable. 4. Auxiliary contacts shall be furnished on the starter contactor and on the overload sensing unit as shown on the drawings. 5. Overload Relays: a. Solid-State Overload Relay: 1) Switch or dial selectable for motor-running overload protection. 2) Sensors in each phase. 3) Class 20 4) Coordinate overload Class tripping characteristic with motor and load supplier. b. Overload relays shall be resettable from outside the enclosure by means of an insulated bar or pushbutton. 6. Manufactured by GE by ABB, Eaton, Rockwell Automation, Square D, or Siemens. H. Variable Frequency Drives 1. Basic Features BCRUA - Phase 1D WTP Expansion Issued for Bid Industrial Control Panels 26 29 13 .01 - 7 a. VFDs shall be capable of producing an adjustable AC voltage/frequency output for continuous operation over the normal system 30 to 100 percent speed range. The VFDs must be capable of sustained operation at 1/10 speed to facilitate checkout and maintenance of the driven equipment. b. Membrane keypad with integral two-line, 2. Unit Rating a. 100% rated current continuous, 150% rated current for 1 minute, at rated temperature. I. Power Supplies: 1. General Characteristics: a. 120 VAC, 480 VAC, or 125 VDC input as shown in the Drawings b. 24 VDC output with voltage trimmer potentiometer c. Momentary overload capability for downstream fuse breaking d. Input voltage tolerance: +/- 10% e. Minimum efficiency: 90% f. Power factor corrected input to a minimum of 0.9 lagging. g. Load regulation: +/- 2% h. Output ripple: 50 mVpp i. DC OK contact. 2. Manufactured by: a. Altech b. Phoenix Contact c. Sola HD 2.4 CONTROL DEVICES A. General Purpose Relays 1. General purpose relays shall have coil voltages of 120VAC, unless indicated otherwise on drawings. 2. General purpose relays shall be rated for a minimum 100,000 electrical cycles and dielectric withstand voltage a minimum of 1500V. 3. General Purpose Relays: tube style base with pin style terminals, silver nickel contacts, 10A/B300 contact rating, DPDT Form C contacts, ON/OFF flag indicator, LED power present indicator, push-to-test, with electrical schematic printed on relay. Manufactured by Allen-Bradley 700-HA, Square D 8501KP, or Eaton D5 Series. 4. General Purpose Timing Relays: tube style base with pin style terminals, silver nickel contacts, 10A/B300 contact rating, DPDT Form C contacts, LED indicator for power present and device timing initiated, with knob, thumbwheel or dial for adjusting timing range up to as shown on drawings. Refer to drawings for specified timing range. Manufactured by Allen-Bradley 700-HT, Square D 9050JCK, or Eaton TMR5 . 5. General Purpose Tube Base Socket: screw terminal type, DIN rail mounting style, open style terminal construction. B. PLC Isolation/Interposing Relays: tube style base with blade style terminals, silver nickel contacts, 10A/B300 contact rating, DPDT Form C contacts, ON/OFF flag indicator, LED power present indicator, push-to-test, with electrical schematic printed on relay. Manufactured by Allen-Bradley 700-HC. C. CURRENT LOOP ISOLATORS BCRUA - Phase 1D WTP Expansion Issued for Bid Industrial Control Panels 26 29 13 .01 - 8 1. Current isolators shall accept an input of 4-20 mA DC and produce a linearly proportional 4-20 mA DC output signal. Accuracy shall be ±0.1% of scale. Isolators shall operate on 24 VDC. Output load capability shall be 0-1000 ohms. 2. Current isolators shall be Acromag Model 631T-0500 or pre-approved equal by addendum. D. CURRENT SPLITTERS 1. Current splitters shall accept an input of 4-20 mA DC and produce a linearly proportional 4-20 mA DC output signal on each output. Outputs shall be galvanically isolated from each other. Accuracy shall be ±0.1% of scale. Splitter shall operate on 24 VDC. Output load capability shall be 0-1000 ohms. 2. Current splitters shall be Acromag Model 633T-0500 or pre-approved equal by addendum. 2.5 INDICATION AND CONTROL STATION DEVICES A. Pushbuttons, selector switches and indication (pilot) lights shall be 30.5 mm type with a chromium plated metal bezel; dielectric strength of 2200V, 200,000 mechanical cycles, shall be oil-tight, dust-tight and water-tight, and shall match the NEMA rating of the associated enclosure. All push buttons and selector switches will be able to accept additional contact decks to expand number of poles to those indicated in the Drawings. B. Pushbuttons, selector switches and indications lights shall be manufactured by Allen-Bradley 800T/H, Square D 9001K or Eaton 10250T. C. Pushbuttons: Spring return type with head flush to bezel, with finger safeguard, with silver alloy contacts rated for 10A continuous current. D. Mushroom Head Pushbuttons: Metal 40 or 45mm red color head, 2-position maintained push- pull type with silver alloy contacts rated for 10A continuous current. E. Selector Switches: “Stay Put” short knob type, silver alloy contacts rated for 10A continuous current. F. Indication Lights: LED lamp type, with spring return push-to-test function where indicated on design drawings. Unless indicated on the design drawings, indication light lens colors shall be: 1. White – Power On 2. Amber – Alarm 3. Red – Running, Closed or On 4. Green – Stopped, Open or Off G. Beacon Sounder Combination: Synchronized sounder and LED combination, red lens steady LED in NEMA 4X construction. Manufactured by Allen Bradley Bulletin 855PC or Square D Harmony Type XV. 1. Locate on side of control panel. 2. Beacon sounder shall be shipped loose for field installation by Contractor where indicated. H. Elapsed Time Meters: Six-digit electromechanical, non-reset type for totaling of hours; 120VAC power supply, panel face mounted, NEMA 4X rated, manufactured by Yokogawa Type 240, Simpson Electric Model 55ET, or Eaton 6-T-3H. BCRUA - Phase 1D WTP Expansion Issued for Bid Industrial Control Panels 26 29 13 .01 - 9 I. Operator Interface Terminal (OIT): Provide manufacturer’s standard OIT. Each panel provided with an OIT will maintain the enclosure rating. 1. For all outdoor installations, provide OIT protector to prevent UV ray exposure. Protector shall be manufactured by Smith and Loveless. 2.6 PANEL ANCILLARIES A. Receptacle: Each panel supplied with a PLC shall be supplied with a din rail mounted duplex receptacle for laptop use. B. Lights: Provide LED strip lights above each door for panels that are 24” or greater in depth. Each door shall be fitted with a door switch to turn on lights when door is opened. 2.7 PANEL WIRING AND WIRE MANAGEMENT A. Wire 1. Power and discrete control conductors: single conductors, stranded tinned copper with 600V type MTW insulation rated for 90C. a. Minimum 120, 208 and 480VAC conductor size shall be #12 AWG. b. Minimum DC and discrete control conductor size shall be #14 AWG. 2. Analog conductors: #18 AWG shielded, twisted pair, 600V insulation with extruded PVC jacket. 3. Internal panel wiring color code: a. AC circuits: 1) Power wiring: Black. 2) Control interconnections: Yellow. 3) Neutral: White. 4) Ground: Green. b. Low voltage DC circuits: 1) Power wiring: Blue. 2) Control interconnections: Violet. c. Foreign voltage circuits: Pink. d. Annunciator circuits: Red. e. Intrinsically safe circuits: Orange. B. Power Distribution Blocks: Aluminum body with phenolic or thermoplastic holder, rated for 600 VAC at 90C, suitable for termination of copper conductors with finger safe terminal cover. 1. Power distribution blocks shall be used for all conductors #10 AWG or larger entering or routed within control panel. 2. Mount to control panel backplane. C. Terminal Blocks: single high stacked 600 volt rated, suitable for up to #10 AWG conductor size, manufactured by Allen-Bradley 1492 H1 or Allen-Bradley 1492-CA2 or approved equal. Two high stacked terminal blocks will not be permitted. 1. Each terminal strip shall have hinged marking surfaces which snap on. Typewritten labels shall denote terminal strip numbers and shall match numbers shown on shop drawings, O&M manuals and wiring diagrams. Marking surfaces shall be Allen-Bradley 1492-N41 and labels shall be Allen-Bradley 1492-N43. 2. Provide minimum 25% spare terminals on terminal strip for customer’s use. BCRUA - Phase 1D WTP Expansion Issued for Bid Industrial Control Panels 26 29 13 .01 - 10 D. Current Loop Isolators: Current isolators shall accept an input of 4-20 mA DC and produce a linearly proportional 4-20 mA DC output signal. Accuracy shall be ±0.1% of scale. Isolators shall loop powered. Output load capability shall be a minimum of 1000 ohms. Current isolators shall be Phoenix Contact MCR-SL or approved equal. E. Wire Duct: Slotted duct, with flush cover. Snap back wire retention trap with deep slots to allow larger wire sizes. Wire duct shall be sized to be a maximum of 40% fill. Separate wire ducts shall be provided for 480V power, 120V power, and control/instrumentation wiring. F. Braided Expandable Wire Sleeving: Hook and loop fastener; made of 100% nylon. G. Fiber Optic Patch Panel: All fiber connections entering control panel must be terminated on a din rail or backplane mounted patch panel. Provide enough connectors within patch panel to terminate all fibers, including spare. H. Colored, vinyl marking tape shall be allowed only on conductors greater than 8 AWG. Under no condition shall conductors of a different color be spliced together. All wiring shall be identified with wiring markers with alphanumeric characters. The identification of each wire shall be the same as that shown on the electrical schematic. Each wire shall be so identified at each end. Each end of every wire shall be provided with a heat shrinkable or equivalent sleeve-type wire marker-labeled in accordance with the electrical schematic. Use of adhesive and clip-on type markers is prohibited. 2.8 PANEL LAYOUT REQUIREMENTS A. All components in the control panel shall be completely factory wired. All external control connection points shall terminate on power distribution blocks or terminal blocks. B. Control relays, timing relays, control transformers, control circuit fuse blocks, etc., shall be grouped in the corresponding starter with control wiring kept as short as possible. Ample space shall be allowed between devices so that each component is completely accessible without removing any other device. C. If any MCP or circuit breaker operating handle is more than 6'-6" above the floor surface immediately in front of the control panel, a supplementary operating device shall be attached to the operating handle. This supplementary device shall require a person to reach no more than 6'6" above the floor surface at any point of opening or closing the MCP or circuit breaker. D. Wires shall be neatly placed in plastic wireways with the covers installed. Wires not in a wireway shall be zip tied together and fastened to the enclosure or back plane with adhesive mounting base. E. Wiring in the control panel shall terminate on numbered terminal strips or power distribution blocks. No other wire connecting devices, such as wirenuts or split bolts, shall be allowed in the control panel. Each starter shall be provided with an individual terminal strip for control wiring. This terminal strip shall be completely accessible from the front. F. Control panel shall have a single means of disconnecting power to the whole enclosure and a separate 120V control power circuit breaker. BCRUA - Phase 1D WTP Expansion Issued for Bid Industrial Control Panels 26 29 13 .01 - 11 G. Wire extending from the enclosure to the enclosure door shall be wrapped in expandable wire sleeves. H. For door-in-door construction enclosures, all devices intended to be visible while outer door is closed shall have devices located on side of enclosures. I. All reset buttons, VFD keypads and RVSS keypads must be operable without opening the enclosure or inner door of door-in-door enclosures. J. Controls shall be laid out on a removable backboard and backboard. All external fasteners on the control panel shall be stainless steel. PART 3 EXECUTION 3.1 Enclosure Installation schedule A. Outdoor: NEMA 250, 4X 316 stainless steel. B. Indoor 1. Non-conditioned space: NEMA 250, Type 4X, 316 stainless steel. 2. Conditioned space: Painted steel, NEMA 250, Type 1. 3.2 PREPARATION A. Enclosure shall be clean and free of sharp corners. Conductors shall be grouped together and routed in a neat and orderly fashion. 3.3 INSTALLATION A. Make all electrical connections to all equipment specified. Install equipment in accordance with the Manufacturer's recommendations and the plans. If neither are available, install the equipment using recognized practices of the electrical industry and trade. B. The final control schematic shall be printed and placed in a clear plastic sleeve after all the field modifications have been made. C. Conduit penetrations: 1. No top entry of conduit into panels shall be permitted, unless located in dry locations. 2. Where top entry of enclosures is allowed, conduit penetrations must not be located directly over devices that conductors are being terminated to. Resting conductors on non- related devices is not permissible. a. Where conduits enter the top of the enclosure, the must not be terminated or routed directly above or in front of any solid state device. Conductors must not be supported by devices within the enclosure. Conductors routed around in the enclosure, but on the outer edge of the backplane, must be supported by the enclosure and must not restrict access to anything on the enclosure. If the enclosure must be oversized to accommodate the number of conductors to meet this specification, then it must be provided at no additional cost to the Owner. BCRUA - Phase 1D WTP Expansion Issued for Bid Industrial Control Panels 26 29 13 .01 - 12 3. Side entry of conduits is allowed but must not interfere with devices or Panduit mounted to the backplane. Conductors must not rest against devices and routing of conductors must not block maintenance access to any device or terminal blocks. D. Penetrations must not be made into control panels until raceways systems entering and exiting control panel are watertight. E. Floor mounted enclosures in conditioned environments shall have 4” concrete housekeeping pad. F. All wire terminals shall be torqued to manufacturer’s torque value. 3.4 RACEWAY SEALING FIELD QUALITY CONTROL A. Functional Checkout 1. Upon completion of the installation, perform continuity tests and functional checkout to assure the proper operation of all equip B. Acceptance Testing Preparation 1. Test insulation resistance for each enclosed controller, component, connecting supply, feeder, and control circuit. 2. Test continuity of each circuit. C. Tests and Inspections 1. Inspect controllers, wiring, components, connections, and equipment installation. Test and adjust controllers, components, and equipment. 2. Test insulation resistance for each enclosed-controller element, component, connecting motor supply, feeder, and control circuits. 3. Test continuity of each circuit. 4. Verify that voltages at controller locations are within plus or minus 10 percent of motor nameplate rated voltages. If outside this range for any motor, notify Owner/Engineer before starting the motor(s). 5. Perform each electrical test and visual and mechanical inspection stated in NETA Acceptance Testing Specification. Certify compliance with test parameters. 6. Correct malfunctioning units on-site, where possible, and retest to demonstrate compliance; otherwise, replace with new units and retest. 7. Test and adjust controls, remote monitoring, and safeties. Replace damaged and mal- functioning controls and equipment. 3.5 ADJUSTING A. Prior to energizing control panel loads, the following adjustments must be made and documented. 1. Set field-adjustable switches, auxiliary relays, time-delay relays, timers, and overload- relay pickup and trip ranges. 2. Adjust overload-relay heaters or settings. 3. Set field-adjustable circuit-breaker trip ranges. BCRUA - Phase 1D WTP Expansion Issued for Bid Industrial Control Panels 26 29 13 .01 - 13 3.6 CLEANING AND TOUCHUP A. Remove all metal shavings, dirt and dust from panel interior. Do not use compressed air to clean panel interior. B. Painted steel panels will have any scratches to the paint repaired to factory conditions with manufacturer supplied paint. Any rust developed prior to applying touch up paint will be sanded back to bare metal prior to painting. 3.7 PROTECTION A. Temporary Heating: Apply temporary heat to maintain temperature according to manufacturer's written instructions until enclosed controllers are ready to be energized and placed into service. B. Replace controllers whose interiors have been exposed to water or other liquids prior to Substantial Completion. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Variable Frequency Drives 26 29 23 - 1 SECTION 26 29 23 LOW VOLTAGE VARIABLE FREQUENCY DRIVES (Revised by AD-02) PART 1 GENERAL 1.1 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to manufacture, fabricate, test, modify and deliver variable frequency drives (VFDs) as shown on the drawings and as specified herein. The VFDs shall operate on 480 VAC, 3-phase, 60 Hz which shall contain/incorporate harmonic mitigation technology per IEEE-519, drive isolation transformers, and all appurtenances needed to meet the requirements of these specifications. B. The manufacturer shall provide the services of factory field engineers for startup, field tests, troubleshooting, Owner training and the supervision of storage and installation. The minimum time required for the manufacturer field services to be on-site shall include a minimum of the following. These times do not include travel time and include a minimum of 8 hours working per day. Start-up 1 day (1 trip minimum) Field Tests/Testing 2 days (2 trips minimum) Troubleshooting 2 day (2 trips minimum) Owner Training 1 day (1 trip minimum) C. VFD shall be compatible with twelve existing Eaton SVX9000 (SVX00214EAK4P1PF) VFDs. D. VFDs shall be 6 pulse type with input line reactor and 3% load side reactor. E. Contractor shall procure the services of Eaton to modify the existing sludge pump VFDs, two total, to place the VFDs in multipurpose application mode. In this mode, the VFDs will each be able to be controlled by the existing and new Belt Filter Press Control panels via dry contacts and 4-20mA speed reference setpoints, as well as speed and status feedback to each belt filter press control panel. Refer to design drawings for modifications needed. Provide additional expansion I/O cards, hardware and programming as needed for a fully operational VFD per the project manual and design drawings. Eaton shall provide the on-site services for startup, field tests, and troubleshooting of the sludge feed pump VFDs. (AD-02) 1.2 QUALITY ASSURANCE A. ACCEPTABLE MANUFACTURERS: The VFD manufacturer shall demonstrate 5 years experience with the drives of the type and size herein specified. 1. Allen Bradley 2. Eaton 3. No other manufacturers will be accepted. B. Variable frequency drives shall be of sufficient size for the duty to be performed and shall not exceed their full rated capacity when the driven equipment is operating as specified. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Variable Frequency Drives 26 29 23 - 2 C. The variable frequency drive manufacturer shall maintain, as part of a national network (United States), engineering service facilities within 250 miles of the project site to provide start-up service, emergency service calls, repair work, service contracts, and maintenance and training of customer personnel. When requested by the Engineer, documentation shall be provided showing compliance, capabilities, and references for this requirement. D. All equipment shall be NEMA rated. IEC or dual rated IEC/NEMA shall not be acceptable. E. Complete VFD integrated line-up shall be U.L. listed. F. The VFD manufacturer shall be responsible for coordinating with the motor manufacturer to meet the design and performance requirements of the specification. The VFDs shall be installed by the Contractor. G. FACTORY INSPECTION AND TESTS 1. The VFD manufacturer shall provide the following quality assurance steps within its factory: a. Incoming inspection of all components. b. In-process inspection of assemblies. c. 100% test and inspection of power devices. H. The VFD printed circuit boards shall be tested per the manufacturer’s standard testing procedure. The VFD manufacturer shall provide certification that the tests have been completed. I. The VFD manufacturer shall submit the factory test report to the Engineer as an official submittal prior to the equipment being shipped from the factory. J. The variable frequency drive manufacturer shall provide the actual test data, observations and certification that the tests have been completed prior to shipment to the Engineer for approval. K. FIELD QUALITY CONTROL: The manufacturer shall furnish an equipment test report after installation, start-up and testing. L. The VFD and motor shall be completely compatible. The VFD Manufacturer shall issue a guarantee of compatibility letter at the time Shop Drawings are submitted. The VFD and Motor Manufacturer shall determine the insulation voltage rating required to accommodate common mode voltages and prevent insulation failure. 1.3 SUBMITTALS A. Submittals shall be in accordance with this section, the General Requirements, Section 01330, “Submittal Procedures” and shall include the following minimum information: 1. SHOP DRAWINGS a. Any deviations from the specifications should be clearly identified on a separate sheet of paper in the shop drawing submittal. b. Drawings shall show: 1) equipment dimensions, 2) stub-up locations and conduit entry and exit locations. Conduit entry and exit points clearly showing dimensions of entry and exit points. Provide a detailed BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Variable Frequency Drives 26 29 23 - 3 top and bottom view showing how conduits penetrate the top and bottom of the VFD. 3) nameplate schedule 4) Provide a drawing of the front view elevation with designation of equipment and devices on doors, and clearly indicating the maximum mounting height of devices on doors. 5) Project specific control schematics and wiring diagrams. Labels on the control schematic for control relays, level switches, indication lights, etc. shall correspond to equipment tags/labels indicated on the Control Schematic included in the plans. Include a label above each timing relays indicating the range and set point for that timing relay. 6) The motor control schematic shall clearly indicate next to the corresponding device symbol the following: the circuit breaker size, number of cables that can be terminated on the incoming and outgoing, fuse sizes, size of CPT, CTs, etc. The schematic shall include the motor nameplate information (HP, FLA, RPM). 7) Provide a drawing showing the Terminal strip layout showing customer field connections. The terminal strip layout shall also include a label next to each connection indicating signal description. Handwritten terminal numbers are not acceptable. c. Complete bills of materials with model numbers listed for individual components. d. Catalog cut sheets of major components, power equipment clearly identifying make and model number of device being provided. e. Data sheets of miscellaneous electrical equipment. f. Spare Parts List g. Warranty information h. True and displacement power factor and efficiency i. Harmonic distortion analysis: The manufacturer of the drive equipment shall perform a bus voltage and/or current distortion calculation for each bus that supplies a drive. The harmonic study shall be performed to determine the harmonic content expected on the Purchaser's supply bus due to the addition of the variable frequency drive and to determine the harmonic filter requirements. The total harmonic distortion shall not exceed THD values as recommended by IEEE - 519, 1992 under normal worst case operating conditions. The recommended harmonic filter shall be supplied by the drive manufacturer. Harmonic analysis shall be provided prior to or with the VFD shop drawings for approval. The Harmonic Distortion Analysis study shall contain, as a minimum, the following: 1) Project specific information. Using typical pump motor and/or utility information will not be accepted. 2) Preliminary harmonic levels without VFDs installed. 3) Preliminary harmonic levels with the VFDs operating as indicated in section 1.07. 4) Explanation of method used to perform the study. 5) Explanation of study results. 6) All calculations and/or computer printouts used to arrive at the recommendations. 7) Voltage and Current harmonic content up to the fiftieth (50th) harmonic, for the conditions specified above in table format. j. Note: All documentation listed above shall be supplied with the VFD’s initial submittal. Incomplete submittals will be returned “NOT APPROVED, REVISE AND RESUBMIT”. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Variable Frequency Drives 26 29 23 - 4 k. Submit proposed changes to sludge feed pump VFDs, including recommended programming and hardware modifications. Provide updated wiring diagram. (AD- 02) 2. FACTORY TEST DATA a. Factory test data shall include a summary of all tests performed at the factory, both those specifically identified in this specification and other factory standard tests. Factory test data shall be submitted for approval prior to the drives being released for shipment. 3. FIELD TEST DATA – Equipment Installation Report a. The Contractor shall submit a detailed testing agenda a minimum of three (3) weeks in advance prior to testing start date. b. Field test data shall include summary of all tests performed in the field specifically identified in this specification and other factory standard tests. 4. NETA Acceptance Testing Specification (ATS) field tests and inspections tests report. 5. Supplier shall submit a training outline for Owner’s/Engineer’s review and comment a minimum of 4 weeks before training is to take place. 6. OPERATION AND MAINTENANCE MANUALS a. Operation and maintenance manuals shall be prepared by the equipment manufacturer and shall contain the final certified approved shop drawings, submittals, schematics, final wiring diagrams with any changes made during start- up, equipment installation report and maintenance procedures and test data. b. Manuals may be manufacturer's standard instructions, but shall be supplemented as necessary to cover any special feature not included in standard material. c. Operation and maintenance manuals shall include warranty information as well as a warranty information page that shall include information on the warranty start and end date as well as contact information for service. d. Submit preliminary manuals for review prior to start-up of equipment. 1.4 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entity. 1. Local Laws and Ordinances 2. State and Federal Laws 3. National Electrical Code (NEC) 4. Underwriters' Laboratories (UL) 5. American National Standards Institute (ANSI) 6. National Electrical Manufacturers Association (NEMA) 7. Institute of Electrical and Electronics Engineers (IEEE) 1.5 DELIVERY, STORAGE AND HANDLING A. The manufacturer shall be responsible for delivery of the equipment and accessories, f.o.b. to the job site or to such storage site as may be designated by the Contractor in good condition and undamaged. B. Unloading and storage of the equipment shall be the responsibility of the Contractor who shall inspect the equipment for apparent damage. Equipment which is found to be damaged will not be accepted until properly repaired or replaced by the manufacturer. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Variable Frequency Drives 26 29 23 - 5 C. Handling and shipment of the equipment shall be in such a manner to prevent internal component damage, breakage, and denting and scoring of the enclosure finish. D. Equipment must be delivered and stored in accordance with the manufacturer’s recommendation at all times. Equipment shall be stored indoors in a clean, dry, climate controlled heated and air conditioned environment that is free from dust, no exceptions. Protect equipment from exposure to dirt, fumes, water, corrosive substances and physical damage. 100 watt incandescent lamps shall be placed in the VFD enclosure sections as required and energize to prevent the buildup of condensation during extended storage periods. 1.6 WARRANTY A. Manufacturer shall warrant the equipment furnished under this specification for a period of two (2) years from final completion, against defects in materials and workmanship and operational failure. B. In the event of failure of any part or parts of the equipment during the first 2 years of service, provided that the equipment has been operated and maintained in accordance with good practice, the Manufacturer shall furnish, deliver and install the defective part or parts at their own expense. C. The first 2 years of service shall be interpreted as the 24-month period following the final installation completion, adjusting and acceptance testing, and the start of actual operation of the equipment, or 30 months after delivery, whichever occurs first. PART 2 PRODUCTS 2.1 GENERAL A. VFD system must fit in the space indicated on the drawings. The VFD manufacturer shall be responsible to provide the contractor the VFD size prior to bid date. B. Any modifications to a standard product required to meet this specification shall be performed by the VFD manufacturer only. C. Drive shall be air cooled. Liquid cooled systems shall not be acceptable. The VFD shall consist of an incoming main circuit breaker section with an AIC rating of 65,000, input rectifier grade drive isolation transformer or a phase shifting transformer, input converter/DC bus/output inverter and control logic section. All components shall be integral to the VFD lineup, factory wired and tested as a complete system. D. VFD system shall maintain a .95 minimum true power factor from 30% to 100% speed. Power factor shall not become leading at any speeds. VFD manufacturer shall provide written documentation verifying this. VFD system shall include power factor correction and/or harmonic filter and shall never have a leading power factor under utility. VFD manufacturer is to supply a power factor correction system, if required, to meet this requirement. Power factor correction system shall include a separate input isolating contractor with fuses, power factor correction grade capacitors and series harmonic decoupling reactors, all mounted and BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Variable Frequency Drives 26 29 23 - 6 wired as part of the drive system. Power factor correction system shall be mounted in the VFD. 2.2 VARIABLE FREQUENCY DRIVES A. RATINGS 1. Guaranteed minimum VFD efficiency shall be 95% at 100% speed and 100% load and minimum 94% at 75% speed. Losses shall include drive isolation transformer/phase shifting transformer, input harmonic filters and power factor correction system, if applicable, converter/DC bus/Inverter, and dv/dt filter. Auxiliary control, such as internal VFD control boards, cooling fans or pumps, shall be included in all loss calculations. 2. Rated Input Power: Non-phase sequence sensitive, 380-480 Volts, +/-10%, 3-phase, 60 Hz. a. Voltage Dip Ride-through: VFD shall be capable of sustaining continued operation with a 30% dip in nominal line voltage. Output speed may decline only if current limit rating of VFD is exceeded. b. Power Loss Ride-through: VFD shall be capable of 5 cycle power loss ride-through without fault activation. c. All 120VAC power for VFD control logic and cooling fans shall be fused and supplied by the integral to the VFD. 3. Output Power: a. VFD manufacturer shall coordinate with motor manufacturers for exact motor requirements: HP, amps, RPM, etc. VFD and pump/motor manufacturers shall provide a letter stating that the VFD and motor are compatible. 4. Ambient Temperature Range: 0 to 40 degrees C. 5. Humidity: 95% non-condensing. 6. Elevation: Up to 3300 feet (1000 meters) above MSL without derating. 7. Power Unit Rating Basis: 100% rated current continuous, 150% rated current for one minute, at rated temperature. B. CONSTRUCTION The control logic section shall be fully digital and not require analog adjustment pots or fixed selector resistors. A power failure will not necessitate a re-load of any drive parameters or configurations. The controller shall be suitable for any standard NEMA-B squirrel-cage induction motor having a service factor of 1.15. The inverter output shall be generated by IGBT's. The VFD shall not create excessive power losses in the motor. C. BASIC FEATURES 1. The VFD shall be capable of producing an adjustable AC voltage/frequency output to provide continuous operation over the normal system 30%-100% speed range. The VFD must be capable of sustained operation at 1/10 speed to facilitate checkout and maintenance of the driven equipment. 2. The door of each unit shall include the door mounted components (as shown on the VFD control schematic) arranged in a logical manner, subject to the Owner/Engineer’s approval. Operator interface and control logic shall be 120VAC. All control and signal wires shall be shielded and fully protected against EMI/RFI interference. 3. The VFD shall include a customer selectable automatic restart feature. When enabled, the VFD shall automatically attempt to restart after a trip condition resulting from overcurrent, overvoltage, under voltage, or over-temperature. For safety, the drive shall shut down and require manual reset and restart if the automatic reset/restart function is BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Variable Frequency Drives 26 29 23 - 7 not successful within a maximum of three attempts within a customer programmable time period. 4. A door-mounted membrane keypad as provided by the manufacturer as their standard interface shall be furnished, capable of controlling the VFD and setting drive parameters. The keypad shall include the following features: a. The digital display must present all diagnostic message and parameter values in English engineering units when accessed, without the use of codes. b. The keypad module shall contain a "self-test" software program which can be activated to verify proper keypad operations. c. The digital keypad shall allow the operator to enter exact numerical settings in English engineering units. A plain English user menu shall be provided in software as a guide to parameter setting (rather than codes). Driver parameters shall be factory set in EEPROM and resettable in the field through the keypad. Two (2) levels of password security shall be available to protect drive parameters from unauthorized personnel. The EEPROM stored drive variables must be able to be transferred to new boards to reprogram spare boards. d. The following door mounted digital indications shall be supplied: 1) Speed demand in percent 2) Input current in amperes 3) Output current in amperes 4) Output Frequency in hertz 5) Input voltage 6) Output voltage 7) Total 3-phase KW 8) Kilowatt hour meter 9) Elapsed time running meter 10) Output speed in percent e. The following door mounted pushbuttons, control switches and indicating lights shall be supplied: 1) Elapsed time running meter (electro mechanical) 2) Emergency Stop pushbutton (push/pull type) 3) Hand-Off-Auto selector switch 4) Start Pushbutton 5) Stop Pushbutton 6) White push-to-test indicating light (pump ready) 7) Red push-to-test indicating light (pump run) 8) Green push-to-test indicating light (pump stop) 9) White indicating light (power on) 10) Amber push-to-test indicating light (VFD trip) f. VFD shall be capable of direct communication to an IBM or compatible computer for serial link setup of parameters, fault diagnostics, trending and diagnostic log downloading. A USB port shall be door-mounted for computer interface. VFD drawings shall indicate physical location of USB port. D. ENCLOSURE: All VFD components including transformer shall be mounted and wired by the VFD manufacturer in a grounded enclosure meeting the following requirements without exception: 1. Maximum width dimension is 20” and maximum height dimension is 30”. 2. VFD shall be wall mounted. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Variable Frequency Drives 26 29 23 - 8 3. Power conversion and auxiliary equipment enclosure sections shall be NEMA-1 design. Front access only. Enclosure shall be top entry and top exit. Input and output sections of the starter shall be suitable for terminating the number and size of conductors indicated below. See plans for additional information. 4. Printed circuit boards shall be conformal coated. 5. All power conductors (bus or cable) shall be insulated. 6. All relays and pushbuttons shall be NEMA rated, heavy duty type. IEC or dual IEC/NEMA rated equipment shall not be acceptable. 7. All wiring shall be located internally within the VFD enclosure. External ductwork or wireways shall not be utilized. 8. Terminal blocks shall be NEMA rated, 600V. Stacking (two-high) terminal blocks is not acceptable. 9. All wiring shall be identified with wiring markers with alphanumeric characters. The identification of each wire shall be the same as that shown on the electrical schematic. Each wire shall be so identified at each end. Each end of every wire shall be provided with a heat shrinkable or equivalent sleeve-type wire marker-labeled in accordance with the electrical schematic. Use of adhesive and clip-on type markers is prohibited. 10. CONTROL RELAYS: Industrial type; contacts rated for 10 amps at 600 VAC; Allen- Bradley Bulletin 700 Type P, Square D Class 8501 Type X, or approved equal. Relays shall have the capability of having contact decks added in the field. Contacts shall be field convertible to normally open or normally closed. Coils and contacts shall each be replaceable without replacing any other part of the relay. Where control relays are indicated on the Plans, industrial control relays shall be furnished whether the relay coil is operated with 120 VAC or 24 VDC. General purpose “plug-in” type relays are not acceptable. 11. TIMING RELAYS: Solid state. Ranges shall be as shown on the Plans. The timing relays shall have both normally open and normally closed contacts by having two sets of form C contacts. Timing relays where shown on the Plans shall be Square D, Class 9050 Type JCK60, or Allen-Bradley Type 700-FS time delay relay, or approved equal model for operation on the control voltage of the equipment it is used in. Timing relay shall be provided with restraining strap. Terminal shall be front-mounted and readily accessible. 12. INDICATING LIGHTS, SWITCHES, PUSHBUTTONS: Heavy duty and oil tight (30 mm); Square D Class 9001 or approved equal. Pilot lights shall be push to test (LED type) and shall be Square D SK or approved equal. 13. ELAPSED TIME METER: The meter shall be of a non-reset type, for totalizing of hours and shall operate on 120 VAC, 60 Hertz. Starter shall be provided with an elapsed time meter; Yokogawa Model 240, 3 ½” New Big Look type elapsed time meter, or approval equal. Digital time meters are not acceptable. 14. Maximum door swing clearance shall not exceed 36". 15. After fabrication, metal structures shall be thoroughly cleaned, bonderized as a unit and then given a primary coat, a coat of rust preventative and a finishing coat of quick-drying lacquer. Unless otherwise specified, the color of the panels and the exteriors of structures shall be gray ANSI-61 or ANSI-49. Instruments, relays, and meters shall have dull black standard finish. 16. Air shall be exhausted through the top and front of the VFD enclosure. No air shall be exhausted through the rear of the enclosure. 17. Provide a print pocket pouch with the control schematic drawings on the inside of the VFD door. The control schematic drawings shall be the final version of the drawings and shall include any field revisions made during start-up. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Variable Frequency Drives 26 29 23 - 9 18. Lights, pushbuttons, switches, displays, etc. shall be mounted no higher than 5’-6” AFF. Front drive panel layout showing exact mounting heights shall be submitted to the Engineer for approval. 19. VFD manufacturer shall verify with motor manufacturer that the contact from the VFD for energizing the motor space heater is properly sized to handle the space heater load. E. NAMEPLATES 1. Externally visible, permanent nameplates shall be provided to identify each instrument, switch, indicating light, etc. Equipment and terminal blocks shall be suitably identified. This shall include items on the back side of doors and panel mounted items. Nameplates shall be black with white lettering and attached with stainless steel screws. 2. Equipment nameplates and designations shall be 2 in. by 5 in. minimum, not less than 1/16 in. thick, engraved laminated plastic fastened with stainless steel screws. Nameplates shall be 1 in. white lettering on black background, and shall indicate equipment designations as shown on the drawings. 3. Provide legend plates or 1 in. by 3 in. engraved nameplates with ¼ in. lettering for identification of all pilot devices and meters. 4. Provide permanent warning signs as follows: a. “DANGER – HIGH VOLTAGE – KEEP OUT” on all enclosure doors. b. “WARNING – HAZARD OF ELECTRIC SHOCK – DISCONNECT POWER BEFORE OPENING OR WORKING ON THIS UNIT” F. PARAMETER SETTINGS 1. The following system configuring settings shall be provided, without exception, field adjustable through the keypad/display unit or via the serial communication port only. Except for Motor Nameplate Data, all parameters must be adjustable while the processor is on-line and the drive is running. a. Motor Nameplate Data 1) Motor frequency 2) Number of poles 3) Full load speed 4) Motor volts 5) Motor full load amps 6) Motor KW 7) Current limit, max. b. VFD Limits 1) Manual accel. rate 2) Manual decel. rate 3) Auto accel. rate 4) Auto decel. rate 5) Motor flux buildup delay: time/amount 6) I boost 7) Overload trip curve select (Inverse or Constant) 8) Min/Max speed (frequency) 9) Auto reset for load or voltage trip select 10) Overload trip time set c. VFD Parameters 1) Voltage loop gain d. Controller Adjustments 1) PID control enable/disable BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Variable Frequency Drives 26 29 23 - 10 2) Setpoint select 3) Proportional band select 4) Reset time select 5) Rate time select 6) Input signal scaling 7) Input signal select (4-20 mA/0-5 Volts) 8) Auto start functions: On/Off, Delay On/Off, Level Select On/Off 9) Speed Profile: Entry, Exit, Point Select 10) Min, Max Speed Select 11) Inverse Profile Select 12) Critical speed avoidance select 2. All drive setting adjustments and operation parameters shall be stored in a parameter log which lists allowable maximum and minimum points as well as the present set values. This parameter log shall be accessible via Ethernet communications as well as on the keypad display. G. DIAGNOSTIC FEATURES AND FAULT HANDLING 1. The VFDs shall include a comprehensive microprocessor based digital diagnostic system which monitors its own control functions and displays faults and operating conditions. Microprocessor systems must be products of the same manufacturer as the VFD (to assure single source responsibility, availability of service and access to spare parts). 2. A "FAULT LOG" shall record, store, display and print upon demand, the following for the 8 most recent events: a. VFD mode (Hand-Off-Auto) b. Date and time of day c. Type of fault d. Reset mode (Auto/Manual) 3. A "HISTORIC LOG" shall record, store, display and print upon demand, the following control variables at 2.7 M/Sec. intervals for the 50 intervals immediately preceding a fault trip: a. VFD mode (Hand-Off-Auto) b. Speed demand c. VFD output frequency d. Demand (output) Amps e. Feedback (motor) Amps f. VFD output volts g. Type of fault h. Auto enable PART 3 EXECUTION 3.1 GENERAL A. The Manufacturer’s Representative has responsibilities in the installation and field testing of the equipment as described in this Section. Installation of equipment shall be performed by the Contractor who shall be required to assemble the equipment, if required, and install it in accordance with Installation, Operation and Maintenance instructions which shall be furnished by the vendor or manufacturer, and the installation drawings for this project. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Variable Frequency Drives 26 29 23 - 11 1. The Contractor shall furnish all labor, tools, equipment and machinery necessary to receive, inspect, unload, store, protect, and install completely, in proper operating condition, the equipment. Contractor shall protect and store the VFD indoors, as recommended by the manufacturer and as described in section 1.05. 2. Contractor shall furnish such incidental items not supplied with the equipment, but which may or may not be described in the Plans and Specifications, for complete installation, such as wiring, conduit, ducts, anchors and other appurtenances as necessary. B. The Contractor shall schedule the service of the manufacturer to assist in the installation, adjustment, and acceptance test of the equipment. 3.2 INSTALLATION AND START-UP A. Manufacturer’s representative shall be available to advise and assist the installation of the VFDs by the Contractor. B. Furnish the services of a competent manufacturer’s service representative from the factory of the VFD manufacturer who shall be experienced in the assembly and wiring of the VFD drive units of similar size and character. He shall direct the installation of the equipment and shall assist and advise with the electricians or other workmen who are performing the actual work of installing the VFD drive units. He also shall assist in the adjustment and testing of the equipment. C. Adjust the calibration of protective relays/breakers according to the protective device coordination study (provided by others) and test the settings. Prepare a card index for the relays, the settings, the test results and marked thereon, and submit to the Owner. D. Time spent on the job by the service representative shall be adequate for performing the above functions. E. All costs (travel expenses, testing equipment, etc.) required for testing and start-up shall be the responsibility of the equipment manufacturer/Contractor. 3.3 TRAINING A. The Contractor shall provide a training session for the Owner’s representatives at the jobsite or other office location chosen by the Owner. Each eight-hour training session shall be broken up into two segments each of 4-hours with a 15-minute break every two hours. Lunch break will be one hour. Training sessions shall be scheduled and coordinated with the Owner. B. Training sessions shall be conducted by VFD manufacturer personnel. C. Training shall be for all members of the Owner's staff discretion. D. Supplier shall submit a training outline and manual of training course material for Owner’s/Engineer’s review and comment a minimum of 4 weeks before training is to take place. E. Instruct the operating and maintenance personnel in principle of operating of all major devices and the care and maintenance of components included in the VFD drive units, and BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Variable Frequency Drives 26 29 23 - 12 troubleshooting for a period of not less than one (1) eight (8) hour day. Coordinate with Owner for exact requirements. Provide three-ring binders to participants complete with copies of drawings and other course material covered. F. All costs (travel expenses, testing equipment, etc.) required for the training shall be the responsibility of the equipment manufacturer/contractor. 3.4 FIELD QUALITY CONTROL A. Testing, checkout and start-up of the VFD equipment shall be performed under the technical direction of the manufacturer's field service Engineer from the Factory of the VFD manufacturer. Under no circumstances are any portions of the drive system to be energized without authorization from the field service Engineer. B. Manufacturer's Field Service: Engage a factory-authorized service representative to perform the following. Perform the following field tests and inspections and prepare test reports. 1. Inspect controllers, wiring, components, connections, and equipment installation. Test and adjust controllers, components, and equipment. 2. Assist in field testing of equipment (including pretesting and adjusting of solid-state controllers). 3. Report results in writing. 4. Perform each electrical test and visual and mechanical inspection, except optional tests, stated in NETA ATS. Certify compliance with test parameters. 5. Correct malfunctioning units on-site, where possible, and retest to demonstrate compliance; otherwise, replace with new units and retest. 6. A copy of all tests and checks performed in the field, complete with meter readings and recordings, where applicable, shall be submitted to the Engineer and Owner as an official submittal. C. The VFD manufacturer or manufacturer representative shall submit a written Equipment Installation Report certifying the equipment is properly installed and has been operated under all operating conditions and is operating under all operating conditions and is operating satisfactorily per the requirements of the specification. D. Provide for the Engineer's review a complete list of test procedures, standards, equipment and calibration reports of the measuring and testing equipment used. E. Any deficiencies with regard to these specifications shall be corrected by the manufacturer at no expense to the Owner. Prior to any corrective action, a plan of correction shall be submitted to the Engineer for approval. F. During start-up the VFD manufacturer’s representative shall coordinate with the motor supplier for the optimum carrier frequency to operate the VFD at to keep the audible noise of the motor to a minimum. The VFD manufacturer shall also take into account dv/dt to reduce the stresses imposed on the motor windings and efficiency of the drive. G. For Final O&M manual, the Manufacturer shall provide a hard copy of the final VFD set points be provided and revised control schematics including any changes to control schematic made during start up. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Variable Frequency Drives 26 29 23 - 13 3.5 SPARE PARTS A. The following spare parts of the type and size furnished shall be provided: 1. Ten of each type of power and control fuse rated 600V or less. 2. One spare relay and timer of each type. 3. One of each fan or blower installed. 3.6 CLEAN AND ADJUST 1. The manufacturer shall furnish sufficient touch-up paint of the same type and color used at the factory to repair damages incurred in installation. Perform touch up painting to achieve the original paint thickness, quality, and appearance. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Low Voltage Variable Frequency Drives 26 29 23 - 14 ATTACHMENT A SUBMITTAL DATA SHEET FOR 16381 LOW VOLTAGE VARIABLE FREQUENCY DRIVES Submit the following data with the Shop Drawing submittal: Item No. Description For: VFD - RASxx 1 Manufacturer Make and Model (series): 2 Total Equipment Dimensions (inches)/unit: Width x Depth x Height _________W x _________D x _________H 3 Total Weight (lbs.)/unit: 4 VFD Efficiency @80% Load 5 VFD Efficiency @100% load 6 True Power Factor @25% Load 7 True Power Factor @50% Load 8 True Power Factor @75% Load 9 True Power Factor @100% Load 10 Heat Loss (Watts) per unit END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Lightning Protection for Structures 26 41 13-1 SECTION 26 41 13 - LIGHTNING PROTECTION FOR STRUCTURES PART 1 GENERAL 1.1 WORK INCLUDED A. Furnish labor, design, materials, equipment and incidentals necessary to install a complete lightning protection system for the expansion of the Plant in accordance with UL 96A, NFPA 780. Lightning protection system shall be tied to the existing and modified grounding system at the site. Contractor will be required to locate grounding around the treatment structure identified below and provide additional grounding as indicated on the plans. B. Lightning protection shall be installed for flocculation/sedimentation basin, and raw water head tank 1 and 2. The operations building of the structure currently has lighting protection that may required modifications to incorporate the rest of the structure (existing and proposed) to include flocculation/sedimentation basin. Existing and proposed light poles on the structure shall be included as part of the lighting protection system. 1.2 QUALITY ASSURANCE A. The system furnished under this specification shall be the standard product of a manufacturer regularly engaged in the production of lightning protection systems and shall be the manufacturer's latest approved design. Lightning protection supplier and installer shall be a certified installer. B. Listing of the manufacturer in the lightning protection section of the current edition of Underwriters' Laboratories, Inc., Electrical Construction Materials List will be accepted as compliance with this requirement. C. All materials shall be copper and bronze and of the size, weight and construction to suit the application where used in accordance with UL, NFPA, NEC code requirements for this type structure and as per manufacturer's recommendations. Class I sized components may be utilized on roof levels 75 feet and below in height. Class II sized components are required for roof levels over 75 feet in height. 1.3 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittal Procedures”, and shall include: 1. Shop Drawings a. Specifications b. Catalog Sheets for All Products Provided c. Shop drawings showing type, size and location of all equipment, grounds, cable routings, details, etc. 2. Continuity Test Report 3. Copy of U.L. Master Label for the Facility BCRUA - Phase 1D WTP Expansion Issued for Bid Lightning Protection for Structures 26 41 13-2 1.4 STANDARDS AND REFERENCES A. Refer to Section 26 05 00, “Common Work Results for Electrical”, for all standards which apply to this section. NFPA 780 Standard for the Installation of Lightning Protection Systems UL 96A Standard for Installation Requirements for Lightning Protection Systems LPI 175 Lightning Protection Institute Standard of Practice PART 2 PRODUCTS 2.1 MATERIALS A. Materials used in connection with the installation of the lightning protection systems shall be approved for lightning protection systems by the Underwriters' Laboratories, Inc. No combination of materials shall be used that form an electrolytic couple of such a nature that corrosion is accelerated in the presence of moisture unless moisture is permanently excluded from the junction of such metals. When unusual conditions exist which would cause deterioration or corrosion of conductors, conductors with suitable protective coatings or oversize conductors shall be used. If a mechanical hazard is involved, the conductor size shall be increased to compensate therefore, or suitable protection shall be provided. The conductors may be protected by covering them with molding or tubing preferably made of wood or nonmagnetic material. If metal tubing is used, the conductor shall be electrically connected to it at its upper and lower ends. B. All equipment used shall be new and of a design and construction to suit the application in accordance with UL 96A requirements and shall be so marked. 2.2 MANUFACTURED PRODUCTS A. CONDUCTORS - Copper conductors manufactured of copper grade ordinarily required for commercial electrical work generally designated as being 98 percent conductive when annealed. Down conductors of copper cable for installations other than towers shall weigh not less than 187.5 pounds per thousand feet and the size of any wire of this cable shall not be less than No. 17 AWG (0.045 inch). Down conductors shall be tinned. The thickness of any copper ribbon or strip shall be not less than No. 16 AWG (0.051 inch). B. AIR TERMINALS - Air terminals shall be tapered to a blunt point. The rod shall be of solid copper, 1/2 inch in diameter. Air terminals and support shall be designed over 24 inches to handle a 75 pound per square foot wind load. All air terminals shall be supported by a suitable brace, with guide(s) not less than one-half the height of the air terminal. Air terminals shall be located in accordance with the requirements of NFPA 780 and UL 96A. Air terminals shall extend at least ten inches above the object or area they are intended to protect. Air terminals shall be placed around the perimeter of flat or gently sloping roofs at intervals not exceeding 20 feet. C. FASTENERS - Fasteners shall be of the same material as the conductor base material or bracket being fastened, or other equally corrosion resistant material. Galvanized or plated materials shall not be used. BCRUA - Phase 1D WTP Expansion Issued for Bid Lightning Protection for Structures 26 41 13-3 D. FITTINGS - Fittings/bonding devices, cable splicers, and miscellaneous connectors shall be suitable for use with the installed conductor and shall be copper, bronze or aluminum with bolt pressure connections to the cable. Cast or stamped crimp type fittings shall not be used. E. Aluminum material may be used where the installation of dissimilar metals creates problems. The Contractor shall field verify all materials involved in the total installation and shall install system in accordance with all applicable NFPA and U.L. codes and standards. PART 3 EXECUTION 3.1 INSTALLATION A. The Contractor’s shop drawings shall indicate the extent and general arrangement of the lightning protection system. If any departures from the Contractor’s shop drawings are deemed necessary by the Contractor, details of such departures and the reasons therefore shall be submitted to the Engineer for approval. No such departures shall be made without the prior written approval of the Engineer. Lightning protection systems for all applications shall conform to National Fire Protection Association Code No. 780 and the NEC, whichever is more stringent. B. Installation shall be performed by a certified master installer. Installer shall provide an Underwriters' Laboratories Master Label for the facilities. C. Air terminals shall be provided on the highest projections and at intervals not exceeding 20 feet along the perimeter top surface. Air terminals shall extend at least 10 inches above the object or area that they are intended to protect. Air terminals shall be connected to the lightning protection system when specifically authorized by the Engineer. D. Roof and down conductors shall be stranded and shall meet the requirements given in NFPA 780. Roof and down conductors shall maintain a horizontal or downward course. No bend in a roof or down conductor shall form an included angle of less than 90 degrees, nor shall it have a bend radius of less than eight inches. Conductors shall be routed external to buildings and six feet or more from power or signal conductors. Down conductors shall be routed outside of any structure and shall not penetrate or invade that structure. All down conductors except one may be provided with a screw type connector as described in UL 96 where lightning protection system testing may be required. Down connectors shall be supported from and secured to the building exterior using one hole straps of copper or bronze at maximum intervals of three feet. E. Guards shall be provided for down conductors located in or next to driveways, walkways or other areas where they may be displaced or damaged. Guards shall extend at least six feet above and one foot below grade level. Guards shall be metal pipe. Metal guards shall be bonded to the down conductor at both ends. Bonding jumpers shall be of the same size as the down conductor. Crimp type fittings shall not be used. F. Metallic bodies, on or below roof level, that are subject to induced charges from lightning include exhaust fans, radio towers, HVAC units, ladders, railings, antennas, roof drains, plumbing, vents, metal coping, metal flashing, gutters, downspouts, small metal wall vents, door and window frames, metal balcony railings, and in general any isolated metallic body within six feet of an exposed lightning protection system element. When these metallic bodies have a metal thickness of 3/16 inch or greater, they shall be bonded to the nearest main lightning BCRUA - Phase 1D WTP Expansion Issued for Bid Lightning Protection for Structures 26 41 13-4 protection system conductor with UL approved fittings and conductors meeting the requirements of NFPA 780. These bonding fittings shall provide surfaces of not less than three square inches. Provisions shall be made to prevent corrosive effects introduced by galvanic action of dissimilar metals at bonding points. If the metal parts of these units are less than 3/16 inch thick, additional approved air terminals, conductors and fittings, providing a two way path to ground from the air terminals shall be installed. G. If metallic, the mast of roof mounted antennas and obstruction lightning shall be bonded to the nearest roof or down conductor using UL approved fittings and conductors. The bonding jumpers shall be of the same size and material as the roof or down conductor to which they are connected. Provide as a minimum a path to ground at each corner of the building. H. Aluminum material may be used where the installation of dissimilar metals creates problems. The Contractor shall field verify all materials involved in the total installation and shall install system in accordance with all applicable NFPA and U.L. codes and standards. I. The lightning protection system for the concrete storage tanks shall consist of installing air terminals at 20 foot intervals along the perimeter top surface of the tank and anywhere else on the top of the tank that is required by UL, NFPA and LPI. Air terminals shall extend at least 10 inches above the tank. Air terminals shall be connected together with a cable ring conductor. “Down” conductors shall extend from the cable ring conductor down the side of the tank to the earth connecting to the ground rods or ground electrode plates. 3.2 FIELD QUALITY CONTROL A. The lightning protection system will be inspected by the Engineer to determine conformance with the requirements of this specification. No part of the system shall be concealed until so authorized by the Engineer. B. The Contractor shall establish and maintain quality control for the “Lightning Protection System” installation to assure compliance with contract requirements, and shall maintain records of his quality control for all construction operations. A copy of these records and Contractor tests, as well as records of corrective action taken, shall be furnished to Owner’s Representative, as directed by the Engineer. C. Contractor shall obtain an Underwriters' Laboratories Master Label for the facility. 1. Upon completion, an application shall be made to the Underwriters Laboratories, Inc. for inspection and certification. 2. Cost for UL inspection and associated costs to obtain the UL Master Label shall be paid for by the Contractor. D. Testing of Continuity of all Conductors - A copy of these records and tests, as well as the records of corrective action taken, shall be furnished to Owner’s Representative, as directed by the Engineer. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Lighting 26 50 00-1 SECTION 26 50 00 - LIGHTING PART 1 GENERAL 1.1 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install light fixtures, complete with lens, accessories, and other incidentals. Electrical work shall be in accordance with Section 26 05 00, “Common Work Results for Electrical”. 1.2 QUALITY ASSURANCE A. ACCEPTABLE MANUFACTURERS 1. Acceptable manufacturers of light fixtures and related components are noted on the drawings. 1.3 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, “Submittals Procedures” and shall include Shop Drawings: 1. Refer to the Lighting Fixture Schedule on drawings for the manufacturer and model number for each type of fixture. Submittals with alternate manufacturers than those listed in the lighting fixture schedule will not be reviewed and will be returned without review. 2. Bill of Material 3. Product data sheets for each fixture type: a. Product data sheets shall be marked for each fixture type, arranged in the order of the fixture designation. b. Product data for fixtures, lamps, ballasts, drivers and emergency lighting units. c. Outline drawings indicating dimensions and principal features of the fixture. d. Electrical ratings and photometric data provided by certified laboratory tests for the fixture and lamps. e. Provide data on LED Fixture indicating it is rated for maintained 70% lumen output at 60,000 hours. 1.4 DELIVERY AND STORAGE A. Ship light fixtures inside protective cartons and keep packaged until installed. B. Store poles on decay-resistant-treated skids at least 12 inches above grade and vegetation. Support poles to prevent distortion and arrange to provide free air circulation. C. Retain factory-applied pole wrappings on metal poles until right before pole installation. For poles with nonmetallic finishes, handle with web fabric straps. 1.5 JOB CONDITIONS A. Provide special mounting, enclosures and fire-safing, as required by the authorities having jurisdiction so that the integrity of the U.L. listed ceiling assembles is maintained. BCRUA - Phase 1D WTP Expansion Issued for Bid Lighting 26 50 00-2 B. Provide U.L. labels where fixtures are subject to moisture. Provide DL or WL label on fixtures required for the location. C. Contractor shall verify voltages with ballasts and power supplies prior to ordering fixtures. 1.6 WARRANTY A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or replace products that fail in materials or workmanship; that corrode; or that fade, stain, perforate, erode, or chalk due to effects of weather or solar radiation within specified warranty period. Manufacturer may exclude lightning damage, hail damage, vandalism, abuse, or unauthorized repairs or alterations from special warranty coverage. 1. Manufacturer shall warrant the equipment furnished under this specification for a period of two (2) years from final completion, against defects in materials and workmanship and operational failure. PART 2 PRODUCTS 2.1 MATERIALS A. LED DRIVERS AND LAMPS: Drivers and LED lamps shall be integral to the fixture. The fixture shall be rated for operating temperatures of -40°C to +60°C, UL wet location rated with frosted impact rated glass lens. Fixture shall be rated for maintained 70% lumen output at 60,000 hours. B. POLES AND SUPPORT COMPONENTS: 1. Luminaire Attachment Provisions: Comply with luminaire manufacturers' mounting requirements. Use stainless-steel fasteners and mounting bolts, unless otherwise indicated. 2. Mountings, Fasteners, and Appurtenances: Corrosion-resistant items compatible with support components. a. Materials: Shall not cause galvanic action at contact points. b. Anchor Bolts, Leveling Nuts, Bolt Caps, and Washers: Hot-dip galvanized after fabrication, unless stainless-steel items are indicated. c. Anchor-Bolt Template: Plywood or steel. PART 3 EXECUTION 3.1 INSTALLATION A. Provide the lighting fixtures, as specified and scheduled on the plans. If a type designation is omitted, verify the fixture selection with the Engineer before installation. B. Check the architectural finishes and provide fixtures with proper trim, frames, support hangers and other hardware required to coordinate with the proper finishes, regardless of the specified or scheduled catalog number, prefixes and suffixes. C. Test and aim flood lights, when dark outside to provide a uniform and widespread, illuminated area. Direct units as indicated or instructed by the Engineer to prevent objectionable glare. BCRUA - Phase 1D WTP Expansion Issued for Bid Lighting 26 50 00-3 D. Furnish and install a complete exterior lighting control system, as indicated on the plans. Provide materials and equipment to properly interface timing devices and photocells with relays and contactors so that a complete and satisfactory operating system is rendered. 3.2 CLEAN AND ADJUST A. Immediately before final inspection, clean all fixtures, inside and out, including plastics and glassware. Adjust all trim to properly fit adjacent surfaces. Replace broken or damaged parts. Lamp and test all fixtures for electrical, as well as, mechanical operation. 3.3 SPARE PARTS A. LED Driver: Furnish at least one of each type. B. Globes and Guards: Furnish at least one of each type. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Topsoil 31 05 13 - 1 SECTION 31 05 13 - TOPSOIL PART 1 GENERAL 1.1 SUMMARY A. Description: This item shall consist of preparing the ground surface for topsoil application, removing topsoil from designated stockpiles or areas to be stripped on the site or from approved sources off the site, and placing and spreading the topsoil on prepared areas in accordance with this specification at the locations shown on the Drawings or as directed by the Engineer. B. Section Includes: 1. Topsoil materials. C. Related Sections: 1. Section 31 10 00 – Site Clearing: Excavating topsoil. 2. Section 31 23 10 – Structural Excavation and Backfill: Structure excavation. 3. Section 31 23 17 – Trenching: Trenching and backfilling for utilities. 4. Section 31 23 23 – Fill: General construction area backfilling. 5. Section 32 91 19 – Landscape Grading: Finish grading with topsoil to contours. 1.2 REFERENCES A. ASTM International: 1. ASTM D2487 - Standard Classification of Soils for Engineering Purposes (Unified Soil Classification System). 1.3 SUBMITTALS A. Section 01 33 00 - Submittal Procedures. B. Samples: Submit, in air-tight containers, 10 lb sample of each type of fill to testing laboratory. C. Materials Source: Submit name of imported materials source. 1.4 QUALITY ASSURANCE A. Furnish topsoil material from single source throughout the Work, unless directed otherwise by Engineer. PART 2 PRODUCTS 2.1 TOPSOIL MATERIALS A. Topsoil: 1. This material shall consist of approved topsoil material and shall be clean, friable, loamy soil capable of supporting plant life. BCRUA - Phase 1D WTP Expansion Issued for Bid Topsoil 31 05 13 - 2 2. This material can be excavated and reused material from on-site sources or imported from an approved off-site source. 3. Reasonably free of roots, rocks larger than 2 inches in diameter, subsoil, debris, weeds, and foreign matter. 4. Acidity range (pH) of 5.5 to 7.5. 5. Containing minimum of 4 percent and maximum of 25 percent organic matter. 6. Conforming to ASTM D2487 - Standard Classification of Soils for Engineering Purposes (Unified Soil Classification System). Group Symbol OH or PT. 7. Limit decaying matter to 10 percent of total content by volume. 2.2 SOURCE QUALITY CONTROL A. Section 01 40 00 - Quality Requirements. B. When tests and/or observations indicate materials do not meet specified requirements, change material and retest. C. Furnish materials of each type from same source throughout the Work, unless otherwise approved by Engineer. Off-site borrow sources shall be approved by the Engineer. PART 3 EXECUTION 3.1 EXCAVATION A. Perform as specified in Section 31 10 00 – Site Clearing. 3.2 STOCKPILING A. Stockpile materials at locations designated or approved by Engineer. B. Stockpile in sufficient quantities to meet Project schedule and requirements. C. Separate differing materials with dividers or stockpile apart to prevent mixing. D. Stockpile topsoil to only a height which yields safe slope stability. E. Prevent intermixing of soil types or contamination. F. Direct surface water away from stockpile site to prevent erosion or deterioration of materials. 3.3 STOCKPILE CLEANUP A. Remove stockpile, leave area in clean and neat condition. Grade site surface to prevent free standing surface water. B. When borrow area is indicated, leave area in clean and neat condition. Grade site surface to prevent free standing surface water. BCRUA - Phase 1D WTP Expansion Issued for Bid Topsoil 31 05 13 - 3 3.4 PLACING TOPSOIL A. Eliminate uneven areas and low spots. B. Remove debris, roots, branches, and stones in excess of 2 inches in size. C. Scarify surface to depth of 4 inches, or as indicated on the Drawings, where topsoil is scheduled. D. Place topsoil in areas where seeding and/or sodding is required to nominal depth of four inches (plus or minus ½ inch), or as indicated on the Drawings. For areas that will receive sod, leave topsoil low. Place topsoil during dry weather. E. Fine grade topsoil to eliminate rough or low areas. Maintain profiles and contour of subgrade. F. Remove roots, weeds, rocks, and foreign material while spreading. G. Manually spread topsoil close to plant material, structures, water and wastewater appurtenances, concrete paving, and curbs to prevent damage. H. Lightly roll placed topsoil. I. Remove surplus topsoil from site. J. Leave stockpile area and site clean and raked, ready to receive seeding or sodding. K. Prohibit construction traffic over topsoil. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Site Clearing 31 10 00 - 1 SECTION 31 10 00 - SITE CLEARING PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. Removing and disposing of surface debris, rubbish, and other objectionable materials. 2. Removing and disposing of designated building slabs, paving, curbs, driveways, miscellaneous stone, brick, concrete, sidewalks, drainage structures, headwalls, safety end treatments, manholes, inlets, and abandoned railroad tracks. 3. Removing and disposing of designated fencing and signage. 4. Removing and disposing of designated trees, shrubs, and other plant life. 5. Removing and disposing of designated abandoned water and wastewater utilities and septic tanks. 6. Herbicide treatment 7. Excavating topsoil. B. Related Sections: 1. Section 31 05 13 – Topsoil: Soils for fill. 2. Section 31 23 10 – Structural Excavation and Backfill: Structure excavation. 3. Section 31 23 17 – Trenching: Trenching and backfilling for utilities. 4. Section 31 23 23 – Fill: General construction area backfilling. 5. Section 32 91 19 – Landscape Grading: Finish grading with topsoil to contours. 1.2 SUBMITTALS A. Section 01 33 00 - Submittal Procedures. B. Product Data: Submit data for herbicide. Indicate compliance with applicable codes for environmental protection. 1.3 QUALITY ASSURANCE A. Conform to applicable code for environmental requirements, disposal of debris, burning debris on site, and use of herbicides. B. Herbicide: 1. License Requirements: Possess either a commercial pesticide applicator license from the Texas Department of Agriculture, or a Texas Structural Pest Control Service License. Provide documentation of license before beginning work. Conduct on-site supervision of all mixing, transporting, handling, spraying, and disposal of materials with licensed personnel. 2. Records: Document work in accordance with all Federal, State, and Local regulations. Submit a copy of the herbicide records on the next business day following application. Submit a final copy of all the herbicide application records upon completion of the work. BCRUA - Phase 1D WTP Expansion Issued for Bid Site Clearing 31 10 00 - 2 PART 2 PRODUCTS 2.1 MATERIALS A. Herbicide: Furnish herbicide materials in accordance with Section 15 of the 2017 TxDOT Herbicide Operations Manual. B. Pathfinder II, Transline, & Capstone are acceptable products that can be used in conjunction with each other. PART 3 EXECUTION 3.1 EXAMINATION A. Verify existing conditions before starting work. B. Verify existing plant life designated to remain is tagged or identified. C. Identify spoils site for placing removed materials. 3.2 PREPARATION A. Call Texas 811 service at 800-344-8377 not less than three working days before performing Work. 1. Request underground utilities to be located and marked within and surrounding construction areas. B. Prior to commencing this work, all erosion control and environmental measures shall be in place. 3.3 PROTECTION A. Locate, identify, and protect structures and utilities indicated to remain, from damage. B. Areas within the construction limits or as indicated shall be cleared of all trees, stumps, brush, etc. as defined above; except trees or shrubs indicated for preservation which shall be carefully trimmed as directed, and shall be protected from scarring, barking or other injuries during construction operations. Exposed ends of pruned limbs or scarred bark shall be pruned, trimmed and treated with an approved asphaltic material within 24 hours of the pruning or injury. C. Locate, protect, and maintain benchmarks, monuments, control points, and project engineering reference points. Re-establishment of disturbed or destroyed items shall be by a Registered Professional Land Surveyor (licensed in the state of Texas), at no additional cost to Owner. D. Construction equipment shall not be operated within the drip line of trees, unless indicated. Construction materials shall not be stockpiled under the canopies of trees. No excavation or embankment shall be placed within the drip line of trees until tree wells are constructed. BCRUA - Phase 1D WTP Expansion Issued for Bid Site Clearing 31 10 00 - 3 3.4 CLEARING A. Strip and remove from construction area all topsoil, organics, and vegetation to a minimum depth of 6 inches below the existing natural ground surface. B. Remove trees and shrubs within the construction limits unless noted otherwise in the Drawings. Remove stumps, main root ball, and root system. Holes remaining after the removal of all obstructions, objectionable materials, trees, stumps, etc. shall be backfilled with Select Fill and compacted in accordance with Section 31 23 23 - Fill. C. Clear undergrowth and deadwood, without disturbing subsoil. D. Apply herbicide to remaining stumps to inhibit growth. 3.5 REMOVAL A. Remove surface debris, rock, and extracted trees, shrubs and other plant life from site, or as indicated on Drawings. B. Remove designated building slabs, paving, curbs, driveways, miscellaneous stone, brick, concrete, sidewalks, drainage structures, headwalls, safety end treatments, manholes, inlets, and abandoned railroad tracks as indicated on Drawings. Neatly saw cut edges at right angle to surface. C. Remove designated fencing and signage. D. Remove abandoned water and wastewater utilities and septic tanks. Indicated removal termination point for underground utilities on Record Documents. E. Continuously clean-up and remove waste materials from site. Do not allow materials to accumulate on site. F. Do not burn or bury materials on site. Leave site in clean condition. 3.6 HERBICIDE TREATMENT A. Season: Spray herbicide during active growing periods unless otherwise approved. B. Equipment: Furnish all equipment. 1. Broadcast application: furnish self-propelled equipment tractor mounted or pulled spray rigs with a low center of gravity that allows safe traverse on a maximum 3:1 slope. Provide equipment capable of making uniform broadcast application calibrated at a rate between 20 and 40 gallons per acre (GPA). 2. Basel Bark and Cut Tree applications: Furnish sprayers with low volume spray tips (spray system 5500 adjustable spray tip X-1 or X-2, or approved equivalent). 3. Personal Protection Equipment: Follow the manufacturer’s label requirements for personal protection of employees. C. Work Methods: Apply approved herbicide in accordance with the manufacturer’s label recommendations, as shown on the drawings or as approved. Add surfactant and blue dye BCRUA - Phase 1D WTP Expansion Issued for Bid Site Clearing 31 10 00 - 4 marker at the manufacturer’s recommended rate unless otherwise approved. Prepare herbicide solution to the rates shown on the drawing using procedures on the herbicide container label. Dispose of empty containers and unused chemical mixtures in accordance with the label directions and local, state, and federal regulations. Cease spraying operation immediately when wind or other environmental conditions cause off-target spray drift, leaves are wet, or rainfall is imminent. An inspection of the treated areas will be made not less than 14 days and no later than 30 days after the application. Re-treat areas in which the undesirable vegetation has not be controlled for no additional compensation. Repair and replace any damaged desirable vegetation or erosion as a result of negligent applications. 1. Broadcast application: spray undesirable vegetation by broadcasting with spray nozzles at the desired rate. Ensure nozzles spray consistent across the area being covered. 2. Basal Bark treatment: apply herbicide solution with a low-volume, low pressure sprayer which thoroughly wets the lower 12-15 in. of stems on all sides, including the root collar area, but not to the point of run-off. Perform application at any time throughout the year, except when the stumps are wet from rainfall or dew prevents spraying to the base of the plant. 3. Cut-stump treatment: cut plants parallel to the ground, not to exceed 2 in. above the ground line. Apply the herbicide solution with a low-volume, low-pressure sprayer which thoroughly wets the area adjacent to the cambium and bard around the entire circumference of the stump. Thoroughly wet the sides of the stump, but not to the point of run-off. Make the herbicide application within 1 hr. from the time each plant is cut. Dispose of removed materials and debris at appropriate off-site locations in accordance with local, state, and federal requirements. 3.7 TOPSOIL EXCAVATION A. Excavate topsoil from areas to be further excavated, relandscaped, regraded, or within the construction limits of a structure without mixing with foreign materials for use in finish grading. B. Do not excavate wet topsoil. C. Stockpile in area designated on site to a height which yields safe slope stability and protect from erosion. D. Remove excess topsoil not intended for reuse from project. E. Remove excavated materials not meeting specified requirements for topsoil from project. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Structural Excavation and Backfill 31 23 10 - 1 SECTION 31 23 10 STRUCTURAL EXCAVATION AND BACKFILL PART 1 GENERAL 1.1 SUMMARY A. This Section specifies excavation, backfill materials, backfill placement and compaction procedures, and other construction activities incidental to project structures. B. The Specification does not include excavation and backfilling for utility lines, manholes, valve boxes, and other minor structures related to utility lines. Refer to Section 31 23 17 “Trenching, Backfilling and Compacting for Utilities” for utility line related excavation and backfill. 1.2 QUALIFICATION ASSURANCE A. Testing Agency: An independent testing agency that is AASHTO accredited. 1.3 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 “Submittal Procedures” and shall include: 1. Provide list of compaction equipment to be used. 2. Backfill material classifications: For each soil or aggregate backfill material provide a certification by the testing agency. 3. Compaction Test Results: Submit test results within 24 hours of successful testing. 1.4 STANDARDS A. Material classification, placing, and testing shall be in compliance with the latest revisions of the following standards, unless otherwise noted in the Contract Documents. 1. ASTM International (ASTM) Standards: ASTM D698 Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/ft3 (600 kN-m/m3)) ASTM D1556 Standard Test Method for Density and Unit Weight of Soil in Place by Sand-Cone Method ASTM D2487 Standard Practice for Classification of Soils for Engineering Purposes (Unified Soil Classification System) ASTM D4253 Standard Test Methods for Maximum Index Density and Unit Weight of Soils Using a Vibratory Table ASTM D6938 Standard Test Methods for In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods (Shallow Depth) B. Any other testing required by these specifications and not specifically referenced to a standard shall be performed under ASTM or other appropriate standards as designated by the Engineer. BCRUA - Phase 1D WTP Expansion Issued for Bid Structural Excavation and Backfill 31 23 10 - 2 1.5 DELIVERY AND STORAGE A. Deposit material to be used for backfill in storage piles at points convenient for handling of the material during the backfilling operations and as required to prevent contamination with other materials. 1.6 JOB CONDITIONS A. Review subsurface investigations. A limited subsurface investigation has been performed by Schnabel Engineering. A geotechnical memorandum from that investigation is a part of the Construction Documents for information purposes only. The precise profile of soil and rock strata beneath this Site is not known. B. Review the Site and determine the conditions which may affect the structural excavation, prior to the commencement of the excavation. PART 2 PRODUCTS 2.1 BACKFILL MATERIALS A. Structural Fill: Structural fill backfill shall be as indicated on Drawings. B. Lean Concrete Backfill: In accordance with Section 03 30 00 “Cast-In-Place Concrete.” C. Topsoil: Topsoil shall be as specified in Section 31 05 13, “Topsoil.” 2.2 COMPACTION EQUIPMENT A. Compaction equipment shall conform to the following requirements. 1. Heavy Compaction Equipment: a. Tamping Compactor: Steel wheels with rectangular face, tapered pads that prevent fluffing the soil. Compactor shall be equipped with cleaning fingers to remove soil accumulation from between pads. 1) Operating Weight, Minimum: 30,000 pounds. 2) Travel Speed, Maximum: 10 mph. b. Pneumatic Rollers: Minimum eight-tire, pneumatic roller with a modular ballast system and flexible operating weight, and which will equally distribute load between tires to provide compaction uniformity. 1) Operating Weight Range: As required for specified compaction, 36,000 to 50,000 pounds. 2) Tire Pressure Range: 80 psi to 100 psi. 3) Travel Speed, Maximum: 10 mph. 4) Distance Between Edges of Adjacent Tires: Less than 50 percent of tire width. c. Vibratory Rollers: Smooth drum roller with 90 percent of the static weight transmitted through a single drum. 1) Static Weight, Minimum: 20,000 pounds 2) Travel Speed: 5 mph for self-propelled; 2 mph for towed. 3) No backing up of the vibratory roller will be allowed on an embankment unless the vibrating mechanism is capable of being reversed. BCRUA - Phase 1D WTP Expansion Issued for Bid Structural Excavation and Backfill 31 23 10 - 3 2. Hand-Directed Compaction Equipment: Use power tampers and vibratory plate compactors in areas where it is impracticable or unacceptable to use heavy compaction equipment. PART 3 EXECUTION 3.1 PREPARATION A. Clear and grub the area to be excavated prior to the start of excavation. Remove the surficial vegetation, waste and soils to a minimum depth of 12 inches. Depth of removal shall not be less than that required to remove trees, shrubs, stumps, roots, and other organic material above and below ground from within the area to be excavated. Ensure below grade organic material is removed to a minimum depth of 18 inches below bottom of footing/structure. 3.2 EXCAVATION FOR FOUNDATIONS A. General: Excavate subgrade to the depth indicated on Drawings, +/- 0.1 feet tolerance Extend limits of the excavation beyond the perimeter of the foundations as indicated on the Drawings. 1. Exposed subgrade surfaces shall be level and of sound, stable material; free of mud, frost, snow, or ice. Testing agency or Owner’s representative shall confirm exposed subgrade is a suitable bearing material based on the Construction Documents. 2. Proof roll the exposed subgrade in accordance with TxDOT Item 216. Do not proof roll wet or saturated subgrades. 3. Where unsound or unstable material is uncovered, notify Owner’s representative Remove objectionable material and replace after approval is received from Owner’s representative. Replacement material shall be as indicated here unless otherwise indicated on Drawings: a. Rock subgrade replacement material: Lean concrete. b. Soil subgrade replacement material: Compacted structural fill. B. Excavation Safety: All excavations shall be in accordance with OSHA requirements. 3.3 WATER IN FOUNDATION EXCAVATIONS A. General: 1. Prevent water infiltration into foundation excavations. Remove standing water from excavation prior to placing concrete. If removal of standing water is not possible due to continuous water infiltration, then contact Owner’s representative for additional direction regarding placing concrete underwater. 2. Do not dewater a foundation excavation while placing concrete or for a period of at least 24 hours after concrete placement. B. Rock Foundation Subgrade: If rock material becomes weathered due to water infiltration, then remove weathered material and provide rock replacement material to restore foundation subgrade elevation. C. Soil Foundation Subgrade: If foundation subgrade becomes saturated do not disturb the subgrade. Wait for water to evacuate the subgrade and subgrade surface to adequately stiffen prior to placing concrete. If subgrade is disturbed, then wait until subgrade has dried out, excavate disturbed subgrade and provide replacement material as indicated above. BCRUA - Phase 1D WTP Expansion Issued for Bid Structural Excavation and Backfill 31 23 10 - 4 3.4 COMPACTED BACKFILL A. General: Backfill excavated spaces and areas not occupied by the permanent structure. 1. Backfill behind a retaining wall or basement-type wall shall not be placed until the concrete has reached its 28-day compressive strength or 7 days, whichever is longer. 2. Unless otherwise indicated on Drawings, structures with a top slab shall not backfilled until the top slab has been in place at least 4 days. 3. Structures with soil on opposing (opposite) sides shall be backfilled to prevent uneven loading of the structure – evenly raise backfill on opposing sides of the structure. The maximum differential backfill height between opposing sides is 1 foot. 4. Do not permit rollers to operate within 3 feet of structures. 5. Maximum Loose Lift Height: a. Heavy Compaction Equipment: 8 inches. b. Hand-Directed Compaction Equipment: 4 inches. 6. Previous Compacted Layer: If backfill placement occurs over a period of time greater than 24 hours, then scarify and recompact the previous day’s final compacted layer. a. Scarify and Recompact: 6-inch depth; adjust the moisture content; recompact. b. Saturated subgrades shall not be worked on until sufficiently dry and harden so as not to be rutted with compaction equipment. Scarify and recompact layers damaged by weather or construction equipment. B. Moisture: Prior to compacting backfill, mix and aerate or water the loose lift backfill material as necessary to adjust the moisture content and evenly distribute throughout. The material shall contain moisture within the limits specified below. 1. In accordance with ASTM D6938, determine the optimum moisture content for the maximum dry density. 2. Backfill moisture content shall be as indicated in Table 1, “Compacted Fill.” 3. Aggregate fill: Completely cohesionless materials, shall be at a moisture content which will allow use of the specified compaction equipment and consistent achievement of the specified density. C. Compaction: As required to achieve the specified density, increase the number of passes above the minimum specified and/or modify the weight of the equipment. 1. Determine the maximum dry density in accordance with ASTM D698 for cohesive soils and ASTM D4253 for cohesionless soils. Alternatively, use TEX-113-E as applicable. 2. Minimum number of passes for all compacted fill types: 8. 3. Cohesive Soils: A tamping compactor or tamping compactor followed by a pneumatic roller shall be used. 4. Cohesionless or low cohesive soils: A vibratory roller or vibratory plate compactors shall be required if the material is cohesionless or with less than 15 percent passing the No. 200 sieve. Confirm applicability of vibratory compaction equipment in the field. 5. Overlap passes a minimum of 1 feet for heavy compaction equipment and 50 percent of the baseplate width for hand-directed equipment. 6. Backfill density shall be as indicated in Table 1, “Compacted Fill.” Table 1: Compacted Fill Backfill Type Density1,2 Moisture Content3, 4 Comments Structural Fill 95% -2% to +2% N/A 1 The percentage indicated is the minimum required percentage of the maximum dry density as determined by the applicable ASTM. BCRUA - Phase 1D WTP Expansion Issued for Bid Structural Excavation and Backfill 31 23 10 - 5 2 Below Vehicular Pavement: Scarify to a depth of 8, moisture condition, and recompact to not less than 100 percent of the maximum dry density. 3 Range indicated is the acceptable tolerance with respect to the optimum moisture content. 4 Completely cohesionless materials, shall be at a moisture content which will allow use of the specified compaction equipment and result in consistent achievement of the specified density. 3.5 FIELD QUALITY CONTROL A. Owner is responsible for the costs involved in providing an approved testing agency to perform quality control testing of backfill operations and verification of subgrade bearing material. The testing laboratory shall make tests of in-place density and moisture in accordance with ASTM Standards previously mentioned in this Section. The testing agency shall monitor backfill operations continuously or at intervals acceptable to the Owner’s representative. It shall be the responsibility of the Contractor to notify the testing agency a minimum of 2 business days before backfill operations begin. 1. Unless noted otherwise, in-place density tests shall be conducted at a rate of one test per 3000 square feet for every lift. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Trench Safety Systems 31 23 15 - 1 SECTION 31 23 15 - TRENCH SAFETY SYSTEMS PART 1 GENERAL 1.1 SUMMARY A. Section Includes: Furnishing all equipment, materials and labor for a trench safety system meeting appropriate requirements established in Occupational Safety and Health Administration (OSHA) Safety and Health Regulations, 29 CFR Part 1926, OSHA Standards – Excavations; Final Rule, October 31, 1989. In the event of conflict of published and proposed rules, the more stringent requirement shall be used. B. Related Sections: 1. Section 03 30 00 – Cast-In-Place Concrete. 2. Section 31 23 10 – Structural Excavation and Backfill. 3. Section 31 23 17 – Trenching. 4. Section 31 23 23 – Fill. 1.2 UNIT PRICE - MEASUREMENT AND PAYMENT A. Trench Safety Implementation: 1. Basis of Measurement: Trench Safety Implementation shall be measured by the linear foot for the project. 2. Basis of Payment: Payment for Trench Safety Implementation shall be made at the unit price bid for “Trench Safety Implementation.” Payment for all work prescribed under this item shall be full compensation for the Trench Safety System including any additional excavation and backfill required, for furnishing, placing, maintaining and removing all shoring, sheeting, or bracing; for dewatering or diversion of water; for all jacking and jack removal; and for all other labor, materials, tools, equipment, and incidentals necessary to complete the work. a. Trench Safety Implementation – Per Linear Foot, Plan Quantity. 1.3 REFERENCES A. Federal Occupational Safety and Health Administration (OSHA) Standards – 29 CFR, Part 1926, Subpart P, as amended, including Proposed Rules published in the Federal Register (Vol. 52, No. 72) on April 15, 1987; Sections 1926-650 through 1926-653. B. Texas Legislature House Bill No. 662 and House Bill No. 665 with regard to Trench Safety Systems. 1.4 DEFINITIONS A. Trench: A trench shall be defined as a narrow excavation (in relation to its length) made below the surface of the ground. In general, the depth is greater than the width. 1.5 SUBMITTALS A. Section 01 33 00 - Submittal Procedures. BCRUA - Phase 1D WTP Expansion Issued for Bid Trench Safety Systems 31 23 15 - 2 B. Trench Safety Plan: Prior to construction the Contractor shall submit a trench safety system to the Engineer specifically for the construction of trench excavation. The trench safety system shall be in accordance with OSHA standards governing the presence and activities of individuals working in and around trench excavation. The trench safety system must be designed and sealed by a professional engineer registered in the State of Texas with professional experience in Soil Mechanics. The Contractor is responsible for obtaining borings and soil analysis as required for plan design. After receiving the trench safety system plans, the Engineer will forward a copy of the plan to the project inspector, to the Contractor and keep one file copy. The submittal is only for general conformance review with OSHA safety standards and the review does not relieve the Contractor or design professional of any or all construction means, methods, techniques and procedures. Any property damage, bodily injury or death that arises from use of the trench safety system or from the Owner’s failure to note exceptions to the system shall remain the sole responsibility of the Contractor. No trenching in excess of 5 feet below existing grade will be allowed until the plan is submitted. Any changes in the trench safety system after the initiation of construction will not be cause for extension of time or change order and will require the same review process. On some projects, the Owner may elect to provide preliminary soil information to the Contractors for bid purposes only and not as a substitute for required soil data for design use. The Owner assumes no liability nor makes any guarantees by the inclusion of any soil data. 1.6 QUALITY ASSURANCE A. Perform Work in accordance with OSHA Regulations, 29 CFR Part 1926, OSHA Standards. B. Maintain one copy of OSHA Standards on site. 1.7 QUALIFICATIONS A. Prepare Trench Safety Plan under direct supervision of Professional Engineer experienced in design of this Work and licensed in State of Texas. 1.8 COORDINATION A. Section 01 30 00 – Administrative Requirements: Coordination and project conditions. PART 2 PRODUCTS 2.1 TIMBER A. Trench sheeting materials shall be a minimum of 2 inches in thickness, solid and sound, free from weakening defects such as loose knots and splits. Shoring timber sizes shall not be less than that called for on the Trench Safety Plan. 2.2 STEEL SHEET PILING A. Steel sheet piling and steel for stringers and cross braces shall conform to ASTM A36 – Standard Specification for Carbon Structural Steel. BCRUA - Phase 1D WTP Expansion Issued for Bid Trench Safety Systems 31 23 15 - 3 2.3 TRENCH BOXES A. Portable trench boxes shall be constructed of steel conforming to ASTM A36 - Standard Specification for Carbon Structural Steel. Connecting bolts shall conform to ASTM A307 – Standard Specification for Carbon Steel Bolts, Studs, and Threaded Rod 60000 PSI Tensile Strength. Welds shall conform to requirements of AWS Specification D1.1 – Structural Welding-Steel. PART 3 EXECUTION 3.1 GENERAL A. Trench safety systems shall be constructed, installed and maintained in accordance with the design prepared by the Contractor’s registered Professional Engineer licensed to practice in the State of Texas to prevent death or injury to personnel or damage to structures in or near these trench excavations. Materials excavated from trench to be stored no closer to the edge of trench than 1/2 the depth of the trench. 3.2 INSTALLATION A. Timber Sheeting: Installed in accordance with detail shown on drawings. Drive timber sheeting to a depth below trench bottom as shown on Drawings. Size of uprights, stringers, and cross bracing to be in accordance with details shown on Drawings. Place cross braces in true horizontal position, spaced vertically, and secured to prevent sliding, falling or kickouts. B. Steel Sheet Piling: Steel sheet piling of equal or greater strength may be substituted for timber trench shoring shown on the drawings. Contractor to provide certification that steel sheet piling substituted provides equal or greater protection than timber trench shoring shown on drawings. Certification of steel sheet piling to be provided by registered Professional Engineer. Drive steel sheet piling to a minimum depth below trench bottom as recommended by Contractor’s registered Professional Engineer licensed to practice in Texas providing design. Place cross braces in true horizontal position, spaced vertically and secured to prevent sliding, falling or kickouts. C. Trench Boxes: Portable trench box to be substituted for timber trench shoring shown on Drawings shall be designed or the design checked by Contractor’s registered Professional Engineer licensed to practice in Texas. Design trench box to provide equal or greater protection than timber trench shoring shown on Drawings. Certification of the design of trench boxes shall be provided by Contractor prior to its use on project. In cases where top of portable trench box will be below to top of trench, the trench must be sloped to an angle greater than the angle of repose for the soil conditions existing on the project. In areas where sloped trench will affect the integrity of existing structures, Contractor to protect structures prior to sloping trench. D. Trench Jacks: When trench jacks are used for cross bracing and/or stringers, the Contractor shall provide certification by a registered Professional Engineer licensed to practice in Texas that the trench jacks provide protection greater than or equal to the timber cross bracing shown on Drawings. BCRUA - Phase 1D WTP Expansion Issued for Bid Trench Safety Systems 31 23 15 - 4 3.3 SUPERVISION A. Contractor shall provide competent supervisory personnel at each trench while work is in progress to ensure Contractor’s methods, procedures, equipment and materials pertaining to the safety systems in this item are sufficient to meet requirements of OSHA Standards. 3.4 MAINTENANCE OF SAFETY SYSTEM A. The safety system shall be maintained in the condition as shown on Drawings or as specified by the Contractor’s registered Professional Engineer licensed to practice in Texas. The Contractor shall take all necessary precaution to ensure the safety systems are not damaged during their use. If at any time during its use a safety system is damaged, personnel shall be immediately removed from the trench or excavation area and the safety system repaired. The Contractor shall take all necessary precautions to ensure no loads, except those included in the safety system design, are imposed upon the excavation. 3.5 REMOVAL A. Bed and backfill pipe to a point at least one foot above top of pipe prior to removal of any portion of trench safety systems. Bedding and backfill shall be in accordance to other applicable specification items. Backfilling removal of trench supports shall progress together from bottom of trench upward. Remove no braces or trench supports until all personnel have evacuated the trench. Backfill trench to within 4 feet of natural ground prior to removal of entire trench safety systems. 3.6 FIELD QUALITY CONTROL A. Section 01 40 00 – Quality Requirements. B. Inspection: Contractor shall make daily inspection of trench safety systems to ensure that the systems meet OSHA requirements. Daily inspection shall be made by competent personnel. If evidence of possible cave-ins or slides is apparent, all work in the trench shall cease until necessary precautions have been taken to safeguard personnel entering trench. Contractor shall maintain permanent record of daily inspections. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Trenching 31 23 17 - 1 SECTION 31 23 17 - TRENCHING PART 1 GENERAL 1.1 SUMMARY A. Description: This work shall include the furnishing of all labor, materials, tools, equipment and machinery necessary for clearing and removing from the site of the work wherever located, all obstructions, trees, stumps, brush, vegetation, woods and debris; and all earth, rock and other materials to be excavated; the removal of existing structures except where specifically paid for as separate contract pay items; the replacement of topsoil after backfilling is completed; the installation and operation of all pumping, bailing and draining necessary to keep the excavation free from seepage water, water from sewer, drains, ditches, creeks and other sources, and to provide for the uninterrupted flow of sewers and surface waters during progress of the construction; the satisfactory disposal of excess and unsuitable materials not required or which cannot be used for backfilling; compacting and refilling, after settlement of all excavated areas; the restoration of all streets, alleys, rights-of-way and other lands, private or public, damaged or occupied by the Contractor in the performance of the contract to the same (or improved) condition as they were prior to the beginning of the work. B. Section Includes: 1. Excavating trenches for utilities. 2. Embedment material. 3. Compacted fill from top of embedment to subgrade elevations. 4. Backfilling and compaction. C. Related Sections: 1. Section 03 30 00 – Cast-in-Place Concrete. 2. Section 31 23 10 – Structural Excavation and Backfill. 3. Section 31 23 15 – Trench Safety Systems. 4. Section 31 23 23 – Fill. 5. Section 31 23 24 – Flowable Fill. 6. Section 32 05 16 – Aggregates for Civil Site Improvements. 7. Section 32 11 23 – Flexible Base. 8. Section 32 91 19 – Landscape Grading. 1.2 MEASUREMENT AND PAYMENT A. Trenching: Measurement and payment shall be considered subsidiary to the pipe construction for which it pertains. 1.3 REFERENCES A. ASTM International: 1. ASTM D698 - Standard Test Method for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/ft3 (600 kN-m/m3)). 2. ASTM D2922 - Standard Test Method for Density of Soil and Soil-Aggregate in Place by Nuclear Methods (Shallow Depth). BCRUA - Phase 1D WTP Expansion Issued for Bid Trenching 31 23 17 - 2 3. ASTM D3017 - Standard Test Method for Water Content of Soil and Rock in Place by Nuclear Methods (Shallow Depth). 1.4 DEFINITIONS A. Utility: Any buried pipe, duct, conduit, or cable. 1.5 SUBMITTALS A. Section 01 33 00 - Submittal Procedures. B. Trench Safety Plan: A Trench Safety Plan, which describes sheeting, shoring, and bracing materials and installation required to protect excavations and adjacent structures and property shall be submitted in accordance with Section 31 23 15 – Trench Safety Systems. C. Product Data: 1. Acknowledgement that products submitted meet requirements of standards referenced. 2. Manufacturer’s installation instructions. D. Submit respective pipe or conduit manufacturer’s data regarding bedding methods of installation and general recommendations. E. Submit sieve analysis reports on all granular materials. F. Submit data for geotextile fabric (when specified) indicating fabric properties and manufacturing data; and construction methods. G. Materials Source: Submit name of imported fill materials suppliers. 1.6 QUALIFICATIONS A. Prepare Trench Safety Plan per Section 31 23 15 – Trench Safety Systems. 1.7 FIELD MEASUREMENTS A. Verify field measurements prior to construction. 1.8 COORDINATION A. Section 01 30 00 – Administrative Requirements: Coordination and project conditions. B. Verify Work associated with lower elevation utilities is complete before placing higher elevation utilities. BCRUA - Phase 1D WTP Expansion Issued for Bid Trenching 31 23 17 - 3 PART 2 PRODUCTS 2.1 MATERIALS A. Embedment Material: The type of bedding/embedment to be used for storm sewers, sanitary sewers or water mains shall be approved by the Engineer from the following and installed as shown on the Drawings and modified herein: 1. Coarse Aggregate Type A4 (Gravel for Trench Backfill) per Section 32 05 16 - Aggregates for Civil Site Improvements. 2. Flowable Fill per Section 31 23 24 – Flowable Fill. B. Concrete Encasement: Concrete encasement shall consist of lean concrete with a compressive strength of 1,500 psi per Section 03 30 00 – Cast-In-Place Concrete, Class E. C. Trench Backfill: 1. Backfill above embedment material (outside traffic areas): Excavated backfill material outside of traffic areas shall consist of an excavated material of gravel, fine rock cuttings, sandy loam, or clay having dimensions no greater than 2 inches, and compacted per applicable sections of this Specification. 2. Backfill above embedment material (beneath pavements): a. Coarse Aggregate Type A1 (Flexible Base) per Section 32 11 23 – Flexible Base and compacted as specified herein. 2.2 ACCESSORIES A. Geotextile Fabric: Non-biodegradable, woven or non-woven, from the following manufacturers: 1. U.S. Fabrics, Inc. 2. Alkzo Nobel Geosynthetic Co. 3. Huesker, Inc. 4. TC Mirafi. 5. Tenax Corp. 6. Tensar Earth Technologies, Inc. PART 3 EXECUTION 3.1 LINES AND GRADES A. Construct the trenches to lines and grades indicated on Drawings. 1. Engineer reserves right to make changes in lines, grades, and depths of utilities when changes are required for Project conditions. B. Use laser-beam instrument with a qualified operator to establish lines and grades. C. Submit electronic layout plans from the pipe manufacturer for review and approval at least 30 days in advance of any actual construction of the project. The Engineer will forward all comments of the review to the Contractor for revision. Revisions shall be made and forwarded to the Engineer for his acceptance. Prior to commencement of the Project, reviewed layout plans will be sent to the Contractor marked for construction. BCRUA - Phase 1D WTP Expansion Issued for Bid Trenching 31 23 17 - 4 D. Should the Contractor’s procedures not produce a finished pipe placed to grade and alignment, the pipe shall be removed and re-laid, and the Contractor’s procedures modified to the satisfaction of the Engineer. No additional compensation shall be paid for the removal and relaying of pipe required above. 3.2 PREPARATION A. Call Texas 811 service at 800-344-8377 not less than three working days before performing Work. 1. Request underground utilities to be located and marked within and surrounding construction areas. B. Identify required lines, levels, contours, and datum locations. C. Protect plant life, lawns, rock outcropping and other features remaining as portion of final landscaping. D. Protect bench marks, existing structures, fences, sidewalks, paving, and curbs from excavating equipment and vehicular traffic. E. Maintain and protect above and below grade utilities indicated to remain. F. Establish temporary traffic control and detours when trenching is performed in public right-of- way. Relocate controls and reroute traffic as required during progress of Work. 3.3 TRENCHING A. Site Preparation: The construction site shall be prepared for construction operations by the removal and disposal of all obstructions and objectionable materials from the designated construction area. Such obstructions and objectionable materials shall include the removal of designated trees, bushes, grass, miscellaneous stone, brick, concrete, scrap iron and all rubbish and debris whether above or below ground level. It is the intent of this specification to provide for the removal and disposal of all objectionable materials not specifically provided for elsewhere by the Drawings and specifications. The removal of such items shall be accomplished prior to grading and excavation operations. The removal and disposal of such items shall not be measured or paid for as a separate contract pay item. Such items shall be considered as incidental work and the cost thereof shall be included in such contract pay item as provided in the proposal and contract. B. Maintenance of Streets During Construction: 1. Maintain the surfaces of streets being worked on at all times. The maintenance required shall include the filling of holes, blading or otherwise smoothing of the street surfaces (particularly the trench area), cleaning and removal of surplus excavation material, rubbish, etc., sprinkling of streets with water or abate dust nuisances and the elimination of interference resulting from blocking the street to residents thereon. Any or all such operations shall be performed by the Contractor upon demand by the Owner, but the Contractor shall not wait for instruction from the Owner before performing maintenance work obviously in need of being done to meet the requirements of these specifications. All costs of work covered by this paragraph shall be included in the prices bid for the various items of work; and no separate payment shall be made. BCRUA - Phase 1D WTP Expansion Issued for Bid Trenching 31 23 17 - 5 2. In the event the Contractor fails or refuses to properly maintain the surfaces of streets on which he is working or has worked, the Owner, after due notice to the Contractor, shall perform the necessary maintenance. All costs to the Owner incurred in the performance of such work shall be deducted from any monies due or to become due to the Contractor for work performed, or the Contractor shall be billed for such costs directly as the Owner shall elect. Notice to the Contractor to be given by the Owner shall be in writing, and it shall be delivered to the Contractor or his authorized agent. Except in emergency cases, where immediate action is required, the Contractor shall have 24 hours in which to comply with the instructions of the Owner. Should the Contractor fail to do so, the Owner shall proceed with the work as set forth above. 3. Where traffic must cross open trenches, such as street intersections and driveways, the Contractor shall provide suitable backfill bridges, protective barricades and such other safety equipment as required. The use of machinery must be so regulated as to preclude any unnecessary interference with traffic, utilities, etc. The Contractor shall abide by all applicable federal, state or local laws governing excavation work. C. Soil Borings: Whenever the Owner has caused certain test borings to be made on the site, or when any information pertaining of the character or depth of materials is found from observations, records or otherwise, such information revealed thereby may be provided to the Contractor. The action of the Owner in revealing such information shall not, in any manner, be construed as a warranty on the part of the Owner of the exact nature of the subsurface conditions that shall be encountered during construction of the work. Although the information is shown as accurately as possible, the Owner does not guarantee that any materials to be encountered at any point or points are even approximately the same, either in character or elevations, as those shown on the Drawings. The information thus furnished by the Owner is intended only as a guide to the Contractor in making his own investigations preliminary to submitting a bid for the work. D. Existing Structures: 1. All existing structures, improvements and utilities shall be adequately protected, at the expense of the Contractor, from damage that might otherwise occur due to construction operations. Where construction comes in close proximity to existing structures or utilities, or if it becomes necessary to move services, poles, guy wires, pipe lines or other obstructions, the Contractor shall notify and cooperate with the utility or structure Owner. The utility lines and other existing structures shown on the Drawings are for information only and are not guaranteed by the Owner to be complete or accurate as to the location and/or depth. The Contractor shall be liable for damage to any utilities resulting from his operation. During construction, all fire hydrants, valve boxes and other existing utility controls shall be left intact, unobstructed and accessible as noted on the plan. a. Relocation or Replacing Utilities: Unless noted on the Drawings that utilities are to be moved by others, any cost of temporarily or permanently relocating utilities shall be borne by the Contractor. The cost of these replacements shall be included in the Contractor’s bid price for the various items of work; and no separate payment shall be made. In case damage to an existing structure or utility occurs, whether such damage results directly or indirectly from the Contractor’s operations, the Contractor shall be responsible to restore the structure or utility to its original condition and position without extra compensation. Temporary shut down of water and/or sewer services shall not extend overnight, holidays or weekends. The Owner shall approve all shut downs and may assist in the shut down operations. BCRUA - Phase 1D WTP Expansion Issued for Bid Trenching 31 23 17 - 6 b. Sewer Services: All sewer services damaged during construction shall be replaced by the Contractor at his expense. Sewer service reconnections, including necessary adjustments to a sanitary sewer replacement, shall not require the services of a master plumber, if being replaced by a utility Contractor; however, in all cases, repair shall be inspected by the Owner. It shall be the responsibility of the Contractor to maintain such services throughout the construction process. c. Water Services: Service lines shall not be removed during excavation; and the Contractor shall provide adequate support for the services across the open ditch. d. Interrupted Service: Cuts or breaks in sewer mains and laterals, or service connections, shall be restored at the earliest practicable moment in order to give the least possible interruption in service. The Contractor shall be responsible for notifying customers of temporary interruption of service. e. Other Utilities: All water mains, water services, sanitary sewers, sanitary sewer house laterals, storm sewers, power conduits, gas mains, gas service laterals and other appurtenances damaged during construction shall be repaired or replaced. Where the exact depth of any utility or obstruction is not shown on a plan, excavation shall be made prior to reaching the obstruction in order to determine adjustments in grade if needed to prevent interference. Redesign to eliminate conflicts may be necessary. Extra compensation shall not be paid for such delays. When it is necessary to remove or adjust another utility, a representative of that utility shall be notified to decide method and work to be done. The Contractor shall make satisfactory arrangements with other utilities for the required cutting or adjustments at the Contractor’s own expense. Other than for items that may be provided in the contract for such work. No extra compensation shall be paid due to delays caused by removal of public utility structures. f. Street Sign Posts and Signs: The Contractor shall be responsible for all damage to street sign posts and signs within the limits of his operations that remain in place or are removed and replaced. In the event that street sign posts and signs are damaged or destroyed by the Contractor’s operations, they shall be replaced at the Contractors’ expense. g. Methods of Removal and Disposal: Materials or parts of structures which are to be broken up, dismantled or removed, and which are to be salvaged, shall be removed, loaded, cleaned and unloaded at sites designated by the Owner and approved by the Engineer. Materials which are not designated to be salvaged shall become property of the Contractor; and he shall dispose of the material at his own cost and expense. E. Do not advance open trench more than 200 feet ahead of installed pipe, unless preapproved by Engineer. F. Trench Width: 1. Reference Drawing details. 2. If trench width within the pipe zone exceeds maximum, the entire pipe zone shall be refilled with approved backfill material, thoroughly compacted to a minimum of 95 percent of maximum density and then re-excavated to the proper grade and dimensions. Excavation along curves and bends shall be so oriented that the trench and pipe are approximately centered on the centerline of the curve, using short links for pipe and/or bend fillings if necessary. BCRUA - Phase 1D WTP Expansion Issued for Bid Trenching 31 23 17 - 7 3. For all utilities to be constructed in fill above natural ground, the embankment shall first be constructed to an elevation not less than 1 foot above the top of the utility after which excavation for the utility shall be made as indicated. G. Alternative Trench Width for Use with Free-Flowing Granular Embedment Material: 1. Based upon preapproval by Engineer, Contractor may use alternative trench widths in conjunction with free-flowing granular embedment material. The minimum and maximum alternative trench widths are specified below; however, in most instances the minimum trench width shall be that width which is sufficient to insure working space between the outside surface of the pipe and the trench wall to safely place trench safety equipment and to properly place and compact the embedment materials. a. Trenches for pipes less than 18 inches in diameter shall have a minimum width of 8 inches and a maximum width of 24 inches on each side beyond the outside surfaces of the pipe bell or coupling. b. Trenches for pipes 18 inches in diameter or greater shall have a minimum width of 6 inches and a maximum width not to exceed one pipe diameter on each side beyond the outside surfaces of the pipe. H. Trench Depth and Depth of Cover: 1. All pipe and in-line appurtenances shall be laid to the grades indicated. The depth of cover shall be measured from the established finish grade, natural ground surface, subgrade for staged construction, street or other permanent surface to the top or uppermost projection of the pipe. a. Where not otherwise indicated, all water piping shall be laid to the following minimum depths: 1) Water piping installed in undisturbed ground in easements of undeveloped areas which are not within existing or planned streets, roads or other traffic areas shall be laid with at least 36 inches of cover. 2) Water piping installed in existing streets, roads or other traffic areas shall be laid with at least 42 inches of cover below finish grade. 2. Provide uniform and continuous bearing and support for bedding material and pipe. I. Classification of Excavation: Excavation will not be considered or paid for as a separate item of work, so excavated material will not be classified as to type or measured as to quantity. Full payment for all excavation required for the construction shall be included in the various unit or lump sum contract prices for the various items of work installed, complete in place. No extra compensation, special treatment or other consideration will be allowed due to rock, pavement, caving, sheeting and bracing, falling or rising water, working under and in the proximity of trees or any other handicaps to excavation. J. Dewatering Excavation: Underground piped utilities shall not be constructed or the pipe laid in the presence of water. All water shall be removed from the excavation prior to the pipe placing operation to ensure a dry firm granular bed on which to place the underground piped utilities and shall be maintained in such dewatered condition until all concrete and mortar is set. Removal of water may be accomplished by bailing, pumping or by a well-point installation as conditions warrant. In the event that the excavation cannot be dewatered to the point where the pipe bedding is free of mud, a seal shall be used in the bottom of the excavation. Such seal shall consist of lean concrete with a minimum depth of 3 inches. BCRUA - Phase 1D WTP Expansion Issued for Bid Trenching 31 23 17 - 8 K. Trench Conditions: 1. Before attempting to lay pipe, all water, slush, debris, loose material, etc., encountered in the trench must be pumped or bailed out and the trench must be kept clean and dry while the pipe is laid and backfilled. Where needed, sump pits shall be dug adjoining the trench and pumped as necessary to keep the excavation dewatered. 2. Backfilling shall closely follow pipe laying so that no pipe is left exposed and unattended after initial assembly. All open ends, outlets or other openings in the pipe shall be protected from damage and shall be properly plugged and blocked watertight to prevent the entrance of trench water, dirt, etc. The interior of the pipeline shall at all times be kept clean, dry and unobstructed. 3. Where the soil encountered at established footing grade is a quicksand, saturated or unstable material, the following procedure shall be used unless other methods are indicated: a. All unstable soils shall be removed to a depth of 2 feet below bottom of piped utility. Such excavation shall be carried out to the trench widths above. b. All unstable soil so removed shall be replaced with concrete seal foundation rock for the entire trench width or coarse aggregate materials placed in uniform layers not to exceed 6 inches, loose measure and compacted by mechanical tamping or other means which will provide a stable foundation for the utility. c. All forms, concrete seals, sheathing and bracing, pumping, additional excavation and backfill required shall be done at the Contractor’s expense. L. Trench sidewalls shall be sloped, or sheeting and/or shoring shall be used in accordance with the Trench Safety Plan in order to provide safety and protection in, and to, the excavation. M. Trim excavation. Remove loose matter. N. Correct over excavated areas with compacted backfill as specified for authorized excavation or replace with lean concrete, or Flexible Base as directed by Engineer. O. Removing Old Structures: When out of service masonry structures or foundations are encountered in the excavation, such obstructions shall be removed for the full width of the trench and to a depth of 1 foot below the bottom of the trench. When abandoned inlets or manholes are encountered and no plan provision is made for adjustment or connection to the new sewers, such manholes and inlets within the construction limits shall be removed completely to a depth of 1 foot below the bottom of the trench. In each instance, the bottom of the trench shall be restored to grade by backfilling and compacting by the methods provided above. Where the trench cuts through storm or wastewater sewers which are known to be abandoned, these sewers shall be cut flush with the sides of the trench and blocked with a concrete plug in a manner satisfactory to the Engineer. When old structures are encountered, which are not visible from the existing surface and are still in service, they shall be protected and adjusted as required to the finished grade. P. Excess material or material which cannot be made suitable for use in embankments will be declared surplus by the Engineer and shall become the property of the Contractor to dispose of offsite at a permitted fill site, without injury to the Owner or any individual. Such surplus material shall be removed from the work site promptly following the completion of the portion of the utility involved. BCRUA - Phase 1D WTP Expansion Issued for Bid Trenching 31 23 17 - 9 Q. Stockpile subsoil in area designated on site to only a height which yields safe slope stability and protect from erosion. 3.4 SHEETING AND SHORING A. All excavations for trenches, structures, etc. 5 feet in depth or greater are required to have a Trench Safety Plan prepared and sealed by a Registered Professional Engineer in the State of Texas in accordance with OSHA requirements and Section 31 23 15 – Trench Safety Systems of the specifications. B. Submit Trench Safety Plan prior to any excavation. C. When specified in the Drawings, sheeting and shoring to be left in place as part of the completed Work, cut off minimum 18 inches below finished grade. Otherwise, sheeting and shoring shall be removed at completion of excavation work. D. Repair damage caused by failure of the sheeting, shoring, or bracing and for settlement of filled excavations or adjacent soil. E. Repair damage to new and existing Work from settlement, water or earth pressure or other causes resulting from inadequate sheeting, shoring, or bracing. 3.5 PIPE BEDDING AND EMBEDMENT A. Where not otherwise provided, all piping shall be installed in a continuous envelope of embedment material meeting the requirement of materials specified herein. B. Embedment material shall extend below and above the outer parts of the pipe, fittings, and accessories for pipe as illustrated on Drawing details. C. All bracing, struts, etc., installed by the pipe manufacturer (or temporary replacements by the Contractor) shall be kept in place in the pipe, undisturbed, until the trench has been backfilled at least to the top of the pipe. When installing mortar lined and mortar coated steel pipe, all bracings, struts, etc., installed by the pipe manufacturer shall be kept in the pipe, undisturbed until the pipe has been backfilled. 3.6 BACKFILLING A. Backfill Procedure: Backfill procedure is that procedure required to return trenched or excavated areas to a condition satisfactory to the Engineer. Such backfilling occurs in two general areas. They are 1) areas not subjected to vehicular traffic; and 2) areas subjected to, or influenced by, vehicular traffic. The methods of backfilling to be used shall vary with the width of trench, the character of the materials excavated, the method of excavation, the type of conduit and the degree of compaction required. The placing of backfill shall not begin until the pipe structure has been properly bedded and jointed. 1. Trench backfill material is the material required to fill the trench from the top of the embedment to ground elevation or subgrade of a pavement or structure. BCRUA - Phase 1D WTP Expansion Issued for Bid Trenching 31 23 17 - 10 B. Backfill trenches to contours and elevations with unfrozen fill materials. C. Do not backfill over porous, wet, frozen, or spongy subgrade surfaces. D. Place geotextile fabric when specified in the Drawings. E. Place fill material in continuous layers and compact to the density specified herein. F. Employ placement method that does not disturb or damage utilities in trench. G. Maintain optimum moisture content of fill materials to attain required compaction density. H. Do not leave more than 50 feet of trench open at end of working day, unless preapproved by Engineer. I. Protect open trench to prevent danger to the Owner, the public, and users of the Project site. 3.7 COMPACTION A. Compaction of all bedding, embedment, and backfill materials shall be performed in a manner that shall not crack, crush and/or cause the installed pipe to be moved from the established grade and/or alignment, as shown on the Drawings. Satisfactory density shall be obtained at various depths on all backfill material as indicated from random selected test points prior to the required exfiltration or pressure tests that are to be performed on lines being constructed. The required moisture content shall be at not less than 2 percent below nor more than 4 percent above the optimum moisture of the material or as specified by the Engineer. B. Densities for Bedding and Embedment: 1. Coarse Aggregate Type A1 (Flexible Base) embedment shall be mechanically compacted in 6 inch lifts to a minimum of 95 percent Standard Proctor Density (ASTM D698 - Standard Test Method for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/ft3)), unless indicated otherwise on Drawings. 2. Coarse Aggregate Type A2 (Crushed Stone) embedment shall be mechanically compacted in 6 inch lifts to a minimum of 95 percent of Maximum Dry Density in accordance with TEX-113-E – Laboratory Compaction Characteristics and Moisture- Density Relationship of Base Materials, unless indicated otherwise on Drawings. 3. Coarse Aggregate Type A4 (Gravel Trench Backfill) embedment shall be mechanically compacted in 6 inch lifts to a minimum of 95 percent Standard Proctor Density (ASTM D698 - Standard Test Method for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/ft3)), unless indicated otherwise on Drawings. C. Backfill Densities – Areas Subjected to or Influenced by Vehicular Traffic: The trench backfill shall be mechanically compacted to the top of the subgrade in 6 inch loose lifts to at least 95 percent of maximum density as determined by ASTM D698 -Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/ft3), at, or above, optimum moisture content. BCRUA - Phase 1D WTP Expansion Issued for Bid Trenching 31 23 17 - 11 D. Backfill Densities – Areas Not Subjected to or Influenced by Vehicular Traffic: The trench backfill shall be placed in layers not more than 10 inches loose depth and shall be compacted by mechanical means. Compaction methods to at least 95 percent of maximum density as determined by ASTM D698 – Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/ft3), at, or above, optimum moisture content. 3.8 TOLERANCES A. Section 01 40 00 – Quality Requirements: Tolerances. B. Top Surface of Backfilling Under Paved Areas: Plus or minus 1 inch (0.08 feet) from required elevations. C. Top Surface of General Backfilling: Plus or minus 1 inch (0.08 feet) from required elevations. 3.9 FIELD QUALITY CONTROL A. Section 01 40 00 - Quality Requirements. B. Perform laboratory material tests in accordance with ASTM D698 - Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/ft3) or as otherwise specified. C. Perform in place compaction tests in accordance with the following: 1. Density Tests: ASTM D2922 – Standard Test Methods for Density of Soil and Soil- Aggregate in Plane by Nuclear Methods. 2. Moisture Tests: ASTM D3017 – Standard Test Method for Water Content of Soil and Rock in Place by Nuclear Methods. D. Frequency of Tests: The in-place density/moisture content shall be tested and verified at an average frequency of once per 100 linear feet per lift along the trench line or at least once per utility excavation per lift in areas where less than 100 linear feet of pipe is installed. E. When tests indicate Work does not meet specified requirements, remove Work, replace, compact, and retest. 3.10 PROTECTION OF FINISHED WORK A. Reshape and re-compact fills subjected to vehicular traffic during construction. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Fill 31 23 23 - 1 SECTION 31 23 23 - FILL PART 1 GENERAL 1.1 SUMMARY A. Description: This item shall consist of the placing and compacting of suitable materials obtained from approved sources for utilization in the construction of civil site improvements. B. Reference Section 31 23 10 – Structural Excavation and Backfill for requirements related to project structures. C. Section Includes: 1. Fill under minor structural foundations, such as vaults. 2. Fill for embankment for construction of highways, streets, and pavements. 3. Fill for the construction of earthen embankments, berms, levees, dikes, and structures. 4. Fill for over-excavation. 5. Backfilling of minor structural foundations, manholes, and utility structures to subgrade elevations. 6. Backfilling site structures to subgrade elevations. 1.2 SUBMITTALS A. Section 01 33 00 – Submittal Procedures. B. Product Data: Submit data for geotextile fabric indicating fabric and construction. C. Samples: Submit, in air-tight containers, 50 lb sample of each type of fill to testing laboratory. D. Materials Source: Submit name of imported fill materials suppliers. PART 2 PRODUCTS 2.1 FILL MATERIALS A. Subsoil Fill: All subsoil fill shall conform to the following material types: 1. Subsoil Type S1 (Select Fill, or Select Borrow): This material shall consist of sand or other suitable granular material, free from vegetation or deleterious or objectionable matter reasonably free from lumps of earth and when tested by standard TxDOT laboratory methods, shall meet the following requirements: a. The Liquid Limits shall not exceed 35. b. The Plasticity Index shall not be less than 4 nor more than 15. c. Minimum and maximum passing No. 200 sieve: 10% and 70%, respectively. d. No rocks greater than 2 inches in diameter. 2. Subsoil Type S2 (Borrow): a. This material shall consist of suitable non-swelling (soils with plasticity index less than 20) earth material such as loam, clay or other such materials that will form a stable embankment or backfill. BCRUA - Phase 1D WTP Expansion Issued for Bid Fill 31 23 23 - 2 b. This material shall be free of lumps larger than 3 inches in diameter, and rocks larger than 4 inches in diameter. 3. Subsoil Type S3 (On-Site Material): a. This material shall be excavated from on-site and re-used for fills (embankment or backfill). b. This material shall be free of lumps larger than 3 inches in diameter, and rocks larger than 4 inches in diameter, except as follows: i. For landscape berm construction, the material shall be free of rocks larger than 6 inches in the top 2 feet of embankment and free of rocks larger than 12 inches below the top 2 feet of embankment. B. Structural Fill: Refer to Section 31 23 10 - Structural Excavation and Backfill and Drawings for material requirements. C. Coarse Aggregate Fill: Coarse Aggregate Type A2 (Crushed Stone);Coarse Aggregate Type A3 (Gravel Base Course);or Coarse Aggregate Type A4 (Gravel for Trench Backfill) as specified in Section 32 05 16 – Aggregates for Civil Site Improvements. D. Concrete: Lean concrete with a minimum compressive strength of 1,500 psi per Section 03 30 00 – Cast-In-Place Concrete, Class E. E. Flowable Fill: As specified in Section 31 23 24 – Flowable Fill. 2.2 ACCESSORIES A. Geotextile Fabric: Products and execution shall be specified in the drawings. Non- biodegradable, woven or non-woven, from the following manufacturers: 1. Alkzo Nobel Geosynthetic Co. 2. Huesker, Inc. 3. TC Mirafi. 4. Tenax Corp. 5. Tensar Earth Technologies, Inc. PART 3 EXECUTION 3.1 SUBGRADE PREPARATION FOR STRUCTURES AND PAVEMENTS A. Strip and remove from the construction area any topsoil, organics, and vegetation to a minimum depth of 6 inches below the existing, natural ground surface in accordance with Section 31 10 00 - Clearing. B. Cut out soft areas of subgrade not capable of compaction in place. Backfill with structural fill and compact to the density specified herein. C. Prepare the subgrade (subsoil) in accordance with Section 31 23 10 – Structural Excavation and Backfill prior to commencing with subsequent “fill” operations. BCRUA - Phase 1D WTP Expansion Issued for Bid Fill 31 23 23 - 3 D. Proof roll to identify soft spots; fill and compact to density equal to or greater than requirements for subsequent fill material. 3.2 EMBANKMENT/FILLING A. Prior to placing any embankment (fill), all tree protection, tree wells and erosion control devices shall be in place and all “Clearing” operations shall have been completed on the areas over which the embankment (fill) is to be placed. Stump holes or other small excavations in the limits of the embankments shall be backfilled with suitable material and thoroughly tamped by approved methods before commencing embankment construction. The surface of the ground, including plowed loosened ground or surface roughened by small washes, shall be restored to approximately its original slope and the ground surface thus prepared shall be compacted by sprinkling and rolling. B. Construction equipment shall not be operated within the drip line of the trees, unless indicated. Construction materials shall not be stockpiled under the canopies of trees. No excavation or embankment shall be placed within the drip line of trees unless indicated. C. Unless otherwise indicated, the surface of the ground of all unpaved areas, other than rock which are to receive embankment (fill), shall be loosened by scarifying or plowing to a depth of not less than 4 inches. The loosened material shall be recompacted with the new embankment as hereinafter specified. D. The surface of hillsides to receive embankment (fill) shall be loosened by scarifying or plowing to a depth of not less than 4 inches and benches cut before embankment materials are placed. The embankment shall then be placed in layers, as hereinafter specified, beginning at the low side in partial width layers and increasing the widths as the embankment is raised. The material which has been loosened shall be recompacted simultaneously with the embankment material placed at the same elevation. E. Where embankments are to be placed adjacent to or over existing roadbeds, the roadbed slopes shall be plowed or scarified to a depth of not less than 6 inches and the embankment built up in successive layers, as hereinafter specified, to the level of the old roadbed before its height is increased. Then, if indicated, the top of the old roadbed shall be scarified and recompacted with the next layer of the new embankment. The total depth of the scarified and added material shall not exceed the permissible layer depth. F. Trees, stumps, roots, vegetation or other unsuitable materials shall not be placed in embankment (fill). G. All embankment shall be constructed in layers approximately parallel to the finished grade and unless otherwise indicated. H. The embankment (fill) shall be continuously maintained at its finished section and grade until that portion of the work is accepted. After completion of the embankment to the finished section and grade, the Contractor shall proof roll the subgrade and revegetation procedures must commence immediately to minimize the soil loss and air pollution. BCRUA - Phase 1D WTP Expansion Issued for Bid Fill 31 23 23 - 4 I. Except as otherwise indicated, embankments (fills) shall be constructed in successive 6 inch layers, loose measure, for the full width of the individual cross section and in such length as are best suited to the sprinkling and compaction methods utilized. J. Minor quantities of rocks not larger than 4 inches, encountered in constructing earth embankment may be incorporated in the earth embankment layers, provided such placement of rock is not within 10 feet of any structure. K. Each layer of embankment shall be uniform as to material, density and moisture content before beginning compaction. Where layers of unlike materials abut each other, each layer shall be feathered on a slope of 1:20 or the material shall be so mixed as to prevent abrupt changes in soil. No material placed in the embankment by dumping in a pile or windrows shall be incorporated in a layer in that position, but all such piles or windrows shall be moved by blading or similar methods. Clods or lumps of material shall be broken and the embankment material mixed by blading, harrowing, discing or similar methods to the end that a uniform material of uniform density is secured in each layer. L. Water required for sprinkling to bring the material to the moisture content necessary for optimum compaction shall be evenly applied and it shall be the responsibility of the Contractor to secure a uniform moisture content throughout the layer by such methods as may be necessary. M. All cuts, whether full width or partial width cuts in the side of a hill, which are not required to be excavated below subgrade elevation shall be scarified to a uniform depth of at least 6 inches below grade and the material shall be mixed and reshaped by blading and then sprinkled and rolled in accordance with the requirements outlined above for earth embankments and to the same density as that required for the adjacent embankment. N. Compaction of embankments (fills) shall be to a minimum of 95% and less than 100% of its maximum dry density when determined in accordance with ASTM D698 – Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft- lbf/ft3), Method D, Standard Proctor, unless indicated otherwise on Drawings. The subsoil shall be no less than its optimum moisture to not greater than 3 percentage points above its optimum moisture content at the time of testing. After each layer of earth embankment (fill) is complete, density tests as necessary will be made. If the material fails to meet the density specified, the course shall be reworked as necessary to obtain the specified compaction. O. Embankment (fill) shall slope away from building minimum 5 percent slope for minimum distance of 10 ft, unless noted otherwise. P. Grade changes in embankment (fill) shall be made with gradual grade changes. Blend slope into level areas. Q. Remove surplus fill materials from site. 3.3 BACKFILLING A. As soon as practicable, all portions of excavation not occupied by the permanent structure shall be backfilled. Backfill material shall comply with “Subsoil Fill” as specified herein. BCRUA - Phase 1D WTP Expansion Issued for Bid Fill 31 23 23 - 5 B. That portion of backfill which will not support any portion of completed structure, roadbed, or embankment shall be placed in layers not more than 10 inches in depth (loose measurement) and shall be compacted in accordance with Paragraph 3.4, “Compaction” for “Subsoil Fill.” C. That portion of the backfill which will support any portion of the structure, roadbed, or embankment shall be placed in uniform layers not more than 8 inches in depth (loose measurement) and shall be compacted in accordance with Paragraph 3.5, “Compaction” for “Subsoil Fill” and shall be compacted to that density by means of mechanical tampers or rammers, except that the use of rolling equipment of the type generally used in compaction embankments will be permitted on portions which are accessible to such equipment. All portions of embankment too close to any portion of a structure to permit compaction by the use of the blading and rolling equipment used on adjoining sections of embankment, shall be placed and compacted in the same manner as specified above for backfill material. Unless otherwise indicated, hand tamping will not be accepted as an alternate for mechanical compaction. As a general rule, material used in filling or backfilling the portions described in this paragraph shall be “Subsoil Fill,” free of any appreciable amount of gravel or stone particles larger than 4 inches in greater dimension and of a gradation that permits thorough compaction. When required by the Drawings or by written order of the Engineer, structural fill or coarse aggregate material shall be used for backfilling. D. The surface of hillsides to receive embankment (fill) shall be loosened by scarifying or plowing to a depth of not less than 4 inches and benches cut before embankment materials are placed. The embankment shall then be placed in layers, as hereinafter specified, beginning at the low side in partial width layers and increasing the widths as the embankment is raised. The material which has been loosened shall be recompacted simultaneously with the embankment material placed at the same elevation. E. Where embankments are to be placed adjacent to or over existing roadbeds, the roadbed slopes shall be plowed or scarified to a depth of not less than 6 inches and the embankment built up in successive layers, as hereinafter specified, to the level of the old roadbed before its height is increased. Then, if indicated, the top of the old roadbed shall be scarified and recompacted with the next layer of the new embankment. The total depth of the scarified and added material shall not exceed the permissible layer depth. F. No backfill shall be placed against any structural wall until such structure has been in place at least 7 days. Where the top of walls are supported by slabs or intermediate walls, do not begin backfilling operations until the slab or intermediate walls have been placed and the concrete has cured for a minimum of 7 days. Backfill placed simultaneously around all sides of abutments, foundations, walls, piers, etc. shall be deposited on both sides to approximately the same elevation at the same time. G. Care shall be taken to prevent any wedging action of backfill against the structure and the slopes bounding the excavation shall be stepped or serrated to prevent such action. 3.4 COMPACTION A. Subsoil Fill: 1. Subsoil Type S1 (Select Fill, or Select Borrow): Compaction shall be to a dry density of at least 95 percent Standard Proctor maximum dry density (ASTM D698 - Standard Test Method for Laboratory Compaction Characteristics of Soil Using Standard Effort BCRUA - Phase 1D WTP Expansion Issued for Bid Fill 31 23 23 - 6 (12,400 ft-lbf/ft3)) and shall be within the range of the material’s optimum moisture content to 3 percentage points above the material’s optimum moisture content. Placement shall be in lifts not exceeding 8 inches before compaction. 2. Subsoil Type S2 (Borrow) and Subsoil Type S3 (On-Site Material): Compaction shall be to a dry density of at least 95 percent Standard Proctor maximum dry density (ASTM D698 – Standard Test Method for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/ft3)) and shall be within the range of the materials optimum moisture content to 3 percentage points above the materials optimum moisture content. Placement shall be in lifts not exceeding 8 inches before compaction. B. Structural Fill: Reference Section 31 23 10 – Structural Excavation and Backfill. C. Coarse Aggregate Fill: 1. Coarse Aggregate Type A2 (Crushed Stone): Compaction shall be a minimum of 95 percent of the maximum dry density in accordance with TxDOT Test Method TEX-113-E – Laboratory Compaction Characteristics and Moisture-Density Relationship of Base Materials, unless indicated otherwise on Drawings. 2. Coarse Aggregate Type A3 (Gravel Base Course): Gravel Base Course used as structural fill beneath foundations and for backfilling structures shall be placed in loose lifts not exceeding 8 inches before compaction, and shall be compacted mechanically to a minimum 95 percent of Standard Proctor dry density (ASTM D698 - Standard Test Method for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/ft3)) and within 2 percentage points of the materials optimum moisture content, unless indicated otherwise on Drawings. 3. Coarse Aggregate Type A4 (Gravel Trench Backfill): Gravel Trench Backfill shall be placed in loose lifts not exceeding 8 inches before compaction, and shall be compacted mechanically to a minimum 95 percent of Standard Proctor dry density (ASTM D698 - Standard Test Method for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/ft3)) and within 2 percentage points of the materials optimum moisture content. 3.5 TOLERANCES A. Top Surface of Fill Under Paved Areas: Plus or minus 0.50 inches from required elevations. B. Top Surface of General Grading of Fill: Plus or minus 0.10 feet from required elevations. 3.6 FIELD QUALITY CONTROL A. Section 01 40 00 - Quality Requirements. B. Perform laboratory material tests in accordance with ASTM D698 - Standard Test Method for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/ft3). C. Perform in place compaction tests in accordance with the following: 1. Density Tests: ASTM D1556 – Standard Test Method for Density and Unit Weight of Soil in Place by Sand-Cone Method, ASTM D2167 – Standard Test Method for Density and Unit Weight of Soil in Place by the Rubber Balloon Method, ASTM D2922 – Standard Test Methods for Density of Soil and Soil-Aggregate in Place by Nuclear BCRUA - Phase 1D WTP Expansion Issued for Bid Fill 31 23 23 - 7 Methods, or TEX-115-E – Field Method for Determining In-Place Density of Soils and Base Materials as appropriate for the material being tested. 2. Moisture Tests: ASTM D3017 – Standard Test Method for Water Content of Soil and Rock in Place by Nuclear Methods. 3. Unless noted otherwise, in place compaction tests shall be conducted at a rate of one test per 1,000 square feet for every lift or at least one test per structure for every lift for structures less than 1,000 square feet. D. When tests indicate Work does not meet specified requirements, remove Work, replace and retest. E. Proof roll compacted fill surfaces under structural foundations, pavers, paving, and sidewalks. Soft spots shall be removed, replaced, and retested. F. At a minimum, quality assurance shall be as outlined below. Type of Work Item Sample Frequency Sample Size Minimum Testing Select Fill Select Type S1 (Select Fill or Select Borrow) Compaction 1 per soil Type 1 per 1000 sq.ft. per lift (min. of 3 per lift) 50 lbs. - Gradation - P.I. - Moisture-Density Relationship - Field Density Tests Subsoil for Fill and Backfill Subsoil Type S2 (Borrow); Subsoil Type S3 (On-Site) Compaction 1 per soil Type 1 per 1000 sq.ft. per lift (min. of 3 per lift) 50 lbs. - Gradation - P.I. - Moisture-Density Relationship - Field Density Tests Structural Fill Coarse Aggregate Type A2 (Crushed Stone) Compaction 1 per type per 1000 cu. Yds. 1 per 2500 sq.ft. per lift (min. of 3 per lift) 50 lbs - Gradation/sieve - Field Density Tests Structural Fill Coarse Aggregate Type A3; Coarse Aggregate Type A4 Compaction 1 per type per 1000 cu. Yds. 1 per 2500 sq.ft. per lift (min. of 3 per lift) 50 lbs - Sieve - P.I. - Moisture-Density - Field Density Tests *Provide at least 1 compaction test per lift if structural fill area is less than tabulated value. BCRUA - Phase 1D WTP Expansion Issued for Bid Fill 31 23 23 - 8 3.7 PROTECTION OF FINISHED WORK A. Reshape and re-compact fills subjected to vehicular traffic. B. Reshape and re-compact fills subjected to erosion. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Flowable Fill 31 23 24 - 1 SECTION 31 23 24 - FLOWABLE FILL PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. Flowable fill for: a. Site civil structure backfill. b. Utility bedding. c. Utility backfill. d. Filling abandoned utilities. B. Related Sections: 1. Section 31 23 10 – Structural Excavation and Backfill. 2. Section 31 23 17 – Trenching. 1.2 REFERENCES A. ASTM International: 1. ASTM C33 - Standard Specification for Concrete Aggregates. 2. ASTM C94/C94M - Standard Specification for Ready-Mixed Concrete. 3. ASTM C150 - Standard Specification for Portland Cement. 4. ASTM C260 - Standard Specification for Air-Entraining Admixtures for Concrete. 5. ASTM C403/C403M - Standard Test Method for Time of Setting of Concrete Mixtures by Penetration Resistance. 6. ASTM C494/C494M - Standard Specification for Chemical Admixtures for Concrete. 7. ASTM C618 - Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use as a Mineral Admixture in Concrete. 8. ASTM C1017/C1017M - Standard Specification for Chemical Admixtures for Use in Producing Flowing Concrete. 9. ASTM C1040 - Standard Test Methods for Density of Unhardened and Hardened Concrete In Place By Nuclear Methods. 10. ASTM D4832 - Standard Test Method for Preparation and Testing of Controlled Low Strength Material (CLSM) Test Cylinders. 1.3 DEFINITIONS A. Utility: Any buried pipe, duct, conduit, manhole, tank or cable. B. Excavatable Flowable Fill: Lean cement concrete fill used where future excavation may be required such as fill/embedment for utility and pipe trenches, bridge abutments, and culverts. C. Non-Excavatable Flowable Fill: Lean cement concrete fill used where future excavation is not anticipated such as fill below structure foundations and filling abandoned utilities. 1.4 SUBMITTALS A. Section 01 33 00 – Submittal Procedures. BCRUA - Phase 1D WTP Expansion Issued for Bid Flowable Fill 31 23 24 - 2 B. Materials Source: Submit name of flowable fill materials suppliers. C. Manufacturer's Certificate: 1. Certify Product meets or exceeds specified requirements. D. Mix Design: 1. Submit flowable fill mix design for each specified strength. Submit separate mix designs as required for the following: a. Flowable fill work during hot and cold weather. b. Air entrained flowable fill work. 2. Identify design mix ingredients, proportions, properties, admixtures, and tests. 3. Submit test results to certify flowable fill mix design properties meet or exceed specified requirements. E. Delivery Tickets: 1. Submit duplicate delivery tickets indicating actual materials delivered to Project site. 1.5 QUALIFICATIONS A. Manufacturer: Company specializing in manufacturing products specified in this section with minimum three years documented experience. 1.6 ENVIRONMENTAL REQUIREMENTS A. Do not install flowable fill during inclement weather or when ambient temperature is less than 40 degrees F. 1.7 FIELD MEASUREMENTS A. Verify field measurements before installing flowable fill to establish quantities required to complete the Work. PART 2 PRODUCTS 2.1 FLOWABLE FILL A. Flowable Fill - Excavatable Type: Lean cement concrete fill used where future excavation may be required such as fill for utility trenches, bridge abutments, and culverts. B. Flowable Fill - Non-excavatable Type: Lean cement concrete fill used where future excavation is not anticipated such as fill below structure foundations and filling abandoned utilities. 2.2 MATERIALS A. Portland Cement: ASTM C150 (Standard Specification for Portland Cement) Type I - Normal; Type IA - Air Entraining; Type II - Moderate. BCRUA - Phase 1D WTP Expansion Issued for Bid Flowable Fill 31 23 24 - 3 B. Fine Aggregates: ASTM C33 – Standard Specification for Concrete Aggregates. C. Water: Clean and not detrimental to concrete. 2.3 ADMIXTURES A. Air Entrainment: ASTM C620. B. Chemical Admixture: ASTM C494/C494M. 1. Type A - Water Reducing. 2. Type B - Retarding. 3. Type C - Accelerating. 4. Type D - Water Reducing and Retarding. 5. Type E - Water Reducing and Accelerating. 6. Type F - Water Reducing, High Range. 7. Type G - Water Reducing, High Range and Retarding. C. Fly Ash: ASTM C618 Class C or F obtained from residue of electric generating plant using ground or powdered coal. D. Plasticizing: ASTM C1017/C1017M Type I, plasticizing. Type II, plasticizing and retarding. 2.4 MIXES A. Mix and deliver flowable fill in accordance with ASTM C94 - Standard Specification for Ready-Mixed Concrete, Option C. FLOWABLE FILL DESIGN MIX ITEM EXCAVATABLE NON-EXCAVATABLE Cement Content 75-100 lbs/cy 100-150 lbs/cy Fly Ash Content None 150-600 lbs/cy Water Content Per mix design Per mix design Air Entrainment 5-35 percent 5-15 percent 28 Day Compressive Strength Maximum 150 psi. Minimum 250 psi Unit Mass (Wet) 80-110 pcf 100-125 pcf Temperature, Minimum at point of delivery 50 degrees F 50 degrees F B. Provide water content in design mix to produce self-leveling, flowable fill material at time of placement. C. Design mix air entrainment and unit mass are for laboratory design mix and source quality control only. BCRUA - Phase 1D WTP Expansion Issued for Bid Flowable Fill 31 23 24 - 4 2.5 SOURCE QUALITY CONTROL A. Reference Section 01 40 00 – Quality Requirements. B. Test and analyze properties of flowable fill design mix and certify results for the following: 1. Design mix proportions by weight of each material. 2. Fine Aggregate: ASTM C33 – Standard Specification for Concrete Aggregates - for material properties and gradation. 3. Properties of plastic flowable fill design mix including: a. Temperature. b. Slump. c. Wet unit mass. d. Yield. e. Cement factor. 4. Properties of hardened flowable fill design mix including: a. Compressive strength at 1 day, 7 days, and 28 days. Report compressive strength of each specimen and average specimen compressive strength. b. Unit mass for each specimen and average specimen unit mass at time of compressive strength testing. C. Prepare delivery tickets containing the following information: 1. Project Designation. 2. Date. 3. Time. 4. Class and Quantity of flowable fill. 5. Actual batch proportions. 6. Free moisture content of aggregate. 7. Quantity of water withheld. PART 3 EXECUTION 3.1 EXAMINATION A. Verify existing conditions before starting work. B. Verify excavation and trenching is complete. C. Verify utility installation is complete and tested before placing flowable fill. D. Verify excavation is dry and dewatering system is operating. 3.2 PREPARATION A. Support and restrain utilities to prevent movement and flotation during installation of flowable fill. B. Protect structures and utilities from damage caused by hydraulic pressure of flowable fill before fill hardens. BCRUA - Phase 1D WTP Expansion Issued for Bid Flowable Fill 31 23 24 - 5 C. Protect utilities and foundation drains to prevent intrusion of flowable fill. 3.3 INSTALLATION - FILL, BEDDING, AND BACKFILL A. Place flowable fill by chute, pumping or other methods approved by Engineer. 1. When required, place flowable fill under water using tremie procedure. 2. Do not place flowable fill through flowing water. B. Place flowable fill in lifts to prevent lateral pressures from exceeding structural capacity of structures and utilities. C. Place flowable fill evenly on both sides of utilities to maintain alignment. D. Place flowable fill to elevations indicated on Drawings without vibration or other means of compaction. 3.4 INSTALLATION - FILLING ABANDONED UTILITIES A. Verify pipes and conduits are not clogged and are sufficiently empty to permit gravity installation of flowable fill for entire length indicated to be filled. B. Seal lower end of pipes and conduits by method to contain flowable fill and to vent trapped air caused by filling operations. C. Place flowable fill using method to ensure there are no voids. 1. Fill pipes and conduits from high end. 2. Fill manholes, tanks, and other structures from grade level access points. D. After filling pipes and conduits seal both ends. 3.5 FIELD QUALITY CONTROL A. Section 01 40 00 – Quality Requirements. B. Perform inspection and testing in accordance with ASTM C94/C94M. 1. Take samples for tests for every 150 cu yd of flowable fill, or fraction thereof, installed each day. 2. Sample, prepare and test four compressive strength test cylinders in accordance with ASTM D4832. Test one specimen at 3 days, one at 7 days, and two at 28 days. 3. Measure temperature at point of delivery when samples are prepared. C. Perform in place penetration (density) tests using hand held penetrometer to measure penetration resistance of hardened flowable fill, in accordance with ASTM C403. 1. Perform tests at locations as directed by Engineer. D. Perform in-place density tests using nuclear test device, in accordance with ASTM C1040. 1. Perform tests at locations as directed by Engineer. E. Defective Flowable Fill: Fill failing to meet the following test requirements or fill delivered without the following documentation. BCRUA - Phase 1D WTP Expansion Issued for Bid Flowable Fill 31 23 24 - 6 1. Test Requirements: a. Minimum temperature at point of delivery. b. Compressive strength requirements for each type of fill. 2. Documentation: Duplicate delivery tickets. F. Submit delivery tickets indicating actual materials delivered to Project site. Delivery tickets shall contain project description, date, time, class and quantity of mix, actual batch proportions, free moisture content of aggregate and quantity of water withheld. 3.6 CLEANING A. Remove spilled and excess flowable fill from Project site. B. Restore facilities and site areas damaged or contaminated by flowable fill installation to existing condition before installation. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Storm Water Pollution Prevention 31 25 12 - 1 SECTION 31 25 12 – STORM WATER POLLUTION PREVENTION PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. Documentation to be prepared and signed by Contractor before conducting construction operations, in accordance with the Texas Pollutant Discharge Elimination System (TPDES) Construction General Permit Number TXR 150000, latest issue date (the Construction General Permit). 2. Implementation, maintenance inspection, and termination of storm water pollution prevention control measures including, but not limited to, erosion and sediment controls, storm water management plans, waste collection and disposal, off-site vehicle tracking, and other appropriate practices. 3. Review of the Storm Water Pollution Prevention Plan (SWP3) implementation in a meeting with Engineer prior to start of construction. B. Related Sections: 1. Section 03 30 00 – Cast-In-Place Concrete. 2. Section 31 23 10 – Structural Excavation and Backfill. 3. Section 31 23 17 – Trenching. 4. Section 31 23 23 – Fill. 5. Section 32 91 19 – Landscape Grading. 6. Section 32 92 19 – Seeding. 1.2 REFERENCES A. Construction General Permit (TPDES No. TXR 150000). B. Clean Water Act. 1.3 SUBMITTALS A. Section 01 33 00 – Submittal Procedures. B. Submit the SWP3 to Engineer for record retention purposes only. Engineer will not review or approve the SWP3 1.4 QUALITY ASSURANCE A. Perform Work in accordance with the SWP3 as per the submission of the Notice of Intent. B. Maintain one copy of the SWP3 document on site. PART 2 PRODUCTS – Not Used. PART 3 EXECUTION BCRUA - Phase 1D WTP Expansion Issued for Bid Storm Water Pollution Prevention 31 25 12 - 2 3.1 SITE SPECIFIC STORM WATER POLLUTION PREVENTION PLAN (SWP3) A. Fulfill all TPDES Construction General Permit (TXR 150000) requirements. B. Contractor shall fulfill the role of Primary Operator as defined by the TPDES Construction General Permit (TXR 150000) for this project. C. Prepare and submit all required documentation and pay all applicable fees to TCEQ required by the TPDES Construction General Permit (TXR 150000). This includes but is not limited to Notice of Intent, Site Notices, Notice of Termination, and Notification of MS4 Operator. D. SWP3: 1. Prepare a SWP3 following Part III of the TPDES Construction General Permit (TXR 150000). 2. Update or revise the SWP3 as needed during the construction following Part III, Section E of the TPDES Construction General Permit (TXR 150000). 3. Submit the SWP3 and any updates or revisions to the Engineer for review and address comments prior to commencing, or continuing, construction activities. 4. Conduct inspections in accordance with TPDES Construction General Permit (TXR 150000). 5. Maintain copies of SWP3, inspection reports, and other documentation as required by TPDES Construction General Permit (TXR 150000). 3.2 SWP3 IMPLEMENTATION A. Implement SWP3 utilizing state of the art Best Management Practice controls as required by the Construction General Permit, the site specific SWP3, and local government. B. Inspect and maintain controls throughout the course of construction per the Construction General Permit requirements. C. Remove controls per the Construction General Permit requirements. D. On-Site Waste Material Storage: 1. Self-contain on-site waste material storage and satisfy appropriate location, state, and federal rules and regulations. 2. Prepare list of waste material to be stored on-site. Update list as necessary to include up- to-date information. Keep a copy of updated list with the SWP3. 3. Prepare description of controls to reduce pollutants generated from on-site storage. Include storage practices necessary to minimize exposure of materials to storm water, and spill prevention and response measures consistent with best management practices. Keep a copy of the description with the SWP3. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Aggregates for Civil Site Improvements 32 05 16 - 1 SECTION 32 05 16 - AGGREGATES FOR CIVIL SITE IMPROVEMENTS PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. Coarse aggregate materials. 2. Fine aggregate materials. B. Related Sections: 1. Section 31 23 17 – Trenching. 2. Section 31 23 23 – Fill. 3. Section 32 11 23 – Flexible Base. 1.2 MEASUREMENT AND PAYMENT A. Aggregate: 1. Basis of Measurement and Payment: Fine aggregate and coarse aggregate will not be paid for as a separate bid item, but shall be considered incidental to the item for which they pertain. 1.3 REFERENCES A. American Association of State Highway and Transportation Officials: 1. AASHTO M147 - Standard Specification for Materials for Aggregate and Soil- Aggregate Subbase, Base and Surface Courses. 2. AASHTO T180 - Standard Specification for Moisture-Density Relations of Soils Using a 4.54-kg (10-lb) Rammer and a 457-mm (18-in.) Drop. B. ASTM International: 1. ASTM C136 - Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates. 2. ASTM D448 - Standard Classification for Sizes of Aggregate for Road and Bridge Construction 3. ASTM D698 - Standard Test Method for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/ft3 (600 kN-m/m3)). 4. ASTM D1557 - Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Modified Effort (56,000 ft-lbf/ft3 (2,700 kN- m/m3)). 5. ASTM D2487 - Standard Classification of Soils for Engineering Purposes (Unified Soil Classification System). 6. ASTM D4318 - Standard Test Method for Liquid Limit, Plastic Limit, and Plasticity Index of Soils. C. Texas Department of Transportation’s Standard Laboratory Test Procedures: 1. Tex-113-E - Moisture Density Determination (for coarse grained material). 2. Tex-114-E - Moisture Density Determination (for fine grained material). BCRUA - Phase 1D WTP Expansion Issued for Bid Aggregates for Civil Site Improvements 32 05 16 - 2 1.4 SUBMITTALS A. Section 01 33 00 - Submittal Procedures: Requirements for submittals. B. Samples: Submit, in air-tight containers, 10 lb samples of each type of fill to testing laboratory. C. Materials Source: Submit name of imported materials suppliers. D. Manufacturer's Certificate of Compliance: Certify that aggregates meet or exceed specified requirements. 1.5 QUALITY ASSURANCE A. Furnish each aggregate material from single source throughout the Work. B. Perform Work in accordance with Texas Department of Transportation’s Standard Specifications for Construction of Highways, Streets, and Bridges (latest Edition). C. Maintain one copy of Texas Department of Transportation’s Standard Specifications for Construction of Highways, Streets, and Bridges (latest Edition) document on site. PART 2 PRODUCTS 2.1 COARSE AGGREGATE MATERIALS A. Coarse Aggregate Type A1 (Flexible Base): Conforming to TxDOT’s Standard Specifications Item 247, Grade 1 or 2, Type A. B. Coarse Aggregate Type A2 (Crushed Stone): washed; free of shale, clay, friable material and debris; graded in accordance with ASTM C136; within the following limits, based on ASTM D448: Coarse Aggregate Type A2 Grading Grade No. 2 Sieve Size Percent Passing 2 inches 100% 1-1/2 inches 95-100% 3/4 inch 40-70% 3/8 inches 10-30% No. 4 0-5% OR BCRUA - Phase 1D WTP Expansion Issued for Bid Aggregates for Civil Site Improvements 32 05 16 - 3 Coarse Aggregate Type A2 Grading Grade No. 3 Sieve Size Percent Passing 1-1/2 inches 95-100% 3/4 inch 60-90% 1/2 inch 25-60% No. 4 0-5% C. Coarse Aggregate Type A3 (Gravel Base Course): Durable particles of gravel mixed with approved binding material; and shall be free from thin or elongated pieces, clay lumps, soil loam or vegetable matter. The material may be bank-run; or the binder may be added and incorporated by methods approved by Engineer. Should the material be secured from pits, the overburden or stripping from the site of the pits shall be removed to such a distance that none shall fall or wash into the pit; and it shall be placed so as to divert surface drainage away from the pit site. The pit shall be well drained at all times. The pits shall be opened in such a manner as to expose the vertical faces of all strata of acceptable materials; and, unless otherwise directed by Owner, the materials shall be secured in successive vertical cuts extending through all the exposed strata, in order that a uniformity mixed material shall be secured. 1. Tests: The soil binder shall meet the following requirements: a. The liquid limit shall not exceed 35 when tested in accordance with ASTM D423. b. The plastic limit shall be determined by testing in accordance with ASTM D424. c. The plasticity index shall not exceed 12 nor be less than 4 when calculated in accordance with ASTM D424. d. The preparation of samples for testing according to ASTM D423 and D424 shall be in accordance with the requirements of ASTM D2217. e. The linear shrinkage shall not exceed 6 percent. 2. Gradation: The material when tested by standard laboratory methods shall meet the following percentages by weight: a. Material passing the No. 40 sieve (425 µm) shall be known as “soil binder.” b. Materials containing conglomerate or gravel larger than 2” (50 mm) in any dimension shall be broken up and uniformly mixed with the remainder of the materials. Upgrading by the addition of washed gravel in order to meet the requirements of this section shall be permitted. c. If additional binder and/or soil binder are considered necessary by the Owner after gravel materials are spread and shaped, same shall be furnished and applied in the amount directed by the Owner; such additional binder and/or soil binder shall be carefully and evenly Passing 1 ¾ in. sieve (45.0 mm) 100% Passing ¾ in. sieve (9.5 mm) 40 to 80% Passing No. 4 sieve (4.75 mm) 25 to 60% Passing No. 40 sieve (425 µm) 15 to 35% BCRUA - Phase 1D WTP Expansion Issued for Bid Aggregates for Civil Site Improvements 32 05 16 - 4 incorporated with the pit materials in place by scarifying, harrowing or other methods approved by the Owner. 3. Rejection: Gravel which fails to meet the requirements of these specifications may be rejected by the Engineer. Such rejection shall incur no cost to the Owner. D. Coarse Aggregate Type A4 (Gravel for Trench Backfill): Sandy gravel material, free of clay, shale, organic matter; meeting the following requirements: 1. Tests: a. The liquid limit shall not exceed 35 when tested in accordance with ASTM Designation D423. b. The plasticity index shall not exceed 12 nor be less than 4 when calculated in accordance with ASTM Designation D424. c. The linear shrinkage shall not exceed six percent. 2. Gradation: The material when tested by standard laboratory methods shall meet the following percentages by weight: 2.2 FINE AGGREGATE MATERIALS A. Fine Aggregate Type A5 (Sand): Conforming to TxDOT’s Standard Specifications Item 421.2(5), “Fine Aggregate.” 2.3 SOURCE QUALITY CONTROL A. Section 01 40 00 - Quality Requirements: Testing and inspection services. B. Coarse Aggregate Material - Testing and Analysis: Perform in accordance with ASTM D698. C. Fine Aggregate Material - Testing and Analysis: Perform in accordance with ASTM D698. D. When tests indicate materials do not meet specified requirements, change material and retest. PART 3 EXECUTION 3.1 STOCKPILING A. Stockpile materials on site at locations designated by Engineer. B. Stockpile in sufficient quantities to meet Project schedule and requirements. Passing 2 in. sieve 100% Passing 1/2 inch sieve 50 to 85% Passing No. 4 sieve 20 to 65% Passing No. 100 sieve 0 to 5% BCRUA - Phase 1D WTP Expansion Issued for Bid Aggregates for Civil Site Improvements 32 05 16 - 5 C. Separate different aggregate materials with dividers or stockpile individually to prevent mixing. D. Direct surface water away from stockpile site to prevent erosion or deterioration of materials. 3.2 STOCKPILE CLEANUP A. Remove stockpile, leave area in clean and neat condition. Grade site surface to prevent free standing surface water. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Flexible Base 32 11 23 - 1 SECTION 32 11 23 - FLEXIBLE BASE PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. Crushed stone foundation course for backfill of minor structures, embedment, trench backfill, surfacing, pavement or other base courses, furnished and installed on a prepared surface. The “Flexible Base” shall be constructed as herein specified in one or more courses in conformity with the typical sections and to the lines and grades as indicated or as established by the Engineer. B. Related Sections: 1. Section 31 23 17 – Trenching. 2. Section 31 23 23 – Fill. 3. Section 32 05 16 – Aggregates for Civil Site Improvements. 4. Section 32 12 16 – Hot Mix Asphaltic Concrete Paving. 5. Section 32 13 13 – Concrete Paving. 6. Section 32 91 19 – Landscape Grading. 1.2 REFERENCES A. Texas Department of Transportation’s Standard Laboratory Test Procedures: 1. Moisture Content Tex-103-E 2. Liquid Limit Tex-104-E 3. Plasticity Index Tex-106-E 4. Bar Linear Shrinkage Tex-107-E, Part II 5. Sieve Analysis Tex-110-E 6. Moisture-Density Determination Tex-113-E 7. Roadway Density Tex-115-E 8. Wet Ball Mill Tex-116-E 9. Triaxial Tests Tex-117-E (Part I or II as selected by the Engineer) 10. Particle Count Tex-460-A, Part I B. American Association of State Highway and Transportation Officials: 1. AASHTO M288 - Standard Specification for Geotextile Specification for Highway Applications. 1.3 SUBMITTALS A. Section 01 33 00 - Submittal Procedures: Requirements for submittals. B. Product Data: 1. Submit data for flexible base, geotextile fabric, and herbicide. BCRUA - Phase 1D WTP Expansion Issued for Bid Flexible Base 32 11 23 - 2 C. Samples: Submit, in air-tight containers, 10 lb sample of each type of Flexible Base to testing laboratory. D. Materials Source: Submit name of aggregate materials suppliers. E. Manufacturer's Certificate: Certify Flexible Base meets or exceeds specified requirements outlined herein. 1.4 QUALITY ASSURANCE A. Furnish each aggregate material from single source throughout the Work. B. Perform Work in accordance with Texas Department of Transportation’s Standard Specifications for Construction of Highways, Streets, and Bridges (latest Edition). C. Maintain one copy of Texas Department of Transportation’s Standard Specifications for Construction of Highways, Streets, and Bridges (latest Edition) on site. PART 2 PRODUCTS 2.1 FLEXIBLE BASE MATERIAL REQUIREMENTS A. Flexible Base: Texas Department of Transportation’s Standard Specification Item 247, Grade 1 or 2, Type A. 2.2 ACCESSORIES A. Geotextile Fabric: As specified in the Drawings. B. Herbicide: As specified in the Drawings. PART 3 EXECUTION 3.1 EXAMINATION A. Verify existing conditions before starting work. B. Verify compacted substrate is dry and ready to support paving and imposed loads. 1. Proof roll substrate in accordance with Texas Department of Transportation Standard Specification Item 216, “Rolling (Proof)” to identify soft spots. 2. Remove soft substrate and replace with compacted fill as specified in Section 31 23 23 – Fill. 3. No additional compensation will be made for materials, equipment or labor required for “Proof Rolling,” but shall be considered subsidiary to “Flexible Base.” C. Verify substrate has been inspected, gradients and elevations are correct. BCRUA - Phase 1D WTP Expansion Issued for Bid Flexible Base 32 11 23 - 3 3.2 PREPARATION A. Correct irregularities in substrate gradient and elevation by scarifying, reshaping, and re- compacting. B. Do not place fill on soft, muddy, or frozen surfaces. 3.3 BASE PLACEMENT A. When specified in the Drawings, install geotextile fabric over subgrade in accordance with manufacturer's instructions. 1. Lap ends and edges minimum 6 inches. 2. Anchor fabric to subgrade when required to prevent displacement until aggregate is installed. B. When the Flexible Base compacted thickness is less than (or equal to) 6 inches, spread base material over prepared substrate to total compacted thickness indicated on Drawings. C. When the Flexible Base compacted thickness exceeds 6 inches, place base material equal thickness layers to total compacted thickness indicated on Drawings. 1. Maximum Layer Compacted Thickness: 6 inches. 2. Minimum Layer Compacted Thickness: 3 inches. D. Roller compact Flexible Base to density indicated in Texas Department of Transportation’s Standard Specification Item 247. E. Level and contour surfaces to elevations, profiles, and gradients indicated. F. Maintain optimum moisture content of base materials to attain specified compaction density. G. Use mechanical tamping equipment in areas inaccessible to compaction equipment. 3.4 TOLERANCES A. Section 01 40 00 – Quality Requirements and Texas Department of Transportation Item 247.3(1)(f), “Tolerances.” B. Maximum Variation from Flat Surface: 1/4 inch measured with 16 foot straight edge. C. Maximum Variation from Thickness: 1/2 inch. D. Maximum Variation from Elevation: 1/2 inch. 3.5 FIELD QUALITY CONTROL A. Section 01 40 00 – Quality Requirements: Field services and testing and inspection services. BCRUA - Phase 1D WTP Expansion Issued for Bid Flexible Base 32 11 23 - 4 B. Compaction testing will be performed in accordance with Texas Department of Transportation’s Test Method Tex-113-E. C. When tests indicate Work does not meet specified requirements, remove Work, replace and retest. D. Frequency of Tests: One test for every 1000 square foot of each course (layer) of compacted base material, or one test at each location of each course (layer) of compacted base material if less than 1000 square foot. 3.6 COMPACTION A. Each course of flexible base shall be compacted to not less than 100 percent density when tested in accordance with TxDOT Test Method Tex-113-E. Field density determination shall be made in accordance with TxDOT Test Method Tex-115-E. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Hot Mix Asphaltic Concrete Paving 32 12 16 - 1 SECTION 32 12 16 - HOT MIX ASPHALTIC CONCRETE PAVING PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. Asphalt materials. 2. Aggregate materials. 3. Asphalt paving surface course. 4. Asphalt paving overlay for existing paving. B. Related Sections 1. Section 31 23 23 – Fill. 2. Section 32 05 16 – Aggregates for Civil Site Improvements. 3. Section 32 11 23 – Flexible Base. 1.2 REFERENCE STANDARDS A. Texas Department of Transportation’s Standard Specifications for Construction of Highways, Streets and Bridges (latest Edition): 1. Tex-101-E – Preparing Soil and Flexible Base Materials for Testing 2. Tex-107-E – Determining the Bar Linear Shrinkage of Soils 3. Tex-200-F – Sieve Analysis of Fine and Coarse Aggregates 4. Tex-203-F – Sand Equivalent Test 5. Tex-204-F – Design of Bituminous Mixtures 6. Tex-206-F – Compacting Specimens Using the Texas Gyratory Compactor (TGC) 7. Tex-207-F – Determining Density of Compacted Bituminous Mixtures 8. Tex-210-F – Determining Asphalt Content of Bituminous Mixtures by Extraction 9. Tex-217-F – Determining Deleterious Material and Decantation Test for Coarse Aggregates 10. Tex-227-F – Theoretical Maximum Specific Gravity of Bituminous Mixtures 11. Tex-228-F – Determining Asphalt Content of Bituminous Mixtures by the Nuclear Method 12. Tex-229-F – Combined HMAC Cold-Belt Sampling and Testing Procedure 13. Tex-404-A – Determining Unit Mass (Weight) of Aggregates 14. Tex-410-A – Abrasion of Coarse Aggregate Using the Los Angeles Machine 15. Tex-411-A – Soundness of Aggregate Using Sodium Sulfate or Magnesium Sulfate 16. Tex-431-A – Pressure Slaking Test of Synthetic Coarse Aggregate 17. Tex-432-A – Coarse Aggregate Freeze-Thaw Test 18. Tex-433-A – Absorption and Dry Bulk Specific Gravity of Lightweight Coarse Aggregate 19. Tex-438-A – Accelerated Polish Test for Coarse Aggregate 20. Tex-460-A – Determining Crushed Face Particle Count B. American Association of State Highway and Transportation Officials: 1. AASHTO M17 - Standard Specification for Mineral Filler for Bituminous Paving Mixtures. BCRUA - Phase 1D WTP Expansion Issued for Bid Hot Mix Asphaltic Concrete Paving 32 12 16 - 2 2. AASHTO M29 - Standard Specification for Fine Aggregate for Bituminous Paving Mixtures. 3. AASHTO M140 - Standard Specification for Emulsified Asphalt. 4. AASHTO M208 - Standard Specification for Cationic Emulsified Asphalt. 5. AASHTO M288 - Standard Specification for Geotextile Specification for Highway Applications. 6. AASHTO M320 - Standard Specification for Performance-Graded Asphalt Binder. 7. AASHTO M324 - Standard Specification for Joint and Crack Sealants, Hot Applied, for Concrete and Asphalt Pavements. 8. AASHTO MP1a - Standard Specification for Performance-Graded Asphalt Binder. C. Asphalt Institute: 1. AI MS-2 - Mix Design Methods for Asphalt Concrete and Other Hot- Mix Types. 2. AI MS-19 - Basic Asphalt Emulsion Manual. 3. AI SP-2 - Superpave Mix Design. D. ASTM International: 1. ASTM D242 - Standard Specification for Mineral Filler For Bituminous Paving Mixtures. 2. ASTM D692 - Standard Specification for Coarse Aggregate for Bituminous Paving Mixtures. 3. ASTM D946 - Standard Specification for Penetration-Graded Asphalt Cement for Use in Pavement Construction. 4. ASTM D977 - Standard Specification for Emulsified Asphalt. 5. ASTM D1073 - Standard Specification for Fine Aggregate for Bituminous Paving Mixtures. 6. ASTM D1188 - Standard Test Method for Bulk Specific Gravity and Density of Compacted Bituminous Mixtures Using Coated Samples 7. ASTM D2027 - Standard Specification for Cutback Asphalt (Medium-Curing Type). 8. ASTM D2397 - Standard Specification for Cationic Emulsified Asphalt. 9. ASTM D2041 - Standard Test Method for Theoretical Maximum Specific Gravity and Density of Bituminous Paving Mixtures. 10. ASTM D2726 - Standard Test Method for Bulk Specific Gravity and Density of Non- Absorptive Compacted Bituminous Mixtures. 11. ASTM D2950 - Standard Test Method for Density of Bituminous Concrete in Place by Nuclear Methods. 12. ASTM D3381 - Standard Specification for Viscosity-Graded Asphalt Cement for Use in Pavement Construction. 13. ASTM D3515 - Standard Specification for Hot-Mixed, Hot-Laid Bituminous Paving Mixtures. 14. ASTM D3549 - Standard Test Method for Thickness or Height of Compacted Bituminous Paving Mixture Specimens. 15. ASTM D3910 - Standard Practices for Design, Testing, and Construction of Slurry Seal. 16. ASTM D6690 - Standard Specification for Joint and Crack Sealants, Hot Applied, for Concrete and Asphalt Pavements. 1.3 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. BCRUA - Phase 1D WTP Expansion Issued for Bid Hot Mix Asphaltic Concrete Paving 32 12 16 - 3 B. Product Data: 1. Submit product information for asphalt and aggregate materials. 2. Submit mix design with laboratory test results supporting design. C. The Contractor shall designate in writing the source of all materials proposed for use in the mixture. Material certificates signed by the material producer and contractor certifying that each material complies with specification requirements shall be furnished. D. Pavement marking plan indicating lane separations and defined parking places. Note dedicated handicapped spaces with international graphics symbol. 1.4 QUALITY ASSURANCE A. Mixing Plant: Conform to Texas Department of Transportation’s Standard Specifications for Construction of Highways, Streets and Bridges (latest Edition). B. Obtain materials from same source throughout. C. Perform Work in accordance with Texas Department of Transportation’s Standard Specifications for Construction of Highways, Streets and Bridges (latest Edition). D. Maintain one copy of Texas Department of Transportation’s Standard Specifications for Construction of Highways, Streets and Bridges (latest Edition) on site. 1.5 QUALIFICATIONS A. Installer: Company specializing in performing work of this section with minimum 2 years documented experience as approved by Engineer. 1.6 AMBIENT CONDITIONS A. Section 01 50 00 - Temporary Facilities and Controls: Ambient conditions control facilities for product storage and installation. B. Do not place asphalt mixture when ambient air temperature is less than 50 degrees F and is falling (or surface is wet or frozen), but it may be placed when the air temperature is above 40 degrees F and is rising. C. Place asphalt mixture when temperature is not more than 30 degrees F less than initial mixing temperature. PART 2 PRODUCTS 2.1 ASPHALT PAVING A. Asphalt Materials: 1. Asphalt Cement: Asphalt cement for the paving mixture shall meet the requirements of TxDOT Standard Specifications Item 300, “Asphalts, Oils, and Emulsions.” BCRUA - Phase 1D WTP Expansion Issued for Bid Hot Mix Asphaltic Concrete Paving 32 12 16 - 4 2. Tack Coat: Asphaltic materials for tack coats, shown on the plans or approved by the Engineer, shall meet the requirements of TxDOT Standard Specifications Item 300, “Asphalts, Oils, and Emulsions.” 3. Additives: Additives to facilitate mixing and/or improve the quality of the asphaltic mixture shall be used when noted on the Drawings or may be used with the authorization of the Engineer. The Contractor may choose to use either lime or a liquid anti-stripping agent to reduce the moisture susceptibility of the aggregate. The evaluation and addition of anti-stripping agents will be in accordance with TxDOT Standard Specifications Item 301, “Asphalt Anti-stripping Agents.” B. Aggregate Materials: 1. Coarse Aggregate: ASTM D692; crushed stone or crushed gravel in accordance with TxDOT Standard Specifications Item 340. 2. Fine Aggregate: ASTM D1073; natural sand or sand manufactured from stone, gravel, or blast furnace slag in accordance with TxDOT Standard Specifications Item 340. 3. Mineral Filler: ASTM D242; thoroughly dried stone dust or finely ground mineral particles, free of foreign matter; Portland cement, lime, or fly ash, in accordance with TxDOT Standard Specifications Item 340. 2.2 MIXES A. Asphalt Paving Mixtures: Designed in accordance with TxDOT Standard Specifications Item 340 with a maximum 20 percent by weight reclaimed asphalt pavement. 1. Surface Course: TxDOT Standard Specifications Item 340, Type D “Fine Graded Surface Course” composed of angular crushed limestone. Smooth, uncrushed gravel is not allowed. 2. Stability: The materials used in the mixture design shall produce a mixture with a stability of at least 35 when tested in accordance with TxDOT Test Method TEX-208-F. 2.3 SOURCE QUALITY CONTROL A. Section 01 40 00 – Quality Requirements: Testing and inspection requirements. B. Submit proposed mix design for review prior to beginning of Work. C. Test samples in accordance with TxDOT Standard Specifications Item 340. PART 3 EXECUTION 3.1 EXAMINATION A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for installation examination. B. Verify utilities indicated under paving are installed with excavations and trenches backfilled and compacted. C. Verify compacted Flexible Base is dry and ready to support paving and imposed loads. BCRUA - Phase 1D WTP Expansion Issued for Bid Hot Mix Asphaltic Concrete Paving 32 12 16 - 5 D. Verify gradients and elevations of base are correct. E. Verify manhole frames and valve boxes are installed in correct position and elevation. 3.2 INSTALLATION A. Prime Coat: 1. Apply prime coat in accordance with TxDOT Standard Specifications Item 340. 2. Use clean sand to blot excess primer. B. Tack Coat: 1. Apply tack coat in accordance with TxDOT Standard Specifications Item 340. 2. Apply tack coat on asphalt and concrete surfaces and over Flexible Base surface at uniform rate. a. New Surfaces: 0.10 gal/sq yd. b. Existing Surfaces: 0.10 gal/sq yd. 3. Apply tack coat to contact surfaces of curbs, gutters and structures. 4. Coat surfaces of manhole and valve box frames with oil to prevent bond with asphalt paving. Do not tack coat these surfaces. C. Single Course Asphalt Paving: 1. Install Work in accordance with TxDOT Standard Specifications Item 340. 2. Place asphalt within 24 hours of applying primer or tack coat. 3. Place asphalt surface course to thickness indicated on Drawings. 4. Compact paving by rolling to specified density. Do not displace or extrude paving from position. Hand compact in areas inaccessible to rolling equipment. 5. Perform rolling with consecutive passes to achieve even and smooth finish without roller marks. D. Double Course Asphalt Paving: 1. Place asphalt binder course within 24 hours of applying primer or tack coat. 2. Place binder course to thickness indicated on Drawings. 3. Place surface course within 24 hours of placing and compacting binder course. When binder course is placed more than 24 hours before placing wearing course, clean surface and apply tack coat before placing wearing course. 4. Place surface course to thickness indicated on Drawings. 5. Compact each course by rolling to specified density. Do not displace or extrude paving from position. Hand compact in areas inaccessible to rolling equipment. 6. Perform rolling with consecutive passes to achieve even and smooth finish, without roller marks. E. Asphalt Paving Overlay 1. Apply tack coat to existing paving surface at rate recommended by Engineer. 2. When indicated on the Drawings, install geotextile fabric in accordance with manufacturer's instructions to permit asphalt saturation of fabric. Lap fabric edge and end joints 4 inches. 3. Place surface course to thickness indicated on Drawings. 4. Compact overlay by rolling to specified density. Do not displace or extrude paving from position. Hand compact in areas inaccessible to rolling equipment. BCRUA - Phase 1D WTP Expansion Issued for Bid Hot Mix Asphaltic Concrete Paving 32 12 16 - 6 5. Perform rolling with consecutive passes to achieve even and smooth finish, without roller marks. 3.3 COMPACTION A. Hot Mix Asphaltic Concrete (HMAC) Pavement shall be compacted to between 91 and 96 percent of the maximum theoretical density as measured by ASTM D2041 and in accordance with TxDOT Standard Specifications Item 340, “Hot Mix Asphaltic Concrete Pavement” for Air Void Control. 3.4 TOLERANCES A. Section 01 40 00 – Quality Requirements: Tolerances. B. Flatness: Maximum variation of 1/4 inch measured with 10 foot straight edge applied parallel with and at right angles to centerline of paved area. C. Scheduled Compacted Thickness: Within 1/4 inch. D. Variation from Indicated Elevation: Within 1/4 inch. 3.5 FIELD QUALITY CONTROL A. Section 01 40 00 - Quality Requirements: Requirements for testing and inspection. B. Take samples and perform tests in accordance with TxDOT Standard Specifications Item 340. C. Asphalt Paving Mix Temperature: Measure temperature at time of placement. D. Asphalt Paving Thickness: ASTM D3549; test one core sample from every 1000 square yards compacted paving. E. Asphalt Paving Density: Test Method Tex-207-F; test one core sample from every 1000 square yards or 1 per day (minimum) of compacted paving. F. Stability: Test Method Tex-208-F; one test per day during production. G. Extraction: Test Methods Tex-210-F; Tex-228-F; or Tex-229-F; one test per day during production. 3.6 PROTECTION A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for protecting installed construction. B. Immediately after placement, protect paving from mechanical injury until surface temperature is less than 140 degrees F. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Concrete Paving 32 13 13 - 1 SECTION 32 13 13 - CONCRETE PAVING PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. Aggregate base course. 2. Concrete paving for: a. Concrete streets and roads. b. Concrete parking lots. c. Concrete curbs and gutters. d. Concrete median barriers. e. Concrete sidewalks. f. Concrete driveways. B. Related Sections: 1. Section 03 11 00 – Concrete Forming. 2. Section 03 21 00 – Reinforcing Steel. 3. Section 03 30 00 – Cast-In-Place Concrete. 4. Section 07 92 00 – Joint Sealants. 1.2 REFERENCE STANDARDS A. Mixing, sampling, placing, curing and testing of concrete, and the materials used shall comply with the latest revisions of the following standards, unless otherwise noted in the Contract Documents. B. American Association of State Highway and Transportation Officials: 1. AASHTO M324 - Standard Specification for Joint and Crack Sealants, Hot Applied, for Concrete and Asphalt Pavements. C. American Concrete Institute: 1. ACI 301 - Specifications for Structural Concrete. 2. ACI 304 - Guide for Measuring, Mixing, Transporting, and Placing Concrete. 3. ACI 305.1 - Specification for Hot Weather Concreting 4. ACI 306.1 - Standard Specification for Cold Weather Concreting 5. ACI 308.1 - Specification for Curing Concrete D. Concrete Plant Manufacturers Bureau (CPMB) Standards: 1. Concrete Plant Standards. E. ASTM International: 1. ASTM A184/A184M - Standard Specification for Fabricated Deformed Steel Bar Mats for Concrete Reinforcement. 2. ASTM A185/A185M - Standard Specification for Steel Welded Wire Fabric, Plain, for Concrete Reinforcement. 3. ASTM A497/A497M - Standard Specification for Steel Welded Wire Fabric, Deformed, for Concrete Reinforcement. BCRUA - Phase 1D WTP Expansion Issued for Bid Concrete Paving 32 13 13 - 2 4. ASTM A615/A615M - Standard Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement. 5. ASTM A706/A706M - Standard Specification for Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement. 6. ASTM A767/A767M - Standard Specification for Zinc-Coated (Galvanized) Steel Bars for Concrete Reinforcement. 7. ASTM A775/A775M - S Standard Specification for Epoxy-Coated Steel Reinforcing Bars. 8. ASTM A884/A884M - Standard Specification for Epoxy-Coated Steel Wire and Welded Wire Reinforcement. 9. ASTM A934/A934M - Standard Specification for Epoxy-Coated Prefabricated Steel Reinforcing Bars. 10. ASTM C31/C31M - Standard Practice for Making and Curing Concrete Test Specimens in the Field. 11. ASTM C33 - Standard Specification for Concrete Aggregates. 12. ASTM C39/C39M - Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens. 13. ASTM C78/C78M - Standard Test Method for Flexural Strength of Concrete (Using Simple Beam with Third-Point Loading) 14. ASTM C94/C94M - Standard Specification for Ready-Mixed Concrete. 15. ASTM C125/C125M - Standard Terminology Relating to Concrete and Concrete Aggregates. 16. ASTM C183/C183M - Standard Test Method for Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete 17. ASTM C143/C143M - Standard Test Method for Slump of Hydraulic Cement Concrete. 18. ASTM C150 - Standard Specification for Portland Cement. 19. ASTM C172 - Standard Practice for Sampling Freshly Mixed Concrete. 20. ASTM C173/C173M - Standard Test Method for Air Content of Freshly Mixed Concrete by the Volumetric Method. 21. ASTM C192 - Standard Practice for Making and Curing Concrete Test Specimens in the Laboratory. 22. ASTM C231 - Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method. 23. ASTM C260 - Standard Specification for Air-Entraining Admixtures for Concrete. 24. ASTM C309 - Standard Specification for Liquid Membrane-Forming Compounds for Curing Concrete. 25. ASTM C494/C494M - Standard Specification for Chemical Admixtures for Concrete. 26. ASTM C595 - Standard Specification for Blended Hydraulic Cements. 27. ASTM C618 - Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use as a Mineral Admixture in Concrete. 28. ASTM C979 - Standard Specification for Pigments for Integrally Colored Concrete. 29. ASTM C989 - Standard Specification for Ground Granulated Blast-Furnace Slag for Use in Concrete and Mortars. 30. ASTM C1017/C1017M - Standard Specification for Chemical Admixtures for Use in Producing Flowing Concrete. 31. ASTM C1064/C1064M - Standard Test Method for Temperature of Freshly Mixed Hydraulic-Cement Concrete. 32. ASTM C1116 - Standard Specification for Fiber-Reinforced Concrete and Shotcrete. 33. ASTM C1315 - Standard Specification for Liquid Membrane-Forming Compounds Having Special Properties for Curing and Sealing Concrete. BCRUA - Phase 1D WTP Expansion Issued for Bid Concrete Paving 32 13 13 - 3 34. ASTM D1751 - Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types). 35. ASTM D1752 - Standard Specification for Preformed Sponge Rubber and Cork Expansion Joint Fillers for Concrete Paving and Structural Construction. 36. ASTM D6690 - Standard Specification for Joint and Crack Sealants, Hot Applied, for Concrete and Asphalt Pavements. 1.3 SUBMITTALS A. Section 01 33 00 - Submittal Procedures: Requirements for submittals. B. Product Data: 1. Submit data on concrete materials, joint filler, admixtures, and curing compounds. 2. Acknowledgement that products submitted meet requirements of standards referenced. C. Design Data: 1. Submit concrete mix design for each concrete strength. Submit separate mix designs when admixtures are required for the following: a. Hot and cold weather concrete work. 2. Identify mix ingredients and proportions, including admixtures. 3. Identify chloride content of admixtures and whether or not chloride was added during manufacture. 4. Qualifications of concrete installer. 5. Drawings detailing all reinforcing. 6. Concrete cylinder test results from field quality control. D. Source Quality Control Submittals: 1. Indicate results of shop factory tests and inspections. 2. Perform compression tests in accordance with ACI 301, ASTM C39, and ASTM C31 using 6-by-12 cylinders. 3. Provide certified test reports for: a. Materials used in the trial mix design. b. Water: Verification that all potable mix water and curing water sources do not exceed the non-potable water limits listed in ASTM C1602 Table 2. c. Aggregate, conforming to ASTM C33, including the test reports for soundness and abrasion resistance. d. Aggregate: 1) Verification that aggregate is not “potentially reactive” per ASTM C1260. 2) Or a cement chemical analysis indicating that the total alkali content is acceptable per Paragraph 2.02.A. 3) When mix water exceeds 50 percent of the chloride limit indicated in ASTM C1602 Table 2, then all aggregate sources shall be tested for chloride content in accordance with ASTM C1218. e. 7-day and 28-day compressive strength tests results. 1) When more than 15, 28-day compressive tests results are available from the current Project for a given class of concrete, include the 15-test running average compressive strength versus the required average compressive strength (based on the previous 15 tests) in graphical form. BCRUA - Phase 1D WTP Expansion Issued for Bid Concrete Paving 32 13 13 - 4 f. If the sum total of chlorides in mix water and aggregates exceeds 80 percent of the specified limit for hardened concrete, then prior to use of concrete, test mix design to verify acceptable chloride ion concentrations in accordance with ASTM C1218. g. Shrinkage data for mixes which specify a shrinkage limit. 4. Provide documentation of supplier’s National Ready Mixed Concrete Association certification. E. Submit a schedule to the Owner’s representative which shows the sequence of concrete placements. F. Submit a concrete paving jointing plan for acceptance by the Engineer. 1.4 QUALITY ASSURANCE A. Perform Work in accordance with ACI 301 and the requirements of Section 03 10 00, Section 03 20 00, and Section 03 30 00. B. Obtain cementitious materials from same source throughout. 1.5 QUALIFICATIONS A. Manufacturer: Company specializing in manufacturing Products specified in this section with minimum three years documented experience. B. Installer: Company specializing in performing work of this section with minimum three years documented experience. C. Testing Agency: An independent testing agency, acceptable to authorities having jurisdiction and the Engineer, qualified according to ASTM C1077 and ASTM E329 to conduct the testing indicated. 1.6 AMBIENT CONDITIONS A. Section 01 50 00 - Temporary Facilities and Controls: Ambient conditions control facilities for product storage and installation. B. Do not place concrete when base surface temperature is less than 40 degrees F, or surface is wet or frozen. PART 2 PRODUCTS 2.1 CONCRETE PAVING A. Form Materials: 1. Form Materials: As specified in Section 03 11 00 – Concrete Forming. 2. Joint Sealer: Shall be in accordance with Section 07 92 00 – Joint Sealants. B. Reinforcement: BCRUA - Phase 1D WTP Expansion Issued for Bid Concrete Paving 32 13 13 - 5 1. Reinforcing Steel: Type specified in Section 03 21 00 – Reinforcing Steel, except as specified otherwise herein. a. Dowel Bars: 1) Dowel bars shall be plain steel bars conforming to ASTM A615 or ASTM A966 and shall be free from burring or other deformation restricting slippage in the concrete. Before delivery to the construction site each dowel bar shall be painted with one coat of paint conforming to MIL-DTL-24441/20A.SSPC Paint 5 or SSPC Paint 25. Metal or plastic collars (when indicated on Drawings) shall be full circular device supporting the dowel until the epoxy hardens. 2) The sleeves for dowel bars used in expansion joints shall be translucent of an approved design to cover 2 inches (minimum) of the dowel, with a closed end and with a suitable stop to hold the end of the bar at least 1½ inches from the closed end of the sleeve. Sleeves shall be of such design that they will not collapse during construction. C. Concrete Materials: 1. Concrete Materials shall be as specified in Section 03 30 00 – Cast-In-Place Concrete. 2. Concrete for paving shall be Class B in accordance with Section 03 30 00 – Cast in Place Concrete. 2.2 FABRICATION A. Fabricate reinforcing in accordance with CRSI Manual of Practice. B. Form standard hooks for 180 degree bends and 90 degree bends as indicated on the Drawings. 2.3 MIXES A. Concrete Mix: 1. Mix and deliver concrete in accordance with ASTM C94/C94M, Option a. 2. Select proportions for normal weight concrete in accordance with ACI 301 Method 1. 3. Provide concrete meeting the criteria specified in Section 03 30 00 – Cast in Place Concrete, Class B, except as specified otherwise herein. 4. Limit the following cementitious materials to maximum percentage by mass of all cementitious materials: a. Fly Ash: 0 percent. Fly ash shall not be used. 5. Use accelerating admixtures in cold weather only when approved by the Engineer in writing. Use of admixtures will not relax cold weather placement requirements. 6. Use calcium chloride only when approved by the Engineer in writing. 7. Use set retarding admixtures during hot weather only when approved by the Engineer in writing. 2.4 ACCESSORIES A. Curing Compound: ASTM C309, Type 2, Class B. B. Joint Sealers: Specified in Section 07 92 00. C. Premolded Joint Filler: Premolded resilient joint filler for expansion joints shall conform to the requirements of ASTM D1751 and shall be punched to admit the dowels where called for BCRUA - Phase 1D WTP Expansion Issued for Bid Concrete Paving 32 13 13 - 6 on the plans. The filler for each joint shall be furnished in a single piece for the full depth and width required for the joint, unless otherwise specified by the Engineer. When the use of more than one piece is required for a joint, the abutting ends shall be fastened securely and held accurately to shape by stapling or other positive fastening means satisfactory to Engineer. Joint filler shall be compatible with joint sealant. 2.5 SOURCE QUALITY CONTROL A. Section 03 30 00 – Cast in Place Concrete: Testing. B. Submit proposed mix design of each class of concrete to Engineer for review prior to commencement of Work. C. Tests on cement, aggregates, and mixes will be performed to ensure conformance with specified requirements. D. Test samples in accordance with ASTM C94/C94M. PART 3 EXECUTION 3.1 EXAMINATION A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for installation examination. B. Verify compacted base or subgrade is dry and ready to support paving and imposed loads. 1. Proof roll subgrade with two perpendicular passes to identify soft spots. 2. Remove soft subgrade or base and replace with Flexible Base. C. Verify gradients and elevations of base are correct. 3.2 PREPARATION A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for installation preparation. B. Moisten substrate to minimize absorption of water from fresh concrete. C. Coat surfaces of manhole frames with oil to prevent bond with concrete paving. D. Notify Engineer minimum 24 hours prior to commencement of concreting operations. 3.3 INSTALLATION A. Forms: 1. Place and secure forms and screeds to correct location, dimension, profile, and gradient. 2. Assemble formwork to permit easy stripping and dismantling without damaging concrete. B. Reinforcement: 1. Place reinforcing as indicated on Drawings. BCRUA - Phase 1D WTP Expansion Issued for Bid Concrete Paving 32 13 13 - 7 2. Interrupt reinforcing at expansion joints. 3. Provide doweled joints as indicated on Drawings. Dowel bars or other load-transfer units of an approved type shall be placed across joints in the manner as shown on Drawings. They shall be of the dimensions and spacings as shown and held rigidly in the middle of the slab depth in the proper horizontal and vertical alignment of by an approved assembly device to be left permanently in place. The dowel or load-transfer and joint devices shall be rigid enough to permit complete assembly as a unit ready to be lifted and placed into position. A dowel expansion cap or sleeve shall be furnished for each dowel bar used with expansion joints. These caps shall be substantial enough to prevent collapse and shall be placed on the ends of the dowels as shown on Drawings. The caps or sleeves shall fit the dowel bar tightly and the closed end shall be watertight. The portion of each dowel painted with rust preventative paint, as required under paragraph 2.1(B) and shown on Drawings to receive a debonding lubricant, shall be thoroughly coated with asphalt MC-70, or an approved lubricant, to prevent the concrete from bonding to that portion of the dowel. If free-sliding plastic-coated or epoxy-coated steel dowels are used, a lubrication bond breaker shall be used except when approved pullout tests indicate it is not necessary. Where butt-type joints with dowels are designated, the exposed end of the dowel shall be oiled. 4. Repair damaged galvanizing and/or epoxy coating to match shop finish. 5. Install tie bars consisting of deformed bars in joints as shown on Drawings. Tie bars shall be placed at right angles to the centerline of the concrete slab and shall be spaced at intervals shown on Drawings. They shall be held in position parallel to the pavement surface and in the middle of the slab depth. When tie bars extend into an unpaved lane, they may be bent against the form at longitudinal construction joints, unless threaded bolt or other assembled tie bars are specified. These bars shall not be painted, greased, or enclosed in sleeves. When slip-form operations call for tie bars, two-piece hook bolts can be installed in the female side of the keyed joint provided the installation is made without distorting the keyed dimensions or causing edge slump. If a bent tie bar installation is used, the tie bars shall be inserted through the keyway liner only on the female side of the joint. In no case shall a bent tie bar installation for male keyways be permitted. C. Placing Concrete: 1. Place concrete as specified in Section 03 30 00 - Cast in Place Concrete. 2. Ensure reinforcing, inserts, embedded parts, and formed joints are not disturbed during concrete placement. 3. Place concrete continuously over the full width of the panel and between predetermined construction joints. Do not break or interrupt successive pours such that cold joints occur. D. Joints: Joints shall be constructed as shown on Drawings and in accordance with these requirements. All joints shall be constructed with their faces perpendicular to the surface of the pavement and finished or edged as shown on Drawings. Joints shall not vary more than ½-inch from their designated position and shall be true to line with not more than ¼-inch variation in 10 feet. The surface across the joint shall be tested with a 10-foot straightedge as the joints are finished and any irregularities in excess of ¼-inch shall be corrected before the concrete has hardened. All joints shall be so prepared, finished, or cut to provide a groove of uniform width and depth as shown on Drawings. 1. Place expansion joints as indicated on Drawings. Premolded joint filler of the thickness as shown on Drawings shall extend for the full depth and width of the slab at the joint, except for space for sealant at the top of the slab. The filler shall be securely staked or fastened into position perpendicular to the proposed finished surface. A cap shall be BCRUA - Phase 1D WTP Expansion Issued for Bid Concrete Paving 32 13 13 - 8 provided to protect the top edge of the filler and to permit the concrete to be placed and finished. After the concrete has been placed and struck off, the cap shall be carefully withdrawn leaving the space for the premolded filler. The edges of the joint shall be finished and tooled while the concrete is still plastic. Any concrete bridging the joint space shall be removed for the full width and depth of the joint. Align curb, gutter, pavement, and sidewalk joints. 2. Place isolation joints between paving components and building or other structures as indicated on Drawings. Construct isolation joints identically to expansion joints as specified in (1), above. Isolation joints shall not be dowelled. 3. Provide construction joints as indicated on Drawings. Longitudinal construction joints shall be slip-formed or formed against side forms with or without keyways, as shown on Drawings. Transverse construction joints shall be installed at the end of each day’s placing operations and at any other points within a paving lane when concrete placement is interrupted for more than 30 minutes or it appears that the concrete will obtain its initial set before fresh concrete arrives. The installation of the joint shall be located at a planned contraction or expansion joint. If placing of the concrete is stopped, the Contractor shall remove the excess concrete back to the previous planned joint. 4. Install contraction joints at the locations and spacing as shown on Drawings. Contraction joints shall be installed to the dimensions required by forming a groove or cleft in the top of the slab while the concrete is still plastic or by sawing a groove into the concrete surface after the concrete has hardened. When the groove is formed in plastic concrete the sides of the grooves shall be finished even and smooth with an edging tool. If an insert material is used, the installation and edge finish shall be according to the manufacturer’s instructions. The groove shall be finished or cut clean so that spalling will be avoided at intersections with other joints. Groove or saw cut contraction joints ¼- inch wide at an optimum time as soon as possible after finishing. Cut ¼ of depth of slab into the slab. If contraction joint spacing is not indicated on Drawings, maximum contraction joint spacing shall be thirty (30) times the depth of the concrete paving. 5. Seal joints as indicated on Drawings and in accordance with Section 07 92 00. 6. Provide keyways as indicated on Drawings. Form keyways (only female keys permitted) in the plastic concrete by means of side forms or the use of keyway liners that are inserted during the slip-form operations. The keyway shall be formed to a tolerance of ¼ inch in any dimension and shall be of sufficient stiffness to support the upper keyway flange without distortion or slumping of the top of the flange. The dimensions of the keyway forms shall not vary more than plus or minus ¼ inch from the mid-depth of the pavement. Liners that remain in place permanently and become part of the keyed joint shall be made of galvanized, copper clad, or of similar rust-resistant material compatible with plastic and hardened concrete and shall not interfere with joint reservoir sawing and sealing. E. Finishing Schedule: 1. Vehicular Paving: Heavy broom finish, burlap drag finish, or saw groove finish. 2. Sidewalk Paving: Light broom finish. 3. Curbs and Gutters: Light broom finish. 4. Inclined Vehicular Ramps: Heavy broom finish perpendicular to slope. F. Curing and Protection 1. Immediately after placement, protect concrete from premature drying, excessively hot or cold temperatures, and mechanical injury. BCRUA - Phase 1D WTP Expansion Issued for Bid Concrete Paving 32 13 13 - 9 2. Maintain concrete with minimal moisture loss at relatively constant temperature for period necessary for hydration of cement and hardening of concrete. 3. Cure concrete surfaces as specified in Section 03 30 00 – Cast in Place Concrete. 3.4 TOLERANCES A. Section 01 40 00 – Quality Requirements: Tolerances. B. Maximum Variation of Surface Flatness: 1/4 inch in 10 ft. C. Maximum Variation From True Position: 1/4 inch. D. Maximum Variation in Thickness: 1/4 inch. 3.5 FIELD QUALITY CONTROL A. Section 01 40 00 – Quality Requirements: Requirements for inspecting and testing. B. Inspect reinforcing placement for size, spacing, location, support. C. Testing firm will take cylinders and perform slump and air entrainment tests in accordance with ACI 301. D. Strength Test Samples: 1. Sampling Procedures: ASTM C172. 2. Cylinder Molding and Curing Procedures: ASTM C31/C31M, cylinder specimens, standard cured. 3. Sample concrete and make one set of three standard cylinders for every 50 cu yds or less of each class of concrete placed each day and for every 2500 sf of surface area paving. 4. Make one additional cylinder during cold weather concreting, and field cure. E. Field Testing: 1. Slump Test Method: ASTM C143/C143M. 2. Air Content Test Method: ASTM C173/C173M ASTM C231. 3. Temperature Test Method: ASTM C1064/C1064M. 4. Measure slump and temperature for each compressive strength concrete sample. 5. Measure air content in air entrained concrete for each compressive strength concrete sample. F. Cylinder Compressive Strength Testing: 1. Test Method: ASTM C39/C39M. 2. Test Acceptance: Average compressive strength of three consecutive test results equal or exceed specified compressive strength, and no individual strength test result falls below specified compressive by more than 500 psi. 3. Test one cylinder at 7 days. 4. Test one cylinder at 28 days. 5. Retain one cylinder for reserve for testing later when requested by Engineer. 6. Dispose remaining cylinders when testing is not required. BCRUA - Phase 1D WTP Expansion Issued for Bid Concrete Paving 32 13 13 - 10 G. Maintain records of placed concrete items. Record date, location of pour, quantity, air temperature, and test samples taken. 3.6 PROTECTION A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for protecting installed construction. B. Immediately after placement, protect paving from premature drying, excessive hot or cold temperatures, and mechanical injury. C. Do not permit vehicular traffic over paving for 14 days (minimum) after finishing. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Landscape Grading 32 91 19 - 1 SECTION 32 91 19 - LANDSCAPE GRADING PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. Final grade topsoil for finish landscaping. B. Related Sections: 1. Section 31 05 13 – Topsoil. 2. Section 31 23 17 – Trenching. 3. Section 31 23 23 – Fill. 4. Section 32 92 19 – Seeding. 1.2 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Submittal procedures. B. Materials Source: Submit name of imported materials source. 1.3 QUALITY ASSURANCE A. Furnish each topsoil material from single source throughout the Work. PART 2 PRODUCTS 2.1 MATERIAL A. Topsoil: As specified in Section 31 05 13 – Topsoil. PART 3 EXECUTION 3.1 EXAMINATION A. Section 01 30 00 – Administrative Requirements: Verification of existing conditions before starting work. B. Verify structural and trench backfilling have been inspected. C. Verify substrate base has been contoured and compacted. 3.2 PREPARATION A. Protect landscaping and other features remaining as final Work. B. Protect existing structures, fences, sidewalks, utilities, paving, and curbs. BCRUA - Phase 1D WTP Expansion Issued for Bid Landscape Grading 32 91 19 - 2 3.3 SUBSTRATE PREPARATION A. Eliminate uneven areas and low spots. B. Remove debris, roots, branches, stones, in excess of 2 inches in size. Remove contaminated subsoil. C. Scarify surface to depth of 4 inches where topsoil is scheduled. Scarify in areas where equipment used for hauling and spreading topsoil has compacted subsoil. 3.4 PLACING TOPSOIL A. Place topsoil in areas where seeding and/or sodding is required to nominal depth of four inches, or as indicated on the Drawings. Place topsoil during dry weather. B. Fine grade topsoil to eliminate rough or low areas. Maintain profiles and contour of subgrade. C. Remove roots, weeds, rocks, and foreign material while spreading. D. Manually spread topsoil close to plant material, structures, water and wastewater appurtenances, concrete paving, and curbs to prevent damage. E. Lightly roll placed topsoil. F. Remove surplus subsoil and topsoil from site. G. Leave stockpile area and site clean and raked, ready to receive landscaping. 3.5 TOLERANCES A. Section 01 40 00 – Quality Requirements: Tolerances. B. Top of Topsoil: Plus or minus 1/2 inch. 3.6 PROTECTION OF INSTALLED WORK A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for protecting installed construction. B. Prohibit construction traffic over topsoil. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Seeding 32 92 19 - 1 SECTION 32 92 19 - SEEDING PART 1 GENERAL 1.1 SUMMARY A. Description: This item shall consist of preparing a seed bed to the lines and grades indicated, sowing of seed, fertilizing, mulching with straw, asphalt, cellulose fiber and other management practices along and across such areas as are indicated or as directed by the Engineer. B. Section Includes: 1. Fertilizing. 2. Seeding. 3. Hydroseeding. 4. Mulching. 5. Maintenance. C. Related Sections: 1. Section 31 05 13 – Topsoil. 2. Section 32 91 19 – Landscape Grading. 1.2 REFERENCES A. ASTM International: 1. ASTM C602 - Standard Specification for Agricultural Liming Materials. 1.3 DEFINITIONS A. Weeds: Include Dandelion, Jimsonweed, Quackgrass, Horsetail, Morning Glory, Rush Grass, Mustard, Lambsquarter, Chickweed, Cress, Crabgrass, Canadian Thistle, Nutgrass, Poison Oak, Blackberry, Tansy Ragwort, Bermuda Grass, Johnson Grass, Poison Ivy, Nut Sedge, Nimble Will, Bindweed, Bent Grass, Wild Garlic, Perennial Sorrel, Brome Grass, or vegetative species other than specified species to be established in given area. 1.4 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Product Data: Submit data for seed mix, fertilizer, mulch, stabilizer and other accessories. 1.5 CLOSEOUT SUBMITTALS A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for submittals. B. Operation and Maintenance Data: Include maintenance instructions, cutting method and maximum grass height; and types, application frequency, and recommended coverage of fertilizer. BCRUA - Phase 1D WTP Expansion Issued for Bid Seeding 32 92 19 - 2 1.6 QUALITY ASSURANCE A. Provide seed mixture in containers showing percentage of seed mix, germination percentage, inert matter percentage, weed percentage, year of production, net weight, date of packaging, and location of packaging. 1.7 QUALIFICATIONS A. Seed Supplier: Company specializing in manufacturing Products specified in this section with minimum three years documented experience. B. Installer: Company specializing in performing work of this section with minimum three years documented experience. 1.8 DELIVERY, STORAGE, AND HANDLING A. Section 01 60 00 – Product Requirements: Product storage and handling requirements. B. Deliver grass seed mixture in sealed containers. Seed in damaged packaging is not acceptable. C. Deliver fertilizer in waterproof bags showing weight, chemical analysis, and name of manufacturer. 1.9 MAINTENANCE SERVICE A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for maintenance service. B. Maintain seeded areas immediately after placement until grass is well established and exhibits vigorous growing condition. PART 2 PRODUCTS 2.1 SEED A. All seed must meet the requirements of the Texas Seed Law including the labeling requirements for showing pure live seed (PLS), name and type of seed. Seed furnished shall be of the previous season’s crop and the date of analysis shown on each bag shall be within nine months of the time of delivery to the project. Each variety of seed shall be furnished and delivered in separate bags or containers. A sample of each variety of seed shall be furnished for analysis and testing when directed by the Engineer. The amount of seed planted per acre shall be of the type specified below. B. Substitutions: Section 01 60 00 – Product Requirements. 2.2 ACCESSORIES A. Mulching Material: Oat or wheat straw, free from weeds, foreign matter detrimental to plant life, and dry. Hay or chopped cornstalks are not acceptable. Straw mulch shall be spread uniformly over the area indicated or as designated by the Engineer at the rate of 2 to 2 1/2 tons BCRUA - Phase 1D WTP Expansion Issued for Bid Seeding 32 92 19 - 3 of straw per acre. The actual rate of application will be designated by the Engineer. Straw may be hand or machine placed and adequately secured. B. Cellulose Fiber Mulch: Cellulose fiber mulch shall be spread uniformly over the area indicated or as designated by the Engineer at the rate of 45 to 80 lbs per 1000 square feet. C. Fertilizer: All fertilizer shall be delivered in bags or containers clearly labeled showing the analysis. The fertilizer is subject to testing by the State Chemist in accordance with the Texas Fertilizer Law. A pelleted or granulated fertilizer shall be used with an analysis indicated below. The figures in the analysis represent the percent of nitrogen, phosphoric acid and potash nutrients, respectively, as determined by the methods of the Association of Official Agricultural Chemists. Fifty percent or greater of the Nitrogen required shall be in the form of Nitrate Nitrogen (NO3). The remaining Nitrogen required may be in the form of Urea Nitrogen (CO(NH2)2). In the event it is necessary to substitute a fertilizer of a different analysis, it shall be a pelleted or granulated fertilizer with a lower concentration. The total amount of nutrients furnished and applied per acre shall equal or exceed that specified for each nutrient. Fertilizer shall be commercial grade; recommended for grass; of proportion necessary to eliminate deficiencies of topsoil to the following proportions: Nitrogen 15 percent, phosphoric acid 15 percent, soluble potash 15 percent. D. Lime: ASTM C602, Class T agricultural limestone containing a minimum 80 percent calcium carbonate equivalent. E. Water: Clean, fresh and free of industrial wastes and other substances or matter capable of inhibiting vigorous growth of grass. F. Soil Retention Blanket: Jute mesh or matting (open weave), or other material used as a soil retention blanket for erosion control purposes. G. Herbicide: As specified. H. Stakes: Softwood lumber, chisel pointed. I. String: Inorganic fiber. 2.3 SOURCE QUALITY CONTROL A. Section 01 40 00 – Quality Requirements: Testing, inspection and analysis requirements. B. Analyze to ascertain percentage of nitrogen, phosphorus, potash, soluble salt content, organic matter content, and pH value. C. Provide recommendation for fertilizer and lime application rates for specified seed mix as result of testing. BCRUA - Phase 1D WTP Expansion Issued for Bid Seeding 32 92 19 - 4 D. Testing is not required when recent tests and certificates are available for imported topsoil. Submit these test results to testing laboratory. Indicate, by test results, information necessary to determine suitability. PART 3 EXECUTION 3.1 EXAMINATION A. Section 01 30 00 – Administrative Requirements: Verification of existing conditions before starting work. B. Verify prepared soil base is ready to receive the Work of this section. 3.2 PREPARING SEED BED A. After the designated areas have been rough graded to the lines, grades and typical sections indicated or as provided for in other items of this contract and any other soil area disturbed by the construction, a suitable seed bed shall be prepared. The seed bed shall consist of either 4 inches of approved topsoil or 4 inches of approved salvaged topsoil cultivated and rolled sufficiently to a state of good tilth which could prevent the seed from being covered too deep for optimum germination. The optimum depth for seeding shall be 1/4 inch. Water shall be applied as required to prepare the seed bed. Seeding shall be performed in accordance with the requirements hereinafter described. 3.3 FERTILIZING A. Apply lime at application rate recommended by soil analysis. Work lime into top 6 inches of soil. B. Apply fertilizer at application rate as indicated below: Application Rate Use Type Pound Per Acre Broadcast Seeding Any 400 Hydraulic Seeding Water Soluble 653 Sodding Any 300 C. Apply after smooth raking of topsoil and prior to roller compaction. D. Do not apply fertilizer at same time or with same machine used to apply seed. E. Mix fertilizer thoroughly into upper 2 inches of topsoil. F. Lightly water soil to aid dissipation of fertilizer. Irrigate top level of soil uniformly. 3.4 BROADCAST SEEDING A. The seed or seed mixture in the quantity specified shall be uniformly distributed over the prepared seed bed areas indicated or where directed. If the sowing of seed is by hand, rather BCRUA - Phase 1D WTP Expansion Issued for Bid Seeding 32 92 19 - 5 than by mechanical methods, the seed shall be sown in two directions at right angles to each other. If mechanical equipment is used, all varieties of seed, as well as fertilizer, may be distributed at the same time, provided that each component is uniformly applied at the specified rate. After planting, the planted area shall be rolled with a corrugated roller of the “Culitpacker” type. All rolling of the slope areas shall be on the contour. B. Seed Mixture and Rate of Application for Broadcast Seeding: 1. From September 15 to March 1, seeding shall be with a combination of unhulled Bermuda Grass at a rate of 2 pounds per 1000 square feet and winter rye at a rate of 7 pounds per 1000 square feet that has a PLS = 0.83. 2. From March 1 to September 15, seeding shall be with hulled Bermuda Grass at a rate of 2 pounds per 1000 square feet with a PLS = 0.83. Fertilizer shall be applied as specified herein. C. Do not seed areas in excess of that which can be mulched on same day. D. Do not sow immediately following rain, when ground is too dry, or when winds are over 12 mph. E. Lightly roll seeded area with roller not exceeding 112 lbs/linear foot. F. Immediately following seeding and rolling, apply mulch to thickness of 1/8 inch. Maintain clear of shrubs and trees. G. The broadcast seeded areas shall immediately be watered with a minimum of 5 gallons of water per square yard or as needed and in the manner and quantity as directed by the Engineer. Water shall be applied at a minimum rate of 10 gallons per square yard weekly except when rainfall of 1/2 inch or greater occurs on the site, the water can be postponed for one week or as directed, until the grass is uniformly 1 1/2 inches in height. 3.5 HYDRAULIC SEEDING A. The seed bed shall be prepared as specified above and hydraulic seeding equipment, which is capable of placing all materials in a single operation, shall be used. March 1 to September 15: Hydraulic seeding mixture and minimum rate of application per 1000 square feet: Hulled Bermuda Seed (PLS = 0.83) Water Soluble Fertilizer Cellulose Fiber Mulch Soil Tackifier 1 lb. 15 lbs. 45.9 lbs. 1.4 lbs. September 15 to March 1: Add 7 pounds per 1000 square feet of winter rye with a PLS = 0.83 to above mixture. Fertilizer shall be applied as specified herein. B. Watering: Hydraulically planted seeded area shall be watered weekly, except when rainfall of 1/2 inch or greater occurs on the site, the watering can be postponed for one week, BCRUA - Phase 1D WTP Expansion Issued for Bid Seeding 32 92 19 - 6 commencing after the tackifier has dried or until the grass is uniformly 1 1/2 inches in height. The native grass seeded area shall be watered at a minimum rate of 5 gallons per square yard weekly commencing after the tackifier has dried or until the grass is uniformly 1 1/2 inches in height. The watering can be postponed for one week or as directed, when rainfall of 1 1/2 inches or greater occurs on the site. 3.6 SEED PROTECTION A. Cover seeded slopes where grade is 3:1 (Horizontal:Vertical) or greater with soil retention blanket. Roll fabric onto slopes without stretching or pulling. B. Lay fabric smoothly on surface, bury top end of each section in 6 inch deep excavated topsoil trench. Overlap edges and ends of adjacent rolls minimum 12 inches. Backfill trench and rake smooth, level with adjacent soil. C. Secure outside edges and overlaps at 36 inch intervals with stakes. D. Lightly dress slopes with topsoil to ensure close contact between fabric and soil. E. At sides of ditches, lay fabric laps in direction of water flow. Lap ends and edges minimum 6 inches. 3.7 MAINTENANCE A. Mow grass at regular intervals to maintain at maximum height of 2-1/2 inches. Do not cut more than 1/3 of grass blade at each mowing. Perform first mowing when seedlings are 40 percent higher than desired height. B. Neatly trim edges and hand clip where necessary. C. Immediately remove clippings after mowing and trimming. Do not let clippings lay in clumps. D. Water to prevent grass and soil from drying out. E. Lightly roll surface to remove minor depressions or irregularities. F. Control growth of weeds. Apply herbicides. Remedy damage resulting from improper use of herbicides. G. Immediately reseed areas showing bare spots. H. Repair washouts or gullies. I. Protect seeded areas with warning signs during maintenance period. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Precast Concrete Valve Vaults 33 05 17 - 1 SECTION 33 05 17 - PRECAST CONCRETE VALVE VAULTS PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. Precast concrete valve vaults. B. Related Sections: 1. Section 31 23 23 – Fill. 2. Section 32 05 16 – Aggregates for Civil Site Improvements. 1.2 REFERENCE STANDARDS A. ASTM International: 1. ASTM A48/A48M - Standard Specification for Gray Iron Castings. 2. ASTM A185/A185M - Standard Specification for Steel Welded Wire Fabric, Plain, for Concrete Reinforcement. 3. ASTM A536 - Standard Specification for Ductile Iron Castings. 4. ASTM A615/A615M - Standard Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement. 5. ASTM C33 - Standard Specification for Concrete Aggregates. 6. ASTM C150 - Standard Specification for Portland Cement. 7. ASTM C260 - Standard Specification for Air-Entraining Admixtures for Concrete. 8. ASTM B221 - Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes. 9. ASTM C478 - Standard Specification for Precast Reinforced Concrete Manhole Sections. 10. ASTM C497 - Standard Test Methods for Concrete Pipe, Manhole Sections, or Tile. 11. ASTM C890 - Standard Practice for Minimum Structural Design Loading for Monolithic or Sectional Precast Concrete Water and Wastewater Structures. 12. ASTM C913 - Standard Specification for Precast Concrete Water and Wastewater Structures. 13. ASTM C990 - Standard Specification for Joints for Concrete Pipe, Manholes, and Precast Box Sections Using Preformed Flexible Joints Sealants. 14. ASTM D698 - Standard Test Method for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/ft3 (600 kN-m/m3)). 15. ASTM D1557 - Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Modified Effort (56,000 ft-lbf/ft3 (2,700 kN-m/m3)). 16. ASTM D2922 - Standard Test Method for Density of Soil and Soil-Aggregate in Place by Nuclear Methods (Shallow Depth). 17. ASTM D3017 - Standard Test Method for Water Content of Soil and Rock in Place by Nuclear Methods (Shallow Depth). 18. ASTM D4104 - Standard Test Method (Analytical Procedure) for Determining Transmissivity of Nonleaky Confined Aquifers by Overdamped Well Response to Instantaneous Change in Head (Slug Test) BCRUA - Phase 1D WTP Expansion Issued for Bid Precast Concrete Valve Vaults 33 05 17 - 2 1.3 DESIGN REQUIREMENTS A. Design Criteria: 1. Watertight precast reinforced air-entrained concrete structures designed to AASHTO HS20-16 kip and ASTM C890 live loading and installation conditions, and manufactured to conform to ASTM C913. 2. Minimum 28-day Compressive Strength: 4,000 psi. 3. Honeycombed or retempered concrete is not permitted. 1.4 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Shop Drawings: Indicate plan, location and inverts of connecting piping. C. Product Data: Submit data on valve vaults and all appurtenances. D. Manufacturer’s Certificates: Submit Statement of Compliance, supporting data, from materials suppliers attesting that precast concrete valve vaults provided meet or exceed ASTM Standards and specification requirements. E. Manufacturer’s Installation Instructions: Submit special procedures for precast concrete valve vault installation. 1.5 CLOSEOUT SUBMITTALS A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for submittals. B. Project Record Documents: Accurately record actual locations and inverts of buried pipe, components and connections. 1.6 DELIVERY, STORAGE AND HANDLING A. Section 01 60 00 – Product Requirements: Requirements for transporting, handling, storing and protecting products. B. Transport and handle precast concrete units with equipment designed to protect units from damage. C. Do not place concrete units in position to cause overstress, warp or twist. 1.7 ENVIRONMENTAL REQUIREMENTS A. Section 01 60 00 – Product Requirements: Environmental conditions affecting products on site. B. Conduct operations not to interfere with, interrupt, damage, destroy, or endanger integrity of surface or subsurface structures or utilities, and landscape in immediate or adjacent areas. BCRUA - Phase 1D WTP Expansion Issued for Bid Precast Concrete Valve Vaults 33 05 17 - 3 1.8 COORDINATION A. Section 01 30 00 – Administrative Requirements: Requirements for coordination. B. Coordinate work with Brushy Creek Regional Utility Authority and utilities within construction area. PART 2 PRODUCTS 2.1 PRECAST CONCRETE VALVES A. Manufacturers: 1. Forterra, Inc. 2. Capital Precast, Inc. 3. Oldcastle Precast, Inc. 4. Substitutions: Section 01 25 00 - Substitution Procedures. B. Materials: 1. Portland Cement: ASTM C150, Type II. 2. Coarse Aggregates: ASTM C33; Graded 1 inch to No. 4 Sieve. 3. Sand: ASTM C33; 2.35 fineness modulus. 4. Water: Potable; clean and free of injurious amounts of acids, alkalis, salts, organic materials, and substances incompatible with concrete or steel. 5. Air-Entraining Admixtures: ASTM C260. 6. Reinforcing Steel: a. Deformed Bars: ASTM A615/A615M, Grade 60. b. Welded Wire Fabric: ASTM A185/A185M. 7. Joint Sealant: a. ASTM C990. C. Mixes: 1. Design concrete mix to produce required concrete strength, air-entrainment, watertight properties, and loading requirements. D. Access Steps/Ladders: 1. As indicated on Drawings. 2.2 BEDDING AND BACKFILL MATERIALS A. Bedding Material: Coarse Aggregate Type A1, A2, or A3 as specified in Section 32 05 16 – Aggregates for Site Civil Improvements. B. Backfill Materials: Subsoil Type S1 or S3 as specified in Section 31 23 23 - Fill. 2.3 FABRICATION AND MANUFACTURE A. Fabricate precast reinforced concrete structures in accordance with ASTM C913, to dimensions indicated on Drawings, and to specified design criteria. BCRUA - Phase 1D WTP Expansion Issued for Bid Precast Concrete Valve Vaults 33 05 17 - 4 2.4 ACCESS HATCHES A. Manufacturers: 1. The BILCO Company: a. H-20 Load Rating: Type J-AL H20 single leaf or Type JD-AL H20 double leaf. b. 300 PSF Load Rating: Type J-AL single leaf or Type JD-AL double leaf. 2. Halliday Products, Inc.: a. H-20 Load Rating: Model H1R single leaf or Model H2R double leaf. b. 300 PSF Load Rating: Model W1R single leaf or Model W2R double leaf. 3. Substitutions: Section 01 25 00 – Substitution Procedures. B. Access Hatch: Aluminum welded construction, size as indicated; single or double door, as indicated. 1. Cover: Diamond plate aluminum (minimum ¼” thick) reinforced with structural stiffeners to support required loads with a maximum deflection of 1/150th of the span. 2. Frame: Channel type, as indicated; minimum ¼” thick with integral seat to support cover stiffeners; anchor flange around frame perimeter. a. Provide drain coupling for pipe connection. 3. Hinges: Type 316 Stainless steel. 4. Lift Handle: Flush drop handle, non-removable type mounted in cover. 5. Lifting Mechanism: Stainless steel compression springs with automatic hold open and dead stop to retain cover in open position. Cover springs to prevent contact by personnel entering utility structure. 6. Latch Mechanism: Type 316 Stainless steel lock with tamper-proof external handle and permanent internal release mechanism. 7. Hardware: Type 316 Stainless steel. 8. Finish: Mill Finish aluminum with bituminous or epoxy coating applied to the exterior of the frame for isolation from concrete. 2.5 WALL SEAL ASSEMBLIES FOR PIPE PENETRATIONS A. Manufacturers: 1. Link-Seal, Model “C” or “L” by Pipeline Seal and Insulator, Inc. 2. Substitutions: Section 01 25 00 - Substitution Procedures. PART 3 EXECUTION 3.1 EXAMINATION A. Section 01 30 00 – Administrative Requirements: Verification of existing conditions before starting work. B. Verify piping connection, size, location and invert are as indicated on Drawings. 3.2 PREPARATION A. Ream pipe ends and remove burrs. B. Remove scale and dirt from components before assembly. BCRUA - Phase 1D WTP Expansion Issued for Bid Precast Concrete Valve Vaults 33 05 17 - 5 C. Establish invert elevations for each component in system. D. Hand trim excavation to suit valve vaults. Remove stones, roots or other obstructions. 3.3 VAULT BEDDING AND BACKFILL A. Excavate in accordance with Section 31 23 10 – Structural Excavation and Backfill for work of this Section. Hand trim excavation for accurate placement of vaults to elevations indicated. B. Place bedding material level in continuous layers not exceeding 6 inches compacted depth, compact to 95 percent Standard Proctor Density. C. Backfill around sides of vaults, tamped in place and compacted to 95 percent Standard Proctor Density. D. Maintain optimum moisture content of bedding material to attain required compaction density. E. Install vaults and related components on bedding or as indicated on Drawings. 3.4 CONNECTING PIPING A. Connect piping. 3.5 FIELD QUALITY CONTROL A. Sections 01 40 00 – Quality Requirements and 01 70 00 – Execution and Closeout Requirements: Field inspecting, testing, adjusting, and balancing. B. Request inspection by Engineer prior to placing trench backfill over piping. C. Compaction Testing: In accordance with ASTM D698. D. When tests indicate Work does not meet specified requirements, remove Work, replace and retest. E. Frequency of Tests: 2 per vault. 3.6 PROTECTION OF FINISHED WORK A. Section 01 70 00 – Execution and Closeout Requirements: Protecting installed construction. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Potable Water Facility Disinfection 33 13 13 - 1 SECTION 33 13 13 - POTABLE WATER FACILITY DISINFECTION PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Cleaning, flushing and disinfection of Filter 7C, the Disinfection Basin, portions of the Water Treatment Plant (WTP), and appurtenant piping, including conveyance of test water and all disposal thereof. 1.2 REFERENCE STANDARDS A. American Water Works Association: 1. AWWA B300 Hypochlorites. 2. AWWA B301 Liquid Chlorine. 3. AWWA C651 Disinfecting Water Mains. 4. AWWA C652 Disinfection of Water-Storage Facilities. 5. AWWA C653 Disinfection of Water Treatment Plants. B. Standard Methods for the Examination of Water and Wastewater, as published by American Public Health Association, American Water Works Association, and the Water Environment Federation. 1.3 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Shop Drawings: 1. Plan describing and illustrating conformance to appropriate AWWA standards and this Specification. 2. Type of disinfecting solution and method of preparation. 3. Proposed locations within system where Samples will be taken. 4. Testing schedule and proposed procedures and plans for cleaning system, water conveyance, control, disinfection, and disposal of highly chlorinated disinfecting water shall be submitted in writing for Engineer approval a minimum of 14 days before testing is to start. The submittal shall include the Contractor’s plan for the release of water from structures after disinfection has been completed. C. Certification that employees working with concentrated chlorine solutions or gas have received appropriate safety training. 1.4 CLOSEOUT SUBMITTALS A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for submittals. B. Disinfection Report: 1. Type and form of disinfectant used. 2. Date and time of disinfectant injection start and completion. BCRUA - Phase 1D WTP Expansion Issued for Bid Potable Water Facility Disinfection 33 13 13 - 2 3. Test locations. 4. Name of person collecting samples. 5. Initial and 24-hour disinfectant residuals in treated water in ppm for each outlet tested. 6. Date and time of flushing start and completion. 7. Disinfectant residual after flushing in ppm for each outlet tested. 1.5 QUALITY ASSURANCE A. Conform to AWWA C651 for pipes and pipelines, C652 for tanks and reservoirs, and C653 for water treatment plants and filters, except as modified in these Specifications. 1.6 QUALIFICATIONS A. Water Treatment Testing Firm: Company specializing in testing and disinfection of potable water systems specified in this section with minimum three years documented experience. 1. Certified by the State of Texas. 2. Submit bacteriologist's signature and authority associated with testing. PART 2 - PRODUCTS 2.1 MATERIAL REQUIREMENTS A. Temporary valves, bulkheads, or other water control equipment and materials shall be as determined by the Contractor. No materials shall be used which would be injurious to the structure or its future function. B. Chlorine for disinfection shall be in the form of liquid chlorine, sodium hypochlorite solution, or calcium hypochlorite granules or tablets. C. Liquid chlorine shall be in accordance with the requirements of ANSI/AWWA B301. Liquid chlorine shall be used only: 1. In combination with appropriate gas flow chlorinators and ejectors; 2. Under the direct supervision of an experienced technician; 3. When appropriate safety practices are observed. D. Sodium hypochlorite and calcium hypochlorite shall be in accordance with the requirements of ANSI/AWWA B300. 2.2 WATER FOR DISINFECTION AND TESTING: A. Clean, uncontaminated, and potable. 1. OWNER will supply potable quality water. CONTRACTOR shall convey in disinfected pipelines or containers. 2. Except as otherwise indicated, water for disinfection testing will be furnished by the Owner for one test per tank/basin or pipeline. If initial disinfection test fails, Contractor shall be responsible for the cost of water to conduct additional testing. Water for any additional disinfection tests shall be paid for by the Contractor at the Owner’s established potable water rates. Contractor shall make necessary arrangements for conveying test water to the points of use. BCRUA - Phase 1D WTP Expansion Issued for Bid Potable Water Facility Disinfection 33 13 13 - 3 2.3 CONTRACTOR’S EQUIPMENT A. Furnish chemicals and equipment, such as pumps and hoses, to accomplish disinfection. B. Provide protection against cross-connections as required by AWWA C651. PART 3 - EXECUTION 3.1 GENERAL A. Filter7C, including Filter flumes and gullets, the Disinfection Basin, including interior appurtenances, and all associated piping and appurtenances shall be disinfected. Disinfection shall be accomplished by chlorination. All chlorinating and testing operations shall be done in the presence of the Engineer or Owner’s Representative. B. Disinfection operations shall be scheduled by the Contractor to occur when the affected facilities are ready to be placed into service. Bacteriological testing will be performed by a certified testing laboratory appointed and paid for by the Owner. Should initial tests fail, all subsequent testing required for successful disinfection shall be paid for by the Contractor. Results of the bacteriological testing shall be satisfactory to the Texas Department of Health or another appropriate regulatory agency. C. Refer to Section 40 05 40 – Process Piping Leakage Testing and Disinfection for specific information related to pipeline pressure testing and disinfection. 3.2 PRELIMINARY CLEANING AND FLUSHING A. Prior to disinfection, all facilities shall be cleaned and flushed, including appurtenant piping and conveyance channels, by thoroughly hosing down all surfaces with a high-pressure hose and nozzle of sufficient size to deliver a minimum flow of 50 gpm. All water, dirt, and foreign material accumulated in this cleaning operation shall be discharged from the facility in an acceptable manner or otherwise removed. 1. Verify associated piping system has been flushed at a minimum velocity of three feet per second at a 40 psi residual pressure such that all particles are removed from the line. 3.3 SEQUENCING AND SCHEDULING A. Commence disinfection after completion of following: 1. Completion and acceptance of internal painting of system(s). 2. Pressure testing of pipelines and functional and performance testing of pumping systems, treatment systems, structures, and equipment. 3. Disinfection of: a. Pumps and associated system piping. b. Associated treatment plant basins and processes used to supply water to system. 3.4 DISINFECTION OF FACILITIES AND APPURTENANCES A. Disinfect Filter 7C in accordance with the requirements of ANSI/AWWA C653 and the following procedures: BCRUA - Phase 1D WTP Expansion Issued for Bid Potable Water Facility Disinfection 33 13 13 - 4 1. With all other appurtenant valves closed, fill the filter cell from the backwash system while simultaneously dosing disinfectant to the influent water to maintain a chlorine residual of 50 mg/L in the filter cell. 2. Close filter backwash valve and maintain chlorinated water in filter cell. Maintain water level approximately 6-inches below top of filter cell for a minimum of 24 hours. 3. After disinfection, backwash test water to waste, then fill filter cell with settled water. Place filter into operation after confirmation of passing test results. B. Disinfect Disinfection Basin in accordance with the requirements of ANSI/AWWA C652, Chlorination Method 1, 2 or 3. 1. Disinfection area shall include the floor, walls, including baffles, and ceiling. 3.5 DISPOSAL OF HEAVILY CHLORINATED WATER A. Do not allow flow into a waterway without neutralizing disinfectant residual. B. See the appendix of AWWA C652 for acceptable neutralization methods. 3.6 TESTING OF PUMPS, TANKS AND RESERVOIRS, BASINS, FILTERS, AND WELLS A. Collection of Samples: 1. Coordinate activities to allow Samples to be taken in accordance with this Specification. 2. Provide valves at sampling points. 3. Provide access to sampling points. B. Test Equipment: 1. Clean containers and equipment used in sampling and make sure they are free of contamination. 2. Obtain sampling bottles with instructions for handling from an independent testing laboratory. C. Chlorine Concentration Sampling and Analysis: 1. Collect and analyze Samples in accordance with AWWA Standards. 2. Sampling Frequency for Disinfecting Solution: 2 Samples per 24 hours or disinfection event. 3. Residual Free Chlorine Samples: 2 Samples per 24 hours or disinfection event. 4. Dechlorinated Disinfecting Wastewater Residual Samples: 2 Samples per disinfection event. D. Bacteriological Testing of Disinfected Facilities: 1. Samples shall be collected in accordance with ANSI/AWWA C651, C652 and C653. 2. Samples shall be analyzed for coliform concentrations in accordance with latest edition of Standard Methods for the Examination of Water and Wastewater. 3. A minimum of two Samples on each of 2 consecutive days from each separable structure shall be obtained and analyzed by standard procedures outlined by state and local regulatory agencies. 4. Sampling points shall be representative and accepted by ENGINEER. or OWNER’S REPRESENTATIVE. BCRUA - Phase 1D WTP Expansion Issued for Bid Potable Water Facility Disinfection 33 13 13 - 5 5. If minimum Samples required above are bacterially positive, disinfecting procedures and bacteriological testing shall be repeated until bacterial limits are met. E. Replace permanent system devices that were removed for disinfection. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Prestressed Concrete Water Storage Tanks 33 16 33 - 1 SECTION 33 16 33 - PRESTRESSED CONCRETE WATER STORAGE TANKS (Revised by AD-02) PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Requirements for design and construction of two nominal 0.5 million gallon (MG) tanks with an AWWA D110 Type III wire or strand wound, prestressed, concrete circular core wall; including site work, excavation, reinforcing, concrete work, appurtenances, testing, and backfill directly related to the tanks unless otherwise specified. 2. In the event of discrepancy between this Section and other Specification Sections, this Section shall govern for tanks. B. Scope of Work: 1. Tank Contractor shall furnish all labor, materials, tools, and equipment necessary to construct and test the tanks as specified and indicated on the Drawings. 2. If Special Inspections and Observations are required per Section 01 40 01 – IBC Special Inspections, the Owner shall provide these services. C. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Section 00220 – Geotechnical Data: PHASE 1D GEOTECHNICAL MEMORANDUM by Schnabel Engineering dated April 21, 2022. 3. Division 01– General Requirements. 4. Section 01 91 00 – Facility Commissioning. 5. Section 31 23 10 – Structural Excavation and Backfill. 6. Section 31 23 17 – Trenching. 7. Section 31 23 23 – Fill. D. Tank Description: 1. Each tank shall consist of a cast-in-place reinforced concrete floor, a wire or strand wound precast prestressed concrete wall, and a precast or cast-in-place prestressed clear span concrete dome. 1.2 REFERENCE STANDARDS A. American Concrete Institute (ACI): 1. ACI 301 Specifications for Structural Concrete. 2. ACI 305 Hot Weather Concreting. 3. ACI 306 Cold Weather Concreting. 4. ACI 309R Guide for Consolidation of Concrete. 5. ACI 318 Building Code Requirements for Reinforced Concrete and Commentary. 6. ACI 350 Code Requirements for Environmental Engineering Concrete Structures and Commentary. 7. ACI 350.3 Seismic Design of Liquid Containing Concrete Structures and Commentary. 8. ACI 372R Design and Construction of Circular Wire- and Strand Wrapped Prestressed Concrete Structures. 9. ACI 506R Guide to Shotcrete. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Prestressed Concrete Water Storage Tanks 33 16 33 - 2 B. ASTM International (ASTM): 1. ASTM A123/A123M Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products. 2. ASTM A185 Standard Specification for Steel Welded Wire Reinforcement, Plain, for Concrete. 3. ASTM A416 Standard Specification for Steel Strand, Uncoated Seven-Wire for Prestressed Concrete. 4. ASTM A421/A421M Standard Specification for Uncoated Stress-Relieved Steel Wire for Prestressed Concrete. 5. ASTM A475 Standard Specification for Zinc-Coated Steel Wire Strand. 6. ASTM A615/A615M Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement. 7. ASTM A653/A653M Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process. 8. ASTM A706/A706M Standard Specification for Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement. 9. ASTM A821 Standard Specification for Steel Wire, Hard Drawn for Prestressing Concrete Tanks. 10. ASTM A1008/A1008M Standard Specification for Steel, Sheet, Cold-Rolled, Carbon, Structural, High-Strength Low-Alloy, High-Strength Low-Alloy with Improved Formability, Solution Hardened, and Bake Hardenable. 11. ASTM C31 Standard Practice for Making and Curing Concrete Test Specimens in the Field. 12. ASTM C33 Standard Specification for Concrete Aggregates. 13. ASTM C39 Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens. 14. ASTM C231 Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method. 15. ASTM C618, Type F Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete. 16. ASTM D698 Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 Ft. – lbf/ft3) 600 KN-M/M3). 17. ASTM C920 Specification for Elastomeric Joint Sealants. 18. ASTM D1056 Standard Specification for Flexible Cellular Materials – Sponge or Expanded Rubber. 19. ASTM C1116/C1116M Standard Specification for Fiber-Reinforced Concrete and Shotcrete. 20. ASTM D1556 Standard Test Method for Density and Unit Weight of Soil in Place by the Sand-Cone Method. 21. ASTM D1557 Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Modified Effort (56,000 Ft. – lbf/ft3) 2700 KN-M/M3). 22. ASTM D2000 Classification System for Rubber Products in Automotive Applications. C. American Society of Civil Engineers (ASCE): 1. Standard 7 Minimum Design Loads for Buildings and Other Structures. D. American Water Works Association (AWWA): 1. D110 Wire and Strand Wound, Circular, Prestressed Concrete Water Tanks. E. TID-7024, Dynamic Pressure on Fluid Containers of Nuclear Reactors and Earthquakes. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Prestressed Concrete Water Storage Tanks 33 16 33 - 3 F. US Army Corps of Engineers (COE): 1. Specification CRD-C-572, Specification for PVC Water Stop. 1.3 ADMINISTRATIVE REQUIREMENTS A. See Section 01 30 00 – Administrative Requirements. 1.4 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00 – Submittal Procedures. B. All submittals shall be approved by the Engineer prior to delivery and/or fabrication. 1.5 SHOP DRAWINGS A. Product Data: 1. Catalog cuts or shop drawings of all tank appurtenances, i.e., hatch, vent, ladders, water stops. 2. Tank color selection charts. B. Design Submittals: 1. Complete structural design calculations and drawings showing details and procedures of construction. 2. Design calculations and drawings shall be signed and sealed by a professional engineer licensed in Texas who is experienced in the design of AWWA D110, Type III wire or strand wound prestressed concrete tanks. 3. Tank design is the responsibility of the Tank Contractor. Engineer will review shop drawings to verify that design meets specification requirements. Engineer will not review calculations and design details. Approval by the Engineer of the submitted shop drawings and calculations shall not relieve the Tank Contractor of full responsibility for the accuracy and completeness of the drawings and calculations. 4. Tank Contractor qualifications. C. Construction Submittals: 1. Design proportions for all concrete and shotcrete mixes. Concrete strengths of trial mixes. 2. Admixtures to be used in the concrete or shotcrete and their purpose. 3. Reinforcing steel shop drawings showing fabrication and placement. D. Source Quality-Control Submittals: 1. Manufacturer's Certificate: Certify that products meet or exceed specified requirements. E. Field Quality-Control Submittals: 1. As specified in Sections 01 33 00, 01 61 03 and 01 91 00. 2. Indicate results of Contractor-furnished tests and inspections, including concrete and shotcrete strength testing. 3. Certify that tanks have been installed according to manufacturer instructions. 1.6 CLOSEOUT SUBMITTALS A. Provide copy of Warranty Documentation to Engineer. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Prestressed Concrete Water Storage Tanks 33 16 33 - 4 B. Record Documentation shall be submitted to Engineer and approved before the Work is considered complete. 1.7 QUALITY ASSURANCE A. Qualifications and Experience: 1. Singular responsibility for design and construction of tanks is required. Tank design and construction shall be performed by an established Tank Contractor of recognized ability, having at least ten years of experience in the design and construction of tanks with an AWWA D110 Type III wire or strand wound prestressed concrete core wall as specified herein. Design and construction of all aspects of the foundation, floor slab, wall, prestressing, shotcrete and dome roof of the wire or strand wound circular prestressed tank shall be performed by the Tank Contractor. Tank Contractor may subcontract labor for reinforcing steel installation and for concrete slab placement under the Tank Contractor’s direct supervision. 2. All tank work shall be performed by a company that specializes in design and construction of wire or strand wound prestressed concrete tanks using the method of circumferential prestress reinforcing and with proven capability of meeting all the requirements of this specification. Tank Contractor shall have designed and built in its own name or under one of its divisions at least twenty AWWA D110 prestressed concrete tanks with a Type III core wall in the last ten years. 3. Tank Contractor shall have in its employ for this project a design professional engineer with a minimum of ten years’ experience, registered in the State of Texas. Design engineer shall have been the engineer of record for a minimum of ten tanks with an AWWA D110 Type III core wall. 4. Tank Contractor shall have in its employ for this project a team consisting of a tank superintendent, project manager, certified shotcrete foreman, prestressing foreman, and precast erection foreman, each of whom shall have constructed a minimum of three tanks with an AWWA D110 Type III core wall and a capacity of 0.5 MG or greater. B. Design Criteria: 1. The prestressed concrete tanks shall be designed and constructed in accordance with the provisions of AWWA D110 Standard for Wire or Strand Wound Circular Prestressed- Concrete Water Tanks, Type III core wall, ACI 350, ACI 350.3, ASCE 7, and IBC. 2. Horizontal prestressing shall be continuous. Discontinuous prestressing tendons or strands are not allowed. 3. Tank Contractor shall use the following requirements and loadings for design: a. Tag Numbers: Y-RWT-001 and 002. b. Nominal Capacity: 0.5 MG each. c. Inside Diameter: 60’-0”. d. Side Water Depth: 23’-0” to overflow. e. Maximum Inlet/Outlet flow rate: 106 million gallons per day (MGD). f. Overflow Design Capacity: 106 MGD. g. Vents sized for an inlet and withdrawal rate of 106 MGD. h. Dead Load: Estimated weight of all permanent imposed loads. 1) Unit weight of concrete: 150 pounds per cubic foot (pcf). 2) Unit weight of steel: 490 pcf. i. Liquid Load: Weight of all the liquid when the reservoir is filled to overflow. 1) Unit weight of liquid: 62.4 pcf. j. Roof Live Load: 20 pounds per square foot (psf). BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Prestressed Concrete Water Storage Tanks 33 16 33 - 5 k. Wind Loads: As required by ASCE 7-16. l. Backfill Pressure: Earth loads shall be determined by rational methods of soil mechanics. Backfill pressure shall not be used to reduce the amount of required prestressing. m. Foundation Loads: Tank foundations shall be proportioned so that soil pressure shall be less than the soil bearing capacity. For allowable soil bearing capacities, refer to Section 00200 - Geotechnical Data. n. Seismic Criteria: 1) AWWA D110 Seismic Zone 0. 2) IBC Site Class Type D. 4. The precast, wire-wound prestressed tank wall shall be designed as a composite concrete wall with an embedded mechanically bonded steel diaphragm in combination with vertical mild steel reinforcement. a. Wall shall be considered as a cylindrical shell with partial edge restraint. b. Wall shall be reinforced vertically by deformed steel reinforcing rods. The continuous mechanically bonded steel diaphragm can be taken as effective vertical reinforcing. c. Wall shall be of precast construction. Shotcrete or cast-in-place concrete core walls are not permitted. d. A stress plate shall be required at all above grade locations where prestress wires are displaced 24 inches or greater. Stress plate shall be designed to transfer stress across the opening. e. Minimum precast wall thickness shall be four (4) inches. f. No reduction in ring compression or tension in the wall shall be taken due to restraint at the bottom. 5. The floor slab shall be designed as a reinforced floor not less than eight (8) inches thick and shall be placed monolithically. No construction joints are allowed unless otherwise approved by the Engineer. Minimum ratio of floor reinforcement area to concrete area shall be 0.5 percent for tanks with diameters less than 100 feet. Wall footings may be above or below floor grade but shall be placed monolithically with the floor. 6. The dome roof shall have a rise to span ratio within the range of 1:8 to 1:14. The minimum concrete thickness shall be four (4) inches for a precast dome and three (3) inches for a cast-in-place dome. Dome shall be fixed to the tank wall. Columns or interior supports are not allowed. Dome design shall be based on elastic spherical shell analysis. 7. Allowable Stresses: a. Compressive stresses in concrete and shotcrete shall not exceed 0.55 f’c initial (immediately after prestressing) and 0.45 f’c final (after all losses have taken place), where f’c is the 28-day compressive strength of concrete or shotcrete. Vertical tensile stresses shall be taken fully by reinforcing steel and/or the diaphragm. b. Maximum permissible initial stress, f’si, in any prestressing wire on the wall shall not exceed 0.75 fpu, where fpu equals the ultimate tensile strength of the wire. Stress losses due to shrinkage, plastic and elastic shortening of concrete or shotcrete, and relaxation in steel shall be assumed as 25,000 psi. c. Reinforcing steel shall be designed in accordance with the requirements of the Alternate Design Method of ACI 318. The strength requirements of ACI 318 shall also be satisfied. The reinforcement value of the steel wall diaphragm parallel to the direction of its channels may also be used. Mild steel reinforcement shall not be used to resist any portion of circumferential tension. 8. Design for lowest mean ambient temperature of 10 degrees Fahrenheit and for temperature differential of 50 degrees Fahrenheit between the inside and outside of the tank. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Prestressed Concrete Water Storage Tanks 33 16 33 - 6 1.8 WARRANTY A. Reference Section 00700 – General Conditions, Article 7.17 for complete warranty terms. PART 2 - PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. Prestressed Concrete Water Storage Tanks: 1. DN Tanks. 2. Preload. 2.2 CONCRETE A. Concrete shall conform to ACI 301. B. Cement shall be Portland cement Type I or Type II. C. Admixtures, other than air-entraining, superplasticizers, shrinkage reducing and water reducing admixtures, are not permitted unless approved by the Engineer. D. Concrete for tank wall and dome construction shall have a minimum compressive strength of 4,000 psi at twenty-eight days and a maximum water to cementitious ratio of 0.42. All precast wall and dome concrete shall be air entrained. E. Concrete for the tank floor, footings, pipe encasement, and all other work shall have a minimum compressive strength of 4,000 psi at twenty-eight days, shall not be air-entrained, unless exposed to freeze thaw conditions, and have a maximum water to cementitious ratio of 0.42. 1. Coarse and fine aggregate shall meet the requirements of ASTM C33. Coarse aggregate shall be No. 467 with 100% passing the 1½ inch sieve. 2. Superplasticizers, water-reducing, and shrinkage reducing (if applicable) admixtures shall be incorporated into the floor concrete. 3. If fibers are used, they shall be virgin polypropylene or cellulose fibers. Fiber lengths shall be a maximum of ¾ inches. Amount of fiber added to the concrete mix shall conform to the Manufacturer’s recommendations. a. Products and Manufacturers: 1) Microfiber by Grace. 2) Fibermesh 150 by Propex. 3) UltraFiber 500 by Buckeye. 4) Or approved equal. F. Proportioning for concrete shall be in accordance with ACI 301. G. All concrete shall have a maximum water-soluble chloride ion concentration of 0.06% by weight of cementitious material. 2.3 SHOTCRETE A. Shotcrete shall conform to ACI Standard 506, except as modified herein. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Prestressed Concrete Water Storage Tanks 33 16 33 - 7 B. The wet mix process shall be employed for shotcrete placement. C. Shotcrete used for covering prestressed wire or strand shall consist of not more than three parts sand to one-part Portland cement by weight. Additional coats of shotcrete shall consist of not more than four parts sand to one-part Portland cement by weight. 1. Polypropylene fibers shall be included in the shotcrete used for the finish cover coat. Fibers shall be virgin polypropylene and comply with ASTM C-1116 performance level I. Fiber length shall be ¼ inch. Amount of fiber added to the shotcrete used for the finish cover coat shall conform to the Manufacturer’s recommendations. a. Products and Manufacturers: 1) Fibercast 500 by Propex. 2) Fibermesh. 3) Or approved equal. 2. Fly ash may be incorporated into the finish cover coat. Fly ash shall conform to ASTM C618, Type F. 3. Shotcrete shall have a minimum strength of 4,500 psi at twenty-eight days and have a maximum water to cementitious ratio of 0.42. D. Rebound material shall not be reused in any form for shotcrete. E. If used by the Tank Contractor, the total volumetric air content of the shotcrete before placement shall not exceed 7% (±1%) as determined by ASTM C-173 or ASTM C-231. F. Fine Aggregates: 1. The fineness modulus shall be between 2.7 and 3.0. A well-graded coarse sand shall be used for all shotcrete applications. 2. The gradation for the fine aggregates shall adhere to the “Grading No. 1” requirements listed in “Table 1.1 – Grading Limits for Combined Aggregates” of ACI 506. G. Shotcrete shall have a maximum water-soluble chloride ion concentration of 0.06% by weight of cementitious material. 2.4 MORTAR FILL AND NON-SHRINK GROUT A. Mortar fill and non-shrink grout shall have a minimum compressive strength of 4,000 psi at twenty-eight days, have a maximum water to cementitious ratio of 0.42 and meet all requirements for concrete contained in this specification. B. Portland cement grout will not be accepted. 2.5 REINFORCING STEEL A. Reinforcing steel shall be new billet steel Grade 60 meeting the requirements of ASTM A615. Welded wire fabric and weldable reinforcing steel shall conform to ASTM A185 and ASTM A706, respectively. B. Reinforcing steel shall be accurately fabricated and shall be free from loose rust, scale, and contaminants, which reduce bond. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Prestressed Concrete Water Storage Tanks 33 16 33 - 8 C. Reinforcing steel shall be accurately positioned on supports, spacers, hangers, or other reinforcements and shall be secured in place with wire ties or suitable clips. Rebar chair supports may be either steel with plastic tips, turned up legs or plastic. D. Continuous reinforcing is required through floor and cast-in-place dome construction joints, where applicable. 2.6 BASE RESTRAINT CABLES A. Where required by design, the tank designer shall use base restraint cables to resist earthquake and/or wind loads. Base restraint cables shall be hot-dipped galvanized seven-wire strand and shall be manufactured in accordance with ASTM A416 prior to galvanizing, and ASTM A475 after galvanizing. Only seven-wire strand is allowed. B. Hot-dipped galvanized seven-wire strand shall have a nominal strand diameter of 0.375 in, 0.50 in, or 0.60 in. All strands shall have a minimum of weight of Zinc Coating of 0.85 oz/sq-ft. 1. 0.375-inch diameter strand shall have a MUS after galvanization of 21.36 kips and a min. yield at 1% extension of 15.60 ksi. 2. 0.50-inch diameter strand shall have a MUS after galvanization of 38.25 kips and a min. yield at 1% extension of 28.00 ksi. 3. 0.60-inch diameter strand shall have a MUS after galvanization of 54.20 kips and a min. yield at 1% extension of 40.70 ksi. C. Neoprene sleeves for base restraint cables shall be closed cell conforming to ASTM D1056, Type 2, Class A, and Grade 3. The sleeves shall have a compression deflection limited to 25% at 9 to 13 psi, hardness of 60 to 80 durometer, a minimum tensile strength of 175 psi, a minimum elongation of 180%, and a maximum compressive set of 35%. 2.7 STEEL DIAPHRAGM A. The steel diaphragm shall conform to ASTM A1008 and shall be a minimum thickness of 0.017 inches. It shall be vertically ribbed with reentrant angles. The back of the channels shall be wider than the front, providing a mechanical keyway anchorage with the concrete and shotcrete encasement. B. The steel diaphragm shall extend to within 1 inch of the full height of the wall panel with no horizontal joints. Vertical joints within a wall panel shall be roll seamed or otherwise fastened in a fashion that results in a firm mechanical lock. Joints between wall panels that are not roll seamed shall be edge sealed with polysulfide or polyurethane sealant. C. No punctures will be permitted in the diaphragm except those required for pipe sleeves, temporary construction openings, or special appurtenances. Engineer shall approve details of the openings. All openings shall be completely edge sealed with polysulfide or polyurethane sealant. D. Diaphragm steel may be considered as contributing to the vertical reinforcement of the wall. E. Steel closure plates shall be used at wall slots between precast wall panels on the exterior face to create a continuous steel diaphragm. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Prestressed Concrete Water Storage Tanks 33 16 33 - 9 2.8 CIRCUMFERENTIAL PRESTRESSING STEEL A. Steel for prestressing shall either be cold drawn, high carbon wire or galvanized seven wire strands. B. The wire shall meet the requirements of ASTM A821 and have a minimum ultimate tensile strength of 210,000 psi. C. Galvanized strand shall meet the requirements of ASTM A416 prior to galvanizing with zinc coating for galvanizing meeting the requirements of ASTM A641/641M or ASTM A475. Each wire shall be individually hot-dipped galvanized before being stranded. The minimum weight of zinc coating per unit area of uncoated wire surface area shall be no less than 0.85 ounces per square foot. D. Splices for horizontal prestressed reinforcement shall be ferrous material compatible with the reinforcement and shall develop the full strength of the wire or strand. Wire or strand splice and anchorage accessories shall not nick or otherwise damage the prestressing. 2.9 ELASTOMERIC MATERIALS A. A 9-inch minimum water stop with center bulb shall be polyvinyl chloride meeting the requirements of the Corps of Engineers Specification CRD-C 572. Splices shall be made in accordance with the Manufacturer’s recommendations subject to approval by the Engineer. 1. Water stop shall be manufactured by Greenstreak Plastic Products Company, Inc., or equal. B. Bearing pads shall be natural rubber or neoprene. 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 A1 3. 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%, and a maximum compressive set of 50%. Pads shall meet the requirements of ASTM D2000 Line Call-Out M 2 BC 410 A1 4 B14 or M 2 BC 414 A14 C12 F17 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 or 3. Compression deflection limited to 25% at 2 to 5 psi. D. Polysulfide or polyurethane sealant will be a two or three component elastomeric compound meeting the requirements of ASTM C920. Sealants shall 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 EXTERIOR COATINGS A. Coating on tank shall be applied after tank has cured, and should be free of any surface cracking, stretching or other similar irregularities. 1.Precast Dome:(AD-02) Decorative coating shall be applied to the exterior dome surface using one coat of a cementitious based damp-proofing product by “Tamoseal” or approved equal, and one coat of a non-cementitious, high build, 100% acrylic resin polymer using “Tammscoat Smooth” textured protective coating or “Tnemec Envirocrete 156”. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Prestressed Concrete Water Storage Tanks 33 16 33 - 10 2. Cast-In-Place Dome: Decorative coating shall be applied to the exterior dome surfaces using two coats of a non-cementitious, high build, 100% acrylic resin polymer such as “Tammscoat Smooth” textured protective coating or “Tnemec Envirocrete 156”. (AD-02) 3. Decorative coating shall be applied to the above grade exterior wall surfaces using two coats of a non-cementitious, high build, 100% acrylic resin polymer using “Tammscoat Smooth” textured protective coating or “Tnemec Envirocrete 156”. B. Submit color charts for Owner selection of tank exterior color. 2.11 APPURTENANCES A. Tank Contractor shall provide and install all appurtenances as shown on the Drawings, including the following: 1. Inlet-Outlet Piping: Diameter, material, and location as shown on Drawings. 2. Overflow Piping and Weirs: Reference Drawings. 3. Drain Piping: Reference Drawings. 4. Roof Hatches: 3’-6” minimum square aluminum hatch with lockable, hinged cover and curb frame. Hatch shall have a lift handle, padlock tab, padlock and a cover hold open mechanism. All hardware shall be stainless steel. Locate hatches as shown on Drawings. 5. Roof Vents: Fiberglass Reinforced Polymer, with 316 stainless steel 20 x 20 insect screen, minimum diameter per specified venting rates. 6. Interior Ladders: Ladder shall extend from the floor to the hatch. The ladder shall be Type 316 stainless steel and have an OSHA-approved Stainless-Steel fall prevention device consisting of a sliding, locking mechanism and safety belt. 7. Exterior Ladders: Ladder shall be 6061-T6 aluminum and have an OSHA-approved Stainless-Steel fall prevention device consisting of a sliding, locking mechanism and safety belt. 8. Ladder Climbing System: Interior and exterior ladders shall be equipped with ladder/rigid rail climbing systems for fall prevention. Tank Contractor to provide three spare safety harnesses to Owner. Harnesses should be compatible with dome safety tie-off system. a. Manufacturers: 1) French Creek. 2) Fall Tech. 3) Western Safety. 9. Access Manways: Circular 30-inch inside diameter Type 304 stainless steel wall manway with a hinged cover. A Type 316 stainless steel grab bar and ladder shall be installed at the manway location. Locate access manway and appurtenances as shown on Drawings. 10. Dome Guardrails: Guardrails shall be as indicated on Drawings. As a minimum, guardrail shall be provided for a distance of 10 feet to each side of the exterior ladder. All posts and rails shall be 6061-T6, Schedule 80, anodized (AD-02) aluminum pipe. All fittings shall be Hollaender Speed-Rail system or approved equal. Beveled toe board shall be installed at the front edge of handrail only and shall be attached using Hollaender clips or approved equal. 11. Dome Safety Tie-Off Anchors: Provide three (3) permanent, OSHA compliant, anchorage connectors for single person tie-off shall be installed. Anchors shall be located on the dome surface within 1.5 feet of the exterior ladder egress point, within 1 foot of the dome hatch and within 2 feet of the dome vent. Anchors shall be Model 417 SS D-Bolt Anchors by Miller Fall Protection or approved equal. D-Bolts shall be anchored to concrete using 316 SS high strength threaded rods, 316 SS Hex head nuts and suitable epoxy adhesive. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Prestressed Concrete Water Storage Tanks 33 16 33 - 11 12. Instrumentation Dome Sleeves: 6-inch Type 304 Stainless Steel flange x plain end pipe with blind flange as indicated on Drawings. Three sleeves per tank. Locate as illustrated on Drawings. 13. Lighting, Instrumentation and Lightning Protection as illustrated on Electrical Drawings. PART 3 - EXECUTION 3.1 SAFETY A. Tank Contractor shall conform and enforce all Local and Federal OSHA safety rules and regulations. 3.2 CLEARING, GRUBBING, AND STRIPPING A. Reference Section 31 10 00 – Site Clearing. B. All unsuitable material shall be removed to a minimum distance of 15 feet outside the edge of tank foundation, plus additional areas necessary for tank construction. Limits of clearing shall be as indicated on the Drawings, as required by the Tank Contractor, and/or as approved by the Engineer. 3.3 EXCAVATION AND BACKFILL A. Reference Section 00220 – Geotechnical Data and Drawings for tank excavation and subgrade preparation requirements. Additional requirements deemed necessary by the Tank Contractor shall be approved by the Engineer. B. Reference applicable portions of Sections 31 23 10 – Structural Excavation and Backfill, 31 23 17 – Trenching, and 31 23 23 – Fill. 3.4 FLOOR A. The floor and wall footings shall be constructed to the dimensions shown on Approved Shop Drawings. B. Prior to placement of the floor reinforcing, a 6-mil polyethylene moisture barrier shall be placed over the structural fill material. Joints in the polyethylene shall be overlapped a minimum of 6 inches. C. Prior to placement of the floor concrete, all piping that penetrates the floor shall be set and encased in concrete. D. Vertical water stop shall be placed and supported so that the bottom of the center bulb is at the elevation of the top of the footing. Water stop shall be supported without puncturing any portion of the water stop other than pre-manufactured holes, grommets or hog rings for tying at 12 inches O.C. Water stop shall be spliced using a thermostatically controlled sealing iron. E. The floor shall be cured by applying one coat of curing compound, curing blankets and/or flooding with water, and shall remain saturated for a minimum of seven days. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Prestressed Concrete Water Storage Tanks 33 16 33 - 12 3.5 WALL PANEL CONSTRUCTION AND ERECTION A. Precast wall panels shall be constructed with a continuous waterproof steel diaphragm embedded in the exterior of the precast panel. Horizontal joints in the diaphragm are not allowed. B. No holes for form ties, nails, or other punctures are permitted in the wall. C. Temporary wall openings may be provided for access and removal of construction materials from the tank interior subject to approval by the Engineer. D. Wall beds shall be constructed to provide finished panels with the proper curvature of the tank. E. Polyethylene sheeting shall be placed between successive pours to provide a high moisture environment and a long slow cure for the concrete. F. The erecting crane and lifting equipment shall be capable of lifting and placing the precast panels to their proper location without causing damage to the panel. G. The precast panels shall be erected to the correct vertical and circumferential alignment. 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. H. Joints between precast wall panels shall be bridged with a 10-gauge steel plate edge sealed with polysulfide or polyurethane and filled with mortar. Through-wall ties are not permitted. 3.6 PRECAST DOME PANEL CONSTRUCTION AND ERECTION A. Dome panel casting beds shall be constructed to provide finished dome panels with proper dome curvature. B. Polyethylene sheeting shall be placed between successive pours to provide a high moisture environment and a long slow cure for the concrete. C. The erecting crane and lifting equipment shall be capable of lifting and placing the precast dome panels to their proper location without causing damage to the dome panel. D. The precast dome panels shall be erected to the correct radial and circumferential alignment as indicated in the Approved Shop Drawings. Adjacent dome panel offsets shall be constructed to a tolerance of +/- 3/8 inch. 3.7 CAST-IN-PLACE DOME CONSTRUCTION A. The dome shall be constructed to the dimensions and curvature provided on the Approved Shop Drawings. B. Dome roof decking shall not vary from level, or the curvature shown, more than ¼ inch in 10 feet or ½ inch maximum in 20 feet or more. C. The dome shall be constructed to the thickness shown on the Approved Shop Drawings. Screed rails shall be provided to ensure proper curvature and reinforcing cover. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Prestressed Concrete Water Storage Tanks 33 16 33 - 13 D. A curing compound which is compatible with the decorative coating systems shall be applied to the dome in accordance with the Manufacturer’s recommendations. Water curing may be used in conjunction with the curing compound. 3.8 CONCRETE A. All concrete shall be conveyed, placed, finished, and cured as required by pertinent ACI standards. B. Reinforcing steel shall be accurately positioned on supports, spacers, hangers, or other reinforcements and shall be secured in place with wire ties or suitable clips. C. Weather Limitations: 1. Unless specifically authorized in writing by the Engineer, concrete shall not be placed without special protection during cold weather when the ambient temperature is below 35 degrees Fahrenheit and when the concrete is likely to be subjected to freezing temperatures before initial set has occurred and the concrete strength has reached 500 psi. Concrete shall be protected in accordance with ACI 306. The temperature of the concrete shall be maintained in accordance with the requirements of ACI 301 and ACI 306. All methods and equipment for heating and for protecting concrete in place shall be subject to approval by the Engineer. 2. During hot weather, concreting shall be in accordance with the requirements of ACI 305. 3. Placement of concrete during periods of low humidity (below 50%) shall be avoided when feasible and economically possible, particularly when large surface areas are to be finished. In any event, surfaces exposed to drying wind shall be covered with polyethylene sheets immediately after finishing, or flooded with water, or shall be water cured continuously from the time the concrete has taken initial set. Curing compounds may be used in conjunction with water curing, provided they are compatible with coatings that may later be applied, or they are degradable. D. Finishes: 1. Floor slab shall receive a bull float or Fresno finish. The top of the wall footing, exterior to the water stop, shall receive a steel or magnesium trowel finish. 2. Interior of the precast wall panels shall receive a light broom finish. 3. Exterior of the dome shall receive a light broom finish. Interior of the dome shall receive a form finish. 4. Exterior shotcrete shall receive a natural gun / nozzle finish. 5. For all formed concrete surfaces, all irregularities that project greater than 1/4” from the surface shall be ground off. All holes greater than 3/4” wide or 1/2” deep should be patched. E. Curing: 1. Concrete shall be cured using water methods, sealing materials, or curing compounds. Curing compounds shall not be used on surfaces to which decorative coatings, mortar, or shotcrete is to be applied. Curing compounds used within the tank shall be suitable for use with potable water. F. Testing: 1. For concrete placed in precast panels or wall slots, a set of three cylinders shall be made for each truck load of concrete placed. For concrete placed in the floor, dome ring, or dome BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Prestressed Concrete Water Storage Tanks 33 16 33 - 14 slots, two sets of five cylinders for the first 50 cubic yards, and one set of five cylinders for every 100 cubic yards thereafter placed in the same day. Two cylinders shall be tested at seven days, two at twenty-eight days, and one held as a spare. 2. Slump, air content and temperature testing shall be performed on each truck where cylinders are taken. 3. All concrete and shotcrete testing shall be in accordance with ASTM C31 and C39, at the expense of the Tank Contractor, and shall be conducted by an independent testing agency approved by the Engineer. 3.9 SHOTCRETE PLACEMENT A. All shotcrete shall be conveyed, placed, finished, and cured as required by pertinent ACI standards. B. Weather Limitations: 1. Shotcrete shall not be placed in freezing weather without provisions for protection against freezing. Shotcrete placement can start without special protection when the temperature is 35 degrees Fahrenheit and rising and shall be suspended when the temperature is 40 degrees Fahrenheit and falling. The surface to which the shotcrete is applied shall be free from frost. Cold weather shotcrete placement shall be in accordance with ACI 506, ACI 301 and ACI 306. 2. Hot weather shotcrete placement shall be in accordance with the requirements of ACI 506, ACI 301 and ACI 305. C. Coating of Steel Diaphragm: 1. Steel diaphragm shall be covered with a layer of shotcrete at least ½ inch thick prior to prestressing. 2. Total minimum coating over the steel diaphragm shall be 1½ inches including diaphragm cover, wire or strand cover, and finish cover coat. D. Coating Over Prestressing Wire or Strand: 1. Each prestress wire or strand shall be individually encased in shotcrete. Shotcrete thickness shall be sufficient to provide a clear cover over the wire and strand of at least ¼ inch and 3/8 inch, respectively. 2. Finish cover coat shotcrete shall be applied as soon as practical after the last application of wire or strand coat. 3. The minimum final shotcrete cover over the outermost prestressing wire or strand layer shall be 1 inch. E. Placement of Shotcrete: 1. Shotcrete shall be applied by an ACI 506 certified nozzleman. 2. Manually applied shotcrete shall be applied with the nozzle held at a small upward angle not exceeding five degrees and constantly moving during application in a smooth motion with the nozzle pointing in a radial direction toward the center of the tank. Nozzle distance from the prestressing shall be such that shotcrete does not build up or cover the front face of the wire or strand until the spaces behind and between the prestressing elements are filled. 3. Unless applied by an automated shotcrete process, total cover coat thickness shall be controlled by shooting guide wires. Vertical wires shall be installed under tension and spaced no more than two feet apart to establish uniform and correct coating thickness. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Prestressed Concrete Water Storage Tanks 33 16 33 - 15 Monofilament line (100 lb. test) or 18 or 20-gauge high tensile strength steel wire shall be used. Guide wires shall be removed after placement of the cover coat. 4. Shotcrete applied by an automated shotcrete process shall be applied using the wet mix only. Nozzles shall be kept mounted on power driven machinery enabling the nozzle to travel parallel to the surface to be sprayed at a uniform linear or bi-directional speed. The nozzle shall be kept at a uniform constant distance from the surface, always insuring a right-angle spray of the material to the surface. The high velocity impact shall be developed pneumatically by injecting compressed air at the nozzle. F. Curing: 1. Shotcrete shall be cured using water curing methods, sealing materials or curing compounds at the option of the Tank Contractor. Curing compounds shall not be used on surfaces to which decorative coatings, mortar or shotcrete is to be applied. Curing compounds used within the tank wall shall be suitable for use with potable water. Intermediate layers of shotcrete shall be kept damp by water curing or other means no sooner than twelve hours after the shotcrete has been applied. 2. Water curing is not required should additional shotcrete be applied on the entire wall surface within the following twelve hours. 3. Indiscriminate use of continuous water cure for intermediate layers shall be avoided. 4. Complete shotcrete surfaces, which do not receive any additional coatings, may be water cured for a period of at least seven days by encapsulating the shotcrete inside of plastic sheeting. G. Testing: 1. Testing of shotcrete shall be in accordance with ACI 506, except as specified herein. One test panel shall be made for each of the following operations: core wall, wire or strand cover, and cover coat. Test panels shall be made from the shotcrete as it is being placed, and shall, as nearly as possible, represent the material being applied. The method of making a test sample shall be as follows: A frame of wire fabric (1-foot square, 3 inches in depth) shall be secured to a plywood panel and hung or placed in the location where shotcrete is being placed. This form shall be filled in layers simultaneously with the nearby application. After twenty-four hours, the fabric and plywood backup shall be removed, and the sample slab placed in a safe location at the site. 2. The sample slab shall be moist cured in a manner identical with the regular surface application. Sample slab shall be sent to the testing laboratory. Nine 3-inch cubes shall be cut from the sample slab and subjected to compression tests in accordance with current ASTM Standards. Three cubes shall be tested at the age of seven days, three shall be tested at the age of twenty-eight days, and three shall be retained as spares. Testing shall be by an independent testing laboratory, approved by the Engineer and at the Tank Contractor’s expense. 3. At the Tank Contractor’s option, testing of shotcrete applied with an automated process shall be in accordance with ACI 301 and conform to Section 3.8.F “Concrete Testing” of this specification in lieu of that indicated in Section 3.9.G.1 above. 3.10 CIRCUMFERENTIAL PRESTRESSING A. Prestressing shall be performed utilizing continuous wire or strand. Prestressing wire/strand will be placed on the wall with a machine capable of consistently producing a stress in the wire/strand within a range of minus 7% to plus 7% of the stress required by the design. Circumferential movement of the prestressing along the tank wall shall not be permitted during or after stressing. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Prestressed Concrete Water Storage Tanks 33 16 33 - 16 Stressing may be accomplished by drawing the wire through a die or by another process that results in uninterrupted elongation, thus assuring uniform stress throughout its length and over the periphery of the tank. B. Each coil of prestressing shall be temporarily anchored at sufficient intervals to minimize the loss of prestress in case a wire/strand breaks during wrapping. C. Minimum clear space between prestressing wires is 5/16 inch or 1.5 wire diameters, whichever is greater. Minimum clear distance between prestressing strands is 3/8 inch or 1.5 strand diameters, whichever is greater. Any wires or strands not meeting the spacing requirements shall be respaced. Prestressing shall be placed no closer than 2 inches from the top of the wall, edges of openings, or inserts, nor closer than 3 inches from the base of walls or floors where radial movement may occur. D. The band of prestressing normally required over the height of an opening shall be displaced into circumferential bands immediately above and below the opening to maintain the required prestressing force. Bundling of the prestressing steel is prohibited. E. For wire wound tanks, a stress plate shall be used at all permanent wall penetrations above grade that results in displacement of wire/strand equal to or greater than 24 inches in height. The stress plate shall accommodate a portion of the prestressing normally required for the height of the opening. The remaining prestressing normally required shall be displaced into circumferential bands immediately above and below the penetration. The effect of banded prestressing shall be considered in the design. F. Ends of individual coils shall be joined by suitable steel splicing devices capable of developing the full strength of the prestressing wire/strand. G. The Tank Contractor shall furnish a calibrated stress recording device, which can be recalibrated, to be used in determining wire/strand stress levels on the wall during and after the prestressing process. At least one stress reading per vertical foot or one stress reading for every roll of prestressing, whichever is greater, shall be taken immediately after the wire or strand has been applied on the wall. Readings shall be recorded and shall refer to the applicable height and layer of the prestressing for which the stress is being taken. Tank Contractor shall keep a written record of stress readings. All stress readings shall be made on straight lengths of wire/strand. If applied stresses fall below the design stress in the steel, additional wire or strand will be provided to bring the force on the core wall 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. H. When a mechanical stressing system is utilized, a continuous electronically (or substantial equivalent) monitored permanent recording of the applied force shall be made during the entire circumferential prestressing application. All such recordings shall be based on a continuous sensing of the applied force on the wire/strand between the tensioning system and the wall when, and as, the strand is being wrapped and laid on the wall. 3.11 COATINGS A. Coat all exposed exterior dome and exterior exposed wall surfaces with specified coatings. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Prestressed Concrete Water Storage Tanks 33 16 33 - 17 1. Concrete surfaces to be coated shall be clean, free of all laitance, dirt, grease, or other foreign materials. All concrete surface defects shall be filled and/or repaired prior to coating. 2. Coatings shall be applied by workmen skilled in the application of specified products. Apply coatings in strict accordance with coating manufacturer’s instructions. 3. The Owner shall select tank exterior color. 4. Cracks in the finished coating are not acceptable. B. Coat exposed piping in accordance with Section 09 96 00 – High-Performance Coatings. 3.12 WATERTIGHTNESS TEST A. Upon completion, tanks shall be tested to determine water tightness. Tanks shall be filled with raw water (RW) or plant water (PTW) to the overflow level. Test water will be furnished by the Owner. Test shall consist of measuring liquid level over twenty-four hours after filling to determine if any change has occurred. If a change is observed and exceeds the maximum allowance, the test shall be extended to a total of five days. If at the end of five days, the average daily change has not exceeded the maximum allowance, the test shall be considered satisfactory. B. The liquid volume loss for a period of twenty-four hours shall not exceed 1/20th of 1% of the tank capacity, 0.0005 x tank volume. If the liquid volume loss exceeds this amount, it shall be considered excessive, and the tank shall be repaired and retested. 1. Water for retesting shall be paid for by the Tank Contractor as defined in Section 01 50 00 – Temporary Facilities and Controls. C. Damp spots are not permitted at any location on the tank wall. Damp spots are defined as spots where moisture can be picked up on a dry hand. All such areas shall be repaired as necessary. D. Damp spots or standing water on the footing may occur upon tank filling and are permissible within the allowable volume loss. Measurable flow in this area is not permissible and shall be corrected. 3.13 CLEAN-UP A. Reference Section 01 70 00 – Execution and Closeout Requirements. 3.14 DEFECTIVE WORK A. Imperfections, damages, or defects in the concrete surface shall be filled and/or repaired at the Tank Contractor's expense prior to applying the decorative coating system. B. Imperfections, damages, or areas of the final coating system determined to be defective before Final Completion shall be satisfactorily re-placed at the Tank Contractor’s expense, and in conformity with the requirements of the Specifications. C. If necessary, perform removal and/or replacement of concrete/shotcrete work or coating system work in such a manner as not to impair the appearance or strength of the structure or remaining coating system. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Prestressed Concrete Water Storage Tanks 33 16 33 - 18 END OF SECTION BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 1 SECTION 40 05 00 – COMMON REQUIREMENTS FOR PROCESS PIPING (Revised by AD-02) PART 1 GENERAL 1.1 SUMMARY A. Section Includes: Process piping systems. B. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Division 01 – General Requirements. 3. Section 09 96 00 – High Performance Coatings. 4. Section 10 14 00 – Identification for Process Piping and Equipment. 5. Section 23 05 53 – Identification for HVAC. 6. Division 31 – Earthwork. 7. Section 40 05 06 – Couplings, Adapters, and Specials for Process Piping. 8. Section 40 05 07 – Hangers and Supports for Process Piping. 9. Section 40 05 17 – Copper Process Pipe and Tubing. 10. Section 40 05 19 – Ductile Iron Process Pipe. 11. Section 40 05 23 – Stainless Steel Process Pipe and Tubing. 12. Section 40 05 24 – Steel Process Pipe. 13. Section 40 05 31 – Thermoplastic Process Pipe. 14. Section 40 05 40 – Process Piping Leakage Testing and Disinfection. 15. Section 40 05 51 – Common Requirements for Process Valves. 16. Section 40 42 13 – Process Piping Insulation. 1.2 REFERENCE STANDARDS A. The following is a list of standards, which may be referenced in this section. Current editions of standards shall apply. 1. Air Force: A-A-58092, Tape, Antiseize, Polytetrafluorethylene. 2. American Association of State Highway and Transportation Officials (AASHTO): HB- 17, Standard Specifications for Highway Bridges. 3. American Petroleum Institute (API): SPEC 5L, Specification for Line Pipe. 4. American Society of Mechanical Engineers (ASME): a. Boiler and Pressure Vessel Code, Section IX, Qualification Standard for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators. b. B1.20.1, Pipe Threads, General Purpose (Inch). c. B16.1, Gray Iron Pipe Flanges and Flanged Fittings Classes 25, 125, and 250. d. B16.5, Pipe Flanges and Flanged Fittings NPS 1/2 through NPS 24 Metric/Inch Standard. e. B16.9, Factory-Made Wrought Buttwelding Fittings. f. B16.11, Forged Fittings, Socket-Welding and Threaded. g. B16.21, Nonmetallic Flat Gaskets for Pipe Flanges. h. B16.25, Buttwelding Ends. i. B16.42, Ductile Iron Pipe Flanges and Flanged Fittings Classes 150 and 300. j. B31.1, Power Piping. k. B31.3, Process Piping. l. B31.9, Building Services Piping. m. B36.10M, Welded and Seamless Wrought Steel Pipe. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 2 5. American Society for Nondestructive Testing (ASNT): SNT-TC-1A, Recommended Practice for Personal Qualification and Certification in Nondestructive Testing. 6. American Water Works Association (AWWA): a. C104/A21.4, Cement-Mortar Lining for Ductile-Iron Pipe and Fittings. b. C105/A21.5, Polyethylene Encasement for Ductile-Iron Pipe Systems. c. C110/A21.10, Ductile-Iron and Gray-Iron Fittings. d. C111/A21.11, Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings. e. C115/A21.15, Flanged Ductile-Iron Pipe with Ductile-Iron or Gray-Iron Threaded Flanges. f. C151/A21.51, Ductile-Iron Pipe, Centrifugally Cast. g. C153/A21.53, Ductile-Iron Compact Fittings. h. C205, Cement-Mortar Protective Lining and Coating for Steel Water Pipe – 4-inch and Larger – Shop Applied. i. C207, Steel Pipe Flanges for Waterworks Service, Sizes 4 In. Through 144 In. (100 mm Through 3,600 mm). j. C222, Polyurethane Coatings and Linings for Steel Water Pipe and Fittings. k. C606, Grooved and Shouldered Joints. 7. American Welding Society (AWS): a. Brazing Handbook. b. A5.8M/A5.8, Specification for Filler Metals for Brazing and Braze Welding. c. D1.1/D1.1M, Structural Welding Code - Steel. d. QC1, Standard for AWS Certification of Welding Inspectors. 8. ASTM International (ASTM): a. A47/A47M, Standard Specification for Ferritic Malleable Iron Castings. b. A53/A53M, Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc- Coated, Welded and Seamless. c. A105/A105M, Standard Specification for Carbon Steel Forgings for Piping Applications. d. A106/A106M, Standard Specification for Seamless Carbon Steel Pipe for High- Temperature Service. e. A126, Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings. f. A135/A135M, Standard Specification for Electric-Resistance-Welder Steel Pipe. g. A139/A139M, Standard Specification for Electro-Fusion (Arc)–Welded Steel Pipe (NPS 4 Inches and Over). h. A153/A153M, Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware. i. A181/A181M, Standard Specification for Carbon Steel Forgings, for General- Purpose Piping. j. A182/A182M, Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service. k. A183, Standard Specification for Carbon Steel Track Bolts and Nuts. l. A193/A193M, Standard Specification for Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications. m. A194/A194M, Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure or High Temperature Service, or Both. n. A197/A197M, Standard Specification for Cupola Malleable Iron. o. A216/A216M, Standard Specification for Steel Castings, Carbon, Suitable for Fusion Welding, for High-Temperature Service. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 3 p. A234/A234M, Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service. q. A240/A240M, Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications. r. A276, Standard Specification for Stainless Steel Bars and Shapes. s. A269, Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service. t. A307, Standard Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength. u. A312/A312M, Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes. v. A320/A320M, Standard Specification for Alloy-Steel and Stainless Steel Bolting for Low-Temperature Service. w. A351/A351M, Standard Specification for Castings, Austenitic, for Pressure- Containing Parts. x. A395/A395M, Standard Specification for Ferritic Ductile Iron Pressure-Retaining Castings for Use at Elevated Temperatures. y. A403/A403M, Standard Specification for Wrought Austenitic Stainless Steel Piping Fittings. z. A409/A409M, Standard Specification for Welded Large Diameter Austenitic Steel Pipe for Corrosive or High-Temperature Service. aa. A536, Standard Specification for Ductile Iron Castings. bb. A563, Standard Specification for Carbon and Alloy Steel Nuts. cc. A587, Standard Specification for Electric-Resistance-Welded Low-Carbon Steel Pipe for the Chemical Industry. dd. A743/A743M, Standard Specification for Castings, Iron-Chromium, Iron- Chromium-Nickel, Corrosion Resistant, for General Application. ee. A744/A744M, Standard Specification for Castings, Iron-Chromium-Nickel, Corrosion Resistant, for Severe Service. ff. A774/A774M, Standard Specification for As-Welded Wrought Austenitic Stainless Steel Fittings for General Corrosive Service at Low and Moderate Temperatures. gg. A778, Standard Specification for Welded, Unannealed Austenitic Stainless Steel Tubular Products. hh. B32, Standard Specification for Solder Metal. ii. B43, Standard Specification for Seamless Red Brass Pipe, Standard Sizes. jj. B61, Standard Specification for Steam or Valve Bronze Castings. kk. B62, Standard Specification for Composition Bronze or Ounce Metal Castings. ll. B75/B75M, Standard Specification for Seamless Copper Tube. mm.B88, Standard Specification for Seamless Copper Water Tube. nn. B98/B98M, Standard Specification for Copper-Silicon Alloy Rod, Bar and Shapes. oo. B462, Standard Specification for Forged or Rolled UNS N06030, UNS N06022, UNS N06035, UNS N06200, UNS N06059, UNS N10362, UNS N06686, UNS N08020, UNS N08024, UNS N08026, UNS N08367, UNS N10276, UNS N10665, UNS N10675, UNS N10629, UNS N08031, UNS N06045, UNS N06025, and UNS R20033 Alloy Pipe Flanges, Forged Fittings, and Valves and Parts for Corrosive High-Temperature Service. pp. B464, Standard Specification for Welded UNS N08020 Alloy Pipe. qq. B474, Standard Specification for Electric Fusion Welded Nickel and Nickel Alloy Pipe. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 4 rr. C582, Standard Specification for Contact-Molded Reinforced Thermosetting Plastic (RTP) Laminates for Corrosion-Resistant Equipment. ss. D412, Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers-Tension. tt. D413, Standard Test Methods for Rubber Property-Adhesion to Flexible Substrate. uu. D543, Standard Practices for Evaluating the Resistance of Plastics to Chemical Reagents. vv. D1248, Standard Specification for Polyethylene Plastics Extrusion Materials for Wire and Cable. ww. D1330, Standard Specification for Rubber Sheet Gaskets. xx. D1784, Standard Specification for Rigid Poly(Vinyl Chloride) (PVC) Compounds and Chlorinated Poly(Vinyl Chloride) (CPVC) Compounds. yy. D1785, Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40, 80, and 120. zz. D2000, Standard Classification System for Rubber Products in Automotive Applications. aaa. D2310, Standard Classification for Machine-Made “Fiberglass” (Glass-Fiber- Reinforced Thermosetting-Resin) Pipe. bbb. D2464, Standard Specification for Threaded Poly(Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 80. ccc. D2466, Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 40. ddd. D2467, Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 80. eee. D2564, Standard Specification for Solvent Cements for Poly(Vinyl Chloride) (PVC) Plastic Piping Systems. fff. D2837, Standard Test Method for Obtaining Hydrostatic Design Basis for Thermoplastic Pipe Materials or Pressure Design Basis for Thermoplastic Pipe Products. ggg. D2996, Standard Specification for Filament-Wound “Fiberglass” (Glass-Fiber- Reinforced Thermosetting-Resin) Pipe. hhh. F436, Standard Specification for Hardened Steel Washers. iii. F437, Standard Specification for Threaded Chlorinated Poly(Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Schedule 80. jjj. F439, Standard Specification for Chlorinated Poly(Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Schedule 80. kkk. F441/F441M, Standard Specification for Chlorinated Poly(Vinyl Chloride) (CPVC) Plastic Pipe, Schedules 40 and 80. lll. F493, Standard Specification for Solvent Cements for Chlorinated Poly(Vinyl Chloride) (CPVC) Plastic Pipe and Fittings. mmm. F593, Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs. nnn. F656, Standard Specification for Primers for Use in Solvent Cement Joints of Poly(Vinyl Chloride) (PVC) Plastic Pipe and Fittings. 9. FM Global (FM). 10. Manufacturers Standardization Society of the Valve and Fittings Industry, Inc. (MSS): SP-43, Wrought and Fabricated Butt-Welding Fittings for Low-Pressure, Corrosion Resistant Applications. 11. NSF International (NSF): a. NSF 61 - Drinking Water System Components - Health Effects. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 5 b. NSF 372 - Drinking Water System Components - Lead Content. 12. National Electrical Manufacturers Association (NEMA): LI 1, Industrial Laminating Thermosetting Products. 13. National Fire Protection Association (NFPA): 24, Standard for the Installation of Private Fire Service Mains and Their Appurtenances. 1.3 DEFINITIONS A. Working Pressure: Maximum pressure under which a system or zone within a system operates in a static or steady state condition, whichever is greater. Working pressure, operating pressure, and pressure rating are synonymous. B. Test Pressure: Pressure that is used to verify the integrity of an installed piping system or zone of the system. C. Submerged or Wet: 1. Zone below elevation of: a. Top face of channel walls and cover slabs. b. Liquid surface or within 1.5 feet above top of liquid surface. c. Top of tank, basin, wet well or vault wall or under corresponding cover. 1.4 DESIGN REQUIREMENTS A. Where pipe diameter, thickness, pressure class, pressure rating, or thrust restraint is not shown or specified, design piping system in accordance with the following: 1. Process Piping: ASME B31.3, normal fluid service unless otherwise specified. 2. Building Service Piping: ASME B31.9, as applicable. 3. Sanitary Building Drainage and Vent Systems: ICC International Plumbing Code. 4. Buried Piping: H20-S16 traffic load with 1.5 impact factor, AASHTO HB-17, as applicable. 5. Thrust Restraints: a. Design for test pressure shown in Piping Schedule. b. Allowable Soil Pressure: 1,000 pounds per square foot. c. Low Pressure Pipelines: 1) When bearing surface of the fitting against soil provides an area equal to or greater than area required for thrust restraint, concrete thrust blocks will not be required. 2) Determine bearing area for fittings without thrust blocks by projected area of 70 percent of internal diameter multiplied by chord length for fitting centerline curve. 1.5 SUBMITTALS A. See Section 01 33 00 – Submittal Procedures for requirements of submittals. B. Shop Drawings: 1. Product technical data, including: a. Acknowledgement that products submitted meet requirements of standards referenced. b. Copies of manufacturer’s written instructions regarding material handling, delivery, storage, and installation. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 6 c. Separate schedule sheet for each piping system scheduled in this Section showing compliance of all system components. 2. Shop Fabricated Piping: a. Exterior yard piping drawings (minimum scale 1 IN = 10 FT) with information including: 1) Detailed pipe fabrication or spool drawings showing special fittings and bends, tapping locations, dimensions and lengths, linings/coatings, and other pertinent information. 2) Layout drawing showing location of each pipe section and each special length and invert or centerline elevations; number or otherwise designate laying sequence on each piece. 3) Hydraulic Thrust Restraint for Restrained Joints: Details including materials, sizes, assembly ratings, and pipe attachment methods. 4) Acknowledgement of valve, equipment, and instrument tag numbers as applicable. 5) Line slopes and vents. b. Interior piping drawings (minimum scale 1/8 IN = 1 FT) with information including: 1) Dimensions of piping from column lines or wall surfaces. 2) Centerline dimensions of piping. 3) Centerline elevation and size of intersecting ductwork, conduit/conduit racks, or other potential interferences requiring coordination. 4) Location and type of pipe supports and anchors. 5) Locations of valves and valve actuator type. 6) Details of fittings, tapping locations, equipment connections, flexible expansion joints, connections to equipment, and related appurtenances. 7) Acknowledgement of valve, equipment, and instrument tag numbers as applicable. 8) Provisions for expansions and contractions. 9) Line slopes and air release vents. c. Schedule of interconnections to existing piping and method of connection. d. Pipe Wall Thickness: Identify wall thickness and rational method or standard applied to determine wall thickness for each size of each different service including exposed, submerged, buried, and concrete-encased installations for Contractor- designed piping. e. Dissimilar Pipe Joints: Joint types and assembly drawings. C. Informational Submittals: 1. Manufacturer’s Certification of Compliance, in accordance with Section 01 60 00 – Product Requirements. a. Pipe and fittings. b. Factory applied resins and coatings. 2. Qualifications: a. Nondestructive Testing Personnel: SNT-TC-1A Level II certification and qualifications. b. AWS QC1 Certified Welding Inspector: Submit evidence of current certification prior to commencement of welding activities. c. Welders: 1) Continuity log for welders and welding operators. 2) Welder qualification test records conducted by Contractor or manufacturer. 3. Welding Procedures: Qualified in accordance with ASME Boiler and Pressure Vessel Code, Section IX for weld type(s) and base metal(s). BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 7 4. Nondestructive inspection and testing procedures. 5. Test logs. 6. Pipe coating applicator certification. 7. Laboratory Testing Equipment: Certified calibrations, manufacturer’s product data, and test procedures. 8. CWI inspection records and NDE test records. 9. Test Reports: a. Copies of pressure test results on all piping systems. b. Notification of time and date of piping pressure tests. c. Copies of disinfection test reports. 1.6 CLOSEOUT SUBMITTALS A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for submittals and Operation and Maintenance Data. B. Project Record Documents: Record actual locations of piping, valves and other appurtenances, connections, and centerline elevations. C. Identify and describe unexpected variations to subsoil conditions or discovery of uncharted utilities. 1.7 QUALITY ASSURANCE A. Provide services of independent inspection and testing agency for welding operations. 1. The presence of Owner’s Special Inspector or Verification CWI does not relieve Contractor from performing own quality control, including 100 percent visual inspection of welds. 1.8 QUALIFICATIONS A. Independent Inspection and Testing Agency: 1. Ten years’ experience in field of welding and welded pipe and fittings’ testing required for this Project. 2. Calibrated instruments and equipment and documented standard procedures for performing specified testing. 3. Certified in accordance with ASNT SNT-TC-1A for testing procedures required for this Project. 4. Testing Agency: Personnel performing tests shall be NDT Level II certified in accordance with ASNT SNT-TC-1A. 5. Verification Welding Inspector: AWS QC1 Certified. B. Welding Procedures: In accordance with ASME BPVC SEC IX (Forms QW-482 and QW- 483) or AWS D1.1/D1.1M (Annex N Forms). C. Welder Qualifications: In accordance ASME BPVC SEC IX (Form QW-484) or AWS D1.1/D1.1M (Annex N Forms). D. Contractor’s CWI: Certified in accordance with AWS QC1, and having prior experience with specified welding codes. Alternate welding inspector qualifications require approval by Engineer. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 8 1.9 DELIVERY, STORAGE, AND HANDLING A. In accordance with Section 01 60 00 – Product Requirements, and: 1. Flanges: Securely attach metal, hardboard, or wood protectors over entire gasket surface. 2. Threaded or Socket Welding Ends: Fit with metal, wood, or plastic plugs or caps. 3. Linings and Coatings: Prevent excessive drying. 4. Cold Weather Storage: Locate products to prevent coating from freezing to ground. 5. Handling: Use heavy canvas or nylon slings to lift pipe and fittings. B. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage. C. Pipe Storage: Pipe should be stored at the job site in unit packages provided by the manufacturer. Caution shall be exercised to avoid compression damage or deformation to bell ends of the pipe. Pipe shall be stored in such a way as to prevent sagging or bending and shall be protected from exposure to direct sunlight by covering with an opaque material while permitting adequate air circulation above and around the pipe. Gaskets should be stored in a cool, dark place out of the direct rays of the sun, preferably in original cartons. D. Protection: 1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas. 2. Protect piping and appurtenances by storing off ground. 3. Provide additional protection according to manufacturer instructions. 1.10 EXISTING CONDITIONS A. Field Measurements: 1. Verify field measurements prior to fabrication. 2. Indicate field measurements on Shop Drawings. PART 2 PRODUCTS 2.1 GENERAL A. Components and Materials in Contact with Water for Human Consumption: Comply with the requirements of the Safe Drinking Water Act and other applicable federal, state, and local requirements. Provide certification by manufacturer or an accredited certification organization recognized by the Authority Having Jurisdiction that components and materials comply with the maximum lead content standard in accordance with NSF/ANSI 61 and NSF/ANSI 372. 1. Use or reuse of components and materials without a traceable certification is prohibited. 2.2 PIPING A. As specified in Pipe Schedule herein and in subsequent narrow scope Pipe Specifications. B. Diameters Shown 1. Standardized Products: Nominal size. 2. Fabricated Steel Piping (Except Cement-Lined): Outside diameter, ASME B36.10M. 3. Cement-Lined Steel Pipe: Lining inside diameter. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 9 2.3 JOINTS A. Threaded: NPT taper pipe threads in accordance with ASME B1.20.1. B. Grooved End System: 1. Rigid type. 2. Use of flexible grooved joints allowed where specified, shown on Drawings, or with prior approval by Engineer. 3. Flanges: When required, furnish with grooved type flange adapters of same manufacturer as grooved end couplings. C. Solder Joints: 1. Use 95.5 solder on all non-potable water piping. For potable water piping, use lead-free solder. 2. Joints in copper tube shall be soldered using acceptable fittings. Joints shall be made with 5050 tin-lead, 955- tin-antimony solder, Stay-Brite Solder by J.W. Harrison Company, Inc., or cadmium-free brazing. D. Welded Joints: 1. Welded joints shall be welded as set forth in Standard Manual of Pipe Welding of the Heating, Piping, and Air Conditioning Contractors Association. Make welded joints as recommended by standards of the American Welding Society. Ensure complete penetration of deposited metal with base metal. Provide filler metal suitable for use with base metal. Do not use mitered joints. E. Flanged: 1. Flanges shall be selected based on design (rated) pressure and material requirements of adjoining pipe segment. Higher pressure rated flanges are required to mate with equipment when equipment flange is of higher-pressure rating than required for piping. 2. Flat-faced, carbon steel, or alloy flanges when mating with flat-faced cast or ductile iron flanges. 3. Carbon steel flanges conforming to ANSI B16.5 (AWWA C207) or ASME B16.47 with materials conforming to ASTM A105, Grade II or ASTM A108, Grade II. Use slip-on flanges on pipe only. 4. Stainless steel flanges shall be Type 304L of 316L. 5. High strength ANSI 304 stainless steel nuts and bolts for above ground locations. High strength ANSI 316 stainless steel nuts and bolts for underground, outdoors, or in wet locations. a. All threads are not an acceptable substitute to bolts. b. Do not paint stainless steel nuts and bolts. F. Mechanical Joints: 1. Provide a stuffing box type mechanical joint adapted to use gasket, cast iron gland and bolts. Unless noted otherwise in narrow scope specifications, bolts, nuts, and washers shall be corrosion resistant, low alloy, high strength steel. Where polyethylene encasement is not used, coat joints with bitumastic enamel and apply heat shrinkable sleeves. Use joints from one of the following manufacturers. Conform to AWWA C110 or C153. 2. Acceptable Manufacturers: a. American Cast Iron Pipe Company. b. U.S. Pipe and Foundry Company. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 10 G. Mechanical Joint Anchor Gland Follower: 1. Ductile iron anchor type, wedge action, with break-off tightening bolts. 2. Thrust rated to 250 psi minimum or pipe system test pressure, whichever is higher. 3. Rated operating deflection not less than: a. 3 degrees for sizes through 12 inches. b. 2 degrees for sizes 14 inches through 16 inches. c. 1.5 degrees for sizes 18 inches through 24 inches. d. 1 degree for sizes 30 inches through 48 inches. 4. UL and FM approved. 5. Acceptable Manufacturers: a. EBAA Iron, Inc., Series 1100. b. Or accepted equal. H. Flexible Mechanical Compression Joint Coupling: 1. Stainless steel, ASTM A276, Type 305 bands. 2. Acceptable Manufacturers: a. Pipeline Products Corp. b. Fernco Joint Sealer Co. I. Mechanical connections of high-density polyethylene pipe to auxiliary equipment such as valves, pumps, tanks, and other piping systems shall be through-flanged connections consisting of the following: 1. Polyethylene stub end thermally butt-fused to end of pipe. 2. ASTM A240/A240M, Type 304L stainless steel backing flange, 125 pound, ASME B16.1 standard. Use insulating flanges where shown. 3. High strength, 316L stainless steel bolts and nuts of sufficient length to show a minimum of three complete threads when joint is made and tightened to manufacturer’s standard. Retorque nuts after 4 hours. 4. Gaskets as specified. 2.4 GASKET LUBRICANT A. Lubricant shall be supplied by pipe manufacturer and no substitute or “or equal” will be allowed. 2.5 PIPE CORROSION PROTECTION A. Coatings and Linings: See Section 09 96 00 – High-Performance Coatings and individual pipe specifications for details of coating and lining requirements. B. Heat Shrink Wrap: For buried metallic couplings. 1. Type: Cross-linked polyolefin wrap or sleeve with mastic sealant. 2. Comply with AWWA C216. 3. Manufacturer and Product: Raychem; WPC or TPS. C. Polyethylene Encasement: 1. Encasement Tube: Black polyethylene encasement tube, 8 mils minimum thickness, conforming to AWWA C105/A21.5, free of gels, streaks, pinholes, foreign matter, undispersed raw materials, and visible defects such as tears, blisters, and thinning at folds. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 11 2. Securing Tape: Thermoplastic tape, 8 mils minimum thickness, 1 inch wide, pressure sensitive adhesive face capable of bonding to metal, bituminous coating, and polyethylene encasement tube. D. Insulating Pipe Supports: 1. For metallic pipe supported by dissimilar metal, provide layer of EPDM roofing membrane between pipe and support or as specifically detailed otherwise on Drawings. E. Insulating Flanges, Couplings, and Unions: 1. Materials: a. In accordance with applicable piping material specified in Pipe Schedule. Complete assembly shall have ASME B31.9 or B: B31.3 working pressure rating equal to or higher than that of joint and pipeline. b. Galvanically compatible with piping. c. Resistant for intended exposure, operating temperatures, and products in pipeline. 2. Union Type, 2 Inches and Smaller: a. Screwed or solder joint. b. O-ring sealed with molded and bonded insulation to body. 3. Flange Type, 2 1/2 Inches and Larger: a. Flanged, complete with bolt insulators, dielectric gasket, bolts, and nuts. b. Bolt insulating sleeves shall be provided full length between insulating washers. c. Ensure fit-up of components of insulated flange assembly to provide a complete functioning installation. d. AWWA C207 steel flanges may be drilled oversize up to 1/8 inch to accommodate insulating sleeves. e. No less than minimum thread engagement in accordance with specified bolting standards will be permitted to accommodate thicknesses of required washers, flanges, and gasket. 4. Flange Insulating Kits: a. Flange insulating kits shall be installed within 6 months of the date of manufacture of all components. b. Do not store insulating flange gaskets, sleeves, or washers under direct sunlight or at temperatures exceeding 110 deg F. c. Gasket configuration shall be in accordance with AWWA C207. Insulating gaskets shall be full-face, Type E with an EPDM O-ring seal. Minimum total gasket thickness shall not be less than 1/8 inch. The gasket shall have the same outside diameter as the pipe flange. For steel pipe, the gasket inside diameter shall be equal to the inside diameter of the steel pipe cylinder. The complete assembly shall have a pressure rating equal to or higher than that of the joint and pipeline. The gasket material shall be resistant to intended chemical exposure, operating temperatures, and pressures in the pipeline. Gasket shall be NSF 61 certified. d. Insulating sleeves shall be one-piece, full-length, Mylar or NEMA G10 fiberglass reinforced epoxy with a minimum thickness of 1/8 inch. e. Insulating washers shall be NEMA G10 fiberglass reinforced epoxy. f. Steel Washers: Plated, hot-rolled steel, 1/8 inch thick. 1) Provide two washers per bolt for flange diameters less than or equal to 36-inch. 2) Provide for washers per bolt for flange diameters greater than 36-inch. 5. Manufacturers and Products: a. Dielectric Flanges and Unions: 1) PSI, Houston, TX. 2) Advance Products and Systems, Lafayette, LA. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 12 b. Insulating Couplings: Reference Section 40 05 06 – Couplings, Adapters, and Specials for Process Piping. 2.6 THRUST BLOCKS A. Use only where indicated on Drawings. B. Concrete: As specified in Section 03 30 00 – Cast-in-Place Concrete. 2.7 THRUST TIES A. Steel Pipe: Fabricated lugs and rods in accordance with details shown on Drawings. B. Buried Ductile Iron Pipe and Fittings: Unless restraint is otherwise specified or shown, conform to NFPA 24. Tie-rod attachments relying on clamp friction with pipe barrel to restrain thrust are unacceptable. 2.8 VENT AND DRAIN VALVES A. Pipeline 2-Inch Diameter and Smaller: 1/2-inch vent, 1-inch drain unless shown otherwise. B. Pipelines 2-1/2-Inch Diameter and Larger: 3/4-inch vent, 1-inch drain unless shown otherwise. 2.9 FABRICATION A. Mark each pipe length on outside with the following: 1. Size or diameter and class. 2. Manufacturer’s identification and pipe serial number. 3. Location number on laying drawing. 4. Date of manufacture. B. Code markings according to approved Shop Drawings. C. Shop fabricate flanged pipe in shop, not in field, and delivered to Site with flanges in place and properly faced. Threaded flanges shall be individually fitted, and machine tightened on matching threaded pipe by manufacturer. 2.10 FINISHES A. Factory prepare, prime, and finish coat in accordance with Pipe Specifications and Section 09 96 00 – High-Performance Coatings. B. Galvanizing: 1. Hot-dip applied, meeting requirements of ASTM A153/A153M. 2. Electroplated zinc or cadmium plating is unacceptable. 3. Stainless steel components may be substituted where galvanizing is specified. Refer to Section 01 25 00 – Substitution Procedures. PART 3 EXECUTION BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 13 3.1 EXAMINATION A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for installation examination. B. Verify size, material, joint types, elevation, horizontal location, and pipe service of existing pipelines to be connected to new pipelines or new equipment. C. Inspect size and location of structure penetrations to verify adequacy of wall pipes, sleeves, and other openings. 3.2 PREPARATION A. See Section 09 96 00 – High Performance Coatings, for additional requirements. B. Notify Engineer at least 2 weeks prior to field fabrication of pipe or fittings. C. Inspect pipe and fittings before installation, clean ends thoroughly, and remove foreign matter and dirt from inside. D. Damaged Coatings and Linings: Repair using original coating and lining materials in accordance with manufacturer’s instructions. 3.3 WELDING A. Perform in accordance with Section IX, ASME Boiler and Pressure Vessel Code and ASME B31.1 for Pressure Piping, as may be specified in Piping Specifications, and if recommended by piping or fitting manufacturer. Conform to the current recommendation of the American Welding Society for all welding operations. B. Weld Identification: Keep paper record of which welder welded each joint. C. Pipe End Preparation: 1. Machine Shaping: Preferred. 2. Oxygen or Arc Cutting: Smooth to touch, true, and slag removal by chipping or grinding. 3. Beveled Ends for Butt Welding: ASME B16.25. D. Surfaces: 1. Clean and free of paint, oil, rust, scale, slag, or other material detrimental to welding. 2. Clean stainless-steel joints with stainless steel wire brushes or stainless-steel wool prior to welding. 3. Thoroughly clean each layer of deposited weld metal, including final pass, prior to deposition of each additional layer of weld metal with a power-driven wire brush. E. Alignment and Spacing: 1. Align ends to be joined within existing commercial tolerances on diameters, wall thicknesses, and out-of-roundness. Set all fittings and joints square and true and preserve alignment during welding operation. 2. Root Opening of Joint: As stated in qualified welding procedure. 3. Minimum Spacing of Circumferential Butt Welds: Minimum four times pipe wall thickness or 1 inch, whichever is greater. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 14 F. Climatic Conditions: 1. Do not perform welding if there is impingement of any rain, snow, sleet, or wind exceeding 5 mph on the weld area, or if ambient temperature is below 32 degrees F. 2. Stainless Steel and Alloy Piping: If ambient is less than 32 degrees F, local preheating to a temperature warm to the hand is required. G. Tack Welds: Performed by qualified welder using same procedure as for completed weld, made with electrode similar or equivalent to electrode to be used for first weld pass, and not defective. Remove those not meeting requirements prior to commencing welding procedures. H. Surface Defects: Chip or grind out those affecting soundness of weld. I. Weld Quality: Meet requirements of governing welding codes. 3.4 INSTALLATION—GENERAL A. Join pipe and fittings in accordance with manufacturer’s instructions, unless otherwise shown or specified. Make piping layout and installation in the most advantageous manner possible with respect to headroom, valve access, and equipment clearance, and clearance for other work. Give particular attention to piping in the vicinity of equipment. Preserve maximum access to various equipment parts for maintenance. B. Install piping neatly, free from unnecessary traps and pockets. Work into place without springing or forcing. Use fittings to make all changes in direction. Field bending and mitering are prohibited. Make all connections to equipment using flanged joints or unions. Make reducing connections with reducing fittings, only. C. Remove foreign objects prior to assembly and installation. D. Flanged Joints: 1. Install perpendicular to pipe centerline. 2. Bolt Holes: Straddle vertical centerlines, aligned with connecting equipment flanges or as shown. 3. Use torque-limiting wrenches to ensure uniform bearing and proper bolt tightness. 4. Plastic Flanges: Install annular ring filler gasket at joints of raised-face flange. 5. Grooved Joint Flange Adapters: Include stainless steel washer plates as required for mating to serrated faces and lined valves and equipment. 6. Raised-Face Flanges: Use flat-face flange when joining with flat-faced ductile or cast- iron flange. 7. Verify compatibility of mating flange to adapter flange gasket prior to selecting grooved adapter flanging. 8. Flange fillers are to be avoided, but if necessary, may be used to make up for small angles up to 6 degrees and for filling gaps up to 2 inches between flanges. Stacked flange fillers shall not be used. 9. Threaded flanged joints shall be shop fabricated and delivered to Site with flanges in- place and properly faced. 10. Manufacturer: Same as pipe manufacturer or grooved joint flange adapter manufacturer. E. Threaded Joints: 1. Conform to ASME B1.20.1. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 15 2. Produce sufficient thread length to ensure full engagement when screwed home in fittings. 3. Countersink pipe ends, ream and clean chips and burrs after threading. 4. Make connections with not more than three threads exposed. 5. Lubricate male threads only with thread lubricant or tape as specified pipe/fitting manufacturer. F. Grooved-End Joints: 1. Piping shall be grooved in accordance with manufacturer’s latest published instructions and shall be accurately cut or rolled with tools conforming to coupling manufacturer’s standards and to AWWA C606 where applicable. 2. Install grooved joint couplings and gaskets in accordance with manufacturer’s latest published installation instructions. G. Soldered Joints: 1. Use only solder specified for particular service. 2. Cut pipe ends square and remove fins and burrs. Clean exterior of pipe and socket. 3. After thoroughly cleaning pipe and fitting of oil and grease using solvent and emery cloth, apply noncorrosive flux to the male end only. 4. Wipe excess solder from exterior of joint before hardened. 5. Before soldering, remove stems and washers from solder joint valves. H. Pipe Connections at Concrete Structures: As specified in Section 40 05 06 – Couplings, Adapters, and Specials for Process Piping or as illustrated on Drawings. I. Install expansion devices as necessary to allow expansion/contraction movement. J. PVC Piping: See Section 40 05 31 – Thermoplastic Process Pipe. K. Copper Piping: See Section 40 05 17 – Copper Process Pipe and Tubing. L. Ductile Iron Piping: See Section 40 05 19 – Ductile Iron Process Pipe. M. Stainless Steel Piping: See Section 40 05 23 – Stainless Steel Process Pipe and Tubing. N. Steel Piping: See Section 40 05 24 – Steel Process Pipe. O. High-Density Polyethylene (HDPE) Piping: 1. Join pipes, fittings, and flange connections by means of thermal butt-fusion. 2. Perform butt-fusion in accordance with pipe manufacturer’s recommendations as to equipment and technique. 3. Special Precautions at Flanges: Polyethylene pipe connected to heavy fittings, manholes, and rigid structures shall be supported in such a manner that no subsequent relative movement between polyethylene pipe at flanged joint and rigid structures is possible. 3.5 INSTALLATION—EXPOSED PIPING A. Piping Alignment: 1. Parallel to building or column lines and perpendicular to floor, unless shown otherwise. 2. Piping upstream and downstream of flow measuring devices shall provide straight lengths as required for accurate flow measurement. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 16 3. Alignment of piping smaller than 4 IN may not be shown; however, install according to Drawing intent and with clearance and allowance for: a. Expansion and contraction. b. Operation and access to equipment, doors, windows, hoists, moving equipment. c. Headroom and walking space for working areas and aisles. d. System drainage and air removal. 4. Avoid excessive or unnecessary couplings. B. Supports: As specified in Section 40 05 07 – Hangers and Supports for Process Piping. C. Group piping wherever practical at common elevations; install to conserve building space and not interfere with use of space and other work. D. Unions or Flanges: Provide at each piping connection to equipment or instrumentation on equipment side of each block valve to facilitate installation and removal. E. Install piping so that no load or movement in excess of that stipulated by equipment manufacturer will be imposed upon equipment connection; install to allow for contraction and expansion without stressing pipe, joints, or connected equipment. F. Piping clearance, unless otherwise shown: 1. Over Walkway and Stairs: Minimum of 7 feet 6 inches, measured from walking surface or stair tread to lowest extremity of piping system including flanges, valve bodies or mechanisms, insulation, or hanger/support systems. 2. Between Equipment or Equipment Piping and Adjacent Piping: Minimum 3 feet, measured from equipment extremity and extremity of piping system including flanges, valve bodies or mechanisms, insulation, or hanger/support systems. 3. From Adjacent Work: Minimum two inches from nearest extremity of completed piping system including flanges, valve bodies or mechanisms, insulation, or hanger/support systems. 4. Do not route piping in front of or to interfere with access ways, ladders, stairs, platforms, walkways, openings, doors, or windows. 5. Headroom in front of openings, doors, and windows shall not be less than the top of the opening. 6. Do not install piping containing liquids or liquid vapors in transformer vaults or electrical equipment rooms. 7. Do not route piping over, around, in front of, behind, or below electrical equipment including controls, panels, switches, terminals, boxes, or other similar electrical work. 3.6 INSTALLATION—BURIED PIPE A. Joints: 1. Dissimilar Buried Pipes: a. Provide flexible mechanical compression joints for pressure pipe. 2. Concrete Encased or Embedded Pipe: Do not encase joints in concrete, unless specifically shown. B. Placement: 1. Keep trench dry until pipe laying and joining are completed. 2. Bedding and Embedment: As specified in Section 31 23 17 – Trenching. 3. Exercise care when lowering pipe into trench to prevent twisting or damage to pipe. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 17 4. Measure for grade at pipe invert, not at top of pipe. 5. Excavate trench bottom and sides of ample dimensions to permit visual inspection and testing of entire flange, valve, or connection. 6. Do not lay pipe on unstable material, in wet trench, or when trench or weather conditions are unsuitable. 7. Do not lay pipe in same trench with other pipes or utilities unless shown otherwise on Drawings. 8. Prevent foreign material from entering pipe during placement. 9. Close and block open end of last laid pipe section when placement operations are not in progress and at close of day’s work. 10. Lay pipe upgrade with bell ends pointing in direction of laying. 11. Deflect pipe at joints for pipelines laid on a curve using unsymmetrical closure of spigot into bell. If joint deflection of standard pipe lengths will not accommodate horizontal or vertical curves in alignment, provide: a. Shorter pipe lengths. b. Special mitered joints. c. Standard or special fabricated bends. 12. After joint has been made, check pipe alignment and grade. 13. Place sufficient embedment material to secure pipe from movement before next joint is installed. 14. Prevent uplift and floating of pipe prior to backfilling. C. When entering or leaving structures with buried mechanical joint piping, install joint within 2 feet of point where pipe enters or leaves structure. 1. Install second joint not more than 6 feet nor less than 4 feet from first joint. D. Tolerances: 1. Deflection from Horizontal Line: Maximum 2 inches. 2. Deflection from Vertical Grade: Maximum 1/4 inch(es). 3. Joint Deflection: Maximum of 75 percent of manufacturer’s recommendation. 4. Horizontal position of pipe centerline on alignment around curves maximum variation of 1.75 feet from position shown. 5. Pipe Cover: Minimum 3 feet, unless otherwise shown. 6. Maintain 9 ft horizontal separation of water main from sanitary sewer piping in accordance with TCEQ Chapter 290. 3.7 INSTALLATION—CONCRETE ENCASED A. Provide concrete pipe encasement where shown on Drawings and where otherwise required. Some piping may be required to be concrete encased for pipe strength requirements that are included in the Specifications. Piping under and within the influence of buildings, utility trenches, vaults, slabs, and other structures shall be concrete encased. See details on Drawings for encasement requirements and extents. B. Where concrete encased piping crosses structure construction and expansion joints, provide flexible piping joints to coincide with structure joints to prevent excessive pipe stress and breakage. 3.8 CONNECTION TO EXISTING PIPING BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 18 A. Where connection between new work and existing work is made, use suitable and proper fittings to suit conditions encountered. B. Perform connections with existing piping at time and under conditions that will least interfere with service to customers affected by such operation and in a manner that will least disturb the system. C. Provide suitable equipment and facilities to dewater, drain, and dispose of liquid removed without damage to adjacent property. D. Where connections to existing systems necessitate employment of past installation methods not currently part of trade practice, utilize necessary special piping components. E. Once connection to each existing system is initiated, continue work continuously until connection is completed and tested. 3.9 PIPE CORROSION PROTECTION A. Refer to individual pipe specifications. B. Piping Accessories: 1. Exposed: a. Field paint black and galvanized steel, brass, copper, and bronze piping components as specified in Section 09 96 00 as applicable to base metal material. b. Accessories include, but are not limited to, pipe hangers, supports, expansion joints, pipe guides, flexible couplings, vent and drain valves, and fasteners. 2. Buried: a. Ferrous Metal and Stainless Steel Components: Coat as specified in Section 09 96 00, as applicable. b. Bolts, Nuts, and Similar Items: Coat with same paint system as associated pipe. If stainless steel, do not coat. c. Flexible Couplings, Grooved Couplings, Welded Joints, and Similar Items: Wrap with heat shrink wrap. d. Buried Valves and Similar Elements on Wrapped Pipelines: Wrap entire valve in polyethylene encasement. e. Cement-Coated Pipelines: Cement coat appurtenances same as pipe. C. Polyethylene Encasement: Install in accordance with AWWA C105/A21.5 and manufacturer’s instructions. D. Heat Shrink Wrap: Apply in accordance with manufacturer’s instructions to surfaces that are cleaned, prepared, and primed. Use manufacturer’s recommended primer for surface to be wrapped. E. Insulating Flanges, Couplings, and Unions: 1. Applications: a. Dissimilar metal piping connections. b. Cathodically protected piping penetration to buildings and watertight structures. c. Submerged to unsubmerged metallic piping connections. d. Connections to existing metallic pipe. e. Where required for electrically insulated connection. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 19 2. Pipe Installation: a. Insulating joints connecting immersed piping to non-immersed piping shall be installed above maximum water surface elevation. b. Submerged carbon steel, ductile iron, or galvanized piping in reinforced concrete shall be isolated from the concrete reinforcement steel. c. Align and install insulating joints as shown on the Drawings and according to manufacturer’s recommendations. Bolt lubricants that contain graphite or other metallic or electrically conductive components that can interfere with the insulating capabilities of the completed flange shall not be used. 3.10 THRUST RESTRAINT A. Location: 1. Buried Piping: Where shown on Drawings and where required to restrain force developed at pipeline tees, plugs, caps, bends, and other locations where unbalanced forces exist because of hydrostatic testing and normal operating pressure. 2. Exposed Piping: At all joints in piping. B. Thrust Ties: 1. Steel Pipe: Attach with joint harness specified in Section 40 05 06 – Couplings, Adapters, and Specials for Process Piping. 2. Ductile Iron Pipe: Attach with socket clamps anchored against grooved joint coupling or flange. 3. Flanged Coupling Adapters: For exposed installations, install manufacturer’s anchor studs through coupling sleeve or use dismantling joints. C. Mechanical Joint Valve Restraint in Proprietary Restrained Joint Piping: Install pipe joint manufacturer’s adapter gland follower and pipe end retainer, or mechanical joint anchor gland follower. D. Thrust Blocking: 1. Only use where indicated on Drawings. 2. Place between undisturbed ground and fitting to be anchored. 3. Quantity of Concrete: Sufficient to cover bearing area on pipe and provide required soil bearing area as shown. 4. Place blocking so that pipe and fitting joints will be accessible for repairs. 5. Place concrete in accordance with Section 03 30 00 – Cast-in-Place Concrete. 3.11 SLAB, FLOOR, WALL, AND ROOF PENETRATIONS A. Application and Installation: As specified in Section 01 73 20 – Openings and Penetrations in Construction. 3.12 BRANCH CONNECTIONS A. Do not install branch connections smaller than 1/2-inch nominal pipe size, including instrument connections, unless shown otherwise. B. When line of lower pressure connects to a line of higher pressure, requirements of Piping Schedule for higher pressure rating prevails up to and including first block valve in the line carrying the lower pressure, unless otherwise shown. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 20 C. Threaded Pipe Tap Connections: 1. Ductile Iron Piping: Connect only with service saddle or at tapping boss of a fitting, valve body, or equipment casting. 2. Welded Steel or Alloy Piping: Connect only with welded threadolet or half-coupling as specified on Pipe Schedule. 3.13 VENTS AND DRAINS A. Vents and drains at high and low points in piping required for completed system may or may not be shown. Install vents on high points and drains on low points of pipelines. 3.14 INSULATION A. See Section 40 42 13 – Process Piping Insulation. 3.15 FIELD FINISHING A. Notify Engineer at least 3 days prior to start of surface preparation or coating application work. B. As specified in Section 09 96 00 – High-Performance Coatings and/or the individual pipe specification sections, as applicable. 3.16 PIPE IDENTIFICATION A. As specified in Pipe Schedules, Section 10 14 00 – Identification for Process Piping and Equipment and Section 09 96 00 – High-Performance Coatings. 3.17 FIELD QUALITY CONTROL A. Section 01 40 00 – Quality Requirements. B. Leakage Testing and Disinfection: As specified in Section 40 05 40 – Process Piping Leakage Testing and Disinfection. C. Minimum Duties of Welding Inspector: 1. Job material verification and storage. 2. Qualification of welders. 3. Certify conformance with approved welding procedures. 4. Maintenance of records and preparation of reports in a timely manner. 5. Notification to Engineer of unsatisfactory weld performance within 24 hours of weld test failure. D. Required Weld Examinations: 1. Perform examinations in accordance with Piping Code, ASME B31.1. 2. Perform examinations for every pipe thickness and for each welding procedure, progressively, for piping covered by this section. 3. Examine at least one of each type and position of weld made by each welder or welding operator. 4. For each weld found to be defective under the acceptance standards or limitations on imperfections contained in the applicable Piping Code, examine two additional welds BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 21 made by the same welder that produced the defective weld. Such additional examinations are in addition to the minimum required above. Examine, progressively, two additional welds for each tracer examination found to be unsatisfactory. 3.18 CLEANING A. Clean pipe systems thoroughly. Purge pipe of construction debris and contamination before placing the system into service. Provide whatever temporary connections are required for cleaning, purging, and circulating. B. Install temporary strainers in front of pumps, tanks, solenoid valves, control valves, and other equipment where permanent strainers are not indicated. Keep these strainers in service until the equipment has been tested, then remove either entire strainer or straining elements only. Fit strainers with a line size blow-off valve. C. Following assembly and testing, and prior to final acceptance, flush pipelines, except as stated below, with water at 2.5 fps minimum flushing velocity until foreign matter is removed. D. Blow clean of loose debris in plant process air, chemical feed, and instrument air lines with compressed air; do not flush with water. E. If impractical to flush large diameter pipe at 2.5 fps, clean in-place from inside by brushing and sweeping, then flush line at lower velocity. F. Remove accumulated debris through drains 2 inches and larger or by removing spools and valves from piping. 3.19 LOCATION OF BURIED OBSTACLES A. Provide exact location and description of buried utilities encountered and thrust block placement. B. Reference items to definitive reference point locations such as found property corners, entrances to buildings, existing structure lines, fire hydrants and related fixed structures. C. Include such information as location, elevation, coverage, supports and additional pertinent information. D. Incorporate information on "As-Recorded" Drawings. 3.20 PIPE SCHEDULES A. System 1: Steel Water Pipe. 1. Abbreviation and Service: a. BWW – Backwash Water. b. FLW – Filtered Water. c. OVF – Overflow. d. RW – Raw Water. e. WBW – Waste Backwash Water. 2. Testing Requirements: BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 22 a. Weld Testing: Visual inspection of all field welds at fit-up, root pass, and completed weld. b. Pressure Testing: 1) Test medium: Water. 2) Test pressure: a) BWW: 100 psi. b) FLW, RW, WBW: 50 psi. c) OVF: 10 psi. 3) Test duration: 4 hours. 4) Allowable leakage: a) Exposed: None. b) Buried: Per AWWA C604. 3. Gaskets: Rubber, full-face type per AWWA C207. 4. Components: a. Exposed service: 72-IN diameter and less. 1) Material: Steel. 2) Reference: AWWA C200. 3) Lining: Cement mortar per AWWA C205. 4) Coating: Paint per Section 09 96 00. 5) Fittings: Fabricated, AWWA C208. 6) Joints: Butt welded with AWWA C207 flanges at equipment, valves, and structure penetrations, unless shown otherwise on Drawings. b. Buried Service: 72-IN diameter and less. 1) Material: Steel. 2) Reference: AWWA C200. 3) Lining: Cement mortar per AWWA C205. 4) Coating: Polyurethane per AWWA C222. 5) Fittings: Fabricated, AWWA C208. 6) Joints: Butt welded and butt strap joints with AWWA C207 flanges at equipment, valves, and connections. 7) Corrosion Protection: Heat shrink sleeve at joints. Polyethylene encasement per AWWA C105, unless embedded in flowable fill or encased in concrete. B. System 2: Ductile Iron Pipe. 1. Abbreviation and Service: a. DR – Drain. b. DRW – Decant Return Water. c. PTW – Plant Water. d. SL – Sludge. 2. Testing Requirements: a. Test medium: Water. b. Test pressure: 1) DR, DRW, SL: 50 psi. 2) PTW: 200 psi. c. Test duration: 4 hours. d. Allowable leakage: 1) Exposed: None. 2) Buried: Per AWWA C600. 3. Gaskets: Rubber, full-face type per AWWA C111. 4. Components: a. Exposed service: 4-IN to 20-IN diameter. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 23 1) Material: Ductile iron, Pressure Class 250 minimum. 2) Reference: AWWA C115. 3) Lining: Cement mortar per AWWA C104. 4) Coating: Paint per Section 09 96 00. 5) Fittings: AWWA C110 or AWWA C153. 6) Joints: Flanged with screw-on flanges at equipment, valves, and structure penetrations. 7) Insulation: As specified in Section 40 42 13 and noted on Drawings for exterior locations. b. Buried service: 4-IN to 20-IN diameter. 1) Material: Ductile iron, Pressure Class 250 minimum. 2) Reference: AWWA C151. 3) Lining: Cement mortar per AWWA C104. 4) Coating: Asphaltic. 5) Fittings: AWWA C110 or AWWA C153. 6) Joints: Restrained push-on joints and fittings with restrained mechanical (stuffing box type) joints at valves, unless specifically noted otherwise on Drawings. 7) Corrosion Protection: Polyethylene encasement per AWWA C105, unless embedded in flowable fill or encased in concrete. C. System 3: Plastic Pressure Pipe. 1. Abbreviation and Service: a. FLOC – Fluosilicic Acid (Concentrated). b. PTW – Plant Water. c. SHC – Sodium Hypochlorite. d. SPL – Sample. 2. Testing Requirements: a. Test medium: Water. b. Test pressure: 1) FLOC, SHC, SPL: 50 psi. 2) PTW: 200 psi. c. Test duration: 4 hours. d. Allowable leakage: 1) Exposed: None. 2) Buried: Per AWWA C605. 3. Gaskets and O-Rings: Compatible with fluid conveyed or as specified below. 4. Components: a. Exposed service: 3-IN diameter and less. 1) Material: PVC, Type 1, Grade 1, Schedule 80. 2) Reference: ASTM D1784 and D1785. 3) Lining: None. 4) Coating: None, banded per Sections 09 96 00 and 10 14 00. 5) Fittings: Solvent welded, socket type per ASTM D2467. 6) Joints: Solvent welded with unions at equipment, valves and structure penetrations for 2-IN and less; flanges for greater than 2-IN. 7) Insulation: As specified in Section 40 42 13 and noted on Drawings for exterior locations. b. Buried service: 4-IN to 12-IN diameter. 1) Material: PVC, DR 18. 2) Reference: AWWA C900. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 24 3) Gaskets: EPDM, ASTM F477. 4) Lining: None. 5) Coating: None. 6) Fittings: AWWA C110 or AWWA C153. 7) Joints: Restrained push-on joints and fittings with restrained mechanical (stuffing box type) joints at valves, unless specifically noted otherwise on Drawings. c. Buried service: Less than 4-IN diameter. 1) Material: PVC, Type 1, Grade 1, Schedule 40. 2) Reference: ASTM D1784 and D1785. 3) Lining: None. 4) Coating: None. 5) Fittings: Solvent welded, socket type per ASTM D2466. 6) Joints: Solvent welded with unions at equipment and valves. d. Buried service (in casing): 1-IN diameter and less. 1) Material: Linear low density polyethylene (LLDPE) tubing. 2) Reference: Section 40 05 31. 3) Lining: None. 4) Coating: None. 5) Fittings: Compression type with cam operated couplings at equipment and valves. 6) Joints: None. D. System 4: Process Air Pipe. 1. Abbreviation and Service: a. LPA – Low Pressure Air. 2. Testing Requirements: a. Test medium: Air. b. Test pressure: 15 psi. c. Test duration: 2 hours. d. Allowable leakage: Less than 1.0 psi loss in 15 minutes. 3. Gaskets: Neoprene, rated for 250 degF. 4. Components: a. Exposed service: 10-IN diameter. 1) Material: Stainless steel, Type 304L, Schedule 10S. 2) Reference: ASTM A778. 3) Lining: None. 4) Coating: None. 5) Fittings: Seamless per ASTM A774. 6) Joints: Flanged. E. System 5: Stainless Steel Process Pipe and Tube. 1. Abbreviation and Service: a. PTW – Plant Water. b. SPL – Sample. 2. Testing Requirements: a. Test medium: Water. b. Test pressure: 1) PTW: 200 psi. 2) SPL: 50 psi. c. Test duration: 2 hours. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 25 d. Allowable leakage: Zero. 3. Gaskets and O-rings: Rubber compatible with fluid conveyed. 4. Components: a. Exposed service: 1-IN diameter and less pipe for PTW. 1) Material: Stainless steel Type 304L, Schedule 10S. 2) Reference: ASTM A312. 3) Lining: None. 4) Coating: None. 5) Fittings: Compression type. 6) Joints: Compression type couplings with unions at equipment and valves. b. Exposed service: 1-IN diameter and less tubing for SPL. 1) Material: Stainless steel Type 316L, Schedule 10S. 2) Reference: ASTM A269. 3) Lining: None. 4) Coating: None. 5) Fittings: Compression type tube fittings. 6) Joints: Compression type couplings with unions at equipment and valves. F. System 6: Copper Water Pipe. 1. Abbreviation and Service: a. PTW – Plant Water. 2. Testing Requirements: a. Test medium: Water. b. Test pressure: 200 psi. c. Test duration: 4 hours. d. Allowable leakage: Zero. 3. Gaskets and O-rings: Rubber. 4. Components: a. Exposed service: 3-IN diameter and less. 1) Material: Copper, Type L. 2) Reference: ASTM B88. 3) Lining: None. 4) Coating: None. 5) Fittings: Wrought copper or bronze per ASME B16.22. 6) Joints: Soldered or copper and copper alloy press fittings with unions at equipment and valves. a) For 2-IN and larger, mechanical type couplings on roll-grooved pipe may be used. 7) Insulation: As specified in Section 40 42 13 and noted on Drawings for exterior locations. G. System 7: Storm Drain. 1. Abbreviation and Service: a. SD – Storm Drain. 2. Testing Requirements: a. Test medium: Groundwater. b. Test pressure: Hydrostatic. c. Test duration: Per ASTM 969. d. Allowable leakage: Per ASTM 969. 3. Gaskets: Rubber, ASTM F443 for push on joints. 4. Components: BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02)Common Requirements for Process Piping 40 05 00 - 26 a. Buried service: 36-IN diameter and less. 1) Material: Reinforced Concrete Pipe, Class III. 2) Reference: ASTM C76 and TxDOT Item 0464. 3) Lining: None. 4) Coating: None. 5) Fittings: Smooth or mitered, prefabricated meeting ASTM C76. 6) Joints: Bell and spigot push on type with rubber compression gasket. (AD-02) END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Couplings, Adapters, and Specials for Process Piping 40 05 06 - 1 SECTION 40 05 06 - COUPLINGS, ADAPTERS, AND SPECIALS FOR PROCESS PIPING PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Pipe penetrations. 2. Threaded insulating connections. 3. Flexible connectors. 4. Expansion joints. 5. Flexible expansion joints. 6. Service saddles. 7. Tapping sleeves. 8. Sleeve-type couplings. 9. Grooved couplings. 10. Miscellaneous specialties. B. This Section includes requirements for process piping systems. Refer to Related Sections and specific Drawing details for other discipline requirements. C. Related Sections: 1. Section 01 73 20 – Openings and Penetrations in Construction. 2. Section 40 05 00 – Common Requirements for Process Piping. 3. Section 40 05 07 – Hangers and Supports for Process Piping. 1.2 REFERENCE STANDARDS A. American Water Works Association: 1. C153/A21.53, Ductile Iron Compact Fittings for Water Service. 2. C210, Liquid-Epoxy Coating Systems for the Interior and Exterior of Steel Water Pipelines. 3. C213, Fusion-Bonded Epoxy Coating for the Interior and Exterior of Steel Water Pipelines. 4. AWWA C219 – Bolted, Sleeve-Type Couplings for Plain-End Pipe. 5. M11, Steel Pipe—A Guide for Design and Installation. B. American Welding Society: 1. AWS D1.1/D1.1M – Structural Welding Code – Steel. C. ASME International: 1. ANSI/ASME B1.20.1 Pipe Threads, General Purpose (inch) 2. ASME A13.1 – Scheme for the Identification of Piping Systems. 3. B16.1, Gray Iron Pipe Flanges and Flanged Fittings. 4. B16.5, Pipe Flanges and Flanged Fittings: NPS ½ through NPS 24. 5. ASME B31.3 – Process Piping. 6. ASME B31.9 – Building Services Piping. 7. ASME Boiler and Pressure Vessel Code (BPVC), Section IX – Welding, Brazing, and Fusing Qualifications. BCRUA - Phase 1D WTP Expansion Issued for Bid Couplings, Adapters, and Specials for Process Piping 40 05 06 - 2 D. ASTM International: 1. A153/A153M, Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware. 2. A276, Standard Specification for Stainless Steel Bars and Shapes. 3. ASTM D2000 – Standard Classification System for Rubber Products in Automotive Applications. 4. ASTM E84 – Standard Test Method for Surface Burning Characteristics of Building Materials. 5. ASTM E119 – Standard Test Methods for Fire Tests of Building Construction and Materials. 6. ASTM E814 – Standard Test Method for Fire Tests of Penetration Firestop Systems. 7. ASTM E1966 – Standard Test Method for Fire-Resistive Joint Systems E. Expansion Joint Manufacturers Association, Inc.: 1. EJMA Standards. F. NSF International: 1. NSF 61 – Drinking Water System Components – Health Effects. 2. NSF 372 – Drinking Water System Components – Lead Content. 1.3 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Product Data: 1. Submit manufacturer catalog information for each specified product. 2. Flexible Pipe Connectors: Indicate maximum temperature and pressure rating, face-to- face length, live length, hose wall thickness, hose convolutions per foot and per assembly, fundamental frequency of assembly, braid structure, and total number of wires in braid. 3. Expansion Joints: Indicate maximum temperature, pressure rating, and expansion compensation. C. Shop Drawings: 1. Identification: a. Submit list of wording, symbols, letter size, and color coding for pipe identification. b. Comply with ASME A13.1. 2. Indicate restrained joint details and materials. 3. Submit layout drawings showing piece numbers and location, indicating restrained joint locations. 4. Indicate layout and dimensions of piping systems, including flexible connectors, expansion joints and compensators, loops, offsets, and swing joints. 5. Manufacturer’s installation instructions, including special procedures and setting dimensions. D. Schedule of interconnections to existing piping and method of connection. E. Cleaning procedure and schedule. BCRUA - Phase 1D WTP Expansion Issued for Bid Couplings, Adapters, and Specials for Process Piping 40 05 06 - 3 F. Manufacturer’s Certificate of Compliance: Certify that products meet or exceed specified requirements. G. Welder Certificates: Certify welders and welding procedures employed on Work, verifying qualification within previous 12 months. H. Delegated Design Submittals: Submit signed and sealed Shop Drawings with design calculations and assumptions for: 1. Flexible connectors. 2. Expansion joints. 3. Sleeve-type and grooved couplings. 4. Pipe Restraints: a. Determine restrained lengths and submit joint restraint details. b. Use joint restraint devices specifically designed for applications as described in manufacturer data. I. Source Quality-Control Submittals: Indicate results of shop or factory tests and inspections. J. Field Quality-Control Submittals: 1. Indicate results of Contractor-furnished tests and inspections. 2. For grooved couplings, submit written certification from coupling manufacturer stating that Contractor: a. Has been properly trained to install manufacturer’s specified products. b. Has adequate project experience installing manufacturer’s specified products. 3. Provide Manufacturer’s Certificate of Proper Installation (COPI) for components with Delegated Design Submittals specified herein. 1.4 CLOSEOUT SUBMITTALS A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for submittals. B. Project Record Documents: Record actual locations of piping appurtenances. C. Identify and describe unexpected variations to pipe routing or discovery of uncharted utilities. 1.5 QUALITY ASSURANCE A. Materials in Contact with Potable Water: Certified to NSF Standards 61 and 372. B. Perform Work according to ASME B31.9 for installation of piping systems and according to AWS D1.1/D1.1M for welding materials and procedures. C. Perform Work according to ASME B31.3 for installation of piping systems. 1.6 DELIVERY, STORAGE, AND HANDLING A. Section 01 60 00 – Product Requirements: Requirements for transporting, handling, storing, and protecting products. BCRUA - Phase 1D WTP Expansion Issued for Bid Couplings, Adapters, and Specials for Process Piping 40 05 06 - 4 B. Inspection: Accept materials on Site in manufacturer’s original packaging and inspect for damage. C. Store materials according to manufacturer instructions. D. Protection: 1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas. 2. Furnish temporary end caps and closures on piping and fittings and maintain in place until installation. 3. Provide additional protection according to manufacturer instructions. 1.7 EXISTING CONDITIONS A. Field Measurements: 1. Verify field measurements prior to fabrication. 2. Indicate field measurements on Shop Drawings. 1.8 WARRANTY A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for warranties. PART 2 - PRODUCTS 2.1 PIPE PENETRATIONS A. Reference Section 01 73 20 – Openings and Penetrations in Construction and Drawing details. B. Flashing: 1. Metal Flashing: a. Material: Galvanized steel. b. Thickness: 26 gage. 2. Metal Counterflashing: a. Material: Galvanized steel. b. Thickness: 22 gage. 3. Lead Flashing: a. Material: Sheet lead. b. Weight: 1) Waterproofing: 5 psf. 2) Soundproofing: 1 psf. 4. Flexible Flashing Materials: a. Material: Butyl sheet and compatible with service conditions. b. Thickness: 47 mils. 5. Caps: a. Material: Steel. b. Minimum Thickness: 22 gage, and 16 gage at fire-resistive elements. C. Sleeves: 1. Steel Pipe Sleeve: BCRUA - Phase 1D WTP Expansion Issued for Bid Couplings, Adapters, and Specials for Process Piping 40 05 06 - 5 a. Minimum Thickness: Reference Section 01 73 20 – Openings and Penetrations in Construction. b. Seep Ring: 1) Center steel flange for water stoppage on sleeves in exterior or water-bearing walls, minimum thickness to match pipe sleeve. 2) Outside Diameter: Unless otherwise shown, 3 inches greater than pipe sleeve outside diameter. 3) Continuously fillet weld on each side all around. 2. Insulated and Encased Pipe Sleeve: a. Manufacturer and Product: Pipe Shields, Inc.; Models WFB, WFB-CS and -CW Series, as applicable. 3. Modular Mechanical Seal: Reference Section 01 73 20 – Openings and Penetrations in Construction and Drawing details. D. Slab, Floor, Wall and Roof Penetrations: Reference Section 01 73 20 – Openings and Penetrations in Construction and Drawing details. 1. Ductile Iron Wall Pipe: a. Diameter and Ends: Same as connecting ductile iron pipe. b. Thickness: Equal to or greater than remainder of pipe in line. c. Fittings: In accordance with Pipe Schedule in Section 40 05 00 – Common Requirements for Process Piping. d. Thrust Collars: 1) Rated for thrust load developed at 250 psi. 2) Safety Factor: 2, minimum. 3) Material and Construction: Ductile iron or cast iron, cast integral with wall pipe wherever possible, or thrust rated, welded attachment to wall pipe. e. Manufacturers: 1) American Cast Iron Pipe Co. 2) U.S. Pipe and Foundry Co. 2. Steel or Stainless Steel Wall Pipe: a. Same material and thickness as connecting pipe, except ¼-inch minimum thickness. b. Lining: Same as connecting pipe. c. Thrust Collar: 1) Outside Diameter: Unless otherwise shown, 3 inches greater than outside diameter of wall pipe. 2) Continuously fillet welded on each side all around. 2.2 THREADED INSULATING CONNECTIONS A. General: Threaded insulating bushings, unions, and couplings shall be used for joining threaded pipes of dissimilar metals and for piping systems where corrosion control and cathodic protection are indicated. B. Materials: Threaded insulating connections shall be of nylon, Teflon, polycarbonate, polyethylene, or other non-conductive materials, and shall have ratings and properties suitable for the service and loading conditions indicated. BCRUA - Phase 1D WTP Expansion Issued for Bid Couplings, Adapters, and Specials for Process Piping 40 05 06 - 6 2.3 FLEXIBLE CONNECTORS A. Flexible connectors shall be provided in all piping connections to engines, blowers, compressors, vibrating equipment, and where indicated. Flexible connectors for service temperatures above 180 degrees F shall be flanged braided Type 316 stainless steel spools with inner corrugated stainless steel hose rated for minimum 150 psi working pressure, unless indicate otherwise. Fasteners shall be Type 316L stainless steel. B. Teflon Bellows Connector: 1. Type: Two convolutions, unless otherwise shown, with metal reinforcing bands. 2. Flanges: Ductile iron, drilled 150 psi ASME B16.5 standard. 3. Working Pressure Rating: 140 psi, minimum, at 120 degrees F. 4. Thrust Restraint: Limit bolts to restrain force developed by specified test pressure. 5. Manufacturers and Products: a. Garlock; Style 214. b. Resistoflex; No. R6904. c. Unisource Manufacturing, Inc.; Style 112. d. Proco Products, Inc.; Series 442. C. Elastomer Bellows Connector: 1. Type: Fabricated spool, with single filled arch. 2. Materials: Nitrile tube and wrap-applied neoprene cover. 3. End Connections: Flanged, drilled 125-pound ASME B16.1 standard, with full elastomer face and steel retaining rings. 4. Working Pressure Rating: 140 psig, minimum, at 180 degrees F for sizes 12 inches and smaller. 5. Thrust Restraint: Control rods to limit travel of elongation and compression. 6. Manufacturers and Products: a. Goodall Rubber Co.; Specification: E-1462. b. Garlock; Style C: 204. c. Unisource Manufacturing, Inc.; Style 1501. d. Proco Products, Inc.; Series 220. D. Metal Bellows Connector: 1. Type: Single-ply, annular corrugated metal bellows with limit rods. Circumferential convolution welds not permitted. 2. Material: Type 316 stainless steel. 3. End Connections: ANSI 150-pound carbon steel flanges. 4. Minimum Design Working Pressure: 150 psig at 750 degrees F. 5. Length: Minimum of four convolutions and minimum manufacturer recommendation for vibration isolation. 6. Manufacturers and Products: a. Victaulic Depend-O-Lok, Omniflex with short metal bellows. b. Metraflex, Model MN. E. Flexible Metal Hose Connector: 1. Type: Close pitch, annular corrugated with single braided jacket. 2. Material: Bronze. 3. End Connections: Female copper solder joint. 4. Minimum Burst Pressure: 500 psig at 70 degrees F. BCRUA - Phase 1D WTP Expansion Issued for Bid Couplings, Adapters, and Specials for Process Piping 40 05 06 - 7 5. Length: Minimum manufacturer recommendation for vibration isolation. 6. Manufacturers: a. Senior Flexonics. b. Anamet Industrial, Inc. c. Unisource Manufacturing, Inc. d. Proco Products, Inc. F. Quick Connect Couplings for Chemical Services: 1. Type: Twin cam arm actuated, male and female, locking, for chemical loading and transfer. 2. Materials: Glass-filled polypropylene or PVDF with EPDM, Viton-A or Teflon gaskets as recommended for the service by manufacturer. 3. End Connections: NPT threaded or flanged to match piping connections. Hose shank for chemical installations. 4. Plugs and Caps: Female dust cap for each male end; male dust plug for each female end. a. Provide 18-inch long Type 316 stainless steel security chain. 5. Pressure Rating: 125 psi, minimum, at 70 degrees F. 6. Manufacturers and Products: a. OPW; Kamlock. b. Ryan Herco; 1300 Series. 2.4 EXPANSION JOINTS A. Elastomer Bellows: 1. Type: Reinforced molded wide arch. 2. End Connections: Flanged, drilled 125-pound ASME B16.1 standard, with split galvanized steel retaining rings. 3. Washers: Over retaining rings to help provide leak-proof joint under test pressure. 4. Thrust Protection: Control rods to protect the bellows from overextension. 5. Bellows Arch Lining: Buna-N, nitrile, or butyl. 6. Rated Temperature: 250 degrees F. 7. Rated Deflection and Pressure: a. Lateral Deflection: ¾ inch, minimum. b. Burst Pressure: Four times the working pressure. c. Compression deflection and minimum working pressure as follows: 8. Manufacturers and Products: a. General Rubber Corp.; Style 1015 Maxijoint. b. Mercer; Flexmore Style 450. c. Goodall Rubber Co.; Specification E-711 d. Unisource Manufacturing, Inc.; Series 1500. e. Proco Products, Inc.; Series 251. B. Teflon Bellows: 1. Type: Three convolutions, with metal reinforcing bands. Size (inch) Deflection (inch) Pressure (psig) 2-1/2 to 12 1.06 150 14 1.65 130 16 to 20 1.65 110 BCRUA - Phase 1D WTP Expansion Issued for Bid Couplings, Adapters, and Specials for Process Piping 40 05 06 - 8 2. Flanges: Ductile iron, drilled 150 psi ASME B16.5 standard. 3. Working Pressure Rating: 100 psig, minimum, at 120 degrees F. 4. Thrust Restraint: Limit bolts to restrain force developed by specified test pressure. 5. Manufacturers and Products: a. Garlock; Style 215. b. Resistoflex; No. R6905. c. Unisource Manufacturing, Inc.; Style 113. d. Proco Products, Inc.; Series 443. C. Metal Bellows: 1. Type: Single-ply, annular corrugated metal bellows with limit rods. Circumferential convolution welds not permitted. 2. Material: Type 316 stainless steel. 3. End Connections: ASME 150-pound carbon steel flanges. 4. Minimum Design Working Pressure: 150 psig at 750 degrees F. 5. Length: Minimum of four convolutions and minimum axial compression of 3 inches. 6. Manufacturers and Products: a. Victaulic Depend-O-Lok, Omniflex with long metal bellows. b. Metraflex, Model MN. c. Senior Flexonics, Free Flexing Expansion Joints. D. Copper Pipe Expansion Compensator: 1. Material: Stainless steel bellows with female copper solder joint ends. 2. Working Pressure Rating: 175 psig, minimum. 3. Accessories: Anti-torque device to protect bellows. 4. Manufacturers and Products: a. Senior Flexonics; Model HB. b. Hyspan; Model 8510. c. Unisource Manufacturing, Inc.; Style EC-FFS. E. Galvanized and Black Steel Pipe Expansion Compensator: 1. Material: Carbon steel with stainless steel bellows. 2. Working Pressure Rating: 175 psig, minimum. 3. Accessories: Anti-torque device to protect bellows. 4. Manufacturers and Products: a. Senior Flexonics; Model H. b. Hyspan; Model 8503. c. Unisource Manufacturing, Inc.; Style EC-MMT. 2.5 DYNAMIC FLEXIBLE EXPANSION JOINTS A. Design: 1. Ball and socket type for earth settlement compensation. 2. Joints shall be double ball assemblies rated for 15-degree minimum deflection and not less than 4 inches offset from centerline of connecting piping. 3. Assembly shall accommodate up to 4 inches of expansion in length. 4. Ductile iron conforming to AWWA C153/A21.53. 5. Pressure Rating: Joints shall be suitable for the pressure application and not less than 350 psi. BCRUA - Phase 1D WTP Expansion Issued for Bid Couplings, Adapters, and Specials for Process Piping 40 05 06 - 9 6. Components shall be lined and coated by manufacturer with fusion bonded epoxy on all surfaces not bearing gaskets. 7. End Connections: Flanged or mechanical joint as shown and as required by connecting pipe and fittings. 8. Joint connecting to mechanical joint shall be thrust restrained. 9. Bonding: a. Manufacturer shall factory install thermite welded joint bonds for assembled expansion joint. b. Provide 24-inch bond wires for field bonds to adjacent metallic piping. c. Bond wires shall be No. 2 AWG with two 12-inch-long THHN insulated No. 12 AWG wire pigtails. B. Manufacturer and Product: EBAA Iron Sales Co.; Flex-Tend. 2.6 SERVICE SADDLES A. Double-Strap Iron: 1. Pressure Rating: Capable of withstanding internal working pressure of associated pipe and not less than 150 psi without leakage or over stressing. 2. Run Diameter: Compatible with outside diameter of pipe on which saddle is installed. 3. Taps: Iron pipe threads. 4. Materials: a. Body: Malleable or ductile iron. b. Straps: Galvanized steel. c. Hex Nuts and Washers: Steel. d. Seal: Rubber. 5. Manufacturers and Products: a. Romac; Style 202U. b. Smith-Blair; Series 313 or 366. c. Dresser; Style 91. B. Nylon-Coated Iron: 1. Pressure Rating: Capable of withstanding internal working pressure of associated pipe and not less than 150 psi without leakage or over stressing. 2. Run Diameter: Compatible with outside diameter of pipe on which saddle is installed. 3. Taps: Iron pipe threads. 4. Materials: a. Body: Nylon-coated iron. b. Seal: Buna-N. c. Clamps and Nuts: Stainless steel. 5. Manufacturer: a. Romac; Style 202NS. b. Smith-Blair; Style 315 or 317 2.7 TAPPING SLEEVES A. Fabricated Steel: 1. Comply with AWWA C223. 2. Pressure rating: Up to 175 psi working pressure without leakage or over stressing. 3. Run Diameter: Compatible with outside diameter of pipe on which sleeve is installed. BCRUA - Phase 1D WTP Expansion Issued for Bid Couplings, Adapters, and Specials for Process Piping 40 05 06 - 10 4. Flange: AWWA C207, Class D. 5. Provide ¾-inch NPT test outlet welded to outlet nozzle. 6. Materials: a. Body: Carbon steel, ASTM A283, Grade C with fusion-bonded epoxy finish per AWWA C213. b. Gaskets: Buna-N or SBR. c. Nuts and bolts: 1) Buried application: High strength, low alloy steel. 2) Exposed application: Type 304 stainless steel, coated to prevent galling. 7. Manufacturers and Products: a. Romac; Style FTS420. b. Smith-Blair; Style 622. 2.8 SLEEVE-TYPE COUPLINGS A. General. 1. Coupling linings for use in potable water systems shall be in conformance with NSF 61. 2. Couplings shall be rated for working pressure not less than indicated in Piping Schedule for the associated service and not less than 150 psi under any circumstance. 3. Materials, unless noted otherwise: a. Gaskets: Gaskets: Buna-N or EPDM, comply with ASTM D2000. b. Nuts and bolts: Type 304 or 316 stainless steel, coated to prevent galling. c. Coatings: Couplings shall be lined and coated with fusion-bonded epoxy in accordance with AWWA C213 or lined and coated with liquid epoxy in accordance with AWWA C210. 4. Unless thrust restraint is provided by other means, couplings shall be harnessed in accordance with requirements of AWWA Manual M11 and restrained with retainer bar or ring welded to pipe end, or as shown on Drawings. 5. Sleeve type couplings shall conform to AWWA C219 and shall be hydraulically expanded beyond minimum yield for accurate sizing and proofing of tensile strength. B. Straight Coupling: 1. Manufacturers and Products: a. Steel Pipe: 1) Dresser Piping Specialties; Style 38 or 138. 2) Romac; Style 400. 3) Smith-Blair, Inc.; Style 411. b. Ductile Iron Pipe: 1) Dresser Piping Specialties; Style 253. 2) Smith-Blair, Inc.; Style411. C. Transition Coupling for Steel Pipe: 1. Manufacturers and Products: a. Dresser Piping Specialties; Style 62. b. Romac; Style TC400. c. Smith-Blair, Inc.; Style 413. D. Reducing Coupling for Steel Pipe: 1. Manufacturers and Products: a. Dresser Piping Specialties; Style 62. BCRUA - Phase 1D WTP Expansion Issued for Bid Couplings, Adapters, and Specials for Process Piping 40 05 06 - 11 b. Romac; Style RC400. c. Smith-Blair, Inc.; Style 415. E. Insulating Coupling for Steel Pipe: 1. Where insulating couplings are indicated, both ends of the coupling shall have a wedge- shaped gasket which assembles over a rubber sleeve of an insulating compound in order to insulate metal parts of the coupling from the pipe. 2. Manufacturers and Products: a. Dresser Piping Specialties; Style 39. b. Romac; Style IC400. c. Smith-Blair, Inc.; Style 416. F. Flanged Coupling Adapter: 1. Manufacturers and Products: a. Steel Pipe: 1) Dresser Piping Specialties; Style 128. 2) Romac; Style FC400. 3) Smith-Blair, Inc.; Style 913. b. Ductile Iron Pipe: 1) Dresser Piping Specialties; Style 128. 2) Romac; Style FCA501 or FCG. 3) Smith-Blair, Inc.; Style 912. G. Restrained Flange Adapter: 1. Pressure Rating: a. Minimum Working Pressure Rating: Up to the working pressure of associated pipe and not less than 150 psi. b. Safety Factor: Not less than two times working pressure and shall be supported by manufacturer’s proof testing. 2. Thrust Restraint: a. Provide hardened steel wedges that bear against and engage outer pipe surface and allow articulation of pipe joint after assembly while wedges remain in their original setting position on pipe surface. b. Products employing set screws that bear directly on pipe will not be acceptable. 3. Manufacturer and Product: EBAA Iron Sales Co.; Series 2100 Mega-Flange. H. Dismantling Joints: 1. Pressure Rating: a. Minimum working pressure rating shall not be less than rating of the connecting flange. b. Proof testing shall conform to requirements of AWWA C219 for bolted couplings. 2. Flange: AWWA C207, Class to match adjoining pipe, valve, or equipment. 3. Materials a. Flange spool: 1) Up to 12-inch: Sch 40 ASTM A53. 2) 14 – 72-inch: ASTM A36 Carbon Steel. b. End ring and body: 1) Up to 12-inch: ASTM A536 ductile iron, Grade 65-45-12. 2) 14 – 72-inch: ASTM A36 Carbon Steel. 4. Manufacturers and Products: BCRUA - Phase 1D WTP Expansion Issued for Bid Couplings, Adapters, and Specials for Process Piping 40 05 06 - 12 a. Dresser Piping Specialties; Style 131. b. Romac; Style DJ400. c. Smith-Blair; Style 975. I. Restrained Fabricated Solid-Sleeve Couplings: 1. General: Used to connect DI or PVC plain end pipes in buried installations. a. Cast MJ solid sleeves may be used instead of fabricated sleeves for DI pipe. 2. Pressure Rating: a. Minimum working pressure rating shall not be less than rating of the connecting pipe. b. Safety Factor: Not less than two times working pressure and shall be supported by manufacturer’s proof testing. 3. Materials: a. Coupling sleeve: ASTM A536 ductile iron through 12-inch; Carbon steel greater than 12-inch. b. Restraint rings: ASTM A536 ductile iron. c. Gaskets: SBR. d. Tie rods, nuts, and bolts: Corrosion resistant, low alloy, high strength steel per AWWA C111. 4. Manufacturers and Products: a. EBAA Iron Sales Co.; Series 3800 Mega-Coupling. b. Romac; Style 400RG. c. Smith-Blair; Style 471, 472, or 473. 2.9 GROOVED COUPLINGS A. General: 1. Used to join grooved end, exposed steel pipe as shown on the Drawings. 2. Couplings shall be self-restrained against hydrostatic thrust forces equal to not less than a 50% increase over the working pressure rating of the coupling. 3. Couplings shall accommodate limited pipe end separation and angular deflection at the time of installation and after pressurization for joint flexibility. 4. The wall thickness of all grooved piping shall conform with the coupling manufacturer's recommendations suitable for the highest pressure indicated B. Fabrication: Pipe ends shall be roll grooved at a fabrication shop in strict accordance with coupling manufacturer requirements. C. Pressure Rating: Minimum working pressure of 250 psi. D. Materials: 1. Housing: Ductile iron, ASTM A536, Grade 65-45-12. 2. Gaskets: EPDM. Material shall be compatible with the piping service and fluid conveyed in accordance with the coupling manufacturer's recommendations 3. Bolts, Nuts, and Washers: Type 316 stainless steel. 4. Coating: Fusion bonded epoxy per AWWA C213. E. Manufacturer and Product: 1. Victaulic; Style W77 AGS. BCRUA - Phase 1D WTP Expansion Issued for Bid Couplings, Adapters, and Specials for Process Piping 40 05 06 - 13 2.10 COMPRESSION COUPLINGS A. General: Used to join small diameter, Schedule 10S, stainless steel piping as illustrated on the Drawings. B. Pressure Rating: Working pressure not less than rating of connecting pipe up to 500 psi. C. Materials: 1. Housing: Type 304L or 316L stainless steel to match adjoining pipe. 2. Seals: Compatible with fluid conveyed. a. Reference Section 40 05 00, Pipe Schedules. D. Manufacturer and Product: 1. Victaulic; Style P507 or P597 Vic-Press. 2.11 MISCELLANEOUS SPECIALTIES A. Pressure Gauges: 1. General and Design: a. All components suitable for service at 250 degrees F. b. Provide viewer protection from element rupture. c. Unless otherwise shown or required by codes, provide stem mounted or flush mounted, as required, with dial diameter as follows: PIPE SIZE DIAL SIZE GAGE CONNECTION 1-1/2 IN or less 2-1/2 IN 1/4 IN Larger than 1-1/2 IN 4-1/2 IN 1/2 IN a. Equip with white faces, black numerals, and black pointers. b. Gage accuracy: 1 percent of full range. c. Select range so that the normal operating value is in the middle third of the dial and the maximum operating pressure does not exceed 75 percent of the full-scale range. 2. Materials: a. Bourdon tube, socket, connecting tube: 316 stainless steel. b. Case: Phenolic. c. Pressure snubber: 1) Filter disc: 316 stainless steel. 2) Housing: 316 stainless steel. 3. Manufacturers: a. Ashcroft. b. Ametek. 4. Accessories: a. Diaphragm Seals: 1) Provide where indicated to isolate elements from process fluid. Where a pressure switch and a pressure gauge are used at the same location, it is permissible to utilize one (1) diaphragm seal to isolate both elements from the process fluid. 2) Diaphragm seal housing shall include a flushing port. 3) Manufacturers: Ashcroft or Primary Fluid Systems. BCRUA - Phase 1D WTP Expansion Issued for Bid Couplings, Adapters, and Specials for Process Piping 40 05 06 - 14 b. Provide isolation ball valve at point of connection to pipe/equipment and at panel if panel mounted. c. Utilize pressure snubbers with porous metal discs to provide pulsation dampening on gage applications as shown on schedule. B. Rotameters: 1. Type: Glass tube with guided float housed in stainless steel enclosure with front and rear, polycarbonate view ports. 2. Minimum accuracy: 2% over 10:1 range. 3. ANSI 150# stainless steel flanges. 4. Certified corrosion resistant to chemicals measured. 5. Manufacturers: a. King Instrument Company. b. Varea-Meters. c. Or approved equal. C. Strainers, Water Service, 2 Inches and Smaller: 1. Type: Bronze body, Y-pattern, 200 psi non-shock rated, with screwed gasketed bronze cap. 2. Screen: Heavy-gauge Type 304 stainless steel or monel, 20-mesh. 3. Manufacturers and Products: a. Armstrong International; Inc.; Model F. b. Mueller Steam Specialty; Model 351M. D. Strainers, Water Service, 2-1/2 Inches and Larger: 1. Type: Cast iron or ductile iron body, Y-pattern, 175 psi non-shock rated, with flanged gasketed iron cap. 2. Screen: Heavy-gauge Type 316 stainless steel, 0.045-inch perforations. 3. Manufacturers and Products: a. Armstrong International, Inc.; Model A7FL 125. b. Mueller Steam Specialty; Model 751. E. Strainers, Plastic Piping Systems, 4 Inches and Smaller: 1. Type: Y-pattern PVC body, 150 psi non-shock rated, with screwed PVC cap and Viton seals. 2. End Connections: Screwed or solvent weld, 2 inches and smaller. Class 150 ANSI flanged, 2-1/2 inches and larger. 3. Screen: Heavy-gauge PVC, 1/32-inch mesh, minimum 2 to 1 screen area to pipe size ratio. 4. Manufacturer: Hayward. F. Basket Strainer: 1. Service Conditions: a. Compatible with material handled and environment present. b. Temperature of Material Handled: 40 degrees F, minimum to 150 degrees F, maximum. c. Specific Gravity of Material Handled: 2. d. pH Range of Material Handled: <13. e. Range of Total Suspended Solids: <5 mg/L. 2. Strainer Capacity: 5 gpm, maximum pressure drop shall not exceed 1 psi at 5 gpm. BCRUA - Phase 1D WTP Expansion Issued for Bid Couplings, Adapters, and Specials for Process Piping 40 05 06 - 15 3. Screen: Capable of removing material larger than K: 0.01 inch (250 microns) in diameter. 4. Strainer: Single chamber design of stainless steel construction with a quick opening cover. 5. Process Connections: 1-inch flanges faced and drilled 150 pound ASME B16.5. 6. Wearing parts shall be replaceable without removing strainer from line. 7. Manufacturer: S.P. Kinney Engineers, Inc. G. Water Hose: 1. Furnish 50-foot lengths of 1-inch rubber hose. EPDM black cover and EPDM tube, reinforced with two textile braids. Provide each length with brass male and female NST hose thread couplings to fit hose nozzle and hose valve. 2. Rated minimum working pressure of 200 psi. 3. Manufacturers: a. Goodyear. b. Boston. H. Hose Nozzles: As specified on Drawings. 2.12 PIPE THREADS A. Pipe threads shall comply with ANSI/ASME B1.20. 2.13 PIPE INSULATION A. As specified in Section 40 42 13 - Process Piping Insulation. 2.14 FINISHES A. Prepare piping appurtenances for field finishes as specified in Section 09 96 00 – High- Performance Coatings. PART 3 - EXECUTION 3.1 EXAMINATION A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for installation examination. B. Verify that field dimensions are as indicated on Shop Drawings. C. Inspect existing flanges for nonstandard bolt hole configurations or design and verify that new pipe and flanges mate properly. D. Verify that openings are ready to receive sleeves. E. Verify that pipe plain ends to receive sleeve-type couplings are smooth and round for 12 inches from pipe ends. F. Verify that pipe outside diameter conforms to sleeve manufacturer's requirements. BCRUA - Phase 1D WTP Expansion Issued for Bid Couplings, Adapters, and Specials for Process Piping 40 05 06 - 16 3.2 PREPARATION A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for installation preparation. B. Cleaning: Thoroughly clean end connections before installation. C. Close pipe and equipment openings with caps or plugs during installation. D. Surface Preparation: Clean surfaces to remove foreign substances. 3.3 INSTALLATION A. Install according to manufacturer’s written instructions. B. According to ASME B31.3. C. Coating: Finish piping appurtenances as specified in Section 09 96 00 – High-Performance Coatings for service conditions. D. Pipe Penetrations: Reference Section 01 73 20 - Openings and Penetrations in Construction and Drawing details. 1. Flashing: a. Provide flexible flashing and metal counterflashing where piping penetrates weatherproofed or waterproofed walls, floors, and roofs. b. Flash floor drains with topping over finished areas with lead, 10 inches clear on sides, with minimum 36-by-36-inch sheet size. c. Fasten flashing to drain clamp device. E. Piping Flexibility Provisions: 1. General: a. Thrust restraint shall be provided as specified. b. Install flexible couplings to facilitate piping installation, in accordance with approved shop drawings. 2. Flexible Joints at Concrete Backfill or Encasement: Install within 18 inches or one-half pipe diameter, whichever is less, from the termination of any concrete backfill or concrete encasement. 3. Flexible Joints at Concrete Structures: a. Install 24 inches or less from face of structures, or as illustrated on Drawings; joint may be flush with face. F. Piping Transitions: 1. Applications: a. Provide complete closure assembly where pipes meet other pipes or structures. b. Pressure Pipeline Closures: Plain end pieces with double flexible couplings, unless otherwise shown. c. Restrained Joint Pipe Closures: Install with thrust tie-rod assemblies as shown or in accordance with NFPA 24. d. Gravity Pipe Closures: As specified for pressure pipelines, or concrete closures. BCRUA - Phase 1D WTP Expansion Issued for Bid Couplings, Adapters, and Specials for Process Piping 40 05 06 - 17 e. Concrete Closures: Use to make connections between dissimilar pipe where standard rubber gasketed joints or flexible couplings are impractical, as approved. f. Elastomer sleeves bonded to pipe ends are not acceptable. 2. Installation: a. Flexible Transition Couplings: Install in accordance with coupling manufacturer’s instructions to connect dissimilar pipe and pipes with a small difference in outside diameter. b. Concrete Closures: 1) Locate away from structures so there are at least two flexible joints between closure and pipe entering structure. 2) Clean pipe surface before placing closure collars. 3) Wet nonmetallic pipe thoroughly prior to pouring collars. 4) Prevent concrete from entering pipe. 5) Extend collar a minimum of 12 inches on each side of joint with minimum thickness of 6 inches around outside diameter of pipe. 6) Make entire collar in one placement. 7) After concrete has reached initial set, cure by covering with well- moistened earth. G. Piping Expansion: 1. Piping Installation: Allow for thermal expansion due to differences between installation and operating temperatures. 2. Expansion Joints: a. Grooved Joint and Flanged Piping Systems: Elastomer bellows expansion joint as indicated on Drawings. b. Nonmetallic Pipe: Teflon bellows expansion joint. c. Screwed and Soldered Piping Systems: Copper or galvanized and black steel pipe expansion compensator, as applicable. d. Air and Water Service above 120 Degrees F: Metal bellows expansion joint. 3. Anchors Install as specified in Section 40 05 07 - Hangers and Supports for Process Piping to withstand expansion joint thrust loads and to direct and control thermal expansion. H. Service Saddles 1. Ferrous Metal Piping (except stainless steel): Double-strap iron. 2. Plastic Piping: Nylon-coated iron. I. Couplings 1. General: a. Install in accordance with manufacturer’s written instructions. b. Before coupling, clean pipe holdback area of oil, scale, rust, and dirt. c. Do not remove pipe coating. If damaged, repair before joint is made. d. Application: 1) Metallic Piping Systems: Flexible couplings, transition couplings, and flanged coupling adapters. 2) Concrete Encased Couplings: Flexible coupling. J. Flexible Pipe Connections to Equipment 1. Install to prevent piping from being supported by equipment, for vibration isolation, and where shown. BCRUA - Phase 1D WTP Expansion Issued for Bid Couplings, Adapters, and Specials for Process Piping 40 05 06 - 18 2. Product Applications Unless Shown Otherwise: a. Nonmetallic Piping: Teflon bellows connector. b. Copper Piping: Flexible metal hose connector. c. Compressor and Blower Discharge: Metal bellows connector. d. All Other Piping: Elastomer bellows connector. 3. Limit Bolts and Control Rods: Tighten snug prior to applying pressure to system. K. Dismantling Joints: 1. Unless specifically noted otherwise, tighten all tie rod nuts to mechanically restrain the joint. L. Restrained Fabricated Solid-Sleeve Couplings: 1. Deflection in the joint between pipe ends shall not exceed maximum deflection published by the coupling manufacturer. 2. For buried service, provide heat shrink wrap around each coupling per AWWA C216. M. Grooved Couplings: 1. Utilize necessary closure tools approved by coupling manufacturer. 2. Contractor shall be trained on proper installation methods by coupling manufacturer. 3. Support couplings and associated pipe systems according to specifications, Drawings, and manufacturer’s written guidelines. N. Pressure Gauges: 1. Calibrate gauges at jobsite for pressure and temperature in accordance with manufacturer's instructions. 2. Gauge tapping position to be clear of equipment functions and movements, and protected from maintenance and operation of equipment. Gauge to be legible from an accessible standing position. O. Insulation: As specified in Section 40 42 13 - Process Piping Insulation. P. Disinfection: Disinfect potable water piping as specified in Section 33 13 00 - Disinfecting of Water Utility Distribution. 3.4 FIELD QUALITY CONTROL A. Section 01 40 00 – Quality Requirements: Requirements for inspecting and testing. B. After installation, inspect for proper supports and interferences. C. Repair damaged coatings with material equal to original coating. D. Manufacturer’s Services: 1. For grooved couplings, provide services of manufacturer’s qualified field service representative to: a. Train Contractor’s installers on proper installation methods. b. Supervise and assist installation of a minimum of two grooved couplings. c. Certify proper final installation of all split-sleeve and grooved couplings. 1) Submit COPI as specified herein. BCRUA - Phase 1D WTP Expansion Issued for Bid Couplings, Adapters, and Specials for Process Piping 40 05 06 - 19 3.5 CLEANING A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for cleaning. B. Keep equipment interior clean as installation progresses. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Hangers and Supports for Process Piping 40 05 07 - 1 SECTION 40 05 07 - HANGERS AND SUPPORTS FOR PROCESS PIPING PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Pipe hangers and supports. 2. Hanger rods. 3. Structural attachments. 4. Pipe guides. 5. Formed-steel channel. B. This Section includes requirements for process piping systems. Refer to Related Sections and specific Drawing details for other discipline requirements. C. Related Sections: 1. Section 26 05 29 – Hangers and Supports for Electrical Systems. 2. Section 40 05 00 – Common Requirements for Process Piping. 3. Section 40 05 06 – Couplings, Adapters, and Specials for Process Piping. 1.2 REFERENCE STANDARDS A. American Welding Society: 1. AWS D1.1/D1.1M - Structural Welding Code - Steel. B. ASME International: 1. ASME B31.1 - Power Piping. 2. ASME B31.9 - Building Services Piping. C. ASTM International: 1. ASTM A36/A36M - Standard Specification for Carbon Structural Steel. 2. ASTM A47/A47M - Standard Specification for Ferritic Malleable Iron Castings. 3. ASTM A123/A123M, Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products. 4. ASTM A181/A181M - Standard Specification for Carbon Steel Forgings, for General-Purpose Piping. 5. ASTM A576 - Standard Specification for Steel Bars, Carbon, Hot-Wrought, Special Quality. 6. ASTM A653/A653M, Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvanealed) by the Hot-Dip Process. 7. ASTM E84, Standard Test Method for Surface Burning Characteristics of Building Materials. D. Manufacturers Standardization Society of the Valve and Fittings Industry: 1. MSS SP-58 - Pipe Hangers and Supports - Materials, Design, Manufacturer, Selection, Application, and Installation. BCRUA - Phase 1D WTP Expansion Issued for Bid Hangers and Supports for Process Piping 40 05 07 - 2 1.3 DEFINITIONS A. Wetted or Submerged: Submerged, less than 1 foot above liquid surface, below top of channel wall, under cover or slab of channel or tank, or in other damp locations. 1.4 COORDINATION A. Section 01 30 00 – Administrative Requirements: Requirements for coordination. B. Coordinate Work of this Section with piping and equipment connections specified in other Sections and as indicated on Drawings. 1.5 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Product Data: Submit manufacturer information, including load capacity. C. Shop Drawings: 1. Submit manufacturer’s instructions for special procedures and assembly of components. 2. Indicate system layout with location, including critical dimensions, sizes, hanger and support locations, and details of trapeze hangers, anchors, and guides. D. Manufacturer's Certificate of Compliance: Certify that products meet or exceed specified requirements. E. Welder Certificates: Certify welders and welding procedures employed on Work, verifying AWS qualification within previous 12 months. F. Delegated Design Submittals: 1. Submit signed and sealed Shop Drawings with design calculations and assumptions for load carrying capacity of trapeze, multiple pipe, riser, and pipe bracket support hangers and pipe support systems. 2. Indicate calculations used to determine load carrying capacity of trapeze, multiple pipe, riser, and pipe bracket support hangers and pipe support systems. G. Manufacturer Instructions: Submit special procedures and assembly of components. 1.6 CLOSEOUT SUBMITTALS A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for submittals. B. Project Record Documents: 1. Record actual locations of pipe supports. 2. Identify and describe unexpected variations to pipe supports. BCRUA - Phase 1D WTP Expansion Issued for Bid Hangers and Supports for Process Piping 40 05 07 - 3 1.7 DELIVERY, STORAGE, AND HANDLING A. Section 01 60 00 - Product Requirements: Requirements for transporting, handling, storing, and protecting products. B. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage. C. Store materials according to manufacturer instructions. D. Protection: 1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas. 2. Provide additional protection according to manufacturer instructions. 1.8 EXISTING CONDITIONS A. Field Measurements: 1. Verify field measurements prior to fabrication. 2. Indicate field measurements on Shop Drawings. PART 2 - PRODUCTS 2.1 GENERAL A. Piping systems including connections to equipment shall be properly supported to prevent deflection and stresses. B. When specified items are not available, fabricate pipe supports of correct material and to general configuration indicated. C. Special support and hanger details may be required for cases where standard catalog supports are not applicable. D. Design: 1. Design, size, and locate piping support systems throughout facility, whether shown or not. 2. Piping Smaller than 30 Inches: Supports are shown only where specific types and locations are required; additional pipe supports may be required. 3. Piping 30 Inches and Larger: Support systems have been designed for piping shown. 4. Meet requirements of MSS SP 58 and ASME B31.1 or as modified by this section. 5. Pipe Support Systems: a. Design pipe support systems for gravity and thrust loads imposed by weight of pipes or internal pressures, including insulation and weight of fluid in pipes. b. Seismic, wind, and other loads in accordance with governing codes and as noted on Drawings in Structural General Notes. c. Maximum Support Spacing and Minimum Rod Size: In accordance MSS SP 58 Table 3 and Table 4. 1) Ductile-iron Pipe 8 Inches and Under: Maximum span limited to that for standard weight steel pipe for water service. BCRUA - Phase 1D WTP Expansion Issued for Bid Hangers and Supports for Process Piping 40 05 07 - 4 2) Ductile-iron Pipe 10 Inches and Larger: Maximum span limited to 20 feet. 6. Anchoring Devices: Design, size, and space support anchoring devices, including anchor bolts, inserts, and other devices used to anchor support, to withstand shear and pullout loads imposed by loading and spacing on each particular support. 7. Vertical Sway Bracing: 10-foot maximum centers or as shown. 8. Reference Drawing details. 9. Existing Support Systems: Use existing supports systems to support new piping only if Contractor can show they are adequate for additional load, or if they are strengthened to support additional load. E. Materials: In accordance with Table 1 and Table 2, attached as Supplements at end of section, or as specifically noted in Drawings. 2.2 HANGERS A. Clevis: MSS SP 58, Type 1: 1. Anvil; Figure 260 for steel pipe and Figure 590 for ductile-iron pipe, sizes 1/2 inch through 30 inches. 2. Insulated Steel Pipe: Anvil; Figure 260 with insulated saddle system (ISS), sizes 1/2 inch through 16 inches. 3. B-Line; Figure B3100, sizes 1/2 inch through 30 inches. B. Adjustable Swivel Split-Ring Pipe Clamp: MSS SP 58, Type 6: 1. Anvil; Figure 104, sizes 3/4 inch through 8 inches. 2. B-Line; Figure B3171, sizes 3/4 inch through 8 inches. C. Steel Yoke Pipe Rolls and Roller Supports: MSS SP 58, Type 41 or Type 43: 1. Anvil; Figure 181 for sizes 2-1/2 inches through 24 inches, and Figure 171 for sizes 1 inch through 30 inches. 2. B-Line; Figure B3110 for sizes 2 inches through 24 inches and Figure B3114 for 30 inches. D. Pipe Rollers and Supports: MSS SP 58, Type 44: 1. Anvil; Figure 175, sizes 2 inches through 30 inches. 2. B-Line; Figure B3120, sizes 2 inches through 24 inches. 2.3 WALL BRACKETS, SUPPORTS, AND GUIDES A. Welded Steel Wall Bracket: MSS SP 58, Type 33 (heavy-duty): 1. Anvil; Figure 199, 3,000-pound rating. 2. B-Line; Figure B3067, 3,000-pound rating. B. Adjustable “J” hanger MSS SP 58, Type 5: 1. Anvil; Figure 67, sizes 1/2 inch through 8 inches. 2. B-Line; Figure B3690, sizes 1/2 inch through 8 inches. C. Offset Pipe Clamp: Anvil; Figure 103, sizes 3/4 inch through 8 inches. BCRUA - Phase 1D WTP Expansion Issued for Bid Hangers and Supports for Process Piping 40 05 07 - 5 2.4 PIPE SADDLES A. Provide 90-degree to120-degree pipe saddle for pipe 6 inches and larger with baseplates drilled for anchors bolts. 1. Sizes 20 inches though 60 inches, Piping Technology & Products, Inc.; Fig. 2000. B. Saddle Supports, Pedestal Type: 1. Minimum standard weight pipe stanchion, saddle, and anchoring flange. 2. Nonadjustable Saddle: MSS SP, Type 37 with U-bolt. a. Anvil; Figure 259, sizes 4 inches through 36 inches with Figure 63C base. b. B-Line; Figure B3095, sizes 1 inch through 36 inches with B3088S base. 3. Adjustable Saddle: MSS SP 58, Type 38 without clamp. a. Anvil; Figure 264, sizes 2-1/2 inches through 36 inches with Figure 62C base. b. B-Line; Figure B3092, sizes 3/4 inch through 36 inches with Figure B3088S base. 2.5 CHANNEL TYPE SUPPORT SYSTEMS A. Channel Size: 12-gauge, 1-5/8-inch wide minimum steel, or 1-1/2-inch wide, minimum FRP. B. Members and Connections: Design for loads using one-half of manufacturer’s allowable loads. C. Fasteners: Vinyl ester fiber, polyurethane base composite nuts and bolts, or encapsulated steel fasteners. D. Manufacturers and Products: 1. B-Line; Strut System. 2. Unistrut. 3. Anvil; Power-Strut. 4. Aickinstrut (FRP System). 5. Enduro-Durostrut (FRP Systems). 2.6 FRP PIPE SUPPORTS SYSTEMS A. General: 1. FRP with UV additive, protective veil, and vinyl ester resins resistance to chemicals used in Project. 2. Fire Retardant: ASTM E84. 3. Include hangers, rods, attachments, and fasteners. B. Clevis Hangers: 1. Factor of Safety: 3 to 1. 2. Minimum Design Load: 200 pounds. C. Design: 1. Design pipe supports spacing, hanger rod sizing based upon manufacturer’s recommendations. 2. Identify and highlight non-FRP fasteners or components in Shop Drawing. BCRUA - Phase 1D WTP Expansion Issued for Bid Hangers and Supports for Process Piping 40 05 07 - 6 D. Manufacturers: 1. Aickinstrut. 2. Enduro. 3. Century Composite. 2.7 PIPE CLAMPS A. Riser Clamp: MSS SP 58, Type 8. 1. Anvil; Figure 261, sizes 3/4 inch through 24 inches. 2. B-Line; Figure B3373, sizes 1/2 inch through 30 inches. 2.8 ELBOW AND FLANGE SUPPORTS A. Elbow with Adjustable Stanchion: Sizes 2 inches through 18 inches, Anvil; Figure 62C base. B. Elbow with Nonadjustable Stanchion: Sizes 2-1/2 inches through 42 inches, Anvil; Figure 63A or Figure 63B base. C. Flange Support with Adjustable Base: Sizes 2 inches through 24 inches, Standon; Model S89. 2.9 INTERMEDIATE PIPE GUIDES A. Type: Hold down pipe guide. 1. Manufacturer and Product: B-Line; Figure B3552, 1-1/2 inches through 30 inches. B. Type: U-bolts with double nuts to provide nominal 1/8-inch to 1/4-inch clearance around pipe; MSS SP 58, Type 24. 1. Anvil; Figure 137 and Figure 137S. 2. B-Line; Figure B3188 and Figure B3188NS. 2.10 PIPE ALIGNMENT GUIDES A. Type: Spider. B. Manufacturers and Products: 1. Anvil; Figure 255, sizes 1/2 inch through 24 inches. 2. B-Line; Figure B3281 through Figure B3287, sizes 1/2 inch through 24 inches. 2.11 PIPE ANCHORS A. Type: Anchor chair with U-bolt strap. B. Manufacturer and Product: B-Line; Figure B3147A or Figure B3147B. 2.12 SEISMIC RESTRAINTS A. Solid pipe bracing attachment to pipe clevis with clevis cross brace and angle rod reinforcement. BCRUA - Phase 1D WTP Expansion Issued for Bid Hangers and Supports for Process Piping 40 05 07 - 7 B. Manufacturers: 1. Mason Industries. 2. B-Line. 3. Anvil. 2.13 ACCESSORIES A. Anchor Bolts: 1. Size and Material: Sized by Contractor for required loads, and as specified in Section 05 50 00 - Metal Fabrications and in Drawings in Structural General Notes. 2. Bolt Length (Extension Above Top of Nut): a. Minimum Length: Flush with top of nut preferred. If not flush, shall be no more than one thread recessed below top of nut. b. Maximum Length: No more than a full nut depth above top of nut. B. Dielectric Barriers: 1. Plastic coated hangers, isolation cushion, or tape. 2. Manufacturer and Products: a. B-Line; B1999 Vibra Cushion. b. B-Line; Iso Pipe, Isolation Tape. C. Insulation Shields: 1. Type: Galvanized steel or stainless steel, MSS SP 58, Type 40. 2. Manufacturers and Products: a. Anvil; Figure 167, sizes 1/2 inch through 24 inches. b. B-Line; Figure B3151, sizes 1/2 inch through 24 inches. D. Welding Insulation Saddles: 1. Type: MSS SP 58, Type 39. 2. Manufacturers and Products: a. Anvil; Figure Series 160, sizes 1 inch through 36 inches. b. B-Line; Figure Series B3160, sizes 1/2 inch through 24 inches. E. Plastic Pipe Support Channel: 1. Type: Continuous support for plastic pipe and to increase support spacing. 2. Manufacturer and Product: B-Line; Figure Series B3106V, sizes 1/2 inch through 6 inches with Figure B3106 Vee bottom hanger. F. Hanger Rods, Clevises, Nuts, Sockets, and Turnbuckles: In accordance with MSS SP 58. G. Attachments: 1. I-Beam Clamp: Concentric loading type, MSS SP 58, Type 21, Type 28, Type 29, or Type 30, which engage both sides of flange. 2. Concrete Insert: MSS SP 58, Type 18, continuous channel insert with load rating not less than that of hanger rod it supports. 3. Welded Beam Attachment: MSS SP 58, Type 22. a. Anvil; Figure 66. b. B-Line; Figure B3083. 4. U-Channel Concrete Inserts: As specified in Section 05 50 00, Metal Fabrications. 5. Concrete Attachment Plates: BCRUA - Phase 1D WTP Expansion Issued for Bid Hangers and Supports for Process Piping 40 05 07 - 8 a. Anvil; Figure 47, Figure 49, or Figure 52. b. B-Line; Figure B3084, Figure B3085, or Figure B3086. PART 3 - EXECUTION 3.1 EXAMINATION A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for installation examination. B. Verify that field dimensions as indicated on Shop Drawings. 3.2 INSTALLATION A. General: 1. Install support systems in accordance with manufacturer’s instruction and MSS SP 58, unless shown otherwise. 2. Install pipe hanger rods plumb, within 4 degrees of vertical during shut down, start up or operations. 3. Support piping connections to equipment by pipe support and not by equipment. 4. Support large or heavy valves, fittings, and appurtenances independently of connected piping, unless specifically illustrated otherwise on Drawings. 5. Do not support any pipe from pipe above it. 6. Support pipe at changes in direction or in elevation, adjacent to flexible joints and couplings, and where shown. 7. Do not use adhesive anchors for attachment of supports to ceiling or walls. 8. Do not install pipe supports and hangers in equipment access areas or bridge crane runs. 9. Brace hanging pipes against horizontal movement by both longitudinal and lateral sway bracing and to reduce movement after startup. 10. Install lateral supports for seismic loads at changes in direction. 11. Install pipe anchors where required to withstand expansion thrust loads and to direct and control thermal expansion. 12. Heat Transmission: Supports, hangers, anchors, and guides shall be designed so that excessive heat shall not be transmitted to the structure or to other equipment. 13. Supports on plastic piping shall be equipped with extra wide pipe saddles or galvanized steel shields. 14. Noise Reduction: To reduce transmission of noise in piping systems, copper tubes shall be wrapped with a 2-inch-wide strip of rubber fabric at each pipe support, bracket, clip, and hanger. 15. Install hangers and supports to produce a neat and orderly piping system with runs parallel or perpendicular to project elements, other piping, and conduits. Hangers shall be adjusted to line up groups of pipes at the proper grade for drainage and venting, as close to ceilings as possible and without interference with other work. 16. Repair mounting surfaces to original condition after attachments are completed. B. Standard Pipe Supports: As specified below or as illustrated on Drawings. 1. Horizontal Suspended Piping: a. Single Pipes: Clevis hangers or adjustable swivel split-ring. BCRUA - Phase 1D WTP Expansion Issued for Bid Hangers and Supports for Process Piping 40 05 07 - 9 b. Grouped Pipes: Trapeze hanger system. 2. Horizontal Piping Supported from Walls: a. Single Pipes: Wall brackets, or attached to wall, or to wall mounted framing with anchors. b. Stacked Piping: Wall mounted framing system and “J” hangers acceptable for pipe smaller than 3-inch. c. Pipe clamp that resists axial movement of pipe through support is not acceptable. Use pipe rollers supported from wall bracket. 3. Horizontal Piping Supported from Floors: a. Saddle Supports: 1) Pedestal Type, elbow and flange. 2) Provide minimum 1-1/2-inch grout beneath baseplate. b. Floor Mounted Channel Supports: 1) Use for pipe smaller than 3-inch running along floors and in trenches at pipe elevations lower than can be accommodated using pedestal pipe supports. 2) Attach channel framing to floors with baseplate on minimum 1-1/2-inch non-shrink grout and with anchor bolts. 3) Attach pipe to channel with clips or pipe clamps. c. Concrete Cradles: Use for pipe larger than 3 inches along floor and in trenches at pipe elevations lower than can be accommodated using stanchion type. 4. Insulated Pipe: a. Pipe hanger and support shall be on outside of insulation. Do not enclose within insulation. b. Provide precut 120-degree sections of rigid insulation (minimum length same as shield), shields and oversized hangers or insulated saddle system (ISS). c. Wall-mounted pipe clips not acceptable for insulated piping. 5. Vertical Pipe: Support with wall bracket and elbow support, or riser clamp on floor penetration. C. Standard Attachments: 1. New Concrete Ceilings: Concrete inserts, concrete attachment plates, or concrete anchors as limited below: a. Single point attachment to ceiling allowed only for 3/4-inch rod and smaller (8 inches and smaller pipe). b. Where there is vibration or bending considerations, do not connect a single pipe support hanger rod directly to a drilled concrete anchor (single point attachment) regardless of size. 2. Existing Concrete Ceilings: Channel type support with minimum of two anchor points, concrete attachment plates or concrete anchors as limited below: a. Single point attachment to ceiling is allowed only for 3/4-inch rod and smaller (8 inches and smaller pipe). b. Where there is vibration or bending considerations do not connect a single pipe support hanger rod directly to a drilled concrete anchor (single point attachment) regardless of size. 3. Steel Beams: I-beam clamp or welded attachments. 4. Wooden Beams: Lag screws and angle clips to members not less than 2-1/2 inches thick. 5. Concrete Walls: Concrete inserts or brackets or clip angles with concrete anchors. BCRUA - Phase 1D WTP Expansion Issued for Bid Hangers and Supports for Process Piping 40 05 07 - 10 6. Concrete Beams: Concrete inserts, or if inserts are not used attach to vertical surface similar to concrete wall. Do not drill into beam bottom. D. Saddles for Steel or Concrete Pipe: Provide 90-degree to120-degree pipe saddle for pipe sizes 6 inches and larger when installed on top of steel or concrete beam or structure, pipe rack, trapeze, or where similar concentrated point supports would be encountered. E. Intermediate and Pipe Alignment Guides: 1. Provide pipe alignment guides, or pipe supports that provide same function, at expansion joints and loops. 2. Guide pipe on each side of expansion joint or loop at 4 pipe and 14 pipe diameters from each joint or loop. 3. Install intermediate guides on metal framing support systems not carrying pipe anchor or alignment guide. F. Accessories: 1. Insulation Shield: Install on insulated piping with oversize rollers and supports. 2. Welding Insulation Saddle: Install on insulated steel pipe with oversize rollers and supports. 3. Dielectric Barrier: a. Provide between painted or galvanized carbon steel members and copper or stainless steel pipe or between stainless steel supports and non-stainless steel ferrous metal piping. b. Install rubber wrap between submerged metal pipe and oversized clamps. 3.3 FIELD FINISHING A. Paint as specified in Section 09 96 00 – High-Performance Coatings. 3.4 FIELD QUALITY CONTROL A. Section 01 40 00 – Quality Requirements: Requirements for inspecting and testing. 3.5 SUPPLEMENTS A. The supplements listed below, following “End of Section,” are a part of this specification: 1. Table 1: Nonchemical Areas. 2. Table 2: Chemical Areas. BCRUA - Phase 1D WTP Expansion Issued for Bid Hangers and Supports for Process Piping 40 05 07 - 11 END OF SECTION Table 1 Nonchemical Areas Exposure Conditions Support Material Pipe Galleries Galvanized steel or precoated steel, plastic coated hangers for uninsulated copper or stain- less steel piping Process Areas: High Humidity Stainless steel or FRP Process Areas: Wetted or Submerged Stainless steel or FRP Pipes conveying chemicals listed in Table 2 Provide with corresponding support per Table 2. Notes: 1. Precoated steel to be fusion bonded epoxy or vinyl copolymer (Plastisol). 2. Stainless steel to be Type 304 minimum. 3. Galvanized steel to be per ASTM A653/A653M, Class G90, or hot-dip galvanized after fabrica- tion to ASTM A123/A123M. 4. Do not use galvanized steel or aluminum where lime dust can accumulate on these surfaces. BCRUA Phase 1D WTP Expansion Issued for Bid Hangers and Supports for Process Piping 40 05 07 - 12 Table 2 Chemical Areas Exposure Conditions Support for Direct Exposure Support for Remote Expo- sure Coagulants FRP Precoated steel or galvanized steel Hydrofluorosilicic Acid FRP Precoated steel Liquid Ammonium Sulfate FRP Precoated steel Polymers FRP Precoated steel Sodium Hypochlorite FRP Precoated steel Sodium Permanganate FRP Precoated steel Notes: 1. Direct exposure includes entire area within containment area; area within 20 feet horizontal and 10 feet vertical of chemical pumps or chemical mixing stations; or as specified. 2. Remote exposure is area beyond area defined as direct exposure, but within designated building. 3. Precoated steel to be fusion bonded epoxy or vinyl copolymer (Plastisol). 4. Stainless steel to be Type 304, minimum. 5. Galvanized steel to be per ASTM A653/A653M, Class G90, or hot-dip galvanized after fabrica- tion to ASTM A123/A123M. 6. Do not use galvanized steel or aluminum where lime dust can accumulate on these surfaces. BCRUA - Phase 1D WTP Expansion Issued for Bid Copper Process Pipe and Tubing 40 05 17 - 1 SECTION 40 05 17 - COPPER PROCESS PIPE AND TUBING PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Copper pipe and fittings. 2. Accessories. B. Related Sections: 1. Section 40 05 00 – Common Requirements for Process Piping. 2. Section 40 05 06 – Couplings, Adapters, and Specials for Process Piping: Piping appurtenances. 3. Section 40 05 40 – Process Piping Leakage Testing and Disinfection. 4. Section 40 05 51 – Common Requirements for Process Valves: Common product requirements for valves for placement by this Section. 1.2 REFERENCE STANDARDS A. American Welding Society: 1. AWS A5.8/A5.8M - Specification for Filler Metals for Brazing and Braze Welding. B. ASME International: 1. ASME B1.1 - Unified Inch Screw Threads, UN and UNR Thread Form. 2. ASME B1.20.1 - Pipe Threads, General Purpose, Inch. 3. ASME B16.5 - Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24 Metric/Inch Standard. 4. ASME B16.15 - Cast Copper Alloy Threaded Fittings: Classes 125 and 250. 5. ASME B16.18 - Cast Copper Alloy Solder Joint Pressure Fittings. 6. ASME B16.20 - Metallic Gaskets for Pipe Flanges: Ring-Joint, Spiral-Wound, and Jacketed. 7. ASME B16.21 - Nonmetallic Flat Gaskets for Pipe Flanges. 8. ASME B16.22 - Wrought Copper and Copper Alloy Solder Joint Pressure Fittings. 9. ASME B16.23 - Cast Copper Alloy Solder Joint Drainage Fittings: DWV. 10. ASME B16.24 - Cast Copper Alloy Pipe Flanges and Flanged Fittings: Classes 150, 300, 600, 900, 1500, and 2500. 11. ASME B16.26 - Cast Copper Alloy Fittings for Flared Copper Tubes. 12. ASME B16.29 - Wrought Copper and Wrought Copper Alloy Solder Joint Drainage Fittings - DWV. 13. ASME B31.3 - Process Piping. C. ASTM International: 1. ASTM B88 - Standard Specification for Seamless Copper Water Tube. 2. ASTM B32 - Standard Specification for Solder Metal. 3. ASTM B42 - Standard Specification for Seamless Copper Pipe, Standard Sizes. 4. ASTM B61 - Standard Specification for Steam or Valve Bronze Castings. 5. ASTM B62 - Standard Specification for Composition Bronze or Ounce Metal Castings. 6. ASTM B75/B75M - Standard Specification for Seamless Copper Tube. BCRUA - Phase 1D WTP Expansion Issued for Bid Copper Process Pipe and Tubing 40 05 17 - 2 7. ASTM B98/B98M - Standard Specification for Copper-Silicon Alloy Rod, Bar and Shapes. 8. ASTM B124/B124M - Standard Specification for Copper and Copper Alloy Forging Rod, Bar, and Shapes. 9. ASTM B150/B150M - Standard Specification for Aluminum Bronze Rod, Bar, and Shapes. 10. ASTM B251 - Standard Specification for General Requirements for Wrought Seamless Copper and Copper-Alloy Tube. 11. ASTM B302 - Standard Specification for Threadless Copper Pipe, Standard Sizes. 12. ASTM B306 - Standard Specification for Copper Drainage Tube (DWV). D. Manufacturers Standardization Society: 1. MSS SP-58 - Pipe Hangers and Supports - Materials, Design, Manufacture, Selection, Application, and Installation. E. NSF International: 1. NSF 61 - Drinking Water System Components - Health Effects. 2. NSF 372 - Drinking Water System Components - Lead Content. 1.3 COORDINATION A. Section 01 30 00 - Administrative Requirements: Requirements for coordination. 1.4 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Section 40 05 00 – Common Requirements for Process Piping subsection for Submittals. C. Product Data: Submit manufacturer information regarding pipe, tube, and fittings. D. Shop Drawings: Indicate layout of piping systems, including equipment, critical dimensions, sizes, and materials list. E. Manufacturer's Certificate: Certify that products meet or exceed specified requirements. F. Field Quality-Control Submittals: Indicate results of Contractor-furnished tests and inspections. 1.5 CLOSEOUT SUBMITTALS A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for submittals. B. Project Record Documents: Record actual locations of piping, valves and other appurtenances, connections, and centerline elevations. C. Identify and describe unexpected variations to subsoil conditions or discovery of uncharted utilities. BCRUA - Phase 1D WTP Expansion Issued for Bid Copper Process Pipe and Tubing 40 05 17 - 3 1.6 QUALITY ASSURANCE A. Section 40 05 00 – Common Products for Process Piping: Requirements of subsection for Quality Assurance B. Permanently mark each length of pipe with manufacturer's name or trademark and indicate conformance to standards. C. Materials in Contact with Potable Water: Certified according to NSF 61 and NSF 372. 1.7 QUALIFICATIONS A. Manufacturer: Company specializing in manufacturing products specified in this Section with minimum ten years' experience. B. Installer: Company specializing in performing Work of this Section with minimum three years’ experience and approved by manufacturer. 1.8 DELIVERY, STORAGE, AND HANDLING A. Section 01 60 00 – Product Requirements: Requirements for transporting, handling, storing, and protecting products. B. Section 40 05 00 – Common Requirements for Process Piping: Requirements of subsection for Delivery, Storage, and Handling. C. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage. D. Store materials according to manufacturer instructions. E. Protection: 1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas. 2. Protect piping and appurtenances by storing off ground. 3. Provide additional protection according to manufacturer instructions. 1.9 EXISTING CONDITIONS A. Field Measurements: 1. Verify field measurements prior to fabrication. 2. Indicate field measurements on Shop Drawings. PART 2 - PRODUCTS 2.1 COPPER PIPE, TUBE, AND FITTINGS A. Pipe: 1. Material: Seamless copper. 2. Comply with ASTM B42. BCRUA - Phase 1D WTP Expansion Issued for Bid Copper Process Pipe and Tubing 40 05 17 - 4 3. Temper: Annealed. 4. Type: L. B. Tube: 1. Material: Seamless copper alloy. 2. Comply with ASTM B88. 3. Type: L. 4. Temper: Annealed. C. Fittings: 1. Material: Copper alloy. 2. Temper: Comply with ASTM B61. 3. Solder-Joint Fittings: Comply with ASME B16.22. 4. Flared Fittings: Comply with ASME B16.26. 5. Threaded Fittings: a. Material: Cast bronze. b. Comply with ASME B16.15. c. Threads: Comply with ASME B1.20.1. 6. Flanges and Flanged Fittings: a. Comply with ASME B16.24. b. Class 150. c. Gaskets: 1) Material: Neoprene. 2) Comply with ASME B16.5 and ASME B16.21. 3) Thickness: 1/16 inch. 7. Seals: a. Material: EPDM. 8. Tubing Compression Fittings: a. Material: Forged brass alloy. b. Comply with ASTM B124/B124M. c. Threads: Comply with ASME B1.1. d. Press Fittings: 1) Material: Copper or Bronze. 2) Comply with ASME B16.18, B16.22. D. Pipe Joints: 1. Type: a. Soldered. b. Connections to Equipment: Unions. E. Tube Joints: 1. Type: Soldered or Press compression per Pipe Schedule. 2.2 ACCESSORIES A. Bolting: Comply with ASTM B98/B98M. B. Solder: 1. Comply with ASTM B32. BCRUA - Phase 1D WTP Expansion Issued for Bid Copper Process Pipe and Tubing 40 05 17 - 5 C. Piping Supports: 1. Material: Padded steel. 2. Comply with MSS SP-58. 2.3 SOURCE QUALITY CONTROL A. Section 01 40 00 – Quality Requirements: Requirements for testing, inspection, and analysis. B. Provide shop inspection and testing of completed assembly. PART 3 - EXECUTION 3.1 Section 40 05 00 – Common Requirements for Process Piping: Requirements listed in subsection PART 3 EXECUTION. 3.2 INSTALLATION A. Provide expansion joints as specified in Section 40 05 06 – Couplings, Adapters, and Specials for Process Piping to compensate for pipe expansion due to temperature differences. B. Pressure Testing: As indicated on piping schedule and according to Section 40 05 40 – Process Piping Leakage Testing and Disinfection. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Ductile Iron Process Pipe 40 05 19 - 1 SECTION 40 05 19 - DUCTILE IRON PROCESS PIPE PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Ductile-iron pipe. 2. Ductile-iron, malleable-iron, and cast-iron fittings. 3. Accessories. B. Related Sections: 1. Section 40 05 00 – Common Requirements for Process Piping. 2. Section 40 05 06 – Couplings, Adapters, and Specials for Process Piping. 1.2 REFERENCE STANDARDS A. American Water Works Association: 1. AWWA C104 - Cement-Mortar Lining for Ductile-Iron Pipe and Fittings. 2. AWWA C105 - Polyethylene Encasement for Ductile-Iron Pipe Systems. 3. AWWA C110 - Ductile-Iron and Gray-Iron Fittings. 4. AWWA C111 - Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings. 5. AWWA C115 - Flanged Ductile-Iron Pipe with Ductile-Iron or Gray-Iron Threaded Flanges. 6. AWWA C150 - Thickness Design of Ductile-Iron Pipe. 7. AWWA C151 - Ductile-Iron Pipe, Centrifugally Cast. 8. AWWA C153 - Ductile-Iron Compact Fittings. 9. AWWA C606 Grooved and Shouldered Joints. B. ASME International: 1. ASME B16.1 - Gray Iron Pipe Flanges and Flanged Fittings: Classes 25, 125, and 250. 2. ASME B16.21, Nonmetallic Flat Gaskets for Pipe Flanges 3. ASME B16.42, Ductile Iron Pipe Flanges and Flanged Fittings Classes 150 and 300. 4. ASME B31.3 - Process Piping. C. ASTM International: 1. ASTM A48/A48M - Standard Specification for Gray Iron Castings. 2. ASTM A126, Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings. D. NSF International: 1. NSF 61 - Drinking Water System Components - Health Effects. 2. NSF 372 - Drinking Water System Components - Lead Content. E. Society for Protective Coatings: 1. SSPC SP 6 - Commercial Blast Cleaning. BCRUA - Phase 1D WTP Expansion Issued for Bid Ductile Iron Process Pipe 40 05 19 - 2 1.3 COORDINATION A. Section 01 30 00 – Administrative Requirements: Requirements for coordination. 1.4 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Section 40 05 00 – Common Requirements for Process Piping subsection for Submittals. C. Product Data: Submit manufacturer information regarding pipe and fittings. D. Shop Drawings: Indicate layout of piping systems, including equipment, critical dimensions, sizes, and materials lists. E. Manufacturer's Certificate: Certify that products meet or exceed specified requirements. F. Field Quality-Control Submittals: Indicate results of Contractor-furnished tests and inspections. 1.5 CLOSEOUT SUBMITTALS A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for submittals. B. Project Record Documents: Record actual locations of piping, valves and other appurtenances, connections, and centerline elevations. C. Identify and describe unexpected variations to subsoil conditions or discovery of uncharted utilities. 1.6 QUALITY ASSURANCE A. Section 40 05 00 – Common Products for Process Piping: Requirements of subsection for Quality Assurance. B. Permanently mark each length of pipe with manufacturer's name or trademark and indicate conformance to standards. C. Materials in Contact with Potable Water: Certified according to NSF 61 and NSF 372. 1.7 QUALIFICATIONS A. Manufacturer: Company specializing in manufacturing products specified in this Section with minimum five years' experience. B. Installer: Company specializing in performing Work of this Section with minimum three years' experience and approved by manufacturer. BCRUA - Phase 1D WTP Expansion Issued for Bid Ductile Iron Process Pipe 40 05 19 - 3 1.8 DELIVERY, STORAGE, AND HANDLING A. Section 01 60 00 – Product Requirements: Requirements for transporting, handling, storing, and protecting products. B. Section 40 05 00 – Common Requirements for Process Piping: Requirements of subsection for Delivery, Storage, and Handling. C. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage. D. Store materials according to manufacturer instructions. E. Protection: 1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas. 2. Protect piping and appurtenances by storing off ground. 3. Provide additional protection according to manufacturer instructions. 1.9 EXISTING CONDITIONS A. Field Measurements: 1. Verify field measurements prior to fabrication. 2. Indicate field measurements on Shop Drawings. PART 2 - PRODUCTS 2.1 DUCTILE IRON PIPE AND FITTINGS A. Piping: 1. Buried Liquid Service Using Push-on, Mechanical or Proprietary Restrained Joints: AWWA C111/A21.11, and AWWA C151/A21.51, pressure class conforming to Table 5 and Table 7 for Type 4 trench, 250 psi minimum working pressure or as indicated on Pipe Schedule. Follower glands shall be ductile iron. 2. Exposed Pipe Using Grooved End and Flange Joints: AWWA C115/A21.15, thickness Class 53 minimum, 250 psi minimum working pressure or as indicated on Pipe Schedule. B. Fittings: 1. Material: ASTM A48/A48M, gray iron,[AWWA C110, ductile iron, AWWA C153, ductile iron. 2. Pressure Rating: As indicated on Drawings or Pipe Schedule. 3. Push-on: AWWA C110/A21.10, AWWA C111/A21.11, and AWWA C153/A21.53 ductile iron, 250 psi minimum working pressure. a. Manufacturers: 1) American Cast Iron Pipe Co., Fastite Joint. 2) U.S. Pipe and Foundry, Tyton Joint. 4. Mechanical: AWWA C110/A21.10, AWWA C111/A21.11, and AWWA C153/A21.53 ductile iron, 250 psi minimum working pressure or as indicated on Pipe Schedule. Follower glands shall be ductile iron. BCRUA - Phase 1D WTP Expansion Issued for Bid Ductile Iron Process Pipe 40 05 19 - 4 5. Proprietary Restrained: AWWA C110/A21.10, AWWA C111/A21.11, and AWWA C153/A21.53, ductile iron, 250 psi minimum working pressure or as indicated on Pipe Schedule. Restraint shall be achieved with removable metal elements fitted between a welded bar on the pipe barrel and the inside of the joint bell or fitting sizes smaller than 16 inches may be mechanical joint, restrained by anchor gland followers, ductile iron anchor type, wedge action, with break-off tightening bolts. Assembled joints shall be rated for deflection in operation at rated pressure. Rated deflection shall be not less than 1 1/2 degrees for 36 inch and smaller pipe. Rated deflection shall be not less than 1/2 degree for 42 inch and larger pipe. Restrained joints relying on metal teeth molded into the gasket to prevent joint separation under pressure will not be accepted. a. Manufacturers: 1) American Cast Iron Pipe Co. 2) U.S. Pipe. 6. Grooved End: AWWA C606 and AWWA C110/A21.10, ductile iron, 250 psi minimum working pressure. a. Manufacturer: Victaulic. 7. Flange: AWWA C110/A21.10 ductile iron, faced and drilled, Class 125 or 250. C. Joints: 1. Push-on: 250 psi minimum working pressure, AWWA C110/A21.10 and AWWA C111/A21.11. a. Manufacturers: 1) American Cast Iron Pipe Co., Fastite Joint. 2) U.S. Pipe and Foundry, Tyton Joint. 2. Mechanical: 250 psi minimum working pressure or as indicated on Pipe Schedule. 3. Proprietary Restrained: 250 psi minimum working pressure or as indicated on Pipe Schedule. a. Manufacturers: 1) American Cast Iron Pipe Co., Flex-Ring. 2) U.S. Pipe, TR Flex. 4. Grooved End: Rigid type radius cut conforming to AWWA C606, 250 psi minimum working pressure. a. Manufacturer: Victaulic. 5. Flange: Class 125 flat face or Class 250 raised face, ductile iron, threaded conforming to AWWA C115/A21.15. Gray cast iron will not be allowed. 6. Branch connections 3 inches and smaller shall be made with service saddles. D. Cement-Mortar Lining: 1. AWWA C104. 2. Thickness: Standard. E. Outside Coating: 1. Buried Service: a. Type: Asphaltic. b. Thickness: 1 mil. 2. Exposed Service: As specified in Section 09 96 00 – High-Performance Coatings. 2.2 ACCESSORIES A. Couplings: BCRUA - Phase 1D WTP Expansion Issued for Bid Ductile Iron Process Pipe 40 05 19 - 5 1. Grooved End: 250 psi minimum working pressure, malleable iron per ASTM A47/A47M or ductile iron per ASTM A536. a. Manufacturer: Victaulic. 2. Grooved End Adapter Flanges: 250 psi minimum working pressure, malleable iron per ASTM A47/A47M or ductile iron per ASTM A536. a. Manufacturer: Victaulic. B. Bolting: 1. Mechanical, Proprietary Restrained, and Grooved End Joints: Manufacturer’s standard. 2. Class 125 Flat-Faced Flange and Class 250 Raised-Face Flange; Stainless steel per Section 40 05 00 – Common Requirements for Process Piping. C. Gaskets: 1. General: Gaskets in contact with potable water shall be NSF 61 certified. 2. Water Service: Rubber conforming to AWWA C111/A21.11. 3. Grooved End Joints: Halogenated butyl conforming to ASTM D2000 and AWWA C606. 4. Full face for Class 125 flat-faced flanges, flat-ring type for Class 250 raised-face flanges. Blind flanges shall be gasketed covering entire inside face with gasket cemented to blind flange. 5. Gasket pressure rating to equal or exceed the system hydrostatic test pressure. D. Joint Lubricant: 1. Manufacturer’s standard. PART 3 - EXECUTION 3.1 Section 40 05 00 – Common Requirements for Process Piping: Requirements listed in PART 3 EXECUTION. 3.2 INSTALLATION A. Install according to manufacturer instructions and applicable AWWA Standards. B. Field Cutting: 1. Do not damage interior lining material during cutting. 2. Use abrasive wheel cutters or saws. Do not flame cut. Make square cuts. 3. After cutting, bevel and remove sharp edges or projections from cut ends. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Stainless Steel Process Pipe and Tubing 40 05 23 - 1 SECTION 40 05 23 - STAINLESS STEEL PROCESS PIPE AND TUBING PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Stainless-steel pipe and fittings. 2. Stainless-steel tube and fittings. 3. Accessories. B. Related Sections: 1. Section 40 05 00 – Common Requirements for Process Piping. 2. Section 40 05 06 – Couplings, Adapters, and Specials for Process Piping. 1.2 REFERENCE STANDARDS A. American Welding Society: 1. AWS D1.1/D1.1M - Structural Welding Code - Steel. B. ASME International: 1. ASME B1.20.1 - Pipe Threads, General Purpose, Inch. 2. ASME B16.1 - Cast Iron Pipe Flanges and Flanged Fittings, Classes 25, 125, 250 and 800. 3. ASME B16.5 - Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24 Metric/Inch Standard. 4. ASME B16.9 - Factory-Made Wrought Buttwelding Fittings. 5. ASME B16.11 - Forged Fittings, Socket-Welding and Threaded. 6. ASME B16.20 - Metallic Gaskets for Pipe Flanges: Ring-Joint, Spiral-Wound, and Jacketed. 7. ASME B16.21 - Nonmetallic Flat Gaskets for Pipe Flanges. 8. ASME B31.3 - Process Piping. 9. ASME Boiler and Pressure Vessel Code (BPVC), Section IX - Welding and Brazing Qualifications. C. ASTM International: 1. ASTM A182/A182M - Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service. 2. ASTM A193/A193M - Standard Specification for Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications. 3. ASTM A194/A194M - Standard Specification for Carbon Steel, Alloy Steel, and Stainless Steel Nuts for Bolts for High Pressure or High Temperature Service, or Both. 4. ASTM A269/A269M - Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service. 5. ASTM A312/A312M - Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes. 6. ASTM A351/A351M - Standard Specification for Castings, Austenitic, for Pressure- Containing Parts. 7. ASTM A403/A403M - Standard Specification for Wrought Austenitic Stainless Steel Piping Fittings. BCRUA - Phase 1D WTP Expansion Issued for Bid Stainless Steel Process Pipe and Tubing 40 05 23 - 2 8. ASTM A479/A479M - Standard Specification for Stainless Steel Bars and Shapes for Use in Boilers and Other Pressure Vessels. 9. ASTM A632 - Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing (Small Diameter) for General Service. 10. ASTM A789/A789M - Standard Specification for Seamless and Welded Ferritic/Austenitic Stainless Steel Tubing for General Service. 11. ASTM A813/A813M - Standard Specification for Single- or Double-Welded Austenitic Stainless Steel Pipe. 12. ASTM A814/A814M - Standard Specification for Cold-Worked Welded Austenitic Stainless Steel Pipe. 13. ASTM D3308 - Standard Specification for PTFE Resin Skived Tape. D. NSF International: 1. NSF 61 - Drinking Water System Components - Health Effects. 2. NSF 372 - Drinking Water System Components - Lead Content. 1.3 COORDINATION A. Section 01 30 00 - Administrative Requirements: Requirements for coordination. 1.4 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Section 40 05 00 – Common Requirements for Process Piping subsection for Submittals. C. Product Data: Submit manufacturer information on pipe materials, tube materials, and fittings. D. Shop Drawings: Indicate layout of piping systems, including equipment, critical dimensions, sizes, and materials lists. E. Manufacturer's Certificate: Certify that products meet or exceed specified requirements. F. Welder Certificates: Submit welders' certification of compliance with AWS D1.1/D1.1M, verifying qualification within previous 12 months. G. Field Quality-Control Submittals: Indicate results of Contractor-furnished tests and inspections. 1.5 CLOSEOUT SUBMITTALS A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for submittals. B. Project Record Documents: Record actual locations of valves, fittings, and appurtenances. 1.6 QUALITY ASSURANCE A. Section 40 05 00 – Common Products for Process Piping: Requirements of subsection for Quality Assurance. BCRUA - Phase 1D WTP Expansion Issued for Bid Stainless Steel Process Pipe and Tubing 40 05 23 - 3 B. Permanently mark each length of pipe with manufacturer's name or trademark and indicate conformance to standards. C. Materials in Contact with Potable Water: Certified according to NSF 61 and NSF 372. 1.7 QUALIFICATIONS A. Manufacturer: Company specializing in manufacturing products specified in this Section with minimum ten years' experience. B. Installer: Company specializing in performing Work of this Section with minimum three years' experience and approved by manufacturer. C. Welders: AWS qualified within previous 12 months for employed weld types. 1.8 DELIVERY, STORAGE, AND HANDLING A. Section 01 60 00 - Product Requirements: Requirements for transporting, handling, storing, and protecting products. B. Section 40 05 00 – Common Requirements for Process Piping: Requirements of subsection for Delivery, Storage, and Handling. C. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage. D. Store materials according to manufacturer instructions. E. Protection: 1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas. 2. Protect piping and appurtenances by storing off ground. 3. Provide additional protection according to manufacturer instructions. 1.9 EXISTING CONDITIONS A. Field Measurements: 1. Verify field measurements prior to fabrication. 2. Indicate field measurements on Shop Drawings. PART 2 - PRODUCTS 2.1 STAINLESS-STEEL PIPE AND FITTINGS A. General Service Piping: 1. 2-1/2" & smaller: Schedule 10S: ASTM A312/A312M, Type 304L or 316L as scheduled, seamless, pickled and passivated. 2. 3" thru 6": Schedule 10S: ASTM A778, “as-welded” grade, Type 304L, pickled and passivated. BCRUA - Phase 1D WTP Expansion Issued for Bid Stainless Steel Process Pipe and Tubing 40 05 23 - 4 3. 8" and larger: Schedule 10S: ASTM A778, “as-welded” grade, Type 304L or 316L, pickled and passivated. B. Joints: 1. 1-1/2" & smaller: Compression type couplings with threaded unions at equipment and valves as required or shown. 2. 2" and larger: Flanged at valves and equipment. C. Fittings: 1. 1-1/2" and smaller: Compression type, Grade 304L or 316L as scheduled. a. Reference Section 40 05 06 – Couplings, Adapters and Specials for Process Piping. 2. 2" and 2-1/2": Butt Welded: ASTM A403/A403M, Grade WP304L conforming to ASME B16.9 and MSS SP 43, annealed, pickled and passivated; fitting wall thickness to match adjoining pipe; long radius elbows, unless shown otherwise. 3. 3" and larger: Butt-Welded: ASTM A774/A774M Grade 304L or 316L conforming to MSS SP 43, “as-welded” grade, pickled and passivated; fitting wall thickness to match adjoining pipe; long radius elbows, unless shown otherwise. D. Branch Connections: 1. 1-1/2" and smaller: Tee or reducing tee in conformance with fittings above. 2. 2" and larger: Butt-welding tee or reducing tee in accordance with fittings above. E. Flanges: 1. Forged Stainless Steel: ASTM A182/A182M, Grade F304L or F316L, ASME B16.5 Class to match pressure service, slip-on weld neck. Weld slip-on flanges inside and outside. 2. Blind Flanges, exposed to the atmosphere and not buried nor immersed in liquid, will be stainless steel with gaskets as specified herein. F. Unions: 1. 2" and smaller: Compression type threaded adapter: Grade 304L or 316L as scheduled, meet or exceed working pressure of adjoining pipe, bore to match pipe. G. Bolting: 1. Type 304 stainless steel, ASTM A320/A320M Grade B8M hex head bolts, ASTM A194/A194M Grade 8M hex head nuts and ASTM F436/F436M Type 3 alloy washers at nuts and bolt heads. Achieve 40 percent to 60 percent of bolt minimum yield stress. 2. Flanged Joints in Sumps, Wet Wells, and Submerged and Wetted Installations: Type 316 stainless steel, ASTM A320/A320M, Grade B8M hex head bolts and ASTM A194/A194M, Grade 8M hex nuts and ASTM F436/F436M Type 3 alloy washers at nuts and bolt heads. Achieve 40 percent to 60 percent of bolt minimum yield stress. H. Gaskets: 1. Suitable for service conditions. 2. Per AWWA C228 where applicable. 3. Flanges: 1/8-inch thick, homogeneous black rubber (EPDM), hardness 60 (Shore A), rated to 250 degrees F. continuous and conforming to ASME B16.21 and ASTM D1330, Steam Grade. 4. Blind flanges shall be gasketed covering entire inside face with gasket cemented to blind flange. BCRUA - Phase 1D WTP Expansion Issued for Bid Stainless Steel Process Pipe and Tubing 40 05 23 - 5 I. Thread Lubricant: 1. 2" and smaller: a. General Service: 100 percent virgin PTFE Teflon tape. 2.2 STAINLESS-STEEL TUBE AND FITTINGS A. Tube: 1. ASTM A269, Type 316 stainless steel, seamless, fully annealed hydraulic tubing, 0.065- inch wall thickness minimum. B. Tubing Joints: 1. Flareless compression fitting C. Tubing Fittings: 1. Flareless Compression Type Forged: ASTM A182/A182M, Grade F316. 2. Manufacturer and Products: a. Parker-Hannifin, Ferulok. b. Flodar, BA Series. D. Tubing Branch Connections: 1. Compression type tees or reducing tees in accordance with Tubing Fittings above. PART 3 - EXECUTION 3.1 Section 40 05 00 – Common Requirements for Process Piping: Requirements listed in PART 3 EXECUTION. 3.2 INSTALLATION A. Install according to manufacturer instructions. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 1 SECTION 40 05 24 - STEEL PROCESS PIPE PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Steel pipe. 2. Fittings. 3. Accessories. B. Related Sections: 1. Section 09 96 00 – High-Performance Coatings: Finishes as specified by this Section. 2. Section 31 23 17 – Trenching. 3. Section 31 23 23 – Fill. 4. Section 40 05 00 – Common Requirements for Process Piping. 5. Section 40 05 06 – Couplings, Adapters, and Specials for Process Piping: Pipe penetrations, restrained joints, flexible connections, expansion joints and loops, and sleeve-type couplings. 6. Section 40 05 40 – Process Piping Leakage Testing and Disinfection. 1.2 REFERENCE STANDARDS A. American Water Works Association: 1. AWWA C200 - Steel Water Pipe, 6 In. (150 mm) and Larger. 2. AWWA C203 - Coal-Tar Protective Coatings and Linings for Steel Water Pipe. 3. AWWA C205 - Cement-Mortar Protective Lining and Coating for Steel Water Pipe - 4 In. (100 mm) and Larger - Shop Applied. 4. AWWA C206 - Field Welding of Steel Water Pipe. 5. AWWA C207 - Steel Pipe Flanges for Waterworks Service, Sizes 4 In. Through 144 In. (100 mm Through 3,600 mm). 6. AWWA C208 - Dimensions for Fabricated Steel Water Pipe Fittings. 7. AWWA C210 - Liquid-Epoxy Coatings and Linings for Steel Water Pipe and Fittings. 8. AWWA C213 - Fusion-Bonded Epoxy Coating for the Interior and Exterior of Steel Water Pipelines. 9. AWWA C222 - Polyurethane Coatings for the Interior and Exterior of Steel Water Pipe and Fittings. 10. AWWA C550 - Protective Epoxy Interior Coatings for Valves and Hydrants. 11. AWWA 602 - Cement-Mortar Lining of Water Pipelines in Place - 4 In. (100 mm) and Larger. 12. AWWA C606 - Grooved and Shouldered Joints. 13. AWWA M11 - Steel Water Pipe - A Guide for Design and Installation. B. American Welding Society: 1. A2.4, Standard Symbols for Welding, Brazing, and Nondestructive Examination. 2. A3.0M/A3.0, Standard Welding Terms and Definitions Including Terms for Adhesive Bonding, Brazing, Soldering, Thermal Cutting, and Thermal Spraying. 3. AWS D1.1/D1.1M - Structural Welding Code - Steel. 4. QC 1, Standard for AWS Certification of Welding Inspectors. BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 2 C. ASME International: 1. ASME B1.20.1 - Pipe Threads, General Purpose, Inch. 2. ASME B16.1 - Gray Iron Pipe Flanges and Flanged Fittings: Classes 25, 125, and 250. 3. ASME B16.3 - Malleable Iron Threaded Fittings: Classes 150 and 300. 4. ASME B16.5 - Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24 Metric/Inch Standard. 5. ASME B16.9 - Factory-Made Wrought Buttwelding Fittings. 6. ASME B16.11 - Forged Fittings, Socket-Welding and Threaded. 7. ASME B16.20 - Metallic Gaskets for Pipe Flanges: Ring-Joint, Spiral-Wound, and Jacketed. 8. ASME B16.21 - Nonmetallic Flat Gaskets for Pipe Flanges. 9. ASME B16.42 - Ductile Iron Pipe Flanges and Flanged Fittings: Classes 150 and 300. 10. ASME B36.10M - Welded and Seamless Wrought Steel Pipe. 11. ASME Boiler and Pressure Vessel Code (BPVC) Section IX - Welding, Brazing, and Fusing Qualifications. 12. BPVC SEC VIII, Div. 1, Rules for Construction of Pressure Vessels. D. American Society for Nondestructive Testing Inc. (ASNT): SNT-TC-1A, Recommended Practice for Personnel Qualification and Certification in Nondestructive Testing. E. ASTM International: 1. ASTM A20/A20M - Standard Specification for General Requirements for Steel Plates for Pressure Vessels. 2. ASTM A47/A47M - Standard Specification for Ferritic Malleable Iron Castings. 3. ASTM A53/A53M - Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc- Coated, Welded and Seamless. 4. ASTM A105/A105M - Standard Specification for Carbon Steel Forgings for Piping Applications. 5. ASTM A106/A106M - Standard Specification for Seamless Carbon Steel Pipe for High- Temperature Service. 6. ASTM A108 - Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished. 7. ASTM A193/A193M - Standard Specification for Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications. 8. ASTM A194/A194M - Standard Specification for Carbon Steel, Alloy Steel, and Stainless Steel Nuts for Bolts for High Pressure or High Temperature Service, or Both. 9. ASTM A216/A216M - Standard Specification for Steel Castings, Carbon, Suitable for Fusion Welding, for High-Temperature Service. 10. ASTM A234/A234M - Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service. 11. ASTM A334/A334M - Standard Specification for Seamless and Welded Carbon and Alloy-Steel Tubes for Low-Temperature Service. 12. ASTM A370 - Standard Test Methods and Definitions for Mechanical Testing of Steel Products. 13. ASTM A423/A423M - Standard Specification for Seamless and Electric-Welded Low- Alloy Steel Tubes. 14. ASTM A435/A435M - Standard Specification for Straight-Beam Ultrasonic Examination of Steel Plates. 15. ASTM A516/A516M - Standard Specification for Pressure Vessel Plates, Carbon Steel, for Moderate and Lower-Temperature Service BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 3 16. ASTM A576 - Standard Specification for Steel Bars, Carbon, Hot-Wrought, Special Quality. 17. ASTM A727/A727M -Standard Specification for Carbon Steel Forgings for Piping Components with Inherent Notch Toughness. 18. ASTM A770/A770M - Standard Specification for Through-Thickness Tension Testing of Steel Plates for Special Applications. 19. ASTM A858/A858M - Standard Specification for Heat-Treated Carbon Steel Fittings for Low-Temperature and Corrosive Service. 20. ASTM A865/A865M - Standard Specification for Threaded Couplings, Steel, Black or Zinc-Coated (Galvanized) Welded or Seamless, for Use in Steel Pipe Joints. 21. ASTM A1018/A1018M - Standard Specification for Steel, Sheet and Strip, Heavy- Thickness Coils, Hot-Rolled, Carbon, Commercial, Drawing, Structural, High-Strength Low-Alloy, High-Strength Low-Alloy with Improved Formability, and Ultra-High Strength. 22. ASTM C33/C33M - Standard Specification for Concrete Aggregates. 23. ASTM C150/C150M - Standard Specification for Portland Cement. 24. ASTM C600 - Standard Test Method of Thermal Shock Test on Glass Pipe. 25. ASTM D1418 - Standard Practice for Rubber and Rubber Latices - Nomenclature. 26. ASTM D3308 - Standard Specification for PTFE Resin Skived Tape. 27. ASTM E329, Standard Specification for Agencies Engaged in Construction Inspection, Testing, or Special Inspection. 28. ASTM E438 - Standard Specification for Glasses in Laboratory Apparatus. 29. E1255 - Standard Practice for Radioscopy. 30. ASTM F336 - Standard Practice for Design and Construction of Nonmetallic Enveloped Gaskets for Corrosive Service. 31. ASTM F1476 - Standard Specification for Performance of Gasketed Mechanical Couplings for Use in Piping Applications. 32. ASTM F1545 - Standard Specification for Plastic-Lined Ferrous Metal Pipe, Fittings, and Flanges. F. International Organization for Standardization (ISO): 9001:2000, Quality Management Systems – Requirements. G. NSF International: 1. NSF 61 - Drinking Water System Components - Health Effects. 2. NSF 372 - Drinking Water System Components - Lead Content. H. Steel Pipe Fabricators Association (SFPA). I. SSPC - The Society for Protective Coatings: 1. SSPC-SP 6 - Commercial Blast Cleaning. 1.3 COORDINATION A. Section 01 30 00 - Administrative Requirements: Requirements for coordination. 1.4 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 4 B. Section 40 05 00 – Common Requirements for Process Piping subsection for Submittals. C. Shop Drawings: Indicate layout of piping systems, including equipment, critical dimensions, sizes, and material lists. D. Material list and steel reinforcement schedules for materials specified. E. Product Data: Submit manufacturer information regarding pipe and fittings. 1. Steel Pipe and Fittings: a. Material data. b. Chemical and physical test reports showing data consistent with specified requirements for each heat of steel proposed for use. 2. Cement Mortar Linings: a. Technical data sheets itemizing composition, technical, and performance information that indicates compliance with this Specification. b. Cement mortar mix design and admixtures. c. Fiber reinforcement and method of attachment to pipe. 3. Flanged Joints: For each flanged connection, show referenced standard for pressure class, dimensional data, bolt hole number, pattern, and diameter. F. Fabrication Information: 1. Pipe and fitting details for temporary and permanent facilities indicating: a. Cylinder thickness. b. Manufacturing tolerances. c. Maximum angular deflection limitations of field joints. d. Closure sections and cutoffs for field length adjustment. e. Dished heads. f. Weld lead outlets and plugs. g. Stulling size, spacing, and layout. 2. Welded joint details including: a. Butt joints. b. Miter-cut ends for alignment conformance. c. Lap joints. d. Butt strap joints. G. Welding Data (Shop and Field Welding) 1. Show on a weld map, complete information regarding base metal specification designation location, type, size, and extent of welds with reference called out for WPS and NDE numbers in tail of welding symbol. 2. Distinguish between shop and field welds. 3. Indicate, by welding symbols or sketches, details of welded joints and preparation of base metal. Provide complete joint welding details showing bevels, groove angles, and root openings for all welds. 4. Welding and NDE symbols shall be in accordance with AWS A2.4. 5. Welding terms and definitions shall be in accordance with AWS A3.0M/A3.0. 6. Submit welding data together with Shop Drawings as a complete package. 7. Fittings: Provide a joint weld beveling diagram. Refer to AWS D1.1/D1.1M, Annex P Local Dihedral Angle that can be used to calculate bevels for weld joint details of intersecting pipes. BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 5 H. Pipe Manufacturer’s written Quality Assurance/Quality Control Plan. I. Statement of Qualifications: 1. Pipe manufacturer. 2. Fittings fabricator. 3. Contractor’s shop inspector. 4. Contractor’s field inspector. 5. NDT quality control personnel. 6. Field lining personnel. J. Procedures: 1. Shop and field welding information; at a minimum include complete welding code paper trail with linkage to Shop Drawings. 2. Welder Qualifications and Welding Procedure Specifications as specified below: a. Provide complete joint dimensions and details showing bevels, groove angles, root face, and root openings for all welds. b. Notch-tough welding procedures required. For shop welding, address supplementary essential variables in addition to essential variables as indicated in ASME Section IX, QW 251.2. For field welding, heat-input, control PQR essential variables as indicated in AWS D1.1/D1.1M, Table 4.6 shall be included. For shop and field welding, provide heat-input table on WPSs for welder guidance. c. PQRs for notch-tough welding shall document heat-input control by monitoring volts, amps, and travel speed or time-rate of change of weld metal volume as calculated by measuring change in electrode length over a period of time. Charpy V notch tests shall be conducted on weld metal and heat affected zone. Test coupons shall be oriented transverse to final direction of rolling. Full size Charpy specimen test acceptance shall be same as base metal specified herein. d. Written NDT procedures. e. Written description of proposed sequencing of events or special techniques such as: 1) Minimizing distortion of steel. 2) Shop-Applied Cement-Mortar Lining: Include description of machine to be used and list of similar projects where machine was used. Identify pipe size and total footage. 3) Field-Applied Cement-Mortar Lining: a) Include description of machine/method to be used, list of similar projects where machine/method was used, and identify pipe size and total footage. b) Procedures for pipe surface preparation, lining application, and curing. 3. Written weld repair procedures for the Work. 4. Field coating application and repair. 5. Field lining application and repair. K. Reports: 1. Source Quality Control Test Reports: a. Nondestructive weld testing. b. Steel impact testing using Charpy V-notch method. c. Letter from independent testing agency certifying pipe furnished meets requirements of this Specification. 2. Field Quality Control Test Reports: Indicate results of Contractor-furnished tests and inspections.: BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 6 a. Weld tests, including re-examination of repaired welds, on each weld joint for the following tests, as applicable: 1) RT 2) UT 3) VT 4) MT 5) PT 3. Cement-mortar lining compressive strength tests in accordance with AWWA C205. L. Field Testing Plan: Submit at least 15 days prior to testing and include the following information: 1. Testing dates. 2. Piping systems and sections to be tested. 3. Method of isolation. 4. Method of conveying water from source to system being tested. 5. Calculation of maximum allowable leakage for piping sections to be tested. M. Delegated Design Submittals: Submit signed and sealed Shop Drawings with piping layout and with design calculations prepared by a licensed professional engineer in the State of Texas, including opening reinforcement details of collars, wrappers, crotch plates, and harnessed joint assemblies. N. Pipe manufacturer’s field representative’s certification of training of Contractor’s pipe installation crews. O. Manufacturer's Certificate: Certify that products meet or exceed specified requirements. P. Welder Certificates: Submit welders' certification of compliance. 1. Shop Welders: In accordance with ASME BPVC Section IX, verifying qualification within previous 12 months. 2. Field Welders: In accordance with AWS D1.1/D1.1M, verifying qualification within previous 12 months. 1.5 CLOSEOUT SUBMITTALS A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for submittals. B. Project Record Documents: Record actual locations of piping, valves and other appurtenances, connections, and centerline elevations. C. Identify and describe unexpected variations to subsoil conditions or discovery of uncharted utilities. 1.6 QUALITY ASSURANCE A. Section 40 05 00 – Common Requirements for Process Piping: Requirements of subsection Quality Assurance. B. Permanently mark each length of pipe with manufacturer's name or trademark and indicate conformance to standards. BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 7 C. Materials in Contact with Potable Water: Certified according to NSF 61 and NSF 372. D. Contractor’s Shop Inspector: 1. In accordance with AWWA C200. 2. Responsibilities: a. Verify conformance to use of specified materials and their proper storage. b. Monitor conformance to approved WPS. c. Monitor conformance to approved NDT procedure specifications. d. Monitor conformance of WPQ. e. Provide 100 percent visual inspection before, during, and after shop welding. f. Coordinate NDT work and review test results. g. Maintain records and prepare report confirming results of inspection and testing. E. Contractor’s Field Inspector: 1. In accordance with AWWA C206 and AWS D1.1/D1.1M. 2. Responsibilities: a. Verify conformance to use of specified materials and their proper storage. b. Monitor conformance to approved WPS. c. Monitor conformance to approved NDT procedure specifications. d. Monitor conformance of WPQ. e. Provide 100 percent VT before, during, and after field welding. f. Coordinate NDT work and review test results. g. Maintain records and prepare report confirming results of inspection and testing. F. Inspection of Coating and Lining Application: Qualified manufacturer’s technical representative shall visit pipe coating and lining shop at beginning of application process to verify proper workmanship associated with coating and lining application and as may be required to resolve shop or field problems. Submit written report of visit to Engineer. 1.7 QUALIFICATIONS A. Manufacturer: Company specializing in manufacturing products specified in this Section with minimum ten years' experience. B. Installer: Company specializing in performing Work of this Section with minimum three years' experience and approved by manufacturer. C. Shop Welders: ASME qualified within previous 12 months for employed weld types. D. Field Welders: AWS qualified within previous 12 months for employed weld types. E. Licensed Professional: Professional engineer experienced in design of specified Work and licensed in State of Texas. F. Contractor’s Inspector for Shop and Field Welding: 1. In accordance with AWS QC 1, with knowledge of welding code for the Work. 2. After receiving CWI qualification, at least one Shop CWI and one Field CWI shall have 5 years’ minimum professional experience related to welding inspection similar to the Work. Other CWIs may work under the supervision of 5-year CWI, provided they have 1 year of related professional experience after receiving CWI qualification. BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 8 G. NDT Quality Control Personnel: 1. In accordance with requirements of ASNT SNT TC 1A, NDT Level II. 2. After receiving NDT qualification, at least one NDT person shall have 5 years minimum professional experience related to NDT inspection similar to the Work. Other NDT personnel may work under the supervision of 5-year NDT, provided they have 1 year of related professional experience after receiving NDT qualification. 1.8 DELIVERY, STORAGE, AND HANDLING A. Section 01 60 00 – Product Requirements: Requirements for transporting, handling, storing, and protecting products. B. Section 40 05 00 – Common Requirements for Process Piping: Requirements of subsection for Delivery, Storage, and Handling. C. All pipe, fittings, etc., shall be carefully handled and protected against damage to lining and coating/interior and exterior surfaces, impact shocks, and free fall. The pipe and specials shall be handled by use of wide slings, padded cradles, or other devices designed and constructed to prevent damage to the pipe coating/exterior. The use of chains, hooks, or other equipment which might damage the pipe coating/exterior will not be permitted. Pipe shall not be placed directly on rough ground but shall be supported in a manner which will protect the pipe against damage whenever stored at the trench site or elsewhere. The Contractor shall be fully liable for the cost of replacement or repair of pipe and specials which are damaged. D. Pipe Markings: 1. Legibly mark installation sequence number on pipe and fittings in accordance with piping layout. Standard pipe sections do not need sequence number labeled provided wall thickness is clearly marked. 2. Fittings shall be marked at each end with notation “TOP FIELD CENTERLINE”. 3. The word “TOP” shall be painted or marked on outside top spigot of each fitting. 4. Mark “TOP MATCH POINT” for compound bends per AWWA C208 so end rotations can be easily oriented in field. E. Delivery: 1. Securely bulkhead or otherwise seal ends of pipe and fittings prior to loading at manufacturing site. 2. Pipe ends shall remain sealed until installation. 3. Damage to pipe and fittings, including linings and coatings, found upon delivery to Site shall be repaired to Engineer’s satisfaction or removed from Site and replaced. F. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage. G. Storage: 1. Support pipe securely to prevent accidental rolling and to avoid contact with mud, water, or other deleterious materials. 2. Support on sand or earth berms free of rock exceeding 3 inches in diameter. 3. For mortar lined pipe, after the completed pipe and fittings have been removed from the final cure at the manufacturing plant, the pipe lining shall be protected from drying by means of plastic end covers banded to the pipe ends. Covers shall be maintained over the BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 9 pipe ends at all times until ready to be placed in the trench. Moisture shall be maintained inside the pipe by periodic addition of water as necessary. H. Protection: 1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas. 2. Protect piping and appurtenances by storing off ground. 3. Provide additional protection according to manufacturer instructions. 1.9 EXISTING CONDITIONS A. Field Measurements: 1. Verify field measurements prior to fabrication. 2. Indicate field measurements on Shop Drawings. 1.10 DESIGN REQUIREMENTS A. Pipe: 1. Design in accordance with AWWA M11, AWWA C200, and as modified herein. 2. Design Working Pressure (by service): a. Backwash Water (BWW): 100 psig. b. Filtered Water (FLW), Overflow (OVF), and Waste Backwash Water (WBW): 50 psig. c. Raw Water (RW): 150 psig. 3. Submit design calculation for review prior to manufacture of steel pipe fittings. B. Fittings: 1. Design reinforcement, unless otherwise shown. 2. Design in accordance with AWWA M11, AWWA C200, AWWA C208, and this Specification. 3. Submit design calculation for review prior to manufacture of steel pipe fittings. C. Pipe Layout: Design in accordance with AWWA M11: 1. General: a. Base stationing, or dimensioned lengths, and elevation convention as shown on Drawings. b. Maximum Laying Lengths: 1) Not limited, unless specifically shown on Drawings. 2) Select lengths to accommodate installation operation and minimize field welded joints. 2. Include, as minimum: a. Specific number, location, and direction of each pipe, joint, and fitting. Number each pipe in installation sequence. b. Station, or dimensioned length, and centerline elevation to which end of pipe will be laid. c. Station, or dimensioned length, and centerline elevation at changes in grade or horizontal alignment. d. Elements of curves and bends, both in horizontal and vertical alignment. e. Location of mitered pipe sections, beveled ends, and/or pulled joints for alignment conformance, or butt straps. BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 10 f. Location of closures, cutoff sections, and closure sections for length adjustment, temporary access manways, vents, and weld lead outlets for construction convenience. 1) Provide for adjustment in pipe laying headings and to conform to indicated stationing or dimensioned lengths. 2) Changes in location or number will require Engineer approval. g. Location of dished heads. D. Welding Procedure Specification (WPS): 1. Qualified by testing in accordance with ASME BPVC SEC IX for shop welds and AWS D1.1/D1.1M for field welds. 2. PQRs conducted on unlisted base metal to be production welded as required in the referenced welding Code shall be traceable to heat lots. 3. Written WPS required for welds, both shop and field. 4. Notch-tough welding procedures that require heat input control are required for welding pipe and/or crotch plates with thicknesses equal to 7/16-inch or greater. a. AWS D1.1/D1.1M prequalified welding procedures are not allowed. b. WPS used to shop fabricate pipe shall be qualified in accordance with ASME BPVC SEC IX, and shall include Supplementary Essential Variables. c. WPS used to field install pipe shall be qualified for heat input control in accordance with AWS D1.1/D1.1M. d. PQRs shall be qualified for notch tough welding with consideration for thickness of steel, test temperature, and Charpy V-notch CVN values. Refer to AWS D1.1/D1.1M, Table 4.6 PQR Supplementary Essential Variable Changes for CVN Testing Applications Requiring WPS Requalification for SMAW, SAW, GMAW, FCAW, and GTAW, and Section 4, Part D Requirements for CVN Testing, Option A (three specimens). CVN test temperature and acceptance shall be same as pipe base metal specified herein. E. Stulling (Strutting): Design for pipe and fittings such that over-deflection and damage is avoided during handling, storage, shipment, and installation, including backfill and compaction. PART 2 - PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. Steel Pipe, Fittings, and Specials: 1. American Spiral Weld Pipe Company. 2. Northwest Pipe Company. 3. Or approved equal. 2.2 GENERAL A. The pipe shall be of the diameter shown, furnished complete with rubber gaskets or welded joints, as indicated in the Contract Documents, and all specials and bends shall be provided as required under the Contract Documents. For all steel pipe, the inside diameter after lining shall not be less than the nominal diameter indicated. B. Stulling: Adequate stulling(strutting) shall be provided on all specials, fittings, and straight pipe so as to avoid damage to the pipe and fittings during handling, storage, hauling, and installation. In addition, the following requirements shall apply: BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 11 1. The strutting shall be placed as soon as practicable after the mortar lining has been applied and shall remain in place while the pipe is loaded, transported, unloaded, installed and backfilled at the jobsite. 2. The strutting materials, size and spacing shall be adequate to support the earth backfill plus any greater loads which may be imposed by the backfilling and compaction equipment. 3. Any pipe damaged during handling, hauling, storage, or installation due to improper strutting shall be repaired or replaced. 4. The details of the strutting assembly shall be submitted for review by the Engineer prior to the start of pipe manufacture. C. Lining: The pipe lining shall have smooth dense interior surfaces and shall be free from fractures, excessive interior surface cracking and roughness. D. Closures and Correction Pieces: Closures and correction pieces shall be provided as required so that closures may be made due to different headings in the pipe laying operation and so that correction may be made to adjust the pipe laying to conform to pipe stationing shown on the Drawings. Approximate locations of correction pieces and closure assemblies are shown on the Drawings. Any change in location or number of said items shall be submitted for review by the Engineer. 2.3 PIPE BARREL A. Minimum Wall Thickness for Internal Pressure: 1. As calculated below: a. T = (Pw)*(D)/(2*(Y/Sw)) b. T = (Pt)*(D)/(2*(Y/St)) Where: T = Pipe wall thickness, in. D = Outside diameter of pipe, in. Pw = Design working pressures, psi. Pt = Design transient pressure, psi. Y = Specified minimum yield stress of steel, psi. Sw = Safety factor of 2.0 at design working pressure St = Safety factor of 1.5 at design transient pressure 2. Unless otherwise indicated, Pw shall be assumed to equal the indicated pipe pressure class and design transient pressure shall be assumed to equal 1.33*Pw. In no case shall the design stress (Y/Sw) exceed 16,500 psi at design working pressure, Pw, nor shall the design stress (Y/St) exceed 22,000 psi at design transient pressure, Pt. For buried steel pipe, the steel shell thickness shall be no less than No. 10 gauge (0.135 in.) or the nominal pipe diameter divided by 240, whichever is greater, as shown in the following table: Nominal Pipe Diame- ter (in) Minimum Cylinder Thickness (in) 6 0.135 12 0.135 18 0.135 24 0.135 30 0.135 36 0.155 BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 12 Nominal Pipe Diame- ter (in) Minimum Cylinder Thickness (in) 42 0.175 48 0.2 54 0.225 60 0.25 66 0.275 72 0.3 78 0.325 84 0.35 90 0.375 96 0.4 102 0.425 108 0.45 114 0.475 120 0.5 For exposed steel pipe, the steel shell thickness shall be no less than 0.1875 in., or the nominal pipe diameter divided by 140, whichever is greater, as shown in the following table: Nominal Pipe Diame- ter (in) Minimum Cylinder Thickness (in) 6 0.1875 12 0.1875 18 0.1875 24 0.1875 30 0.21 36 0.26 42 0.30 48 0.34 54 0.39 60 0.43 66 0.47 72 0.51 78 0.56 84 0.60 90 0.64 96 0.69 102 0.73 108 0.77 114 0.81 120 0.86 BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 13 B. Minimum Wall Thickness for External Load: Upon determination of minimum wall thickness for internal pressure, deflection of the pipe shall be checked by the following equation: 1. Where ΔX = Horizontal deflection of pipe (in), not to exceed 0.015 times the nominal diameter. DL = Deflection lag factor, 1.25 K = Bedding constant, 0.1 W = Vertical load on pipe, lb/in r = Mean radius of pipe shell, inches EI = Pipe wall stiffness, lb-in E’ = Modulus of soil reaction, lb/in2 = 700 a. For pipe in a trench condition: Wd = Cd*w*Bd2 Where Wd = Earth load, pounds per linear foot Cd = Calculation coefficient, f(Ku’) Ku’ = 0.13 w = Unit weight of soil, 135 lb/ft3 Bd = Trench width at top of pipe, feet. b. For positive projecting embankment condition: Wc = Cc*w*Bc2 Where Wc = Earth load, pounds per linear foot Cc = Calculation coefficient (based on rsd*p = 0.25) Ku’ = 0.013 w = Unit weight of soil, 135 lb/ft3 Bc = Outside diameter of pipe, feet. rsd = Settlement ratio p = Projection ratio. 2. If the calculated deflection exceeds 0.015 times the nominal diameter, the composite pipe section shall be thickened. 2.4 FITTINGS AND SPECIALS A. General: Reinforcement shall be designed for the pressure indicated and shall be in accordance with the Standard Details. Specials and fittings shall be equal in pressure design strength and shall have the same lining and coating as the adjoining pipe. B. Fabrication 1. Shop fabricate. No field fabrication will be allowed, unless approved by Engineer. 2. Fabricate from materials or straight pipe in conformance with specified requirements and dimensions of AWWA C208, unless otherwise indicated. C. Crotch Plate: Fabricate from fully-killed, fine grain, pressure vessel steel conforming to ASTM A516/A516M, Grade 65 or Grade 70, and as follows: BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 14 1. Plates shall be normalized. 2. Perform through-thickness tension testing of plates in accordance with ASTM A770/A770M. 3. Charpy V-notch tests in direction transverse to final rolling shall be performed per ASTM A370 on full size specimens of coupons taken from each plate. Acceptance shall be 25 foot-pounds at 30 degrees F. 4. Pin, if needed for 3-plate design shall be ASTM A350, LF2. D. Wall Thickness: The minimum thickness of plate for pipe from which fittings are to be fabricated shall be the greater of that determined by the following two formulas: 1. T = (Pw)*(D)/(2*(Y/Sw)) 2. T = (Pt)*(D)/(2*(Y/St)) Where T = Pipe wall thickness, in. D = Outside diameter of pipe, in. Pw = Design working pressure, psi. Pt = Design transient pressure, psi. Y = Specified minimum yield stress of steel, psi. Sw = Safety factor of 2.5 at design working pressure. St = Safety factor of 1.88 at design transient pressure. 3. In no case shall the design stress at design working pressure (Y/Sw) for mortar-coated steel pipe exceed 16,500 psi or 22,000 psi at design transient pressure (Y/St), nor shall plate thickness be less than the thickness of adjacent mainline pipe or the following: Diameter (in) Min. Wall Thick- ness (in) 24 and un- der 3/16 25 to 48 1/4 over 48 5/16 E. Outlets: 1. 24 Inches and Smaller: Fabricate from ASTM A53/A53M, Type E or S, Grade B, standard weight steel pipe. 2. Larger than 24 Inches: Fabricate from ASTM A106/A106M, Grade B, standard weight pipe. 3. The design of outlet reinforcement shall be in accordance with the procedures given in Chapter 13 of AWWA Manual M-11, except that the design pressure, P, used in the M-11 procedure shall equal the greater of 1.25 Pw or 0.9375 Pt. Unless otherwise indicated, outlets 2 inches in diameter and smaller need not be reinforced. a. In lieu of saddle or wrapper reinforcement as required by the design procedure in Manual M-11, pipe or specials with outlets may be fabricated in their entirety of steel plate having a thickness equal to the sum of the pipe wall plus the required reinforcement. 2.5 JOINTS A. Shop Welded: 1. Fabricate in accordance with AWWA C200 as modified herein. 2. Complete joint penetration (CJP) butt joints shall be used for longitudinal, girth, and spiral welds, unless otherwise indicated. BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 15 3. Length of pipe shall not be shop joined using lap joints. B. Field Joints: 1. The standard field joint for steel pipe shall be a single welded lap joint for buried service and a flanged joint per AWWA C207 on pipe above grade or exposed in a vault. Mechanically coupled, or flanged joints shall be required where shown. Butt-strap joints shall be used only where required for closures or where shown. The joints furnished shall have a pressure rating equal to or higher than the abutting pipe. 2. Lap Joints: Lap joints prepared for field welding shall be in accordance with AWWA C200. The method used to form, shape, and size bell ends shall be such that the physical properties of the steel are not substantially altered. Unless otherwise approved by the Engineer, bell ends shall be formed by an expanding press or by being moved axially over a die in such a manner as to stretch the steel plate beyond its elastic limit to form a truly round bell of suitable diameter and shape. No process will be permitted in which the bell is formed by rolling. Faying surfaces of the bell and spigot shall be essentially parallel, but in no case shall the bell slope vary more than 2 degrees from the longitudinal axis of the pipe. a. For pipe 30 inches in diameter and larger, provide one of the following: 1) Tack weld four metal tabs at equal intervals around inside circumference of bell ends to indicate location at which spigot end has reached maximum penetration into bell. Remove stops after welding of joint. 2) Paint a 3/4-inch-wide white stripe on outside of circumference of spigot end of pipe. Side of stripe furthest from pipe end shall indicate location at which spigot end has reached maximum penetration into bell. Side of stripe closest to end of pipe will indicate limit of maximum joint pull. 3. Butt Joint Welded: a. Plain ends beveled as required by AWWA C200 and Contractor’s field WPS. b. Provide protection for factory beveled pipe ends so ends are not damaged during transport. 4. Restrained Joints: Where indicated, restrained joints shall be field-welded joints. Designs shall include considerations of stresses induced in the steel cylinder, the joint rings, and any field welds, caused by thrust at bulkheads, bends, reducers, and line valves resulting from the design working pressure. For field welded joints, design stresses shall not exceed 50 percent of the indicated minimum yield strength of the grade of steel utilized, or 16,500 psi, whichever is less, for the part being examined when longitudinal thrust is assumed to be uniformly distributed around the circumference of the joint. At the Contractor's option, the steel cylinder area may be progressively reduced from the point of maximum thrust to the end of the restrained length. All joints to be field welded for thrust restraint shall have the joint rings attached to the cylinder with double fillet welds. 2.6 PIPE APPURTENANCES A. Pipe appurtenances shall be in accordance with the requirements under Division 40 of these specifications. 2.7 STULLING A. Materials: 1. Shop-Lined Pipe: Wood stulls and wedges. 2. Unlined Pipe: Steel or Wood. BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 16 B. Install stulling for pipe and fittings in accordance with approved submittal as soon as practical after pipe is fabricated or, for shop-lined pipe, after lining has been applied. C. Install stulling in a manner that will not harm lining. 2.8 CEMENT MORTAR LINING A. Cement-Mortar Lining for Shop Application: Except as otherwise required, interior surfaces of all steel pipe, fittings, and specials shall be cleaned and lined in the shop with cement-mortar lining applied centrifugally in conformity with ANSI/AWWA C205. During the lining operation and thereafter, the pipe shall be maintained in a round condition by suitable bracing or strutting. The lining machines shall be of a type that has been used successfully for similar work. Every precaution shall be taken to prevent damage to the lining. If lining is damaged or found faulty at delivery site, the damaged or unsatisfactory portions shall be replaced with lining conforming to these Specifications at no additional cost to the Owner. B. The minimum lining thickness and tolerances shall be as provided in ANSI/AWWA C205. C. The pipe shall be left bare where field joints occur as indicated. Ends of the linings shall be left square and uniform. Feathered or uneven edges will not be permitted. D. Defective linings, as determined by the Engineer, shall be removed from the pipe wall and shall be replaced to the full thickness required. Defective linings shall be cut back to a square shoulder in order to avoid feather edged joints. E. The progress of the application of mortar lining shall be regulated in order that all hand work, including the repair of defective areas is cured in accordance with the provisions of ANSI/AWWA C205. Cement-mortar for patching shall be the same materials as the mortar for machine lining, except that a finer grading of sand and mortar richer in cement shall be used when field inspection indicates that such mix will improve the finished lining of the pipe. F. Cement-Mortar Lining for Field Application: The materials and design of in-place cement- mortar lining shall be in accordance with ANSI/AWWA C602 and the following supplementary requirements. 1. Portland cement shall conform to Type II, ASTM C 150. 2. Pozzolanic material shall not be used in the mortar mix. 3. Admixtures shall contain no calcium chloride. 4. The minimum lining thickness shall be as indicated for shop-applied cement-mortar lining and the finished inside diameter after lining shall be as shown. G. Specials and fittings that cannot be mechanically lined shall be lined by hand application using the same materials as are used for the pipe and in accordance with applicable ANSI/AWWA C602 Standards. Lining applied in this manner shall provide protection equal to that indicated for the pipe. H. Protection of Pipe Lining/Interior: For all pipe and fittings with cement-mortar linings, the Contractor shall provide a polyethylene or other suitable bulkhead on the ends of the pipe and on all special openings to prevent drying out of the lining. All bulkheads shall be substantial enough to remain intact during shipping and storage until the pipe is installed. BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 17 2.9 GALVANIZED STEEL PIPE AND MALLEABLE IRON FITTINGS A. Pipe: 1. Galvanized carbon steel, ASTM A106, Grade B seamless or ASTM A53, Grade B seamless or ERW. 2. 2" and smaller: Schedule 80. B. Joints: 1. 2" and smaller: Threaded or flanged at valves and equipment, or grooved end meeting requirements of AWWA C606. C. Fittings: 1. Threaded: 150- or 300-pound malleable iron, ASTM A197 or ASTM A47, dimensions in accordance with ASME B16.3. 2. Grooved End: Malleable iron ASTM A47 or ductile iron ASTM A536, 250 psi working pressure, grooved ends to accept couplings without field preparation. Victaulic; Anvil International, Inc., Gruvlok. D. Branch Connections: 1. 2" and smaller: Tee or reducing tee in conformance with Fittings above, galvanized 2,000-pound WOG threadolet or welding boss; galvanize after welding. E. Flanges: 1. Galvanized forged carbon steel, ASTM A105/A105M, ASME B16.5 Class 150 or Class 300, threaded, 1/16-inch raised face. 2. Grooved end adapter flange, malleable iron ASTM A47 or ductile iron ASTM A536. Victaulic; Anvil International, Inc., Gruvlok. F. Unions: 1. Threaded malleable iron, ASTM A197 or ASTM A47, 300-pound WOG, brass to iron seat, meeting the requirements of ASME B16.3. G. Couplings: 1. Grooved End: Rigid joint malleable iron, ASTM A47 or ductile iron, ASTM A536, 250 psi working pressure. Victaulic; Anvil International, Inc., Gruvlok. H. Plugs: 1. Forged carbon steel, ASTM A181/A181M, Grade II, round head, threaded, galvanized. I. Bolting: 1. Grooved End Couplings: Carbon steel, ASTM A183 bolts and nuts, 110,000 psi minimum tensile strength. 2. Flanges: Carbon steel ASTM A307, Grade A hex head bolts and ASTM A563, Grade A hex head nuts. J. Gaskets: 1. All flanges a. Flanged, Water and Sewage Service: 1/8-inch thick, homogeneous black rubber (EPDM), hardness 60 (Shore A), rated to 250 degrees F. continuous and conforming to ASME B16.21 and ASTM D1330, Steam Grade. BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 18 b. Blind flanges shall be gasketed covering entire inside face with gasket cemented to blind flange. 2. Grooved end couplings a. EPDM or chlorinated butyl per ASTM D2000 for water, and air to 230 degrees F, dimensions conforming to AWWA C606. K. Thread Lubricant: 1. 2" and smaller: Teflon tape or joint compound that is insoluble in water. 2.10 FINISHES A. Coat machined faces of flanges with temporary rust-inhibitive coating. B. Exterior Coating of Exposed Piping: Exposed steel piping shall be coated per Section 09 96 00 – High Performance Coatings. C. Exterior Coating of Buried Piping: Buried piping shall have a polyurethane coating in accordance with AWWA C222. 1. Polyurethane coating shall be ASTM D16 Type V, 100 percent solids, two-component rigid type and shall be applied to a minimum 25 mils DFT. The coating shall have a tension adhesion (ASTM D4541) greater than 1,500 psi and an impact resistance (ASTM D2794) greater than 40 pounds. 2. The coating shall be applied by an applicator that shall have been certified by the coating Manufacturer in the use and application of this coating system. 3. Field joint connections shall be coated by means of a slip-on type heat shrink sleeve method to provide protection of the joint and shall be approved by coating Manufacturer. 4. All repairs shall be completed in accordance with coating Manufacturer’s approved materials and procedures. a. Surface preparation and prime coat shall be as recommended by coating manufacturer. D. Exterior Field Joint Coating for Buried Piping: 1. Pipe joints shall be field coated after pipe assembly in accordance with AWWA C216 for open-cut pipelines. 2. Field joint coating shall be compatible with the shop-applied coating system and provided by the same manufacturer or a manufacturer approved by the pipe coating manufacturer. 3. All joints on pipe 24 inches in diameter or greater shall be coated with a heat shrink coating material. 4. Field joint coating materials shall be as follows or an approved equal. a. Heat Shrink Sleeves: 1) Filler Material: a) Provide filler material for all push-on, flange, and coupling type joints and at all changes in outside diameter greater than 1/8 inch. b) Filler material shall adhere to the pipe and heat shrink sleeve. Size and type shall be as recommended by the sleeve manufacturer for type of pipe and joint. c) Filler mastic for joints subject to weld after backfill shall exceed 500 degree F melt point temperature. d) Filler material shall be applied in a manner and thickness that no tenting or voids remain under the heat shrink sleeve. e) Filler material shall be Polyken 939 filler. BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 19 2) Joint Coating: a) Heat shrink, cross-linked polyolefin wrap or sleeve with a mastic sealant, 85-mil nominal thickness, suitable for pipeline operating temperature, as recommended by the manufacturer. b) Provide standard recovery sleeve for welded or bell and spigot steel pipe joints. High recovery sleeves shall be provided for flange joints and coupling style joints. c) Width of heat shrink sleeves shall overlap existing coating 2 inches minimum. d) Consider sleeve shrinkage during installation and joint profile in determining sleeve width required. Overlapping of two or more heat shrink sleeves to achieve the necessary width on pipe joints will not be permitted without Engineer acceptance. 3) Holdback Primer: Inorganic zinc primer. 4) Heat Shrink Outer Sleeve: SFL Covalence WaterWrap. 2.11 SOURCE QUALITY CONTROL A. Section 01 40 00 - Quality Requirements: Requirements for testing, inspection, and analysis. B. Inspection: All pipe shall be subject to inspection at the place of manufacture in accordance with the provisions of ANSI/AWWA C200 and C205, as supplemented by the requirements herein. The Contractor shall notify the Engineer in writing of the manufacturing starting date not less than 14 calendar days prior to the start of any phase of the pipe manufacture. C. Tests: Except as modified herein, all materials used in the manufacture of the pipe shall be tested in accordance with the requirements of ANSI/AWWA C200 and C205, as applicable. 1. Shop testing of steel pipe: a. After the joint configuration is completed and prior to lining with cement-mortar, each length of pipe of each diameter and pressure class shall be shop-tested and certified to a pressure of at least 80 percent of the yield strength of the pipe steel. b. Production weld tests shall be conducted in compliance with ANSI/AWWA C200. In addition to the frequency of tests required in ANSI/AWWA C200, weld tests shall be conducted on each 5,000 feet of production welds and at any other times there is a change in the welding procedure or welding equipment. 2. Shop testing of steel plate special: a. Upon completion of the welding, but prior to lining and coating, each steel plate special shall be bulk-headed and tested under a hydrostatic pressure of 1-1/2 times the design pressure; provided, that if straight pipe used in fabricating the specials has been previously tested and meets the requirements of the applicable piping Section, no further hydrostatic testing will be required; or provided, that all other welded seams are tested by the liquid penetrant inspection procedure conforming to ASTM E 165, under Method "B" and "Leak Testing" or where applicable by the soap and compressed air method at an air pressure of 25 psi. Any pin holes or porous welds which may be revealed by the test shall be chipped out and rewelded and the pipe or fitting retested. b. No outside coating shall be applied over a seam prior to testing; however, mortar lining may be applied over a seam prior to hydrostatic testing, but under such conditions said pressure test shall be held on the pipe or fitting for a period of not less than 30 minutes. BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 20 D. The Contractor shall perform said material tests at no additional cost to the Owner. The Engineer may witness testing, at his expense, conducted by the Contractor; provided, that the Contractor’s schedule is not delayed for the convenience of the Engineer. E. Welding Requirements: All welding procedures used to fabricate pipe shall be prequalified under the provisions of ANSI/AWS D1.1. Welding procedures shall be required for, but not necessarily limited to, longitudinal and girth or spiral welds for pipe cylinders, spigot and bell ring attachments, reinforcing plates and ring flange welds, and plates for lug connections. F. Welder Qualifications: All welding shall be done by skilled welders, welding operators, and tackers who have had adequate experience in the methods and materials to be used. Welders shall be qualified under the provisions of ANSI/AWS D1.1 by an independent local, approved testing agency not more than 6 months prior to commencing work on the pipeline. Machines and electrodes similar to those used in the Work shall be used in qualification tests. The Contractor shall furnish all material and bear the expense of qualifying welders. PART 3 - EXECUTION 3.1 INSTALLATION OF PIPE A. Install in accordance with Section 40 05 00 – Common Requirements for Process Piping, and modified herein. B. Immediately before placing each section of pipe in final position for jointing, the bedding for the pipe shall be checked for firmness and uniformity of surface. When the pipe is being laid, it shall be turned and placed where possible, so that any slightly damaged portion will be on top. The damaged area shall be repaired for the protection of any exposed steel. All damaged areas shall be repaired using materials and methods acceptable to the Engineer. C. Moderate deflections and long radius curves may be made by means of beveled joint rings, by pulling standard joints, by using short lengths or pipe, or a combination of these methods; provided that pulled joints shall not be used in combination with bevels. The maximum total allowable angle for beveled joints shall be 5 degrees per pipe joint. Bevels shall be provided on the bell ends. Mitering of the spigot ends will not be permitted. The maximum allowable angle for pulled joints shall be in accordance with the manufacturer's recommendations or the angle which results from a 3/4-inch pull out from normal joint closure, whichever is less. All horizontal deflections or fabricated angles shall fall on the alignment. In locations where underground obstructions may be encountered, the chord produced by deflecting the pipe shall be no further than 6 inches from the alignment indicated. D. All vertical deflections shall fall on the alignment and at locations adjacent to underground obstructions, points of minimum earth cover, and pipeline outlets and structures. The pipe angle points shall match the angle points indicated. E. For pipe 42 inches in diameter and larger, pipe struts shall be left in place until backfilling operations have been completed. Struts in pipe smaller than 42 inches may be removed immediately after laying, provided, that the deflection of the pipe during and after backfilling does not exceed that indicated. After the backfill has been placed, the struts shall be removed and shall remain the property of the Contractor. BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 21 F. The openings of all pipe and specials where the pipe and specials have been cement-mortar lined in the shop shall be protected with suitable bulkheads to maintain a moist atmosphere and to prevent unauthorized access by persons, animals, water or any undesirable substance. The bulkheads shall be so designed to prevent drying out of the interior of the pipe. The Contractor shall introduce water into the pipe to keep the mortar moist where moisture has been lost due to damaged bulkheads. 3.2 WELDED JOINTS A. General: Field welded joints shall be in accordance with ANSI/AWWA C206, AWS D1.1/D1.1M, approved welding procedures, and referenced welding codes. In case of conflict, AWS D1.1/D1.1M shall govern. B. Where exterior welds are performed, adequate space shall be provided for welding and inspection of the joints. C. During installation of welded steel pipe in either straight alignment or on curves, the pipe shall be laid so that the lap joint clearance, at any point around the circumference of the joint, shall comply with the requirements of AWWA C206. Unless double fillet welds are indicated, field welded lap joints may, at the Contractor’s option, be made on either the inside or the outside of the pipe. D. Butt straps, where used or required, shall be a minimum of 6 inches wide, the same thickness as the pipe wall and shall provide for a minimum of 2-inch lap at each pipe joint. The pipe ends shall be cut straight on joints where butt straps are used for realignment, adjustment, or deflection, and fillet welds shall be made as indicated. E. After the pipe and pipe joint are properly positioned in the trench, the length of pipe between joints shall be backfilled to at least one foot above the top of the pipe. Care shall be exercised during the initial backfilling to prevent movement of the pipe and to prevent any backfill material from being deposited on the joint. F. To control temperature stresses, the un-backfilled joint areas of the pipe shall be shaded from the direct rays of the sun by the use of properly supported awnings, umbrellas, tarpaulins, or other suitable materials for a minimum period of 2 hours prior to the beginning of the welding operation and until the weld has been completed. Shading materials at the joint area shall not rest directly on the pipe but shall be supported to allow air circulation around the pipe. Shading of the pipe joints need not be performed when the ambient air temperature is below 45 degrees F. G. Prior to the beginning of the welding procedure, any tack welds used to position the pipe during laying shall be removed. Any annular space between the faying surfaces of the bell and spigot shall be equally distributed around the circumference of the joint by shimming, jacking, or other suitable means. The weld shall then be made in accordance with ANSI/AWWA C206. Where more than one pass is required, each pass except the first and final one shall be peened to relieve shrinkage stresses; and all dirt, slag, and flux shall be removed before the succeeding bead is applied. H. As soon as practicable after welding of each joint, all field-welded joints shall be tested by the liquid penetrant inspection procedure conforming to the requirements of ANSI/ASTM E 165 BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 22 under Method "B" and "Leak Testing." All defects shall be chipped out, rewelded and retested. Upon retest, the repaired area shall show no leaks or other defects. I. Following tests of the joint, the exterior joint spaces shall be coated in accordance with these specifications after which backfilling may be completed. J. Interior of welded joints shall be coated according to the requirements of ANSI/AWWA C602. 3.3 FLANGED JOINTS A. General: Install in accordance with Section 40 05 00 – Common Requirements for Process Piping. B. Before the joint is assembled, the flange faces shall be thoroughly cleaned of all foreign material with a power wire brush. The gasket shall be centered, and the connecting flanges drawn up watertight without unnecessarily stressing the flanges. All bolts shall be tightened in a progressively diametrically opposite sequence and torqued with a suitable, approved, and calibrated torque wrench. All clamping torque shall be applied to the nuts, only. 3.4 COATING AND LINING A. General: Inspect shop applied linings and coatings upon delivery of materials and following installation. 1. Damaged cement mortar lining shall be repaired according to AWWA C602. 2. Damaged coatings shall be repaired according to Section 09 96 00, High Performance Coatings and pipe manufacturer’s recommendations. B. Cement-Mortar Lining, Field-Applied: For pipe diameters of 60-IN or larger, the Contractor may construct the cement-mortar lining in-place. The application of in-place cement-mortar lining shall be in accordance with ANSI/AWWA C602. 1. The lining machine shall be of a type that has been used successfully for a similar size of pipe. The Contractor shall perform all work in a thorough and workmanlike manner by trained personnel, under the supervision of experienced personnel skilled in machine application of cement-mortar lining to pipelines of size comparable to this work. 2. Curing of the in-place cement-mortar lining shall be in accordance with ANSI/AWWA C602. The Contractor shall provide additional protective devices as required to ensure that the airtight covers, which maintain a moist condition in the pipeline, are not damaged. 3. Defective areas encompassing the full diameter of the pipe shall be replaced by machine wherever the length measured along the pipe centerline is greater than 5 feet; otherwise, defective areas may be replaced by hand. C. Field Coating Joints: 1. Remove all oil or grease contamination by solvent wiping the pipe and adjacent coating in accordance with SSPC-SP1, Solvent cleaning. 2. Clean pipe surface and adjacent coating of all mud, corrosion, and other foreign contaminates in accordance with SSPC-SP11, Power Tool Cleaning to Bare Metal or abrasive blast joints in accordance with SSPC-SP10, near white metal blast, that exhibit any surface corrosion or staining. When required, clean the full circumference of the pipe and a minimum of 6 inches onto the existing coating. BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 23 3. Remove all loose or damaged pipe coating at joint and either repair the coating as specified herein or increase the length of the joint coating, where reasonable and practical. 4. Complete joint bonding of pipe joints before application of joint coating. Joint bonds shall be low profile bonds and all gaps and crevices around the bonds shall be filled with mastic sealant. 5. Contractor to electrically test completed joint coating for holidays with high voltage spark tester. D. Heat Shrink Sleeve Joint Coating: 1. Store, handle, and apply field heat shrink sleeve coatings in accordance with AWWA C216 and this Section. 2. Store sleeves in shipping box until use is required. Keep dry and sheltered from exposure to direct sunlight. Store off the ground or concrete floors and maintain at a temperature between 60 and 100 degrees as recommended by the sleeve manufacturer. 3. Metal surface shall be free of all dirt, dust, and surface corrosion prior to sleeve application. Surface preparation shall be in accordance with the joint coating manufacturer’s recommendations. 4. Where corrosion in the holdback area is visible, surfaces shall be prepared in accordance with SSPC-SP10, near white metal blast, or SSPC-SP11, power tool cleaning to bare metal. 5. Preheat pipe uniformly as recommended by the sleeve manufacturer. Monitor pipe temperature using a surface temperature gauge, infrared thermometer, or color changing crayons. Protect preheated pipe from rain, snow, frost, or moisture with tenting or shields and do not permit the joint to cool. 6. Fill all cracks, crevices, gaps, and step-downs greater than 1/4 inch with filler mastic in accordance with the manufacturer’s recommendations for the full circumference of the pipe. 7. Apply heat shrink sleeve when it is at a minimum temperature of 60 degrees and while maintaining the pipe temperature above the preheat temperature specified. Apply sleeve in accordance with the manufacturer’s instructions and center the sleeve over the joint to provide a minimum 2-inch overlap onto the existing pipe coating. 8. Completed joint sleeve shall be fully bonded to the pipe and existing coating surface without voids. Mastic beading shall be visible along the full circumference of the sleeve. There shall be no wrinkling or excessive burns on the sleeves. Sleeves that do not meet these requirements shall be removed and the joint recoated as directed by the Engineer. Minor repairs may be repaired using heat applied patch material specified for minor coating repairs. 9. Allow the sleeve to cool before backfilling. In hot climates, provide shading from direct sunlight. Water quenching will be allowed only when permitted by the sleeve manufacturer. 10. Heat shrink joint coatings which have become wrinkled or disbonded because of prolonged exposure to UV light or thermal cycling shall be removed and replaced. 11. Double coating of defective or damaged heat shrink coatings will not be permitted. Any double coated heat shrink sleeves shall be immediately rejected and Contractor shall remove and recoat the joint. 3.5 INSTALLATION OF PIPE APPURTENANCES A. Install in accordance with Section 40 05 00 – Common Requirements for Process Piping, Section 40 05 06 - Coupling, Adapters, and Specials for Process Piping, and Section 40 05 51 – Common Requirements for Process Valves, and modified herein. BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 24 B. Protection of Appurtenances: Where the joining pipe is concrete or coated with cement mortar, buried appurtenances shall be coated with a minimum thickness of one-inch of cement mortar having one-part cement to not more than 2 parts plaster sand. Following coating with cement mortar, the appurtenances shall be encased in polyethylene in accordance with AWWA C105. C. Installation of Valves: All valves shall be handled in a manner to prevent any injury or damage to any part of the valve. All joints shall be thoroughly cleaned and prepared prior to installation. The Contractor shall adjust all stem packing and operate each valve prior to installation to insure proper operation. D. All buried valves shall be coated and protected in accordance with Section 40 05 51 – Common Requirements for Process Valves and Section 09 96 00 – High-Performance Coatings. E. All valves shall be installed so that the valve stems are plumb and in the location indicated. F. All buried flanges shall be coated and protected in accordance with Section 09 96 00 – High- Performance Coatings. G. Insulated Joints: Insulated joints and appurtenant features shall be made by the Contractor as specified or shown on the Drawings. The Contractor shall exercise special care when installing these joints to prevent electrical conductivity across the joint. After the insulated joint is completed, an electrical resistance test will be performed by the Owner. Should the resistance test indicate a short circuit, the Contractor shall remove the insulating units to inspect for damage, replace all damaged portions, and reassemble the insulating joint. The insulated joint shall then be retested to assure proper insulation. H. Flexible Coupled Joints: When installing flexible couplings, care shall be taken that the connecting pipe ends, couplings, and gaskets are clean and free of all dirt and foreign matter with special attention being given to the contact surfaces of the pipe, gaskets and couplings. The couplings shall be assembled and installed in conformity with the recommendation and instruction of the coupling manufacturer. I. Wrenches used in bolting couplings shall be of a type and size recommended by the coupling manufacturer. Coupling bolts shall be tightened in a manner to secure a uniform annular space between the follower rings and the body of the pipe with all bolts tightened approximately the same amount. Diametrically opposite bolts shall be tightened progressively and evenly. Final tightening shall be done with a suitable, approved, and calibrated torque wrench set for the torque recommended by the coupling manufacturer. All clamping torque shall be applied to the nut only. J. Upon completion of the coupled joint, the coupling and bare metal of the pipe shall be cleaned, primed, and protected in accordance with the requirements of this section and Section 09 96 00 – High-Performance Coatings. K. Bonding and Electrical Conductivity: All unwelded pipe joints shall be bonded for electrical conductivity in accordance with the details indicated and specified. BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 25 3.6 CORROSION CONTROL A. Joint Bonding: Except where indicated otherwise, all joints shall be bonded in accordance with the specifications and details indicated. The pipe shall be cleaned to bare bright metal at the point where the bond is installed. The pipe manufacturer shall be responsible for determining and implementing a suitable procedure and schedule for installation of bonding—field versus factory versus combination—in manner that the corrosion resistance of the lining and coating is not degraded by the bonding process. It may involve welding the bonding wires in the factory before applying the lining and coating specified and/or may involve patching impaired areas in the factory or the field. 3.7 FIELD QUALITY CONTROL A. Field Welding: 1. All welds, 100 percent inspection, shall be VT inspected by Contractor’s Field Inspector and marked to indicate acceptance or rejection. 2. Test butt-strap or double-welded lap joint welds by pressurizing connection between the two fillet welds in accordance with AWWA C206. a. Apply air or other Engineer-approved gas into connection between the two fillet welds. b. Paint welds with soap solution. c. Mark leaks indicated by escaping gas bubbles. d. Close threaded openings with flush pipe plugs or by welding them. 3. CJP Welds: a. Inspect 25 percent of butt joint welds with full circumference RT. b. Inspect 25 percent of other groove welds with UT. 4. Inspect 10 percent of lap joint welds with PT or MT. 5. Weld Acceptance: a. If, in the opinion of Engineer, inspections indicate inadequate quality of welds, percentage of welds inspected shall be increased. b. Welds to be inspected, if less than 100 percent rate, shall be selected at random by Engineer. c. VT: Perform VT per AWS D1.1/D1.1M Paragraph 6.9, Visual Inspection, Statically Loaded Nontubular Connections. d. UT: Perform UT of CJP groove welds in accordance with AWS D1.1/D1.1M, Paragraph 6.13.1. e. RT: Perform RT of CJP butt joint welds in accordance with AWS D1.1/D1.1M, Paragraph 6.12.1. f. PT or MT: 1) Perform on fillet and PJP groove welds in accordance with AWS D1.1/D1.1M, Paragraph 6.10. 2) Acceptance shall be in accordance with VT standards specified above. g. Remove in manner that permits proper and complete repair by welding. h. Caulking or peening of defective welds is not permitted. i. Retest unsatisfactory welds. 6. Verification Acceptance: Owner or Engineer may conduct random nondestructive inspections of field-welded joints. Inspections will be of an appropriate type for weld being evaluated. Possible types of inspection include, but are not limited to, RT, UT, PT, and VT. Testing will be performed and evaluated per AWS D1.1/D1.1M. Provide Owner’s Verification Inspector access to the Work. BCRUA - Phase 1D WTP Expansion Issued for Bid Steel Process Pipe 40 05 24 - 26 END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Thermoplastic Process Pipe 40 05 31 - 1 SECTION 40 05 31 - THERMOPLASTIC PROCESS PIPE PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. PVC pipe. 2. PVC tube. 3. Polyethylene (PE) tube. 4. Fittings. 5. Accessories for plastic piping. B. Related Requirements: 1. Section 40 05 00 – Common Requirements for Process Piping. 2. Section 40 05 06 – Couplings, Adapters, and Specials for Process Piping: Pipe penetrations, restrained joints, flexible connections, expansion joints and loops, and sleeve-type couplings. 3. Section 40 05 40 – Process Piping Leakage Testing and Disinfection. 4. Section 40 05 51 – Common Requirements for Process Valves: Common product requirements for valves for placement by this Section. 1.2 REFERENCE STANDARDS A. American Water Works Association: 1. AWWA C111 - Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings. 2. AWWA C900 - Polyvinyl Chloride (PVC) Pressure Pipe and Fabricated Fittings, 4 In. through 12 In., for Water Transmission and Distribution. 3. AWWA C901 - Polyethylene (PE) Pressure Pipe and Tubing, 1/2 In. (13 mm) through 3 In. (76 mm), for Water Service. 4. AWWA C906 - Polyethylene (PE) Pressure Pipe and Fittings, 4 In. (100 mm) through 63 In. (1,600 mm), for Water Distribution and Transmission. B. ASME International: 1. ASME B1.1 - Unified Inch Screw Threads (UN and UNR Thread Form). 2. ASME B1.20.1 - Pipe Threads, General Purpose (Inch. 3. ASME B1.20.2M - Pipe Threads, 60 deg., General Purpose. 4. ASME B16.1 - Cast Iron Pipe Flanges and Flanged Fittings, Classes 25, 125, 250 and 800. 5. ASME B16.5 - Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24 Metric/Inch Standard. 6. ASME B16.20 - Metallic Gaskets for Pipe Flanges: Ring-Joint, Spiral-Wound, and Jacketed. 7. ASME B16.21 - Nonmetallic Flat Gaskets for Pipe Flanges. 8. ASME B31.3 - Process Piping. C. ASTM International: 1. ASTM A193/A193M - Standard Specification for Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications. BCRUA - Phase 1D WTP Expansion Issued for Bid Thermoplastic Process Pipe 40 05 31 - 2 2. ASTM A194/A194M -Standard Specification for Carbon Steel, Alloy Steel, and Stainless Steel Nuts for Bolts for High Pressure or High Temperature Service, or Both. 3. ASTM D1784 - Standard Specification for Rigid Poly(Vinyl Chloride) (PVC) Compounds and Chlorinated Poly(Vinyl Chloride) (CPVC) Compounds. 4. ASTM D1785 - Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40, 80, and 120. 5. ASTM D2235 - Standard Specification for Solvent Cement for Acrylonitrile-Butadiene- Styrene (ABS) Plastic Pipe and Fittings. 6. ASTM D2241 - Standard Specification for Poly(Vinyl Chloride) (PVC) Pressure-Rated Pipe (SDR Series). 7. ASTM D2447 - Standard Specification for Polyethylene (PE) Plastic Pipe, Schedules 40 and 80, Based on Outside Diameter. 8. ASTM D2464 - Standard Specification for Threaded Poly(Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 80. 9. ASTM D2466 - Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 40. 10. ASTM D2467 - Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 80. 11. ASTM D2564 - Standard Specification for Solvent Cements for Poly(Vinyl Chloride) (PVC) Plastic Piping Systems. 12. ASTM D2609 - Standard Specification for Plastic Insert Fittings for Polyethylene (PE) Plastic Pipe. 13. ASTM D2657 - Standard Practice for Heat Fusion Joining of Polyolefin Pipe and Fittings. 14. ASTM D2661 - Standard Specification for Acrylonitrile-Butadiene-Styrene (ABS) Schedule 40 Plastic Drain, Waste, and Vent Pipe and Fittings. 15. ASTM D2683 - Standard Specification for Socket-Type Polyethylene Fittings for Outside Diameter-Controlled Polyethylene Pipe and Tubing. 16. ASTM D2737 - Standard Specification for Polyethylene (PE) Plastic Tubing. 17. ASTM D2837 - Standard Test Method for Obtaining Hydrostatic Design Basis for Thermoplastic Pipe Materials or Pressure Design Basis for Thermoplastic Pipe Products. 18. ASTM D2855 - Standard Practice for Making Solvent-Cemented Joints with Poly(Vinyl Chloride) (PVC) Pipe and Fittings. 19. ASTM D3035 - Standard Specification for Polyethylene (PE) Plastic Pipe (DR-PR) Based on Controlled Outside Diameter. 20. ASTM D3139 - Standard Specification for Joints for Plastic Pressure Pipes Using Flexible Elastomeric Seals. 21. ASTM D3222 - Standard Specification for Unmodified Poly(Vinylidene Fluoride) (PVDF) Molding Extrusion and Coating Materials. 22. ASTM D3261 - Standard Specification for Butt Heat Fusion Polyethylene (PE) Plastic Fittings for Polyethylene (PE) Plastic Pipe and Tubing. 23. ASTM D3350 - Standard Specification for Polyethylene Plastics Pipe and Fittings Materials. 24. ASTM D3892 - Standard Practice for Packaging/Packing of Plastics. 25. ASTM D3965 - Standard Classification System and Basis for Specifications for Rigid Acrylonitrile-Butadiene-Styrene (ABS) Materials for Pipe and Fittings. 26. ASTM F402 - Standard Practice for Safe Handling of Solvent Cements, Primers, and Cleaners Used for Joining Thermoplastic Pipe and Fittings. 27. ASTM F437 - Standard Specification for Threaded Chlorinated Poly(Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Schedule 80. BCRUA - Phase 1D WTP Expansion Issued for Bid Thermoplastic Process Pipe 40 05 31 - 3 28. ASTMF438 - Standard Specification for Socket-Type Chlorinated Poly(Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Schedule 40. 29. ASTM F439 - Standard Specification for Chlorinated Poly (Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Schedule 80. 30. ASTM F441/F441M - Standard Specification for Chlorinated Poly(Vinyl Chloride) (CPVC) Plastic Pipe, Schedules 40 and 80. 31. ASTM F442/F442M - Standard Specification for Chlorinated Poly(Vinyl Chloride) (CPVC) Plastic Pipe (SDR-PR). 32. ASTM F477 - Standard Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe. 33. ASTM F493 - Standard Specification for Solvent Cements for Chlorinated Poly(Vinyl Chloride) (CPVC) Plastic Pipe and Fittings. 34. ASTM F593 - Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs. 35. ASTM F656 - Standard Specification for Primers for Use in Solvent Cement Joints of Poly(Vinyl Chloride) (PVC) Plastic Pipe and Fittings. 36. ASTM F714 - Standard Specification for Polyethylene (PE) Plastic Pipe (DR-PR) Based on Outside Diameter. 37. ASTM F876 - Standard Specification for Crosslinked Polyethylene (PEX) Tubing. 38. ASTM F1055 - Standard Specification for Electrofusion Type Polyethylene Fittings for Outside Diameter Controlled Polyethylene and Crosslinked Polyethylene (PEX) Pipe and Tubing. 39. ASTM F1056 - Standard Specification for Socket Fusion Tools for Use in Socket Fusion Joining Polyethylene Pipe or Tubing and Fittings. 40. ASTM F1290 - Standard Practice for Electrofusion Joining Polyolefin Pipe and Fittings. D. NSF International: 1. NSF 61 - Drinking Water System Components - Health Effects. 1.3 COORDINATION A. Section 01 30 00 – Administrative Requirements: Requirements for coordination. 1.4 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Section 40 05 00 – Common Requirements for Process Piping subsection for Submittals. C. Product Data: Submit manufacturer's information on pipe materials and fittings, including technical data and installation instructions. D. Shop Drawings: Indicate layout of piping systems, including equipment, critical dimensions, sizes, and materials lists. E. Test Reports: 1. Hydrostatic testing. F. Manufacturer's Certificate: Certify that products meet or exceed specified requirements. BCRUA - Phase 1D WTP Expansion Issued for Bid Thermoplastic Process Pipe 40 05 31 - 4 G. Field Quality-Control Submittals: Indicate results of Contractor-furnished tests and inspections. 1.5 CLOSEOUT SUBMITTALS A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for submittals. B. Project Record Documents: Record actual locations of piping, valves and other appurtenances, connections, and centerline elevations. C. Identify and describe unexpected variations to subsoil conditions or discovery of uncharted utilities. 1.6 QUALITY ASSURANCE A. Section 40 05 00 – Common Requirements for Process Piping: Requirements of subsection for Quality Assurance. B. Permanently mark each length of pipe with manufacturer's name or trademark and indicate conformance to standards. C. Materials in Contact with Potable Water: Certified according to NSF 61. 1.7 QUALIFICATIONS A. Manufacturer: Company specializing in manufacturing products specified in this Section with minimum ten years’ experience. B. Installer: Company specializing in performing Work of this Section with minimum three years’ experience and approved by manufacturer 1.8 DELIVERY, STORAGE, AND HANDLING A. Section 01 60 00 – Product Requirements: Requirements for transporting, handling, storing, and protecting products. B. Section 40 05 00 – Common Requirements for Process Piping: Requirements of subsection for Delivery, Storage, and Handling C. Inspection: 1. Accept materials on Site in manufacturer’s original packaging and inspect for damage. 2. Manufacturer’s Packaging: Comply with ASTM D3892. D. Store materials according to manufacturer instructions. E. Protection: 1. Protect materials from puncture, abrasion, moisture, dust, and UV by storing in clean, dry location remote from construction operations areas. 2. Protect piping and appurtenances by storing off ground. 3. Provide additional protection according to manufacturer instructions. BCRUA - Phase 1D WTP Expansion Issued for Bid Thermoplastic Process Pipe 40 05 31 - 5 1.9 EXISTING CONDITIONS A. Field Measurements: 1. Verify field measurements prior to fabrication. 2. Indicate field measurements on Shop Drawings. PART 2 - PRODUCTS 2.1 GENERAL A. All polyvinyl chloride (PVC) water pipe shall be of the rigid (UNPLASTICIZED) type. B. Pipe used for potable water must bear the National Sanitation Foundation seal of approval for potable water pipe. C. Each joint of pipe shall consist of single continuous extrusion; bells or other components attached by solvent welding are not acceptable. 2.2 PVC PIPE, TUBE, AND FITTINGS A. PVC Pipe and Fittings: 1. Pipe: a. Schedule 40 and 80 PVC: Type I, Grade I or Class 12454 B conforming to ASTM D1784 and ASTM D1785. Pipe shall be manufactured with titanium dioxide for ultraviolet protection. b. Threaded Nipples: Schedule 80 PVC. 2. Fittings: Schedule 40 and 80: ASTM D2466 and ASTM D2467 for socket weld type and Schedule 80 ASTM D2464 for threaded type. a. Fittings shall be manufactured with titanium dioxide for ultraviolet protection. b. Fittings shall have the same pressure and temperature rating as adjoining pipe. 3. Joints: Solvent socket weld except where connection to threaded valves and equipment may require future disassembly. 4. Flanges: Schedule 80; One-piece, molded hub type PVC flat face flange in accordance with Fittings above, ASME B16.1, Class 125 drilling. Flange gaskets shall be compatible with conveyed fluid. 5. Bolting: a. Flat Face Mating Flange and In Corrosive Areas: ASTM A193/A193M, Type 316 stainless steel Grade B8M hex head bolts, ASTM A194/A194M Grade 8M hex head nuts and ASTM F436 Type 3 alloy washers at nuts and bolt heads. Achieve 40 percent to 60 percent of bolt minimum yield stress. b. With Raised Face Mating Flange: Carbon steel ASTM A307 Grade B square head bolts, ASTM A563 Grade A heavy hex head nuts and ASTM F436 hardened steel washers at nuts and bolt heads. Achieve 40 percent to 60 percent of bolt minimum yield stress. Use spacers supplied by pipe manufacturer when mating raised-faced flanges to other flanges. 6. Unions: Use socket type PVC unions with O-rings compatible with conveyed fluid. 7. Gaskets: a. Flat Face Mating Flange: Full faced 1/8 inch-thick ethylene propylene (EPR) rubber. BCRUA - Phase 1D WTP Expansion Issued for Bid Thermoplastic Process Pipe 40 05 31 - 6 b. Raised Face Mating Flange: Flat ring 1/8 inch ethylene propylene (EPR) rubber, with filler gasket between OD of raised face and flange OD to protect the flange from bolting moment. 8. Solvent Cement: Socket type joints shall be made employing solvent cement that meets or exceeds the requirements of ASTM D2564 and primer that meets or exceeds requirements of ASTM F656, chemically resistant to the fluid service, and as recommended by pipe and fitting manufacturer. PVC pipe, fittings, joints, and solvent cement used for sodium hypochlorite service shall be free of silica filler and shall be certified by the manufacturer to be suitable for that service; IPS Weld-On 724 or approved equal. Certification shall be submitted. Solvent cement and primer shall be listed by NSF 61 for contact with potable water. 9. Thread Lubricant: Teflon Tape 10. Marking: Refer to Sections 09 96 00 – High-Performance Coatings and 10 14 00 – Identification for Process Piping and Equipment. B. PVC Pipe and Fittings: 1. Pipe: a. Comply with AWWA C900. b. Class: 235. 2. Fittings: a. Material: Cast iron. b. Comply with AWWA C111 or AWWA C153. 3. Joints: a. Type: Compression gasket ring. b. Comply with ASTM D3139. 4. Materials: a. Comply with ASTM D1784. b. Minimum Cell Classification: 12545-C. C. PVC Tube and Fittings: 1. Tube: a. Type: Clear outer braided tubing with braid permanently encapsulated in the walls of the flexible tubing. b. Working temperature from 5 to 140 degrees Fahrenheit. c. Self-extinguishing and fire resistant. d. Size and Wall Thickness: As indicated in piping schedule or on drawings. e. Pressure Rating: Minimum working pressure of 130 psi at 70 degrees Fahrenheit, or as indicated on Drawings or in piping schedule. f. Design tubing with minimum safety factor or 4 to 1 ratio of burst pressure to working pressure at maximum working temperature. 2. Fittings: a. Type: Compression. b. Materials: Polypropylene or suitable for application. c. Suitable for intended working pressure and temperature of tubing. 3. Threads: a. Type: Straight. b. Comply with ASME B1.1. BCRUA - Phase 1D WTP Expansion Issued for Bid Thermoplastic Process Pipe 40 05 31 - 7 2.3 HIGH DENSITY POLYETHYLENE (HDPE) TUBING A. General: Pipe lengths, fittings, and connections to be joined by thermal butt-fusion shall be of the same type, grade, and class of polyethylene compound and supplied from the same raw material supplier. B. Tube: 1. HDPE tubing shall meet the requirements of AWWA C901. 2. HDPE tubing shall be rated for use at a pressure class of at least 150 psi. 3. Polyethylene tubing shall be made from HDPE resin having a material designation code of PE4710 or higher. 4. Tubing material shall meet the requirements of ASTM D 3350 and shall have a minimum cell classification of PE445474C. 5. HDPE Pressure tubing for potable water shall meet the requirements of NSF 61. 6. Pressure tubing shall be approved by the Underwriter’s Laboratory (UL) or Factory Mutual (FM). 7. Tubing Markings shall meet the minimum requirements of AWWA C901. 8. Only smooth wall HDPE will be permitted. C. Fittings: Molded fittings, butt-fusion joined, conforming to ASTM D1248-84. Shall have the same pressure rating as the adjoining pipe unless otherwise specified. D. Joints: Butt-fusion joints per ASTM D3261. Joints shall have same pressure rating as the adjoining pipe. 2.4 LINEAR LOW DENSITY POLYETHYLENE (LLDPE) TUBING A. Tube: 1. Type: Natural, flexible. 2. Nominal durometer (Shore D): 44. 3. Minimum working pressure of 130 psi at 70 degrees Fahrenheit. 4. Working temperature from 5 to 140 degrees Fahrenheit. 5. Plain end for use with compression fittings and couplers. B. Fittings: a. Type: Compression. b. Materials: Polypropylene or suitable for application. c. Suitable for intended working pressure and temperature of tubing. 2.5 FINISHES A. Coat machined faces of metallic flanges with temporary rust-inhibitive coating. BCRUA - Phase 1D WTP Expansion Issued for Bid Thermoplastic Process Pipe 40 05 31 - 8 PART 3 - EXECUTION 3.1 Section 40 05 00 – Common Requirements for Process Piping: Requirements listed in subsection PART 3 EXECUTION. 3.2 INSTALLATION A. Field threading of PVC pipe not permitted. Perform required threaded connections or attachments by the use of factory molded socket by threaded adapters. Female adapters are not acceptable. B. Field cutting with hacksaws not permitted. Use PVC cutters. C. Join pipe and fittings in accordance with manufacturer’s instructions, unless otherwise shown or specified. D. Remove foreign objects prior to assembly and installation. E. Provide Schedule 80 threaded nipple where necessary to connect to threaded valve or fitting. Provide Teflon tape for lubrication of threads. F. Do not clamp PVC tightly or restrict movement for expansion and contraction. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Process Piping Leakage Testing and Disinfection 40 05 40 - 1 SECTION 40 05 40 – PROCESS PIPING LEAKAGE TESTING AND DISINFECTION PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: Leakage and disinfection testing for process piping systems. 1.2 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Informational Submittals: 1. Pressure and Disinfection Testing Plan: a. Submit at least three weeks prior to testing and include at least the information that follows. 1) Proposed testing dates. 2) Piping systems and section(s) to be tested. 3) Test type. 4) Plans for test fluid conveyance, control and disinfection before, during, and after testing. 5) Method of isolation. 6) Calculation of maximum allowable leakage for piping section(s) to be pressure tested. 2. Certifications of Calibration: Testing equipment. 3. Certified Test Reports. PART 2 - PRODUCTS 2.1 MATERIALS REQUIREMENTS A. Chlorine for disinfection shall be in the form of liquid chlorine, sodium hypochlorite solution, or calcium hypochlorite granules or tablets. B. Liquid chlorine shall be in accordance with the requirements of ANSI/AWWA B301. Liquid chlorine shall be used only: 1. In combination with appropriate gas flow chlorinators and ejectors; 2. Under the direct supervision of an experienced technician; 3. When appropriate safety practices are observed. C. Sodium hypochlorite and calcium hypochlorite shall be in accordance with the requirements of ANSI/AWWA B300. PART 3 - EXECUTION 3.1 GENERAL A. Water for Testing: BCRUA - Phase 1D WTP Expansion Issued for Bid Process Piping Leakage Testing and Disinfection 40 05 40 - 2 1. Unless otherwise indicated, water for testing pipelines will be furnished by the Owner. However, water for any retesting resulting from failing initial tests shall be paid for by the Contractor at the Owner’s established raw water or potable water rates. 2. The Contractor shall make all necessary arrangements for conveying water to test points. B. All pressure pipelines shall be pressure tested. Disinfection shall be accomplished by chlorination. C. Disinfection operations shall be scheduled by the Contractor to occur when the pipeline system is ready to be placed into service. 3.2 PREPARATION A. Notify Owner’s Representative and Engineer in writing 7 days in advance of testing. Notify Resident Project Representative at least 48 hours in advance of testing. Perform testing in presence of Resident Project Representative or Engineer. B. All test equipment, temporary valves, temporary blow-offs, bulkheads, or other water control equipment and materials shall be determined and furnished by the Contractor. No materials shall be used that could be damage pipelines or their future function. C. Pressure Piping: 1. Install temporary thrust blocking or other restraint as necessary to protect adjacent piping or equipment and make taps in piping prior to testing. 2. Wait 28 days minimum after concrete thrust blocking is installed to perform pressure tests. If high-early strength cement is used for thrust blocking, wait may be reduced to 7 days. 3. Prior to test, remove or suitably isolate appurtenant instruments or devices that could be damaged by pressure testing. 4. New Piping Connected to Existing Piping: a. Isolate new piping with grooved-end pipe caps, spectacle blinds, blind flanges, or as acceptable to Engineer. b. Test joint between new piping and existing piping by methods that do not place entire existing system under test load, as accepted by Engineer. 5. Items that do not require testing include equipment seal drains, tank overflows to atmospheric vented drains, and tank atmospheric vents. 6. Test Pressure: As indicated on Piping Schedule in Section 40 05 00 - Common Requirements for Process Pipe. 7. Chlorine Piping: Test, dry, and clean in accordance with requirements of Chlorine Institute Pamphlet 6. D. Test section may be filled with water and allowed to stand under low pressure prior to testing. 3.3 HYDROSTATIC TEST FOR PRESSURE PIPING A. Prior to hydrostatic testing, all pipelines shall be flushed as appropriate. B. Fluid: Clean water of such quality to prevent corrosion of materials in piping system. C. Exposed Piping: BCRUA - Phase 1D WTP Expansion Issued for Bid Process Piping Leakage Testing and Disinfection 40 05 40 - 3 1. Perform testing on installed piping prior to application of insulation. 2. Maximum Filling Velocity: 0.25 foot per second, applied over full area of pipe. 3. Vent piping during filling. Open vents at high points of piping system or loosen flanges, using at least four bolts, or use equipment vents to purge air pockets. 4. Maintain hydrostatic test pressure continuously for duration specified in Pipe Schedule in Section 40 05 00 – Common Requirements for Process Piping, and for such additional time as necessary to conduct examinations for leakage. 5. Examine joints and connections for leakage. 6. Correct visible leakage and retest as specified. 7. Empty pipe of water prior to final cleaning or disinfection. D. Buried Piping: 1. Test after backfilling has been completed. 2. Expel air from piping system during filling. 3. Cement mortar lined pipe should be filled with water and allowed to stand for at least 24- hours prior to pressure testing to permit maximum absorption of water by the lining. 4. Apply and maintain specified test pressure with hydraulic force pump. Valve off piping system when test pressure is reached. 5. Maintain hydrostatic test pressure continuously for duration specified in the Pipe Schedule in Section 40 05 00 – Common Requirements for Process Piping, reopening isolation valve only as necessary to restore test pressure. Test pressure can not vary more than +-5% psi for the duration of the test. 6. Determine actual leakage by measuring quantity of water necessary to maintain specified test pressure for duration of test. 7. Maximum Allowable Leakage: a. Steel Pipe: Per AWWA C604 or as specified in the Pipe Schedule in Section 40 05 00 Common Requirements for Process Pipe. b. Ductile Iron Pipe and AWWA Rubber Gasket Pipe 000,148 )D(PS = L 2/1 where: L = Allowable leakage, in gallons per hour. S = Length of pipe tested, in feet. D = Nominal diameter of pipe, in inches. P = Test pressure during leakage test, in pounds per square inch. b. When testing against closed metal-seated valves, an additional testing allowance per closed valve of 0.0078 gallons per hour per inch diameter of valve size. 8. See Section 40 05 00 – Common Requirements for Process Piping and individual pipe specification for other buried piping not described above. 3.4 PNEUMATIC TEST FOR PRESSURE PIPING A. Do not perform on: 1. PVC or CPVC pipe. 2. Compressed air piping. 3. Piping larger than 18 inches. 4. Buried and other non-exposed piping. BCRUA - Phase 1D WTP Expansion Issued for Bid Process Piping Leakage Testing and Disinfection 40 05 40 - 4 B. Fluid: Oil-free, dry air. C. Procedure: 1. Apply preliminary pneumatic test pressure of 25 psig maximum to piping system prior to final leak testing, to locate visible leaks. Apply soap bubble mixture to joints and connections; examine for leakage. 2. Correct visible leaks and repeat preliminary test until visible leaks are corrected. 3. Gradually increase pressure in system to half of specified test pressure. Thereafter, increase pressure in steps of approximately one-tenth of specified test pressure until required test pressure is reached. 4. Maintain pneumatic test pressure continuously for minimum of 10 minutes and for such additional time as necessary to conduct soap bubble examination for leakage. 5. Correct visible leakage and retest as specified. D. Allowable Leakage: Piping system, exclusive of possible localized instances at pump or valve packing, shall show no visual evidence of leakage. E. After testing and final cleaning, purge with nitrogen those lines that will carry flammable gases to assure no explosive mixtures will be present in system during filling process. 3.5 DISINFECTING PIPELINES A. General: All water pipelines, except those listed herein shall be disinfected in accordance with the requirements of ANSI/AWWA C651 using the Continuous-Feed Method as modified herein. Preliminary and final flushing shall be completed at the ends of pipelines that have been hydrostatically tested. B. Chlorination: A chlorine solution shall be uniformly introduced into the pipeline by means of a solution-feed chlorinating device. The chlorine solution shall be introduced at one end of the pipeline through a tap in such a manner that as the pipeline is filled with water, the dosage applied to the water entering the pipe shall be approximately 50 mg/l. C. Chlorine Residual Test: The Owner will make chlorine residual tests and notify the Contractor of the test results. Chlorinated water shall be retained in the pipeline for at least 24 hours. After the chlorinated water has been retained for the required time, the free chlorine residual at the pipeline extremities and at other representative points shall be at least 25 mg/l. D. Repetition of Test: The disinfection testing procedure shall be repeated if the initial tests fail to produce satisfactory results. Two consecutive satisfactory test results shall be required after any unsatisfactory test. The tablet method shall not be used for repeated disinfection. E. Chlorinating Valves: During the process of chlorinating pipelines, all valves and other appurtenances shall be operated while the pipeline is filled with the heavily chlorinated water. F. Final Flushing: Final Flushing shall be done by the Contractor after notification of satisfactory chlorine residual tests. After the applicable retention period, the heavily chlorinated water shall be flushed from the pipeline until measurements show that the chlorine concentration in the water leaving the pipeline is no higher than that generally prevailing in the system or is acceptable for the intended use. If necessary to reduce chlorine concentration to acceptable level, a neutralizing agent shall be applied to the water at no additional cost to the Owner. BCRUA - Phase 1D WTP Expansion Issued for Bid Process Piping Leakage Testing and Disinfection 40 05 40 - 5 G. Disinfection of Connections: Pipe and appurtenances used to connect the newly installed water main shall also be disinfected in accordance with AWWA C651. H. Neutralization of Chlorinated Water: Neutralizing and disposing of chlorinated water shall be in accordance with Appendix "B" of AWWA Standard C651. 3.6 BACTERIOLOGICAL TESTING OF DISINFECTED PIPELINES A. The Owner will collect 2 sets of samples at least 24 hours apart after completion of final flushing as indicated above. Samples will be taken at locations indicated in ANSI/AWWA C651 and will be tested according to the latest edition of the Standard Methods for the Examination of Water and Wastewater. Laboratory costs of initial testing will be the Owner’s responsibility. B. If bacteriological tests fail, the pipe shall be flushed and retested. If counts from analysis of the second samples exceed the criteria in Standard Methods, the pipe shall be re-disinfected and retested until satisfactory results are obtained. The Contractor shall be responsible for all repeat bacteriological testing costs. 3.7 FIELD QUALITY CONTROL A. Test Report Documentation: 1. Test date. 2. Description and identification of piping tested. 3. Test fluid. 4. Test pressure. 5. Remarks, including: a. Leaks (type, location). b. Repair/replacement performed to remedy excessive leakage. 6. Signed by Contractor and Resident Project Representative to represent that test has been satisfactorily completed. END OF SECTION BCRUA – Phase 1D WTP Expansion Issued for Bid Common Requirements for Process Valves 40 05 51 - 1 SECTION 40 05 51 - COMMON REQUIREMENTS FOR PROCESS VALVES PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Common requirements for valves. B. Related Sections: 1. Section 01 91 00 – Facility Commissioning. 2. Section 40 05 57 – Actuators for Process Valves. 1.2 REFERENCE STANDARDS A. American Water Works Association: 1. AWWA C111/A21.11, Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings. 2. AWWA C550 - Protective Interior Coatings for Valves and Hydrants. 3. AWWA C606, Grooved and Shouldered Joints. 4. AWWA C800, Underground Service Line Valves and Fittings. B. ASTM International: 1. ASTM A276, Standard Specification for Stainless Steel Bars and Shapes. 2. ASTM A351/A351M, Standard Specification for Castings, Austenitic, for Pressure- Containing Parts. 3. ASTM A380, Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems. 4. ASTM A564/A564M, Standard Specification for Hot-Rolled and Cold-Finished Age- Hardening Stainless Steel Bars and Shapes. 5. ASTM B61, Standard Specification for Steam or Valve Bronze Castings. 6. ASTM B62, Standard Specification for Composition Bronze or Ounce Metal Castings. 7. ASTM B98/B98M, Standard Specification for Copper-Silicon Alloy Rod, Bar, and Shapes. 8. ASTM B127, Standard Specification for Nickel-Copper Alloy (UNS N04400) Plate, Sheet, and Strip. 9. ASTM B139/B139, Standard Specification for Phosphor Bronze Rod, Bar and Shapes. 10. ASTM B164, Standard Specification for Nickel-Copper Alloy Rod, Bar, and Wire. 11. ASTM B194, Standard Specification for Copper-Beryllium Alloy Plate, Sheet, Strip, and Rolled Bar. 12. ASTM B584, Standard Specification for Copper Alloy Sand Castings for General Applications. 13. ASTM D429, Standard Test Methods for Rubber Property-Adhesion to Rigid Substrates. 14. ASTM D1784, Standard Specification for Rigid Poly(Vinyl Chloride) (PVC) Compounds and Chlorinated Poly(Vinyl Chloride) (CPVC) Compounds. C. Manufacturers Standardization Society: 1. MSS SP-25 - Standard Marking System for Valves, Fittings, Flanges, and Unions. D. National Electrical Manufacturers Association: 1. NEMA 250 - Enclosures for Electrical Equipment (1000 Volts Maximum). BCRUA – Phase 1D WTP Expansion Issued for Bid Common Requirements for Process Valves 40 05 51 - 2 E. NFPA: 1. NFPA 70 - National Electrical Code (NEC). F. NSF International: 1. NSF 61 - Drinking Water System Components - Health Effects. 2. NSF 372 - Drinking Water System Components - Lead Content. 1.3 DEFINITIONS A. CWP—Cold Working Pressure: Maximum rated non-shock pressure of valve at temperature range of minus 20 degrees F to 150 degrees F. B. NRS—Non rising Stem: Valve stem configuration in which threads are inside body and moves disc up and down stem when stem is turned (disc is threaded internally). C. OS&Y—Outside Screw and Yoke: Valve configuration which has outside screw and yoke and rising stem (RS). A valve in which the operating screw is driven by a threaded nut that is built into the handle. D. RS—Rising Stem: Valve stem configuration which allows stem to raise and lower moving disc with it. E. SWP—Steam Working Pressure: Allowable working pressure of valve when used in steam service. F. WOG—Water, Oil, Gas: Valve can be used for water, oil, or gas service. 1.4 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Product Data: 1. Submit manufacturer product information including details for valve and actuator with model numbers indicated. 2. Submit Cv curves for each valve larger than 4-inches nominal pipe size. 3. Submit valve cavitation limits. C. Shop Drawings: 1. Indicate parts list, materials, sizes and dimensions, position indicators, limit switches, actuator mounting, wiring diagrams, control system schematics. 2. Valve-Labeling Schedule: Indicate valve locations and nametag text for all valves. 3. Submit manufacturer installation instructions and special requirements. 4. Delegated Design Submittals: Submit signed and sealed Shop Drawings with design calculations and assumptions for sizing of control valves. 5. Submit operating torque requirements for motor operated valves, including torques for seating/unseating, open/close, and modulating. D. Source Quality-Control Submittals: 1. Indicate results of shop or factory tests and inspections. BCRUA – Phase 1D WTP Expansion Issued for Bid Common Requirements for Process Valves 40 05 51 - 3 2. Manufacturer's Certificate of Compliance: Certify that products meet or exceed specified requirements. 3. Submit Affidavit of Compliance for AWWA valves in accordance with referenced AWWA Standard. 4. Certification of Valves 12 Inches and Larger: Furnish certified copies of hydrostatic factory tests, indicating compliance with applicable standards. E. Field Quality-Control Submittals: 1. Indicate results of Contractor-furnished tests and inspections, including factory-applied coatings. 2. Manufacturer’s Certificate of Proper Installation (COPI): Manufacturer’s representative to certify that valves and actuators have been installed in accordance with manufacturer’s instructions and are properly supported. 1.5 CLOSEOUT SUBMITTALS A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for submittals and Operation and Maintenance data. 1. O&M manuals are required for all process valves included in Project. B. Project Record Documents: Record actual locations of valves and actuators, and centerline elevations. 1.6 QUALITY ASSURANCE A. Maintain clearances as indicated on manufacturers’ installation instructions. B. Ensure that materials of construction of wetted parts are compatible with process liquid. C. Materials in Contact with Potable Water: Certified to NSF 61 and NSF 372. 1.7 QUALIFICATIONS A. Manufacturer: Company specializing in manufacturing products specified in this Section with minimum five years' experience. 1.8 DELIVERY, STORAGE, AND HANDLING A. Section 01 60 00 – Product Requirements: Requirements for transporting, handling, storing, and protecting products. B. Equipment shall not be shipped to the job site until the contractor notifies the supplier/manufacturer that they are ready for the material. C. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage. D. Store materials according to manufacturer instructions. E. Protection: BCRUA – Phase 1D WTP Expansion Issued for Bid Common Requirements for Process Valves 40 05 51 - 4 1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas. 2. Protect valve ends from entry of foreign materials by providing temporary covers and plugs. 3. Provide additional protection according to manufacturer instructions. 1.9 EXISTING CONDITIONS A. Field Measurements: 1. Verify field measurements prior to fabrication. 2. Indicate field measurements on Shop Drawings. PART 2 - PRODUCTS 2.1 VALVES A. Description: Valves, operator, actuator, handwheel, chainwheel, extension stem, floor stand, worm and gear operator, operating nut, chain, wrench, and other accessories as required. B. Valve shall be suitable for intended service. C. Valve size: Valve shall be same size as adjoining pipe unless otherwise called out on drawings, in valve schedule or individual valve specifications. D. Valve Ends: Compatible with adjacent piping system. E. Operation: 1. Open by turning counterclockwise; close by turning clockwise. 2. Cast directional arrow on valve or actuator with OPEN and CLOSE cast on valve in appropriate location. F. Valve Marking and Labeling: 1. Marking: Comply with MSS SP-25. 2. Provide stainless steel nameplate permanently attached to valve. 3. Labeling: All tagged valves shall have the tag number affixed to the valve in accordance with Section 10 14 00 – Identification for Process Pipping and Equipment. G. Provide buried valves with valve boxes, covers, and extensions as specified and shown on Drawings. H. Valve Construction: 1. Components and Materials in Contact with Water for Human Consumption: Comply with the requirements of the Safe Drinking Water Act and other applicable federal, state, and local requirements. Provide certification by manufacturer or an accredited certification organization recognized by the Authority Having Jurisdiction that components and materials comply with the maximum lead content standard in accordance with NSF/ANSI 61 and NSF/ANSI 372. a. Use or reuse of components and materials without a traceable certification is prohibited. b. Coatings shall be formulated from materials deemed acceptable to NSF/ANSI 61. BCRUA – Phase 1D WTP Expansion Issued for Bid Common Requirements for Process Valves 40 05 51 - 5 2. Bronze and brass valve components and accessories that have surfaces in contact with water to be alloys containing less than 16 percent zinc and 2 percent aluminum. a. Approved alloys are of the following ASTM designations: B61, B62, B98/B98M (Alloy UNS No. C65100, C65500, or C66100), B139/B139M (Alloy UNS No. C51000), B584 (Alloy UNS No. C90300 or C94700), B164, B194, and B127. b. Stainless steel Alloy 18 8 may be substituted for bronze. 3. Provide certification that the product is certified as suitable for contact with drinking water by an accredited certification organization in accordance with NSF/ANSI 61. Provide certification for each valve type used for drinking water service. 4. Bodies: Rated for maximum temperature and pressure to which valve will be subjected as specified in valve and adjoining pipe Sections. 5. Bonnets: a. Flanged to body and of same material and pressure rating as body. b. Furnish glands, packing nuts, or yokes as specified in valve Sections. 6. Stems and Stem Guides: a. Materials and Seals: As specified in valve Sections. b. Bronze Valve Stems: According to ASTM B62 and B584. c. Space stem guides 10 feet O.C maximum. d. Submerged Stem Guides: Type 304 stainless steel. 7. Nuts and Bolts: As specified in narrow scope valve and pipe Sections. 2.2 VALVE ACTUATORS A. See Section 40 05 57 – Actuators for Process Valves. B. Size operators and actuators to operate valve for full range of pressures and velocities. C. Factory mount operator, actuator, and accessories, when practical. D. Motors: As specified in Sections 01 61 03 – Common Requirements for Equipment and 40 05 57 – Actuators for Process Valves. 2.3 INSULATION A. As specified in Section 40 42 13 – Process Piping Insulation and as indicated on Drawings. 2.4 FINISHES A. Valve Lining and Coating: Comply with AWWA C550. B. Exposed Valves: As specified in Section 09 96 00 – High-Performance Coatigns. C. Do not coat flange faces of valves unless otherwise specified. D. Material in contact with potable water shall conform to NSF/ANSI 61. E. Exposed safety isolation valves and lockout valves with handles, handwheels, or chain wheels shall be “safety yellow.” F. Where epoxy lining and coating are specified, factory finishing shall be as follows: 1. In accordance with AWWA C550. BCRUA – Phase 1D WTP Expansion Issued for Bid Common Requirements for Process Valves 40 05 51 - 6 2. Either two-part liquid material or heat-activated (fusion) material, except only heat- activated material if specified as “fusion” or “fusion bonded” epoxy. 3. Minimum 7 mil dry film thickness except where limited by valve operating tolerances. 2.5 SOURCE QUALITY CONTROL A. Testing: Test valves according to manufacturer's standard testing protocol, including hydrostatic, seal, and performance testing. PART 3 - EXECUTION 3.1 EXAMINATION A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for installation examination. B. Verify that piping system is ready for valve installation. 3.2 INSTALLATION A. General: 1. Install valves, actuators, extensions, valve boxes, and accessories according to manufacturer instructions. 2. Firmly support valves to avoid undue stresses on piping. 3. Coat studs, bolts, and nuts with anti-seizing lubricant. 4. Clean field welds of slag and splatter to provide a smooth surface. 5. Install valves with stems upright or horizontal, not inverted. 6. Install brass male adapters on each side of valves in copper-piped system and solder adapters to pipe, unless noted otherwise. 7. Install 3/4-inch ball valves with cap for drains at main shutoff valves, low points of piping, bases of vertical risers, and equipment. 8. Install valves with clearance for installation of insulation and to allow access. 9. Comply with Division 40 - Process Integration and the Pipe Schedule in Section 40 05 00 for piping materials applying to various system types. 10. Install insulation as specified in Section 40 42 13 - Process Piping Insulation and as indicated on Drawings. 11. Flange Ends: a. Flanged valve bolt holes shall straddle vertical centerline of pipe. b. Clean flange faces, insert gasket and bolts, and tighten nuts progressively and uniformly. Torque to manufacturers’ recommendation and document the setting of the torque wrench. 12. Screwed Ends: a. Clean threads by wire brushing or swabbing. b. Apply joint compound. 13. PVC and CPVC Valves: Install using solvents approved for valve service conditions, or as otherwise specified or shown on Drawings. 14. Extension Stem for Operator: Where depth of valve operating nut is 3-feet or greater below finish grade, furnish operating extension stem with 2-inch operating nut to bring operating nut to a point within 6-inches of finish grade. BCRUA – Phase 1D WTP Expansion Issued for Bid Common Requirements for Process Valves 40 05 51 - 7 B. Valve Applications: 1. Gate, Globe, and Ball Valves: a. Install operating stem vertical when valve is installed in horizontal runs of pipe having centerline elevations 4 feet 6 inches or less above finished floor, unless otherwise shown. b. Install operating stem horizontal in horizontal runs of pipe having centerline elevations greater than 4 feet 6 inches above finish floor, unless otherwise shown. c. Install ¾-inch (or diameter required for valve) 316 stainless steel ball valve for valve flushing on valves that have drains and horizontal stems. Place on lowest valve drain. 2. Eccentric Plug Valves: a. Unless otherwise restricted or shown on Drawings, install valve as follows: 1) Liquids with suspended solids service with horizontal flow: Install valve with stem in horizontal position with plug up when valve is open. Install valve with seat end upstream (flow to produce unseating pressure). 2) Liquids with suspended solids service with vertical flow: Install valve with seat in highest portion of valve (seat up). 3) Clean Liquids and Gas Service: Install valve with seat end downstream of higher pressure when valve is closed (higher pressure forces plug into seat). 3. Butterfly Valves: a. Unless otherwise restricted or shown on Drawings, install valve a minimum of 8 diameters downstream of a horizontal elbow or branch tee with shaft in horizontal position. b. For vertical elbow or branch tee immediately upstream of valve, install valve with shaft in vertical position. c. For horizontal elbow or branch tee immediately upstream of valve, install valve with shaft in horizontal position. d. When installed immediately downstream of swing check, install valve with shaft perpendicular to swing check shaft. e. For free inlet or discharge into basins and tanks, install valve with shaft in vertical position. 4. Check Valves: a. Install valve in accordance with manufacturer’s instructions and provide required distance from immediate upstream fitting. b. Install valve in vertical flow (up) piping only for gas services, unless otherwise shown. c. Install swing check valve with shaft in horizontal position. d. Install double disc swing check valve to be perpendicular to flow pattern when discs are open. 5. Solenoid Valves: a. Install in accordance with manufacturer’s instructions. b. Unless specifically shown otherwise, install line size ball valve and union upstream of each solenoid valve, in-line flow switch, or other in-line electrical device, excluding magnetic flowmeters, for isolation during maintenance. 3.3 FIELD QUALITY CONTROL A. Section 01 40 00 – Quality Requirements. BCRUA – Phase 1D WTP Expansion Issued for Bid Common Requirements for Process Valves 40 05 51 - 8 B. Section 01 70 00 - Execution and Closeout Requirements: Requirements for testing, adjusting, and balancing. 3.4 TESTS AND INSPECTION A. Valve may be either tested while testing pipelines, as a separate step, or as specified. B. Test that valves open and close smoothly under operating pressure conditions. Test that two- way valves open and close smoothly under operating pressure conditions from both directions. C. Inspect air and vacuum valves as pipe is being filled to verify venting and seating is fully functional. D. Count and record number of turns to open and close valve, account for discrepancies with manufacturer’s data. E. Set, verify, and record set pressures for relief and regulating valves. F. Automatic valves to be tested in conjunction with control system testing. Set opening and closing speeds, limit switches, as required or recommended by Engineer. G. Test hydrostatic relief valve seating; record leakage. Adjust and retest to maximum leakage of 0.1 gpm per foot of seat periphery. 3.5 VALVE SCHEDULES A. Water service valves 8-IN and larger and electric motor operated valves are tabulated in the schedules at the end of this section. 1. Other manual valves less than 8-IN are not scheduled, but size and type are defined on Drawings in plan, section, or schematic. 2. Some valves 8-IN and larger shown on Drawings may not be scheduled. Nonetheless, such valves shall be included in proposal price for the project. B. Design pressure is synonymous with working pressure. C. Valve tag numbers listed in the schedules correspond to those listed on the Drawings. BCRUA – Phase 1D WTP Expansion Issued for Bid Common Requirements for Process Valves 40 05 51 - 9 WTP Valve Schedule Tag Number Size (IN) Type Process Fluid Maximum Flow (GPM) Maximum Design Pressure (PSI) Pressure Rating (PSI) Actuator Service Y-BFV-015 72 AWWA C504 RW 74,000 15 150 Manual, EB, ON Buried, Actuator Vault Y-BFV-016 72 AWWA C504 RW 74,000 15 150 Manual, EB, ON Buried, Actuator Vault TSC-MV-SB401 12 Mud Valve DR 4,300 5.5 NA Manual, FB Submerged TSC-MV-SB402 12 Mud Valve DR 4,300 5.5 NA Manual, FB Submerged TSC-PV-SLV202 12 AWWA C517 SL 1,000 10 175 EMO, FS Exposed, Sludge Vault ST1-PV-001 8 AWWA C517 SL 1,000 10 175 Manual, HW Exposed TSC-BFV-F701 24 AWWA C504 STW 4,300 10 150 EMO, FS Exposed TSC-BFV-F702 30 AWWA C504 WBW 12,400 10 150 EMO Exposed TSC-BFV-F704 10 ANSI B16.104 LPA 5,000 scfm 14 250 0F EMO Exposed TSC-BFV-F705 24 AWWA C504 BWW 12,400 34 150 EMO Exposed TSC-BFV-F706 20 AWWA C504 FLW 4,300 10 150 EMO Exposed, Modulating TSC-BFV-F708 20 AWWA C504 FLW 4,300 10 150 Manual, HW Exposed TSC-FCV-001 18 AWWA C517 BWW 12,400 38 175 EMO Exposed, Modulating Process Unit Abbreviations: TSC – Treatment Structure Central, Y – Yard, ST1 – Sludge Thickener 1 Valve Abbreviations: BFV – Butterfly Valve, FCV – Flow Control Valve, MV – Mud Valve, PV – Plug Valve. Process Fluid Abbreviations: BWW – Backwash Water, DR – Drain, FLW – Filtered Water, LPA – Low Pressure Air, RW – Raw Water, SL – Sludge, STW – Settled Water, WBW – Waste Backwash Water. Actuator Abbreviations: CW – Chain Wheel, EB – Extension Bonnet, EMO – Electric Motor Operator, Open/Close unless noted otherwise, FB – Floor Box, FS – Floor Stand, HW – Hand Wheel, ON – Operating Nut. BCRUA – Phase 1D WTP Expansion Issued for Bid Common Requirements for Process Valves 40 05 51 - 10 END OF SECTION BCRUA – Phase 1D WTP Expansion Issued for Bid Actuators for Process Valves 40 05 57 - 1 SECTION 40 05 57 - ACTUATORS FOR PROCESS VALVES PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Manual actuators. 2. Electric motor actuators. B. Related Sections: 1. Section 01 61 03 – Common Requirements for Equipment. 2. Section 40 05 51 - Common Requirements for Process Valves: Common product requirements and Schedule for valves for placement by this Section. 1.2 REFERENCE STANDARDS A. American Bearing Manufacturers Association: 1. ABMA 9 - Load Ratings and Fatigue Life for Ball Bearings. 2. ABMA 11 - Load Ratings and Fatigue Life for Roller Bearings. B. American Water Works Association: 1. AWWA C500 - Metal-Seated Gate Valves for Water Supply Service. 2. AWWA C541 - Hydraulic and Pneumatic Cylinder and Vane-Type Actuators for Valves and Slide Gates. 3. AWWA C542 - Electric Motor Actuators for Valves and Slide Gates. C. NFPA: 1. NFPA 70 - National Electrical Code. 1.3 SUBMITTALS A. Section 01 33 00 - Submittal Procedures: Requirements for submittals. B. Product Data: Submit manufacturer information for actuator with model number and size indicated. C. Shop Drawings: 1. Indicate parts list, materials, sizes, position indicators, limit switches, control system, actuator mounting, wiring diagrams, control system schematics, and local control panel on assembly drawings. 2. Submit actuator Shop Drawings with valve submittal. 3. Submit manufacturer installation instructions and special requirements. 4. Each motor actuator for existing valves shall be submitted within the associated valve submittal and shall include: a. Product data, including size, dimensions, capacity, settings, and operating characteristics of selected models. b. Operator sizing calculations. BCRUA – Phase 1D WTP Expansion Issued for Bid Actuators for Process Valves 40 05 57 - 2 c. Actuator and mounting stand assembly drawings and attachment to existing valves. Contractor is responsible for field verifying and coordinating actuator requirements for existing valves and submitting modifications as part of the shop drawings. d. Actuator specific wiring diagram with all options clearly identified. e. Cable datasheet and cable lengths for each actuator where provided. f. Table showing the required valve opening/closing torque compared to the actuator torque. D. Source Quality-Control Submittals: 1. Indicate results of all off-site tests and inspections. 2. Manufacturer's Certificate of Compliance: Certify that products meet or exceed specified requirements. E. Field Quality-Control Submittals: 1. Indicate results of Contractor-furnished tests and inspections. 2. Manufacturer’s Certificate of Proper Installation (COPI). a. For electric actuators, include verification that all limit switches and position potentiometers have been properly adjusted and that actuator correctly responds to valve position commands. 1.4 CLOSEOUT SUBMITTALS A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for submittals and operation and maintenance manuals. B. Project Record Documents: Record actual locations and types of actuators. 1.5 QUALITY ASSURANCE A. Valve Actuators in NEC Class I, Group D, Division 1 or 2 Hazardous Locations: Comply with NFPA 70. 1.6 QUALIFICATIONS A. Manufacturer: Company specializing in manufacturing products specified in this Section with minimum 10 years' documented experience. B. Installer: Company specializing in performing Work of this Section shall be approved by manufacturer. 1.7 DELIVERY, STORAGE, AND HANDLING A. Section 01 60 00 - Product Requirements: Requirements for transporting, handling, storing, and protecting products. B. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage. C. Store materials according to manufacturer instructions. BCRUA – Phase 1D WTP Expansion Issued for Bid Actuators for Process Valves 40 05 57 - 3 D. Protection: 1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas. 2. Furnish temporary end caps and closures on piping and fittings and maintain in place until installation. 3. Provide additional protection according to manufacturer instructions. 1.8 EXISTING CONDITIONS A. Field Measurements: 1. Verify field measurements prior to fabrication. 2. Indicate field measurements on Shop Drawings. PART 2 - PRODUCTS 2.1 MANUAL ACTUATORS A. General: 1. Provide actuators as indicated on Drawings and specified. 2. Counterclockwise opening as viewed from above, unless specifically shown otherwise. 3. For AWWA valves, operator force not to exceed requirements of applicable valve standard. Provide gear reduction operator when force exceeds requirements. 4. For non-AWWA valves, operator force not to exceed applicable industry standard or 80 pounds, whichever is less, under operating condition, including initial breakaway. Provide gear reduction operator when force exceeds requirements. 5. Operator self-locking type or equipped with self-locking device. 6. Position indicator on quarter-turn valves. 7. Worm and gear operators of one-piece design, worm-gears of gear bronze material. Worm of hardened alloy steel with thread ground and polished. Traveling nut type operator’s threaded steel reach rod with internally threaded bronze or ductile iron nut. B. Exposed Operator: 1. Galvanized and painted handwheel. 2. Lever operators for ball and plug valves 3 inch diameter and less. 3. Cranks on gear type operator. 4. Chain wheel operator with tieback, extension stem, floor stand, and other accessories to permit operation from normal operation level. 5. Valve handles to take a padlock and wheels a chain and padlock. C. Buried Operator: 1. Buried service operators on valves larger than 2-1/2 inches shall have a 2-inch AWWA operating nut. Buried operators on valves 2 inches and smaller shall have cross handle for operation by forked key. Enclose moving parts of valve and operator in housing to prevent contact with the soil. 2. Buried service operators to be grease packed and gasketed to withstand submersion in water to 20 feet minimum. 3. Buried valves shall have extension stems, bonnets, and valve boxes. BCRUA – Phase 1D WTP Expansion Issued for Bid Actuators for Process Valves 40 05 57 - 4 2.2 ELECTRIC MOTOR ACTUATORS, 480 VOLTS A. General: 1. Provide actuators as indicated on Drawings and specified. 2. Size to 1-1/2 times required operating torque. Motor stall torque not to exceed torque capacity of valve. 3. Controls integral with actuator and fully equipped as specified in AWWA C542. 4. Stem protection for rising stem valves. 5. Actuators shall be factory mounted to valves by valve manufacturer and delivered as a completely assembled and operational valve and actuator combination. B. Actuator Operation – General: 1. Actuator shall have integrated electronics and be able to operate in ambient temperatures of -40°F (-40°C) to 185°F (85°C). 2. The actuator shall be furnished with a 120 volt AC, single phase, 60 Hz, permanent magnet, synchronous, no-burnout motor rated for 100% continuous duty. Motor shall be capable of withstanding 60 starts / stops per minute or a temporary stall condition without overheating. Design of the motor shall be such that electrical and thermal overload protection is not required. 3. Power: 480V/3 phase input power is accommodated via internal step-down transformer (sized and provided by the actuator manufacturer). Power requirements must be coordinated with the drawings. Alternative power modifications, other than what’s indicated on the drawings, will not be allowed. 4. Motor bearings shall be maintenance-free. Motor shall be non-coasting with instant magnetic braking and shall be self-locking and self-releasing without the use of a separate brake winding, mechanical brake, or worm gear mechanism. Control drive shall be designed to stay in place upon loss of power and shall be capable of holding a load equal to at least 200% of its rated output without AC power. The actuator motor shall be TENV with Class H insulation. 5. Stall torque shall be self-limiting, not exceeding two- and one-half times the rated torque; torque switches shall not be required. Gear train shall have high efficiency spur gears constructed of heat-treated alloy steel or ductile iron only; no worm gears. Actuator gearing shall be lubricated with a premium, heavy-duty lithium-based lubricant. No oil baths shall be used for lubrication. Control actuators shall be able to operate in any mounting orientation. 6. Inputs/Outputs: a. Two SPDT over-travel limit switches shall be provided for over-travel protection and two auxiliary SPDT switches, adjustable over the full range of travel for remote indication of full open and full close status. b. Switches shall be rated for AC or DC voltages (refer to plans for contact voltage ratings). c. Actuator shall be provided with a dry contact for remote indication of actuator trouble, including loss of power, loss of control signal, over travel, and/or over torque with LED indicator lights on the actuator to indicate which condition has caused the alarm. d. Auxiliary contacts on the H/O/A (Hand/Off/Auto) hand switch shall be provided for remote indication for when the switch is in AUTO. e. Modulating actuator (M) shall provide control through an integral, digital control module which positions the actuator in proportion to a 4-20 mA control input signal. The control module shall be capable of initiating shaft movement in steps down to BCRUA – Phase 1D WTP Expansion Issued for Bid Actuators for Process Valves 40 05 57 - 5 0.1°. Upon loss of input signal, the actuator shall be field configurable to move to any predetermined position. f. Modulating actuator (M) shall also be equipped with a contactless position sensing device and be capable of providing an isolated 4–20 mA feedback signal in linear proportion to the 0-100% valve position. The sensing device shall have infinite resolution. g. Actuators for open / close service (O/C) shall use a 120/1/60 discrete or pulsed input signal (or if SCADA requires 24VDC (or any other voltage), then actuator manufacturer must coordinate requirements with SCADA provider the required modifications at no additional cost) from an automatic controller or relay to energize the motor directly without any electronics in the actuator required. This configuration can also be used for modulating service without limitation to the duty cycle. Actual signal type used shall be coordinated with the plans and SCADA specifications. h. Number of available contacts required from the actuators shall be as indicated on the plans. No exceptions. 7. Actuator shall have integral mechanical stops capable of limiting travel of the actuator and load. Actuator shall be provided with a dry contact for remote indication of actuator trouble, including loss of power, loss of control signal, over travel, and/or over torque with LED indicator lights on the actuator to indicate which condition has caused the alarm. 8. Actuator shall include a low-speed, disc-type hand wheel to permit manual operation of the actuator without electrical power and without a declutching mechanism. 9. A five-position, actuator-mounted electric hand switch shall be provided to permit local electrical operation upon loss of control signal. With the hand switch in AUTO mode, actuator shall respond to remote control signals automatically. 10. Enclosure shall be totally enclosed, cast, weatherproof, dust-tight, NEMA 4X and IP68 construction. All field connections shall be made in one terminal compartment. Separate conduit entrances shall be available for power and control wiring. C. Manufacturer and Product: 1. Beck, Group 11. 2.3 REPLACEMENT ELECTRIC MOTOR ACTUATORS A. Summary: This section includes the requirements for actuators being replaced on existing valves at the WTP. The actuator requirements shall conform to the entirety of this section, including paragraph 2.2. B. The Contractor is responsible for coordinating electric motor operator replacements for existing valves, including but not limited to torque requirements, mounting requirements and support stands, and any modifications required to the valve to accommodate the electric motor operator in addition to the requirements specified herein. Modifications to the exiting valves and support systems will be provided at no additional cost to the Project. C. New motor operators for existing valves must match the existing valve travel times. D. Refer to the Table 1 for information on existing valves and electric motor operators to be replaced and installed as part of the Project. Contractor must field verify information included in the Schedule prior to providing Submittals. The table is provided for the Contractor’s BCRUA – Phase 1D WTP Expansion Issued for Bid Actuators for Process Valves 40 05 57 - 6 convenience and may not include every valve, gate or actuator and is not intended to be all inclusive. E. Torque Rating: For existing valves, the operator shall meet or exceed the unseating torque and the required running torque under actual operating conditions of the existing electric motor operators. F. Existing actuators are to be removed, and new actuators are to be installed on existing valves by the certified service representative of the approved actuator manufacturer. Before removing the existing actuators, the existing actuator and valve must be stroked three times by the Owner in the presence of the Contractor to verify and confirm the operation. G. New mounting brackets or couplings required for mounting new actuators to the existing valves must be supplied with the actuators and coordinated by the Contractor and certified service representative of the approved actuator manufacturer. H. The Contractor must furnish electric motor operator stands to replace the existing installation. Table 1- Existing Motor Actuator To Be Replaced Dwg Tag No. Valve Size and Type Open/Close or Modulat- ing? Location Actuator Indoor/ Outdoor? Floor Stand Req.? Existing Actuator Brand Existing Ac- tuator Model/ Serial # Existing Actuator V/A/Ph/HP M-6 TSC- BFV-002 30” BFV Modulating RW Gallery Indoor No Auma ADOR63-4/80 4910MM76943 480V/1.6A/ 3PH/1/2HP M-6 TSC- BFV-004 30” BFV Modulating RW Gallery Indoor No Bettis 2.4 ACCESSORIES A. Tagging: Per Section 10 14 00. Include valve tag number shown on Valve Schedule and/or Drawings. B. Limit Switch: Provide with manual operators as indicated in drawings and loop diagrams. 1. Factory installed NEMA 4X limit switch by actuator manufacturer. 2. SPST, rated at 5 amps, 120 volts AC. 3. Coordinate final number of limit switches with control schematics and limit switch tables. C. T-Handled Operating Wrench: 1. Two (2) galvanized operating wrenches, 4 feet long. 2. Manufacturers and Products: a. Mueller; No. A-24610. b. Clow No.; F-2520. D. Extension Bonnet for Valve Operator: Complete with enclosed stem, extension, support brackets, and accessories for valve and operator. 1. Manufacturers: a. Pratt. b. DeZurik. BCRUA – Phase 1D WTP Expansion Issued for Bid Actuators for Process Valves 40 05 57 - 7 E. Floor Stand: 1. Non-rising, heavy pattern, indicating type. 2. Complete with solid extension stem, coupling, handwheel, stem guide brackets, and yoke attachment. Stem length as required to connect valve operating nut and floor stand. 3. Stem Guide: Space such that stem L/R ratio does not exceed 200. 4. Anchor Bolts: Type 304 stainless steel. 5. Manufacturers and Products: a. Clow; Figure F-5515. b. Mueller, Figure A-26426. F. Floor Box: 1. Plain type, for support of non-rising type stem. 2. Complete with solid extension stem, operating nut, and stem guide brackets. Stem length as required to extend valve operating nut to within 3 inches of finish floor. 3. Stem Guide: Space such that stem L/R ratio does not exceed 200. 4. Anchor Bolts: Type 304 stainless steel. 5. Manufacturers and Products: a. Neenah Foundry; R 7506. b. Clow; No. F5690. G. Chain Wheel and Guide: 1. Handwheel direct-mount type. 2. Complete with chain. 3. Galvanized. 4. Manufacturers and Products: a. Clow Corp.; Figure F-5680. b. Walworth Co.; Figure 804. c. DeZurik Corp.; Series W or LWG. H. Cast-Iron Valve Box: Designed for traffic loads, sliding type, with minimum of 5-1/4-inch ID shaft. 1. Box: Cast iron with minimum depth of 9 inches. 2. Lid: Cast iron, minimum depth 3 inches, nonlocking type. 3. Extensions: Cast iron 4. Two-piece box and lid for valves 4 inches through 12 inches, three-piece box and lid for valves larger than 12 inches with base sized for valve. 5. Valve extension stem for valves with operating nuts 3 feet or greater below finish grade. 6. Manufacturers and Products: a. East Jordan Iron Works; Cast-Iron Valve Boxes. b. Bingham & Taylor; Cast-Iron Valve Boxes. PART 3 - EXECUTION 3.1 PRE-DEMOLITION A. The Owner will operate the existing electric motor operators on the existing valves in the presence of the Contractor and Engineer to verify operation status prior to the demolition of the electric motor operators. BCRUA – Phase 1D WTP Expansion Issued for Bid Actuators for Process Valves 40 05 57 - 8 3.2 EXAMINATION A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for installation examination. B. Verify that field dimensions are as indicated on Shop Drawings. 3.3 INSTALLATION OF ACTUATORS ON EXISTING VALVES A. After installing the electric motor actuator on the existing valve, the actuators must be stroked to set the open and close limits. B. Actuators must be stroked at least three additional times in the Owner’s presence to verify and confirm the operation. 3.4 INSTALLATION A. Install in accordance with manufacturer’s instructions. B. Extension Stem for Operator: Where depth of valve operating nut is 3 feet or greater below finish grade, furnish operating extension stem with 2-inch operating nut to bring operating nut to a point within 6 inches of finish grade. C. Torque Tube: Where operator for quarter-turn valve is located on floor stand, furnish extension stem torque tube of a type properly sized for maximum torque capacity of valve. D. Floor Box and Stem: Steel extension stem length shall locate operating nut in floor box. E. Chain Wheel and Guide: Install chain wheel and guide assemblies or chain lever assemblies on manually operated valves over 6 feet above finish floor. Install chain to within 3 feet of finish floor. Where chains hang in normally traveled areas, use appropriate “L” type tie-back anchors. Install chains to within operator horizontal reach of 2 feet 6 inches maximum, measured from normal operator standing location or station. F. Install electric actuators above or horizontally adjacent to valve and gear box to optimize access to controls and external handwheel. 3.5 TESTS AND INSPECTION A. Automatic valves to be tested in conjunction with control system testing. Set opening and closing speeds, limit switches, as required or recommended by Engineer. 3.6 MANUFACTURER’S SERVICES A. Electric valve operators as listed in Schedules and shown on Drawings require manufacturer’s field services. B. Manufacturer’s Representative: Present at Site for minimum person-days listed below, travel time excluded: BCRUA – Phase 1D WTP Expansion Issued for Bid Actuators for Process Valves 40 05 57 - 9 1. Two (2) person-days on-site for inspection, functional and performance testing, and completion of Manufacturer’s Certificates of Proper Installation. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02) Fabricated Stainless Steel Slide Gates 40 05 59.23 - 1 SECTION 40 05 59. 23 - FABRICATED STAINLESS STEEL SLIDE GATES (Reissued by AD-02) PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Fabricated Stainless Steel Slide Gates. B. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Division 01 – General Requirements. 3. Section 01 91 00 – Facility Commissioning. 4. Section 09 96 00 – High-Performance Coatings. 5. Section 10 14 00 – Identification for Process Piping and Equipment. 6. Section 40 05 51 – Common Requirements for Process Valves. 7. Section 40 05 57 – Actuators for Process Valves. 1.2 REFERENCE STANDARDS A. American Water Works Association (AWWA): 1. C561, Fabricated Stainless Steel Slide Gates. B. National Sanitation Foundation International (NSF): 1. 61, Drinking Water System Components - Health Effects. C. Society for Protective Coatings/NACE International (SSPC/NACE): 1. SP 5/NACE No. 1, White Metal Blast Cleaning. 1.3 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Product Data: 1. Submit manufacturer product information for system materials and component equipment, including performance characteristics. 2. Include descriptive literature, bulletins, and/or catalogs of the equipment. 3. Include the total weight of the equipment including the weight of the single largest item or component. 4. Provide a complete total bill of materials for all equipment. C. Shop Drawings: 1. Indicate system materials and component equipment. Submit drawings showing details of construction, dimensions, weld requirements, and anchor bolt layout for each component of the system. 2. Calculations that demonstrate compliance with the deflections, stress and factor of safety specified. 3. Submit detailed instructions on installation requirements, including storage and handling procedures. 4. Submit qualifications for manufacturer. BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02) Fabricated Stainless Steel Slide Gates 40 05 59.23 - 2 5. Warranty information. D. Source Quality-Control Submittals: 1. Affidavit of Compliance: See AWWA C561. 2. Manufacturer's Certificate: Certify that products meet or exceed specified requirements. a. Section 01 33 00 – Submittal Procedures: Supplement 01. 3. Submit results of factory tests of equipment at the time of shipment. E. Field Quality-Control Submittals: 1. Section 01 33 00 – Submittal Procedures: Supplements 02 and 03. 2. Section 01 91 00 – Facility Commissioning: Submittal requirements. 3. Indicate results of Contractor-furnished tests and inspections. 4. Certify that equipment has been installed according to manufacturer instructions. 1.4 CLOSOUT SUBMITTALS A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for Operation and Maintenance Manual. B. Section 01 91 00 – Facility Commissioning: Closeout Submittal requirements. C. Project Record Documents: Record actual location and final orientation of gates. 1.5 QUALITY ASSURANCE A. All system components shall be supplied to the Contractor by a single Manufacturer. The equipment shall be manufactured, constructed, and installed in accordance with the best practices and methods and operate satisfactorily when installed as shown on the Drawings. B. Should equipment which differs from these Specifications be offered and determined to be equal to that specified, such equipment shall be acceptable only on the basis that any revisions in the design and/or construction of affected areas, including structure, piping, appurtenant equipment, electric, etc., required to accommodate such a substitution be made at no additional cost to the Owner and be as approved by the Engineer. 1.6 QUALIFICATIONS A. Manufacturer: Company specializing in manufacturing products specified in this Section with minimum ten years' experience. 1.7 DELIVERY, STORAGE, AND HANDLING A. Section 01 60 00 - Product Requirements: Requirements for transporting, handling, storing, and protecting products. B. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage. C. Store materials according to manufacturer instructions. BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02) Fabricated Stainless Steel Slide Gates 40 05 59.23 - 3 D. Protection: 1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas. 2. Provide additional protection according to manufacturer instructions. 1.8 EXISTING CONDITIONS A. Field Measurements: 1. Verify field measurements prior to fabrication. 2. Indicate field measurements on Shop Drawings. 1.9 WARRANTY A. Reference Section 00700 – General Conditions, Article 7.17 for warranty terms. PART 2 - PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. Subject to compliance with the Contract Documents, the following manufacturers are acceptable: 1. Fontaine. 2. Golden Harvest. 3. Hydro-Gate. 4. Rodney Hunt. 5. Whipps. 6. Waterman. B. Submit request for substitution in accordance with Section 01 25 00 – Substitution Procedures. 2.2 DESIGN REQUIREMENTS AND MATERIALS A. General: Provide gates, stems, lifts and other appurtenances of size, type, material and construction shown on Drawings and as specified herein. B. Comply with requirements of Section 01 61 03 – Common Requirements for Equipment. C. Gates: Meet all requirements of AWWA C561 as modified per this Section. D. Maximum leakage rate: Per AWWA C561, allowable leakage shall not exceed 0.10 gpm/ft of seating perimeter under specified design head, seating or unseating. E. Materials: 1. Materials subject to dezincification or dealuminization prohibited. 2. “L” grades for all welded components. 3. Thimble, frame, guides, slide, yoke and stem guides: a. Stainless steel, Type 304 and Type 304L. 4. Gear housing: a. Cast iron, steel or ductile iron. 5. Actuator pedestal: BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02) Fabricated Stainless Steel Slide Gates 40 05 59.23 - 4 a. Stainless steel, Type 304. 6. Rising stem thrust nuts: a. Bronze, ASTM B584. 7. Stem couplings: a. Stainless steel, Type 304. 8. Stem guide bushings: a. Cast or extruded UV stabilized UHMW-PE, or b. Stainless steel, Type 304. 9. Stems: a. Stainless steel, Type 304. 10. Self-adjusting Seals: a. UV stabilized UHMW-PE. 11. Flush-bottom seals: a. EPDM. 12. Anchor bolts and fasteners: Stainless steel, Type 316. 13. Flush-bottom sill retainer: Stainless steel, Type 304. 14. Wedges and Pressure Pads: UV stabilized UHMW-PE, if required. F. Frame Fabrication: 1. One-piece frame: Conventional pedestal or wall mounted as indicated on Drawings. 2. Frame assembly, including guide members shall have a minimum thickness of ¼-inch. G. Slide Fabrication: 1. All structural components shall have a minimum thickness of 1/4-inch. 2. Slide deflection shall not exceed 1/720 of gate width at maximum design head or 1/16- inch, whichever is less. H. Seals: 1. All seals must be bolted or otherwise mechanically fastened to the frame or slide. 2. Flush bottom seals: Replaceable without disassembly of the gate. 3. Side and top seals of gate: Replaceable without removing gate. 2.3 GATE OPERATORS AND LIFTS A. General: Provide lifts in accordance with AWWA C561 or as modified in this Section. B. Rising Stem: Provide clear butyrate plastic stem cover with Mylar open-close indicator. C. Manual Operators: 1. Equip lift mechanism with a pedestal, torque tube, or baseplate, machined and drilled for mounting the lift housing and ready for bolting to the operating floor, top wall mounting bracket, or gate yoke, as shown on Drawings or specified. 2. Centerline of crank or handwheel: Approximately 36 IN above operating floor. 2.4 FABRICATION A. Specified in AWWA C561. B. All structural components of the frame and slide shall have adequate strength to prevent distortion during normal handling, installation, and while in service. BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02) Fabricated Stainless Steel Slide Gates 40 05 59.23 - 5 C. Welded Stainless Steel: Passivated to remove weld burn and scale after fabrication. 2.5 SOURCE QUALITY CONTROL A. Factory Test Reports: 1. Shop leakage tests. PART 3 - EXECUTION 3.1 EXAMINATION A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for installation examination. B. Verify layout, type, material, and orientation of connections. 3.2 INSTALLATION A. Install products in accordance with manufacturer's instructions. B. Install anchor bolts in accordance with the manufacturer’s recommendations and setting drawings. C. For identification and tagging, and for warning or caution signs, comply with Section 10 14 00– Identification for Process Piping and Equipment. 3.3 FIELD QUALITY CONTROL A. Section 01 40 00 – Quality Requirements. B. Sections 01 70 00 – Execution and Closeout Requirements, and 01 91 00 – Facility Commissioning: Testing, Startup, Demonstration, and Training requirements. C. Field Testing: 1. Leakage: Test gate under design seating head and adjust to maximum leakage specified. D. Services of Manufacturer: 1. See Sections 01 40 00 – Quality Requirements and 01 70 00 – Execution and Closeout Requirements. 2. Provide the services of a manufacturer’s representative specifically trained in the installation, testing, and maintenance of equipment specified herein. Such services shall be provided by a representative who is a direct, full-time employee of the manufacturer. 3. Services of equipment manufacturer's representative shall include: a. Inspect equipment covered by this Section. b. Supervise adjustments and installation checks. c. Provide test equipment, tools, and instruments necessary to accomplish equipment testing. d. Conduct initial start-up of equipment, perform operational checks, and supervise acceptance testing. BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02) Fabricated Stainless Steel Slide Gates 40 05 59.23 - 6 e. Provide a written statement that manufacturer's equipment has been installed properly, started up and is ready for operation by Owner. f. Instruct Owner on operation and maintenance of furnished equipment. 4. Services of manufacturer’s representative shall be provided for the amount of time specified below. a. Supervision and start-up: 6 hours. b. Instruct Owner on operation and maintenance: 2 hours. 3.4 GATE SCHEDULE A. The following table is a schedule for fabricated stainless steel slide gates. Gate Tag No.Size WxH (IN) Design Head, (FT) a Approx. IE g (FT) Opening Direction b Type of Closure c Type of Lift Mechanism d Stem e Wall Thimble Required f TSC-SLG-FL702 30 x 30 2 1076 Up Op FM CH R No TSC-SLG-FL802 30 x 30 2 1076 Up Op FM CH R No TSC-SLG-SB401 48 x 36 2 1074 Up Op FB CH R No TSC-SLG-SB402 42 x 42 5.5 1071 Up Op FB Ped w/ CH R No TSC-SLG-SB403 42 x 42 5.5 1071 Up Op FB Ped w/ CH R No Abbreviations: a Design Head: Measured from surface of water to centerline of gate, in FT. b Opening Direction: Dn Op = Downward Opening; Up Op = Upward Opening. c Type of Closure: W = Weir Service; FB = Flush Bottom (Embedded); FM = Face Mounted. d Type of Lift Mechanism: Ped = Pedestal; Elec = Electric; Hdwl = Handwheel; Hyd = Hydraulic, CH = Crank Handle, SQN = Square Nut. e Rising or Nonrising Stem: R = Rising; NR = Nonrising. f Thimble Required: Wall Thimble is required = YES; Wall Thimble is not required = No. g IE = Invert Elevation (Reference Drawings). END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Cast Iron Slide Gates 40 05 59.33 - 1 SECTION 40 05 59. 33 - CAST IRON SLIDE GATES (Revised by AD-02) PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Cast Iron Slide Gates. B. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Division 01 – General Requirements. 3. Section 01 91 00 – Facility Commissioning. 4. Section 09 96 00 – High-Performance Coatings. 5. Section 10 14 00 – Identification for Process Piping and Equipment. 6. Section 40 05 51 – Common Requirements for Process Valves. 7. Section 40 05 57 – Actuators for Process Valves. 1.2 REFERENCE STANDARDS A. American Water Works Association (AWWA): 1. C560, Cast-Iron Slide Gates. B. National Sanitation Foundation International (NSF): 1. 61, Drinking Water System Components - Health Effects. C. Society for Protective Coatings/NACE International (SSPC/NACE): 1. SP 5/NACE No. 1, White Metal Blast Cleaning. 1.3 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Product Data: 1. Submit manufacturer product information for system materials and component equipment, including performance characteristics. 2. Include descriptive literature, bulletins, and/or catalogs of the equipment. 3. Include the total weight of the equipment including the weight of the single largest item or component. 4. Provide a complete total bill of materials for all equipment. C. Shop Drawings: 1. Indicate system materials and component equipment. Submit drawings showing details of construction, dimensions, weld requirements, and anchor bolt layout for each component of the system. 2. Calculations that demonstrate compliance with the deflections, stress and factor of safety specified. 3. Provide complete description of surface preparation and shop prime painting. 4. Submit detailed instructions on installation requirements, including storage and handling procedures. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Cast Iron Slide Gates 40 05 59.33 - 2 5. Submit qualifications for manufacturer. 6. Warranty information. D. Source Quality-Control Submittals: 1. Affidavit of Compliance: See AWWA C560. 2. Manufacturer's Certificate: Certify that products meet or exceed specified requirements. a. Section 01 33 00 – Submittal Procedures: Supplement 01. 3. Submit results of factory tests of equipment at the time of shipment. E. Field Quality-Control Submittals: 1. Section 01 33 00 – Submittal Procedures: Supplements 02 and 03. 2. Section 01 91 00 – Facility Commissioning: Submittal requirements. 3. Indicate results of Contractor-furnished tests and inspections. 4. Certify that equipment has been installed according to manufacturer instructions. 1.4 CLOSEOUT SUBMITTALS A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for Operation and Maintenance Manual. B. Section 01 91 00 – Facility Commissioning: Closeout Submittal requirements. C. Project Record Documents: Record actual location and final orientation of gates. 1.5 QUALITY ASSURANCE A. All system components shall be supplied to the Contractor by a single Manufacturer. The equipment shall be manufactured, constructed, and installed in accordance with the best practices and methods and operate satisfactorily when installed as shown on the Drawings. B. Should equipment which differs from these Specifications be offered and determined to be equal to that specified, such equipment shall be acceptable only on the basis that any revisions in the design and/or construction of affected areas, including structure, piping, appurtenant equipment, electric, etc., required to accommodate such a substitution be made at no additional cost to the Owner and be as approved by the Engineer. 1.6 QUALIFICATIONS A. Manufacturer: Company specializing in manufacturing products specified in this Section with minimum ten years' experience. 1.7 DELIVERY, STORAGE, AND HANDLING A. Section 01 60 00 - Product Requirements: Requirements for transporting, handling, storing, and protecting products. B. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage. C. Store materials according to manufacturer instructions. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Cast Iron Slide Gates 40 05 59.33 - 3 D. Protection: 1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas. 2. Provide additional protection according to manufacturer instructions. 1.8 EXISTING CONDITIONS A. Field Measurements: 1. Verify field measurements prior to fabrication. 2. Indicate field measurements on Shop Drawings. 1.9 WARRANTY A. Reference Section 00700 – General Conditions, Article 7.17 for warranty terms. PART 2 - PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. Subject to compliance with the Contract Documents, the following manufacturers are acceptable: 1. Golden Harvest. 2. Hydro-Gate. 3. Rodney Hunt. 4. Whipps. 5. Waterman. B. Submit request for substitution in accordance with Section 01 25 00 – Substitution Procedures. 2.2 DESIGN REQUIREMENTS AND MATERIALS A. General: Provide gates, stems, lifts and other appurtenances of size, type, material and construction shown on Drawings and as specified herein. B. Comply with requirements of Section 01 61 03 – Common Requirements for Equipment. C. Gates: Meet all requirements of AWWA C560, except as modified per this Section. D. Maximum leakage rate: Per AWWA C560. E. Materials: 1. Materials subject to dezincification or dealuminization prohibited. 2. “L” grades for all welded components. 3. Thimble, frame, guides, slide, yoke, pedestal, stem guides and gear housing: a. Cast iron, ASTM A126, class B or ASTM A48, class 30. 4. Gears: a. Steel, AISI 8620, 4140 or 1117 or Bronze, ASTM B148 or B584. 5. Bearings: a. Bronze, ASTM B148. 6. Rising stem thrust nuts, wedges, stem couplings and stem guide bushings: BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Cast Iron Slide Gates 40 05 59.33 - 4 a. Bronze, ASTM B584. 7. Stems: a. Stainless steel, Type 304. 8. Seating faces: a. Bronze, ASTM B21. 9. Anchor bolts and fasteners: Stainless steel, Type 304. 10. Flush-bottom seal: Elastomeric, ASTM D2000. 11. Flush-bottom sill retainer: Stainless steel, Type 304. F. Fabrication: One-piece frames. 1. One-piece frame: Conventional pedestal or wall mounted. 2. Flush bottom seals: Easily replaceable without disassembly of the gate. 3. Side and top seals of gate: Replaceable without removing gate or without dewatering. 2.3 GATE OPERATORS AND LIFTS A. General: Provide lifts in accordance with AWWA C560, or as modified in this Section. B. Rising Stem: Provide clear butyrate plastic stem cover with Mylar open-close indicator. C. Manual Operators: 1. Equip lift mechanism with a pedestal, torque tube, or baseplate, machined and drilled for mounting the lift housing and ready for bolting to the operating floor, top wall mounting bracket, or gate yoke, as shown on Drawings or specified. 2. Centerline of crank or handwheel: Approximately 36 IN above operating floor. 2.4 FABRICATION A. Specified in AWWA C560. 2.5 SOURCE QUALITY CONTROL A. Factory Test Reports: 1. Shop leakage tests. PART 3 - EXECUTION 3.1 EXAMINATION A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for installation examination. B. Verify layout, type, material, and orientation of connections. 3.2 INSTALLATION A. Install products in accordance with manufacturer's instructions. 1. Gates will be installed onto existing wall thimbles as indicated on Drawings. Contractor shall verify compatibility of wall thimbles with gate manufacturer. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Cast Iron Slide Gates 40 05 59.33 - 5 B. Install anchor bolts in accordance with the manufacturer’s recommendations and setting drawings. C. For identification and tagging, and for warning or caution signs, comply with Section 10 14 00– Identification for Process Piping and Equipment. 3.3 FIELD QUALITY CONTROL A. Section 01 40 00 – Quality Requirements. B. Sections 01 70 00 – Execution and Closeout Requirements, and 01 91 00 – Facility Commissioning: Testing, Startup, Demonstration, and Training requirements. C. Field Testing: 1. Leakage: Test gate under design seating head and adjust to maximum leakage specified. D. Services of Manufacturer: 1. See Sections 01 40 00 – Quality Requirements and 01 70 00 – Execution and Closeout Requirements. 2. Provide the services of a manufacturer’s representative specifically trained in the installation, testing, and maintenance of equipment specified herein. Such services shall be provided by a representative who is a direct, full-time employee of the manufacturer. 3. Services of equipment manufacturer's representative shall include: a. Inspect equipment covered by this Section. b. Supervise adjustments and installation checks. c. Provide test equipment, tools, and instruments necessary to accomplish equipment testing. d. Conduct initial start-up of equipment, perform operational checks, and supervise acceptance testing. e. Provide a written statement that manufacturer's equipment has been installed properly, started up and is ready for operation by Owner. f. Instruct Owner on operation and maintenance of furnished equipment. 4. Services of manufacturer’s representative shall be provided for the amount of time specified below. a. Supervision and start-up: 6 hours. b. Instruct Owner on operation and maintenance: 2 hours. 3.4 GATE SCHEDULE A. The following table is a schedule for cast iron slide gates. Gate Tag No.Size WxH (IN) Design Head, (FT)a Approx. IEg (FT) Opening Directionb Type of Closurec Type of Lift Mechanismd Steme Wall Thimble Requiredf TSC-SLG-FL701 30 x 30 15 1063.25 Up Op FM CH Ped with CH (AD-02) R No, existing TSC-SLG-FL801 30 x 30 15 1063.25 Up Op FM CH Ped with CH (AD-02) R No, existing Abbreviations: a Design Head: Measured from surface of water to centerline of gate, in FT. b Opening Direction: Dn Op = Downward Opening; Up Op = Upward Opening. c Type of Closure: W = Weir Service; FB = Flush Bottom (Embedded); FM = Face Mounted. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Cast Iron Slide Gates 40 05 59.33 - 6 d Type of Lift Mechanism: Ped = Pedestal; Elec = Electric; Hdwl = Handwheel; Hyd = Hydraulic, CH = Crank Handle, SQN = Square Nut. e Rising or Nonrising Stem: R = Rising; NR = Nonrising. f Thimble Required: Wall Thimble is required = YES; Wall Thimble is not required = No. g IE = Invert Elevation (Reference Drawings). END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Gate Valves 40 05 61 - 1 SECTION 40 05 61 - GATE VALVES PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Resilient-seated gate valves. 2. General duty gate valves smaller than 3 inches. B. Related Sections: 1. Section 40 05 51 – Common Requirements for Process Valves: Basic materials and methods related to valves commonly used for process systems. 2. Section 40 05 57 – Actuators for Process Valves. 1.2 REFERENCE STANDARDS A. American Water Works Association: 1. AWWA C509 - Resilient-Seated Gate Valves for Water Supply Service. 2. AWWA C515, Reduced-Wall, Resilient-Seated Gate Valves for Water Supply Service. B. ASME International: 1. ASME B16.1 - Gray Iron Pipe Flanges and Flanged Fittings: Classes 25, 125, and 250. 2. ASME B16.5 - Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24 Metric/Inch Standard. 3. ASME B16.42 - Ductile Iron Pipe Flanges and Flanged Fittings: Classes 150 and 300. 4. ASME B1.20.1 - Pipe Threads, General Purpose, Inch. C. ASTM International: 1. ASTM A126 - Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings. 2. ASTM B62 - Standard Specification for Composition Bronze or Ounce Metal Castings. 3. ASTM B584 - Standard Specification for Copper Alloy Sand Castings for General Applications. 4. ASTM D1784 - Standard Specification for Rigid Poly(Vinyl Chloride) (PVC) Compounds and Chlorinated Poly(Vinyl Chloride) (CPVC) Compounds. D. Manufacturers Standardization Society of the Valve and Fittings Industry: 1. MSS SP-70 - Gray Iron Gate Valves, Flanged and Threaded Ends. 2. MSS SP-80 - Bronze Gate, Globe, Angle and Check Valves. 1.3 SUBMITTALS A. See Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. As specified in Section 40 05 51 – Common Requirements for Process Valves: Submittal requirements for compliance with this Section. BCRUA - Phase 1D WTP Expansion Issued for Bid Gate Valves 40 05 61 - 2 1.4 CLOSEOUT SUBMITTALS A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for submittals and Operation and Maintenance data. B. Project Record Documents: Record actual locations of valves and actuators, and centerline elevations. PART 2 - PRODUCTS 2.1 GENERAL A. AWWA gate valves to be in full compliance with stated AWWA standard and the following requirements: 1. Reference Valve Schedule in Section 40 05 51 – Common Requirements for Process Valves. 2. End connection as listed in Valve Schedule or shown on Drawings. Pressure class shall meet or exceed adjoining pipe system. 3. Unless specified or shown otherwise, provide 2-inch operating nut and handwheel for AWWA gate valves 12 inches and smaller. 4. Provide totally enclosed spur or bevel gear operator with indicator for AWWA gate valves 14 inches and larger. 5. Furnish actuator integral with valve. Reference Section 40 05 57 – Actuators for Process Valves. 6. Provide Affidavit of Compliance per the applicable AWWA standard for AWWA gate valves. 7. Mark AWWA gate valves with manufacturer’s name or mark, year of valve casting, valve size, and working water pressure. 8. Repaired AWWA gate valves shall not be submitted or supplied. 9. Supply AWWA gate valves with stainless steel bolting. 2.2 RESILIENT-SEATED GATE VALVES A. Resilient Seated Gate Valve 3 Inches to 12 Inches: 1. Ductile iron body and gate, resilient wedge fully encapsulated with EPDM rubber, bronze stem and stem nut, non-rising stem, counterclockwise open rotation, in accordance with AWWA C515, minimum design working water pressure 250 psig, full port, fusion-epoxy coated inside and outside per AWWA C550, NSF/ANSI 61 certified. 2. Manufacturers and Products: a. American Flow Control; Series 2500. b. M&H Valve; AWWA C515. c. U.S. Pipe; A-USPO. d. J&S Valve; Series 6000. 2.3 GENERAL-DUTY GATE VALVES - SMALLER THAN 3 INCHES A. Gate Valve 3 Inches and Smaller: 1. All-bronze, screwed bonnet, packed gland, single solid wedge gate, non-rising stem, Class 125 rated 200 psi CWP, complies with MSS SP-80 Type 1. 2. Manufacturers and Products: BCRUA - Phase 1D WTP Expansion Issued for Bid Gate Valves 40 05 61 - 3 a. Crane; Figure 438, NPT threaded ends. b. Stockham; Figure B103, NPT threaded ends. c. Crane; Figure 1324, soldered ends. d. Stockham; Figure B104, soldered ends. B. Gate Valve 3 Inches and Smaller: 1. All-bronze, screwed bonnet, packed gland, single solid wedge gate, rising stem, Class 125 rated 200 psi CWP, complies with MSS SP-80 Type 2. 2. Manufacturers and Products: a. Crane; Figure 428, NPT threaded ends. b. Stockham; Figure B-100, NPT threaded ends. c. Crane; Figure 1334, soldered ends. d. Stockham; Figure B-108, soldered ends. 2.4 SOURCE QUALITY CONTROL A. Section 01 40 00 - Quality Requirements: Requirements for testing, inspection, and analysis. B. As specified in Section 40 05 51 - Common Requirements for Process Valves. C. Testing: Test gate valves according to AWWA C509. PART 3 - EXECUTION 3.1 As specified in Section 40 05 51 - Common Requirements for Process Valves: PART 3 EXECUTION requirements for compliance with this Section. 3.2 INSTALLATION A. Do not install gate valves inverted or with stems sloped more than 45 degrees from upright unless the valve is specified and manufactured specifically for such orientation. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Plug Valves 40 05 62 - 1 SECTION 40 05 62 - PLUG VALVES PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Eccentric plug valves. B. Related Sections: 1. Section 40 05 51 – Common Requirements for Process Valves: Basic materials and methods related to valves commonly used for process systems. 2. Section 40 05 57 – Actuators for Process Valves. 1.2 REFERENCE STANDARDS A. American Water Works Association: 1. AWWA C517 - Resilient-Seated Cast-Iron Eccentric Plug Valves. B. ASME International: 1. ASME B16.1 - Gray Iron Pipe Flanges and Flanged Fittings: Classes 25, 125, and 250. 2. ASME B16.5 - Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24 Metric/Inch Standard. 3. ASME B16.11 - Forged Fittings, Socket-Welding and Threaded. 4. ASME B16.42 - Ductile Iron Pipe Flanges and Flanged Fittings: Classes 150 and 300. 5. ASME B1.20.1 - Pipe Threads, General Purpose, Inch. C. ASTM International: 1. ASTM A536 - Standard Specification for Ductile Iron Castings. 2. ASTM B62 - Standard Specification for Composition Bronze or Ounce Metal Castings. 1.3 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. As specified in Section 40 05 51 – Common Requirements for Process Valves: Submittal requirements for compliance with this Section. 1.4 CLOSEOUT SUBMITTALS A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for submittals and Operation and Maintenance data. B. Project Record Documents: Record actual locations of valves and actuators, and centerline elevations. BCRUA - Phase 1D WTP Expansion Issued for Bid Plug Valves 40 05 62 - 2 PART 2 - PRODUCTS 2.1 GENERAL A. Reference Valve Schedule in Section 40 05 51 – Common Requirements for Process Valves. End connection as listed in Valve Schedule or shown on Drawings. Pressure class shall meet or exceed adjoining pipe system. B. Furnish actuator integral with valve. Reference Section 40 05 07 – Actuators for Process Valves. C. Supply valves with stainless steel bolting. 2.2 ECCENTRIC PLUG VALVES A. Eccentric Plug Valve 2 Inches and Smaller: 1. Nonlubricated type, rated 175 psig CWP, drip-tight shutoff with pressure from either direction, cast-iron body, threaded ends, lever operator, cast-iron plug with round or rectangular port, plug coated with Buna-N, stem bearing lubricated stainless steel or bronze, stem seal multiple V-rings, or U-cups with O-rings of nitrile rubber. 2. Manufacturers and Products: a. Pratt; Ballcentric. b. DeZurik; Style PEC. c. Milliken; Millcentric Series 603. B. Eccentric Plug Valve 4 Inches to 20 Inches: 1. Comply with AWWA C517. 2. Nonlubricated type, rated 150 psig CWP, drip-tight shutoff with pressure from either direction, cast-iron body, plug cast iron with round or rectangular port of no less than 100 percent of connecting pipe area, plug facing EPDM, seats welded nickel, stem bearings lubricated stainless steel or bronze, stem seal multiple V-rings or U-cups with O-rings of EPDM, grit seals on both upper and lower bearings. 3. Size operator for 1.5 times maximum operating shutoff pressure differential for direct and reverse pressure, whichever is higher. 4. Stem seal shall be adjustable and replaceable without disassembling valve or bonnet. 5. Manufacturers and Products: a. Pratt; Ballcentric. b. DeZurik; Style PEC. c. Milliken; Millcentric Series 600. d. Val-Matic; Cam-Centric. 2.3 SOURCE QUALITY CONTROL A. As specified in Section 40 05 51 – Common Requirements for Process Valves. B. Testing: Test AWWA plug valves according to AWWA C517. BCRUA - Phase 1D WTP Expansion Issued for Bid Plug Valves 40 05 62 - 3 PART 3 - EXECUTION 3.1 As specified in Section 40 05 51 – Common Requirements for Process Valves: PART 3 EXECUTION requirements for compliance with this Section. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Ball Valves 40 05 63 - 1 SECTION 40 05 63 - BALL VALVES PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Metallic ball valves. 2. Plastic ball valves. B. Related Sections: 1. Section 40 05 51 – Common Requirements for Process Valves: Basic materials and methods related to valves commonly used for process systems. 2. Section 40 05 57 – Actuators for Process Valves. 1.2 REFERENCE STANDARDS A. American Water Works Association: 1. AWWA C507 - Ball Valves, 6 In. Through 60 In. (150 mm Through 1,500 mm). B. ASME International: 1. ASME B16.1 - Gray Iron Pipe Flanges and Flanged Fittings: Classes 25, 125, and 250. 2. ASME B16.5 - Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24 Metric/Inch Standard. 3. ASME B16.11 - Forged Fittings, Socket-Welding and Threaded. 4. ASME B16.42 - Ductile Iron Pipe Flanges and Flanged Fittings: Classes 150 and 300. 5. ASME B1.20.1 - Pipe Threads, General Purpose, Inch. C. ASTM International: 1. ASTM D1784 - Standard Specification for Rigid Poly(Vinyl Chloride) (PVC) Compounds and Chlorinated Poly(Vinyl Chloride) (CPVC) Compounds. 2. ASTM D3222 - Standard Specification for Unmodified Poly(Vinylidene Fluoride) (PVDF) Molding Extrusion and Coating Materials. 3. ASTM D4101 - Standard Specification for Propylene Injection and Extrusion Materials. D. Manufacturers Standardization Society of the Valve and Fittings Industry: 1. MSS SP-110 - Ball Valves Threaded, Socket-Welding, Solder Joint, Grooved and Flared Ends. 1.3 SUBMITTALS A. Reference Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. As specified in Section 40 05 51 – Common Requirements for Process Valves: Submittal requirements for compliance with this Section. 1.4 CLOSEOUT SUBMITTALS A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for submittals and Operation and Maintenance data. BCRUA - Phase 1D WTP Expansion Issued for Bid Ball Valves 40 05 63 - 2 B. Project Record Documents: Record actual locations of valves and actuators, and centerline elevations. PART 2 - PRODUCTS 2.1 METALLIC BALL VALVES A. Stainless Steel Ball Valve 2 Inches and Smaller: 1. Two-piece, full port, ASTM A276 GR 316 or ASTM A351/A351M GR CF8M stainless steel body and end piece, NPT threaded ends, ASTM A276 Type 316 stainless steel ball, reinforced PTFE seats, seals, and packing, adjustable packing gland, blowout proof stainless steel stem, stainless steel lever operator with vinyl grip, rated 1,000 psig cold working pressure, complies with MSS SP-110. 2. Manufacturers and Products: a. Conbraco Apollo; 76F-100 Series. b. Nibco; T-585-S6-R-66-LL. c. Or approved equal. B. Forged Carbon Steel Ball Valve 3 Inches and Smaller: 1. Two piece ASTM A108-CS body; NPT threaded ends, ASTM A276 Type 316 or 304 stainless steel ball; reinforced PTFE seats, seals, and packing; adjustable packing gland; blowoff proof ASTM A108 stem; steel liver operator with vinyl grip; minimum rated 2,000 psig cold working pressure; complies with MSS SP-110. 2. Acceptable Manufacturers and Products: a. Conbraco Apollo; 72-100 Series. b. Nibco; T-580-CS-R-25. c. Or approved equal. C. Bronze Ball Valve 2 Inches and Smaller: 1. Quarter turn, two piece, bronze bodied with full port orifice. Valves shall have Type 316 stainless steel ball and stem with PTFE seats and seals. Ball shall be floating, non- lubricated type. Conform to Federal Specification WW-V-35C, Type II, Class A, Style 3. 2. Valves shall have bottom loaded, pressure retaining stems with NPT ends, unless illustrated otherwise. Install threaded brass nipples and unions on each side of valve, unless illustrated otherwise. 3. Valves shall have minimum working pressure rating of 150 psi. 4. Acceptable Manufacturers: a. Watts. b. Jamesbury. c. Crane. d. Stockham. e. Nibco. f. Or approved equal. 2.2 PLASTIC BALL VALVES A. General Requirements: Plastic ball valves designed for use with corrosive fluids shall be fabricated of polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), or BCRUA - Phase 1D WTP Expansion Issued for Bid Ball Valves 40 05 63 - 3 polyvinylidene fluoride (PVDF), as recommended by the manufacturer for use in the service indicated. Valves shall have manual operators except as otherwise indicated. B. Provide vented ball valve for sodium hypochlorite service. C. PVC Ball Valve 2 Inches and Smaller: 1. Rated 150 psi at 73 degrees F, with ASTM D1784, Type I, Grade 1 polyvinyl chloride body, ball, and stem, end entry, double union design, solvent-weld socket ends, elastomer seat, Viton or Teflon O-ring stem seals, to block flow in both directions. 2. Manufacturers and Products: a. Nibco; Chemtrol Tru-Bloc. b. ASAHI/America; Type 21. c. Spears; True Union. d. Georg Fischer. D. PVC Ball Valve 3 Inches and 4 Inches: 1. Rated 150 psi at 73 degrees F, with ASTM D1784 Type I, Grade 1 PVC full port body, Teflon seat, Viton O-ring stem, face and carrier seals, end entry design with dual union, solvent-weld socket ends, or single union ball valve with flanged ends drilled to ASME B16.1. 2. Manufacturers and Products: a. Nibco; Chemtrol Tru-Bloc. b. ASAHI/America; Type 21. c. Georg Fischer. E. CPVC Ball Valve 2 Inches and Smaller: 1. Rated 150 psi at 100 degrees F, 80 psi at 140 degrees, with ASTM D1784, Type IV, Grade 1 chlorinated polyvinyl chloride (CPVC) body, ball, and stem, end entry, double union design, with solvent-weld socket ends or single union ball with flanged ends drilled to ASME B16.1, replaceable Teflon seat, Viton or Teflon O-ring stem seals, to block flow in both directions. 2. Manufacturers and Products: a. Nibco; Chemtrol Tru-Bloc. b. ASAHI/America; Type 21. c. Spears; True Union. d. Georg Fischer. 2.3 SOURCE QUALITY CONTROL A. Section 01 40 00 – Quality Requirements: Requirements for testing, inspection, and analysis. B. As specified in Section 40 05 51 – Common Requirements for Process Valves. PART 3 - EXECUTION 3.1 As specified in Section 40 05 51 – Common Requirements for Process Valves: PART 3 EXECUTION requirements for compliance with this Section. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Butterfly Valves 40 05 64 - 1 SECTION 40 05 64 - BUTTERFLY VALVES PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Rubber-seated butterfly valves. B. Related Sections: 1. Section 40 05 51 – Common Requirements for Process Valves: Basic materials and methods related to valves commonly used for process systems. 2. Section 40 05 57 – Actuators for Process Valves. 1.2 REFERENCE STANDARDS A. American Water Works Association: 1. AWWA C504 - Rubber-Seated Butterfly Valves. B. ASME International: 1. ASME B16.1 - Gray Iron Pipe Flanges and Flanged Fittings: Classes 25, 125, and 250. 2. ASME B16.5 - Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24 Metric/Inch Standard. 3. ASME B16.42 - Ductile Iron Pipe Flanges and Flanged Fittings: Classes 150 and 300. C. ASTM International: 1. ASTM A536 - Standard Specification for Ductile Iron Castings. 2. ASTM D1784 - Standard Specification for Rigid Poly(Vinyl Chloride) (PVC) Compounds and Chlorinated Poly(Vinyl Chloride) (CPVC) Compounds. 3. ASTM D3222 - Standard Specification for Unmodified Poly(Vinylidene Fluoride) (PVDF) Molding Extrusion and Coating Materials. 4. ASTM D4101 - Standard Specification for Propylene Injection and Extrusion Materials. 1.3 FACTORY TESTING A. As applicable, valves shall be tested in compliance with AWWA C504 and Section 40 05 51 – Common Requirements for Process Valves. B. Proof-of-design tests reports shall be submitted in compliance with Section 40 05 51 – Common Requirements for Process Valves and AWWA C504, as applicable. 1.4 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. As specified in Section 40 05 51 – Common Requirements for Process Valves: Submittal requirements for compliance with this Section. C. For AWWA valves 8 Inches and larger, submit “Affidavit of Compliance” in accordance with AWWA C504. BCRUA - Phase 1D WTP Expansion Issued for Bid Butterfly Valves 40 05 64 - 2 1.5 CLOSEOUT SUBMITTALS A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for submittals and Operation and Maintenance data. B. Project Record Documents: Record actual locations of valves and actuators, and centerline elevations. PART 2 - PRODUCTS 2.1 GENERAL A. In full compliance with ANSI/AWWA C504 and following requirements: 1. Suitable for isolation, throttling operations, and infrequent operation after periods of inactivity. 2. Elastomer seats which are bonded or vulcanized to the body shall have adhesive integrity of bond between seat and body assured by testing, with minimum 75-pound pull in accordance with ASTM D429, Method B. 3. Bubble-tight with rated pressure applied from either side. Test valves with pressure applied in both directions. 4. No travel stops for disc on interior of body. 5. Self-adjusting V-type or O-ring shaft seals. 6. Isolate metal-to-metal thrust bearing surfaces from flow stream. 7. Provide traveling nut or worm gear actuator integral with valve. a. Valve actuators to meet the requirements of AWWA C504. b. Buried service operators shall withstand 450 foot-pounds of input torque at fully open and fully closed positions. c. Reference Section 40 05 07 for additional actuator requirements. 8. Provide linings and coatings per AWWA, unless otherwise indicated on Drawings or specified herein. 9. Valves to be in full compliance with NSF/ANSI 61 and NSF/ANSI 372. 10. Supply butterfly valves with stainless steel bolting. 2.2 RUBBER-SEATED BUTTERFLY VALVES A. Butterfly Valve Water Works Service 3 Inches to 72 Inches: 1. AWWA C504, Class 150B. 2. Seat: Resilient. Comply with AWWA C504. Seat shall be bonded, vulcanized, or mechanically retained in valve body or disc and fully adjustable without removal of the valve. 3. Short body type, flanged ends. a. Flanges: Short body with Class 125/150 flanges complying with ASME B16.1/B16.5. Use wafer body only where indicated with fully tapped anchor lugs drilled per ASME B16.5. 4. Shaft seals: Designed for use with standard split-V type packing per AWWA C504. 5. Working pressure: Rated for 150 psi. 6. Materials: a. Valve body: ASTM A126, Class B cast iron or ASTM A536, Grade 65-45-12 ductile iron. BCRUA - Phase 1D WTP Expansion Issued for Bid Butterfly Valves 40 05 64 - 3 b. Valve disc: ASTM A536, Grade 65-45-12 ductile iron. c. Valve shaft: Stainless steel, 18-8, Type 304 or 316. d. Seat: EPDM. e. Seating surface: ASTM A276, 18-8, stainless steel. 7. Provide epoxy lining and coating in compliance with AWWA C550. 8. Manufacturers and Products: a. Pratt; Model 2FII or Triton XR-70. b. DeZurik; AWWA Valve. c. Crispin; K-Flo. d. Val-Matic; Series #2000 AWWA Valve. B. Butterfly Valves for Air Service: 1. General: Butterfly valves for air systems shall be designed to meet or exceed the requirements of ANSI B16.104 and MSS-SP-67. Butterfly valves shall be designed for pressures from vacuum to 125 psi, and temperatures from minus 40 degrees F to 250 degrees F continuous service and 300 degrees F intermittent service. Provide ANSI Class VI shutoff. 2. Body: Fabricated with Type 304 stainless steel with either wafer or lug design, and drilled to comply with ANSI B16.1, Class 125. 3. Disc: Fabricated with Type 304 stainless steel with an edge of Type 316 stainless steel; designed with an air-profile. 4. Seat: Resilient seat shall be mounted in the valve body. The seat shall be field-replaceable without special tools. Seat material shall be Viton or RTFE rated for 300 degrees F minimum. Seat shall provide a tight shut-off at the indicated temperatures. 5. Shaft: Fabricated with stainless steel, Type 316. Shaft seals shall be self-adjusting and made from Viton. 6. Bearings: Self-lubricating corrosion resistant sleeve type made of RTPE. 7. Packing: PTFE adjustable or self-adjustable type, suitable for the temperature and service conditions. 8. Manufacturers and Products: a. Keystone Valve – USA; K-LOK. b. Flowseal; Soft Seat high performance butterfly valve. c. Fisher; Posiseal. d. Jamesbury; Wafersphere. e. Or approved equal. 2.3 SOURCE QUALITY CONTROL A. Section 01 40 00 – Quality Requirements: Requirements for testing, inspection, and analysis. B. As specified in Section 40 05 51 – Common Requirements for Process Valves. C. Testing: Test butterfly valves according to AWWA C504. BCRUA - Phase 1D WTP Expansion Issued for Bid Butterfly Valves 40 05 64 - 4 PART 3 - EXECUTION 3.1 As specified in Section 40 05 51 - Common Requirements for Process Valves: PART 3 EXECUTION requirements for compliance with this Section. 3.2 INSTALLATION A. Exposed butterfly valves shall be installed to permit removal of valve assembly without dismantling the valve or operator. B. For buried valves larger than 48 Inches, install according to Drawing details and AWWA C504 recommendations. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Check Valves 40 05 65 - 1 SECTION 40 05 65 - CHECK VALVES PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Plastic ball check valves of the types and sizes indicated with appurtenances and accessories. B. Related Sections: 1. Section 40 05 51 – Common Requirements for Process Valves. 2. Section 40 05 57 – Actuators for Process Valves. 1.2 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. As specified in Section 40 05 51 – Common Requirements for Process Valves: Submittal requirements for compliance with this Section. 1.3 CLOSEOUT SUBMITTALS A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for submittals and Operation and Maintenance data. PART 2 - PRODUCTS 2.1 PLASTIC BALL CHECK VALVES A. General: Plastic ball check valves designed for corrosive fluids, in sizes up to 4-inch, shall be used for vertical up-flow conditions only, unless the valves include spring returns. B. Construction: The valve bodies and balls shall be fabricated with polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), polyvinylidene fluoride (PVDF), or polypropylene (PP) and recommended by the manufacturer for the service indicated. Valve material shall match adjoining piping unless noted otherwise. Valves shall include unions with socket connections, or flanged ends conforming to ANSI B16.5, Class 150 for valves greater than 2-inch diameter. Seals shall have Viton O-rings or as required for chemical compatibility and valve design shall minimize possibility of the balls sticking or chattering. Spring returns shall be PTFE coated and suitable for intended chemical service. Valves shall be suitable for a maximum working non- shock pressure of 150 psi at 73 degrees F. C. Manufacturers and Products: 1. PVC Ball Check Valve 4-IN and Smaller: a. Georg Fischer. b. Nibco; Chemtrol Tru-Union. c. ASAHI/America. d. Spears; True Union. BCRUA - Phase 1D WTP Expansion Issued for Bid Check Valves 40 05 65 - 2 2.2 PLASTIC FOOT VALVES A. General: Plastic ball check foot valves designed for service in chemical storage tanks. B. Construction: PVC or CPVC body and screen, and recommended by the manufacturer for the service indicated. Valve material shall match adjoining piping unless noted otherwise. Valves shall include unions with socket connections, or flanged ends conforming to ANSI B16.5, Class 150 for valves greater than 2-inch diameter. Seals shall have Viton O-rings or as required for chemical compatibility. C. Manufacturers: 1. Georg Fischer. 2. ASAHI/America. 3. Or approved equal. PART 3 - EXECUTION 3.1 As specified in Section 40 05 51 - Common Requirements for Process Valves: PART 3 EXECUTION requirements for compliance with this Section. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Miscellaneous Valves 40 05 81 - 1 SECTION 40 05 81 – MISCELLANEOUS VALVES PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Yard Hydrants. 2. Diaphragm Valves. 3. Globe Valves. 4. Mud Valves. 5. Solenoid Valves. 6. Pressure Reducing Valves and Back-Pressure Valves. 7. Downstream Pressure Regulating Valves. 8. Flap Gate Valves. B. Related Requirements: 1. Section 40 05 00 – Common Requirements for Process Piping. 2. Section 40 05 51 – Common Requirements for Process Valves. 3. Section 40 05 57 – Actuators for Process Valves. 1.2 REFERENCE STANDARDS A. American Water Works Association (AWWA): 1. C550, Protective Interior Coatings for Valves and Hydrants. B. NSF International: 1. NSF 61 - Drinking Water System Components - Health Effects. 2. NSF 372 - Drinking Water System Components - Lead Content. 1.3 FACTORY TESTING A. Valves shall be tested in compliance with Section 40 05 51 – Common Requirements for Process Valves. 1.4 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. As specified in Section 40 05 51 – Common Requirements for Process Valves: Submittal requirements for compliance with this Section. 1.5 CLOSEOUT SUBMITTALS A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for submittals and Operation and Maintenance data. B. Project Record Documents: Record actual locations of valves and actuators, and centerline elevations. BCRUA - Phase 1D WTP Expansion Issued for Bid Miscellaneous Valves 40 05 81 - 2 PART 2 - PRODUCTS 2.1 NON-FREEZE YARD HYDRANTS A. Description: 1. Type: Non-freeze. 2. Closure Valve: Free-floating, compression type. 3. Barrel: Automatic drain after use. 4. Stem: Nourishing. 5. Main Valve: 1-1/2 inches. 6. Lubrication: Furnish access hole in operating nut. B. Materials: 1. Body: Galvanized steel. 2. Head: Cast iron or Bronze. 3. Outlets: Brass. 4. Main Valve: Bronze. 5. Drain Valve: Bronze. 6. Operating Rod: Stainless steel. C. Operation: 1. Cam-type, cast-iron lever control. 2. Drain Valve: Actuated when main valve is in CLOSED position. D. Connections: 1. Hose Connection: One each, 3/4-inch hose connections, with threaded quick-disconnect adapters. 2. Drain Port: 1/2 inch. 3. Inlet: a. Size: 1 inch. b. Type: Threaded. E. Accessories: 1. Operating handle lock. F. Casing Guard: Aluminum. 2.2 DIAPHRAGM VALVES A. Diaphragm Valve, 1/2 Inch to 4 Inches: 1. Weir type with PVC Type 1, Grade 1 body, PTFE with EPDM backing diaphragm, solvent weld socket ends, handwheel operator, position indicator, adjustable travel stop, clear molded acrylic stem cap. B. Acceptable Manufacturers and Products: 1. ASAHI/AMERICA; Diaphragm Valve Type 14. 2. ITT Engineered Valves; Dia-Flo. 3. Saunders Valve; Diaphragm Valve. 4. Georg Fischer. BCRUA - Phase 1D WTP Expansion Issued for Bid Miscellaneous Valves 40 05 81 - 3 2.3 GLOBE VALVES A. Metallic Globe Valves: 1. 3 Inches and Smaller: a. All-bronze, union bonnet, packed gland, inside screw, rising stem, TFE disc, Class 150 rated 150 psi SWP/300 CWP, complies with MSS SP-80 Type 2. b. Acceptable Manufacturers and Products: 1) Stockham; Figure B-22T. 2) Crane Co.; Figure 17TF. 3) Or approved equal. B. Plastic Globe Valves: 1. 3 Inches and Smaller: a. Rated 150 psi at 73 degrees F, with ASTM D1784, Type I, Grade 1 polyvinyl chloride body and stem, end entry, double union design, solvent-weld socket ends, PTFE seats and seals. Designed for throttling and bubble-tight shut-off service. b. Acceptable Manufacturers: 1) NIBCO. 2) ASAHI/America. 3) Spears. 4) Georg Fischer. 5) Or approved equal. 2.4 MUD VALVES A. Cast Stainless Steel Mud Valve 4 Inches to 20 Inches: 1. Heavy-duty CF8M stainless steel yoke, flange, guides, and gate; Buna-N seat mechanically retained with Type 316 stainless steel fasteners, non-rising stem. Stainless steel casting to be passivated per ASTM A380. Type 316 stainless steel one-piece stem with integral thrust collar and coated with anti-galling compound. 2. Stem extension one-piece Type 316 stainless steel, 2-inch operating nut, 14-inch diameter ductile iron handwheel, indicating stainless steel floor stand and wall bracket, floor box with position indicator, wall bracket with position indicator. Stem guides Type 316 stainless steel with bronze bushings for L/R of 200 maximum. Cast top and bottom stem couplings Type 316 stainless steel. 3. Manufacturers: a. Troy Valve. b. Trumbull Industries, Inc. c. Or approved equal. 2.5 SOLENOID VALVES A. Solenoid Valve 1/4 Inch to 2 Inches: 1. Two-way internal pilot operated diaphragm type, brass body, resilient seat suitable for air or water, solenoid coil molded epoxy, NEMA insulation Class F, 120 volts ac, 60-Hz, unless otherwise indicated. Solenoid enclosure NEMA 250, Type 4 unless otherwise indicated. Size and normal position (when de-energized) as indicated on the Drawings. 2. Minimum operating pressure differential no greater than 5 psig, maximum operating pressure differential not less than 125 psig. BCRUA - Phase 1D WTP Expansion Issued for Bid Miscellaneous Valves 40 05 81 - 4 3. Manufacturers and Products: a. ASCO. b. Skinner. 2.6 PRESSURE REDUCING AND BACK-PRESSURE VALVES A. PVC Pressure Relief and Back-Pressure (Anti-Siphon) Valves, 1/2 IN to 2 IN: 1. Direct acting diaphragm, spring controlled with threaded adjustment knob and lock nut, in- line pattern, NPT threaded inlet and outlet, 150 psi design pressure. 2. PVC body, Teflon or Viton diaphragm, PVC or Teflon piston, high density polyethylene or stainless steel adjusting bolt and locknut, stainless steel or coated steel spring, stainless steel fasteners. 3. End Connection: True-Union. 4. Valves shall be the same diameter as connecting pipe. Connection reducers are not acceptable. 5. Designed to open when upstream pressure reaches setpoint; set pressure field adjustable for intended service and initially set by Contractor and recorded on installation certificate. 6. Acceptable Manufacturers and Products: a. Plast-O-Matic; Series RVDT. b. Griffco; Series BPV. c. Primary Fluid Systems; TOP Valve. d. Or approved equal. 2.7 DOWNSTREAM PRESSURE REGULATING VALVES A. PVC Pressure Regulating Valve, 1/2 to 1-1/2 IN: 1. Diaphragm operated assembly, spring controlled, in-line pattern, NPT threaded inlet and outlet, 150 psi design pressure. 2. PVC body, Viton seals and diaphragm, coated stainless steel spring, stainless steel adjusting bolt, locknut, and fasteners. 3. Designed to regulate downstream pressure by closing when pressure reaches setpoint; set pressure adjustable from 5 to 50 psi. 4. Acceptable Manufacturers and Products: a. Plast-O-Matic, Series PR. b. Hayward; Pressure Regulator. c. Or approved equal. 2.8 FLAP GATE VALVES A. Flap Gate 4 Inches to 96 Inches: 1. Cast-iron body and cover, bronze-mounted, flanged frame type, dual pivot-point hinge arms, hinge arms bronze, hinge pins Type 304 stainless steel, seat bronze and impacted into grooves in body and cover flap, lubrication fittings for each pivot, upper and lower pivot adjustment. 2. Manufacturers and Products: a. Rodney Hunt Co.; Series FV AC or FV AR. b. Hydro Gate; Model 50C or 50. c. Or approved equal. BCRUA - Phase 1D WTP Expansion Issued for Bid Miscellaneous Valves 40 05 81 - 5 PART 3 - EXECUTION 3.1 As specified in Section 40 05 51 – Common Requirements for Process Valves: PART 3 – EXECUTION requirements for compliance with this Section. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Process Piping Insulation 40 42 13 - 1 SECTION 40 42 13 - PROCESS PIPING INSULATION PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Process piping insulation. 2. Jacketing. 3. Accessories. B. Related Sections: 1. Section 09 96 00 – High-Performance Coatings. 2. Division 40, as applicable Piping. 1.2 REFERENCE STANDARDS A. ASTM International: 1. ASTM A240 - Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications. 2. ASTM A666 - Standard Specification for Annealed or Cold-Worked Austenitic Stainless Steel Sheet, Strip, Plate, and Flat Bar. 3. ASTM B209 - Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate. 4. ASTM C195 - Standard Specification for Mineral Fiber Thermal Insulating Cement. 5. ASTM C449 - Standard Specification for Mineral Fiber Hydraulic-Setting Thermal Insulating and Finishing Cement. 6. ASTM C450 - Standard Practice for Fabrication of Thermal Insulating Fitting Covers for NPS Piping, and Vessel Lagging. 7. ASTM C533 - Standard Specification for Calcium Silicate Block and Pipe Thermal Insulation. 8. ASTM C534 - Standard Specification for Preformed Flexible Elastomeric Cellular Thermal Insulation in Sheet and Tubular Form. 9. ASTM C547 - Standard Specification for Mineral Fiber Pipe Insulation. 10. ASTM C553 - Standard Specification for Mineral Fiber Blanket Thermal Insulation for Commercial and Industrial Applications. 11. ASTM C578 - Standard Specification for Rigid, Cellular Polystyrene Thermal Insulation. 12. ASTM C585 - Standard Practice for Inner and Outer Diameters of Thermal Insulation for Nominal Sizes of Pipe and Tubing. 13. ASTM C591 - Standard Specification for Unfaced Preformed Rigid Cellular Polyisocyanurate Thermal Insulation. 14. ASTM C612 - Standard Specification for Mineral Fiber Block and Board Thermal Insulation. 15. ASTM C795 - Standard Specification for Thermal Insulation for Use in Contact with Austenitic Stainless Steel. 16. ASTM C921 - Standard Practice for Determining the Properties of Jacketing Materials for Thermal Insulation. 17. ASTM C1136 - Standard Specification for Flexible, Low Permeance Vapor Retarders for Thermal Insulation. BCRUA - Phase 1D WTP Expansion Issued for Bid Process Piping Insulation 40 42 13 - 2 18. C1729, Standard Specification for Aluminum Jacketing for Insulation. 19. ASTM D1785 - Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe, Schedule 40, 80, and 120. 20. ASTM E84 - Standard Test Method for Surface Burning Characteristics of Building Materials. 21. ASTM E96 - Standard Test Methods for Water Vapor Transmission of Materials. B. Manufacturers Standardization Society of the Valve and Fittings Industry: 1. MSS SP-69 - Pipe Hangers and Supports - Selection and Application. 1.3 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Product Data: Submit product description, thermal characteristics, list of materials, and thickness for each service and location. 1.4 CLOSEOUT SUBMITTALS A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for submittals and Operation and Maintenance data. 1.5 QUALIFICATIONS A. Installer: Authorized installer of manufacturer. 1.6 DELIVERY, STORAGE, AND HANDLING A. Section 01 60 00 – Product Requirements: Requirements for transporting, handling, storing, and protecting products. B. Accept materials on-Site in original factory packaging, labeled with manufacturer's identification, including product density and thickness. C. Inspection: Accept insulation on-Site in manufacturer's packaging. Inspect for damage. D. Store insulation according to manufacturer's instructions. E. Protect insulation from weather and construction traffic, dirt, water, chemicals, and damage by storing in original wrapping. 1.7 EXISTING CONDITIONS A. Field Measurements: 1. Verify field measurements prior to fabrication. 2. Indicate field measurements on Shop Drawings. BCRUA - Phase 1D WTP Expansion Issued for Bid Process Piping Insulation 40 42 13 - 3 PART 2 - PRODUCTS 2.1 PIPE INSULATION A. Type P-1: Fiberglass: 1. Material: UL rated, preformed, sectional bonded fiberglass per ASTM C585 with factory applied, Kraft paper with aluminum foil vapor barrier jacket with pressure-sensitive, self- sealing lap. 2. Insulation Temperature Rating: Zero to 850 degrees F. 3. Conductivity in accordance with ASHRAE 90.1 and maximum numerical value of 0.23 Btu in./hr square foot degrees F at 75 degrees F. 4. Jacketing per ASTM C1136 with minimum water vapor transmission for jacket of 0.02 perm-inch per ASTM E96/E96M. Furnish with no jacket if field finish system specified. 5. Joints: Matching pressure-sensitive butt strips for sealing circumferential joints. 6. Flame Spread Rating: Less than 25 per ASTM E84. 7. Smoke Developed Index: Less than 50 per ASTM E84. 8. Manufacturers and Products: a. Owens Corning Fiberglass; ASJ/SSL 11. b. John Manville; Micro-Lok with Jacket. B. Type P-2 Foamglass: 1. Material: Cellular glass per ASTM C552. 2. Nominal Density: 7.5 pcf. 3. Compressive Strength: 90 psi per ASTM C165. 4. Temperature Rating: Minus 290 degrees F to 900 degrees F. 5. Conductivity in accordance with ASHRAE 90.1 and maximum numerical value of 0.29 Btu in./hr square foot degrees F. 6. Minimum water vapor transmission for insulation of 0.00 perm-inch per ASTM E96/E96M. 7. Joints: Matching pressure-sensitive butt strips for sealing circumferential joints. 8. Flame Spread Rating: 0 per ASTM E84. 9. Smoke Developed Index: 0 per ASTM E84. 10. Follow manufacturer’s recommendation, based upon temperature of piping to be insulated. 11. Manufacturer and Product: Pittsburgh Corning; Foamglas One. C. Type P-3 Elastomeric: 1. Material: Flexible elastomeric pipe insulation, closed-cell structure in accordance with ASTM C534/C534M. 2. Temperature Rating: Minus 297 degrees F to 220 degrees F. 3. Nominal Density: 3 pcf to 6 pcf. 4. Conductivity in accordance with ASHRAE 90.1 and maximum numerical value of 0.25 Btu in./hr square foot degrees F at 75 degrees F per ASTM C177 or ASTM C518. 5. Maximum water vapor transmission of 0.06 perm inch per ASTM E96/E96M, Procedure A. 6. Joints: Manufacturer’s adhesive. 7. Flame Spread Rating: Less than 25 per ASTM E84. 8. Smoke Developed Index: Less than 50 per ASTM E84. 9. Manufacturers and Products: a. Nomaco; K Flex. BCRUA - Phase 1D WTP Expansion Issued for Bid Process Piping Insulation 40 42 13 - 4 b. Armacell; AP Armaflex. D. Type P-5: 1. Description: Polyisocyanurate foam insulation, formed into shapes for use as pipe insulation. 2. Comply with ASTM C591, Type IV. 3. Density: 6 pcf. 4. Thermal Conductivity: 180-day aged value of 0.19 Btu-in./h-ft.-deg. F at 75 degrees F. 5. Operating Temperature Range: Minus 297 to 300 degrees F. 6. Vapor Barrier Jacket: a. Comply with ASTM C1136, Type I. b. Factory-Applied Film Thickness: 6 mils. c. Water Vapor Permeance: 0.01 perms. E. Type P-6: 1. Description: Extruded polystyrene insulation, formed into shapes for use as pipe insulation. 2. Comply with ASTM C578, Type XIII. 3. Thermal Conductivity: 180-day aged value of 0.259 Btu-in./h-ft.-deg. F at 75 degrees F. 4. Operating Temperature Range: Minus 297 to 165 degrees F. 5. Vapor Barrier Jacket: a. Comply with ASTM C1136, Type I. b. Factory-Applied Film Thickness: 6 mils. c. Water Vapor Permeance: 0.01 perms. 2.2 INSULATION AT PIPE HANGERS AND SUPPORTS A. Refer to Section 40 05 07 - Hangers and Supports For Process Piping. B. Copper, Ductile Iron, and Nonmetallic Pipe: High-density insert, thickness equal to adjoining insulation of Type 3 or other rigid insulation or manufactured pre-insulated pipe hanger and insulation shield. Extend insert beyond shield. C. Steel Pipe: Insulation saddle or high-density insert, thickness equal to adjoining insulation of Type 3 or other rigid insulation or manufactured pre-insulated pipe hanger and insulation shield at support location. Extend insert beyond shield. 2.3 PIPE INSULATION JACKETS A. Type J1Vapor-Retarder Jacket: 1. Description: White kraft paper with glass-fiber yarn, bonded to aluminized film. 2. Water Vapor Permeance: a. ASTM E96. b. 0.02 perms. B. Type J2 PVC Plastic Pipe Jacket: 1. Polyvinyl chloride (PVC) jacketing, minimum 20 mils indoors and 30 mils outdoors, for straight run piping and fitting locations, temperatures to 140 degrees F. BCRUA - Phase 1D WTP Expansion Issued for Bid Process Piping Insulation 40 42 13 - 5 2. Color: PVC jacketing shall be color coded to match colors listed in pipe schedule where suitable matching colors are available. If no suitable colors are available jacketing shall be white. 3. Flame Spread Rating: 25 per ASTM E84. 4. Smoke Developed Index: 50 per ASTM E84. 5. Manufacturers and Products: a. Knauf Insulation; Proto 1000. b. Johns Manville; Zeston 2000 or 300. c. Speedline; 25/50 Smoke-Safe. C. Type J3 - Paint: 1. Type P3 Insulation: Acrylic latex paint, white, and suitable for outdoor use. a. Manufacturer and Product: Armacell; WB Armaflex finish. 2. Type P1 Insulation: In accordance with Section 09 90 00, Painting and Coating. D. Type J4 - Aluminum: 1. Aluminum Roll Jacketing: For straight run piping, wrought aluminum Alloy 3003, 5005, 1100, or 3105 to ASTM B209 with H-14 temper, in accordance with ASTM C1729, minimum 0.016-inch thickness, with smooth mill finish. 2. Vapor Barrier: Provide factory applied vapor barrier, heat and pressure bonded to inner surface of aluminum jacketing. 3. Fitting Covers: Material as for aluminum roll jacketing, premolded, one or two piece covers, which includes elbows, tee/valves, end caps, mechanical line couplings, and specialty fittings. 4. Metal Jacket Bands: a. Width: 3/8 inch. b. Thickness and Material: 0.015 inch, aluminum. 5. Manufacturers: a. RPR Products; Insul-Mate. b. ITW, Pabco-Childers. E. Type J5 - Foamglass Jacketing: 1. Type P2 Insulation—Buried and Up to 1 Foot Above Grade: 70-mil bituminous resin with woven, glass fabric, aluminum foil layer, and plastic film coating, self-sealing manual pressure seals; Pittsburgh Corning Pittwrap SS. 2. Type P2 Insulation—Greater that 1 Foot Above Grade: 30-mil modified bituminous membrane with self-sealing manual pressure seals; Pittsburgh Corning Pittwrap CW30. 2.4 PIPE INSULATION ACCESSORIES A. Vapor-Retarder Lap Adhesive: Compatible with insulation. B. Covering Adhesive Mastic: Compatible with insulation. C. Piping 1-1/2-Inch Diameter and Smaller: 1. Description: Galvanized-steel insulation protection shield. 2. Comply with MSS SP-69, Type 40. 3. Length: Based on pipe size and insulation thickness. D. Piping 2-Inch Diameter and Larger: BCRUA - Phase 1D WTP Expansion Issued for Bid Process Piping Insulation 40 42 13 - 6 1. Description: Wood insulation saddle, hard maple. 2. Inserts Length: Not less than 6 inches. 3. Thickness and Contour: Match adjoining insulation. E. Closed-Cell Elastomeric Insulation Pipe Hangers: 1. Description: Polyurethane insert with aluminum single-piece construction and self- adhesive closure. 2. Thickness: Match pipe insulation. F. Tie Wire: 0.048-inch stainless steel with twisted ends on maximum 12-inch centers. G. Insulating Cement: 1. Comply with ASTM C195. 2. Hydraulic setting on mineral wool. H. Adhesives: Compatible with insulation. PART 3 - EXECUTION 3.1 APPLICATION A. General: 1. Insulate valve bodies, flanges, and pipe couplings. 2. Insulate and vapor seal hangers, supports, anchors, and other piping appurtenances that are secured directly to cold surfaces. 3. Do not insulate flexible pipe couplings and expansion joints. 4. Service and Insulation Thickness: Refer to Supplement Service and Insulation Thickness table following “End of Section” and to Piping Schedule in Section 40 05 00 Common Requirements For Process Piping. 3.2 INSTALLATION A. General: 1. Install in accordance with manufacturer’s instructions and as specified herein. 2. Install after piping system has been pressure tested and leaks corrected. 3. Install over clean dry surfaces. 4. Use insulating cements, lagging adhesives, and weatherproof mastics recommended by insulation manufacturer. 5. Do not allow insulation to cover nameplates or code inspection stamps. 6. Run insulation or insulation inserts continuously through pipe hangers and supports, wall openings, ceiling openings, and pipe sleeves, unless otherwise shown. 7. Install removable insulation sections on devices that require access for maintenance of equipment or removal, such as unions and strainer end plates. 8. Personnel Protection: Install on pipes from floor to 8 feet high. Install on pipes within 4 feet of platforms and to 8 feet high above platforms. B. Connection to Existing Piping: Cut back existing insulation to remove portion damaged by piping revisions. Install new insulation. BCRUA - Phase 1D WTP Expansion Issued for Bid Process Piping Insulation 40 42 13 - 7 C. Cold Surfaces: Provide continuous vapor seal on insulation on cold surfaces where vapor barrier jackets are used. D. Placement: 1. Insulate valves and fittings with sleeved or cut pieces of same material. 2. Seal and tape joints. E. Heat Traced Piping: Apply insulation after heat-tracing work is completed and inspected. F. Roof Drains: Insulate vertical drops from roof drains to horizontal pipe, exposed and concealed horizontal piping, and 2 feet down on vertical risers from horizontal pipe. G. Roof Drain and Overflow Drain Sumps: Insulate entire sumps. H. Vapor Barrier: 1. Provide continuous vapor barrier at joints between rigid insulation and pipe insulation. 2. Install vapor barrier jackets with pipe hangers and supports outside jacket. 3. Do not use staples and screws to secure vapor sealed system components. I. Aluminum Jacket: 1. Use continuous friction type joint to hold jacket in place, providing positive weatherproof seal over entire length of jacket. 2. Secure circumferential joints with preformed snap straps containing weatherproof sealant. 3. On exterior piping, apply coating over insulation and vapor barrier to prevent damage when aluminum fitting covers are installed. 4. Do not use screws or rivets to fasten fitting covers. 5. Install removable prefabricated aluminum covers on exterior flanges and unions. 6. Caulk and seal exterior joints to make watertight. 3.3 FIELD FINISHING A. Apply coating of insulating cement where needed to obtain smooth and continuous appearance. B. Where pipe labels or banding are specified, apply to finished insulation, not to pipe. C. Painting Piping Insulation (Exposed to View): 1. Aluminum or color coded PVC jacketing does not require painting. 2. If insulated piping system is indicated to be painted in Section 40 27 00, Process Piping—General, piping shall receive the following: a. Prime coat in accordance with Section 09 90 00, Painting and Coating. b. Finished insulation (and not pipe) shall be painted in accordance with Section 09 90 00, Painting and Coating. 3.4 SUPPLEMENTS A. The supplement listed below, following “End of Section,” is a part of this specification: 1. Service and Insulation Thickness Table. BCRUA - Phase 1D WTP Expansion Issued for Bid Process Piping Insulation 40 42 13 - 8 END OF SECTION BCRUA Phase 1D WTP Expansion Issued for Bid Process Piping Insulation 40 42 13 - 9 Service and Insulation Thickness Service Type Thickness Insulation Finish Systems Concealed from View Indoors Exposed Out- doors Buried Outdoor Ex- posed or as In- dicated Water and Chemical Feed Piping Pipe Size: Insu- lation Thickness Inches: * 1/4 - 3: 1 3.5 - 10: 1.5 Type P-3 (pipes 6 inch or less in diame- ter) None J2 in chemical ar- eas J4 all other indoor areas J4 J5 Inches*: Based upon insulation with glass fiber per ASTM C547, outdoors with 20 mph wind with 10 percent safety and no value assigned to cladding or air space at cladding. 2012 IECC requires 1-inch minimum thickness. BCRUA - Phase 1D WTP Expansion Issued for Bid Process Control and Instrumentation Systems – General Provisions 40 90 00 - 1 SECTION 40 90 00 – PROCESS CONTROL AND INSTRUMENTATION SYSTEMS – GENERAL PROVISIONS PART 1 GENERAL 1.1 SCOPE A. General Requirements for Instrumentation. B. There are two areas of work in the Instrumentation Work in this project as described below: 1. The Instrumentation Contractor shall provide all hardware, software, and configuration associated with the PLC based Instrumentation and Process Control system. Provide a complete and operational system in accordance with these Contract Documents: a. Provide instrumentation, hardware, conductors and raceway required for a complete and operable system that is above that specified in the Contract Documents. b. Provide all labor and materials specified in the Contract Documents. c. Provide all required labor, materials, and instrumentation configuration to interconnect with Remote I/Os, to the existing SCADA system. d. Provide New RWT-PLC-01 in Raw Water Head Tanks. e. Provide data highway cable to interconnect the new PLCs to the existing SCADA system. f. Provide Remote Input/Output (RI/O) in existing Filter Consoles units. g. Provide data highway cable to interconnect the PLCs with the RI/Os and operator interface units in the Filter Consoles Provide personnel to check out, test and commission the system. h. Provide personnel to train the Owner's staff as specified. i. 2. Contractor shall be responsible for the following work to provide a complete and operational system in accordance with these Contract Documents: a. Provide software programming to create new screens and modify existing screens as specified. b. Provide the required drivers to receive and transmit data over the specified data highway to fully communicate with the PLC system. c. Provide all software programming required in their system for a complete and operational system as specified. d. Create or modify all required data bases in their system. e. Provide personal to check out, test and commission the system. f. Provide personnel to train the Owner's staff as specified. 1.2 QUALITY ASSURANCE A. GENERAL: Should there be a conflict between various standards, codes, specifications, and contract drawings, bring the matter immediately to the attention of the Owner's Representative. B. REFERENCE STANDARDS: 1. American Society of Testing Materials: A269 Seamless and Welded Austenitic Stainless Steel Tubing for General Service B 68 Seamless Copper Tube BCRUA - Phase 1D WTP Expansion Issued for Review Instrumentation and Control for Process Systems – General Provisions 40 90 00 - 2 D 1047 Polyvinyl Chloride Jacket for Wire and Cable A 36 Specification for Structural Steel Zinc Coating (Hot-Dip) on Iron and Steel Hardware 2. Research Council on Riveted and Bolted Structural Joints (RCRBSJ). 3. American Institute of Steel Construction (AISC). 4. Steel Structures Painting Council (SSPC): Painting Specifications for weather exposure. 5. American Welding Society (AWS): Welding Code D 1.1-75. 6. Federal Specifications: Primer, Paint Zinc, Chromate, Alkyd Type, Fed. Spec. TT-P- 645a. 7. National Electrical Manufacturers Association (NEMA). 8. National Fire Protection Association (NFPA): National Electrical Code (NEC), 1990 edition. 9. Instrument Society of America (ISA): RP 3.1-1960 Flow Meter Installations, Seal and Condensate Chambers S5.1-1973 Instrumentation Symbols and Identification RP7.1-1956 Pneumatic Control Circuit Pressure Test S7.3-1975 Quality Standard for Instrument Air RP18.1-1965 Specifications and Guides for the Use of General Purpose Annunciators S5.4-1976 Instrument Loop Diagrams S8.1-1968 Instrument Enclosures for Industrial Environments RP12.1-1960 Electrical Instruments in Hazardous Atmospheres RP20.1, 20.2 Specification Forms for Instruments S39.1-1972 Control Valve Sizing Equations S39.2-1972 Control Valve Capacity Test Procedures S51.1 Process Instrumentation Terminology 10. American Petroleum Institute (API): API RP 550 Manual on Installation of Refinery Instruments and Control Systems API RP 520 Recommended Practice for the Design and Installation of Pressure-Relieving Systems in Refineries 11. Scientific Apparatus Makers Association (SAMA): PM 20.1-1973 Process Measurement and Control Terminology RC5-10-1963 Resistance Thermometers 12. Underwriters' Laboratory (UL): Subject 13, Subject 1227. 13. Factory Mutual (FM). 14. American National Standard Institute (ANSI): 15. Supplement to C37.90-1971, Relays and Relay Systems Associated with Electric Power Apparatus (IEEE Std. 313-1971), C37.90a-1974. 16. National Bureau of Standards (NBS). 17. Institute of Electrical and Electronics Engineers (IEEE): Tray Fire Tests, IEEE 383. BCRUA - Phase 1D WTP Expansion Issued for Review Instrumentation and Control for Process Systems – General Provisions 40 90 00 - 3 1.3 GUARANTEE A. GUARANTEE PERIOD: The Contractor shall provide guarantees as defined hereunder for a period of one year after final acceptance by the Owner. B. GUARANTEE REQUIREMENTS FOR ANALOG DEVICES: Each device shall perform its intended function within the specified operating accuracy and repeatability without more than 12 adjustments for any consecutive period of 12 months. The availability of each device shall be not less than 98.0 percent for any consecutive period of six months. Downtime of analog devices affecting more than 8 loops shall be considered a system failure. 1.4 DEFINITIONS A. The terms used in this specification conform to definitions in ISA S51.1, SAMA PMC 20.1- 1973 and RC 5-10-1963, except as modified below. 1. Device: An electronic or mechanical apparatus designed to perform a specific measurement or control function. 2. Equipment: The machinery used in a process, e.g., pumps, fans, etc. 3. Interchangeability error: The algebraic difference between the indication and true value of the measured variable as a result of exchanging a device with a replacement. 4. Loop: Any combination of interconnected transmitters, receivers, switches, alarms, indicators, controllers, computers, or final control elements. 5. Operating accuracy: Conformity of indicated value to accepted standard value or true value throughout specified operating conditions with a confidence level of 95 percent includes, but is not limited to, hysteresis, linearity, and operating influence of temperature, pressure, supply voltage, and transmitter power supply. Operating accuracy for loop is defined as root-mean-square (RMS) of individual device operation accuracies. 6. Process: A progressively continuing operation that consists of a series of controlled actions systemically directed toward a particular result, e.g., a process to mix, filter, heat, and/or cool air to a particular condition. 7. Response: The results of the act, or process of measuring the time difference between the time of a change in an input signal or a measured variable, and the time when the output, display, and final control element in the loop has changed to at least 60 percent of the change which should result from the input change. 8. Subsystem: A discrete subdivision of a system and an assemblage of parts, devices, or software modules designed to perform one or more of the specific tasks required for the system to accomplish its functions. 9. System: An assemblage of sometimes diverse parts, devices, or software modules serving a common set of measurement or control functions. 10. Time resolution: The result of the act or process of rendering distinguishable events occurring at nearly the same time. Expressed as a measurement of time in seconds. 11. Unit: Any combination of equipment items interconnected in a predetermined manner, performing one or more controlled actions toward a particular result. A discrete subdivision of a process. 12. Concealed - Accessible: Out of general sight, but can be easily reached by removing panels or access doors. 13. Concealed - Inaccessible: Out of general sight and cannot be easily reached except by removing a permanent part of the building or using special tools. 14. Exposed: Open to general view without removing panels, access doors, or a permanent part of the building. BCRUA - Phase 1D WTP Expansion Issued for Review Instrumentation and Control for Process Systems – General Provisions 40 90 00 - 4 15. Field termination point: Termination of a run of raceway from an instrument panel to the vicinity of a field instrument. Field termination point is usually within five horizontal feet from the field instrument. 16. Analog device: Any sensor, transmitter, indicator, recorder, controller, computing relay, or control valve which transmits or receives an analog signal. Excludes the analog portion of a digital system or I/O subsystems. 1.5 SUBMITTALS A. SHOP DRAWINGS AND PRODUCT DATA: 1. Detail: Give sufficient detail to permit system configuration, installation, and wiring without reference to design drawings. Refer to Division 1 - General Provisions. 2. As a minimum, shop drawings shall include a bill of materials with original manufacturer's name and catalog number (re-labeled component information is not acceptable), original manufacturer's catalog cut sheets, front views, assembly drawings, nameplate schedules, electrical schematics, electrical connections diagrams, and piping connection diagrams. 3. Electrical, piping, and interconnection diagrams shall show all terminations of equipment, complete with conduit, cable, and equipment designations, and shall include terminal identification information. 4. Include size of all conduits, pipe, cables, and conductors. 5. Physical arrangement drawings shall include operating and servicing clearance requirements, cooling requirements, electrical power requirements, and cabling information. 6. Operator console configuration drawings shall include specific location of all keys and pushbuttons. 7. Logic drawer drawings shall show used space and expansion space. 8. Show appropriate tag numbers on all product data. 9. Software specifications for all software provided in addition to existing standard software. a. Include fully annotated source listings, input-output requirements, memory requirements, timing and sequencing requirements, flow chart showing functions performed, operating sequences and decision points, required system configuration, list of known or anticipated limitations of software modules, list of malfunction procedures to be followed for recovering from operator error or other malfunction, and description of how each module interfaces with calling and called programs. b. Provide proposed screen layouts showing modifications to existing screens, and new screens: Show all displays, inputs, outputs, recorders, alarms and indications along with the associated signal tag number. B. TECHNICAL MANUALS: 1. Supply six (6) sets of technical manuals with software specifications to Owner's Representative no later than the equipment shipment date. Each set shall be bound in a standard size, three-ring, loose-leaf, vinyl plastic, hard-cover binder suitable for bookshelf storage. Binder ring size shall not exceed 2.5 inches. BCRUA - Phase 1D WTP Expansion Issued for Review Instrumentation and Control for Process Systems – General Provisions 40 90 00 - 5 2. Each set of technical manuals shall include a general and detailed description, a theory of operation description, detailed schematic drawings, specifications, and installation, connection, calibration, operating, troubleshooting, preventive maintenance, and overhaul instructions in complete detail with a clear and specific description of the steps the operators must take to perform each of the tasks and modes of operating specified. These manuals shall provide the Owner with comprehensive information on all systems and components to enable operation, service, maintenance and repair. Exploded or other detailed views of all instruments, assemblies, and accessory components shall be included together with complete parts lists and ordering instructions. These manuals are in addition to all applicable requirements of Division 1 - General Provisions. C. SPARE PARTS LIST: 1. Contractor shall prepare and submit for Engineer's review a master spare parts list of all Division 40 items. All division 40 spare parts shall be turned over to the Owner at one time and stored into lockable cabinets. PART 2 PRODUCTS 2.1 INFORMATION ON DRAWINGS A. The following information is indicated on the drawings: 1. Loop diagram on flow sheet for each control loop. Diagrams are schematic in nature and intended only as a guide to work to be performed. 2. Approximate location of primary elements, instrument panels, and final control elements. 3. Location of electrical distribution panel boards for instrument electrical power. 4. Location of equipment having alarms and equipment status contacts. 5. Location of equipment being controlled by system. B. The following information is not shown on drawings, but shall be the responsibility of the Contractor to determine, furnish, and coordinate with other divisions based upon systems specified. Show this information on project record drawings. 1. Instrument loop drawings per ISA S5.4 minimum, desired and optional items. 2. Location of electrical distribution panel boards supplying power to any device supplied under this Contract. 3. Detailed enclosure and instrument panel layouts, PLC enclosure layouts, filter console layouts, fabrication details, and wiring diagrams. 4. Detailed system configuration. 5. Raceway and cable routing for instrumentation wiring. 2.2 OPERATING CONDITIONS A. AMBIENT CONDITIONS: Provide equipment suitable for ambient conditions specified. Provide system elements to operate properly in the presence of radio frequency fields produced by portable RF transmitters with output of five watts operated at 24 inches from instruments in the presence of plant telephone lines, power lines, and electrical equipment, and in the presence of digital data transmission systems. B. FIELD LOCATIONS: Field equipment may be subjected to ambient temperatures from -5 to 50°C with direct radiation and relative humidity from 45 to 100 percent with condensation. BCRUA - Phase 1D WTP Expansion Issued for Review Instrumentation and Control for Process Systems – General Provisions 40 90 00 - 6 C. POWER SUPPLY: Power supply will be 117 volts a-c, single-phase, 60-hertz commercial power. Voltage variations will be at least plus or minus 8 percent. Certain loops shall have integral power supply as specified in the Contract Documents. Power supplies shall be provided in the panels as specified in the Contract Documents or required for a complete system, plus one spare. 2.3 SPARE PARTS A. Supply spare parts as indicated in these Specifications. B. Spare parts shall become property of the Owner. 2.4 MATERIALS AND EQUIPMENT A. Provide equipment of solid-state construction utilizing second source semiconductors, unless otherwise specified. Derate components to assure dependability and long-term stability. Provide printed or etched circuit boards of glass epoxy, hand or wave soldered, of sufficient thickness to prevent warping. Coat printed circuit boards in field-mounted equipment with two mils of solderable conformal coating complying with MIL-I-46058B. Alignment and adjustments shall be noncritical, stable with temperature changes or aging, and accomplished with premium grade potentiometers. Do not insert components of specially selected values into standard electronic assemblies to meet performance requirements. Use parts indicated in instruction manuals, replaceable with standard commercial components of the same description without degrading performance of completed assembly. B. Use test equipment and instruments to simulate inputs and read outputs suitable for purpose intended and rated to an accuracy of at least five times greater than the required accuracy of device being calibrated. Such test equipment shall have accuracies traceable to the National Bureau of Standards as applicable. 2.5 SPECIAL PROJECT REQUIREMENTS A. As a part of this Contract, the instrumentation systems Contractor shall coordinate with all the sub-systems suppliers and manufacturers, during bidding, construction, testing, installation and start-up phases of the project. The coordination is to assure that the instruments and sub- systems are in compliance with the Contract Documents and that the necessary tie-ins and interface signals with the system are provided as specified or required. B. The instrumentation system Contractor shall provide the Owner's staff with all required training and operating procedures, at no extra cost to the Owner, in addition to In-Plant SCADA training specified in Section 40 90 02. The training schedule shall be coordinated with the Owner's Representative. Training shall include operating, testing, calibration and programming of the system, and simple troubleshooting of the system. The training shall include manuals which are specifically written for the system provided as described in Division 01 - General Provisions of these Specifications. BCRUA - Phase 1D WTP Expansion Issued for Review Instrumentation and Control for Process Systems – General Provisions 40 90 00 - 7 C. The calibration, testing, and start-up of all the instruments whether existing or provided new, shall be done by the manufacturer's field technician/Engineer in the presence of the Owner. The Contractor shall provide a list of all manufacturers whose technicians will perform this work. The Contractor shall also provide a certified calibration report stating that each instrument shown or specified in the Contract Documents has been installed, tested and calibrated per manufacturer's recommendations and per these Contract Documents. D. Follow-up Services: After the acceptance of the system, the Contractor shall make four (4) trips to the project site for calibration and adjustment of all the instruments and devices, including the In-Plant SCADA system. The first trip shall be three months after acceptance of the complete system, and thereafter every three months for a total of four trips. These trips are in addition to all warranty items, and shall be at no extra cost to the Owner. The Contractor shall provide the services of a trained technician for each trip with appropriate calibration and testing instruments. All defects shall be immediately remedied. The trips shall be coordinated with the Owner. E. All control software developed for this contract shall be delivered to the Owner, stored on electronic media, in a format suitable for installing on the existing equipment and new equipment installed under this contract. This includes all source code, complied code, link libraries, run-time libraries or other modules necessary to recreate an operational system in the event of a catastrophic failure or cessation of business by any of the Contractors. In addition, copies of all data bases and necessary associated files as configured after the final test shall be supplied on the same medium. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Instrumentation 40 90 01 - 01 SECTION 40 90 01 – INSTRUMENTATION (Revised by AD-02) PART 1 GENERAL 1.1 WORK INCLUDED A. Furnish labor, materials, equipment and incidentals necessary to install all equipment for complete instrumentation and controls. Contractor's work shall include but not be limited to the following: 1. Installation of equipment furnished under this contract. 2. Interconnections between equipment furnished under this contract. B. The Contractor's attention is directed to the fact that instrumentation is an integrated system and as such shall be furnished by one vendor or system integrator who shall provide all the equipment and appurtenances, regardless of manufacture, and be responsible to the Contractor for satisfactory operation of the entire system. C. Supervision, labor, tools, and materials necessary for installation of the instrumentation equipment and material furnished herein and their interconnection shall be provided by the Contractor. Installation work shall conform to applicable city, state, and national building and electrical codes. D. Coordinate the work of the system manufacturer's service personnel during construction, testing, calibration and acceptance of the instruments. 1.2 QUALITY ASSURANCE A. GENERAL: Equipment shall be the Manufacturer's latest and proven design. Specifications and drawings call attention to certain features, but do not purport to cover all details entering into the design of the instrumentation system. The completed system shall be compatible with the functions required and the equipment furnished by the Contractor. B. OPERATING VOLTAGE: Electrical components of the system shall operate on 120 volt, single-phase, 60 Hertz, except as otherwise noted in the specifications. C. POWER SUPPLIES: The drawings and specifications indicate the energy sources that will be provided. Any other devices or power supplies necessary to obtain proper operation of the instrument system from these energy sources shall be furnished with the instrumentation. POWER SUPPLIES: The drawings and specifications indicate the energy sources that will be provided. Any other devices or power supplies necessary to obtain proper operation of the instrument system from these energy sources shall be furnished with the instrumentation. For instruments or transmitters with 120VAC power supplies, provide 20A toggle switch with weatherproof cover. Mount the toggle switch next to instrument. (AD-02) D. PROTECTION 1. The instrumentation system supplier shall be responsible for input-output isolation of all incoming and outgoing signals. 2. Each 4-20 mA DC process measurement current loop installed on this contract which extends outside the PLC enclosure shall be protected by insertion of a 1/16 amp fuse, BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Instrumentation 40 90 01 - 02 Buss Type MKB. Fuses shall be installed in standard fuse blocks behind the PLC enclosure door. 3. The necessary fuses or switches required by the Instrumentation Manufacturer shall be provided with the equipment. The instruments requiring an internal power supply shall have an internal ON-OFF switch. a. INPUT/OUTPUT 4. In general, and unless specifically stated otherwise, inputs and outputs involving instrumentation systems shown shall be 4-20 mA DC process measurement signals. Current loop isolators, current repeaters, or other signal isolators shall be furnished and installed as required to meet instrument specifications and to make instrumentation system fully operational. 1.3 SUBMITTALS A. Submittals shall be in accordance with Section 01 33 00, SUBMITTALS and shall include: 1. Shop Drawings a. Shop drawings shall be submitted to the Engineer for approval before fabrication or shipment to the job. Equipment shall not be fabricated or shipped to the job before receipt of approved shop drawings from the Engineer. Submittals for approval shall include component manufacturing data sheet indicating pertinent data and identifying each component by item number and nomenclature: b. The submittal shall be organized with a cover sheet listing each instrument being provided. Each instrument shall be listed with the associated tag name, model number, and specified options. c. Separated by tabbed sections, each section shall include the product cut sheets from the manufacturer. d. wiring schematic. e. The manufacturer shall be responsible for preparation of the required sets of these drawings for distribution as indicated in Division 0 and Division 1 specifications. f. Shop drawings submitted for all equipment furnished under this section of the specifications, shall be submitted at the same time in the same package. Partial submittals will not be reviewed. Sales bulletins and other general publications are not acceptable as submittals for approval. 2. Equipment installation report. a. Contractor shall provide an Equipment Installation Report for each instrument (flow meter, level transmitter, etc.) to the Engineer for approval. The equipment installation report shall include documentation stating that the instrument was installed and properly calibrated per the manufacturer’s recommendations by an Authorized representative of the instrument manufacturer. All parameters required for programming of the instrument shall be provided in a hard copy format as part of the equipment installation report. Documentation stating that the person performing the calibration and start-up is an authorized representative shall be provided as well. b. Submit separate equipment installation report for all existing instrumentation specified to be calibrated or rescaled. 3. Operation and Maintenance Manuals a. Operating instructions shall incorporate a functional description of the entire system including the system schematics which reflect "as-built" modifications. b. Wiring diagrams clearly show terminal numbers and wire numbers as they actually are in the instrumentation system. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Instrumentation 40 90 01 - 03 c. Setup parameters: O&M shall include an ISA datasheet with each instrument. The ISA form shall be filled out with ordering information, setup parameters, ranges, and approximate location. d. Special maintenance requirements particular to the system shall be clearly defined along with special calibration and test procedures. 1.4 STANDARDS A. The applicable provisions of the following standards shall apply as if written here in their entirety: 1. ASTM A-126 Specification for Gray Iron Castings for Valves, Flanges and Pipe Fittings 2. ASTM B-61 Specification for Steam and Valve Bronze Castings 1.5 JOB CONDITIONS A. SPARE PARTS 1. Furnish all standard recommended spare parts as indicated in the Manufacturer's instruction manuals, for each component in the system. B. SPECIAL TOOLS: Furnish a kit which contains special size wrenches and other types of tools, not normally available, which are necessary for assembling, disassembling, aligning, and calibrating each piece of equipment. In addition, any piece of equipment (meter, test set, etc.) required by the Manufacturer to align, adjust, or otherwise calibrate any item under this section of the specification shall be furnished. PART 2 PRODUCTS 2.1 REMOTE EQUIPMENT A. Controls for remote electrically operated or motor driven equipment shall be complete, including the necessary auxiliary relays so as to require only wiring and connections to the equipment control circuit. Contacts for control of remote motor operated or electrically operated equipment shall be rated not less than 10 amperes at 120 volts unless otherwise specified herein. B. Remote motor operated, or electrically operated equipment shall have a separate 120-volt control circuit which operates through the dry contacts provided by the instrumentation system. 2.2 TUBING A. Instrument tubing shall be 316 stainless steel for use with or flared fittings. Hydraulic connections to instruments shall be made with separable flared fittings so that fittings may be separated and reassembled without reflaring tubing ends and without incurring any leaks. B. Tubing shall be 1/4" trade size (wall thickness =.030"), shall be rated for 810 psi working pressure at 150°F and shall be manufactured by Halstead or approved equal. Stainless Steel tubing shall be stainless steel fitted. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Instrumentation 40 90 01 - 04 2.3 ELECTROMAGNETIC FLOW TRANSMITTER A. Flow element shall be of the electromagnetic type utilizing the pulsed DC type coil excitation principle with high preamp input impedance. The flow measuring system, consisting of low element, transmitter, and appurtenances, shall have an overall accuracy of ±.5% of rate with a 100:1 turndown for all flows resulting from pipe velocities of 1' to 31' per second. Stream fluid, meter size, and flow range shall be as noted. System shall operate on 120 volt (±10%), 60 Hz power. Unit shall have zero stability feature thereby eliminating the need to stop flow to check zero alignment. B. The flow element shall be of water-tight, IP68 construction, unless otherwise noted. Meter shall consist of a 304SS meter tub, 150-pound ANSI carbon steel raised-face flanges, Ebonite liner, and hastelloy C electrodes, unless otherwise noted. Electrodes shall be either flush or bullet nose type as recommended by the manufacturer. Suitable covers shall be provided for flow elements ends to protect the tube liner during shipment. C. Electromagnetic flowmeters shall be Siemens Sitrans MAG5100W with MAG6000, or equal by McCrometer, Endress + Hauser, or Rosemount. D. Tag Flow Range Line Size Stream Description Approximate Remote Transmitter Distance TSC-FIT-F701 700-4,500 gpm 16” Filter Effluent 80 SDF-FIT-001 0-200 gpm 6” Belt Filter Press 1 30 SDF-FIT-002 0-200 gpm 6” Belt Filter Press 2 30 2.4 FILTER LOSS OF HEAD TRANSMITTERS A. Differential 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 0.075 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 mA, 24 VDC. Power supply shall be 24 VDC, two-wire design. 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. Transmitter shall be supplied with a local operator interface (LOI) for display and programming capabilities. B. Transmitters shall be ABB 264ds, Rosemount 3051CD, Foxboro IDP10, Siemens DSIII, or approved equal. Each transmitter shall include an integrally mounted transient protector to protect the instrument against lightning-produced voltage spikes and other transient surges. Each transmitter shall be furnished with a 316 stainless steel service block and zeroing manifold with NORMAL, ZERO, BLOCKED, CALIBRATE, and BLOWDOWN functions, D/A Manufacturing Model SBZ-43AT. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Instrumentation 40 90 01 - 05 C. Transmitters shall be as follows: Tag Service Range TSC-DPIT-F701 FILTER 7 0-45psig 2.5 BACKWASH FLOW (VENTURI) TRANSMITTER A. Existing backwash flow meter venturi tube is being relocated. New differential pressure transmitter and tubing shall be provided as specified. B. Differential pressure transmitter 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 0.075 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 mA, 24 VDC. Power supply shall be 24 VDC, two-wire design. 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. Transmitter shall be supplied with a local operator interface (LOI) for display and programming capabilities. C. Transmitter shall be ABB 264ds, Rosemount 3051CD, Foxboro IDP10, Siemens DSIII, or approved equal. Transmitter shall include an integrally mounted transient protector to protect the instrument against lightning-produced voltage spikes and other transient surges. Transmitter shall be furnished with a 316 stainless steel service block and zeroing manifold with NORMAL, ZERO, BLOCKED, CALIBRATE, and BLOWDOWN functions, D/A Manufacturing Model SBZ-43AT. Transmitters shall be as follows: D. Tag Service Range TSC-FIT-003 Backwash Flow 0-15,500 gpm 2.6 LEVEL FLOATS A. Certifications: 1. UL recognized, CSA certified. 2. FDA/NSF Compliant B. Environmentally friendly, non-mercury C. Made of 316 stainless steel D. The switch shall be SPDT (snap switch), rated 1A Max, 120VAC/150VDC Max with a mechanical life of 10 million operations. 1. Include one normally open and one normally closed connection. E. Operation levels: BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Instrumentation 40 90 01 - 06 1. ON setpoint 4” above the fixed mounting level. 2. OFF setpoint 4” below the fixed mounting level. F. Float cable shall be 1. rated “continuous service” for high flexibility 2. 16gauge, 4 cond. G. Mounting hardware shall be 316 stainless steel and include flared cable fittings to prevent damage to the cable jacketing. 1. Cable mounting clip (as required) 2. Pipe mounting clip (as required) H. Cable length shall be ordered so that terminations are made above the finish structure elevation out of water submergence height. Provide an additional 10’ of cable to be wound outside the termination cabinet. Unit Tag No. Parameters TSC-LSL-F701 CABLE MOUNT TSC-LSH-F701 CABLE MOUNT ST1-LSH-001 CABLE MOUNT DB-LSL-001 CABLE MOUNT RWT-LSH-01 CABLE MOUNT RWT-LSH-02 CABLE MOUNT 2.7 HYDROSTATIC SUBMERSIBLE PRESSURE TRANSMITTER A. The level transmitter shall consist of a submersible bonded strain gauge pressure-sensing element, encased in a watertight case. It shall be supplied with standard polyurethane shielded and vented cable, with enough cable length to meet the application per the drawings. B. Performance requirements 1. Sensor shall have an accuracy of 0.5% of full scale (including the effects of non-linearity, hysteresis, non-repeatability, zero point and full scale errors). 2. Repeatability shall 0.5% of full scale or better. C. Physical requirements 1. The unit shall be designed for severe service/chemical storage environment with turbulence and shall have wetted parts compatible with sodium hypochlorite and fluoride. No cage required. 2. The unit shall have NEMA 6P, IP 68 environmental protection rating. D. Electrical requirements 1. The submersible level transmitter shall be a two-wire device that provides a 4-20 mA DC output proportional to level and shall be powered by 24 VDC. 2. Output shall be a standard 4-20mADC control signal, factory set proportional to the selected fixed range of the transducer. E. Cable shall be long enough to route to junction box or transmitter as shown on drawings without splice, plus 5 feet of looped cable. F. Accessories: BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Instrumentation 40 90 01 - 07 1. Humidity filter: Each vent tube shall be fitted to a field replaceable vent tube humidity filter with desiccant to prevent condensation from entering vent tube. a. Provide breather drain for each termination cabinet or enclosure containing a humidity filter. 2. Calibration Kit 3. Raw Water Tanks only: Provide 4” schedule 40 PVC conduit stilling well for level transducer. Strap conduit to interior access ladder with stainless steel bands. Provide vertical slots cut into still well conduit to equalize level between tank and stilling well. Conduit shall be continuous from top of ladder to one foot from the tank floor. 4. Filter 7C only: Provide 6” schedule 40 PVC conduit to use as stilling well for level transducer. Strap conduit to interior access ladder with stainless steel bands. Provide vertical slots cut into still well conduit to equalize level between filter and stilling well. Match stilling well mounting height and length to existing filters. (AD-02) G. Hydrostatic submersible pressure transducer shall be manufactured by: 1. TE Connectivity Model AST4530 2. Pre-approved equal by addendum. H. Transmitter: 1. Display provided with high visibility LED 6 digit display, with lettering at least .46” high. Each display shall be capable of displaying value in Level. 2. Inputs: One (2) 4-20mA input signal. Transmitter shall loop power the level transducer. 3. Outputs: One (2) 4-20mA, Two (2) Form C programmable discrete outputs (high level, high high level). 4. Power supply: 120VAC. 5. Enclosure: Display shall be provided with a 316 stainless steel NEMA 4X enclosure, unless noted otherwise. a. Displays identified to be remote mounted shall have an aluminum hood sunshield. See design drawings for detail. b. Raw Water Tank displays and power supply will be located in RWT PLC cabinet. c. Sodium Hypochlorite Bulk Storage Tank 3 display shall be mounted in a NEMA 4X FRP enclosure. d. Fluoride Bulk Storage Tank Level will be remote mounted from transducer. e. Fluoride Bulk Day Tank Level will be mounted in NEMA 4X 316 stainless steel enclosure. 6. Display shall be manufacturer by Precision Digital PD6000 or approved equal. 7. Unit Tag No. Location Range Y-LE-RWT-101 Raw Water Tank 1 0-25 FT Y-LE-RWT-102 Raw Water Tank 1 0-25 FT Y-LE-RWT-201 Raw Water Tank 2 0-25 FT Y-LE-RWT-202 Raw Water Tank 2 0-25 FT DF-LE/LIT-SHST3 Sodium Hypochlorite Bulk Storage Tank 3 0-17 FT CFA-LE/LIT-FLST-1 Fluoride Bulk Storage Tank Yard (Outside) 0-13 FT CFA-LE/LIT-FLDT-001 Fluoride Day Storage Tank Yard (Inside) 0-6 FT BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Instrumentation 40 90 01 - 08 2.8 NON-CONTACT ULTRASONIC LEVEL TRANSDUCER WITH TRANSMITTER A. Ultrasonic transducer shall be non-contact type, measuring level of fluid surface by using temperature dependent time-of-flight level measurement. Unit shall be continuous level measuring system consisting of level element, transmitter, and cable for connection from level element to transmitter. B. Interconnecting cable between transducer and transmitter shall be furnished with the unit with length as indicated. C. Transducer 1. General performance and functional requirements a. Accuracy: +/- .17% b. Blocking distance from transducer due to transient response time shall not exceed 1 foot. c. Ambient Temperature: 0C to 60C d. Relative Humidity: 0 to 100% e. Frequency: 42 to 44 kHz f. Beam Angle: 10 to 12 degrees g. Transducer shall include integral temperature sensor for temperature compensation. 2. Physical requirements a. Transducer material (for open channel applications): PVDF enclosure with CSM rubber face b. Transducer wetted material (for chemical tank applications): ETFE or PVDF with 2” NPT tapered threads, compatible with chemical stored within tank. 3. Mounting/Connection Type a. For open wet well applications, provide angle bracket for wall mounting. b. Provide 6” schedule 40 PVC stilling well with flange fitting and blind flange for level transducer. Mount stilling well to filter wall. Match stilling well mounting height and length to existing filters. (AD-02) D. Transmitter 1. Power Supply: 120V AC. 2. Enclosure shall be NEMA 4X. 3. Outputs a. Two (2) - 4-20mA b. Three (3) discrete dry contact programmable relays rated for 5 A and 230VAC. 4. Transmitters identified on drawings to be installed outside shall have an aluminum hood sunshield. See design drawings for detail. E. Ultrasonic level transducer and transmitter shall be manufactured by: 1. Siemens SITRANS ST-H with LUT420 Transmitter 2. Endress and Hauser FDU91 with Prosonic S FMU90 Transmitter. 3. Rosemount 3101 with 3493 Transmitter 4. Pre-approved equal by addendum. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Instrumentation 40 90 01 - 09 Unit Tag No. Location Range TSC-LE/LIT-F701 Filter 7 0-12 FT 2.9 ONLINE LOW RANGE TURBIDITY ANALYZER A. Instruments shall be a continuous reading low range nephelometer, utilizing a light beam passed through a water sample to measure the amount of light scattered by the turbidity particles. Each instrument shall consist of an instrument body and master indicator. The master indicator shall be of the indicating type with ranges of 0.001- 10 NTU. Master indicator output shall be 4-20 mA DC. B. The Turbidimeter shall be a microprocessor-based, continuous reading, on-line nephelometric instrument. C. Measurement Range .0001 to 10 NTU D. Accuracy +-2% of reading from 0-10NTU E. Stray Light – PTV Rl (EPA) <.008/8NTU F. Limit of Quantitation - PTV 2000: Better than .001NTU G. Repeatability/Precision – Better than 1% at 1 NTU H. Initial Response – 10% Change: 15 seconds @ max flow I. Step Response – T-90 J. Ambient/Operating Temperature Range – 5-50 degree C K. Ambient/Operating Humidity Range – 5 to 95% L. Power Requirements – 120VAC, 60Hz M. Analog Output: one (1) 4-20mA N. Enclosure Type: Fiber Reinforced Polyester O. Provide additional accessories: 1. Integrated flow Indicator 2. Include Bluetooth Module 3. Bubble Trap Kit 4. Cleaning Pad 5. PTV Detergent solution 6. PTV Cleaning solution 7. Fittings and Tubing Replacement Kit 8. PTV Complete Cleaning Kit 9. Slotted Mounting Bracket 10. Junction box BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Instrumentation 40 90 01 - 010 P. Utilizes a laser-based 360° x 90° optical system that measures turbidity from multiple different angles. Q. Continuous particle removal using a vortex created by the fluid path. R. Utilizes an identical laser-based optical system that matches the laboratory turbidimeter for direct comparison between laboratory and online measurements. S. Includes capability to actively monitor all internal components and present diagnostics on the overall health of the turbidimeter and time to next required maintenance. T. Controller: 1. Provide a controller for turbidimeter operation. U. Calibration Standards 1. Frequency of use of calibration standards determined by recommendation of local regulator. 2. Manufacturer must make available certified calibration standards that can be used in online and bench top instruments for highest calibration accuracy 3. Calibration standards must be capable of being used to calibrate laboratory turbidimeters with similar optics systems. 4. Calibration standards must be capable of functioning with the instrument’s optional RFID module. V. Manufacturer 1. PTV 2000 by Lovibond a. Tag Service Range TSC-AIT-F701 FILTERED WATER 0-10 NTU 2.11 PRESSURE GAUGES W. The gauges shall be the Manufacturer's standard commercial product for pressure-indicating service. The gauges shall be new and shall embody the design characteristics stated for the respective class, size, type, etc. scheduled herein. Gauge cases shall be type 304 stainless steel. Inlet shall be 1/4" size with bottom connections. Gauges shall be glycerin filled. X. Gauges shall be Ashcroft Type 3005 or approved equal. PART 3 EXECUTION 3.1 INSTALLATION A. Wire each device requiring power so that when wires are removed from any one device, power is not being disrupted to any other device. Ground the case of each device either by mounting directly on a steel frame or by a third wire. B. For existing installations, Calibrate and scale the existing instruments listed in the table below. System integrator shall provide necessary tools or software to calibrate and scale as needed. Provide installation report for all existing instruments identified to be calibrated or rescaled. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Instrumentation 40 90 01 - 011 C. Tag Flow Range Line Size Stream Description Approximate Remote Transmitter Distance TSC-FIT-F508 700-4,500 gpm 16’’ Filter Effluent 80 TSC-FIT-F608 700-4,500 gpm 16’’ Filter Effluent 80 (AD-02) 3.2 FIELD QUALITY CONTROL A. The supervisory service of a factory-trained service engineer who is specifically trained on the type of equipment herein specified shall be provided during construction to assist the Contractor in the location of sleeves; methods of installing conduit and special cable; mounting, piping, and wiring one of each type of device, and the methods of protecting all of the equipment prior to placing it into service. Upon completion of the installation, the services of the above service engineer shall be provided for calibration and startup of the equipment and for instructing the operating personnel. The Manufacturer shall provide sufficient service to place the system in satisfactory operation. B. Upon completion of installation of sample pumps, an acceptance test to verify the satisfactory operation of each unit shall be conducted. The test shall be conducted in a manner approved by and in the presence of the Engineer. The unit shall be checked for excessive noise, vibration, alignment, general operation, etc. The unit must perform in a manner acceptable to the Engineer before final acceptance will be made by the Owner. C. Check out and calibrate the system upon completion of the installation. D. Prior to the Owner turning on any form of energy to the system, the Contractor shall provide the Engineer with a certified statement of approval of the installation including his supplier's authorization for turning on energy to the system 3.3 Existing Installations A. Calibrate and scale the existing instruments listed in the table below. System integrator shall provide necessary tools or software to calibrate and scale as needed. Provide installation report for all existing instruments identified to be calibrated or rescaled. B. For existing instrumentation terminating into an existing PLC to remain, system integrator shall update the instrument scale at the Ignition HMI and the PLC it is terminated to. Tag Instrument Type Location Process Description Scale Existing PLC Location TSC-LIT-F801 Non-Contact Ultrasonic Filter 8 Filter Level 0-12 FT N/A TSC-LE-F801 Non-Contact Ultrasonic Filter 8 Filter Level 0-12 FT N/A TSC-DPIT-F801 Differential Pressure Filter 8 Filter Loss of Head 0-45 psig N/A TSC-AIT-F801 Turbidity Analyzer Filter 8 Turbidity 0-10 NTU N/A TSC-FIT-F801 Venturi Flow Meter Filter 8 Effluent Flow 700-4,5000 gpm N/A BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Instrumentation 40 90 01 - 012 TSC-FIT-001 Venturi Flow Meter Train 1 Influent Flow Meter Influent Flow 700-4,500 gpm N/A **TSC-FIT-002 Magnetic Flow Meter Train 2 Influent Flow Meter Influent Flow 700-4,500 gpm N/A ** Instrument is not required to be recalibrated, must be rescaled. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 1 SECTION 40 90 02 - SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM (Revised by AD-02 & AD-03) PART 1 GENERAL 1.1 SCOPE A. This section specifies furnishing, installing, testing, and start-up operations of a complete control system as indicated in the Plans and as specified herein. The system shall be totally integrated with the existing SCADA system. The system shall be configured to operate over an open system architecture. B. Project consists of expanding the existing plant to include the following: 1. New PLC cabinet (RWT-PLC-01) for two raw water tanks. 2. Fiber tie-in for raw water tank PLC cabinet to electrical building PLC cabinet (EB-PLC- 01). Provide fiber patch panel, fiber to copper media converter and connection to PLC cabinet ethernet switch. 3. Ethernet tie in at dewatering facility PLC cabinet (SDF-PLC-01) for new belt filter press cabinet. 4. Remote I/O and OIT for new additional filter console TSC-RIO-F7. Console enclosure is existing. 5. Add enclosure side wall backplane for new PLC, PLC I/O modules, relays, analog surge suppressors, and terminal blocks within TSC-PLC-02 cabinet. 6. Replace existing TSC-PLC-02 ethernet switch with 8 port ethernet switch. 7. Expanding existing PLC cabinets for additional points associated with: a. Additional Flocculators. b. Additional Sedimentation basin, sludge collection system, and sludge vault blow down valve. c. Additional fluoride transfer pumps, replacement fluoride bulk storage tank, and fluoride day tank. d. Additional sodium hypochlorite bulk storage tank. 8. Fluorosilicic Acid Fill Station a. Refer to design drawings for schematic and elevation. b. Refer to Section 26 29 13.01, Industrial Control Panels for panel fabrication requirements. 9. Polymer Selector Control Panel (SDF-PSP-01) (AD-02) C. System Components: The system will consist of the following major components and subsystems: 1. Remote I/O 2. Remote I/O communications 3. PLC CPU, PLC power supplies, backplane, 4. PLC I/O modules 5. PLC Programming 6. Operator Work Station HMI modifications 7. Filter 7 RIO OIT 8. UPS 9. Spare parts. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 2 D. SCADA PLC programming and top end programming/development shall be performed by the Contractor. Contractor shall coordinate software scope with hardware identified within the contract documents for a complete and operational system. 1.2 SYSTEM DESCRIPTION A. Control functions shall include digital logic control, PID control, analog scaling and set point control, and peer to peer communications. B. Include all hardware, firmware, software, and application programming and configuration, as necessary, to make the system completely functional and operational in accordance with the Contract Documents. All necessary components and equipment which are not specifically described in the Contract Documents, but which are necessary to configure an operational distributed control system as described herein, shall be identified, furnished, and installed by the CONTRACTOR. The system provided shall be the vendor's standard; a prototype system will not be accepted. C. Owners existing system: 1. HMI: Ignition 2. PLCs and Remote I/O: Allen Bradley 1756 3. Network: See drawings for system architecture (ControlNet). 4. PLC Programming Software: RSLogix 5000 Professional Software Bundle. 1.3 REFERENCE STANDARDS A. American National Standards Institute (ANSI)/Institute of Electrical and Electronic Engineers (IEEE) B. Electronic Industries Association (EIA) C. National Electrical Manufacturers Association (NEMA): 1. ICS 1, General Standards for Industrial Control and Systems. 2. ICS 1.1, Safety Guidelines for the Application, Installation and Maintenance of Solid State Control. 3. ICS 2, Industrial Control and Systems Controllers, Contactors and Overload Relays Rated 600V 4. ICS 4, Terminal Blocks for Industrial Use. 5. ICS 6, Enclosures for Industrial Controls and Systems. 6. ICS 19, Diagrams, Device Designations, and Symbols for Industrial Control and Systems. 7. Publication No. 250, Enclosures for Electrical Equipment (1000 V maximum). D. National Electric Code E. ISA Standards F. IEC 2 KV Isolation test G. IEEE472/ANSI C37-90A Surge withstand capability test H. IEEE 802.3 BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 3 I. Factory Mutual (FM) J. Underwriters Laboratories, Inc. (UL) K. National Fire Protection Association (NFPA) L. Joint Industrial Council (JIC) 1.4 SUBMITTAL A. Submittals shall conform to the requirements set forth in Section 01 33 00. B. Loop diagrams shall be prepared according to ISA Standard ISA-S5 and using loop numbers provided. C. Schematic ladder diagrams shall include all terminal blocks, hardware devices, software interlocks, software data links, and control. D. PLC/RIO panel layout, plans, elevations, sections, details, etc. E. A schedule defining all I/O, database reference, and point of origin or destination, and PLC or Remote I/O system internal address. F. Software manuals shall be provided to configure the central system and technical review information. Provide sample program documentation from previous projects. G. Submit written description of functions, loops, and logic. H. Submit all SAMA Logic and Wiring Diagrams and ISA Logic Diagrams for all equipment requiring programming at the PLCs, with all set points and ranges indicated. I. Complete spare parts list with catalog and part numbers and quantities. J. Bill of materials showing product ordering information K. Software being submitted shall include the product information and version with the purchased license agreements. Licensed agreements shall show product key number, the number of points purchased, and length of purchase agreement. L. Integrator shall provide additional submittals that shall be approved prior to delivery to the job site and downloaded on the PLC system: 1. At least six weeks prior to start-up, submit detailed programming information consisting of ladder logic and proposed program code, complete input, output, relay, register and controller identification labels, memory allocation table, and written description of program operation. 2. HMI screen additions and modifications for Owner and Engineers review. 3. Tests a. Factory Test Reports b. Coordination meeting agendas c. Preliminary Testing plan (for field test in this specification section) d. Preliminary Training plan BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 4 1.5 QUALITY ASSURANCE A. Suppliers Qualifications: The complete system shall be configured, programmed, and installed by one qualified system supplier who is regularly engaged and qualified in designing and building instrument control systems. The systems company shall have been in existence under its own name for at least 10 years. Qualifications shall include five years of successfully providing similar systems technical staff and design office, physical facilities, and personnel to complete the work specified, and competent service personnel to service and operate the equipment provided. The system suppliers shall assume complete systems responsibility, including coordination and interfacing with all subsystems and equipment suppliers and manufacturers. The installation supervisor shall have had experience in overseeing installation and start-up of at least three similar installations. The bidder shall submit, upon ENGINEER's request, complete company history, resumes of full time project manager for this project, other key full-time system analysts, programmers, technicians, and submit project list with costs, OWNER, contact person, phone number, etc. B. Tests: The complete system shall be assembled and tested at the job site. The OWNER'S representative and the ENGINEER'S presence will be required at the time of final testing at the system supplier's facilities. C. Standards: All applicable NEC, ISA, IEEE, NEMA, UL, ANSI, IEC, FCC, FM standards shall apply. All equipment shall be new, and UL listed and labeled. D. Assembly, Storage, & Handling: The complete system, including all individual electronic component units, shall be assembled and stored in air-conditioned and heated facilities with low humidity. Once assembled and tested, the system shall be stored in air-conditioned and heated rooms. Ship the unit to job site only after the control room has been built and its HVAC system is in operation. E. Acceptable PLC and Remote I/O Manufacturers: 1. Rockwell Automation Allen Bradley 1756 ControLogix 2. No others approved. F. Acceptable SCADA Programmer: 1. Alterman Electric 2. Prime Controls 3. McKim & Creed 4. No others approved. 1.6 SPARE PARTS, TOOLS, AND SUPPLIES A. As a minimum, provide the following compatible spare parts, tools, and supplies as a part of this CONTRACT: 1. Two (2) spare 24 V. DC power supplies of the type furnished. 1.7 WARRANTY A. The Equipment supplier and the CONTRACTOR shall warrant to the OWNER that the equipment delivered with reference to this specification complies with this specification. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 5 B. The equipment supplier and the CONTRACTOR shall warrant the equipment as to defects in material and workmanship for a period of one year from the date of final acceptance of the project. Vendor shall include a copy of his special equipment warranty with the shop drawings. The warranty specified by this specification shall be exclusive, and in lieu of all other warranties whether written, implied, orally presented, or statutory. PART 2 PRODUCT 2.1 FILTER REMOTE I/O A. Filter consoles 7shall include at a minimum the following: 1. Filter console is existing to remain. Contractor shall provide the enclosure back plane. 2. GFCI Convenience receptacle 3. LED light. 4. Coax Cable T-Tap 5. Operator Interface Terminal – Allen-Bradley PanelView Plus 7 10” 6. Relay output module – Allen-Bradley 1756-OW16I 7. Analog Input Module – Allen Bradley 1756-IF6I 8. Analog Output Module – Allen Bradley 1756-OF6CI 9. Relay input module – Allen Bradley 1756-IA16I 10. ControlNet Bridge Module - Allen Bradley 1756-CNB 11. PLC Chassis, 10 slot – Allen Bradley 1756-A10 12. Redundant Power Supplies and module (Sola SDN2.5-20RED) 13. Surge Suppressor – Control Concepts IC+107 or approved equal 14. Ground Bar 15. Furnish all the necessary cables, face plates, connectors, modems, transceivers, repeaters, modules, splice kits, etc. required for a complete and operational Remote I/O data highway. 2.2 PLC Cabinets (RWT-PLC-01, SDF-PLC-01, TSC-PLC-01 and TSC-PLC-02) A. Contractor shall provide hardware as required to match existing components: 1. Relay output module – Allen-Bradley 1756-OW16I 2. Analog Input Module – Allen Bradley 1756-IF6I 3. Analog Output Module – Allen Bradley 1756-OF6CI 4. Relay input module – Allen Bradley 1756-IA16I 5. ControlNet Bridge Module - Allen Bradley 1756-CNB 6. PLC Chassis, 10 slot – Allen Bradley 1756-A10 7. Redundant Power Supplies and module (Sola SDN2.5-20RED) 8. Surge Suppressor – Control Concepts IC+107 or approved equal 9. Ground Bar 10. Furnish all the necessary cables, face plates, connectors, modems, transceivers, repeaters, modules, splice kits, etc. required for a complete and operational Remote I/O data highway 2.1 FILTER REMOTE I/O A. Filter consoles 7 shall include at a minimum the following: 1. Filter console is existing to remain. Contractor shall provide the enclosure back plane. 2. GFCI Convenience receptacle. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 6 3. LED light. 4. Coax Cable T-Tap. 5. Operator Interface Terminal – Allen-Bradley PanelView Plus 7 10”. 6. Relay output module – Allen-Bradley 1756-OW16I. 7. Analog Input Module – Allen Bradley 1756-IF6I. 8. Analog Output Module – Allen Bradley 1756-OF6CI. 9. Relay input module – Allen Bradley 1756-IA16I. 10. ControlNet Bridge Module - Allen Bradley 1756-CN2. 11. PLC Chassis, 10 slot – Allen Bradley 1756-A10 12. Redundant Power Supplies and module (Sola SDN2.5-20RED). 13. Surge Suppressor – Control Concepts IC+107 or approved equal. 14. Ground Bar. 15. Furnish all the necessary cables, face plates, connectors, modems, transceivers, repeaters, modules, splice kits, etc. required for a complete and operational Remote I/O data highway. 2.2 PLC Cabinets (RWT-PLC-01, SDF-PLC-01, TSC-PLC-01 and TSC-PLC-02) A. Contractor shall provide hardware as required to match existing components: 1. Relay output module – Allen-Bradley 1756-OW16I. 2. Analog Input Module – Allen Bradley 1756-IF6I. 3. Analog Output Module – Allen Bradley 1756-OF6CI. 4. Relay input module – Allen Bradley 1756-IA16I. 5. PLC Chassis, 10 slot – Allen Bradley 1756-A10. 6. Redundant Power Supplies and module (Sola SDN2.5-20RED). 7. Surge Suppressor – Control Concepts IC+107 or approved equal. 8. Ground Bar. 9. Furnish all the necessary cables, face plates, connectors, modems, transceivers, repeaters, modules, splice kits, etc. required for a complete and operational Remote I/O data highway. 10. RWT-PLC-02 Only: CPU – Control Logix 1756-L71. 11. TSC-PLC-02a only: CPU – ControlLogix 1756-L73 with 1756-RM2 redundancy module. 12. RWT-PLC-01 Only: UPS sized for 15 minutes of runtime. (AD-03) 2.3 PROGRAMMABLE LOGIC CONTROLLERS A. The control system shall be configured using microprocessor-based programmable controllers for local process control functions. Each controller shall be equipped with central processing unit, power supplies and individual uninterruptible power supply (UPS) to perform logic control functions based on the program stored in memory and the status of inputs and outputs. Memory will be required such that there is a minimum of 20 percent spare, and will be non- volatile. Automatic shutdown feature shall be selectable such that the desired field condition will be the default condition in the event of power loss or system failure. Power supplies shall be provided for the process controller as required with built-in protection against short- circuits, overcurrent, and overvoltage. Two communications ports shall be provided for each programmable controller. B. The programmable controller shall be capable of complete control, including PID control, digital logic control, batch, and setpoint control. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 7 C. The entire PLC system shall immediately shut down and annunciate the occurrence of any of the following abnormal circumstances: 1. Memory parity error. 2. Loss of signal communication between CPU and I/O's. 3. Loss of logic power to any portion of the system. 4. Halt or interruption of memory scan. 5. Detection of any incomplete relay ladder rungs in memory. D. The PLC system shall accomplish the control requirements of the loop descriptions, and Contract Documents. E. The design application and installation of the PLC system shall conform to NEMA ICS 1.1. F. PLC programming shall be documented annotated in detail, and factory tested. 2.4 HUMAN-MACHINE INTERFACE (HMI) A. HMI shall utilize system monitor displays, mouse, and keyboard(s). Interface functionality shall include: 1. Graphics representing process 2. Individual process/equipment screens 3. Alarm screen 4. Display of real time and historical process trends 5. Set point parameters that are password protected 6. Graphic representation of plant operations with interactive status and measurement symbols 7. Annunciation 8. PLC Clock displays for monitoring time synchronization 9. Communication and network monitor screens 10. Navigational menus such as header/footer buttons B. The HMI and historian system shall report the following events: 1. All entries initiated by operator including the following: a. Console key changes b. Beginning and final values of setpoint and output changes c. Mode changes (i.e., auto to manual) d. Which console changes were made from e. Time change was made 2. Events: a. Description of event b. Time of event c. Resolution of 100 milliseconds maximum. 2.5 ENVIRONMENTAL CONDITIONS A. The PLC system shall operate in: 1. Ambient conditions of 0-40°C temperature. 2. 0- 95 percent relative humidity without the need for purging or air conditioning. 3. Elevation: 1000’ above sea level. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 8 2.6 INPUT/OUTPUT CONNECTION REQUIREMEMTS A. Outputs shall be fused: 1. External fusing shall be provided if output module does not possess internal fusing. 2. Fuses provided external to output model shall: a. Be in accordance with module manufacturer's specifications. b. Be installed at terminal block. B. Install bleeding resistors across input from field devices which leak current sufficiently to flicker input status light. C. Make connections to I/O subsystem by terminating all field wiring on terminal blocks within the I/O enclosure. D. Prewire I/O modules to terminal blocks. E. Provide terminal blocks with continuous marking strip. F. Size terminals to accommodate all active data base points and spares. G. Provide terminals for individual termination of each signal shield. Stripping back twisted shielded pair and twisting together all the shields is not acceptable. H. Field wiring shall not be disturbed when removing or replacing an I/O module. I. PLC I/O arrangement: 1. Where the PLC is utilized to control multiple trains of equipment, the PLC components (I/O modules, power supplies, etc.) shall be assigned so that the failure of one component does not affect equipment on all trains. I/O modules shall be segregated on a train basis unless required otherwise for safety reasons. J. All PLC control system components shall be capable of meeting or exceeding electromagnetic interference tests per ANSI/IEEE C37.90.2. K. Incorporate the following minimum safety measures: 1. Master Safety Relay: a. Cuts off power to I/O devices upon de-energization b. Multiple Master Safety Relays shall be available as required to provide ability to control separate designated blocks of the control program. 2. Watchdog Function to Monitor: a. Internal processor clock failure b. Processor memory failure c. Loss of communication between processor and I/O modules d. Processor ceases to execute logic program e. Peer to Peer communication between PLCs. 3. Safety Function Wiring: a. Emergency shutdown switches shall not be wired directly into the controller. 4. An emergency power disconnect shall be placed in the power circuit feeding the power supply as a means of removing power from the entire PLC system. a. Capacitor shall be placed across the disconnect to protect against current outrush through trails. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 9 5. Safe Wiring: a. Equipment failure mode shall be selected so that the loss of power or control signal to the equipment will result in the equipment either shutting down or operating safely. b. Activation of alarms and stopping of equipment shall result from the de-energization of control circuits, rather than the energization of control circuits. c. Low voltage control signal wires: 1) Place in conduit segregated for that purpose only 2) Twisted shielded wire pair 3) Not located in the same conduit or bundle with power wiring 6. Initial Safety Conditions: a. Utilize program module to dictate output states in a known and safe manner prior to running of control program. b. Utilize program each time PLC is re-initiated, and the control program activated. 7. PLC Fault Relay: a. Placed in series with any other emergency stop conditions b. Opening of PLC Fault Contact: 1) Upon unsafe or undesirable system operation, including: a) Loss of memory b) Processor fault c) Power supply fault d) Isolation failure e) Communications failure f) Scan time overrun g) Module failure 2) Results from de-energization of PLC fault relay 3) Causes Master Safety Relay to de-energize 8. Monitoring of Internal Faults and Display: a. Internal PLC system status and faults shall be monitored and displayed. Monitored items shall include: 1) Memory ok/loss of memory 2) Processor ok/processor fault 3) Battery ok/battery low 4) Power supply ok/power supply fault 5) Isolation failure 6) High CPU temperature 7) Scan time overrun 8) Module failure 9. Control of Programs: a. Protect access to PLC program loading with locked, key operated selector switches. 10. Effects of Failure: a. PLC system shall incorporate safe responses to the following failure effects: 1) Power losses, interruptions, excursions, dips, and transients. 2) Loss or corruption of memory 3) Information transfer corruption or loss 4) "Fail on" or "Fail off" of inputs or outputs 5) Unreadable signals 6) Addressing errors 7) Processor faults BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 10 11. Design PLC system with high noise immunity to prevent occurrence of false logic signals resulting from switching transients, relay and circuit breaker noise or conducted and radiated radio frequency interference. 12. Incorporate noise suppression and inductive load suppression design into input, output, and logic modules 2.7 COMPONENTS A. PLC System Central Processor Unit (CPU): 1. Completely solid state CPU designed to provide: a. Digital relay logic b. Analog loop control c. Other required control functions: 1) Counting 2) Floating point math computations 3) Timing 4) Analog Scaling 2. To provide communications with other control systems and man-machine interfaces as specified. 3. To use ladder logic, function block, sequential function chart or structure text style programming for discrete logic applications. 4. Memory: TBD by system integrator. 5. Flash non-battery ram. 6. Memory battery backup shall be capable of 60 days memory retention with fresh batter. 7. Provide visual indication of battery status and alarm low battery voltage. 8. Memory battery backup shall be capable of 14 days memory retention after the "Battery Low" indicating LED is on. 9. 20 percent minimum spare useable memory capacity after all required programming is in place and operating. 10. Capable of executing all control functions required by the Contract Drawings including digital and analog loops. 11. Built-in three-mode (proportional-integral-derivative) control capabilities. a. As directly selectable algorithms requiring no user knowledge of programming languages. b. On line reconfigurable. c. Lighted status indicators for "RUN" and "FAILURE." d. Capable of manual or automatic control mode transfer from the HMI system or from within the control strategy. Transfer shall be bumpless and balanceless. B. Fiber optic patch panel (RWT-PLC-01, EB-PLC-01): 1. Provide compact fiber patch panel which consists of: a. Compact wall-mount connector housing, two panel minimum, ST compatible connectors, OM2 50um b. six (6) fiber minimum 2. Mount to enclosure backplane. 3. Terminate all fibers to patch panel. 4. Manufactured by Corning, Panduit, Tripp Lite or equal. C. Media Converter (EB-PLC-01): BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 11 1. Provide media with one 10BASE FX port with ST connector and one 10/100BaseT(X) RJ45 port. Media converter shall be din rail mounted suitable for temperatures ranging from -10C to 60C. 2. 100Base FX port shall be OM2 multimode, 50/125 um with a tx/rx distance of 5 km. Link budget shall not exceed 12 dB. 3. Power input shall be 12 to 48VDC and media converter shall include integral overload current protection. Provide a compatible power supply within cabinet. 4. Model shall be Moxa IMC-21 series or equal. D. Raw Water Tank Displays (RWT-PLC-01): 1. Single Input Display a. Provide four (4) level displays to power raw water tank submersible transducers. Transducers are loop powered. Display provided shall have high visibility red LED 6 digit display with lettering at least 0.46” high. Displays shall be mounted to PLC enclosure door. b. Inputs: Two (2) 4-20mA input signals. c. Outputs: Two (2) 4-20mA, isolated. d. Power supply: 120VAC or 24 VDC, powered from PLC UPS. e. Enclosure: Display shall be NEMA 4X while face-mounted to PLC enclosure door and shall maintain the NEMA 4X rating of PLC enclosure. Provide sunshield for each display to prevent direct sunlight on display. f. Display shall be manufactured by Precision Digital, model PD6000 or equal. E. Ethernet Switch 1. General a. Mounting: Din rail or backplane mountable. b. Operating temperature: -10C to 60C. 2. RWT-PLC-01: a. 10/100BaseT(X) Ports, RJ45 Connectors: 4, minimum. b. 100BaseFX Ports, Multimode, ST Connectors: 1 pair. c. Manufactured by Moxa model EDS-308, Phoenix Contact or equal. 3. TSC-PLC-02: a. 10/100BaseT(X) Ports, RJ45 Connectors: 8, minimum. b. 100BaseFX Ports, Multimode, ST Connectors: None. c. Manufactured by Moxa model EDS-308, Phoenix Contact or equal. (AD-02) 2.8 INPUT/OUTPUT (I/O) MODULES A. Provide plug-in modular-type I/O racks with cables to connect to all other required PLC system components. B. Provide I/O system with: 1. I/O solid state boards with status lights indicating I/O status and board failure. 2. Electric isolation between logic and field device. 3. Individually fused outputs with blown fuses indication. 4. Capability of withstanding low energy common mode transient to 1500 V without failure. 5. Incorporate noise suppression design. 6. Capable of meeting or exceeding surge-withstand capability tests, per ANSI/IEEE C37.90.1. 7. Capable of meeting or exceeding electrical noise tests, NEMA ICS1 BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 12 C. Discrete I/O Modules: 1. Interface to ON/OFF devices 2. I/O status indicator module front 3. Voltage rating to match circuit voltage 4. Output current rating: a. Match maximum circuit current draw b. Minimum 1.5 A/point for 120 V AC applications 5. Isolated modules for applications where one module interfaces with devices utilizing different sources of power. 6. Individually fused with blown fuse indication. D. Analog I/O Modules: 1. Inputs to accept signals indicated on Drawings or Specifications 2. 16 bit resolution 3. I/O chassis supplied power for powering connected field devices 4. Isolated (differential) inputs and outputs 5. User configurable for desired fault response state 6. Provide output signals as indicated on Drawings and Specifications 7. Individual D/A converter for each output module 8. Individual A/D converter for each input module 2.9 HMI CENTRAL CONTROL AND DATA ACQUISITION SYSTEM A. The HMI central computer system shall be configured and programmed to maintain a real- time database of all input/output points within the system. The central system shall monitor and control the local process controllers; it will log selectable points within the system and be capable of data management such that all data is available while monitoring concurrently. B. The system provided shall include the following features: 1. Multi -tasking Operating System 2. Data Collection of Analog and Digital I/O 3. Historical and Archival Data Logging 4. Alarming 5. Trending - Historical and Real-Time 6. Networking 7. Real-Time Multi-tasking 8. Event Processing - Control Strategy Initiation 9. Easily Configured Displays and Display Modification with Graphic icons. 10. Real-Time Display with Status Change Color Change Feature 11. Pre-emptive multitasking 12. Dynamic objects for configuring I/O devices 13. I/O Driver software for PLCs provided C. Data Collection: The real-time database shall be modified to manage an additional 1,000 points minimum in any combination of analog/digital I/O. D. Data Logging: Real-time database points shall be selectable for logging. E. Report Generation: Contractor shall develop or modify reports for up to 20 daily and 20 monthly reports. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 13 F. Alarm/event logs shall record all alarms immediately as they occur. The message is to include the time of the alarm, point name, and a description of the alarm. Time of the operator acknowledgment and return to normal are also to be recorded. Events, including operator log on, system control point change, and operator control functions, are also to be reported. G. The system is to be equipped with a facility for time-generated reports such as alarm summary, shift log of events, etc. 1. The following custom reports shall be generated: a. Standard Format: 1) User configurable 2) Contain selected information from any log, event, or alarm list 3) Capable of producing custom log report for periodic and on-demand printing of a list of process or calculated variables a) Variable Format: 4) User configurable 5) Ability to include any system data including: a) Calculated time based on averages b) Totalizations c) Minimum values d) Minimum times e) Maximum values f) Maximum times b. Reports shall not require software programming to setup. c. All data setup in reports shall be output to Microsoft Excel unless specified otherwise. H. Trending: Trend graphics are to be provided as either a stand-alone tool for analysis, or as a real-time recorder. Compression techniques shall be provided for automatic rescaling, optimal resolution, and time slot averaging to give the operator an efficient interface for analysis. Datapoints for trending are to be selectable directly from the database by scrolling through the tag database and selecting the desired points to trend. The trend facility is to provide the ability to generate reports to provide the operator with a hard copy of his analysis. I. Networking: Facilities shall be provided to network the system such that the real-time database generated within the system can be easily transferred to other computers for manipulation and analysis. J. Displays: Displays are to be accessible through the use of the mouse and/or touch screen. Status is displayed on the screen through the use of color and alphanumerics. The mouse and/or touch screen can change the status of a discrete device or the output value of an analog device. Displays shall be easily built or reconfigured through the use of an established library of symbols. The system shall be easily modified to change the values displayed, the format and arrangement of the display. Status colors changed within each display shall include tanks, line, rotating equipment, etc. K. The graphic displays shall have the following additional capabilities: 1. Utilize ISA symbols for devices 2. Have selectable colors 3. Utilize loop numbers, equipment numbers, and valve number 4. Devices shall dynamically change colors on status change 5. Graphics shall be pixel oriented BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 14 6. Level indication shall be dynamic 7. Have bar-graph capability 8. Have complete touch screen interface. 9. Graphic icon library. 2.10 POWER SUPPLIES A. The PLC and/or Remote I/O shall have chassis mounted power supplies to power the chassis backplane and provide power for the processor and applicable modules. B. Power supplies shall have a clearly visible LED to indicate that the incoming power is acceptable, and the output voltage is present. C. Power supplies shall feature over-current and over-voltage protection and should be designated to operate in most industrial environments without the need for isolation transformers. D. Power supplies shall be sized to accommodate the calculated peak loads plus 30% at 100% duty. E. DC power supplies shall be capable of handling ripple up to 2.4V peak to peak. F. AC input line voltage of 85 to 265VAC, 60Hz. G. Provide surge protection, isolation, and outage carry-over up to 2 cycles of the AC line. Capable of meeting or exceeding electrical noise tests, NEMA ICS1 H. Capable of meeting or exceeding surge-withstand capability tests per ANSI/IEEE C37.90.1. I. Power Distribution: 1. Immune to transients and surges resultant from noisy environment. 2. Shall provide constant voltage level DC distribution to all devices. 2.11 LIGHTNING/SURGE PROTECTION A. General – Lightning/Surge protection shall be provided to protect the electronic instrumentation system from induced surges propagating along the signal and power supply lines from lightning, utility, or the internal plant electrical distribution system. The protection systems shall be such that the protective level shall not interfere with normal operation but shall be lower than the instrument surge withstand level. Protection shall be maintenance free and self-restoring. B. Field Instrumentation Protection – Provide individual device protection for the 4-20mA signal to each field instrument mounted outside the building or facility housing the control panel. Instruments mounted within the structure as the associated control panel shall not require surge protection. Instruments shall be housed in a suitable metallic case, properly grounded. Ground wires for all instrumentation device surge protectors shall be connected to a good earth ground. Where practical route each ground wire individually and insulated from each other. Device surge protectors shall be mounted within the instrument enclosure or a separate junction box coupled to the enclosure. Provide surge protection devices as manufactured by Phoenix Contact, Telecommunication Industries Inc., or equal. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 15 C. Control Panel Power Feed – Provide protection of all 120VAC power feeds into control panels. Source voltage to cabinets/panels regardless of location (indoor or outdoor), shall be protected by isolation transformers and surge suppressors. Provide metal oxide varisters located at the point where the 120V source supply enters the enclosure. Install the surge device in strict compliance with the manufacturer’s recommendation for maximum allowable circuit length between protective device and incoming circuit. Provide signal surge suppression devices as manufactured by Phoenix Contact or approved equal. D. Instrument 120V Power Supply – Provide protection for 120VAC power to all four-wire field instruments. Provide individual metal oxide varisters located at the instrument end of the circuit. Provide surge suppression devices as manufactured by Phoenix Contact or approved equal. E. 4-20mA Signal Lines and Non-Fiber Based Data Highway Circuits – Provide protection on all signal and data highway circuits that leave a building or are routed external to a building. Provide Zener Diode protectors. Circuit protection shall be provided at both ends of the signal or data highway lines within the control panel at one end as close to the instrument or terminal device as possible. Provide signal surge suppression devices as manufactured by Phoenix (S- PT-EX-24DC and PT-IQ-1X2-EX-24DC-UT) or approved equal. 2.12 NOMENCLATURE AND IDENTIFICATION A. Field Instrument Tags 1. A permanent stainless-steel tag firmly attached and permanently and legibly marked with the instrument tag number, as indicated in the drawings, shall be provided on each piece of equipment. 2. Provide 1/8” X 3/8”, Type 316 stainless steel button head machine screws. 3. All supplied field instrument transmitters and field instrument transmitter elements shall have a stainless-steel identification tag attached to each transmitter and element prior to shipment. Tag shall be attached via stainless steel chain or stainless-steel wire (24 gauge min) to a non-removable part of the device. The tag size shall be a minimum of 1.5square inches. Tag shall include the ISA alphanumeric instrument number as identification in the P&ID, loop, and detail drawings. The alphanumeric instrument number shall be stamped into the tag and shall have a minimum of 3/16” high characters. B. Polymer Selector Control Panel (SDF-PSP-01): 1. It is the intent of this panel description to provide a general overview of the operation of the polymer selector control panel. The Contractor is responsible for providing the necessary relays and wiring to ensure the existing and proposed belt filter press controls and polymer system controls operate as a complete and operable system. 2. The existing belt filter press control panel has the capability to monitor and control the two existing polymer systems. A second belt filter press control panel will be added under this contract and will have the same capabilities as the existing belt filter press control panel. 3. The existing belt filter press control panel as-builts can be made available upon request by the Contractor. 4. General panel requirements a. Panel will be powered by a 120VAC power supply from a nearby lighting panel. b. Panel will be NEMA 4X 304 stainless steel. The panel door shall swing horizontally and be held closed with mechanical spring-loaded fasteners. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 16 c. Refer to Section 26 29 13.01, Industrial Control Panels for panel materials and fabrication requirements. d. Provide all necessary conduit and wiring to interconnect existing conduits between belt filter press control panel and polymer panels. e. Wiring and relay configuration of polymer selector panel will prevent backfeed of voltage between belt filter press control panels regardless of selector switch position. 5. The polymer selector panel will have the following included with panel: a. Indicators 1) Power On (White). b. Selector Switches 1) Polymer System 1 - 3 Position ( Belt Filter Press 1/None/ Belt Filter Press 2). 2) Polymer System 2 - 3 Position ( Belt Filter Press 1/None/ Belt Filter Press 2). c. Discrete signals from each polymer control panel to each belt filter press control panel. The discrete signals between the control panels are currently dry contacts and will remain dry contacts after the polymer selector panel is installed. 1) Polymer system 1 running (To belt filter control panel 1). 2) Polymer system 1 fail (To belt filter control panel 1). 3) Polymer system 1 In Auto (To belt filter control panel 1). 4) Polymer system 1 running (To belt filter control panel 2). 5) Polymer system 1 fail (To belt filter control panel 2). 6) Polymer system 1 In Auto (To belt filter control panel 2). 7) Polymer system 2 running (To belt filter control panel 1). 8) Polymer system 2 fail (To belt filter control panel 1). 9) Polymer system 2 In Auto (To belt filter control panel 1). 10) Polymer system 2 running (To belt filter control panel 2). 11) Polymer system 2 fail (To belt filter control panel 2). 12) Polymer system 2 In Auto (To belt filter control panel 2). 13) Start/Stop polymer system 1 (From belt filter press control panel 1). 14) Start/Stop polymer system 2 (From belt filter press control panel 1). 15) Start/Stop polymer system 1 (From belt filter press control panel 2). 16) Start/Stop polymer system 2 (From belt filter press control panel 2). d. 4-20mA analog signals from each polymer control panel to each belt filter press control panel. 1) Polymer system 1 speed feedback (To belt filter control panel 1) 2) Polymer system 2 speed feedback (To belt filter control panel 1) 3) Polymer system 1 speed setpoint (From belt filter control panel 2) 4) Polymer system 2 speed setpoint (From belt filter control panel 2) e. Polymer system discrete and analog feedback signals will be split via control relays and analog splitters for continuous feedback to each belt filter press control panel. f. When the polymer system selector switch is assigned to one of the two belt filter press control panels, the discrete start/stop command and the 4-20mA analog speed setpoint signal will be available only to that polymer system. Only one belt filter press will utilize a polymer system at a time. (AD-02) BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 17 2.13 EXECUTION 2.14 INSTALLATION A. System equipment shall be installed where indicated in the Contract Documents. Power and signal connections between components shall provide the specified functions. Install according to equipment manufacturer's instruction. B. The system Supplier Contractor shall utilize their own printers, monitor's, and computers for programming, testing, and start-up. The use of the OWNER's computers, monitor's, or printers shall not be acceptable until the entire system has been installed, debugged, programmed, and operated to ENGINEER's satisfaction. Where installations require the Owners PLC or HMI to remain operational as the work is integrated, the contractor shall coordinate operations with the Owner at least two weeks prior to commencing work and shall have planning in place to operate the system manually during the transition and must backup all original software prior to installing the proposed software. 2.15 PROGRAMMING A. The loop descriptions and diagrams shown in the Contract Documents are functional only and do not attempt to specify detail program coding that may be required. The CONTRACTOR shall utilize this functional information to develop complete application programming for the PLC equipment provided under this CONTRACT. Programs shall be designed to provide fail- safe operation of equipment in case of PC logic or power supply failure. Fail-safe shall be defined as "stopped" for all drives and "closed" for valves, unless otherwise specified. Up to fifty (50) graphic pages shall be required for the operator-interface and will be developed via a menu-driven color graphics editor. Interrupting logic between the LPU and central computer system shall be required as per system sequence of operation. An additional 15 graphics shall be developed in the field in coordination with the OWNER and the ENGINEER. The graphics shall be sufficiently detailed to include all equipment, pipes, valves, solenoids, meters, switches, etc. Graphics shall include equipment tag numbers and display the current flow rates, levels, quantities, status, elapsed time of equipment, etc. All such work shall be done at no extra cost to the OWNER. Before programming the graphics, the CONTRACTOR shall furnish a set of drawings for ENGINEERS review. 2.16 DOCUMENTATION A. Following delivery to the site, the equipment manufacturer, in the presence of the ENGINEER, shall demonstrate operation of the complete system. B. The CONTRACTOR shall provide documentation for all application software. Documentation system shall be diagrams in ladder-rung format and shall show all input devices to the left of the left "power rail" and all outputs to the right of the right "power rail." The diagrams shall show all device codes and functional description used in the project manual, and shall also show PLC address codes, element codes, and I/O assembly codes, modules numbers, and terminal numbers. 2.17 TESTS A. All elements of the SCADA system, both hardware and software, shall be tested to demonstrate that the total system satisfies all of the requirements of the Specifications. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 18 B. The Contractor shall furnish and install the field instruments, PLC, remote input/output (RI/O), and interface equipment in a schedule to meet the construction sequencing. C. As a minimum, the testing shall include the following: 1. Software Acceptance Tests (SAT) 2. Field Testing - Operational Readiness Tests (ORT) 3. Functional Demonstration Tests (FDT) 4. 30-Day Acceptance Test D. Each test shall be in the cause and effect format. The person conducting the test shall initiate an input (cause) and, upon the system's or subsystem's producing the correct result (effect), the specific test requirement will have been satisfied. E. All tests shall be conducted in accordance with Engineer-approved procedures and documented. Each specific test to be performed shall be described and a space provided after it for signoff by the appropriate party after its satisfactory completion. F. Copies of signoff test procedures, forms, and checklists will constitute the required test documentation. G. Provide all special testing materials and equipment. Wherever possible, perform tests using actual process variables, equipment, and data. Where it is not practical to test with real process variables, equipment, and data, provide suitable means of simulation. Define these simulations techniques in the test procedure. H. Coordinate all testing with other Contractors, the OWNER, and the Engineer. I. The OWNER and/or ENGINEER will actively participate in many of the tests. The OWNER and/or ENGINEER reserves the right to test or retest any and all specified functions whether or not explicitly stated in the approved test procedures. The OWNER and/or ENGINEER reserves the right to observe and/or inspect the work during any phase. J. The Engineer's decision shall be final regarding the acceptability and completeness of all testing. 2.18 SOFTWARE ACCEPTANCE TEST (SAT) A. Prior to start of the witnessed Software Acceptance Test (SAT), the entire system shall be installed on site, inspected and tested to ensure that it is fully operational and ready for the process integration control system SAT demonstration testing. B. All panels and assemblies of the subsystem shall be completely installed except I/O signals to field elements or devices shall not be connected. The system shall be inspected and tested to verify that they are in conformance with related submittals and the Contract Documents. C. The PLC and subsystem primary elements, shall be interconnected and tested to ensure that the system is fully operational. The system shall be operated without signals leaving or entering from the field elements or devices for at least one week to verify that it is capable of continuous operation. Outputs to and inputs from the excluded primary elements shall be simulated. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 19 D. The system shall be tested, installed on site to demonstrate that it is operational and in conformance with the Contract Documents. E. Notify the Engineer and OWNER in writing a minimum of 30 days in advance of the proposed starting date for the Software Acceptance Test. At the time of notification, submit any revisions to the detailed test procedure previously approved by the Engineer in the Project System Plan. F. The purpose of the test shall be to witness and verify the function ability, performance, and stability of the hardware and software. The system must operate continually for 24 hours without failure before the test shall be judged successful. Successful completion of this test shall be the basis for approval of the system. G. The Software Acceptance tests shall be performed on all the equipment installed including the HMI system, PLC panels and subsystems. The SAT shall be a two-part text procedure; Part I shall include the PLC sub-system to verify all I/O addresses and proper step sequence for all features. Part II shall add the HMI to verify all screen displays, addressing and report generation. H. Where hardware items are of standard manufacture and in current production, the manufacturer shall certify that applicable tests have been performed and met, in accordance with IEEE and ISA Standards, and be prepared to supply copies of data to Engineer upon request. Such statements shall accompany the equipment submittals called for in SUBMITTALS of this Section. Any assemblage of devices together with operating programs shall be tested together as provided herein. I. The various tests performed during Software Acceptance Test shall be designed to demonstrate that the hardware and software fulfill all the requirements of the Contract Documents. The test conditions shall resemble, as closely as possible, actual conditions. Any additional hardware or software that may be required to successfully verify system operation shall be supplied at no cost to the OWNER. J. Some of tests to be performed shall include, but not be limited to, the following: 1. Conduct online modifications to the database. 2. Demonstrate operability of the interfaces (hardware and software). 3. Demonstrate operability of the data communication network. 4. Demonstrate all system software functions specified. 5. Verify the displays and interactive capabilities of an operator's console. 6. Simulate selected normal and abnormal operating conditions to verify the performance of the monitoring and control functions. 7. Simulate every I/O point by opening or shorting digital inputs, inject appropriate signals into every analog input point, and measure the output signal from each analog output point. K. All deficiencies identified during these tests shall be corrected and retested prior to completing the Software Acceptance Test. L. The following documentation shall be made available to the Engineer at the test site both before and during the Software Acceptance Test. 1. All drawings and specifications, addenda, and change orders. 2. Master copy of the test procedure. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 20 3. List of the equipment to be tested including make, model, and serial number. 4. Design-related hardware submittals applicable to the equipment being tested. 5. Preliminary software documentation submittal. M. The daily schedule during these tests shall be as follows: 1. Testing and meetings: Nominally 8 hours per day; 24 hours per day if required to meet schedule. 2. Morning meetings to review the day's test schedule. 3. Evening meetings to review the day's test results and to review or revise the next day's test schedule. N. All test data and procedures followed during testing shall be logged, and certified copies of the logs shall be provided to the Engineer and OWNER. O. The Engineer will observe each test once on a pass-fail basis. The Engineer alone has the authority to determine if a test passes or fails. Only four (4) fifteen-minute windows per day will be allowed during the test procedure to make corrections to software and successfully pass a re-test. Otherwise, that test will be declared a failure. If a test fails, it will be put on a retest schedule. If other tests to follow rely on a particular test passing, then the following tests will also be placed on a retest schedule even though they were not tested before. Retesting shall not interrupt the test schedule. The CONTRACTOR may schedule retest days during the testing period, but not more than two per week. All retesting shall only occur on a day designated in the schedule or at the end of testing. P. All time and expense incurred by the Engineer and/or OWNER’S staff for all retests shall be borne by the CONTRACTOR and paid to the OWNER. Time and expense incurred shall be on a time and material basis tracked by the Engineer and OWNER for their own staff and presented to the CONTRACTOR on a periodic basis. Q. The CONTRACTOR shall expedite the correction of any deficiency discovered during testing. The CONTRACTOR shall have personnel from each trade to standby during the test period to immediately correct or adjust any item of software or hardware or equipment causing a test to fail. 2.19 OPERATIONAL READINESS TEST (ORT) A. General: Prior to start-up, the installed system shall be certified (inspected, tested, and documented) that it is ready for operation. Download all database on job computers from this test onwards. B. The OWNER and ENGINEER shall be notified when ORT starts. Copies of ORT forms that have been signed off by the CONTRACTOR shall be copied and sent to the OWNER and ENGINEER on a daily basis for record purposes only. No signature by the ENGINEER or OWNER is required for ORT forms. C. Loop/Component Inspections and Tests: The system shall be checked for proper installation, calibrated, and adjusted on a loop-by-loop and component-by-component basis to ensure that it is in conformance with related submittals and these specifications. Actual real-time signals generated from the field devices shall be used. Simulation of field signals shall not be permitted. This test is intended to actually operate the entire process and to find and correct all real-time operational deficiencies. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 21 D. The Loop/Component Inspections and Tests shall be implemented using Engineer-approved forms and checklists. 1. Each loop shall have a Loop Status Report to organize and track its inspection, adjustment, and calibration. These reports shall include the following: a. Project name b. Loop number c. Tag number for each component d. Checkoffs/signoffs for each component 1) Tag/identification 2) Installation 3) Termination - wiring 4) Termination - tubing 5) Calibration/adjustment e. Checkoffs/signoffs for the loop 1) Panel interface terminations 2) I/O interface terminations 3) I/O signal operation 4) Inputs/outputs operational: received/sent, processed, adjusted 5) Total loop operational f. Space for comments g. Space for signoff by Contractor 2. Each active analog subsystem element and each I/O module shall have a Component Calibration Sheet. These sheets shall include the following: a. Project name b. Loop number c. Component tag number or I/O module number d. Component code number analog system e. Manufacturer (for analog system element) f. Model number/serial number (for analog system) g. Summary of functional requirements, for example: 1) For indicators and recorders: Scale and chart ranges 2) For transmitters/converters: Input and output ranges 3) For computing elements: Function 4) For controllers: Action (direct/reverse) control modes (PID) 5) For switching elements: Unit range, differential (fixed/adjustable), reset (auto/manual) 6) For I/O modules: Input or output h. Calibrations; for example: 1) For analog devices: Required and actual inputs and outputs at 0, 10, 50, and 100 percent of span, rising and falling 2) For discrete devices: Required and actual trip points and reset points 3) For controllers: Mode settings (PID) 4) For I/O modules: Required and actual inputs or outputs of 0, 10, 50, and 100 percent of span, rising and falling i. Space for comments j. Space for signoff by the Contractor 3. Maintain the Loop Status Reports and Component Calibration Sheets at the jobsite and make them available to the Engineer and Owner upon request. 4. These inspections and tests do not require witnessing. However, the Engineer will review the Loop Status Reports and Component Calibration Sheets and spot-check their BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 22 entries periodically and upon completion of the Operational Readiness Test. Any deficiencies found shall be corrected. 2.20 FIELD TESTING - FUNCTIONAL DEMONSTRATION TEST (FDT) A. Once ORT has been completed and operational readiness has been confirmed, a witnessed Functional Demonstration Test shall be performed on the complete system to demonstrate that it is operating and in compliance with the Contract Documents. The FDT is intended to be completed to be completed before the facilities are operational. Each specified function shall be demonstrated on a paragraph-by-paragraph, loop-by-loop, and component-by-component basis. B. Loop-specific and non-loop-specific tests shall be the same as specified under SOFTWARE and OPERATIONAL ACCEPTANCE TESTS except that the entire installed shall be tested and all functions demonstrated. C. Simulation of field signals, or simulation of the response of the process, or the response of individual components, or the functions being monitored or controlled, shall not be permitted. Simulation may be permitted with the express permission of the ENGINEER. The decision to simulate is the ENGINEER's alone. The CONTRACTOR shall include in the Contract Price the time necessary to wait for all process responses. D. Updated versions of the documentation called for under SOFTWARE and OPERATIONAL ACCEPTANCE TESTS shall be made available to the Engineer at the jobsite both before and during the test. In addition, one copy of the approved Instrumentation O&M Manual shall be made available to the Engineer at the jobsite both before and during testing. The approved schedule shall be followed strictly on an item-by-item basis. Combining of test items shall be at the discretion of the ENGINEER alone. The CONTRACTOR shall include in the Control Price adequate time necessary to complete each test item one at a time. E. The daily schedule called for under SOFTWARE and OPERATIONAL ACCEPTANCE TESTS shall also be followed during the Functional Demonstration Test. F. The Engineer will observe each test once on a pass-fail basis. The Engineer alone has the authority to determine if a test passes or fails. Only one (1) fifteen-minute window per day will be allowed during the test procedure to make corrections to software or to field equipment and successfully pass a re-test; otherwise, that test will be declared a failure. If a test fails, it will be put on a retest schedule. If other tests to follow rely on a particular test which has failed, then the following tests will also be placed on a retest schedule even though they were not tested. Retesting shall not interrupt the test schedule. The CONTRACTOR may schedule retest days during the testing period, but not more than two per week. All retesting shall only occur on a day designated in the schedule or at the end of testing. G. All time and expense incurred by the Engineer and/or OWNER’S staff for all retests shall be borne by the CONTRACTOR and paid to the OWNER. Time and expense incurred shall be on a time and material basis tracked by the Engineer and OWNER for their own staff and presented to the CONTRACTOR on a periodic basis. H. The CONTRACTOR shall expedite the repair or correction of any deficiency discovered during testing. The CONTRACTOR shall have personnel representing each trade to standby BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 23 during the test period to immediately correct, repair, or adjust any item of hardware, software or field equipment causing a test to fail. I. The system shall operate continuously for 100 hours without failure before this test will be considered successful. The 100 hours test shall be started after completing of the testing. 2.21 30-DAY ACCEPTANCE TEST A. All database errors must be corrected prior to the start of the 30-Day Acceptance Test. The 30-Day Acceptance Test will not be considered successful until all database is correct. B. Any malfunction during the test shall be analyzed and corrections made by the Contractor. The Engineer and Owner will determine whether any such malfunctions are sufficiently serious to warrant a repeat of the test. The cost of a retest shall be borne by the CONTRACTOR as specified. C. After completion of the Functional Demonstration Test and project Start-up, the Owner shall be responsible for operation of the entire System for a period of 30 consecutive days, under conditions of full plant process operation, without single non-field repairable malfunction. D. During this test, Contractor’s Commissioning Authority shall be present during startup and as required. The Contractor shall provide personnel for this test who have an intimate knowledge of the hardware and software of the system and also are familiar with the overall plant process. E. While this test is proceeding, the Owner shall have full use of the system. Only plant operating personnel shall be allowed to operate equipment associated with live plant processes. F. Any malfunction, during this 30-consecutive day test period, which cannot be corrected within 24 hours of occurrence by the Contractor's personnel, or more than two similar failures of any duration, will be considered as a non-field-repairable malfunction. G. Upon completion of repairs, by the Supplier, the test shall be repeated as specified herein. H. In the event of rejection of any part or function, the Supplier shall perform repairs within 5 days or replacement within 30 days. I. Upon successful completion of the 30-Day Acceptance Test, approval of all as-built drawing and O&M Manuals, completion of all related Owner training, and delivery of all spare, expendable, and test equipment, the systems shall be considered substantially complete and the warranty period shall commence. 2.22 TRAINING A. Provide an integrated training program for the Owner's personnel at the jobsite. The Contractor shall submit a detailed training schedule and syllabus for approval. Tailor the training program to meet the specific needs of the Owner's personnel. Include training sessions, classroom and field, for managers, engineers, operators, and maintenance personnel. B. The training shall be carried out by technically competent and experienced instructors. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03) Supervisory Control and Data Acquisition (SCADA) System 40 90 02 - 24 C. An "instructor week" shall consist of 40 hours of actual instruction time. An "instructor day" shall consist of 8 hours of actual instruction time. Provide 16 hours of instruction on any or all three working shifts as needed to accommodate the Owner's personnel schedule. The actual training schedule shall be coordinated with thee Owner. 2.23 OPERATIONS AND MAINTENANCE TRAINING A. O&M training for each main and sub-system shall be in accordance with the requirements specified under the related Instrumentation specification sections. B. All training shall be given using only equipment identical to the equipment provided on this Contract or currently owned by the Owner. C. Unless otherwise specified, hardware maintenance training shall be suitable for instrument technicians who have at least a 2-year associate engineering or technical degree, or equivalent education and experience in electronics, instrumentation, or digital systems. 2.24 ON-SITE SUPERVISION A. The Supplier shall provide, on-site, an experienced resident engineering manager to supervise and coordinate all of the on-site activities. This resident engineering manager shall be on-site as required during the total period to witness all the activities relating to the process integration control system. 2.25 START-UP AND TESTING TEAM A. The Supplier shall provide, on-site, a team of experienced engineering, technician, trades personnel, and software/configuring personnel during the total construction period to: 1. Thoroughly check the installation, termination, and adjustment of all the subsystems and their components. 2. Perform and complete all on-site tests. 3. Provide start-up assistance. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 1 SECTION 40 90 02.01 - SCADA LOOP DESCRIPTIONS (Reissued by AD-02) PART 1 GENERAL 1.1 SCOPE A. All SCADA system PLC and RIO controller programming, SCADA System Operator Interface Terminal (OIT), and Operator Work Station (OWS) graphics and programming shall be provided by one System Integrator. This section is to clarify control strategies to be used to program the system, and is provided for reference only. PART 2 PRODUCTS (not used) PART 3 EXECUTION 3.1 PHASE 1D EXPANSION: CONTROL LOOP DESCRIPTIONS A. Existing Raw Water Intake Barge and Proposed Raw Water Head Tanks 1. Process Overview: a. The existing Raw Water Intake Barge (RWIB) on Lake Travis delivers water to two proposed Raw Water Head Tanks, which distribute water by gravity to the existing Water Treatment Plant (WTP). The WTP has an existing communications interface with the RWIB. Integration of the proposed Raw Water Head Tanks will result in the operator using the raw water head tanks as their basis for manual control of the RWIB pumps. b. PLC: TSC-PLC-RW, & TSC-PLC-02 c. P&ID: M-5 d. Equipment: 1) Existing Raw Water Pumps: RWP-01 through RWP-07 2) Proposed Y-LIT-RWT101, 102, 201, and 202 (Head Tanks) 3) Proposed Y-LSH-RWT001, 002 (Head Tanks) 2. Level measurement: a. Operator will select at SCADA whether a single or both raw water head tank transducers are used to generate instantaneous tank level via the Level Transducer A/Level Transducer B/Both selector switch on the SCADA HMI. b. When Both is selected, both transducer values are read by SCADA. The first transducer to reach a level alarm setpoint will be used to initiate an alarm. The average of the two transducer signals will be the instantaneous tank level. c. If Both is selected and the values between the two transducers drift by more than 5% from one another, SCADA will generate an alarm and prompt the operator to select which transducer to be used. 3. Calculated Alarms (User adjustable): a. Raw Water Head Tank High Level Alarm: EL 1094 feet, or when high level float switch is activated. b. Raw Water Head Tank Low Level Alarm: EL 1084 feet. B. Raw Water Flow Control Valves and Meters 1. Process Overview: BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 2 a. Prior to water flowing into Central Treatment Structure from the head tanks, the raw water is split through two separate flow meters and flow control valves. An existing venturi flow meter and existing butterfly valve with a new electric motor operator is upstream of rapid mix box No. 1C. An existing magnetic flow meter and existing butterfly valve with a new electric motor operator is upstream of rapid mix box No. 2C. b. The operator currently manually selects a flow control valve position. The proposed modifications include adding an automatic control operation to automatically modulate the flow control valves based on the upstream influent flow meter for the desired flow rate. 2. Flow Control Valves: a. PLC: TSC-PLC-02 b. P&ID: M-6, M-7 c. Equipment: 1) TSC-FIT-001, 002 2) TSC-BFV-002, 004 d. Computer Automatic Control: 1) The operator will enter a desired flow rate through the Central Treatment Structure, as well as which flocculation/sedimentation trains are in service (1C, 2C, 3C, 4C). The flow control valve will then modulate to maintain the desired flow rate measured by the associated upstream influent flow meter. If one or more of the flocculation/sedimentation trains are out of service (operator selectable), then the flow will split between through the two flow control valves proportional to the number of flocculation/sedimentation basins in service. 2) General control notes: a) Valve position must be adjusted based on influent flow meter; look up tables are not permitted. Upstream head conditions will vary based on head tank level. b) Only one valve can adjust position at a time. c) Sufficient operator adjustable deadband must be provided to limit valve hunting and unnecessary valve wear. d) Measured flow must be within 5% (operator adjustable) of flow rate setpoint at all times. e) Measured flow rate must be averaged during valve dead time to limit valve overshooting and valve position oscillations. Control loop must be field calibrated and proven. C. Rapid Mix, Flocculation and Sedimentation 1. Process Overview: a. Water flows into the WTP from the RWIB. Water enters the Central Treatment Structure where it is sequentially treated by coagulation, flocculation and sedimentation. After coagulation by a hydraulic mix plate, water passes into the flocculation process. There are six existing and two proposed flocculation basins, each consisting of three chambers in series. Following flocculation, water enters four parallel sedimentation basins, three existing and one proposed. b. The proposed pretreatment system includes the following control sequences: 1) Flocculator Drives 2) Sedimentation Basin Sludge Collector Drives 3) Sludge Vault Blow Down Valve 2. Flocculators: BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 3 a. PLC: TSC-PLC-02 b. P&ID: M-6, M-7 c. Equipment: 1) TSC-FL-07A, B, C (Basin 7) 2) TSC-FL-08A, B, C (Basin 8) d. Process Overview: 1) From rapid mix, water flows to flocculation basins, where is gently mixed to promote floc formation. Flocculator drive speed can be adjusted to vary mixing energy. Under normal operating conditions, flocculators shall run continuously via manual control from the SCADA system. e. Local Manual Control: 1) Local control of each flocculator shall be provided at the local VFD panel in the electrical room, in conjunction with the flocculator field local control panel. 2) At the field local control panel, the operator may place the flocculator into Local or Remote control mode. While in Local control mode, the operator can start and stop the flocculator. With the flocculator Local/Remote switch in the Remote position, and the flocculator VFD Hand/Auto Switch in the Hand position, the operator may start, stop and vary the speed of the flocculator drive motor. f. Local Automatic Control: None. g. Computer Manual Control: 1) A flocculator shall be available for remote control if the field local control panel Local/Remote switch is in Remote position, and the VFD panel Hand/Auto switch is in the Auto position. While in SCADA manual control mode, the operator may start, stop and vary the speed of a flocculator drive from the HMI screen. h.Computer Automatic Control: None. i.Field Alarms: 1) Common alarm (drive failure, overload, emergency stop, motor winding high temp alarm). 3. Sedimentation Basin Sludge Collector: a. PLC: TSC-PLC-02 b. P&ID: M-6, M-7 c. Equipment: 1) TSC-SC-004 d. Process Overview: 1) From flocculation, water enters the sedimentation basins, where flow velocity decreases to allow settling of floc particles. Each sedimentation basin includes a sludge collector that transports settled solids into sludge hoppers. Under normal operating conditions, the sedimentation basin sludge collectors shall run continuously via manual control from the SCADA system. e. Local Manual Control: 1) There shall be a local field control panel for the sludge collector drive. With the drive Local/Remote switch in the Local position, the operator may start and stop the drive using the supplied Start and Stop pushbutton operators. With the switch in the Remote position, the operator may also control the drive at the MCC by putting the associated MCC Hand/Auto switch in the Hand position, and using the supplied Start and Stop pushbutton operators. f. Local Automatic Control: None. g. Computer Manual Control: BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 4 1) The sludge collector shall be available for remote control if its local control station Local/Remote switch is in Remote and the MCC Hand/Auto switch is in Auto. While in SCADA manual control, the operator may start and stop a sludge collector from the HMI screen. h. Computer Automatic Control: None. i. Field Alarms: 1) Common alarm (motor overload, shear, loss of motion, emergency stop, motor winding high temp alarm). This alarm shall require a manual reset in the field. 2) Alignment warning alarm. 4. Sludge Vault Blow Down Valve: a. PLC: TSC-PLC-02 b. P&ID: M-6, M-7 c. Equipment: 1) TSC-PV-SLV202 (Sludge Vault 2C). d. Process Overview: 1) The proposed treatment train will utilize existing Sludge Vault 2C for sludge blow down. Sludge collected in the proposed sedimentation basin sludge hoppers shall be periodically wasted by gravity to Sludge Vault 2C by opening motor operated plug valve TSC-PV-SL202. e. Local Manual Control: 1) Local control for blow down from the sludge hoppers is provided at the valve actuator. The operator may place the valve in Local or Remote control mode. While in Local control mode, the operator may open and close the valve. f. Local Automatic Control: None. g. Computer Manual Control: 1) When the valve actuator Local/Remote switch is in the Remote position and the valve is in computer manual control mode, the operator may open and close the valve from the HMI screen. h. Computer Automatic Control: 1) The computer automatic sequence will control one (1) sedimentation basin sludge hopper drain valve. The drain valve shall be opened at intervals based on HMI adjustable cycle time in minutes and shall remain open for an HMI adjustable length of time in seconds. 2) If the conditions listed below are not met while the drain valve is open, an alarm shall be generated, which shall close the drain valve. The intent of this sequence is to drain sludge from the sedimentation basin at a consistent rate to avoid overloading the solids handling system. 3) Sequence of Events: Step Action Result Fault Trigger Time (minutes) 1 READY valve placed in queue. Each valve has fixed position in queue READY valve up counter increments Any faulted valve becomes NOT READY and is removed from queue NA NA 2 Whenever a valve is added to or removed from queue, Frequency setpoint changes NA Formula: n = # of valves, t = period, d = open duration NA BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 5 frequency setpoint is adjusted such that cycle time for all valves is ‘t’ minutes ( t - dn ) / n = frequency 3 Frequency timer setpoint Valve issued open command Sludge Blowdown is initiated, i.e. Valve opens and duration timer starts Faulted valve must close if possible, then become NOT READY Drain Valve OPEN limit 2 4 Valve issued close command Valve closes Faulted valve must close if possible, then become NOT READY Drain Valve CLOSED limit 1 5 Start frequency timer Increment queue counter Elapsed frequency increases Faulted valve must close if possible, then become NOT READY Go to step 1 Variable Total 3 i. Conditions: The following conditions shall be met to enable automatic loop to open sludge hopper drain valve. 1) The sedimentation basin sludge collector is running 2) The sedimentation basin drain valve is available for control 3) No other sedimentation basin drain valves are open 4) At least one of the existing Sludge Pump Station Pumps is available 5) At least one Gravity Thickener sludge collector is running 6) The existing Sludge Pump Station is not reporting a high wetwell level (SLPS-LSH-001) 7) The associated Sludge Vault is not reporting a high level alarm (TSC-LSH- SLV201) j. Interlocks: 1) The proposed sedimentation basin drain valve shall include a hardwired interlock with the vault's high level float switch. In the event of a high sludge level in the vault, the associated valve shall be closed in all control modes until the condition is cleared. k. Field Alarms: 1) Sludge Vault 2C high sludge level. l. Calculated Variables: 1) Sludge vault drain valve “Open” frequency = (t – dn) / n, where: a) t = cycle time for all applicable valves in minutes b) d = valve open duration in seconds c) n = number of valves available to the sequence D. WTP Filtration and Backwashing 1. Process Overview: BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 6 a. After sedimentation, settled water flows into seven existing and one proposed dual- media filters to remove remaining particulate matter. During normal operation, (Filter in service), settled water enters the top of the filter via the filter influent valve and gravity forces the water through the filter media. b. The filtration process normally operates using existing filter inlet channel level controllers for each treatment structure train. The level controllers work in conjunction with filter effluent rate-of-flow controllers (a combination of a Venturi flow tube with differential flow measurement (Filters 1C-4C and 8C) or electromagnetic flow meter (Filters 5C-7C), and a modulating filter effluent control valve). The filter effluent rate-of-flow controller at each filter allows plant operators to maintain operation at a relatively constant filtration rate. An increase in the plant influent flow causes an increase in the filter inlet channel level. The channel level controller shall then signal all associated filter flow controllers to open their respective filter effluent valves to increase filtration rate in response to increased influent flow. Similarly, a decrease in influent plant flow causes an inverse adjustment. Additionally, water level in the filter inlet channel is used as a criterion to determine if additional filters should be placed into or taken out of service. Plant operators shall manually add or remove filters from service as required. c. As filter run time continues, particulates build-up in filter media and reduce filter efficiency and performance. A filter backwash cycle, using an existing air/water wash system removes particulate matter trapped in the filter media, thus restoring filtration capacity. d. Filter media head loss, filtered water turbidity, and filter basin water level are all measured and monitored by the SCADA system and indicated at the HMI and filter control console on existing filters. A filter that requires a backwash is alarmed by high turbidity; high media head loss, or high filter run time. Filter backwashing can be performed manually or automatically by the control system. e. The filtration system includes the following control sequences: 1) Filter Discrete Valves 2) Filter Flow Control Valves 3) Filtration 4) Existing Air Scour Blowers 5) Existing Master Backwash Flow Control Valve 6) Filter Backwash Sequence 2. Filter Discrete Valves: a. PLC: TCS-PLC-01 b. P&ID: M-8, M-9 c. Equipment: 1) TSC-BFV-F701 (Filter influent valve) 2) TSC-BFV F702 (Filter drain valve) 3) TSC-BFV-F704 (Filter air scour valve) 4) TCS-BFV-F705 (Filter backwash valve) d. Process Overview: 1) Filter discrete valves are used for filtration and backwashing. The influent valve allows settled water to enter the filter. The drain valve allows waste backwash water to flow out of the filter to the wash water recovery system. The air scour valve allows low pressure air to enter the filter during a backwash sequence. The backwash valve allows backwash water to enter the filter during a backwash sequence. e. Local Manual Control: BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 7 1) Local control shall be provided at the valve actuator. The operator may place a valve in Local or Remote control mode. While in Local control mode, the operator may open and close the valve from the actuator. f. Local Automatic Control: None g. Computer Manual Control: 1) When a valve actuator Local/Remote switch is in the Remote position and the associated filter control mode is Manual, the operator may open and close the valve from the HMI screen. For the filter influent valve, the operator may also stop the valve at a point in mid position. h. Computer Automatic Control: 1) When the valve actuator Local/Remote switches are in Remote position and the associated filter computer control mode is Automatic, the filter valves shall be automatically controlled by the SCADA system filtration and backwash control sequences. 2) The filter influent valve is unique such that during the filter backwash sequence, it can be partially opened during filter equalization, as described below in the filter backwash sequence. 3. Filter Flow Control Valve: a. PLC: TSC-PLC-01 b. P&ID: M-8, M-9 c. Equipment: 1) TSC-BFV-F706 (Filter flow control valve) d. Process Overview: 1) The filter flow control valve regulates effluent flow from the associated filter. A flow controller shall be provided in the PLC to control valve position in computer auto and manual control modes. e. Local Manual Control: 1) Local control shall be provided at the valve actuator. The operator may place the valve in Local or Remote control mode. While in Local control mode, the operator may position the valve via actuator controls. f. Local Automatic Control: None g. Computer Manual Control: 1) When the valve actuator Local/Remote switch is in the Remote position and the associated filter control mode is Manual, the operator may enter a valve position from the HMI screen. h. Computer Automatic Control: 1) When the valve actuator Local/Remote switch is in Remote position and the associated filter computer control mode is Automatic, the filter control valve shall be automatically controlled by the SCADA system filtration and backwash control sequences. 4. Filtration: a. PLC: TSC-PLC-01 b. P&ID: M-8, M-9 c. Equipment: 1) TSC-LIT-001, 002 (Existing filter inlet channel level transmitters) 2) TSC-LIT-F701 (Filter level transmitter) 3) TSC-LSH-F701 (Filter level control switch) 4) TSC-LSL-F701 (Filter level control switch) 5) TSC-DPIT-F701 (Filter media differential pressure transmitter) 6) TSC-FIT-F701 (Filter effluent flow transmitter) d. Process Overview: BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 8 1) The central treatment structure consists of two existing filter inlet channels separated by an existing slide gate (TSC-SLG-004) and eight filters: seven existing (Filters 1C-6C and 8C) and one proposed (Filter 7C). The slide gate is located between Filters 4C and 5C. 2) Each filter includes a Filter Control Console (FCC). Valves and backwash equipment associated with the proposed filter shall have monitoring and control capability at both the FCC via a portable device (laptop or tablet) and the main HMI. 3) Computer Automatic/Manual soft switches shall be provided at the main HMI and FCC for each proposed filter. If Automatic mode is selected, all associated filter valves shall be placed in Computer Automatic Control mode. If Computer Manual mode is selected at the HMI, all associated filter valves shall be placed into Computer Manual Control mode. e. Local Manual Control: 1) The filter is operated manually using valve actuators in the field. f. Local Automatic Control: None g. Computer Manual Control: 1) Filters can be operated manually via the SCADA system by controlling required valves using Computer Manual Control mode. h. Computer Automatic Control: 1) Filter are automatically controlled by the SCADA system. Each filter can be in one of four stages of operation as follows. a) In Service: Filter is operating. Influent valve is open and effluent control valve is modulating to control filter output. All other associated filter valves are closed. b) Available: Filter backwash is complete and influent valve is open. All other associated filter valves are closed. Filter is ready to be placed into operation. c) Out of Service: All associated filter valves are closed. d) Backwash: Filter backwash is in progress. Filter valves are controlled according to the Filter Backwash Sequence. 2) Each filter shall have a flow controller in the PLC to control filter effluent flow using the associated effluent control valve and flow transmitter. 3) The filter effluent flow controllers have two HMI selectable control modes: a) Level Mode: The filter effluent flow controller is activated and uses the output of the associated existing filter inlet channel level controller as a flow setpoint. The controller compares the setpoint to the actual measured flow and makes output changes in response, which modulates the effluent flow control valve. b) Set Mode: The filter effluent flow controller is deactivated and assumes a tracking state. A manual, HMI adjustable flow setpoint can be entered to control filter effluent flow. 4) If a filter effluent flow transmitter fails, an alarm shall be generated and the associated flow controller shall hold its last output value. 5) If during filtration, filter water level drops to "filter drain down level" as indicated by level switch, an alarm shall be generated and the filter effluent valve shall be closed. 6) The operator shall be able to manually request that a filter be placed In- Service from the HMI or FCC via portable device. If requested while a backwash sequence is active, the sequence shall be terminated. All running equipment (backwash pumps and air scour blowers) shall be requested to perform an orderly shutdown as described in the Filter Backwash Sequence. BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 9 All filter valves shall be commanded to the filter Out of Service position. The filter shall then be equalized. When equalization is complete, the filter shall transition to In Service. 7) When a filter is placed into service after completing a backwash cycle, it shall begin a ripening sequence to settle filter media. There are three stages in the ripening process. All three stages shall be enable/disabled via HMI selection. Filter ripening progresses as follows: a) An operator places the filter into service. b) If Stage 1 ripening is enabled, the filter effluent flow control valve shall be partially opened to an HMI adjustable stage-1 position setpoint and held there for the duration of the Stage 1 timer parameter (HMI adjustable, up to 15 minutes). c) When the Stage 1 timer expires and Stage 2 ripening is enabled, the filter effluent flow control valve shall be opened further to an HMI adjustable Stage 2 position setpoint and held there for the duration of the Stage 2 timer parameter (HMI adjustable, up to 15 minutes). d) When the Stage 2 timer expires and Stage 3 ripening is enabled, the filter effluent flow control valve shall be opened further to an HMI adjustable Stage 3 position setpoint and held there for the duration of the Stage 3 timer parameter (HMI adjustable, up to 15 minutes). e) When the Stage 3 timer expires, the filter effluent valve shall be released for control by the filters effluent flow controller. 8) The operator shall be able to request that a filter be taken Out of Service from the HMI or FCC via portable device. If requested while a backwash sequence is active, the sequence shall be terminated. All running equipment (backwash pumps and air scour blowers) shall be requested to perform an orderly shutdown as described in the Filter Backwash Sequence. When complete, all the filter valves shall be commanded to Out of Service positions. 9) In the event of WTP power failure, the SCADA system shall close any open filter effluent control valves. Existing backup power shall be provided to the valve actuators to perform this function. Any In Service filters shall be placed in Available mode. Out of Service filters shall remain as such. If a filter is in Backwash mode, the backwash sequence shall be suspended and operator intervention shall be required like an alarm condition. When WTP power returns, the operator must manually evaluate each filter to determine subsequent action. i. Conditions: 1) Utility power must be available to perform filtration. In the event WTP power failure, the SCADA system shall use existing backup power to close effluent flow control valves. 5. Filter Backwash Sequence: a. PLC: TSC-PLC-01 b. P&ID: M-8, M-9 c. Equipment: 1) TSC-LIT-F701 (Filter level transmitter) 2) TSC-LSH-F701 (Filter level control switch) 3) TSC-LSL-F701 (Filter level control switch) 4) TSC-FCV-001 (Proposed master backwash flow control valve) 5) TSC-FIT-003 (Existing backwash flow meter) 6) TSC-BLR-001, 002 (Existing Air Scour Blowers) 7) All filter control valves BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 10 8) WDB-SC-LT (Existing Washwater Decant Basin level transmitter) 9) WSB-LSH-001 (Existing Washwater Settling Basin high level switch) 10) TSC-PSH-001 (Existing Backwash Pump pressure switch) d. Process Overview: 1) As filter run time increases, particulates build-up in filter media and reduce filter efficiency and performance. A filter backwash cycle, using an existing air/water wash system removes particulate matter trapped in the filter media, thus restoring filtration capacity. 2) General requirements for a Filter Backwash Sequence are as follows: a) When a filter is in Computer Manual Control mode, its equipment shall be controlled individually by the operator using the HMI or FCC via portable device. b) When the filter equipment and backwash equipment are in Computer Automatic Control mode, the SCADA system shall automatically execute the backwash sequence. c) Only one filter shall be backwashed at one time, regardless of whether it is being backwashed manually or automatically. d) At the HMI, the operator shall have the capability to monitor and enter all setpoints and parameters necessary for automatic backwash sequence for all filters. The setpoints and parameters shall reside in the controlling PLC. The individual filter FCC shall have controls, status, and parameter adjustments available for its associated filter. e. Local Manual Control: 1) Filter backwash shall be manually conducted using local equipment control panels and valve actuators as required. f. Local Automatic Control: None g. Computer Manual Control: 1) Filter backwash shall be manually conducted using SCADA to control the required equipment in computer manual mode at the HMI or FCC via portable device. The operator may control valves and pumps as required to achieve backwashing. h. Computer Automatic Control: 1) A filter backwash shall be initiated by SCADA or manually by an operator. Computer or manual backwash initiation for a filter shall be operator selectable at the HMI. When a filter backwash sequence is initiated, the SCADA system shall proceed with a backwash. 2) The following alarms shall indicate that a filter backwash is necessary: a) High filter effluent turbidity b) High media headloss c) High filter run time (1) All alarms shall be operator adjustable at the HMI. If automatic backwashing is disabled for a filter, the operator shall be notified when a backwash is necessary. After notification, the operator will be required to manually initiate automatic backwashing at the HMI. 3) If automatic backwashing is enabled, a filter shall be placed into queue for backwashing. While in queue, filters shall be backwashed based on the order they enter the queue, as permitted. 4) For an automatic backwash sequence to run, all necessary equipment shall be available for automatic control and all conditions shall be satisfied. 5) The Filter Backwash Sequence includes the following steps: a) Filter is placed in Backwash state automatically or by an operator. BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 11 b) All Conditions are verified. c) Filter influent valve is signaled to close. d) After confirmation of influent valve closure, HMI adjustable filter draw down timer is initiated. e) When filter water level falls below filter draw down level limit switch (currently 12 inches above media), draw down timer is canceled and filter flow control valve is signaled to close. If the desired drawn down level is not reached when the draw down timer expires, an alarm shall be generated. f) After confirmation of filter flow control valve closure, filter drain valve is signaled to open. g) After confirmation that filter drain valve is open, filter air scour valve is signaled to open. h) After confirmation that filter air scour valve is open, lead air scour blower is signaled to start. i) After confirmation that air scour blower is running, the air scour only timer starts (operator adjustable parameter, currently 4 minutes). If the blower fails to run, an alarm shall be generated and the blower shall be commanded to stop. Subsequently, the filter air scour valve shall be commanded to close. The backwash sequence shall proceed without the air scour. j) After the air scour only timer expires, filter backwash valve is signaled to open. k) After confirmation that filter backwash valve is open and master backwash flow control valve is closed, lead backwash pump is signaled to start. l) After confirmation that backwash pump is running, backwash pressure timer starts (operator adjustable parameter). The backwash pump pressure switch is monitored as a condition to open the master backwash control valve. If the backwash pressure timer expires and the backwash line does not have adequate pressure, backwash pump shall be commanded to stop and backwash sequence shall be terminated. An alarm shall be generated to indicate incomplete backwash pump start sequence. m) After the backwash pump head pressure switch indicates adequate pressure, the master backwash flow control valve is signaled to open. A timer starts to detect valve opening (operator adjustable parameter, approximately 8 seconds). n) After detection of opening, backwash flow controller activates to modulate master backwash flow control valve to low flow rate setpoint (operator adjustable parameter, currently 4,650 gpm). If the valve does not open before timer expires, an alarm shall be generated, backwash pump shall be commanded to stop, and backwash sequence shall be terminated. An alarm shall be generated to indicate incomplete backwash pump start sequence. o) Timers start for both low flow rate backwash (operator adjustable parameter, currently 4 minutes) and air scour (operator adjustable parameter). With concurrent air scour and low flow water backwash, filter cell water level rises. p) After air scour timer expires, or air scour stop level limit switch is energized, filter air scour blower is signaled to stop. q) After confirmation of air scour blower shutdown, filter air scour valve is signaled to close and blower lead/lag assignments rotate. r) After backwash low flow rate timer expires, master backwash flow controller shall receive signal to achieve high flow rate setpoint (operator adjustable parameter, currently 11,160 gpm). High flow rate timer starts BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 12 (operator adjustable parameter, currently 14 minutes). Master backwash flow controller modulates to maintain high flow rate setpoint. s) When high flow rate backwash timer reaches two minutes remaining, the HMI shall request operator input for extension of high flow rate backwash (operator selectable parameter, Yes or No). If extended, high flow rate timer shall add time to sequence (operator selectable parameter, approximately 2 minutes). t) After high flow rate backwash timer expires, including any extension, an extended low flow rate backwash setpoint (operator adjustable parameter, currently 6,200 gpm) is issued to master backwash flow controller. Extended low flow rate timer starts (operator adjustable parameter, currently 5 minutes). Master backwash flow controller modulates to maintain extended low flow rate setpoint. u) After extended low flow rate timer expires, filter backwash valve is signaled to close while master backwash control valve is held in current position. v) After confirmation of filter backwash valve closure, backwash pump is signaled to stop. w) After confirmation of backwash pump shutdown, master backwash control valve and filter drain valve are signaled to close. x) After confirmation of master backwash control valve and filter drain valve closure, filter influent valve shall be signaled to partially open (operator adjustable parameter, currently 25%). Filter equalization timer starts (operator adjustable parameter, up to 20 minutes). Filter slowly fills with settled water to prevent disruption of filter media. y) After filter equalization timer expires or filter water level reaches a setpoint, filter influent valve is signaled to fully open. z) After confirmation that filter influent valve is fully open, filter is ready for service and shall indicate Available state on HMI. aa) Start filter ripening timer. bb) After timer expires (operator adjustable parameter, currently 5 minutes), partially open filter flow control valve (operator adjustable parameters, currently 10% open for 3 minutes). Filter is operational at reduced forward flow rate. cc) After completion of first filter ripening step, further open filter flow control valve (operator adjustable parameters, currently 12% open for 3 minutes) dd) After completion of second filter ripening step, further open filter flow control valve (operator adjustable parameters, currently 14% open for 3 minutes) ee) After completion of third filter ripening step, open filter flow control valve to full service forward flow rate. Filter ripening phase is complete. Filter flow control valve modulates to maintain filter flow setpoint. 6) If during a backwash sequence, any of the Conditions listed below are not met, the backwash sequence shall be terminated and the filter shall be placed into Out of Service mode. 7) If any Filter Backwash Sequence steps fail, an alarm shall be generated and indicate "Backwash Sequence Failure" at the HMI. The HMI shall request the operator to choose one of three options: 1) Continue backwash sequence; 2) Place filter In Service; or 3) Place filter Out of Service. a) If “continue backwash sequence” is selected by the operator, the sequence shall skip the current step and proceed to the next. BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 13 b) If “place filter In Service” is selected by the operator, backwash sequence shall be terminated. All running equipment (backwash pumps and air scour blowers) shall be signaled to perform orderly shutdown as described in the Filter Backwash Sequence. All filter valves shall be commanded to filter Out of Service state. The filter shall then equalize according to the Filter Backwash Sequence. When equalization is complete, the filter shall transition to In Service. c) If “place filter Out of Service” is selected by operator, the Filter Backwash Sequence shall be terminated. All running equipment (backwash pumps and air scour blowers) shall be signaled to perform orderly shutdown as described in the Filter Backwash Sequence. When complete, all filter valves shall be commanded to filter Out of Service state. i. Conditions: 1) All required equipment is available for Automatic control. 2) There is no other Filter Backwash Sequence in progress. 3) There is sufficient volume available in the Washwater Decant Basin to hold washwater from a filter backwash. The decant basin level transmitter shall be compared to an HMI adjustable level parameter. 4) A high water level alarm in the Washwater Settling Basin shall prevent SCADA from starting a Filter Backwash Sequence. 5) One Backwash Pump shall be available for Computer Automatic Control. 6) One Air Scour Blower shall be available for Computer Automatic Control. 7) Communications to the Electrical Building PLC shall be active to start a Backwash Pump. 8) The filter to be backwashed does not have a high-high or low-low water level alarm from the filter level transmitter. E. Sludge Dewatering Facility 1. Process Overview: a. Existing sludge pumps convey sludge from the existing sludge pump station to the Gravity Thickeners (one existing, one proposed). The Gravity Thickeners concentrate sludge, which is transferred to Belt Filter Presses (one existing, one proposed) by existing belt press feed pumps. The Belt Filter Presses dewater sludge with assistance from an existing polymer feed system. Screw Conveyors (two existing, three proposed) transport sludge cake to roll-off dumpsters. b. The proposed sludge dewatering system includes the following control sequences: 1) Existing Sludge Pump Station 2) Gravity Thickener Drive 3) Belt Filter Press Sludge Dewatering System 2. Sludge Pump Station: a. PLC: SDF-PLC-01 b. P&ID: M-10 c. Proposed Equipment: ST1-LSH-001 d. Process Overview: 1) The existing sludge pumps convey sludge to the Gravity Thickeners. e. Local Manual Control: Existing. f. Local Automatic Control: None. g. Computer Manual Control: Existing. h. Computer Automatic Control: Existing. i. Proposed Conditions: BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 14 1) If the proposed Gravity Thickener reaches the high level parameter (HMI adjustable), all running sludge pumps shall be stopped by SCADA. Pumps shall be prohibited from operation until the alarm is cleared. j. Proposed Field Alarms: 1) Gravity Thickener high level: EL 1067.50 feet. 3. Gravity Thickener Sludge Collector: a. PLC: SDF-PLC-01 b. P&ID: M-10 c. Equipment: ST1-SC-001 d. Process Overview: 1) Under normal conditions, the Gravity Thickener drive shall run continuously. The proposed thickener will operate in parallel with the existing thickener. e. Local Manual Control: 1) The collector drive shall have a field mounted local control panel. To gain local control of the drive, the operator must place the drive’s Hand/Auto switch in the Hand position. While in local, the operator may start/stop the drive with the Start/Stop push buttons. f. Local Automatic Control: None. g. Computer Manual Control: 1) The collector drive can be started and stopped from the SCADA system HMI while in SCADA manual mode. The drive shall be available for remote control if the field mounted local control panel Hand/Auto switch is in Auto. h. Computer Automatic Control: None. i. Field Alarms: 1) Common alarm (high torque, over torque, overload). 4. Belt Filter Press Sludge Dewatering System: a. The Belt Filter Press (BFP) system and associated existing polymer feed system, existing belt press feed pumps (two), and sludge conveyors are monitored and controlled by the BFP manufacturer supplied control panel PLC. The SCADA system shall monitor the BFP system and associated components through a network connection to the BFP control panel PLC. b. PLC: SDF-PLC-BFP2 c. P&ID: M-11, M-12 d. Equipment: Reference Section 46 76 21 – Belt Filter Press. e. Process Overview: 1) The existing belt press feed pumps convey sludge from the gravity thickeners to the proposed Belt Filter Press. The existing polymer feed system injects polymer into sludge upstream of the BFP to assist dewatering. Three proposed Screw Conveyors transport sludge cake from the proposed BFP to a roll-off dumpster outside the SDF. f. Local Manual and Local Automatic Control: 1) Provided by the proposed BFP manufacturer and describe in Section 46 76 21 – Belt Filter Press. g. Computer Manual and Computer Automatic Control: None. h. Field Alarms: 1) Described in the following Monitored Data section. 5. Belt Filter Press Sludge Dewatering System Monitored Data: a. Equipment alarm and status information shall be monitored by SCADA through the network connection to the BFP system control panel PLC. The System Integrator shall coordinate with the BFP system supplier to obtain available signals and BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 15 information required to read data from the BFP control panel PLC. At a minimum, the signals monitored by SCADA shall include the following. b. Belt Filter Press Control Panel PLC 1) General: a) Equipment alarm conditions such as FAIL TO START/STOP, Speed DEVIATION, FAIL TO OPEN/CLOSE, Valve position DEVIATION, etc. for all equipment controlled by the BFP System PLC. b) Equipment run times (current and total). 2) SDF-PLC-BFP2: Control Panel PLC. a) Communications watchdog signal. The use of a watchdog communications timer shall be coordinated with the BFP system supplier to detect a loss of communications between the SCADA system and the BFP System PLC. In the event of a communications failure, the SCADA system shall flag all data coming from the PLC as OLD (bad quality). b) System Ready c) System Failure d) UPS battery low e) AC power failure f) DC Power supply failure(s) 3) SDF-BFP-002: Belt Filter Press. a) System Ready b) Belt drive running c) Belt drive speed d) Wash-down pump running e) Hydraulic pump running f) Pre-wash cycle on g) Wash-down cycle on h) Belt Press Feed Pump (BPFP) control mode (speed/flow) i) BFFP number selected j) Polymer feed system number selected k) Hand/Auto control l) Field local control panel Local/Remote m) Emergency Stop Alarm n) Sludge flow o) Sludge flow totalized (current, previous) p) Belt drive failure q) Low water pressure r) Broken belt s) Low hydraulic pressure t) Belt misaligned c. Existing Belt Filter Press Feed Pumps 1) SDF-BPFP-001 and 002: a) Speed b) Running c) Local/Remote d) Common alarm (Failure, High discharge pressure, Low inlet pressure, emergency stop, motor winding high temp alarm) d. Existing Polymer Feed Systems 1) SDF-PFS-001 and 002: a) Speed b) Running BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 16 c) Local/Remote d) Common alarm (Failure, High discharge pressure) e. Proposed Screw Conveyors 1) SDF-SSC-003, 004, and 005: a) Running b) Local/Remote c) Common alarm (Motor overload, current surge, emergency stop) F. Disinfection Facility Chemical Feed Systems 1. Process Overview: a. The Disinfection Facility provides chemicals to various points in the water treatment process for disinfection. The existing Sodium Hypochlorite (SHC) chemical feed system will be modified during the Phase 1D WTP Expansion and the subsequent sections provide control loop descriptions for the proposed improvements. 2. Sodium Hypochlorite Storage and Feed System: a. PLC: DF-PLC-01 b. P&ID: M-14 c. Equipment: 1) DF-SHFP-001 through 005 (Existing SHC metering pumps) 2) DF-LIT-SHST1 and 2 (Existing SHC storage tank level transmitters) 3) DF-LIT-SHST3 (Proposed SHC storage tank level transmitter) d. Process Overview: 1) The existing SHC metering pumps feed chlorine for disinfection purposes. The SHC system includes three bulk storage tanks (two existing, one proposed) that provide chlorine to the metering pumps. e. Local Manual Control: Existing. f. Local Automatic Control: None. g. Computer Manual Control: Existing. h. Computer Automatic Control: 1) The metering pump control panel Local/Remote switch shall be placed in Remote position and the pump shall be in Automatic control mode on the HMI display. 2) On the HMI, the operator shall be able to designate the primary storage tank (1, 2, or 3) that will be used by the feed system for level conditions. i. Conditions: 1) The selected SHC storage tank Low-Low level condition shall shutdown any running metering pumps. The pumps shall be locked out from Automatic and Local service by SCADA until the alarm is cleared. j. Calculated Alarms: 1) High-High storage tank level. 2) High storage tank level. 3) Low storage tank level. 4) Low-Low storage tank level. 5) Rate-of-Change storage tank level alarm: When tank level decreases at a rate faster than a specified, operator adjustable parameter, an alarm shall be generated. G. WTP Central Treatment Structure Chemical Feed Systems 1. Process Overview: a. Specific chemical feed systems used for treatment at the WTP are located in the Central Treatment Structure. The existing Fluorosilicic Acid (FLOC) chemical feed BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 17 system will be modified during the Phase 1D WTP Expansion. The subsequent sections provide control loop descriptions for the proposed improvements. 2. Fluorosilicic Acid Storage and Feed System a. PLC: TSC-PLC-02 b. P&ID: M-13 c. Equipment: 1) CFA-FLST-001 (Proposed bulk storage tank) 2) CFA-LIT-FLST1 (Proposed bulk tank level transmitter) 3) CFA-FLTP-001, 002 (Proposed transfer pumps) 4) CFA-FLDT-001 (Proposed day storage tank) 5) CFA-LIT-FLDT1 (Proposed day tank level transmitter) 6) CFA-FLFP-001, 002 (Existing metering pumps) d. Process Overview: 1) The Fluorosilicic Acid storage and feed system adds fluoride to filtered water as part of the treatment process One proposed bulk storage tank and one proposed day tank store fluorosilicic acid. Two proposed transfer pumps convey fluorosilicic acid from bulk to day storage. Two existing FLOC metering pumps convey fluoride to the filtered water injection point. e. Fluorosilicic Acid Transfer Pumps 1) Local Manual Control: a) To control a transfer pump, the operator must press and hold the transfer pump run button to fill the day tank. 2) Fluorosilicic Acid Transfer Pump Local Automatic Control: None. 3) Fluorosilicic Acid Transfer Pump Computer Manual Control: None. 4) Fluorosilicic Acid Transfer Pump Computer Automatic Control: None. 5) Conditions: a) A transfer pump shall be shut down in the event of a common alarm or bulk tank low-low level condition. 6) Interlocks: a) A transfer pump common alarm or tube leak shall be hardwired to shut down the associated pump. f. Existing Fluorosilicic Acid Metering Pumps 1) Local Manual Control: Existing. 2) Local Automatic Control: Existing. 3) Computer Manual Control: None. 4) Computer Automatic Control: None. 5) Conditions: a) While the pumps are in Local Automatic mode, the proposed day tank low- low level condition, existing pump common alarm, or existing pump discharge high pressure switch shall shut down metering pumps via SCADA. SCADA controls shall not allow pump restart until the condition is cleared. g. Field Alarms: 1) Transfer pump common alarm. 2) Metering pump common alarm. 3) High-high bulk storage tank level. 4) High-high day storage tank level. h. Calculated Alarms: 1) High storage tank level, Bulk and day tanks. 2) Low storage tank level, Bulk and day tanks. 3) Low-Low storage tank level, Bulk and day tanks. BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 18 4) Rate-of-Change storage tank level alarm, Bulk and day tanks: When tank level decreases at a rate faster than a specified, operator adjustable parameter, an alarm shall be generated. BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 19 PLC/RIO # Point Type I/O Tag Instrument/ Equipment Loop Number Equipment Description Function description Range Units TSC-RIO-T2 AI TSC-FL-07A Flocculator No. 7A Speed Feedback Indication 0-100 % TSC-RIO-T2 AO TSC-FL-07A Flocculator No. 7A Speed Control Control 0-100 % TSC-RIO-T2 DO TSC-FL-07A Flocculator No. 7A Remote Start/Stop Control TSC-RIO-T2 DI TSC-FL-07A Flocculator No. 7A In Remote Indication TSC-RIO-T2 DI TSC-FL-07A Flocculator No. 7A Running Indication TSC-RIO-T2 DI TSC-FL-07A Flocculator No. 7A Common Alarm Indication TSC-RIO-T2 AI TSC-FL-07B Flocculator No. 7B Speed Feedback Indication 0-100 % TSC-RIO-T2 AO TSC-FL-07B Flocculator No. 7B Speed Control Control 0-100 % TSC-RIO-T2 DO TSC-FL-07B Flocculator No. 7B Remote Start/Stop Control TSC-RIO-T2 DI TSC-FL-07B Flocculator No. 7B In Remote Indication TSC-RIO-T2 DI TSC-FL-07B Flocculator No. 7B Running Indication TSC-RIO-T2 DI TSC-FL-07B Flocculator No. 7B Common Alarm Indication TSC-RIO-T2 AI TSC-FL-07C Flocculator No. 7C Speed Feedback Indication 0-100 % TSC-RIO-T2 AO TSC-FL-07C Flocculator No. 7C Speed Control Control 0-100 % TSC-RIO-T2 DO TSC-FL-07C Flocculator No. 7C Remote Start/Stop Control TSC-RIO-T2 DI TSC-FL-07C Flocculator No. 7C In Remote Indication TSC-RIO-T2 DI TSC-FL-07C Flocculator No. 7C Running Indication TSC-RIO-T2 DI TSC-FL-07C Flocculator No. 7C Common Alarm Indication TSC-RIO-T2 AI TSC-FL-08A Flocculator No. 8A Speed Feedback Indication 0-100 % TSC-RIO-T2 AO TSC-FL-08A Flocculator No. 8A Speed Control Control 0-100 % TSC-RIO-T2 DO TSC-FL-08A Flocculator No. 8A Remote Start/Stop Control TSC-RIO-T2 DI TSC-FL-08A Flocculator No. 8A In Remote Indication TSC-RIO-T2 DI TSC-FL-08A Flocculator No. 8A Running Indication TSC-RIO-T2 DI TSC-FL-08A Flocculator No. 8A Common Alarm Indication TSC-RIO-T2 AI TSC-FL-08B Flocculator No. 8B Speed Feedback Indication 0-100 % TSC-RIO-T2 AO TSC-FL-08B Flocculator No. 8B Speed Control Control 0-100 % TSC-RIO-T2 DO TSC-FL-08B Flocculator No. 8B Remote Start/Stop Control TSC-RIO-T2 DI TSC-FL-08B Flocculator No. 8B In Remote Indication TSC-RIO-T2 DI TSC-FL-08B Flocculator No. 8B Running Indication TSC-RIO-T2 DI TSC-FL-08B Flocculator No. 8B Common Alarm Indication BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 20 PLC/RIO # Point Type I/O Tag Instrument/ Equipment Loop Number Equipment Description Function description Range Units TSC-RIO-T2 AI TSC-FL-08C Flocculator No. 8C Speed Feedback Indication 0-100 % TSC-RIO-T2 AO TSC-FL-08C Flocculator No. 8C Speed Control Control 0-100 % TSC-RIO-T2 DO TSC-FL-08C Flocculator No. 8C Remote Start/Stop Control TSC-RIO-T2 DI TSC-FL-08C Flocculator No. 8C In Remote Indication TSC-RIO-T2 DI TSC-FL-08C Flocculator No. 8C Running Indication TSC-RIO-T2 DI TSC-FL-08C Flocculator No. 8C Common Alarm Indication TSC-RIO-T2 DO TSC-SC-004 Sed. Basin No. 4C Sludge Collector Drive Remote Start/Stop Control TSC-RIO-T2 DI TSC-SC-004 Sed. Basin No. 4C Sludge Collector Drive In Remote Status TSC-RIO-T2 DI TSC-SC-004 Sed. Basin No. 4C Sludge Collector Drive Running Status TSC-RIO-T2 DI TSC-SC-004 Sed. Basin No. 4C Sludge Collector Drive Common Alarm Status TSC-RIO-T2 DI TSC-SC-004 Sed. Basin No. 4C Sludge Collector Drive Alignment Alarm Status TSC-RIO-T2 DI TSC-PV- SLV202 Sludge Vault No. 2 Sed. Basin Valve Open Status TSC-RIO-T2 DO TSC-PV- SLV202 Sludge Vault No. 2 Sed. Basin Valve Open Control TSC-RIO-T2 DO TSC-PV- SLV202 Sludge Vault No. 2 Sed. Basin Valve Closed Control TSC-RIO-T2 DI TSC-PV- SLV202 Sludge Vault No. 2 Sed. Basin Valve In Remote Status TSC-RIO-T2 DI TSC-PV- SLV202 Sludge Vault No. 2 Sed. Basin Valve Closed Status TSC-RIO-F7 DI TSC-BFV- F701 Filter 7 Influent Valve Opened Status TSC-RIO-F7 DO TSC-BFV- F701 Filter 7 Influent Valve Open Control TSC-RIO-F7 DO TSC-BFV- F701 Filter 7 Influent Valve Close Control TSC-RIO-F7 DI TSC-BFV- F701 Filter 7 Influent Valve In Remote Status TSC-RIO-F7 DI TSC-BFV- F701 Filter 7 Influent Valve Closed Status BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 21 PLC/RIO # Point Type I/O Tag Instrument/ Equipment Loop Number Equipment Description Function description Range Units TSC-RIO-F7 DI TSC-BFV- F702 Filter 7 Backwash Waste Valve Opened Status TSC-RIO-F7 DO TSC-BFV- F702 Filter 7 Backwash Waste Valve Open Control TSC-RIO-F7 DO TSC-BFV- F702 Filter 7 Backwash Waste Valve Close Control TSC-RIO-F7 DI TSC-BFV- F702 Filter 7 Backwash Waste Valve In Remote Status TSC-RIO-F7 DI TSC-BFV- F702 Filter 7 Backwash Waste Valve Closed Status TSC-RIO-F7 DI TSC-BFV- F704 Filter 7 Air Scour Valve Opened Status TSC-RIO-F7 DO TSC-BFV- F704 Filter 7 Air Scour Valve Open Control TSC-RIO-F7 DO TSC-BFV- F704 Filter 7 Air Scour Valve Close Control TSC-RIO-F7 DI TSC-BFV- F704 Filter 7 Air Scour Valve In Remote Status TSC-RIO-F7 DI TSC-BFV- F704 Filter 7 Air Scour Valve Closed Status TSC-RIO-F7 DI TSC-BFV- F705 Filter 7 Backwash Water Valve Opened Status TSC-RIO-F7 DO TSC-BFV- F705 Filter 7 Backwash Water Valve Open Control TSC-RIO-F7 DO TSC-BFV- F705 Filter 7 Backwash Water Valve Close Control TSC-RIO-F7 DI TSC-BFV- F705 Filter 7 Backwash Water Valve In Remote Status TSC-RIO-F7 DI TSC-BFV- F705 Filter 7 Backwash Water Valve Closed Status TSC-RIO-F7 DI TSC-BFV- F706 Filter 7 Filtered Water Valve Opened Status TSC-RIO-F7 AI TSC-BFV- F706 Filter 7 Filtered Water Valve Position Feedback Indication 0-100 % TSC-RIO-F7 AO TSC-BFV- Filter 7 Filtered Water Valve Set Point Control 0-100 % BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 22 PLC/RIO # Point Type I/O Tag Instrument/ Equipment Loop Number Equipment Description Function description Range Units F706 TSC-RIO-F7 DI TSC-BFV- F706 Filter 7 Filtered Water Valve In Remote Status TSC-RIO-F7 DI TSC-BFV- F706 Filter 7 Filtered Water Valve Closed Status TSC-RIO-F7 AI TSC-AIT- F701 Filter 7 Effluent Turbidity Analyzer Indication 0-10 NTU TSC-RIO-F7 AI TSC-DPIT- F701 Filter 7 Loss of Head Indication 0- XXX Feet TSC-RIO-F7 DI TSC-LSH- F701 Filter 7 Air Scour Off Level Status TSC-RIO-F7 DI TSC-LSL- F701 Filter 7 Drain Down Level Status TSC-RIO-F7 AI TSC-LIT-F7 Filter 7 Level Transmitter Status TSC-RIO-F7 AI TSC-LE-F7 Filter 7 Level Status SDF-PLC-01 DI ST1-LSH-001 Sludge Thickener No. 1 High Level Control 0-100 % SDF-PLC-01 DO ST2-CP-001 Sludge Thickener No. 1 Remote Start/Stop Control SDF-PLC-01 DI ST2-CP-001 Sludge Thickener Running Status SDF-PLC-01 DI ST2-CP-001 Sludge Thickener In Remote Status SDF-PLC-01 DI ST2-CP-001 Sludge Thickener Common Alarm Status SDF-PLC-01 AI SDF-FIT-001 Sludge Dewatering Facility Flow Meter Indication 0- XXX GPM SDF-PLC-01 AI SDF-FIT-002 Sludge Dewatering Facility Flow Meter Indication 0- XXX GPM SDF-PLC-01 AI SDF-BFP-002 Sludge Dewatering Facility Belt Filter Press No. 2 Indication DF-PLC-01 AI DF-LIT- SHST3 Sodium Hypochlorite Tank Level 3 Indication RWT-PLC-01 AI Y-LIT- RWT201 Raw Water Tank No 2. Level Indication 0-XX Feet RWT-PLC-01 AI Y-LIT- RWT202 Raw Water Tank No 2. Level Indication 0-XX Feet RWT-PLC-01 AI Y-LIT- RWT101 Raw Water Tank No. 1 Level Indication 0-XX Feet BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 23 PLC/RIO # Point Type I/O Tag Instrument/ Equipment Loop Number Equipment Description Function description Range Units RWT-PLC-01 AI Y-LIT- RWT102 Raw Water Tank No. 1 Level Indication 0-XX Feet RWT-PLC-01 DI RWT-LSH-01 Raw Water Tank No. 1 Status RWT-PLC-01 DI RWT-LSH-02 Raw Water Tank No. 2 Status TSC-PLC-02 DI CFA-FLTP- 001 Fluorosilicic Acid Running Status TSC-PLC-02 DI CFA-FLDT- 002 Fluorosilicic Acid Running Status TSC-PLC-02 DI CFA-FLTP- 001 Fluorosilicic Acid Tube Leak Status TSC-PLC-02 DI CFA-FLDT- 002 Fluorosilicic Acid Tube Leak Status TSC-PLC-02 AI CFA-FLTP- 001 Fluorosilicic Acid Tank Level Status TSC-PLC-02 AI CFA-FLTP- 002 Fluorosilicic Acid Tank Level Status TSC-PLC-02 DI CFA-LIT- FLST1 Fluorosilicic Acid Fill Station High Level Status TSC-PLC-02 AI CFA-LIT- FLST1 Fluorosilicic Acid Fill Station Tank Level Indication 0-XX Feet TSC-RIO-F7 DO TSC-BFV- F706 Filter 7 Open Control TSC-RIO-F7 DO TSC-BFV- F706 Filter 7 Closed Control BCRUA - Phase 1D WTP Expansion Issued for Bid (Reissued by AD-02)SCADA Loop Descriptions 40 90 02.01 - 24 END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Shaftless Screw Conveyors 41 12 13 - 1 SECTION 41 12 13 – SHAFTLESS SCREW CONVEYORS (Revised by AD-02) PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Shaftless screw conveyors. B. Scope of Work: 1. Furnish all labor, materials, equipment, and incidentals required to install, complete and ready for operation, the shaftless screw conveyors and appurtenant equipment as illustrated on the Drawings and specified herein. 2. The shaftless screw conveyor starters shall be in an MCC as illustrated on the Drawings and controlled from the Belt Filter Press (SDF-BFP-002) control panel. C. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Division 01 – General Requirements. 3. Division 03 – Concrete. 4. Division 05 – Metals. 5. Section 09 96 00 – High-Performance Coatings. 6. Section 10 14 00 – Identification for Process Piping and Equipment. 7. Section 26 29 13.01 – Industrial Control Panels. 8. Section 40 05 00 – Common Requirements for Process Piping. 9. Section 40 05 07 – Hangers and Supports for Process Piping. 10. Section 40 05 51 – Common Requirements for Process Valves. 11. Section 40 90 00 – Process Control and Instrumentation Systems – General Provisions. 12. Section 40 90 01 – Instrumentation. 13. Section 40 90 02 – Supervisory Control and Data Acquisition (SCADA) System. 14. Section 46 76 21 – Belt Filter Press. 1.2 SUBMITTALS A. See Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Product Data: 1. Submit manufacturer information for system materials and component equipment, including performance characteristics. 2. Include descriptive literature, bulletins, and/or catalogs of the equipment. 3. Include the total weight of the equipment including the weight of the single largest item or component. 4. Provide complete bill of materials for all equipment components. 5. Include generic model numbers for all bearings in equipment. 6. Motor: a. Complete nameplate data. b. Special features (i.e. space heaters and space heater wattage, corrosion resistant features, etc.). 7. Electrical wiring diagram of each component supplied. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Shaftless Screw Conveyors 41 12 13 - 2 C. Shop Drawings: 1. Section 01 61 03 – Common Requirements for Equipment: Shop drawing submittal requirements. 2. Indicate system materials and component equipment. Submit drawings showing details and dimensions, including anchor bolt layout, for each component of the system. 3. Provide nameplate data and arrangement. 4. Provide coordination sketches or sequences considering related work. 5. Submit detailed instructions on installation requirements, including storage and handling procedures. 6. Submit qualifications for manufacturer. 7. Refer to specification Section 26 29 13.01 - Industrial Control Panels for control panel submittal requirements. Control panels submitted that do not conform to this Section will be returned without review. 8. Project specific control details and electrical schematic and wiring diagrams. 9. Warranty information. D. Source Quality-Control Submittals: 1. Manufacturer's Certificate: Certify that products meet or exceed specified requirements. a. Section 01 33 00 – Submittal Procedures: Supplement 01. 2. Section 01 61 03 – Common Requirements for Equipment: Submittal requirements. 3. Submit results of factory tests of equipment at the time of shipment. E. Field Quality-Control Submittals: 1. Section 01 33 00 - Submittal Procedures: Supplements 02 and 03. 2. Section 01 61 03 – Common Requirements for Equipment: Submittal requirements. 3. Section 01 91 00 – Facility Commissioning: Submittal requirements. Indicate results of Contractor-furnished tests and inspections. 4. Certify that equipment has been installed according to manufacturer instructions. 1.3 CLOSEOUT SUBMITTALS A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for Operation and Maintenance Manuals. In addition to the requirements of Section 01 70 00, the manual shall include the following at a minimum: 1. Procedures for replacing the liner in each conveyor. Include the required clearances in the building wall penetration and method of removing and replacing the screw. 2. Step-by-step disassembly and reassembly instructions including tolerances and special requirements. 3. Dimensional drawings of all provided equipment. B. Section 01 91 00 – Facility Commissioning: Closeout Submittal requirements. C. Project Record Documents: Record actual locations and final orientation of equipment. 1.4 QUALITY ASSURANCE A. All system components shall be supplied to the Contractor by a single Manufacturer. B. Manufacturer shall operate, test, and adjust each screw conveyor to ensure proper assembly and operation prior to shipment. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Shaftless Screw Conveyors 41 12 13 - 3 C. Should equipment which differs from these Specifications be offered and determined to be equal to that specified, such equipment shall be acceptable only on the basis that any revisions in the design and/or construction of affected areas, including structure, piping, appurtenant equipment, electric, etc., required to accommodate such a substitution be made at no additional cost to the Owner and be as approved by the Engineer. 1.5 QUALIFICATIONS A. Manufacturer: Company specializing in manufacturing products specified in this Section with minimum ten years' experience. 1.6 DELIVERY, STORAGE, AND HANDLING A. Section 01 60 00 - Product Requirements: Requirements for transporting, handling, storing, and protecting products. B. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage. C. Store materials according to manufacturer instructions. D. Protection: 1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas. 2. Provide additional protection according to manufacturer instructions. 1.7 EXISTING CONDITIONS A. Field Measurements: 1. Proposed screw conveyors will be installed in existing Sludge Dewatering Facility. a. The overall dimensions of the shaftless screw conveyors and appurtenances shall fit within the space shown on the Drawings. Verify dimensions and clearances within the structure and coordinate the installation of the shaftless screw conveyors with the related work included in other Sections. Verify equipment supports, structure dimensions and arrangement and notify the Engineer of any discrepancy before submitting shop and erection drawings for approval. 2. Verify field measurements prior to fabrication. 3. Indicate field measurements on Shop Drawings. 1.8 WARRANTY A. Reference Section 00700 – General Conditions, Article 7.17 for warranty terms. PART 2 - PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. Shaftless Screw Conveyors: 1. Spirac, Inc. 2. JDV Equipment Co. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Shaftless Screw Conveyors 41 12 13 - 4 3. Parkson Corp. 4. KWS Manufacturing Company, Ltd. 5. Jim Myers & Sons, Inc (JMS). (AD-02) B. Conveyor Liner: 1. Durawear Corp., Duraslide Xylethon. 2. Or approved equal. C. Submit substitutions in accordance with Section 01 25 00. 2.2 GENERAL REQUIREMENTS A. Tag Numbers: SDF-SSC-003, SDF-SSC-004, SDF-SSC-005. B. System Description: 1. All the equipment specified herein is intended to be standard equipment for use in screw conveyor systems designed for carrying dewatered aluminum coagulant sludge and shall be installed as an integral part of the dewatering system as shown on the Drawings. 2. The control of the conveyors shall be from the belt filter press control panel. 3. Conveyor manufacturer and Contractor shall coordinate system to function as shown on the Drawings and specified. a. Coordinate all interfaces of the shaftless screw equipment with all related equipment specified in other related Sections. The shaftless screw conveyor shall comprise complete coordinated systems including, but not limited to the shaftless screw, drives, troughs, supports, trough covers, liners, gear reducers, motors, discharge chutes, limit switches, and all appurtenances as shown on the Drawings and specified. C. The exact length of each conveyor will depend on the equipment selected. Ample room and facilities shall be provided for inspection, repairs, lubrication, and adjustment. 2.3 PERFORMANCE AND DESIGN CRITERIA A. Shaftless Screw Conveyors: 1. Maximum auger diameter: 12-inches 16-inches (AD-02) 2. Minimum capacity: 700 cubic feet per hour 350 cubic feet per hour (AD-02), each. a. Designed for both continuous and for intermittent operation at specified capacity. 3. Maximum fill: 50% active trough area for horizontal screw conveyors. 4. Incline and length as required. Incline angle of SDF-SSC-005 shall not exceed 30 degrees. (AD-02) 5. Axial transfer with discharge chute. 6. Drive motor: a. 3 HP maximum. 5 HP maximum for SDF-SSC-003 and 004; 10 HP maximum for SDF-SSC-005. (AD-02) b. Horizontal TEFC, squirrel cage induction, Class F insulation, rated for 460 VAC. c. Constant speed, maximum 1800 rpm. d. Drive system shall be designed for starting a fully loaded conveyor. 7. Conveyor liners: a. Minimum thickness: ½-inch. b. Liner shall extend full length of the trough, covering entire semicircular bottom portion of trough. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Shaftless Screw Conveyors 41 12 13 - 5 c. Liners shall be installed as parallel strips secured at intervals not to exceed 10-feet using Type 304 stainless steel retaining clips. 8. Support framework: a. All necessary supports for the conveyors shall be provided by the manufacturer. b. Designed to a minimum of twice the natural frequency of the screw conveyor unit under all loading conditions. c. Ratio of unbraced length to the least radius of gyration (slenderness ratio) shall not exceed 120 for any compression member and shall not exceed 240 for any tension member (of angles about the Z-Z axis). d. All structural members and connections shall be designed so that the unit stresses will not exceed AISC allowable stresses by more than 1/3 when subject to loading of twice the running torque of the drive motor. e. Designed and constructed such that each conveyor is independently supported and can be installed and disassembled without disturbing the other equipment. 9. Spiral flights: a. Designed to convey material without a center shaft. b. Designed with necessary stability to prevent distortion and jumping in the trough while operating at design capacity. c. Maximum allowable stress in extreme fiber shall not exceed 0.5 Fy, 0.2 percent offset, under torsional loading at brake horsepower requirement. B. The shaftless screw conveyor shall convey dewatered sludge in a neat, quiet, dependable, and nuisance-free manner. The equipment furnished shall have adequate capacity to convey the specified quantity of sludge without failure and without exceeding specified trough fill area. C. The equipment shall be of high quality design and construction that will ensure satisfactory operation at all times under the conditions specified and satisfy the following requirements: 1. There shall be no projecting set screws or other parts to endanger operators. All devices required for the compliance with safety laws shall be provided. 2. Sharp corners of all cut or sheared edges shall be smoothed by power grinders. 3. Provision shall be made for ample and convenient lubrication of all machinery without danger of injury to operators. 4. All shafting shall be of ample diameter and provided with suitable bearings for the service required. Suitable means for making adjustment on parts subject to wear shall be provided where necessary. 5. Installations shall be easy to maintain and keep clean. The equipment shall be capable of withstanding a daily washdown using high pressure water. 6. Each conveyor shall be assembled to the greatest extent possible in the manufacturer's shop to ensure proper fitting of parts. Assembled sections shall then be match marked for field installation and disassembled prior to shipment. Components shall be shipped in the maximum shipping lengths permitted. 7. Furnish all required anchor bolts and other anchorage for the structure. 2.4 MATERIALS A. Conveyor framework and supports: AISI Type 304 stainless steel. B. Conveyor troughs, drive end plates, end flanges, stiffener channels: Type 304 stainless steel. C. Chutes: 10 gauge, Type 304 stainless steel. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Shaftless Screw Conveyors 41 12 13 - 6 D. Conveyor liner material: UHMW polyethylene. 1. Yield strength: 5,000 psi. 2. Ultimate tensile strength: 8,500 psi. 3. Break elongation: 250 %. 4. Dynamic coefficient of friction when running dry against polished steel: 0.10, work hardened: 0.08. 5. Resistant to acids, grease, and chemicals with no water penetration. E. Cover plates, handles, and backing plate: Type 304 stainless steel. F. Gear reducers: Cast iron housing with alloy steel gears. G. Piping, valves, and hose connection: Type 304 or 316 stainless steel. H. Gaskets: Neoprene, minimum 50 Durometer. I. Spiral flights: Cold formed spring steel of minimum hardness 200 Brinell. J. Anchor bolts, nuts and washers: Type 316 stainless steel unless otherwise specified. 2.5 FABRICATION AND MANUFACTURE A. Support Framework: 1. Designed in conformance with the requirements of the latest revision of the AISC Standards for the Design, Fabrication and Erection of Structural Steel for Buildings; support loads shall be based on a completely filled trough plus dead weight of the equipment. Shop connections may be welded, riveted, or bolted. 2. Supports shall be provided near the drive units (approximately 1 to 2 feet) and at locations necessary to support the length of trough segment. 3. Supports shall be welded construction with bolted connections to conveyor casings, feet, and support points. Field connections shall be bolted using reamed, sub punched holes and finished bolts as follows: a. Supporting members attached to concrete shall be by minimum 1/2-inch diameter Type 304 stainless steel anchor bolts. A minimum of two (2) bolts shall be used per supporting member. b. Supporting members attached to structural steel elements shall be by minimum 1/2- inch diameter Type 304 stainless steel hex bolts with one flat washer and one lock washer. A minimum of two (2) bolts shall be used at each connection point. B. Cover Plates: 1. Provide along the entire conveyor length to contain splatter. 2. Conveyor trough covers shall be clamped covers of 3/32-inch thick, single-piece formed sheet metal, not greater than 40-inches in length, and attached to the screw conveyor trough using toggle clamps. Clamps shall require no tools to place or remove and when disconnected, clamps shall not allow any of their parts to become detached from the conveyor trough. 3. Trough covers are to be complete with turned-down edges parallel to the sides of the screw conveyor trough flange and turned up at 90 degrees for receiving a clamping bar at cover joints. Clamps shall be at less than 32-inch centers along the length of the screw conveyor trough. Each cover section shall have two (2) handles for ease of removal. The handles BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Shaftless Screw Conveyors 41 12 13 - 7 shall be 3/8-inch diameter and formed into a "U". The handles shall be welded to the covers to a pre-drilled backing plate. The backing plate shall be welded to the cover as reinforcing. The handle shall be fully welded to the cover and to the backing plate. 4. Each conveyor trough cover shall be equipped with a wear strip manufactured from the same material as the liner attached to the underside of the cover. This strip shall be used to restrain vertical movement of the flights. In lieu of the strip attached to the covers, alternate hold down provisions may be provided as designed by and recommended by the conveyor manufacturer. A minimum 3/32-inch thick gasket shall be applied with an appropriate adhesive to the mating surfaces of the trough covers. C. Spiral Flights: 1. Outer spiral shall be a minimum of 2-1/2-inches by 3/4-inches. 2. Flight shall be formed in a spiral forming machine to the diameter and pitch specified within a tolerance of plus or minus 0.080-inch from the theoretical for both pitch and diameter. 3. Provide full penetration welds at all splice connections. 4. Aligned to assure true alignment when assembled. 5. Connected to drive system through a flanged connection plate that is welded to the spiral forming a smooth and continuous transformation from the flange plate to the spiral. The drive shaft shall have a mating flange and shall be bolted to the spiral connection plate. A gland packing ring consisting of Teflon coated packing rings shall seal the drive shaft at its penetration through the end plate. The flanged connection shall be welded to the spiral flights with welded gusset plates for additional reinforcing. If necessary, bushings shall be used between the pipe sleeve and the end shaft. Neither end nor intermediate bearings will be allowed. A compression packing gland shall be provided around the shaft at its penetrations through the trough end plates. Snap rings shall make the bearings and seals capable of supporting maximum thrust loads and preventing angular misalignment of the shafts. D. Conveyor Troughs: 1. Minimum 3/16-inch thick. 2. At the drive end of each trough, provide a minimum 5/8-inch thick end plate and drive support base of all welded construction upon which the conveyor drive assembly shall be mounted. 3. Trough segments shall consist of rolled sections with flanges butt welded together. The maximum length of a single segment shall not exceed 20-feet in length. The rolled trough sections shall have the specified diameter within a tolerance of plus or minus 0.010-inch. 4. Trough end flanges shall be roll formed of minimum 1-inch by 3/8-inch thick bar welded to the ends of the trough segments. Transition flange offset angles shall be accurate to plus or minus 0.25 degrees. 5. Bolt holes for joining trough sections shall be located on the centerline of the roll formed flange within a tolerance of plus or minus 0.005-inch of the theoretical radius centerline and. Distances between adjacent bolt holes shall have a tolerance of plus or minus 0.010- inch. Bolt holes shall be uniformly located on either side of the trough's vertical centerline. 6. A minimum 1/8-inch thick gasket shall be applied with an appropriate adhesive to flange faces. Alternatively, an approved compressible flow type string gasket material shall be applied to the flange faces. 7. Support feet shall be provided at each vertical support location. The dimensions and arrangement of the steel members for the support feet shall be as recommended by the conveyor manufacturer. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Shaftless Screw Conveyors 41 12 13 - 8 8. Trough stiffener channels approximately 2-1/2-inches wide by 7/8-inch deep by 1/8-inch thick shall be installed across the width of all troughs at a maximum center-to-center distance of 40-inches. Each trough stiffener channel shall have down turned end. Each down turned end shall be drilled for and bolted with a Type 304 stainless steel bolt. Trough stiffener channel center to center spacing shall be set to seal the faces upon which the trough covers and chutes are bolted. Trough stiffener channels shall be bolted in place prior to shipment from the manufacturer. 9. Flushing appurtenances: a. Each screw conveyor trough shall have a 3-inch diameter dewatering pipe connection at its lower end. b. The last trough cover of each conveyor (discharge end) shall include a welded 3/4- inch male hose thread to provide a hose connection for flushing and water lubrication. The weldment shall be located at the center of the cover, approximately 1.3-feet upstream of the conveyor discharge. Weld shall be continuous and free of voids. c. Each conveyor shall be provided with a ¾” diameter water line and isolation ball valves as shown on the drawings as part of the equipment. A flexible section shall be included to allow removal of the cover for access to the screw. E. Chutes: 1. Each trough shall be equipped with filling and/or discharge chutes for transferring material from the belt filter to the roll off container. 2. Chutes shall be of all welded construction. The juncture of all joints in plates shall be continuously seal welded inside and out so that the chutes are watertight. 3. External stiffening ribs shall be provided as required to limit stresses and deformation in plates during shipping, installation, and operation. 4. Filling chutes shall be supported from the conveyor trough or support framework, but not from the equipment itself. F. Motor and Gear Reducer: 1. Each screw conveyor shall be driven by an electric motor connected to a gear reducer. The gear reducer shall be mounted to the trough end. 2. Conveyor manufacturer shall provide motor that is adequate to drive the equipment under all operating conditions. The service factor shall not be reduced under normal maximum loadings. Motors shall have anti-condensation heaters. 3. All gear reducers shall be commercially built, to minimum Quality Class No. II per AGMA Standard 390.03 Gear Classification Manual. 4. Gear reducers shall be single or double reduction, helical gear units with high-capacity roller bearings. Gears shall be made of protuberance hobbed, gas carburized, oil quenched hardened, steel shot peened and ground, with a surface hardness after grinding of Rockwell RC-60 or greater and meeting the requirements of AGMA Standard 218.01. 5. Gear reducers shall be suitable for the loading conditions imposed on the input shaft in the mounting arrangement shown on the Drawings. 6. The gear reducers shall be suitable for continuous duty service with moderate shock loadings and sized at the gear reducer's output shaft speed for not less than the greater of: a. 1.5 times the break horsepower at the gear reducer output shaft. b. 1.0 times the name plate motor horsepower of the drive motor. 7. Bearings shall be designed for the thrust loads from the spiral flights and shall have an ABMA B-10 life of 30,000 hours. 8. The reducers shall be standard oil lubricated, air-cooled units with no auxiliary cooling allowed. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Shaftless Screw Conveyors 41 12 13 - 9 9. Low speed output shaft shall be chrome plated. 10. Shaft seals shall be triple lipseal with taconite packing designed for severe conditions. 11. The gear reducer housing shall include removable inspection covers, oil breathers, oil level indicators and oil drain plugs. 12. Gear reducers that are shipped from the factory without an initial factory oil fill shall be adequately treated or coated before shipment to protect the units during shipment and storage. Prior to installing the units, they shall be drained, flushed and filled with oil. G. Safety Components: 1. Each conveyor shall be furnished with emergency trip cord and trip switch. The safety trip cords shall be provided along both sides of each conveyor. Trip switch shall include at a minimum two sets of normally closed DPDT Form C contacts. Trip switch shall immediately stop conveyor when trip cord is pulled and open the send an alarm signal to the associated Belt Filter Press control panel. 2. Each conveyor shall be compatible with a shock relay that will trip when the current draw of the motor exceeds the trip current, and the shock time is exceeded. This relay trip shall immediately cause the conveyor to stop and send an alarm signal to the associated Belt Filter Press control panel. Relay shall be located in motor control center. Conveyor manufacturer shall provide the recommended start time, shock time, and load current shock relay settings to the MCC manufacturer. H. Conveyor Controls: 1. Motor starter shall be located in motor control center. Refer to Drawings for control schematic. 2. Contractor shall provide local control panel per Drawings. Refer to 26 29 13.0 Industrial Control Panels for local control panel requirements. I. Pivot Supports: 1. Conveyor SDF-SSC-005 shall have a pivot support as indicated on the Drawings. The pivot shall include a bearing, with appropriate shock dampener plate, designed by the conveyor manufacturer for the intended service and provide for smooth operation through the pivot range shown on the Drawings. 2. The support for the movement end of conveyor SDF-SSC-005 shall be such that one person can manually rotate the conveyor through the pivot range shown on the Drawings. 3. When stopped, the conveyor shall maintain its stationary position. 4. Castors shall be polyurethane with sealed bearings appropriate for the environment and of the size recommended by the conveyor manufacturer. The support/castor arrangement shall be such that the castors roll freely through the pivot range. Wheel locks shall be provided on the castors as recommended by the manufacturer. 2.6 FINISHES A. Surface preparation and shop priming shall be as specified in Section 09 96 00 – High- Performance Coatings. B. Ensure that shop painting and field painting are compatible. C. Stainless steel shall not be painted. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Shaftless Screw Conveyors 41 12 13 - 10 2.7 SOURCE QUALITY CONTROL A. Shop Testing: 1. Each conveyor shall be fully shop assembled and tested for conformance to the specified requirements. 2.8 SPARE PARTS A. At a minimum, manufacturer shall provide an adequate supply of consumables and calibration materials necessary to continuously operate and maintain each conveyor for a period of one year after Substantial Completion. PART 3 - EXECUTION 3.1 EXAMINATION A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for installation examination. B. Verify layout, type, material, and orientation of connections. 3.2 INSTALLATION A. Section 01 61 03 – Common Requirements for Equipment: Installation requirements. B. Installation shall be in strict accordance with the manufacturer's instructions and as indicated on Drawings. C. Coordinate with the requirements of related equipment, including the shock relay, to obtain a complete, integrated, and satisfactory operating installation of the conveying equipment. D. Furnish the required oil and grease for initial operation. The grades of oil and grease shall be in accordance with the manufacturer’s recommendations. E. Install anchor bolts accordance with the manufacturer’s recommendations and setting drawings. F. Installation Checks: 1. Adjust, repair, modify, or replace components failing to perform as specified. 2. Make final adjustments to equipment under direction of manufacturer's representative. 3.3 FIELD QUALITY CONTROL A. Section 01 40 00 - Quality Requirements. B. Sections 01 61 03 - Common Requirements for Equipment , 01 70 00 – Execution and Closeout Requirements, and 01 91 00 – Facility Commissioning: Testing, Startup, Demonstration, and Training requirements. C. Acceptance Testing: Working under the direction of the manufacturer, field tests shall be performed as follows. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Shaftless Screw Conveyors 41 12 13 - 11 1. Upon completion of installation, the conveyors shall be operated by the Contactor in the presence of the Engineer to demonstrate the ability of the conveyors to operate smoothly and the drive unit to operate continuously without sludge cake and without noise, vibration, or generation of excessive heat. The test shall also indicate no other apparent deficiencies in the system. 2. When sludge becomes available, a Final Acceptance test shall be made under regular operating conditions to further demonstrate the ability of each conveyor to convey the dewatered sludge and discharge it to the roll off container for a period of not less than 100 operating hours. 3. Any deficiencies found in the equipment shall be remedied by the Contractor at no additional cost to the Owner. D. Services of Manufacturer: 1. Reference Sections 01 61 03 – Common Requirements for Equipment, 01 70 00 – Execution and Closeout Requirements, and 01 91 00 – Facility Commissioning for general requirements. 2. Provide the services of a factory certified service engineer specifically trained in the installation, start-up, testing, operation, and maintenance of equipment specified herein. Such services shall be provided by a representative who is a direct, full-time employee of the manufacturer or their certified representative. 3. Services of equipment manufacturer's representative shall include: a. Inspect equipment covered by this Section. b. Supervise adjustments and installation checks. c. Provide test equipment, tools, and instruments necessary to accomplish equipment testing. d. Conduct initial check-out and start-up of equipment, perform operational checks, and supervise acceptance testing. e. Provide a written statement that manufacturer's equipment has been installed properly, started up and is ready for operation by Owner. f. Instruct Owner on operation and maintenance of furnished equipment. 4. Operation and maintenance training shall include the following, at a minimum: a. Theory of operation. b. Troubleshooting guidance. c. Step-by-step start-up and shut-down procedures. d. Step-by-step, “hands-on” assembly and disassembly procedural instructions. e. Replacement part identification and ordering procedures. f. Lubrication procedures, including drain-down and refill procedures. g. Recommended routine maintenance procedures. h. Troubleshooting and diagnostic procedures. i. Instrument adjustment. 5. Services of manufacturer's representative shall be provided for the amount of time specified below. a. Supervision, start up, and testing: 16 hours. b. Instruct Owner on operation and maintenance: 8 hours (2 sessions, 4 hours each). END OF SECTION BCRUA – Phase 1D WTP Expansion Issued for Bid Common Requirements for Pumping Equipment 43 21 00 - 1 SECTION 43 21 00 – COMMON REQUIREMENTS FOR PUMPING EQUIPMENT PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. Common requirements for pumping equipment. B. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Division 01 – General Requirements. 3. Section 01 91 00 – Facility Commissioning. 4. Division 03 – Concrete. 5. Section 09 96 00 – High-Performance Coatings. 6. Section 46 33 44 – Peristaltic Transfer Pumps. 1.2 REFERENCE STANDARDS A. American Institute of Steel Construction (AISC). B. Hydraulic Institute (HI): 1. 9.6.4, Rotodynamic Pumps for Vibration Measurements and Allowable Values. 2. 14.6, Rotodynamic Pumps for Hydraulic Performance Acceptance Tests. 1.3 DEFINITIONS A. Abbreviations are defined as follows: 1. IPS: Iron Pipe Size. 2. NPSHr: Net Positive Suction Head required. 3. TDH: Total Dynamic Head. 4. TEFC: Totally Enclosed Fan Cooled. 5. VFD: Variable Frequency Drive. 6. POR: Preferred operating region. 7. AOR: Allowable operating region. 8. MCSF: Minimum continuous stable flow. 1.4 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Product Data: 1. Submit manufacturer information for system materials and components, including performance characteristics. a. Performance data and curves with flow (gpm), head (FT), horsepower, efficiency, NPSH requirements, submergence requirements. b. Show the POR, AOR, and MCSF on the pump curves. c. All units to be U.S. standard. d. Pump accessory data. BCRUA – Phase 1D WTP Expansion Issued for Bid Common Requirements for Pumping Equipment 43 21 00 - 2 e. Bearing supports, shafting details and lubrication provisions. 1) Bearing life calculations. 2) Critical speed calculations. f. Solids passage information. 2. Include descriptive literature, bulletins, and/or catalogs of the equipment. 3. Include the total weight of the equipment. 4. Provide a complete total bill of materials for all equipment. 5. Motor: a. Complete nameplate data. b. Special features (i.e., space heaters and space heater wattage, corrosion resistant features, etc.). 6. Electrical wiring diagram of each component supplied. C. Shop Drawings: 1. Section 01 61 03 – Common Requirements for Equipment: Shop drawing submittal requirements. 2. Certified pump performance curves as described in SOURCE QUALITY CONTROL. 3. Submit drawings showing details of construction and dimensions. 4. Submit detailed instructions on installation requirements, including storage and handling procedures. 5. Submit qualifications for manufacturer. 6. Project specific control details and electrical schematic and wiring diagrams. 7. Warranty information. D. Source Quality-Control Submittals: 1. Manufacturer's Certificate: Certify that products meet or exceed specified requirements. a. Section 01 33 00 – Submittal Procedures: Supplement 01. 2. Section 01 61 03 – Common Requirements for Equipment: Submittal requirements. 3. Test reports: a. Factory hydrostatic tests. b. Factory performance tests. E. Field Quality-Control Submittals: 1. Section 01 33 00 - Submittal Procedures: Supplements 02 and 03. 2. Section 01 61 03 – Common Requirements for Equipment: Submittal requirements. 3. Section 01 91 00 – Facility Commissioning: Submittal requirements. Indicate results of Contractor-furnished tests and inspections. 4. Certify that equipment has been installed according to manufacturer instructions. 1.5 CLOSEOUT SUBMITTALS A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for Operation and Maintenance Manual. B. Section 01 91 00 – Facility Commissioning: Closeout Submittal requirements. C. Project Record Documents: Record actual locations and final orientation of equipment. BCRUA – Phase 1D WTP Expansion Issued for Bid Common Requirements for Pumping Equipment 43 21 00 - 3 1.6 QUALITY ASSURANCE A. Fully coordinate all mechanical seal systems specified to ensure pump and seal compatibility. B. Pump/motor and VFD coordination: See Sections 01 61 03 – Common Requirements for Equipment and 26 29 23 – Low Voltage Variable Frequency Drives. 1.7 DELIVERY, STORAGE, AND HANDLING A. Section 01 60 00 - Product Requirements: Requirements for transporting, handling, storing, and protecting products. B. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage. C. Store materials according to manufacturer instructions. D. Protection: 1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas. 2. Provide additional protection according to manufacturer instructions. 1.8 EXISTING CONDITIONS A. Field Measurements: 1. Verify field measurements prior to fabrication. 2. Indicate field measurements on Shop Drawings. PART 2 PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. Pumps: 1. See individual pump sections. 2. The pumping units shall be a standard product of a company that has been routinely engaged in the business of manufacturing similar pumps for a period of at least 10 years. 3. All pumps of the same size and duty are to be manufactured by the same pump manufacturer. B. Mechanical seals: a. Chesterton. b. John Crane c. Garlock. d. Or as noted in the individual pump sections. C. Motors: 1. Reference Section 01 61 03 – Common Requirements for Equipment. 2. Motors shall be a standard product of a company that has been continuously in the business of manufacturing similar electric motors for at least ten years. BCRUA – Phase 1D WTP Expansion Issued for Bid Common Requirements for Pumping Equipment 43 21 00 - 4 3. Unless indicated otherwise, the motors shall have a service factor of 1.15. 4. The motors shall be standard NEMA frames. 5. Unless indicated otherwise the motors shall be totally enclosed and fan cooled (TEFC). 6. The motors are to be provided by the pump manufacturer. 7. The pump manufacturer is to confirm that the motor being supplied is adequate, appropriate, and functionally correct for the application. D. Submit substitutions in accordance with Section 01 25 00. 2.2 CENTRIFUGAL PUMP DESIGN A. Provide pumps that have their best efficiency point (BEP) close to the duty point for the pump. B. Provide pumps that, when operated over their intended operating range, remain within the AOR and preferably within the POR. C. Provide pumps that have NPSH requirements that are functionally compatible with the installation requirements. Provide NPSH margins that meet or exceed the requirements of the Hydraulic Institute. D. Provide pumps that will fit within the physical space provided, as shown on the drawings. E. Provide pumps that are consistent with the electrical supply available, without the addition of any additional electrical devices, such as add-a-phase, VFDs, additional transformers, etc. F. Provide pumps with increasing head characteristics from the run-out portion of the curve to shut-off condition. 2.3 ACCESSORIES A. See Section 01 61 03. B. Reference narrow-scope pump sections for specific requirements. C. Each Unit - Unless specified otherwise in narrow-scope pump sections: 1. Lifting eye bolts or lugs. 2. Plugged gage cock connection at suction and discharge nozzles. 3. Tapped and plugged openings for casing and bearing housing vents and drains. 4. Fittings for properly adding flushing lubricant. 5. Pressure relief fittings for grease lubrication. D. Packing Seal: 1. Provide packing unless mechanical seal is specified in narrow-scope pump sections. 2. Minimum of five (5) rings graphite impregnated synthetic packing. 3. Provide minimum 1/4 IN DIA supply tap and 1/2 IN DIA minimum drain tap. 4. Provide split Teflon or bronze water seal ring. 5. Adjustable split follower cast iron or bronze gland. E. Mechanical Seals: BCRUA – Phase 1D WTP Expansion Issued for Bid Common Requirements for Pumping Equipment 43 21 00 - 5 1. Provide as specified in the narrow-scope pump sections. 2. Provide rotating (up to a 6 IN shaft) or stationary (greater than 6 IN shaft) balanced O- ring type. 3. Provide water lubrication. 4. Materials: a. Metal parts except springs: 316 stainless steel. b. Springs: Hastelloy C. c. Seal faces: Unfilled carbon graphite versus silica-free Grade 99.5 ceramic. d. Elastomers: Viton. 2.4 FABRICATION A. Pump Support - Unless specified otherwise in narrow-scope pump sections: 1. Design base to support weight of drive, shafting, pump, and any other accessories that will be supported by the pump base. 2. Comply with HI vibration limitations. 3. Mount horizontal pump, motor and coupling on single piece drip lip type baseplate. 4. Mount vertical pumps on single piece pedestal baseplate. 5. Fabricate to withstand all operating loads transmitted from the pump and drive. 6. Provide leveling grout beneath base plate. 7. Provide leveling bolts for pump installation. 2.5 SOURCE QUALITY CONTROL A. Reference narrow-scope pump sections for specific requirements. B. Factory hydrostatic test all pumps at 150 percent of shut-off head for a minimum of 5 minutes. C. Unless otherwise indicated, factory tests are to be conducted with the job driver, not the factory driver. D. If specifically required in the individual pump sections, provide factory tests: 1. All units: a. Conduct tests in accordance with HI. 1) Shut-off head and design condition: Positive unilateral performance tolerance meeting Grade 1U per HI 14.6 for Rotodynamic Pumps. 2. Adjustable speed units: a. Head (FT) verses flow (gpm) pump curves: 1) Maximum, minimum and two (2) equally spaced intermittent speeds. 2) Efficiencies along each curve. 3) Brake horsepower along each curve. 3. Constant speed units: a. Head (FT) versus flow (gpm) pump curves: 1) Efficiencies along curve. 2) Brake horsepower along each curve. 4. Obtain and provide NPSH required curves for each pump that are obtained from the factory testing. 5. Provide test results that are certified by a licensed professional engineer. E. Statically and dynamically balance each pump per HI standards. BCRUA – Phase 1D WTP Expansion Issued for Bid Common Requirements for Pumping Equipment 43 21 00 - 6 1. If specifically required in the individual pump sections or in Section 01 61 03, field vibration test pumps: a. Meet requirements of HI 9.6.4 for Rotodynamic Pumps at any point on the pump and motor. PART 3 EXECUTION 3.1 INSTALLATION A. Comply with requirements of Section 01 61 03. B. Install following the manufacturer’s recommendations and instructions. C. Floor, Platform or Pad-Mounted Units (Non-Submersible): 1. Install the pump either level or plumb, depending on the pump type. Level to be confirmed with a machinist’s precision level, or a laser with equivalent accuracy. Level pump in both directions. 2. Align piping vertically and horizontally level to match pump interfaces. 3. Assure no unnecessary stresses are transmitted to equipment flanges. 4. Tighten flange bolts at uniform rate and manufacturer's recommended torque for uniform gasket compression. 5. Support and match flange face to uniform contact over entire face area prior to bolting pipe flange and equipment. 6. Permit piping connecting to equipment to freely move in directions parallel to longitudinal centerline when and while bolts in connection flange are tightened. 7. Grout equipment into place prior to final bolting of piping, but not before initial fitting and alignment. 8. Assemble connecting piping with gaskets in place and minimum of four (4) bolts per joint installed and tightened. a. Test alignment by loosening flange bolts to see if there is any change in relationship of piping flange with equipment connecting flange. b. Realign as necessary, install flange bolts and make equipment connection. 9. Carefully align the driver and pump shafts, following the recommendations of the coupling manufacturer. 10. Connect and test all pump and driver instrumentation prior to field testing of the pump. D. Field paint units in accordance with Section 09 96 00 – High-Performance Coatings. E. Provide pressure gage on discharge of all pumps. 3.2 FIELD QUALITY CONTROL A. Section 01 40 00 – Quality Requirements. B. Sections 01 61 03 – Common Requirements for Equipment, 01 70 00 – Execution and Closeout Requirements, and 01 91 00 – Facility Commissioning: Testing, Startup, Demonstration, and Training requirements. BCRUA – Phase 1D WTP Expansion Issued for Bid Common Requirements for Pumping Equipment 43 21 00 - 7 C. All pumping units are to be field tested to confirm that they are operating properly and meet all conditions given in the individual pump specifications. D. Services of Manufacturer: 1. Section 01 40 00 – Quality Requirements. 2. Sections 01 61 03 – Common Requirements for Equipment, 01 70 00 – Execution and Closeout Requirements, and 01 91 00 – Facility Commissioning: Testing, Startup, Demonstration, and Training requirements. 3. Services of equipment manufacturer's field service representative(s) shall include: a. Inspect equipment covered by this Section. b. Supervise pre-start adjustments and installation checks. c. Provide test equipment, tools, and instruments necessary to accomplish equipment testing. d. Conduct initial check-out and start-up of equipment, perform operational checks, and supervise acceptance testing. e. Instruct Owner's personnel at jobsite on operation and maintenance of pumping equipment that is specific to the pumping units being installed. f. Services of manufacturer’s representative shall be provided for the amount of time specified in narrow scope Specification Sections. END OF SECTION BCRUA – Phase 1D WTP Expansion Issued for Bid Crosslinked Polyethylene Tanks 43 41 43 - 1 SECTION 43 41 43 – CROSSLINKED POLYETHYLENE TANKS PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. High density crosslinked polyethylene (XLPE) chemical storage tanks and appurtenances. B. Scope of Work: 1. The work under this Section includes the furnishing of all labor, materials, equipment, documentation, installation and startup services for the manufacture and installation of XLPE tanks suitable for storage of chemicals as illustrated on the Drawings and specified herein. 2. XLPE tanks specified herein shall be the end product of one fabricator in order to achieve standardization for appearance, operation, maintenance, spare parts and fabricator’s service. C. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Division 01 – General Requirements. 3. Section 10 14 00 – Identification for Process Piping and Equipment. 4. Division 40 – Process Integration. 1.2 REFERENCE STANDARDS A. American National Standards Institute (ANSI): 1. B16.5, Pipe Flanges and Flanged Fittings. B. American National Standards Institute/National Sanitation Foundation (ANSI/NSF): 1. Standard 61, Drinking Water System Components. 2. NSF 372 - Drinking Water System Components - Lead Content. C. Association of Rotational Molders (ARM): 1. Low Temperature Impact Resistance (Falling Dart Test Procedure). D. American Society for Testing and Materials (ASTM): 1. D638, Tensile Properties of Plastics. 2. D883, Standard Definitions of Terms Relating to Plastics. 3. D1505, Density of Plastics by the Density-Gradient Technique. 4. D1525, Test Method for Vicat Softening Temperature of Plastics. 5. D1693, ESCR Specification Thickness 0.125" F50-10% Igepal. 6. D1998, Standard Specification for Polyethylene Upright Storage Tanks. 7. F412, Standard Terminology Relating to Plastic Piping Systems. 1.3 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. BCRUA – Phase 1D WTP Expansion Issued for Bid Crosslinked Polyethylene Tanks 43 41 43 - 2 B. Product Data: 1. Submit manufacturer information for tank materials and components. 2. Include descriptive literature, bulletins, and/or catalogs of the tanks. 3. Include the total weight of the tank. 4. Provide a complete total bill of materials for tank and components. 5. Acknowledgement that products submitted meet requirements of standards referenced. 6. Tank resin data sheet. 7. Structural calculations for tanks assuming full conditions with specified liquid, signed and sealed by a 3rd party, licensed structural engineer for record purposes. 8. Tank insulation data. 9. Flanged instrument sleeve locations. C. Shop Drawings 1. Detailed fabrication drawings for each tank with dimensions, orientation, fittings, accessories and fasteners. 2. Submit detailed instructions on installation requirements, including storage and handling procedures. 3. Submit tank manufacturer qualifications. 4. Submit a copy of manufacturer’s warranty. D. Source Quality-Control Submittals: 1. Manufacturer's Certificate: Certify that products meet or exceed specified requirements. a. Section 01 33 00 – Submittal Procedures: Supplement 01. 2. Submit results of factory tests of tanks. 3. Manufacturer’s certification that resin used for tanks is suitable for use with chemicals specified. 4. Submit Quality Control Reports for specified Shop Testing. E. Field Quality-Control Submittals: 1. Section 01 33 00 – Submittal Procedures: Supplements 02 and 03. 2. Section 01 91 00 – Facility Commissioning: Submittal requirements. 3. Indicate results of Contractor-furnished tests and inspections. 4. Certify that tank has been installed according to manufacturer instructions. 1.4 CLOSEOUT SUBMITTALS A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for Operation and Maintenance Manual. B. Section 01 91 00 – Facility Commissioning: Closeout Submittal requirements. C. Project Record Documents: Record actual locations and final orientation of tanks. 1.5 QUALITY ASSURANCE A. All components and materials of tanks shall be compatible with the specified chemical service. B. All materials in contact with chemicals added to water being treated for potable use must be certified to NSF 61 and NSF 372. BCRUA – Phase 1D WTP Expansion Issued for Bid Crosslinked Polyethylene Tanks 43 41 43 - 3 1.6 QUALIFICATIONS A. Manufacturer Experience: 1. Tank manufacturer shall have a minimum of 10 years of experience with a successful record of manufacturing tanks as specified herein. 2. Tank manufacturer shall have manufactured at least 100 tanks of similar size and design within the last five years. 1.7 DELIVERY, STORAGE, AND HANDLING A. Section 01 60 00 – Product Requirements: Requirements for transporting, handling, storing, and protecting products. B. Upon delivery, check tanks closely for damage. If damaged, tanks will not be accepted, unless repairs are made in accordance with manufacturer's recommendations, and the manufacturer certifies in writing that the repairs were made in accordance with their recommendations and the tank is completely sound and suitable for service. Handle the tanks with care to prevent inadvertent damage during installation. C. Store materials according to manufacturer instructions. D. Protection: 1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas. 2. Provide additional protection according to manufacturer instructions. 1.8 EXISTING CONDITIONS A. Field Measurements: 1. Proposed tanks will be installed in the existing Chemical Feed Area and Disinfection Facility. 2. Verify existing space and field measurements prior to fabrication. 3. Indicate field measurements on Shop Drawings. 1.9 WARRANTY A. Tank manufacturer shall warrant that tanks are suitable for storage of specified chemicals, without structural failure or chemical leakage due to design, fabrication or resin defects, for a period of five (5) years from date of Substantial Completion. 1. If leakage or other defects appear within 5-year warranty period, tank manufacturer shall promptly repair tank at their own expense upon written notice by Owner that defects have been found. 2. Leakage is defined as liquid appearing on exterior of tank, the source of which is from inside of tank. BCRUA – Phase 1D WTP Expansion Issued for Bid Crosslinked Polyethylene Tanks 43 41 43 - 4 PART 2 PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. XLPE bulk and day storage tanks: 1. Assmann Corporation. 2. Poly Processing Company. 3. Snyder Industries. B. Submit substitutions in accordance with Section 01 25 00. 2.2 DESIGN REQUIREMENTS A. General: 1. Hydrostatic design of tanks: ASTM D1998, SG = 1.5. 2. Shell configuration: Vertical, cylindrical. 3. Top: Closed dome. 4. Bottom: Flat. 5. Manway/Cover: Top mount. 6. Chemical compatibility: Suitable for storage of the following chemicals. a. Fluosilicic Acid: 1) Concentration: 20-25%. 2) pH: 1.2. 3) Specific gravity: 1.2. b. Sodium Hypochlorite: 1) Concentration: 12.5%. 2) pH: 12-13. 3) Specific gravity: 1.25. 7. Design temperature: 120 degF ambient fluid temperature. 8. Exterior color: White. B. Tanks for Fluosilicic Acid storage shall have top penetrations only. Sidewall penetrations below the tank overflow invert are not acceptable. C. Minimum capacities noted below shall be defined as the volume below the invert of tank overflow nozzle. D. Sodium Hypochlorite Bulk Chemical Storage Tank: 1. Tag number: DF-SHST-003. 2. Minimum capacity: 12,150 gallons. 3. Maximum diameter: 12-FT. 4. Maximum height: 16-FT, 8-IN. 5. Location: Disinfection Facility, indoor. 6. Fill connection: 3-IN diameter. 7. Overflow: 3-IN diameter. 8. Manway: 24-IN diameter. 9. Flanged instrument flanged sleeve: 6-IN diameter. 10. Vent: 4-IN diameter, minimum. 11. Discharge flange: 2-IN diameter. a. Discharge shall be integrally molded flanged outlet located at tank bottom. BCRUA – Phase 1D WTP Expansion Issued for Bid Crosslinked Polyethylene Tanks 43 41 43 - 5 b. Provide eccentric reducer for connection to piping, if required. E. Fluosilicic Acid Bulk Chemical Storage Tank: 1. Tag number: CFA-FLST-001. 2. Minimum capacity: 6,000 gallons. 3. Maximum diameter: 10-FT, 2-IN. 4. Maximum height: 12-FT, 9-IN. 5. Location: Chemical Storage Area, outdoor. 6. Fill connection: 3-IN diameter. 7. Overflow: 3-IN diameter. 8. Manway: 24-IN diameter. 9. Flanged instrument flanged sleeve: 6-IN diameter. 10. Vent: 6-IN diameter, minimum. 11. Discharge flange: 2-IN diameter. a. Discharge connection shall be through the tank dome. F. Fluosilicic Acid Day Chemical Storage Tank: 1. Tag number: CFA-FLDT-001. 2. Minimum capacity: 250 gallons. 3. Maximum diameter: 48-IN. 4. Maximum height: 72-IN. 5. Location: Chemical Feed Area, indoor. 6. Fill connection: 2-IN diameter. 7. Overflow: 2-IN diameter. 8. Cover: 8-IN diameter, minimum. 9. Flanged instrument flanged sleeve: 6-IN diameter. 10. Vent: 2-IN diameter, minimum. 11. Discharge: 1-IN diameter. a. Discharge connection shall be through the tank dome. 2.3 MATERIALS A. Resin: 1. Marlex CL-200 YJN as manufactured by Phillips Petroleum Company, Plastics Division. 2. Paxon 7004 as manufactured by Paxon, Inc. 3. Resin of equal physical and chemical properties approved by the Engineer. B. Filler and pigments: 1. Plastic shall not contain any fillers. All plastic shall contain a minimum of 0.25% U.V. stabilizer and maximum of 0.60%. 2. Pigments may be added as approved by Engineer, not to exceed 0.5% of dry blended or 2% of total weight of the tank. C. Mechanical properties of tank material: Parameter Reference Standard Value Density ASTM D1505 0.940-0.945 g/mL Environmental Stress Cracking, F50 ASTM D1693 >1,000 hours BCRUA – Phase 1D WTP Expansion Issued for Bid Crosslinked Polyethylene Tanks 43 41 43 - 6 Parameter Reference Standard Value Tensile strength, ultimate, 2-inch minimum ASTM D638 2,600 psi Elongation at Break, 2-inch minimum ASTM D638 >300% Flexural Modulus ASTM D790 100,000 psi Vicat softening point ASTM D1525 240-250 degF Brittleness temperature ASTM D746 < -130 degF Impact resistance at -40 degF Phillips SSL-193 >120 ft/lb Low temperature Impact ARM (Low impact for 1/8- inch specimen NA 75 ft-lbs Polyethylene notch test (PENT) (176 degF, 350 psi) ASTM F1473 >1,000 hours Long term hydrostatic (LTHS) (Creep) at 140 degF NA 900 psi Specific gravity ASTM D1998 1.9 D. Fittings and accessories: 1. All mechanical fittings, piping, hardware and accessories supplied with tank shall be compatible with stored fluid. 2. Fittings: PVC. 3. Gaskets: Compatible with stored chemical. a. Viton. 4. Hardware: Compatible with stored chemical. a. Sodium Hypochlorite tank: Titanium. b. Fluosilicic Acid tanks: Hastelloy C. 5. Fasteners and other metallic components inside of tank that are exposed to contents shall be encapsulated in polyethylene or other suitable plastic. 2.4 FABRICATION AND MANUFACTURE A. Tanks shall be constructed by the rotational molding process. B. Tank diameter shall be measured externally. Tolerance on the outside diameter, including out of roundness, shall be plus or minus three percent (3%). Measurement shall be taken in a horizontal position. Knuckle radius at bottom of wall shall be a minimum of one inch. C. Tank wall thickness: 1. Design in accordance with ASTM D1998. 2. Design using a hoop stress no greater than 600 psi. 3. Wall thickness calculations shall assume tank contents have a specific gravity not less than 1.5. 4. In no case shall tank thickness be less than design thickness. 5. Minimum wall thickness shall be sufficient for tank to support its own weight in an upright position without external support, but shall not be less than 0.187-IN thick. D. All cut out edges shall be trimmed to have smooth edges. BCRUA – Phase 1D WTP Expansion Issued for Bid Crosslinked Polyethylene Tanks 43 41 43 - 7 2.5 TANK ACCESSORIES A. Fittings, general: 1. Refer to Drawings for orientation. 2. All sidewall fittings shall prevent chemicals from contacting tank wall cross section. B. Flanged nozzles: 1. Integrally molded into tank and designed to withstand 1,500 LBS bending, 2,000 FT-LBS torque. 2. Flange diameter and drilling per ANSI B16.5, 150 LB. 3. Same material as tank. 4. PVC flanges on vents attached to vessel not allowed. 5. Provide flanges for manways, openings, and connections with 40 to 50 Durometer 1/8-IN thick full-face gaskets. C. Furnish flanged fill port, outlet, and overflow connections as follows: 1. Locate fill port on tank roof 6 IN horizontally from sidewall. 2. Discharge Outlets: a. Sidewall: Locate on tank sidewall as detailed on Drawings. b. Dome: Locate on tank roof 6 IN horizontally from sidewall. 3. Orient fill ports and outlets on bulk and day tanks so that discharge/fill lines are greater than 20 degrees from other discharge/ fill lines. 4. Locate overflow on tank sidewall 4 IN below top of shell. D. Ventilation openings: 1. Furnish vent on tank roof 6 IN horizontally from sidewall. 2. Furnish with gooseneck and corrosion resistant bug screen on outdoor tanks. 3. For indoor tanks, connect vent to piping as indicated on Drawings. E. Exterior pipe supports on bulk tanks: 1. Provide to support overflow piping, tank fill/inlet piping, and as required to support tank discharge piping and electrical conduits. 2. Supports shall allow easy installation of the pipe or conduit, as well as easy removal for repair or replacement, if necessary. 3. Supports shall be spaced 5 FT on center, and within 1 FT of elbows or valves. F. Interior fill pipes for chemical storage tanks: 1. Schedule 80 PVC pipe extending from inlet connection to 12 IN above tank bottom. 2. Interior flanged connection to tank nozzle at top and base support for 90 degree elbow at bottom. 3. Pipe size to match exterior fill pipe. 4. Pipe supports at 8 FT maximum for bulk tanks, designed for easy pipe removal and replacement. 5. 3/4 IN DIA by 6 IN long horizontal PVC vacuum breaking pipe from interior tank nozzle at top of tank, and pointed toward tank center. G. Exterior electrical conduit supports for chemical storage tanks: 1. Provide to support electrical conduit routed to flanged instrument sleeve. 2. Supports shall allow easy installation of the conduit, as well as easy removal for repair or replacement, if necessary. BCRUA – Phase 1D WTP Expansion Issued for Bid Crosslinked Polyethylene Tanks 43 41 43 - 8 3. Supports shall be spaced 5 FT on center, and within 1 FT of the top of the tank. H. Flanged instrument sleeves: 1. Each tank shall include a system integrator provided hydrostatic submersible level transmitter. Locate sleeve such that the suspended hydrostatic submersible level transmitter is directly above the bottom of the tank and is not obstructed by the tank wall or any tank accessories, nor in-line with the fill port of the tank. Sleeve flange shall be parallel to the bottom of the tank. 2. Provide a blind flange with a 3/4" NPT connection to route instrument cable through strain relief fitting. Blind flange and mounting hardware shall be compatible with the contained fluid. 3. Coordinate level sensors and attachment requirements with Electrical Drawings, Section 40 90 01, and instrument supplier. I. Bulk tank manway: 1. Integrally molded with the tank. Manway cover shall be flanged and bolted sealing type and vapor tight. 2. All manways shall be equipped with an emergency pressure relief device designed to allow a minimum flow rate of 4000 CFM in the event the tank is pressurized. J. Tie down lugs for bulk tanks: Number, strength, location and anchor bolt size as required per design loading. K. Cable restraint system for bulk tanks: 1. Metal components shall be stainless steel. 2. Provide edge softeners, and tension ring with stainless steel cables and clamps. 3. Design shall conform to the most recent edition of the IBC for seismic and wind load. L. Lifting lugs for bulk tanks: 1. Provide at least 3 lifting lugs capable of withstanding weight of empty tank with safety factor of 5 to 1. 2. Lifting lugs shall be Type 316L stainless steel or polyethylene and attached to tank wall with hand-layed up laminate equal to or greater than the tank wall thickness. M. Bulk tank ladder: 1. Total length: As required from finished floor level to a minimum of 3 FT from top of each tank to allow access to dome components. 2. Maximum center-to-center distance on mounting supports is 5 FT. 3. Design in accordance with OSHA standards. a. Safety cage shall be added to ladder as required. 4. Material: FRP. 5. Stainless steel angle clips shall be furnished for mounting bottom of ladder to concrete pad. 6. Design to account for insulation thickness in order to provide adequate horizontal space between outside of tank wall and ladder. N. Day tank cover: 1. Threaded cover with viton gasket. 2. Equip with emergency pressure relief device to vent tank in case tank is pressurized. BCRUA – Phase 1D WTP Expansion Issued for Bid Crosslinked Polyethylene Tanks 43 41 43 - 9 O. Day tank containment: 1. Provide portable, polyethylene spill containment basin sized to contain full day tank volume. a. Dimensions: 1) Width: Less than 60-IN. 2) Length: As required up to 84-IN. 3) Sidewall height: 24-IN minimum. 2. Account for day tank volume displacement when sizing spill containment basin. P. Tank level indication: 1. Level indicator shall be assembled to tank and consist of PVC float, indicator, polypropylene rope, perforated interior pipe, PVC roller guides, clear UV resistant PVC sight tube, and necessary pipe supports. Level indicator shall act inversely to tank contents and shall not allow entrance of tank contents into sight tube at any time. Indicator shall be neon orange color for visibility. a. Manufacturer & Product: EnviroKing by C.F. Harvel or approved equal. Q. Insulation: Fluosilicic Acid Bulk Chemical Storage Tank only. 1. Provide polyurethane foam insulation with a density of 2.5 lb/ft3 with a minimum “R” value of 6.3/IN. Foam shall be applied with a nominal thickness of 2-IN to all external tank surfaces, except tank bottom. Insulation shall be uniform density and thickness. 2. After completion of application and curing of insulation, a minimum of two full coverage coats of latex mastic coating shall be applied to surface of insulation in such manner as to seal the insulation from the outside environment. Color shall be white. 3. Insulation and coating shall be factory applied. R. Tank certification label: 1. Chemical contents, including: a. Concentration. b. Specific gravity. c. Maximum temp. 2. Exterior resin. 3. Interior resin. 4. Tank capacity. 5. Manufacturer. 6. Manufacturer location. 7. Date of manufacture. 8. Seismic requirements. S. Safety signs: 1. See Section 10 14 00 - Identification for Process Piping and Equipment. 2.6 SOURCE QUALITY CONTROL A. Shop Testing: Provide following tests prior to shipment and submit corresponding documentation. B. Material testing: BCRUA – Phase 1D WTP Expansion Issued for Bid Crosslinked Polyethylene Tanks 43 41 43 - 10 1. Perform gel and low temperature impact tests in accordance with ASTM D1998 on condition samples cut from each XLPE chemical storage tank. 2. Degree of Crosslinking. Use Method C of ASTM D1998: Section 11.4 to determine ortho-xylene insoluble fraction of crosslinked polyethylene gel test. Samples shall test at no less than 60 percent. C. Tank testing: 1. Dimensions: Take exterior dimensions with the tank empty, in the vertical position. Outside diameter tolerance, including out-of-roundness, shall be per ASTM D1998. Fitting placement tolerance shall be +/- 1/2-IN vertical and +/- 1 degree radial. 2. Visual: Inspect for foreign inclusions, air bubbles, pimples, crazing, cracking, and delamination. 3. Hydrostatic test: Following fabrication, the bottom of tanks, including inlet and outlet fittings, shall be hydraulically tested with water by filling to the top sidewall for a minimum of 30 minutes and inspected for leaks. Following successful testing, the tank shall be emptied and cleaned prior to shipment. PART 3 EXECUTION 3.1 INSTALLATION A. Install the tanks in complete accordance with the manufacturer's installation instructions. B. Install bulk tanks on 1/4-inch thick neoprene pad or similar pad as recommended by tank manufacturer. C. Do not grout tanks. 3.2 FIELD QUALITY CONTROL A. Reference Sections 01 40 00 – Quality Requirements, 01 70 00 – Execution and Closeout Requirements, and 01 91 00 – Facility Commissioning. B. Field Testing: 1. The tanks shall be field tested by filling the entire tank with water and monitoring the tanks, as well as fitting connections, for at least 24 hours. Any leaks shall be corrected by manufacturer's representative prior to acceptance. Following successful field tank testing, tanks shall be completely emptied and dried. C. Field Repair: 1. If after filling tank with chemical, a leak is detected, Contractor shall be responsible for all expenses associated with removing tank contents, repair of tank by manufacturer's representative and replacing tank contents. D. Services of Manufacturer: 1. Reference Sections 01 70 00 – Execution and Closeout Requirements, and 01 91 00 – Facility Commissioning for general requirements. 2. Provide the services of a manufacturer’s representative specifically trained in the installation, testing, and maintenance of tanks specified herein. Such services shall be BCRUA – Phase 1D WTP Expansion Issued for Bid Crosslinked Polyethylene Tanks 43 41 43 - 11 provided by a representative who is a direct, full-time employee of the manufacturer or their certified representative. 3. Manufacturer shall certify in writing that the tanks are correctly installed before initial filling. 4. Services of manufacturer’s representative shall be provided for the amount of time specified below. a. Supervision and testing: 8 hours. b. Instruct Owner on operation and maintenance: 4 hours. END OF SECTION BCRUA – Phase 1D WTP Expansion Issued for Bid Rotating Pipe Skimmers 46 25 40 - 1 SECTION 46 25 40 – ROTATING PIPE SKIMMERS PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. Rotating pipe skimmers. B. Scope of Work: 1. The work under this Section includes the furnishing of all labor, materials, equipment, documentation and training for installation of rotating pipe skimmers, manual operators, operating stems, wall bearings, end brackets, bearing sleeves, worm gear drive, wall spools and reducer pipe fittings, and appurtenances as illustrated on the Drawings and specified herein. C. System Description: 1. Rotating pipe skimmers shall be furnished with all necessary components and accessories to provide a complete and operating system as shown on the Drawings and specified herein. Rotating pipe skimmers shall include the following major components of supply: a. Scum collection pipe. b. Manual operators with worm gear drive, floor stand and stem. c. Wall bearings. d. End brackets. e. Bearing sleeves. f. Set collars. g. Wall spools and reducer pipe fittings. h. Seals, hardware and anchors. D. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Division 01 – General Requirements. 3. Section 01 91 00 – Facility Commissioning. 4. Division 03 – Concrete. 5. Division 40 – Process Integration. 1.2 REFERENCE STANDARDS A. American Institute of Steel Construction (AISC). B. American Society of Testing and Materials (ASTM). C. American Welding Society (AWS). D. NSF International: 1. NSF 61 - Drinking Water System Components - Health Effects. 2. NSF 372 - Drinking Water System Components - Lead Content. BCRUA – Phase 1D WTP Expansion Issued for Bid Rotating Pipe Skimmers 46 25 40 - 2 1.3 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Product Data: 1. Submit manufacturer information for system materials and component equipment, including performance characteristics. 2. Include descriptive literature, bulletins, and/or catalogs of the equipment. 3. Include the total weight of the equipment. 4. Provide a complete total bill of materials for all equipment. C. Shop Drawings: 1. Section 01 61 03 – Common Requirements for Equipment: Shop drawing submittal requirements. 2. Certified shop and erection drawings of proposed equipment, including materials and details of construction, dimensions, and connections to process components. 3. Provide complete description of surface preparation and shop prime painting. 4. Provide nameplate data and arrangement. 5. Submit detailed instructions on installation requirements, including storage and handling procedures. 6. Submit qualifications for manufacturer. 7. Warranty information. D. Source Quality-Control Submittals: 1. Manufacturer's Certificate: Certify that products meet or exceed specified requirements. a. Section 01 33 00 – Submittal Procedures: Supplement 01. 2. Section 01 61 03 – Common Requirements for Equipment: Submittal requirements. 3. Submit results of factory tests of equipment. E. Field Quality-Control Submittals: 1. Section 01 33 00 - Submittal Procedures: Supplements 02 and 03. 2. Section 01 61 03 – Common Requirements for Equipment: Submittal requirements. 3. Section 01 91 00 – Facility Commissioning: Submittal requirements. 4. Indicate results of Contractor-furnished tests and inspections. 5. Certify that equipment has been installed according to manufacturer instructions. 1.4 CLOSEOUT SUBMITTALS A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for Operation and Maintenance Manual. B. Section 01 91 00 – Facility Commissioning: Closeout Submittal requirements. C. Project Record Documents: Record actual locations and final orientation of equipment. 1.5 QUALITY ASSURANCE A. All components that contact process water shall be ANSI/NSF 61 certified. BCRUA – Phase 1D WTP Expansion Issued for Bid Rotating Pipe Skimmers 46 25 40 - 3 1.6 QUALIFICATIONS A. The manufacturer shall have a minimum of 10 years of experience with a successful record of manufacturing pipe skimmers and related appurtenances as specified herein. B. The manufacturer shall supply a list of at least ten separate references where substantially similar installations for the equipment as specified have been in satisfactory operation for a minimum of five years. 1.7 DELIVERY, STORAGE AND HANDLING A. Section 01 60 00 - Product Requirements: Requirements for transporting, handling, storing, and protecting products. B. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage. C. Store materials according to manufacturer instructions. D. Protection: 1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas. 2. Provide additional protection according to manufacturer instructions. 1.8 EXISTING CONDITIONS A. Field Measurements: 1. Verify field measurements prior to fabrication. 2. Indicate field measurements on Shop Drawings. 1.9 WARRANTY A. Reference Section 00700 – General Conditions, Article 7.17 for warranty terms. PART 2 PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. Pipe skimmers and appurtenances: 1. Evoqua - Envirex. 2. Walker Process Equipment. 3. Brentwood Industries (Polychem Systems). B. Submit substitutions in accordance with Section 01 25 00. 2.2 DESIGN REQUIREMENTS A. Pipe Skimmers: 1. Tag Number: TSC-PSK-SB4. BCRUA – Phase 1D WTP Expansion Issued for Bid Rotating Pipe Skimmers 46 25 40 - 4 2. Pipe skimmers shall collect floating scum and convey it by gravity to a downstream sludge vault. 3. Location and Diameter: a. Flocculated water channel (TSC-PSK-SB4): 12 inch. 4. Nominal water surface elevations: a. Flocculated water channel: 1078.2 ft above MSL. b. Centerline elevations shown on Drawings may be modified as recommended by manufacturer to best handle water surface elevations listed above. 5. Channel width: a. Flocculated water channel: 4 ft. 2.3 MATERIALS A. All wetted parts, anchor bolts, hardware and fasteners shall be Type 316 stainless steel. 1. Anchor bolts and structural fasteners shall be minimum ½ inch diameter and supplied by manufacturer. B. Scum collection pipe: 1. Type 316 stainless steel. 2. Wall thickness: 0.25 inch, minimum. 3. Cut a 60 degree slot cut symmetrical about the vertical axis of pipe with edges serving as a weir over which scum flows into skimmer when rotated. Edges of slot shall be parallel to the longitudinal axis of the pipe. 4. Full periphery bands not less than 2-inch wide shall be left in the pipe at intervals not exceeding 30-inch to act as stiffeners. Corners of slot openings shall be rounded. C. End supports: 1. Collection pipe shall be supported by and revolve in a Type 316 stainless steel collar that shall be welded to an adjustable stainless steel plate. 2. End supports shall have a replaceable UHMW-PE bearing liner securely fitted within the collar to provide a bearing surface for the scum collection pipe, and to prevent load transfer through the seal. 3. Neoprene gaskets shall be provided with the open-end supports to provide watertight connections to channel walls without grouting. PVC or polypropylene may be used in conjunction with the neoprene gaskets as fillers or spacers. 4. Collection pipe shall be supported at each end in such a manner that a slight vertical or horizontal misalignment will not interfere with the smooth operation of the pipe. D. Set collars and seals: 1. Seal: Provide a watertight D seal at each end of collection pipe. Seal shall be constructed to maintain watertight contact with pipe walls, even with a slight misalignment of the pipe and collar. Seal shall not be affected by grease, mild acids or alkalis, shall be readily renewable without removing pipe from the supporting brackets, and shall not bind or impede smooth action of the revolving pipe. 2. Set collar: a. Type 316 stainless steel, 0.25-inch thick. b. Provide at each end support to retain the skimmer pipe end seals. E. Manual Operator: 1. Gear operator shall consist of the following components: BCRUA – Phase 1D WTP Expansion Issued for Bid Rotating Pipe Skimmers 46 25 40 - 5 a. Removable handwheel: Cast iron 24-inch diameter, keyed to shaft extension and located approximately 42-inch above operating floor. 1) Indicate direction of handwheel rotation on operator. b. Shaft extension: 1.5-inch Type 316 stainless steel pipe connecting handwheel to worm drive shaft. c. Drive shaft: 1.5-inch Type 316 stainless steel shaft key-seated through worm and bolted to shaft extension pipe. d. Floor stand: Type 316 stainless steel, 3.5 inch schedule 40 steel pipe and 5/8 inch plate stiffened for all torque and moment loads. e. Angle worm gear: 4-inch by 4-inch cut steel 3 pitch, single thread, 14.5 degree worm bored and key-seated for 1.5-inch diameter shaft. As an alternative, the angle worm may be made of Nylon-6. f. Collector pipe worm gear: 22-inch, 16 tooth, 3 pitch, single thread, 14.5 degree, cast iron gear mounted on pipe. As an alternative, collector pipe gear may be made of UHMW-PE. g. Bearings: Two rigid, babbitt lined, grease lubricated pillow block bearings for supporting 1.5-inch diameter worm shaft. 2. Gear operator shall be capable of rotating collection pipe 180 degrees in either direction. 3. All parts of operator shall be amply proportioned for all stresses that may occur during intermittent or continuous operation. 4. Thrust to actuate skimmer with operator shall not exceed 25 ft-lbs at handwheel. 5. Provide grease fittings to lubricate all necessary gears and bearings. Provide Type 316 stainless steel extensions accessible from walkways. 2.4 SHOP FABRICATION A. All pipe skimmer parts and accessories shall be accurately machined, conform to design dimensions and be free of defects of material and workmanship. All attaching bolt holes shall be drilled accurately to layout indicated on the drawings. B. All castings shall be free of defects that impair functionality. 2.5 SOURCE QUALITY CONTROL A. Shop Testing: 1. Rotating pipe skimmers shall be given manufacturer’s standard quality control inspections and tests to ensure the quality of materials used in the manufacture of the units and workmanship conform to specified requirements, and units operate properly. 2.6 SPARE PARTS A. Furnish the manufacturer's recommended spare parts for one year of normal operation and maintenance of the equipment. Spare parts shall include the following, as a minimum: 1. Two (2) D seals for each skimmer. 2. One (1) set of any special tools required for normal operation and maintenance. B. All spare parts shall be suitably packaged or boxed for long-term storage. Each part shall be clearly identified by part description, part number and other pertinent information or data. BCRUA – Phase 1D WTP Expansion Issued for Bid Rotating Pipe Skimmers 46 25 40 - 6 2.7 FINISHES A. All ferrous surfaces shall be shop cleaned and primed in accordance with Section 09 96 00. B. Passivate stainless steel per ASTM A380. PART 3 EXECUTION 3.1 INSTALLATION A. Section 01 61 03 – Common Requirements for Equipment: Installation requirements. B. Install as detailed on the Drawings and in accordance with the manufacturer's instructions and recommendations. 3.2 FIELD QUALITY CONTROL A. Section 01 40 00 – Quality Requirements. B. Sections 01 61 03 - Common Requirements for Equipment, 01 70 00 – Execution and Closeout Requirements, and 01 91 00 – Facility Commissioning: Testing, Startup, Demonstration, and Training requirements. C. Services of Manufacturer: 1. Reference Sections 01 61 03 – Common Requirements for Equipment, 01 70 00 – Execution and Closeout Requirements, and 01 91 00 – Facility Commissioning for general requirements. 2. Provide the services of a certified manufacturer’s representative specifically trained in the installation, start-up, testing, operation, and maintenance of specified equipment. Such services shall be provided by a representative who is a direct, full-time employee of the Manufacturer or their certified representative. 3. Services of equipment manufacturer's representative shall include: a. Inspect equipment covered by this Section. b. Supervise adjustments and installation checks. c. Provide test equipment, tools, and instruments necessary to accomplish equipment testing. d. Conduct initial check-out and start-up of equipment, perform operational checks, and supervise acceptance testing. e. Provide a written statement that manufacturer's equipment has been installed properly, started up and is ready for operation by Owner. f. Instruct Owner on operation and maintenance of furnished equipment. 4. Operation and maintenance training shall include the following at a minimum: a. Theory of operation. b. Step-by-step, “hands-on” assembly and disassembly procedural instructions. c. Replacement part identification and ordering procedures. d. Recommended routine maintenance procedures. e. Troubleshooting and diagnostic procedures. f. Equipment adjustment. BCRUA – Phase 1D WTP Expansion Issued for Bid Rotating Pipe Skimmers 46 25 40 - 7 5. Services of manufacturer’s representative shall be provided for the amount of time specified below. a. Supervision and start-up: 2 hours. b. Instruct Owner on operation and maintenance: 2 hours. END OF SECTION BCRUA – Phase 1D WTP Expansion Issued for Bid Peristaltic Transfer Pumps 46 33 44 - 1 SECTION 46 33 44 – PERISTALTIC TRANSFER PUMPS PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. Peristaltic hose pumps and appurtenances for liquid chemical transfer. B. Scope of Work: 1. The work under this Section includes the furnishing of all labor, materials, equipment, documentation, training and startup services for the manufacture and installation of peristaltic chemical transfer pumps suitable for application of chemicals as illustrated on the Drawings and specified herein. C. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Division 01 – General Requirements. 3. Section 01 91 00 – Facility Commissioning. 4. Division 40 – Process Integration. 5. Section 26 29 13.01 – Industrial Control Panels. 6. Section 43 21 00 – Common Requirements for Pumping Equipment. 7. Section 43 41 43 – Crosslinked Polyethylene Tanks. 1.2 REFERENCE STANDARDS A. American Gear Manufacturers Association (AGMA). B. American National Standards Institute (ANSI). C. American Society for Testing and Materials (ASTM): 1. A48, Standard Specification for Gray Iron Castings. 2. A126, Gray Iron Castings for Valves Flanges, and Pipe Fittings. D. American Bearing Manufacturers Association (ABMA). E. NSF International: 1. NSF 61 - Drinking Water System Components - Health Effects. 2. NSF 372 - Drinking Water System Components - Lead Content. 1.3 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. As specified in Section 43 21 00 – Common Requirements for Pumping Equipment: Submittal requirements for compliance with this Section. C. Shop Drawings: BCRUA – Phase 1D WTP Expansion Issued for Bid Peristaltic Transfer Pumps 46 33 44 - 2 1. All applicable items required in Sections 01 61 03 – Common Requirements for Equipment and 43 21 00 – Common Requirements for Pumping Equipment, including product data for equipment provided. 2. Detailed drawings of proposed chemical feed system layouts, including materials of construction, placements of pumps and accessories, and connection points to process piping and electrical components. 3. Refer to specification Section 26 29 13.01 - Industrial Control Panels for control panel submittal requirements. Control panels submitted that do not conform to this Section will be returned without review. 4. Submit a list of the manufacturers recommended spare parts, any special tools and lubricants. List shall include local source for supply of all parts and professional service. 5. Submit list of references for five projects where similar chemical metering systems have been in successful operation for a minimum of 2 years. 6. Submit a copy of each warranty and local parts/service center information. 1.4 CLOSEOUT SUBMITTALS A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for Operation and Maintenance Manual. B. Section 01 91 00 – Facility Commissioning: Closeout Submittal requirements. C. Project Record Documents: Record actual locations and final orientation of equipment. 1.5 QUALITY ASSURANCE A. All components and materials of peristaltic transfer pumps shall be compatible with the specified chemical service. B. All materials in contact with chemicals added to water being treated for potable use must be certified to NSF 61 and NSF 372. 1.6 QUALIFICATIONS A. Manufacturer Experience: 1. The manufacturer shall have a minimum of 5 years of experience with a successful record of manufacturing pumps as specified herein. 2. The manufacturer shall supply five separate references with contact names and phone numbers, where substantially similar installations for the equipment as specified have been in satisfactory operation for a minimum of two years. B. System Integrator: 1. Chemical feed systems using peristaltic pumps shall be designed, coordinated, supplied, and assembled by a competent system integrator. System integrator shall be regularly engaged in business of designing and assembling liquid chemical feed systems for WTP projects. System integrator shall be responsible for ensuring supply of complete, operational chemical feed systems, and shall coordinate mounting of all equipment, piping, valves and appurtenances for each system. BCRUA – Phase 1D WTP Expansion Issued for Bid Peristaltic Transfer Pumps 46 33 44 - 3 1.7 DELIVERY, STORAGE, AND HANDLING A. Reference Section 01 60 00 – Product Requirements and Section 43 21 00 – Common Requirements for Pumping Equipment. 1.8 EXISTING CONDITIONS A. Field Measurements: 1. Proposed transfer pumps will be installed in the existing Chemical Feed Area. 2. Verify existing space and field measurements prior to fabrication. 3. Indicate field measurements on Shop Drawings. 1.9 WARRANTY A. System integrator shall provide a two (2) year parts and labor warranty from Final Completion of chemical feed systems, including pumps, equipment, piping and valves. This warranty shall be in addition to and not in lieu of warranty provided by the manufacturer of the peristaltic pumps. PART 2 PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. Peristaltic Hose Pumps: 1. Prominent DulcoFlex DFC Series. 2. Verder Verderflex Dura Series. B. Diaphragm Seals: 1. Ashcroft. 2. Or approved equal. C. Pulsation Dampeners: 1. Primary Fluid Systems. 2. Or approved equal. D. Pressure Gauges: Reference Section 40 05 06 – Couplings, Adapters, and Specials for Process Piping. E. Submit substitutions in accordance with Section 01 25 00. 2.2 DESIGN AND PERFORMANCE REQUIREMENTS A. Hose Pump: 1. Tag numbers: CFA-FLTP-001, 002. 2. Pumped fluid: Hydrofluosilicic acid, 20-25% concentration. a. pH: 1.2. 3. Basis of design: Prominent DulcoFlex DFC60. 4. Flow rate: 25 gpm. a. Design: 25 gpm. BCRUA – Phase 1D WTP Expansion Issued for Bid Peristaltic Transfer Pumps 46 33 44 - 4 b. Maximum: 41.2 gpm. 5. Minimum suction lift: 16 feet (static). 6. Maximum discharge pressure: 30 psi. 7. Maximum driver horsepower: 3.0 hp. 8. Operating speed: a. Design: 28 rpm. b. Maximum: 100 rpm. 9. Drive type: Constant speed. 10. Motors: a. TEFC, severe duty. b. 230/460 VAC, 60 Hz, 3 Ph. c. Meet all applicable requirements of Section 01 61 03. 11. Hose diameter: 2 inch or as required by manufacturer. 12. Inlet/Outlet connection: a. Size: 2 inch. b. Type: ANSI 150# flange. 13. Orientation: Standard (right facing). 14. Rotor Assembly: a. Rollers shall have the ability to shim for compression adjustment. b. Mount rollers 180 Degrees apart. c. Rollers must be adjustable without removing housing cover or housing. d. Hose must be replaceable without removing pump from installed position. e. Pump housing liquid lubricant shall not be required. 15. Bearings: a. Use antifriction type, minimum ABMA B-10 life of 100,000 hours at maximum operating speed and pressure. 16. Performance requirements: a. Capable of self-priming and when completely dry, peristaltic pump must have lift capability to pump from associated bulk storage tank, which will have top penetration outlet for transfer pump suction. b. Capable of operation in either direction without flow variation. c. Continuous operation. d. Capable of running dry without damage to pump or hose. e. Capable of pulling 95 percent of full vacuum. f. Provide pump head housing capable of rotation in 90-degree increments. g. Valve-less/glandless with no dynamic seals in contact with the pump product. 2.3 MATERIALS A. Pump manufacturer shall confirm material compatibility with pumped fluid. B. Hose Pump: 1. Pump body/housing: Cast iron, ASTM A48, Class 40. 2. Pump cover: Carbon steel with acrylic view port; include breather cap and Buna-N O- ring seal. 3. Integral bearing: Steel, minimum 125,000 psi yield strength. 4. Shaft: Steel SAE 1045, minimum 125,000 psi yield strength with two-way seals. 5. Rotor Assembly: a. Rotor: Cast iron, ASTM A48, Class 40 or Type 316 stainless steel. b. Rollers and Shims: Type 316 stainless steel. BCRUA – Phase 1D WTP Expansion Issued for Bid Peristaltic Transfer Pumps 46 33 44 - 5 6. Coupling: a. Elastomeric type. 1) Sleeves: Polypropylene. 7. Flanges: PVDF. 8. Hose: a. EPDM. b. Burst rating: 600 psi. c. 53 – 68 shore durometer. 9. Base: Painted steel. 10. Hardware: Stainless steel. 2.4 ACCESSORIES A. Provide the following accessories for Hose Pumps: 1. Provide leak detection system to detect hose failure with automatic pump shutoff capabilities. 2. If required, provide single diaphragm type pulsation dampener with isolation ball valve on each pump discharge sized for pump capacity and medium pumped. a. Dampener shall be air-charged type with pressure gauge to indicate charge pressure and dampening effectiveness. Initial charge shall be set by the System Integrator and noted on Certificate of Proper Installation. b. Dampener shall be sized by pump manufacturer based on pump’s displacement (gallons) per revolution. c. Dampener materials: 1) Body: Type 316L stainless steel. 2) Bellows: Viton. 3. Isolation and process valves shall be as indicated on the Drawings and as specified in applicable sections. 4. Control panel: a. Each pump shall have a dedicated control panel with a main circuit breaker, motor starter, CPT, AC to DC power supplies, pushbuttons, indication lights and necessary relays for a fully operational system. b. Each control panel shall have a single power supply to power and control the pump. Convert incoming power as needed. c. Install where shown on Drawings. d. Refer to Drawings for panel control schematic. e. Provide the following form c contacts for signals to be sent to plant SCADA: 1) Running. 2) Leak. 3) High Pressure. f. Coordinate all control requirements with Division 40. g. Construction of control panels shall meet requirements of Section 26 29 13.01 – Industrial Control Panels. Control panel enclosures shall be NEMA 4X rated, Type 316 stainless steel construction. 2.5 FINISHES A. Manufacturer shall provide factory prime and finish paint system for all surfaces scheduled for painting. BCRUA – Phase 1D WTP Expansion Issued for Bid Peristaltic Transfer Pumps 46 33 44 - 6 1. Pump housing and cover shall be factory coated with Halar ECTFE (ethylene chlorotrifluoroethylene) for chemical service. B. Do not prime or paint stainless steel, plastic, aluminum, packing glands, flexible connectors, and mechanical mating and bearing surfaces. 2.6 SOURCE QUALITY CONTROL A. As specified in Section 43 21 00 – Common Requirements for Pumping Equipment. B. Pumps shall be given manufacturer’s standard quality control inspections and tests to ensure the quality of materials used in the manufacture of the units and workmanship conform to the specified requirements and highest industry practice, the units operate properly, and the units have been correctly and adequately prepared for shipment, long term site storage and initial operation. 2.7 SPARE PARTS A. Furnish the manufacturer's recommended spare parts for two years of normal operation and maintenance of the equipment. Spare parts shall include the following as a minimum: 1. Two hoses per pump. 2. One year supply of lubricant assuming continuous operation. 3. Provide any other materials or parts that require replacement more than once every 2 years under normal operating conditions. 4. Provide any special tools necessary to maintain the pumps. B. All spare parts shall be suitably packaged or boxed for long-term storage. Each part shall be clearly identified by part description, part number, and other pertinent information or data. PART 3 EXECUTION 3.1 INSTALLATION A. Comply with requirements of Sections 01 61 03 – Common Requirements for Equipment and 43 21 00 – Common Requirements for Pumping Equipment. B. Install as detailed on the Drawings. C. Pumps shall be installed in accordance with the manufacturer's instructions and recommendations. Field installation of chemical feed systems shall be supervised by System Integrator. 3.2 FIELD QUALITY CONTROL A. Section 01 40 00 – Quality Requirements. B. Sections 01 61 03 – Common Requirements for Equipment, 01 70 00 – Execution and Closeout Requirements, and 01 91 00 – Facility Commissioning: Testing, Startup, Demonstration, and Training requirements. BCRUA – Phase 1D WTP Expansion Issued for Bid Peristaltic Transfer Pumps 46 33 44 - 7 C. Acceptance Testing: 1. After the chemical feed systems have been completely installed and the installation approved by the System Integrator, and after acceptance by the Engineer, all pumps shall be tested under the supervision of an appropriately suited third party to oversee functionality and performance testing. Pumps shall be field tested to verify that the performance and functionality, including all controls, statuses,, and interlocks of all system components conforms to design requirements. 2. In the event the pumps fail to meet the requirements specified above, necessary changes shall be made and the pumps retested. If pumps remain unable to meet the specified requirements to the satisfaction of the Owner, pumps shall be removed and replaced with satisfactory pumps at no cost to the Owner. D. Services of Manufacturer: 1. Reference Sections 01 61 03 – Common Requirements for Equipment, 01 70 00 – Execution and Closeout Requirements, 01 91 00 – Facility Commissioning , and 43 21 00 – Common Requirements for Pumping Equipment for general requirements. 2. Provide the services of a Technician specifically trained in the installation, start-up, testing, operation, and maintenance of the equipment specified herein. Such services shall be provided by a person who is a direct, full-time employee of the Manufacturer or their certified representative. 3. Services of Technician: Reference Section 43 21 00 – Common Requirements for Pumping Equipment. 4. Operation and maintenance training shall include the following at a minimum: a. Theory of operation. b. Step-by-step start-up and shutdown procedures. c. Step-by-step, “hands-on” assembly and disassembly procedural instructions. d. Replacement part identification and ordering procedures. e. Recommended routine maintenance procedures. f. Troubleshooting and diagnostic procedures. g. Instrument adjustment. 5. Services of Technician shall be provided for the amount of time specified below. a. Supervision and start-up: 8 hours. b. Instruct Owner on operation and maintenance: 8 hours (2 sessions, 4 hours each). END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid Liquid Chemical Diffusers 46 33 73 - 1 SECTION 46 33 73 – LIQUID CHEMICAL DIFFUSERS PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Open-channel liquid chemical diffusers. 2. Control panel. B. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Division 01 – General Requirements. 3. Section 10 14 00 – Identification for Process Piping and Equipment. 4. Section 26 29 13.01 – Industrial Control Panels. 1.2 REFERENCE STANDARDS A. NSF International: 1. NSF 61 - Drinking Water System Components - Health Effects. 2. NSF 372 - Drinking Water System Components - Lead Content. 1.3 COORDINATION A. Section 01 30 00 – Administrative Requirements: Requirements for coordination. 1.4 SUBMITTALS A. See Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Product Data: 1. Submit manufacturer information for system materials and component equipment, including performance characteristics. C. Shop Drawings: 1. See Section 01 61 03 – Common Requirements for Equipment for applicable shop drawing submittal requirements. 2. Complete bill of materials. 3. Indicate system materials and component equipment. Submit dimensional drawings, including anchor bolt layout, for each component of the system. 4. Electrical Schematic showing control panel layout and wiring diagrams in sufficient detail to allow installation of instrumentation and controls, and electrical components. Include control panel front elevation showing all face-mounted instruments. 5. Motor Data a. For each motor, furnish a certified complete nameplate motor data sheet for the actual motor. b. Special features (i.e. space heaters and space heater wattage, corrosion resistant features, leak detection, thermostats, etc.) 6. Electrical wiring diagram of each component supplied. BCRUA - Phase 1D WTP Expansion Issued for Bid Liquid Chemical Diffusers 46 33 73 - 2 7. Refer to specification Section 26 29 13.01, Industrial Control Panels for control panel submittal requirements. Control panels submitted that do not conform to this Section will be returned without review. 8. Project specific control details and electrical schematic diagrams and wiring diagrams. 9. Submit detailed instructions on installation requirements, including storage and handling procedures. 10. Submit qualifications for manufacturer. 11. Warranty information. D. Source Quality-Control Submittals: 1. Manufacturer's Certificate: Certify that products meet or exceed specified requirements. 2. Submit results of factory tests of equipment at the time of shipment. E. Field Quality-Control Submittals: 1. As specified in Sections 01 33 00, 01 61 03 and 01 91 00. 2. Indicate results of Contractor-furnished tests and inspections. 3. Certify that equipment has been installed according to manufacturer instructions. 1.5 CLOSEOUT SUBMITTALS A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for Operation and Maintenance Manuals. B. Project Record Documents: Record actual locations and final orientation of equipment. 1.6 QUALITY ASSURANCE A. Materials in Contact with Potable Water: Certified to NSF 61 and NSF 372. B. All system components shall be supplied to the Contractor by a single Manufacturer. C. Manufacturer shall operate, test, and adjust each chemical diffuser to ensure proper assembly and operation prior to shipment. D. The Manufacturer shall submit results of factory tests of equipment at the time of shipment. Testing records shall include motor amperage draw, maximum liquid flow rate produced, and peak amperage draw at dead-head conditions. 1.7 QUALIFICATIONS A. Manufacturer: Company specializing in manufacturing products specified in this Section with minimum ten years' experience. 1.8 DELIVERY, STORAGE, AND HANDLING A. Section 01 60 00 – Product Requirements: Requirements for transporting, handling, storing, and protecting products. B. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage. BCRUA - Phase 1D WTP Expansion Issued for Bid Liquid Chemical Diffusers 46 33 73 - 3 C. Store materials according to manufacturer instructions. D. Protection: 1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas. 2. Provide additional protection according to manufacturer instructions. 1.9 EXISTING CONDITIONS A. Field Measurements: 1. Verify field measurements prior to fabrication. 2. Indicate field measurements on Shop Drawings. B. Service Conditions: 1. Proposed chemical mixer will be installed below an underflow baffle wall in the existing Disinfection Basin at the BCRUA water treatment plant (WTP) as indicated on Drawings. Manufacturer shall satisfy themselves with arrangement shown and specified requirements. WTP flow rates and corresponding flow velocities in the Disinfection Basin at the proposed mixer location are summarized below. a. Current Minimum (Occurs during winter months): 1) Flow: 8 million gallons per day (MGD). 2) Velocity: 0.16 feet per second (ft/sec). b. Phase 1D Design: 1) Flow: 42 MGD. 2) Velocity: 0.71 ft/sec. c. Future Maximum: 1) Flow: 106 MGD. 2) Velocity: 1.58 ft/sec. 2. The Disinfection Basin disinfects filtered water produced by the WTP, which withdraws raw surface water from Lake Travis. Raw water characteristics are summarized below: a. Temperature (ºF): 1) Minimum: 50. 2) Average: 72. 3) Maximum: 90. b. pH: 1) Minimum: 7.9. 2) Average: 8.3. 3) Maximum: 8.9. c. Alkalinity (mg/L): 1) Minimum: 151. 2) Average: 156. 3) Maximum: 161. 3. Liquid sodium hypochlorite (12.5%) will be pumped to the proposed chemical mixer by existing peristaltic feed pumps located in the Disinfection Facility. Chemical feed pipe diameter is 1-inch. 1.10 WARRANTY A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for warranties. BCRUA - Phase 1D WTP Expansion Issued for Bid Liquid Chemical Diffusers 46 33 73 - 4 B. Reference Section 00700 – General Conditions, Article 7.17 for warranty terms. PART 2 - PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. Open-Channel Liquid Chemical Diffusers: 1. Evoqua Water Technologies; Water Champ Model 15FX. 2. The MASTRRR Company; GAS MASTRRR Model 32 PT-15. B. Lifting Device: 1. Thern, Inc. 2. Or approved equal. C. Submit substitutions in accordance with Section 01 25 00. 2.2 GENERAL REQUIREMENTS A. Tag Number: DB-SHM-001. B. Chemical mixing unit shall be: 1. Able to mix the liquid chemical to be fed from the source to the point of application at or above the minimum flow rate required to operate the chemical feed equipment. 2. Capable of diffusing the chemical into the water stream at a velocity of approximately 60 ft/sec without requiring pre-dilution before contact with the eye of the propeller. Unit shall be capable of dispersing the chemical within an axial discharge pattern, as created by the rotating propeller. 3. Sized using a minimum mixing ratio of 0.5 HP/MGD unless a lower mixing ratio can be substantiated by results from performance testing by a recognized independent agency. 4. Sodium hypochlorite chemical shall be fed through an external titanium chemical feed pipe assembly to prevent the potential of chemical scale build-up on the shaft or propeller. 2.3 PERFORMANCE AND DESIGN CRITERIA A. Process: 1. Process Liquid: Filtered water. 2. Chemical: Liquid sodium hypochlorite (12.5%). 3. Chemical Feed Rate: a. Average: 72 gallons per hour (gph). b. Maximum: 235 gph. B. Liquid Chemical Diffuser: 1. Induction Capacity: 50 gpm. 2. Installation Orientation: Horizontal. 3. Approximate Submergence: 15 feet. 4. Approximate Dimensions: 6-inch diameter x 37-inch length. a. Capable of installation through roof access hatch as illustrated on Drawings. Propeller Type: Exposed, four bladed airfoil design, high camber. 5. Shaft: a. Close-coupled. BCRUA - Phase 1D WTP Expansion Issued for Bid Liquid Chemical Diffusers 46 33 73 - 5 b. Sealed from the chemical process and utilize a hardened disc of compatible material and appropriate thickness to absorb shaft end play. 6. Motor: a. 15 HP maximum. b. Constant speed, maximum 3450 rpm. c. Electrical supply: 460 volt, 3 phase, 60 Hz. d. Service Factor: 1.15. e. Class F insulation. f. Continuous duty. g. Enclosure: Submersible, hermetically sealed, externally water cooled. h. Motor shall have a splined shaft, 15 tooth 16/32 diametral pitch, with a mechanical seal using silicon carbide seal faces. i. Windings shall be hermetically sealed and resin filled. j. Electrical cable connection shall be through a removable water-block lead connector that is field replaceable. k. Thrust bearing shall be designed for a minimum of 3500 lbs. l. The motor, cable, and electrical controls shall be sized, furnished, and installed so that the motor shall never exceed the nameplate rating at any point on the pumping curve. 7. Power Cables: a. Diffuser shall be furnished complete with submersible type power cable. b. Length: As required for installation. Refer to Drawings and coordinate with Contractor for length needed. c. Provide stainless steel cable strain relief on cable on the Disinfection Basin roof slab. d. Cable shall have UL and/or CSA approved insulation. e. Cable shall be four conductor, copper and shall be sized per NFPA 70. 8. Feed Hose Assembly: a. Diameter: 1-inch. b. Length: As required for installation. c. Shall accommodate a maximum chemical feed rate of 15 gallons/minute liquid. d. Hose shall be fitted with OPW Kamlok or equal fittings on each end. e. Hose shall have smooth inside bore with helically wound reinforcement. f. Include both hose shank couplers on all hose and the male adapters which will be connected to the chemical feed piping, including a backpressure valve and diaphragm check valve to help minimize gravity flow of chemical. 2.4 MATERIALS A. All wetted parts of induction mixer system, or material coming in direct contact with non-diluted chemical, shall be made of titanium. B. Piping Connection on Mixer: Grade 2 (unalloyed) titanium. C. Mixing Chamber Housing: Grade 2 (unalloyed) titanium. D. Shaft: Grade 5, (Ti-6Al-4V) titanium, case hardened to 45R. E. Propeller: Grade 2 (unalloyed) titanium. F. Motor Casing: All 316 stainless steel. BCRUA - Phase 1D WTP Expansion Issued for Bid Liquid Chemical Diffusers 46 33 73 - 6 G. Fasteners: Type 316 stainless steel. H. Mounting System: 1. Guiderail and Supports, Lifting Cable, Bolts & Fasteners: Type 316 stainless steel. I. Feed Hose: Braided PVC tubing. J. Control Panel Enclosure: NEMA 4X Type 316 stainless steel. 2.5 MOUNTING SYSTEM A. Reference Drawings for general configuration. B. Components: 1. Guiderail: a. The manufacturer shall supply one guide rail system for each mixer as recommended by the manufacturer of sufficient length to raise the entire mixing unit above the mounting elevation as indicated on the Drawings for service and removal. b. Guiderail shall include a pivot bracket assembly that will guide the mixer along the guiderail and allow the unit to pivot and/or remain fixed in the proper orientation when in operation. 2. Lifting Device: a. Stationary davit crane with hand operated winch that shall include a manual stop device and free-fall brake. The crane and winch shall be rated for at least two times the weight of the chemical mixing unit. b. Lifting device shall have sufficient hook reach and height to provide adequate clearance with adjacent work (open access hatch doors, etc.) to enable removal of chemical mixing unit from Disinfection Basin. c. Lifting cable shall be rated for lifting at least two times the weight of the chemical mixing unit. 3. Mounting Bolts: a. Provide adhesive anchor bolts of the size recommended by the lifting device manufacturer. 2.6 MOTOR CONTROL PANEL (MCP) A. Functional Requirements: 1. Provide a control panel in accordance with the mixer manufacturer's standard specification, unless noted otherwise. 2. Each mixer shall be provided with a prewired Motor Control Panel (MCP) with a submersible motor protection system as recommended by the manufacturer. 3. The control panel shall be sized to match the voltage and horsepower of the motor to be controlled. 4. The control panel shall have a hand-off-automatic control switch, hour meter and status indicating pilot lights for run and stop. 5. Provide the following dry contacts: a. In Auto. b. Running. c. Common Alarm, consisting of motor overloads tripped and alarm for motor protection device activated, leak detected (If leak detection provided by manufacturer). BCRUA - Phase 1D WTP Expansion Issued for Bid Liquid Chemical Diffusers 46 33 73 - 7 6. A low level float switch shall be provided by Contractor. When the low level float switch is activated due to low basin water level, the float switch shall be wired to control panel so that the mixer will shutdown. Control panel shall include a low level reset timing relay so that upon the float switch deactivating due to rising water level, the mixer will restart only after the timing relay clears. B. Control Functions: 1. Under normal operating conditions the control panel shall function to control the start and stop action of the mixer, either locally or remotely. 2. The control panel shall function to monitor the mixer for overcurrent, undercurrent, high temperature, rapid cycling and shall respond by tripping the starter/contactor off line whenever a fault occurs. 3. Each motor shall be provided with a microprocessor based submersible Motor Protection Device, or MPD. The submersible motor protection device shall be: a. Designed to shut down the mixer. b. Capable of automatically restarting the mixer after a recovery period. If after restart the same condition exists, the mixer shall be automatically shut down an additional two times with timed intervals between restarts. After third shut down occurs, the submersible motor protection system shall require a manual reset. c. Designed to have a lighted display identifying motor status, high temperature, overload, underload, and alarm conditions. 4. The control panel shall have a non-resettable, mechanical type hour meter. Battery operated LCD type will not be acceptable. Hour meter shall record hours of operation while the motor is running up to 99,999.0 hours before automatically resetting to zero. 5. The control panel shall be provided with a three phase fused, lockable disconnect switch. The disconnect operator shall indicate status and not allow the inner panel door to be opened while the switch is in the on position. 6. The control panel shall provide a contact brought to field terminals for alarm condition to be monitored remotely. 7. The control panel shall be provided with contacts brought to field terminals for remote alarm monitoring of run and stop status. 8. The panel shall be provided with a surge arrestor which exceeds ANSI/IEEE standard C62.11. 9. Provide a phase failure relay. Relay shall open control circuit when relay detects loss of phase, phase reversal, and over and under voltage. 10. Doors shall have continuous heavy-duty piano hinge with stainless steel hinge pins and a foamed polyurethane gasket with tongue and groove labyrinth at all seal points. 11. All operator usable functions shall be located behind the main door on a separate hinged control panel. The main door shall have a window large enough to view all operation functions and diagnostics. The main door shall have non-locking stainless steel latches. 12. All non-operator maintained parts and devices shall be located directly behind the control panel on a metallic back panel. All parts shall have easy access. 13. All exposed metallic hardware components of the panel shall have grounding bonds to the main field grounding connection. 14. The enclosure shall have integral wall mounting flanges. 15. All wiring shall be color coded and plainly marked at all terminations. a. Black wire for all live power conductors. b. White wire for all neutral conductors. c. Green wire for all ground conductors. d. Red wire for all control circuits. BCRUA - Phase 1D WTP Expansion Issued for Bid Liquid Chemical Diffusers 46 33 73 - 8 e. Yellow wire for all circuits not de-energized when the panel disconnect is opened. 16. Wires shall be routed within wireway as much as possible. 17. Terminal blocks shall be rail mountable type. All terminal blocks shall be consecutively numbered. 18. Provide spare terminal blocks. 19. No mounting or fastening hardware other than conduit penetration shall penetrate the enclosure other than that supplied by the enclosure manufacturer. 20. A warning label shall be provided in plain sight to alert maintenance personnel of potential live circuits even when the main disconnect is open C. Design: 1. The control panel enclosure shall be fabricated to meet NEMA 4X standards with lockable disconnect. 2. The control panel shall be built in accordance with UL-508 standards and shall be UL labeled. D. Features: 1. Input power shall be 460 VAC, 3 phase, 60 Hz. 2. Disconnect shall be rated for 600 VAC. Wiring shall be copper and rated for 600 VAC, 105 degrees C. Terminal blocks shall be rated for 600 VAC on motor power circuits and 300 VAC for control circuits. 3. Fuses shall be rated 600 VAC. 2.7 SPARE PARTS A. At a minimum, manufacturer shall provide the following spare parts: 1. One (1) preventative maintenance kit. 2. One (1) feed hose with fittings. 3. One (1) set of quick disconnect seals. 4. One (1) shelf spare mixing unit with pivot bracket and any other appurtenances required for quick and easy replacement. 5. One (1) set of each fuse type, minimum of three fuses of each type. B. Spare parts shall be properly packed and labeled according to manufacturer part number. PART 3 - EXECUTION 3.1 EXAMINATION A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for installation examination. B. Verify layout, type, material, and orientation of piping connections. 3.2 INSTALLATION A. Reference Section 01 61 03 – Common Requirements for Equipment for general requirements. B. According to manufacturer instructions and as indicated on Drawings. BCRUA - Phase 1D WTP Expansion Issued for Bid Liquid Chemical Diffusers 46 33 73 - 9 3.3 FIELD QUALITY CONTROL A. Reference Sections 01 40 00 - Quality Requirements, 01 61 03 - Common Requirements for Equipment , 01 70 00 – Execution and Closeout Requirements for inspecting and testing, and Section 01 91 00 – Facility Commissioning. B. Equipment Acceptance: 1. Adjust, repair, modify, or replace components failing to perform as specified and rerun tests. 2. Make final adjustments to equipment under direction of manufacturer's representative. C. Services of Manufacturer: 1. Reference Sections 01 61 03 and 01 91 00 for general requirements. 2. Provide the services of a manufacturer’s representative specifically trained in the installation, testing, and maintenance of equipment specified. Such services shall be provided by a representative who is a direct, full-time employee of the manufacturer or their certified representative. 3. Services of equipment manufacturer's representative shall include: a. Inspect equipment covered by this Section. b. Supervise adjustments and installation checks. c. Provide test equipment, tools, and instruments necessary to accomplish equipment testing. d. Conduct initial start-up of equipment, perform operational checks, and supervise acceptance testing. e. Provide a written statement that manufacturer's equipment has been installed properly, started up and is ready for operation by Owner. f. Instruct Owner on operation and maintenance of furnished equipment. 4. Operation and maintenance training shall include the following, at a minimum: a. Theory of operation. b. Troubleshooting guidance. c. Step-by-step start-up and shut-down procedures. d. Step-by-step, “hands-on” assembly and disassembly procedural instructions. e. Replacement part identification and ordering procedures. f. Recommended routine maintenance procedures. g. Troubleshooting and diagnostic procedures. h. Instrument adjustment. 5. Services of manufacturer's representative shall be provided for the amount of time specified below. a. Supervision, start up, and testing: 8 hours. b. Instruct Owner on operation and maintenance: 8 hours (2 sessions, 4 hours each). END OF SECTION BCRUA – Phase 1D WTP Expansion Issued for Bid Vertical Shaft Flocculators 46 41 34 - 1 SECTION 46 41 34 – VERTICAL SHAFT FLOCCULATORS PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. Vertical Shaft Flocculators. B. Scope of Work: 1. Furnish all labor, material, equipment and incidentals required to install, ready for operation, vertical shaft flocculators for six (6) flocculation basins as detailed on the Drawings and specified herein. 2. The flocculators shall be furnished and installed with all necessary accessory equipment and auxiliaries as required for a complete, operational installation. 3. Variable frequency drives (VFDs) shall meet the requirements of Section 26 29 23 and drive motors shall meet the requirements of Section 01 61 03. The flocculator manufacturer shall coordinate VFD requirements with VFD supplier. C. System Description: 1. Six (6) vertical shaft type flocculators shall be furnished and installed in the flocculation basins as detailed on the Drawings. All units shall be of the same design and manufacturer. The units shall consist of an axial flow impeller mounted to a vertical shaft, which is coupled to and driven by a base-mounted gear reducer and horizontally or vertically mounted drive motor controlled by a VFD. The units shall be complete and shall consist of drive motor and support, gear reducer assembly, mounting pedestal and base plate for connection to a concrete bridge, anchor bolts, couplings and guards, shafting and impeller assembly. 2. Each inverter duty rated motor shall be controlled by a VFD. The VFDs shall be provided under Section 26 29 23. D. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Division 01 – General Requirements. 3. Section 01 91 00 – Facility Commissioning. 4. Division 03 – Concrete. 5. Section 09 96 00 – High-Performance Coatings. 6. Division 26 – Electrical. 7. Section 26 29 23 – Low Voltage Variable Frequency Drives. 8. Division 40 – Process Integration. 1.2 REFERENCE STANDARDS A. Anti-Friction Bearing Manufacturers Association (AFBMA). B. American Gear Manufacturers Association, Inc. (AGMA). 1. AGMA 297.01 - Sound for Enclosed Helical, Herringbone, and Spiral Bevel Gear Drives. 2. AGMA 390.03 - Gear Handbook Volume 1: Gear Classification, Materials and Measuring Methods for Unassembled Gears. BCRUA – Phase 1D WTP Expansion Issued for Bid Vertical Shaft Flocculators 46 41 34 - 2 3. AGMA 420.04 - Enclosed Speed Reducers or Increasers Using Spur, Helical, Herringbone and Spiral Bevel Gears. 4. AGMA 6010.E - Standard for Spur, Helical, Herringbone and Bevel Enclosed Drives. C. NSF International: 1. NSF 61 - Drinking Water System Components - Health Effects. 2. NSF 372 - Drinking Water System Components - Lead Content. 1.3 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Product Data: 1. Submit manufacturer information for system materials and component equipment, including performance characteristics. 2. Include descriptive literature, bulletins, and/or catalogs of the equipment. 3. Include the total weight of the equipment including the weight of the single largest item or component. a. The weight of each component: motor, gearbox, shafting and impeller. 4. Provide a complete total bill of materials for all equipment. 5. Motor: a. Complete nameplate data. b. Special features (i.e., space heaters and space heater wattage, corrosion resistant features, etc.). 6. Electrical wiring diagram of each component supplied. 7. Design data: a. Design calculations demonstrating that the equipment process design requirements are met. Design loads including vertical download, torque and bending moment imposed by the flocculator on the support system C. Shop Drawings: 1. Section 01 61 03 – Common Requirements for Equipment: Shop drawing submittal requirements. 2. Submit drawings showing details of construction, dimensions, weld requirements, and anchor bolt layout for each component of the system. 3. Provide complete description of surface preparation and shop prime painting, including certification that the paint to be used to shop prime the equipment is compatible with the finish coat paint to be applied to the equipment. 4. Submit detailed instructions on installation requirements, including storage and handling procedures. 5. Submit qualifications for manufacturer. 6. Refer to specification Section 26 29 13.01 - Industrial Control Panels for control panel submittal requirements. Control panels submitted that do not conform to this Section will be returned without review. 7. Project specific control details and electrical schematic and wiring diagrams. 8. Warranty information. D. Source Quality-Control Submittals: 1. Manufacturer's Certificate: Certify that products meet or exceed specified requirements. a. Section 01 33 00 – Submittal Procedures: Supplement 01. BCRUA – Phase 1D WTP Expansion Issued for Bid Vertical Shaft Flocculators 46 41 34 - 3 2. Section 01 61 03 – Common Requirements for Equipment: Submittal requirements. 3. Submit results of factory tests of equipment. 4. Certified letter that the VFD being furnished is of proper size and will properly function over the operating range with the motor being furnished. E. Field Quality-Control Submittals: 1. Section 01 33 00 - Submittal Procedures: Supplements 02 and 03. 2. Section 01 61 03 – Common Requirements for Equipment: Submittal requirements. 3. Section 01 91 00 – Facility Commissioning: Submittal requirements. 4. Indicate results of Contractor-furnished tests and inspections. 5. Certify that equipment has been installed according to manufacturer instructions. 1.4 CLOSEOUT SUBMITTALS A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for Operation and Maintenance Manual. 1. Operating and maintenance manuals shall be prepared specifically for this installation and shall include all required cuts, drawings, equipment lists, descriptions, etc. that are required to instruct operating and maintenance personnel. B. Section 01 91 00 – Facility Commissioning: Closeout Submittal requirements. C. Project Record Documents: Record actual locations and final orientation of equipment. 1.5 QUALITY ASSURANCE A. The equipment covered by this Section shall be furnished by one manufacturer and shall be complete, including motor suitable for VFD controlled operation. The equipment shall be the product of a manufacturer regularly engaged in the production of flocculation equipment for the specified use. The manufacturer shall have the sole responsibility for the proper functioning of the equipment as furnished. B. All components that contact process water shall be ANSI/NSF 61 approved. 1.6 DELIVERY, STORAGE AND HANDLING A. Reference Section 01 60 00 – Product Requirements. B. Factory assembled parts and components shall not be disassembled for shipment unless permission is received in writing from the Engineer. C. Finished iron and steel surfaces not painted shall be properly protected to prevent rust and corrosion. D. All equipment parts shall be properly protected so that no damage or deterioration will occur during shipment or prolonged delay from the time of shipment until installation is completed and the equipment is ready for operation. E. All equipment and parts shall be properly protected against damage and deterioration during prolonged storage at the site. BCRUA – Phase 1D WTP Expansion Issued for Bid Vertical Shaft Flocculators 46 41 34 - 4 1.7 EXISTING CONDITIONS A. Field Measurements: 1. Verify field measurements prior to fabrication. 2. Indicate field measurements on Shop Drawings. 1.8 WARRANTY A. Reference Section 00700 – General Conditions, Article 7.17. PART 2 PRODUCTS 2.1 GENERAL A. Tag Numbers: TSC-FL-07A, TSC-FL-07B, TSC-FL-07C, TSC-FL-08A, TSC-FL-08B and TSC-FL-8C. B. This Section is intended to give a general description of what is required, but does not cover all details, which may vary in accordance with the exact requirements of the equipment as offered. It is, however, intended to cover the furnishing, delivery, installation, field testing and field calibration of all materials and appurtenances as required. All additional equipment necessary for the proper operation of the proposed installation not specifically mentioned in this Section or shown on the Drawings shall be furnished and installed at no additional cost to the Owner. C. Reference is made to Section 01 61 03 for additional requirements for equipment, especially concerning motors, equipment settings, nameplates, etc. D. Each drive assembly shall be designed and built for 24 hours per day continuous service and shall be of adequate capacity to supply the required power and torque output over the entire range of speed settings. The drive assemblies shall be suitable for outdoor use and shall be of weatherproof construction, protected so water, dust, temperature, and dirt will not interfere with its proper operation. E. Flocculators shall be pedestal type units. F. Equipment weighing over 100 pounds shall be provided with lifting lugs. G. Stainless steel nameplates giving the name of the manufacturer, equipment model number, speed, rated capacity, and other pertinent data shall be attached to each flocculator unit and motor. 2.2 ACCEPTABLE MANUFACTURERS A. Vertical Shaft Flocculators: 1. Hayward Gordon. 2. Lightnin. 3. Philadelphia. BCRUA – Phase 1D WTP Expansion Issued for Bid Vertical Shaft Flocculators 46 41 34 - 5 B. Submit substitutions in accordance with Section 01 25 00. 2.3 DESIGN REQUIREMENTS A. The flocculator units shall meet all design criteria and requirements, and shall be designed to transmit to the water the velocity gradient "G" values as specified below. Calculations shall be submitted with shop drawings to substantiate that the equipment proposed will transmit the required energy to the water. The impellers shall impart mixing action over the entire volume of each flocculation basin compartment with a minimum of shear at the impeller. The flocculators shall be designed and powered to meet the following conditions. 1. Process liquid: Raw surface water with chemicals added. 2. Process chemicals: a. Primary coagulant: Aluminum Chlorohydrate. 1) Average dose: 14 mg/L. b. Coagulant aid: Cationic Polymer. 1) Average dose: 1.5 mg/L. c. Primary oxidant: Sodium Permanganate. 1) Average dose: 0.5 mg/L. 3. Number of Flocculators: 6 (2 trains, 3 stages each). 4. Individual Flocculation Compartment Volume: 14.5-FT by 14.5-FT by 16.53-FT side water depth. 5. Flocculator Drive: Electric motor drive with VFD controller. 6. Velocity Gradient G (sec-1): 70 to 5 in 50 °F water. 7. Minimum Pumping Capacity (at G = 70 sec-1): 17,500 gpm. 8. Minimum Pumping Capacity (at G = 5 sec-1): 3,000 gpm. B. Hydrofoil Flocculator: 1. Motor: 2 HP, 1200 rpm max., TEFC, 480 V, 3-phase, 60 Hz, inverter duty, premium efficiency (without power factor correction capacitors), 1.15 service factor, with winding temperature detectors. 2. Flow Direction: Downward pumping. 3. Maximum Tip Speed: 8.0 fps. 4. Minimum Impeller Height Above Basin Floor: 60-IN. 5. Maximum Impeller Diameter: 80-IN. 6. Maximum Impeller Speed: 30 rpm. 7. Impeller Type: 3 or 4 blade Hydrofoil. 2.4 MATERIALS A. All submerged components, including shafting, studs, bolts, washers, and cap screws shall be Type 316 stainless steel. Nuts shall be stainless steel of lesser hardness than the bolts to prevent galling. B. Impeller: 1. Hydrofoil: 316 stainless steel. C. Equipment anchor bolts and washers shall be Type 316 stainless steel. Nuts shall be stainless steel of lesser hardness than the bolts to prevent galling. BCRUA – Phase 1D WTP Expansion Issued for Bid Vertical Shaft Flocculators 46 41 34 - 6 2.5 DRIVE ASSEMBLY A. Flocculator gear reducers shall be helical gear or a combination of helical and spiral bevel gearing in a housing of either high quality close-grained cast iron or stress-relieved and reinforced fabricated steel. The reducer output shaft shall be directly connected to impeller shaft. The gear reducer shall be constructed in accordance with AGMA 420.04. The reducer shall be suitable for AGMA Class II 24-hour continuous service under moderate shock conditions. Each bearing incorporated within the reducer shall be of the anti-friction type having a minimum B-10 life of 100,000 hours based on the latest AFBMA Standards when operating continuously at the maximum rated motor horsepower and speed. All gearing shall be contained within a single housing and shall be lubricated by a common oil bath. Worm gears and/or planetary gear assemblies are not acceptable. B. The gear reducers shall be a parallel-shaft or horizontal right-angle type, triple reduction design, with the reduction gearing in a single housing. Combination gear reducer output shafting shall consist of oversized solid output shaft supported by tapered roller bearings located above and below the main spiral bevel output gear. Oversized output shaft shall have a minimum AGMA service factor of 2.0 based on the drive motor nameplate horsepower. Output shaft from the gear drive shall be larger in diameter than impeller shaft. Gears shall be alloy steel precision generated and hardened, and shall have a minimum AGMA 390.03 quality number 10 or greater. All bevel gears shall be lapped as matched pairs. All gears shall be rated in accordance with AGMA 601O-E88. The AGMA calculated drive horsepower rating shall be stamped on the nameplate affixed to the gear reduction housing. C. Gear reducer bearings shall be oil lubricated by immersion in a food grade oil bath, or by splash lubrication accomplished by means of gears or a slinger rotating on a horizontal shaft in an oil bath to ensure the positive displacement of oil to lubricate all critical bearings. Oil pumps will not be allowed. A dry well seal shall be provided to prevent oil leakage down the output shaft. A dip stick shall be furnished to measure the oil level in the reducer housing. Sight glasses, or other visible means to measure oil levels will not be allowed. Reducer output shaft bearings (both solid and hollow shaft types) shall be grease lubricated or permanently lubricated. All oil fill and drain lines and grease fittings shall be easily accessible. D. The full load operating noise level of the gear reducer shall meet the more stringent requirements of current OSHA occupational noise standards or AGMA 297.01, and shall not exceed 85 dBA at a distance of 3-FT from any part of the drive assembly. E. The flocculator gear reducer and motor assembly shall be mounted on either a cast iron or fabricated steel pedestal support with a solid base plate suitable for installation onto a concrete bridge as shown on the Drawings. Base plate shall be of sufficient size to provide rigid mounting of the unit under maximum power output. Provide rubber buffers as required to absorb start-up torque and prevent any transfer of equipment vibration to support bridge. The equipment manufacturer shall furnish the pedestal support. F. The reducer output shaft shall be connected to the mixer shaft by means of a Type 316 stainless steel flanged coupling. The coupling shall be located above the drive assembly base plate in the mounting deck. BCRUA – Phase 1D WTP Expansion Issued for Bid Vertical Shaft Flocculators 46 41 34 - 7 2.6 SHAFTING AND IMPELLER ASSEMBLY A. Structural members and connections shall be designed to withstand, within normal working stresses and deflections, all loads imposed on them by rotation of the assembly at maximum design speeds in water and air, and loads that may be superimposed during or subsequent to erection while the basins are empty. The shaft shall be of overhung design, and the use of bottom steady bearings shall not be permitted. Lower shaft straightness, rigid coupling squareness and output shaft accuracy shall give a maximum runout at the lower end of the shaft of 1/8-IN for every 10-FT of overhang, as measured when turning over by hand. B. The impeller assembly shall be designed to produce balanced loads on the vertical shaft. C. Hydrofoil: 1. Impeller assembly shall consist of three or four blades hydrofoil with Type 316 stainless steel blades bolted to a shaft hub assembly. The shaft shall be adequately designed for the maximum power output of the drive unit. The impeller assembly shall be securely keyed to a solid shaft fabricated from Type 316 stainless steel. Stress in any impeller component except bolting, shall not exceed 11,000 psi. The impeller shaft shall be rigidly coupled to the reducer output shaft. The rigid shaft coupling shall be located above the support pedestal base for ease of servicing. Shafts shall be of sufficient diameter to operate without excessive vibration over the entire speed range. The stress in the impeller shaft shall not exceed 1/4 of the yield stress of the shaft material under maximum operating loads. No underwater bearings will be permitted. The impeller shaft design shall be such that the maximum operating speed shall not exceed 65 percent of the first lateral critical speed without stabilization fins or rings. 2.7 DRIVE MOTOR A. Motors shall be of the horizontal or vertical design and shall be coupled to the gear reducer by means of a flexible coupling. B. The motors shall be suitable for operation with a VFD. The motor speed range relative to VFD operation shall be minimum 20 to 100 percent of the rated maximum motor speed. Motor shall be designed to not exceed rated temperature rise throughout its operating speed range. C. Motors shall be furnished with winding temperature detectors (thermostats) for each phase. Thermostats shall be wired in parallel, normally, open, closed upon high temperature. Provide anti-condensation space heaters as specified in Section 01 61 03. 2.8 FINISHES A. The flocculators shall be prepared and shop primed as specified in Section 09 96 00. 2.9 SOURCE QUALITY CONTROL A. Shop Testing: 1. One complete unit shall be factory tested for 24 continuous hours at various speeds. The test report shall be submitted and approved by Engineer, prior to shipping. The remaining units shall be given the manufacturer's standard tests and check for alignment. The flocculator manufacturer shall be responsible for providing the variable speed controller BCRUA – Phase 1D WTP Expansion Issued for Bid Vertical Shaft Flocculators 46 41 34 - 8 and appurtenances required for this testing. The test is not required to utilize the variable frequency controllers supplied under Section 26 29 23. 2. The flocculators shall be given the manufacturer's standard quality control inspections and tests to ensure quality of materials used in the manufacture of the units and workmanship conform to the specified requirements and highest industry practice, the units operate properly, and the units have been adequately and correctly prepared for shipment, long-term site storage and initial operation. 2.10 SPARE PARTS A. Furnish the manufacturer's recommended spare parts for one year of normal operation and maintenance of the equipment. Spare parts shall include the following as a minimum: 1. Two (2) complete sets of seals and gaskets. 2. Two (2) complete bearing sets. 3. One (1) set of mounting base rubber buffers per installed flocculator. 4. One (1) shaft holder for each shaft diameter supplied. 5. One year supply of lubricant assuming continuous operation. 6. One set of all special tools required for normal maintenance of the equipment. B. All spare parts shall be suitably packaged or boxed for long-term storage. Each part shall be clearly identified by part description, part number and other pertinent information or data. PART 3 EXECUTION 3.1 EXAMINATION A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for installation examination. B. Verify layout, type, material, and orientation of connections. 3.2 INSTALLATION A. Section 01 61 03 – Common Requirements for Equipment for general requirements. B. The fabrication and erection details shall permit accurate field erection of the equipment and permit installation within the basins as detailed on the Drawings. C. Flocculator installation shall be in strict accordance with the manufacturer's instructions and recommendations. Field installation of the flocculators shall be supervised by a manufacturer's field technician knowledgeable in the proper installation of the units. D. Furnish and install the anchor bolts for all the flocculator units supplied under this Section. The foundation bolts shall be fabricated and installed in accordance with the equipment manufacturer's details, instructions and recommendations. 3.3 FIELD QUALITY CONTROL A. Section 01 40 00 – Quality Requirements. BCRUA – Phase 1D WTP Expansion Issued for Bid Vertical Shaft Flocculators 46 41 34 - 9 B. Sections 01 61 03 – Common Requirements for Equipment, 01 70 00 – Execution and Closeout Requirements, and 01 91 00 – Facility Commissioning: Testing, Startup, Demonstration, and Training requirements. C. Acceptance Testing: 1. After the flocculators have been completely installed and the installation approved by the manufacturer's field technician, and after acceptance by the Engineer, all flocculators shall be tested under the supervision of the manufacturer's field technician. The field tests shall include the complete system, including VFDs furnished and installed under Section 26 29 23. The flocculators shall be field tested to verify that the performance of all system components conforms to the design requirements. 2. Engineer may require any tests of the equipment which in Engineer’s opinion may be necessary to demonstrate to Engineer’s satisfaction that the equipment is installed correctly and is in proper operating condition and free from vibration and other defects or faults of any kind. Furnish all labor and incidentals required to conduct such tests and to correct to the full satisfaction of Engineer any defects or deficiencies noted. 3. A 7-day continuous operation period for each flocculator shall be required before acceptance. At the end of this period, drain all oil from each gearbox and refill it with the proper grade oil. 4. In the event the mechanisms fail to meet the requirements specified above, the necessary changes shall be made and the mechanisms retested. If the mechanisms remain unable to meet the specified requirements to the satisfaction of the Owner, the mechanisms shall be removed and replaced with satisfactory mechanisms at no cost to the Owner. D. Services of Manufacturer: 1. Reference Sections 01 61 03 – Common Requirements for Equipment, 01 70 00 – Execution and Closeout Requirements, and 01 91 00 – Facility Commissioning for general requirements. 2. Provide the services of a factory certified service engineer specifically trained in the installation, start-up, testing, operation, and maintenance of the equipment specified herein. Such services shall be provided by a representative who is a direct, full-time employee of the Manufacturer or their certified representative. 3. Services of equipment manufacturer's representative shall include: a. Inspect equipment covered by this Section. b. Supervise adjustments and installation checks. c. Provide test equipment, tools, and instruments necessary to accomplish equipment testing. d. Conduct initial check-out and start-up of equipment, perform operational checks, and supervise acceptance testing. e. Provide a written statement that manufacturer's equipment has been installed properly, started up and is ready for operation by Owner. f. Instruct Owner on operation and maintenance of furnished equipment. 4. Operation and maintenance training shall include the following, at a minimum: a. Theory of operation. b. Step-by-step start-up and shutdown procedures. c. Step-by-step, "hands-on" assembly and disassembly procedural instructions. d. Replacement part identification and ordering procedures. e. Lubrication procedures, including drain-down and refill procedures. f. Recommended routine maintenance procedures. g. Troubleshooting and diagnostic procedures. BCRUA – Phase 1D WTP Expansion Issued for Bid Vertical Shaft Flocculators 46 41 34 - 10 h. Instrument adjustment. 5. Services of manufacturer’s representative shall be provided for the amount of time specified below. a. Supervision, start-up and testing: 16 hours. b. Instruct Owner on operation and maintenance: 8 hours (2 sessions, 4 hours each). END OF SECTION BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Chain and Flight Sludge Collection Equipment 46 43 11 - 1 SECTION 46 43 11 – CHAIN AND FLIGHT SLUDGE COLLECTION EQUIPMENT (Revised by AD- 02) PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. Chain and flight sludge collection equipment and control panel. B. Scope of Work: 1. Furnish all labor, material, equipment and incidentals required to install, complete and ready for operation, sludge collection and appurtenant equipment, including electric motors, in one (1) rectangular sedimentation basin as detailed on the Drawings and specified herein. C. System Description: 1. The rectangular Sedimentation Basin 4C shall have two longitudinal collector mechanisms driven by one, dual drive motor. The basin is approximately 207-FT long by 53-FT wide with a 1-FT, 6-IN wide partial wall separating the two collector mechanisms. The partial wall is approximately 3-feet high. 2. The collector shall operate at a constant speed of two (2) fpm, and shall be designed to scrape sludge off the sedimentation basin floor and deposit it into sludge hoppers as indicated on the Drawings. The collector drive mechanism shall normally operate continuously, but may operate on a time control, intermittent basis. 3. The collector shall be a three (3) shaft design, with the upper shaft being the driven shaft and positioned for the most efficient drive arrangement, generally as indicated on the Drawings. 4. Materials used for the Chain and Flight Sludge Collectors shall be compatible in an environment where the following primary chemical coagulants may be used: a. Aluminum Chlorohydrate (current primary coagulant), Aluminum Sulfate, Ferric Sulfate, or Ferric Chloride. b. A cationic polymer coagulant aid is also currently used. D. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Division 01 – General Requirements. 3. Section 01 91 00 – Facility Commissioning. 4. Division 03 – Concrete. 5. Section 09 96 00 – High-Performance Coatings. 6. Section 26 29 13.01 – Industrial Control Panels. 7. Division 40 – Process Integration. 1.2 REFERENCE STANDARDS A. American Society for Testing and Materials (ASTM): 1. ASTM A36 - Standard Specification for Carbon Structural Steel. 2. ASTM A48 - Standard Specification for Gray Iron Castings. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Chain and Flight Sludge Collection Equipment 46 43 11 - 2 3. ASTM A380-99el- Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems. 4. ASTM 0570 - Standard Test Method for Water Absorption of Plastics. 5. ASTM 0638 - Test Method for Testing Properties of Plastics. 6. ASTM 0785 - Standard Test Method for Rockwell Hardness of Plastics and Electrical Insulating Materials. 7. ASTM 04020 - Ultra High Molecular Weight Polyethylene Molding and Extrusion Materials. B. American National Standards Institute (ANSI): 1. ANSI Bl5 - Ball Bearing, Load Ratings and Fatigue Life. 2. ANSI B29.21M - 700 Class Welded Steel and Cast Chains, Attachments and Sprockets for Water and Sewage Treatment Plants. 3. ANSI/NSF 61, Drinking Water System Components - Health Effects. C. American Institute of Steel Construction (AISC). D. American Welding Society (AWS). E. American Gear Manufacturers Association (AGMA). F. American Society of Mechanical Engineers (ASME). G. Anti-Friction Bearing Manufacturers Association (AFBMA). H. National Electrical Manufacturers Association (NEMA). I. Steel Structures Painting Council (SSPC): 1. SSPC-SP-10 - Surface Preparation Specification No. 10 Near White Blast Cleaning. J. NSF International: 1. NSF 61 - Drinking Water System Components - Health Effects. 2. NSF 372 - Drinking Water System Components - Lead Content. 1.3 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Product Data: 1. Submit manufacturer information for system materials and component equipment, including performance characteristics. 2. Details of fabrication, materials of construction, installation, and leveling data of all items furnished under this Section. 3. Include descriptive literature, bulletins, and/or catalogs of the equipment. 4. Include the total weight of the equipment including the weight of the single largest item or component. 5. Provide a complete total bill of materials for all equipment. 6. Motor: a. Complete nameplate data. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Chain and Flight Sludge Collection Equipment 46 43 11 - 3 b. Special features (i.e., space heaters and space heater wattage, corrosion resistant features, etc.). 7. Electrical wiring diagram of each component supplied. C. Shop Drawings: 1. Section 01 61 03 – Common Requirements for Equipment: Shop drawing submittal requirements. 2. Submit drawings showing details of construction, dimensions, weld requirements, and anchor bolt layout for each component of the system. 3. Provide documentation of the AGMA rating of the drive assembly, including gear tooth quality, and calculations verifying that the drive meets the specifications. 4. Provide complete description of surface preparation and shop prime painting. 5. Submit detailed instructions on installation requirements, including storage and handling procedures. 6. The name, address, and phone number of the sludge collector manufacturer. 7. Submit qualifications for manufacturer. 8. Refer to specification Section 26 29 13.01 - Industrial Control Panels for control panel submittal requirements. Control panels submitted that do not conform to this Section will be returned without review. 9. Control panel layout drawings showing dimensions, finishes, interior and exterior views, bill of materials, wire and terminal numbers. Provide schematic wiring diagrams showing inter- connections with external devices. 10. Project specific control details and electrical schematic and wiring diagrams. 11. Certified design chain pull of the drive and collector chains, including determination of working loads. 12. Selection of gear driver, including design criteria. 13. Finish color samples. 14. Certification that the equipment conforms to the design criteria specified herein. 15. Warranty information. 16. Certification of experience in manufacturing and providing complete sludge collector systems and at least 10 years satisfactory evidence of relevant experience in the manufacture and supply of complete sludge collection systems. D. Source Quality-Control Submittals: 1. Manufacturer's Certificate: Certify that products meet or exceed specified requirements. a. Section 01 33 00 – Submittal Procedures: Supplement 01. 2. Section 01 61 03 – Common Requirements for Equipment: Submittal requirements. 3. Submit results of factory tests of equipment at the time of shipment. E. Field Quality-Control Submittals: 1. Section 01 33 00 - Submittal Procedures: Supplements 02 and 03. 2. Section 01 61 03 – Common Requirements for Equipment: Submittal requirements. 3. Section 01 91 00 – Facility Commissioning: Submittal requirements. 4. Indicate results of Contractor-furnished tests and inspections. 5. Certify that equipment has been installed according to manufacturer instructions. F. Certifications, Test Reports, and Information: 1. Report of independent laboratory analysis of UHMW material. 2. Certified copies of results of proof load, accelerated wear and flight strength tests performed by the manufacturer on the collector chain, as specified herein. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Chain and Flight Sludge Collection Equipment 46 43 11 - 4 3. Mill certificates for the stainless steel chain. 4. Certification of maximum loading calculations for sprockets and shafting. 5. Field alignment measurements for installed equipment. 1.4 CLOSEOUT SUBMITTALS A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for Operation and Maintenance Manual. 1. Operating and maintenance manuals shall be prepared specifically for this installation and shall include all required cuts, drawings, equipment lists, descriptions, etc. that are required to instruct operating and maintenance personnel unfamiliar with the chain and flight sludge collection equipment in its operation and maintenance. B. Section 01 91 00 – Facility Commissioning: Closeout Submittal requirements. C. Project Record Documents: Record actual locations and final orientation of equipment. 1.5 QUALITY ASSURANCE A. All sludge collection equipment shall be furnished by a single manufacturer who is fully experienced, reputable and qualified in the manufacture of the equipment to be furnished. The equipment shall be designed, constructed and installed in accordance with best practices and methods. These Specifications detail certain components, but do not necessarily cover all details for design and construction of the equipment. B. All components of the equipment to be furnished, including chains and sprockets, flights, runway angles, wear shoes and chain link attachments, shall be fully compatible with each other and be designed for extended, continuous service. C. Collector chain manufacturer shall submit previously certified design documentation stating that the collector chain has been tested on an endurance testing apparatus at a minimum load of 1800 lbf (8 kN) and that the attachment link has been tested to a minimum seven (7) degrees of twist in both directions. Collector chains that do not meet these requirements are not allowed. D. All components that contact process water shall be ANSI/NSF 61 approved. 1.6 QUALIFICATIONS A. Manufacturer shall have a minimum of ten years of experience in the design, fabrication and installation of equipment of similar size and type. Provide a listing of ten projects completed within the last five years of similar size and type. 1.7 DELIVERY, STORAGE AND HANDLING A. Reference Section 01 60 00 – Product Requirements. B. All parts shall be properly protected so that no damage or deterioration will occur during a prolonged delay from the time of shipment until installation is completed and the units and equipment are ready for operation. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Chain and Flight Sludge Collection Equipment 46 43 11 - 5 C. All equipment and parts must be properly protected against any damage during a prolonged period at the site. D. Factory assembled parts and components shall not be dismantled for shipment unless approved by the Engineer. E. Finished surfaces of all exposed drive couplings shall be protected by wooden blanks, strongly built and securely bolted thereto. F. Finished iron or steel surfaces not painted shall be properly protected to prevent rust and corrosion; maintain protection until operation. G. After hydrostatic or other tests, all entrapped water shall be drained prior to shipment and proper care shall be taken to protect parts from the entrance of water during shipment, storage and handling. H. Each drive shall be pallet-mounted and shrink-wrapped. Label for location and estimated weight. I. Space heaters shall be provided for the motors and gear boxes of all outdoor equipment, all equipment expected to be stored and installed, but not started for more than 6 months. J. All grease fittings shall have Type 316L stainless steel tubing, fully supported and racked or otherwise brought to an accessible location, with an approved zerk-style grease fitting. K. All motor-driven equipment shall be manually rotated once per month, or more often if recommended by the supplier. 1.8 EXISTING CONDITIONS A. Field Measurements: 1. Verify field measurements prior to fabrication. 2. Indicate field measurements on Shop Drawings. 1.9 WARRANTY A. Reference Section 00700 – General Conditions, Article 7.17 for warranty terms. PART 2 PRODUCTS 2.1 GENERAL A. Tag number: TSC-SC-004. B. The furnished material shall meet the requirements specified below unless more stringent requirements are specified or required by the manufacturer. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Chain and Flight Sludge Collection Equipment 46 43 11 - 6 2.2 ACCEPTABLE MANUFACTURERS A. Chain and Flight Sludge Collection Equipment: 1. Evoqua - Envirex. 2. Brentwood Industries (Polychem Systems). B. Submit substitutions in accordance with Section 01 25 00. 2.3 DESIGN CRITERIA A. The sludge collector components shall comply with the following design criteria: 1. Design for operation under wet and dry tank conditions. 2. Friction factors: a. Nonmetallic on Nonmetallic: 0.08 to 0.30 (both wet and dry conditions). b. Nonmetallic on Dry Steel: 0.25 dry. 3. Bearing friction: 0.05 to 0.20 per shaft assembly. 4. Shaft deflection: not to exceed 0.033 IN per FT of shaft length. 5. Flight deflection: not to exceed 5/8-IN, measured at mid-span. 6. Sludge load – longitudinal collectors: 2 LB per FT of flight length – 8 IN tall flight. 7. Where not specified, design criteria shall be in conformance with accepted industry standards and shall be subject to the approval of the Engineer. B. A radius screed for finishing of grout for the curved end of the basin shall be furnished by the manufacturer. 2.4 MATERIALS - GENERAL A. Structural steel shall conform to ASTM A36. B. Shapes and plates shall have a minimum thickness of 1/4-IN and bolts a minimum diameter of 1/2-IN unless otherwise specified. C. Stainless steel connectors shall be Type 316 stainless steel and shall be bolted using locking washers and a non-galling stainless steel bolt or nut to prevent galling. 1. All shop and all field connections shall be made with an approved anti-seize lubricant, designed to further reduce the possibility of galling. D. Iron castings shall conform to ASTM A48. E. UHMW shall mean Virgin Ultrahigh Molecular Weight material per ASTM D4020, with negligible (less than 1.3 percent by weight) water absorption per ASTM D570, a Rockwell Hardness of R64 per ASTM D785, and a relative abrasion resistance of 12. Provide certified independent laboratory analysis for at least three samples of the material. 1. For the material to be furnished for this equipment, the UHMW shall be made from a powder with a molecular weight of at least 4 million and an intrinsic viscosity greater than 24. F. All submerged hardware, including fasteners, embedded and expansion anchors shall be Type 316 stainless steel. Type 304 stainless steel is not acceptable within the tankage. All stainless BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Chain and Flight Sludge Collection Equipment 46 43 11 - 7 steel hardware shall be fastened using an approved non-galling compound furnished by Loctite or approved equal. G. Bolt sizes shall not be less than 1/2-IN and shapes and plates shall have a thickness not less than 1/4-IN, except as otherwise indicated. 2.5 COLLECTOR AND DRIVE CHAIN A. Collector Chain: Plastic/FRP. 1. The collector chain shall be completely non-metallic, manufactured of glass-reinforced or acetal resin thermoplastic, designed for operation with chain-saver rims, corresponding to NMX-720SC and in conformance with ANSI B29.21M. The collector chain shall be completely non-metallic, manufactured of fiberglass composite material, corresponding to HS730. (AD-02) All chains shall be completely resistant to ultraviolet degradation. 2. The chain shall have a pitch length of 6-IN and an average minimum weight of 1.3 to 1.6 pounds per FT. 3. The chain shall have a working load of 3,000 pounds, minimum 4,500 pounds, minimum (AD-02). 4. The chain strands shall have an ultimate strength of not less than 6,000 pounds and an elongation of not more than 3 percent at ultimate strength. Chain links shall have a minimum ultimate strength of 6,500 pounds. 5. The chain shall have a curved side-bar design, with a 10-IN radius. 6. Chain pins shall be of the same material as the chain and shall be designed to lock in place and prevent rotation, and shall be simply and securely inserted and removed. 7. Chain assembly shall be proof-loaded to a minimum of 4,500 pounds without failure. Submit a certificate of testing. 8. Attachment links shall be capable of twisting a minimum of 15 degrees across the face of the attachment without failure. B. Stainless steel drive chain shall conform to general dimensions and weights for Specification HB78 cottered chain, including 2.61-IN pitch and 7/16-IN diameter pins of the same material as the chain. Chain shall have a minimum weight of not less than 3.9 pounds per FT. Chain shall have a minimum average ultimate strength of 24,000 pounds and shall be proof tested at a minimum load of 10,000 pounds to remove defective links. Cotter pins shall be Type 316 stainless steel. Drive chain shall connect the drive output shaft directly to the head shaft of the collector. Provide a chain tensioning device, accessible above the concrete deck level, to automatically reduce slack in the drive chain. 2.6 SPROCKETS AND SHAFTING A. All sprockets shall be UHMW material, or shall have ASTM A48 cast iron bodies with replaceable UHMW sprocket teeth or rims. All collector sprockets shall be of the same basic design; head-shaft sprockets shall be cast iron and shall be key seated in line, in pairs equipped with two Type 316 stainless steel set screws. B. All collector sprockets shall be of split construction, with each sprocket consisting of two segments, all made from UHMW material, and shall contain suitable ultraviolet (UV) light inhibitors to be resistant to UV light and potential cracking caused by sun exposure. Each sprocket segment shall be fastened to the hub by two bolts. Four bolts shall connect the split hub. All hardware shall be Type 316 stainless steel. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Chain and Flight Sludge Collection Equipment 46 43 11 - 8 1. Head shaft sprockets shall have a pitch diameter of at least 23.18-IN and have a minimum of 12 teeth. Head shaft sprockets shall be key seated in line, in pairs and shall be equipped with two set screws; one over the keyway and one at 180 degrees. 2. Idler shaft sprockets and shall be fabricated of the same materials as the head shaft sprockets. Idler shaft sprockets shall have a pitch diameter of at least 16.61-IN and have a minimum of 17 teeth. Each idler shaft shall be equipped with one sprocket having two set screws at 180 degrees and one sprocket with a plain bore to be mounted midway between safety collars. C. All sprockets shall be designed to operate with the specified chain. All collector sprockets shall be of the extended life type. Sprockets shall be furnished on all shafts. Traction wheels, idler wheels or other substitutions for sprockets will not be acceptable. D. The drive sprockets shall be designed to operate with the specified drive chain. The drive sprocket shall have 11-teeth and the driven sprocket shall have not less than 40-teeth. The hubs for both drive and driven sprocket shall be made of Type 316 stainless steel The drive hub shall be of a solid construction. The driven hub of the 40-tooth sprocket shall be of split construction. The rim teeth sections shall be replaceable, and furnished in segments and shall be fabricated from UHMW material. Each sprocket segment shall be fastened to the hub with Type 316 stainless steel hardware. E. All collars furnished for sludge collector shafting shall be manufactured of nylon or polyurethane. The collars shall be of split construction mounted with 3/8-inch diameter socket head with Type 316 stainless steel hardware. The collars shall have male-female locators to assure proper alignment. F. All shafting shall be solid, cold finished steel or stainless steel, straight and true, and shall be held in alignment with set collars. The shafting shall have keyways with fitted keys and shall be sized to transmit the power required. All shafting shall extend across the full width of the tank and shall rotate in the bearings mounted on the tank walls. The minimum shaft diameter shall be 4-7/16 IN on the longitudinal collectors. Fixed or stub shafts will not be acceptable. G. Submit certification of maximum loading calculations showing maximum mid-span shaft deflection. H. As an alternative to the sprockets specified under Paragraphs A, B and C above, totally molded polyurethane sprockets of a split design, with Type 316 stainless steel bands and clamps for securing the hubs, may be considered; however, the sprockets shall contain suitable UV light inhibitors to be resistant to UV light and potential cracking caused by sun exposure. 2.7 BEARINGS A. Head shaft bearings shall be of Type 316 cast stainless steel per ASTM A351, Grade CF8M, water lubricated, self-aligning type, having a molded polyurethane hub ball. The bearing shall be self-aligning, designed so that the upper portion of the bearing can be removed without removing the shaft or the lower portion of the bearing from the wall bracket. The upper bearing housing shall be designed so that it can be removed from the bracket without sliding along the shaft and the housing bracket does not have to be removed from the wall for removal or replacement of the bearing. The submerged bearing shall be water lubricated and be equipped with a grease fitting for lubrication when the basin is dewatered. The bearing shall BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Chain and Flight Sludge Collection Equipment 46 43 11 - 9 be attached to the wall with a minimum of two 1-IN diameter and 4-IN long expansion anchors. B. Grease fitting extensions, 3/8-IN, shall be provided for all bearings equipped with grease fittings. Extensions and supports shall be of Type 316 stainless steel construction and shall extend from the connection to the grease fitting through the top of the basin cover slab. All grease fittings shall be grouped and mounted on a common stainless steel Unistrut channel. Label each fitting with stainless steel tag. In-basin stainless steel supports shall be located as recommended by the equipment manufacturer, to avoid interference with operating equipment. Equipment manufacturer shall coordinate slab penetration requirements with the Contractor. C. All bushings shall be manufactured of UHMW material, and shall contain suitable UV light inhibitors to be resistant to UV light and potential cracking caused by sun exposure. The bearings shall be furnished with 1/4-IN thick bushings and eight 1/4-IN pins. The bushing length shall be a minimum of 6-IN for 4-7/16 IN shafts, and 4-IN for 2-15/16 IN shafting. 2.8 FLIGHTS AND ATTACHMENTS A. General Requirements: 1. The structural characteristics of the flights shall exhibit a minimum value of the product of the Section Modulus (E) in psi and the Moment of Inertia (I) of not less than 12.14 x 106 lb-in2. The above values are measured in the axis parallel to the flow direction (and perpendicular to the flights). 2. All bolts, nuts, washers and related hardware used to attach flights and wear shoes shall be a minimum of 1/2-IN Type 316 stainless steel. 3. Flights that fail to perform as a result of manufacturing defects, including delamination, shall be replaced at any time during the ten year life of the flight. 4. Flight spacing shall be approximately 10-FT for longitudinal collectors, and shall cover the full width of the tank. B. FRP Flights: 1. The longitudinal flights shall be of fiberglass reinforced isothalic polyester resin, 3-IN by 8-IN nominal size, channel construction, specifically designed for sludge collector service. The flights shall be constructed by the pultrusion method to ensure complete encapsulation of the glass fiber strands in resin. The glass filaments and mat shall run the full length of the flight. The full member shall have 55 percent minimum glass by weight in compliance with ASTM D638. The resin shall contain protection against degradation from UV light. The leading edge of the flight shall include a lip to ensure cleaning of the tank floor. Flights shall be designed such that normal maximum deflection will not allow any portion of the flight to contact the concrete tank bottom. At the attachment to the collector chain links, the flights shall have a plastic filler block. Flights shall be attached to the filler block by four 1/2-IN diameter stainless steel bolts. Flights shall not be buoyant and shall not incorporate weights. 2. FRP flights shall be of composite construction. The flights shall have a maximum water absorption not exceeding 0.6 percent after immersion for 48 hours at 73 degree F (23 degree C) in accordance with ASTM D570. a. The finished composite shall have minimum tensile strength as measured in accordance with ASTM D638 and as follows: 1) Longitudinal: 40,000 psi. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Chain and Flight Sludge Collection Equipment 46 43 11 - 10 2) Transverse: 7,000 psi. 3. All FRP flights cut for any reason, including drilling shall be resin-sealed at the place and time of the cutting. C. Wear Shoes: 1. Wear shoes shall be attached to the flights to protect the flights from wear when running on the wear strips on the tank bottom, the hold down angles and the return rails. The wear shoes furnished on the collectors shall be fabricated from UHMW polyethylene (Polystone M®) having a Durometer "D" of not less than 62, and shall contain suitable UV light inhibitors to be resistant to UV light and potential cracking caused by sun exposure. The wear shoes shall have a minimum thickness of 1/2-IN and shall be reversible. Each leg of the angle shall include two 9/16-IN diameter holes. The carrying shoes shall be 5-1/2 IN wide minimum and the return shoes shall be 4-IN wide minimum. The return shoe is to have one 9/16-IN hole in each leg for mounting. Attachment bolts, lock nuts and washers shall be Type 316 stainless steel. 2.9 FLOOR WEAR STRIP AND RETURN GUIDE TRACKS A. Return tracks shall be furnished for the entire return run. Collector chain hold down angles shall be furnished as required. Return tracks shall be 3-IN by 3-IN by 3/8-IN Type 316 stainless steel angle with 3/8-IN Type 316 stainless steel supporting brackets fastened to the tank walls. Each supporting bracket shall be designed to cantilever the return track approximately 9-IN off the tank and stub wall, supporting brackets shall be spaced at approximately 10-FT intervals and shall have at least two bolts for attachment to the wall. B. The floor, return track and hold down wear strips shall be fabricated from UHMW polyethylene (Polystone M®) having a Durometer "D" of not less than 62, and shall contain suitable UV light inhibitors to be resistant to UV light and potential cracking caused by sun exposure. The floor wear strips shall be 3-IN wide by 1/2-IN thick. The return tracks and hold down angles shall also be equipped with 3-IN by 1/2-IN UHMW wear strips. They shall be anchored either to the floor or the support work at approximately 2-foot on center with 3/8-IN diameter, Type 316 stainless steel fasteners. The floor fasteners shall consist of Type 316 stainless steel convex washers, pan head screws and vinyl anchors. Provide a floor strip fastener within 6-IN of each strip expansion joint to minimize potential for end "curling". Return track metallic fasteners shall be 3/8-IN Type 316 stainless steel, self-drilling and tapping fasteners. All holes in the wear strips shall be furnished counter bored and slotted as required for expansion. A non-metallic bushing or a stainless steel convex washer shall be furnished to assure a non-binding connection. Spot weld studs shall not be acceptable. Ends and sides of the strips shall be beveled to assure proper wear shoe clearances; at the expansion joints bevel all floor strip edges. C. Flight side clearances on the tank floors shall be 1-IN maximum. 2.10 TAKE-UP BEARINGS A. Take-up bearings shall be provided for one shaft of each longitudinal collector, at the bottom of the tank and nearest to the drive end; provide not less than 12-IN horizontal travel. The take-up shall be a cantilevered, fabricated of all Type 316 stainless steel design with non- galling Type 316 stainless steel take-up screws, designed without recesses in the concrete. The take-up shall be equipped with grease fittings and Type 316 stainless extension tubing for BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Chain and Flight Sludge Collection Equipment 46 43 11 - 11 lubrication of all moving parts when tanks are dewatered. Chain tension shall be adjusted by a tensioning adjustment on each end of the idler shaft. The shaft shall be precisely aligned to eliminate binding, and to minimize chain wear. 2.11 DRIVE UNITS A. The collector mechanism pair shall be driven by one, dual drive motor. Drive unit shall consist of a motor driving a gear reducer. 1. Drive motor design criteria: a. 230/460 volt, 3 phase, 60 Hertz. b. Horizontal foot mounted. c. 0.5 HP. d. 1800 rpm maximum. e. Severe duty and shall conform to Section 01 61 03. f. The motor shall be connected to a gear reducer through a flexible coupling complete with guard and mounted on a galvanized steel base plate supported by the reducer. g. Provide internal thermal switches and anti-condensation space heaters as specified in Section 01 61 03. 2. The gear reducer shall be of the helical gear type conforming to all applicable requirements of the AGMA Standards, shall be designed with a service factor of 1.25 based upon 24 hours service applied to motor nameplate rating. Gears shall run in an oil bath and the reducer housing shall be equipped with easily accessible oil fill and drain ports and an oil level indicator. All bearings incorporated in the gear reducer shall be anti-friction type with an AFBMA minimum B-10 life rating of 50,000 hours, based on maximum loading conditions. 3. The gear reducer output shaft shall be connected between the gear reducer and the drive through a rigid coupling. 4. The drive shall have double output shafts for mounting of the drive sprockets as detailed on the Drawings. 5. All exposed rotating components of the equipment drive chain and sprockets, couplings, etc., shall be protected by 14 gauge Type 304 stainless steel guards, arranged to provide easy access to components. Stainless steel guards shall be provided with a pickled, passivated and polished brush finish per ASTM A380-99e1. All such guards shall be secured using Type 316 stainless steel hardware. 6. Means shall be provided to adjust tension of the drive chain, by using an idler wheel on the drive chain. For chain centers in excess of 10-FT, provide a "snap-idle" type take-up with Type 316 stainless steel side members and hardware and removable UHMW chain guards. 7. Motor accessories: a. Anti-condensation heaters shall be provided for motors and shall be cartridge or flexible wrap-around type installed within the motor enclosure adjacent to core iron. Heaters shall be rated for 120VAC/1Ph/60Hz operation and have a heat rating (i.e., wattage) appropriate for the size motor they are protecting. Manufacturer shall coordinate the wattage of the anti- condensation heaters with the size of the control power transformer (CPT) provided and installed as part of the mechanism control panel. The heater wattage and voltage shall be embossed on the motor nameplate. Power leads for the heaters shall be brought out of the motor through the motor lead junction box (i.e., shared box). b. Provide three normally open, close upon high level, motor winding thermostats. Wire in parallel in motor terminal box. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Chain and Flight Sludge Collection Equipment 46 43 11 - 12 2.12 SHEAR PIN ALARM A. The drive sprocket shall be provided with a shear pin, jaw clutch failure detection system. The driver sprocket hub shall be provided with a trip lug that, upon shear pin failure, shall contact the actuator arm of the double throw limit switch which, in turn, will shut off the motor and energize the alarm circuit. The limit switch shall have a NEMA 4X weatherproof enclosure and shall be provided with a steel support bracket for positioning adjacent to the shear pin hub. B. Provide a phenolic resin separator between the shear pin hub and the drive sprocket to prevent corrosion and to facilitate removal and replacement. 2.13 FLIGHT AND CHAIN MONITORING SYSTEM A. A monitoring system shall check sludge collector flights on each longitudinal collector to assure flights are not askew. The system shall also monitor chain breakage and provide an immediate shut down signal to minimize damage to other components. The system shall be made up of two idler sprockets, which follow the two corresponding collector chains. Metallic targets shall be attached to the idler sprockets and are to be sensed by magnetic proximity switches, which report to a control panel. If the collector chain becomes misaligned, the control panel shall recognize a difference in the phase of the sprockets and sound an alarm. If the control panel recognizes a loss of motion, the power shall be disconnected from the drive and provide an alarm. B. A control panel shall be supplied, which contains logic to determine whether the flights are skewed or stalled. Motor starter status contacts shall be used to control when flight monitoring should be active. An alarm contact shall be supplied from this panel to interrupt the motor starter circuit. In the event the flights become skewed or stalled, the cause of the alarm shall be indicated on the control panel. The indication shall stay active until a reset pushbutton on the front of the panel is pushed. The panel shall also have the capability of interlocking a shear pin limit switch from the drive. 2.14 LOCAL CONTROL PANEL A. The sludge collector starter shall be located in a Contractor provided motor control center bucket. A local control panel shall be supplied by the sludge collection equipment supplier. The local control panel shall interface with all field devices, motor space heater and thermostat, as well as the motor control center. B. Control panel requirements: 1. Control panel shall be UL 508A labeled. 2. Refer to Section 26 29 13.01 - Industrial Control Panels for additional control panel product and fabrication requirements not listed within this specification. 3. Environmental Conditions: a. Temperature: 0-45 degC, outdoor, under direct sunlight. b. Humidity: 0-95%, noncondensing. c. Altitude Rating: Not exceeding 1000 feet. d. Electrical equipment supplied shall be fully rated for the environmental conditions. Derate electrical equipment as required to remain below individual component operating temperature ratings. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Chain and Flight Sludge Collection Equipment 46 43 11 - 13 4. Manufacturer shall coordinate with Contractor to provide wiring between all system components as required. 5. At a minimum, the following must be provided with the panel. a. Main circuit protective device (Circuit Breaker or Fuses). b. Relays. c. Phase failure relay. d. Terminal and power distribution blocks to connect field wiring connections to panel. No direct termination to relays and motor controllers will be permitted. e. Condensate and breather drain. f. Pushbutton and indication lights. g. Thermostatically-controlled panel space heater. 6. Refer to Drawings for control schematic. C. Sludge collector mechanism shall be provided with a NEMA 4X stainless steel local control panel as shown on the Drawings and specified herein. The control panel shall be suitable for operation on a 120 Volt, 60 Hz power supply. The components shall conform to the requirements of Divisions 26 and 40. Control panel shall be furnished with fabricated stainless steel floor mounting brackets as manufactured by the enclosure manufacturer. The top of the control panel shall be 5-FT above finished floor elevation. Control panel manufacturer shall design the fabricated floor mounting brackets as required to prevent lateral movement of control panels when a 100-pound lateral force is applied anywhere on the system and in any direction. Each control panel shall be furnished with an integral main power circuit breaker mounted on the door. Type 316 stainless steel hardware shall be provided to mount control panel to concrete. 1. Operating sequence: a. When the local/remote selector switch is in the remote position, the collector drive shall be started and stopped by the WTP SCADA system or by the start/stop pushbuttons at the motor control center starter. If an overload release condition occurs, the collector drive shall shut down and a trouble alarm shall be sent to the WTP SCADA system. The flight monitoring switches in each half of each basin shall activate a trouble alarm during a flight misalignment condition and shut down the drive. All alarm conditions shall be manually reset. The driver shall automatically return to its previous control position after a power failure. When the local/remote switch is in the local position, the drive shall run from the control panel only. 2. Operator controls: a. Door mounted controls shall be provided for collector control panel. Controls shall include: 1) Push-to-test red "RUN'' indication light. 2) Push-to-test amber "MISALIGNMENT" indication light. Provide two lights if alignment switches are provided on both sides of mechanism. 3) Push-to-test amber "LOSS OF MOTION" indication light. Provide two lights if motion sensors are provided on both sides of mechanism. 4) Push-to-test amber "SHEAR PIN FAILURE" indication light. Provide two lights if shear switches are provided on both side of mechanism. 5) Mushroom two-position red "E-STOP" pushbutton. 6) "RESET" black pushbutton. 7) LOCAL/REMOTE selector switch. 8) "START" red pushbutton. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Chain and Flight Sludge Collection Equipment 46 43 11 - 14 9) "STOP" green pushbutton. 3. Inputs: a. From field devices: 1) Proximity switches (flight misalignment monitoring). 2) Motor winding temperature switch (normally open). 3) Shear pin limit. 4) Motor space heater. 5) Disconnect switch early break contacts. b. From motor control center starter: 1) Collector running. c. 4. Outputs: a. Contacts to close for remote "misalignment" alarm. b. Contacts to close for remote "shear pin failure" alarm. c. Contacts to close for remote "loss of motion" alarm. d. Contacts to close when local/remote switch is in local or remote position. 5. Refer to Drawings for control schematics. 2.15 FINISHES A. See Section 09 96 00 – High-Performance Coatings. B. All iron and steel surfaces shall be blast-cleaned in accordance with SSPC-SP-10 and shall be shop primed and finish coated in accordance with Section 09 96 00 unless specified otherwise herein. C. All pre-painted, purchased equipment, such as electric motors shall be coated with an intermediate and final gloss coat of epoxy paint to match the remainder of the unit. An appropriate seal coat cover over the factory finish shall be applied first, if recommended by the paint manufacturer. D. Samples of colors available for painted and plastic surfaces shall be submitted to the Engineer for approval. The unit shall then be furnished in the approved colors. E. Machined or polished ferrous surfaces such as pipe flanges and machined steel shafts, shall be provided with a temporary protective coating of a nondrying oily-type rust preventative compound. F. Fiberglass, plastic and stainless steel surfaces shall not be coated. 2.16 SPARE PARTS A. At a minimum, manufacturer shall provide an adequate supply of consumables and calibration materials necessary to operate and maintain the equipment specified herein for a two year period after Owner's acceptance. B. Spare Parts: 1. All spare parts including gaskets, seals and belts, with rubber or rubber-like components, which age with exposure shall be given to the Owner in sealed, air-tight transparent containers, with the contents clearly labeled, including the date of packaging. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Chain and Flight Sludge Collection Equipment 46 43 11 - 15 2. All spare parts are to be wrapped in waterproof packages suitable for export service. Each individual package is to be labeled with the description and part number. Packages shall be contained in sturdy wooden crates labeled with the description and part number of each package within and stored in a location designated by the Owner. 3. Spare parts furnished shall include the following as a minimum: a. One full replacement set of drive chain. b. Five additional drive chain pins. c. Ten links of collector chain (with pins). d. Five additional collector chain pins. e. Five collector flights with attached wear shoes and bolts. f. Five links of chain with flight attachments and pins. g. Ten shear pins. h. One-year supply of all grease and lubricants, including two grease guns. C. In addition to the spare parts specified, provide a list of all available spare and replacement parts, including a price for each. These prices shall hold firm for the Owner for a period of at least two years after installation. D. Tools: 1. Provide all tools required for normal maintenance. Tools shall be packaged in a steel case, clearly and indelibly marked on the exterior to indicate equipment for which tools are intended. a. One set of special tools and all spare parts required for normal operation and maintenance of the equipment shall be furnished with the equipment by the manufacturer. 1) Special tools shall include all tools necessary to insert and remove collector chain link pins. PART 3 EXECUTION 3.1 PREPARATION A. Concrete floor preparation, including the finish grading of the floor, shall be provided in accordance with Division 03. B. The sludge collection equipment shall not be installed until after concrete floor finishing is completed. C. Prior to energizing the collector drive, the Contractor shall take all measurements necessary to assure proper clearances for the collector flights, measure and record alignment of drive and collector shaft wall bearings. Provide a certified copy of the alignment measurements, keyed to permanent markers or monuments within the basin. 3.2 INSTALLATION A. Installation shall be in strict accordance with manufacturer's instructions and recommendations. Installation shall include flushing of oil and grease chambers and furnishing the required oil and grease for initial operation. Proper disposal of the flushed oil BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Chain and Flight Sludge Collection Equipment 46 43 11 - 16 and grease shall be the responsibility of the Contractor. The grades of oil and grease shall be as recommended by the equipment manufacturer. 3.3 FIELD PAINTING A. See Section 09 96 00 - High-Performance Coatings. 3.4 FIELD QUALITY CONTROL A. Section 01 40 00 – Quality Requirements. B. Sections 01 61 03 – Common Requirements for Equipment, 01 70 00 – Execution and Closeout Requirements, and 01 91 00 – Facility Commissioning: Testing, Startup, Demonstration, and Training requirements. C. Acceptance Testing: 1. The Contractor shall furnish the services of a factory representative who has complete knowledge of proper installation, operation and maintenance to inspect the final installation and supervise a test run of the equipment. 2. Initial inspection of the completed facilities includes examining, inspecting, measuring and performing a dry running test to assess the overall readiness of the installation for field performance testing. Provide a complete report certifying the results of the initial inspection. 3. Working under the direction of the factory representative and in the presence of the Owner’s Representative, the Contractor shall perform field performance tests for each basin, as follows: a. The equipment shall be operated in a dry tank, only to the extent necessary to observe proper alignment of all shafts, bearings, chain, flights and support rails. All submerged water lubricated bearings shall be lubricated with grease for the test. b. After the sedimentation basin is filled with water, the equipment shall be tested to demonstrate proper alignment and level and smooth operation of all components. Shear pin failure and shear pin alarm shall be demonstrated for each drive. c. For the acceptance testing of the sludge collectors, run each collector for a continuous, trouble-free period of not less than 48 hours of continuous operation. In addition, at the completion of the testing, arrange to have the basins cleaned and readied for inspection. The Owner’s Representative, Contractor and an authorized factory representative shall inspect the equipment to verify the condition and security of the wear strips, to note any abnormality in chain or sprocket wear and to identify any items requiring repair, adjustment or replacement. The chain tension shall be checked by the factory representative, demonstrating the signs and the measure of chain slack which would indicate the need for in-basin adjustment. d. In the event the mechanisms fail to meet the test requirements, the necessary changes and adjustments shall be made and the equipment retested. If the equipment remains unable to meet the test requirements to the satisfaction of the Engineer, it shall be removed and replaced with satisfactory equipment at the Contractor's expense. e. The Contractor shall be responsible for all testing arrangements. 4. Water for Testing: See Section 01 50 00 – Temporary Facilities and Controls. 5. Verify the setting and performance of all alarms. Verify the performance of all controls and related panel indicators. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Chain and Flight Sludge Collection Equipment 46 43 11 - 17 D. Services of Manufacturer: 1. Reference Sections 01 61 03 – Common Requirements for Equipment, 01 70 00 – Execution and Closeout Requirements, and 01 91 00 – Facility Commissioning for general requirements. 2. Provide the services of a factory certified service engineer specifically trained in the installation, start-up, testing, operation, and maintenance of the equipment specified herein. Such services shall be provided by a representative who is a direct, full-time employee of the Manufacturer or their certified representative. 3. Services of equipment manufacturer's representative shall include: a. Inspect equipment covered by this Section. b. Supervise adjustments and installation checks. c. Provide test equipment, tools, and instruments necessary to accomplish equipment testing. d. Conduct initial check-out and start-up of equipment, perform operational checks, and supervise acceptance testing. e. Provide a written statement that manufacturer's equipment has been installed properly, started up and is ready for operation by Owner. f. Instruct Owner on operation and maintenance of furnished equipment. 4. Operation and maintenance training shall include the following at a minimum: a. Theory of operation. b. Troubleshooting guidance. c. Unit capacity and design criteria. d. Operational troubleshooting and diagnostic procedures. e. Step-by-step start-up and shut-down procedures. f. Step-by-step, "hands-on" assembly and disassembly procedural instructions, including: 1) One link removal and replacement of collector chain. 2) One link removal and replacement of drive chain. 3) Shear pin replacement. g. Replacement part identification and ordering procedures. h. Lubrication procedures, including drain-down and refill procedures. i. Recommended routine maintenance procedures. j. Equipment adjustment, including collector chain take-up and drive tension adjustment. 5. Services of manufacturer’s representative shall be provided for the amount of time specified below. a. Supervision, start-up and testing: 16 hours. b. Instruct Owner on operation and maintenance: 8 hours (2 sessions, 4 hours each). END OF SECTION BCRUA – Phase 1D WTP Expansion Issued for Bid Filter Underdrain System 46 61 01 - 1 SECTION 46 61 01 – FILTER UNDERDRAIN SYSTEM PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. Filter underdrain system. B. Scope of Work: 1. Furnish all labor, material, equipment and incidentals required to install, complete and ready for operation, a partial underdrain system for each filter as detailed on the Drawings and specified herein. Underdrains shall be installed in existing, epoxy coated concrete filter cell. Cell includes 8-inch filtered water distribution orifices installed 12- inch O.C. into existing filter gullet. 2. The filter underdrain system shall include all items and materials within the filter basin, above the filter basin base slab and below the media as detailed on the Drawings. 3. Existing filter underdrains at the WTP are Xylem Leopold Universal Type S with IMS 200 media retainer. 4. Contractor shall include in their proposal any additional costs required to install underdrain system into existing filter cell arrangement. 5. Reference Section 40 90 02.01 for filter control requirements. C. System Description: 1. The filter underdrain system is intended to allow for the uniform collection of filtered water and uniform distribution of backwash water and air over the total area of the filter floor. The backwash system shall allow for separate air scour air and water backwashing and the simultaneous use of air and water, all at the rates specified herein. D. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Division 01 – General Requirements. 3. Section 01 91 00 – Facility Commissioning. 4. Division 03 – Concrete. 5. Section 09 96 00 – High-Performance Coatings. 6. Division 40 – Process Integration. 7. Section 46 61 13 – Filter Media. 8. Section 46 61 19 – Wash Water Troughs. 1.2 REFERENCE STANDARDS A. American Water Works Association (AWWA): 1. AWWA B100 - Filtering Materials. 2. AWWA B300 – Hypochlorites. B. NSF International: 1. NSF 61 - Drinking Water System Components - Health Effects. 2. NSF 372 - Drinking Water System Components - Lead Content. BCRUA – Phase 1D WTP Expansion Issued for Bid Filter Underdrain System 46 61 01 - 2 C. American Institute of Steel Construction (AISC). 1.3 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Shop Drawings: 1. Product technical data, including details of fabrication, materials of construction, installation, and leveling data of all items furnished under this Section. 2. Details submitted shall include as a minimum, head loss calculations for air, water, and combined air/water backwash; structural design calculations, including the hold-down system; installation details; hydraulic calculations; proposed testing and start-up procedures; and any other data necessary to demonstrate the suitability and stability of the underdrain system and compliance with these Specifications. 3. The headloss data and hydraulic calculations shall include the full range of flow conditions specified; indicate pertinent physical relationships between air and water metering orifices; cross sectional flow areas for water and air during transport to the flow metering elements; relative magnitudes of entrance, transport, metering and discharge losses; and such other data as may be required to demonstrate that the proposed system will provide uniform flow distribution and not exceed head loss limits. 4. Structural design calculations, including hold down systems to resist upward forces resulting from the initiation of air only, air and water, and water only backwash cycles. The calculations shall be stamped by a licensed professional engineer registered in the State of Texas. 5. Installation details and written installation instructions, including shipping, storage, protection and handling procedures. 6. Flow distribution calculations - Computational Fluid Dynamics model results as described herein and resulting baffling and/or distribution enhancement means and methods proposed to be provided to correct maldistribution situations uncovered by the modeling. 7. Copy of warranty. 8. Proposed testing and start-up procedures. C. Quality Control Submittals: 1. Section 01 33 00 – Submittal Procedures. 2. Section 01 61 03 – Common Requirements for Equipment: Submittal requirements. 3. Certification of compatibility of the underdrain system with the filter media specified in Section 46 61 13 – Filter Media. 4. Manufacturer’s Certification of Compliance that the underdrain system and all associated materials of supply have been ANSI/NSF61 certified at the manufacturing plant. 5. Manufacturer’s Certification of Compliance that the underdrain system is in full compliance with requirements of AWWA B100 and as specified herein. 6. Start-up test reports. 1.4 CLOSEOUT SUBMITTALS A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for Operation and Maintenance Manual. 1. Operating and maintenance manuals shall be prepared specifically for this installation and shall include all required cuts, drawings, equipment lists, descriptions, etc. that are BCRUA – Phase 1D WTP Expansion Issued for Bid Filter Underdrain System 46 61 01 - 3 required to instruct operating and maintenance personnel unfamiliar with the filter underdrain system. B. Section 01 91 00 – Facility Commissioning: Closeout Submittal requirements. C. Project Record Documents: Record actual locations and final orientation of equipment. 1.5 QUALITY ASSURANCE A. The underdrain system manufacturer shall be responsible for designing and furnishing a ready-to-install system that meets all requirements specified. The manufacturer shall furnish the Contractor with such installation details and recommendations as are necessary to acceptably interface the filter underdrain system with the existing filter basin, including requirements for dowels, anchorage, sealants, etc. B. All components that contact process water shall be ANSI/NSF 61 approved. 1.6 DELIVERY, STORAGE AND HANDLING A. Section 01 60 00 – Product Requirements: Requirements for transporting, handling, storing, and protecting products. B. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage. C. Store materials according to manufacturer instructions. D. Protection: 1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas. 2. Provide additional protection according to manufacturer instructions. 1.7 EXISTING CONDITIONS A. Field Measurements: 1. Proposed filter underdrains will be installed in an existing filter cell intended to accommodate the proposed equipment. Verify dimensions and clearances within the filter cell, including floor level measurement, and coordinate with requirements of the filter underdrain system. Notify the Engineer of any discrepancy before submitting shop drawings for approval. 2. Verify field measurements prior to fabrication. 3. Indicate field measurements on Shop Drawings. 1.8 WARRANTY A. Reference Section 00700 – General Conditions, Article 7.17 for warranty terms. BCRUA – Phase 1D WTP Expansion Issued for Bid Filter Underdrain System 46 61 01 - 4 PART 2 PRODUCTS 2.1 GENERAL A. Tag number: Filter No. 7C. B. The furnished material shall meet the requirements specified below unless more stringent requirements are specified or required by the underdrain manufacturer. 2.2 ACCEPTABLE MANUFACTURERS A. Filter Underdrain System: 1. De Nora Tetra: LP Blocks. 2. Roberts: Trilateral. 3. Xylem Leopold: Universal Type S. 2.3 MATERIALS A. Reinforcing Bars: Reinforcing bars shall be as specified in Division 3. B. Metals: All submerged metals and metals installed over the water surface, including but not limited to anchor bolts, fasteners, washers, etc. shall be Type 316L stainless steel. Fabricated members shall be low carbon Type 304 or 316 stainless steel. C. Plastic: All plastic used for underdrain blocks, nozzles, and prefabricated formwork panels shall be constructed of a food grade, high strength plastic material suitable for use with a backwash air temperature of 180 degrees F. 2.4 DESIGN REQUIREMENTS A. The filter underdrain system shall be designed for uniform collection of filtered water and uniform distribution of backwash water and air. The system shall be designed to avoid localized areas of excessive flow that may cause mounding, lateral displacement, or other deleterious disturbances in the filter media. The system shall not cause any loss of filter media during backwashing. Tests, as outlined in PART 3 of this Section, shall demonstrate that there is no maldistribution nor disturbance of filter media in excess of the limits specified. B. Any required air piping within the filter basins shall be designed by the underdrain manufacturer to allow air distribution control. Following approval of the piping by the Engineer, the piping may be designed by the underdrain manufacturer or another supplier at the Contractor's option. C. The Contractor and underdrain manufacturer shall have sole responsibility for the performance of the underdrain system, especially with respect to headloss and uniformity of distribution of air and water. The filters will connect to the existing air and water backwash systems as referenced herein. The underdrain manufacturer shall familiarize themselves with these systems and certify the performance of the filters. All additions and/or modifications needed to meet the requirements of this Specification shall be included in the original proposal, and therefore, Owner and Engineer will not accept or recommend any request for additional compensation or time due to the need for any such changes. BCRUA – Phase 1D WTP Expansion Issued for Bid Filter Underdrain System 46 61 01 - 5 2.5 COMPUTATIONAL FLUID DYNAMICS (CFD) MODELING A. The manufacturer shall perform a CFD model analysis of the existing filter gullet in conjunction with the filter underdrain system proposed for installation to determine the necessity, and if required, the location and design of filter gullet velocity baffling or other hydraulic distribution enhancement hardware. The results of the CFD analysis shall be submitted to the Engineer and shall be sealed by a licensed professional engineer registered in the State of Texas. 1. The manufacturer shall design and install all details of necessary baffle plates, including dimensions, shape, placement and anchorage to existing underdrain gullet. Anchorage hardware shall be constructed of Type 316 stainless steel and shall be provided by the Manufacturer as part of the work of this Section. 2. All such details shall be submitted to the Engineer for approval. 2.6 OPERATING REQUIREMENTS A. The underdrain system for each filter shall be designed for the following operating conditions: 1. Number of filters: a. One (1). 2. Existing filter cell dimensions: a. Length: 20 FT. b. Width: 31 FT. 3. Filter media: a. Anthracite: 1) Effective size: 1.0 mm +/- 0.05. 2) Depth: 42 IN. b. Sand: 1) Effective size: 0.5 mm +/- 0.05. 2) Depth: 6 IN. 4. Maximum filtration rate: a. 6.9 gpm/ft2. 5. Maximum headloss at peak filtration rate: a. 12.0 IN. b. Headloss measured from underside of media bed to inside of filtered water plenum. 6. Backwash rates: a. Maximum for simultaneous air and water: 8 gpm/ft2. b. Maximum for water only: 20 gpm/ft2. 7. Maximum headloss due to backwashing with water only at maximum rate: a. 48 IN. b. Headloss measured from inside of filtered water plenum to underside of media bed. 8. Air scour rate: a. Minimum: 2 scfm/ft2. b. Maximum: 4 scfm/ft2. 9. Maximum design air temperature: a. 180 degF. 10. Current, normal backwash sequencing: a. Air scour only: 1) Air: 3 scfm/ft2. 2) Duration: 4 min. BCRUA – Phase 1D WTP Expansion Issued for Bid Filter Underdrain System 46 61 01 - 6 b. Combined air/low-rate water backwash: 1) Air: 3 scfm/ft2. 2) Water: 7.5 gpm/ft2. 3) Duration: 4 min. c. High-rate water only backwash: 1) Water: 18 gpm/ft2. 2) Duration: 14 min. d. Secondary low-rate water only backwash: 1) Water: 10 gpm/ft2. 2) Duration: 5 min. B. Air Bleed Provisions: 1. If in the opinion of the underdrain manufacturer, an air bleed connection is required to release trapped air from the flume under the wash water gullet, or other portions of the backwash water system, to avoid maldistribution or disturbances that might result from trapped air before backwashing or normal operation, then the underdrain manufacturer shall design and supply the necessary equipment to release trapped air. The underdrain manufacturer shall submit drawings and control schematics for any proposed air bleed equipment showing details of valves, orifices, piping materials (Schedule 10, Type 304L stainless steel minimum), concrete penetrations, and how the control of the equipment will be integrated with the filter backwash control system. The installation of an air bleed system, if required, shall be subject to the approval of the Engineer. The air bleed system shall be designed and supplied by the underdrain manufacturer and shall be installed by the Contractor at no additional cost to the Owner. 2.7 FILTER BLOCK SYSTEM A. The filter underdrain system shall be of the dual-parallel lateral type, whereby feeder and compensatory laterals are provided within a single block. The flow metering elements shall consist of an arrangement of orifices properly sized and located, between the feeder and compensatory laterals, and between the compensatory laterals and top of the blocks. The entrance, transport, and orifice losses, and the placement of the orifices shall be coordinated to produce uniform air and water flows throughout the filter at all specified operating conditions. The number and size of orifices shall be uniform throughout the filter cell. The orifices shall be sized as required to introduce necessary metering head losses, but shall be sufficiently large to prevent clogging and excessive head loss. B. The individual blocks shall have uniform smooth surfaces and all orifices properly deburred. The blocks shall have ridges and pockets for structural rigidity and to key into surrounding grout. The blocks shall be mechanically joined to form a contiguous lateral run to fit into the filter. The joints shall be double-gasketed, bell and spigot type with internal registers, and shall be air and water tight. Each joint shall be restrained with an adequate number of steel spring clips. C. Media retainer shall be made of thermoplastic through an injection molded process and sealed to the top of the underdrain. The opening size shall be sufficient to prevent media from obstructing or passing through the underdrain. Vertical baffles shall be located on the bottom side of the media retainer to prevent fluid from moving horizontally along the bottom side of the media retainer, thus ensuring each pattern of slots in the media retainer receives equal quantities of air and/or water during a backwash cycle. Media retainer shall replace the need BCRUA – Phase 1D WTP Expansion Issued for Bid Filter Underdrain System 46 61 01 - 7 for support gravel and shall not increase the underdrain height by more than 1.25 IN. Media retainer shall be attached and sealed to the underdrain system at the factory using Type 316 stainless steel self-tapping screws and sealant tape. D. Air/water distribution system: 1. An air/water distribution system has been installed into each filter cell gullet. The manufacturer of the existing underdrain system is Xylem Leopold. Proposed underdrains shall be compatible with existing filtration system. Any modifications required to existing system shall be included in original proposal and shall be provided without additional cost to the Owner. 2.8 STRUCTURAL DESIGN A. The filter underdrain system, including anchorage for the underdrain system, supports, etc., shall be designed to safely withstand loadings specified. Concrete design shall be per ACI 318. Steel shall be designed in compliance with the AISC steel manual. Complete design calculations showing compliance with all specification requirements and sealed by a structural engineer licensed in the State of Texas shall be submitted to Engineer for review and acceptance. B. The filter underdrain system, when installed, shall be designed for a net internal loading during backwash of the greater of either 800 psf or 200 percent of maximum pressure at a backwash rate of 20 gpm/ft2. No credit shall be taken for the weight of water or filter media in the design calculations. C. The filter underdrain system shall be designed to withstand a net downward loading of not less than 150 percent of the combined possible maximum loading of the filter media with the water level below the underdrain and all materials saturated. D. Adequate safety factors shall be included in the design to account for dynamic loadings that may occur during the initiation and termination of air and/or water backwashing, or power disruption during air and/or water backwashing. E. The design shall adequately provide for all loads incurred during shipment, handling, and installation. F. Any design details of underdrain system, including thicknesses, reinforcing, openings, etc., as detailed on the Drawings, are approximate only. The underdrain system manufacturer shall check these details and confirm or modify the system to meet the criteria specified. However, no members shall be downsized unless it can be conclusively demonstrated that the stated sizes will not function properly. Any modifications required by the underdrain system manufacturer shall be provided by the supplier and the Contractor at no additional cost to the Owner. 2.9 STRUCTURAL GROUT AND ANCHORAGE A. All grout used in conjunction with underdrain installation will be considered structural grout and shall meet all requirements of this Section and Division 3. BCRUA – Phase 1D WTP Expansion Issued for Bid Filter Underdrain System 46 61 01 - 8 B. Grout shall be a mixture of one part Portland cement and two parts sand with a non-shrink admixture as recommended by the underdrain system manufacturer and shall comply with ASTM C1107. C. The minimum compressive strength of the structural grout will be 6,000 psi at 28 days. All compression tests will be performed in accordance with ASTM C1107. D. During the grouting operations, a minimum of three test specimens per filter cell or per day, shall be made, whichever is greater. Three test specimens for between block grout shall be made in addition to the three test specimens for floor grout. E. Installing Contractor shall provide and install additional anchor dowels and any associated hardware as required to secure underdrains to floor of existing epoxy coated, concrete filter cell. Existing epoxy coating shall remain intact. Contractor shall repair any damage to the integrity of the existing coating system at no additional cost to the Owner. 2.10 SPARE PARTS A. Special tools and the Manufacturer's standard set of spare parts required for normal operation and proper servicing shall be furnished with the equipment. B. Provide enough spare lateral blocks with integral media support caps for at least one full lateral replacement including one starter block and two end caps. PART 3 EXECUTION 3.1 INSTALLATION A. Prior to installing any material, the Contractor shall notify the Owner's representative, to demonstrate that all dirt, debris, etc. has been removed from filter cells. The Contractor shall handle and install the filter underdrain system in strict compliance with the manufacturer’s installation drawings, instructions, and recommendations, and as specified. The Contractor shall provide a manufacturer's representative to inspect and supervise the installation and testing of the underdrain system, and all costs of such inspection and supervision shall be borne by the Contractor. The Contractor shall comply fully with the underdrain manufacturer's installation details and recommendations to acceptably mate the filter underdrain system with all surrounding structures, including requirements for dowels, anchorage, etc., and the Contractor shall include all costs of such work in their proposal. The Contractor is cautioned that all such installation details are not shown on the Drawings, as they will vary according to manufacturer requirements. B. The Contractor shall take all necessary precautions recommended by the underdrain manufacturer and as specified to ensure that the underdrain system and piping connected thereto is completely clean and free of debris, dirt, or other foreign materials which could clog the underdrain system or interfere with flow. Connecting backwash air and water piping shall be thoroughly flushed clean. Air piping shall be flushed with air only. All loose debris and dirt within the filter, gullet, and flume shall be removed by sweeping and vacuuming before the introduction of leveling and testing water. Care shall be taken to prevent any grout, concrete, or debris from extruding into any flow passages or ports, and any such grout, concrete, or BCRUA – Phase 1D WTP Expansion Issued for Bid Filter Underdrain System 46 61 01 - 9 debris shall be removed. As installation progresses, underdrain sections partially complete shall continue to be protected by using masking tape and heavy building paper or other acceptable means to maintain cleanliness. Cleanliness shall be maintained through final placement of filter media. 3.2 FILTER BLOCK INSTALLATION A. The filter underdrain sections shall be set in place and grouted such that the air metering orifices are in a true and level plane within plus-or-minus 1/8-inch or the tolerance specified by the manufacturer of the filter underdrain, whichever is less. The filter underdrain supports shall be prepared as necessary to enable installation within the required level tolerance. The Contractor shall flood the underdrain with water to ascertain that this level tolerance is met. As the underdrain sections are set in place, all grouting spaces shall be completely filled and finished off smooth. Reinforcing dowels shall be placed to accurately fit in place without unnecessary bending of the dowel bars in the field. B. As the underdrain sections are set in place, all grouting spaces shall be filled and finished off smooth. Prior to placement of grout between laterals, the space shall be thoroughly cleaned by compressed air. Cleaned spaces shall be covered to prevent reintroduction of contaminants. C. Grout placement shall follow manufacturer's requirements. D. Install additional anchorage as required to secure filter blocks to epoxy coated floor of existing filter cells. 3.3 FIELD QUALITY CONTROL A. Section 01 40 00 – Quality Requirements. B. Sections 01 61 03 – Common Requirements for Equipment, 01 70 00 – Execution and Closeout Requirements, and 01 91 00 – Facility Commissioning: Testing, Startup, Demonstration, and Training requirements. C. Conduct pull-out tests as recommended by Engineer and underdrain manufacturer on at least 10% of anchor dowels installed to secure filter blocks. D. Testing and Correction of Deficiencies: 1. All testing shall be performed under the supervision of the underdrain manufacturer's representative. Each filter shall be tested. The Contractor shall conduct all specified tests and shall furnish all power, material, instrumentation, equipment, personnel, etc., for conducting tests as specified. All costs of such testing shall be borne by the Contractor. The costs of all work and materials to correct deficiencies revealed during testing, and the costs of retesting, shall be borne by the Contractor. The Contractor shall give the Owner's representative and Engineer seven (7) calendar days advance notice of the testing. 2. All test set-ups, procedures, and instrumentation shall be as required to provide data accuracy of plus or minus 2 percent. The Contractor shall submit full and complete test reports for all tests, describing the units tested; the type of test; test set-ups, procedures, and instrumentation; and test flow rates, pressures, levels, and all other data and results as required to demonstrate that all items tested meet specified requirements. BCRUA – Phase 1D WTP Expansion Issued for Bid Filter Underdrain System 46 61 01 - 10 E. Preliminary Distribution Tests: 1. After the installation of the underdrain system is completed and the grout and anchor bolts have had sufficient curing time to permit adequate strength to develop, the underdrain shall be subjected to a preliminary distribution test. Such testing shall occur in two parts, as described below: 2. Part One Testing: a. Part one of the preliminary distribution test shall consist of measuring pressure gradients across the filter underdrain using piezometers. b. The underdrain compensatory lateral or media retention plate (as appropriate) shall be tapped with 3/8-inch diameter fittings in 12 locations at the direction of the Engineer. Clear plastic tubing shall be attached to the fittings and routed to graduated piezometer boards (i.e., one board per filter cell). Graduations shall be in inches of water. Piezometer boards shall be mounted to facilitate easy view of measured pressures. c. Upon installation of piezometers, the outfitted test filter shall be backwashed (water only) at 12 and 20 gpm/ft2. d. The variation in measured pressures shall not be greater than plus or minus 10 percent of the mean of all values across the filter. e. If the variation is greater than that specified, the underdrain manufacturer shall make adjustments as necessary to the underdrain installation to correct the maldistribution including but not limited to, resizing and/or realignment of baffle plates, increasing/decreasing the cross-sectional area of the existing underdrain gullet, and/or resizing the orifices between the feeder lateral and compensatory lateral, or water compartment and media retention plates (as appropriate). The manufacturer shall underwrite the cost of all such adjustments whether performed by the manufacturer or by the installing contractor. f. Additional Part Two testing, as described below, shall not commence until Part One testing is complete and conformance with the specified backwash water maldistribution criteria specified has been proven. 3. Part Two Testing: a. Part Two of the preliminary distribution test will commence only upon satisfactory demonstration of backwash water distribution under Part One Testing. b. Each filter shall be operated through its backwashing cycles using the design maximum water and air rates specified. Visual inspection of the underdrain system will first be made under all modes of backwashing to demonstrate uniformity of air and/or water distribution. The air only mode shall be performed at 3.5 and 4.5 scfm/ft2 with 6 IN of water over the underdrain system. Test flow rates shall be sustained for approximately 2 minutes while visual observations are made. Tests shall be extended or repeated if, in the opinion of the Owner’s representative, additional time is needed to make observations. Headloss at the maximum backwash water rate shall be computed by taking pressure gauge readings at the wash water pipe inlet to the filter just outside the filter box wall minus the static head above the underdrain system. 4. During all testing, the water surface shall present a uniformly turbulent appearance, without dead spots or boils. The Manufacturer shall take such measures as are necessary to correct all deficiencies revealed by these tests, and shall repeat the specified tests until such deficiencies are corrected. F. Final Distribution Tests: BCRUA – Phase 1D WTP Expansion Issued for Bid Filter Underdrain System 46 61 01 - 11 1. After completion of Preliminary Distribution Tests and following the installation of the filter media, all filter underdrain systems shall be tested for acceptable flow uniformity. Final distribution tests shall consist of five (5) backwash cycles as follows: a. Start with initial water surface approximately 12-inch above top of the filter media. b. Air backwash at 4 scfm/ft2 for 5 minutes. c. Simultaneous air and water backwash at 4 scfm/ft2 and 7.5 gpm/ft2 for 2.5 minutes. d. Water backwash at 18.0 gpm/ft2 for 5 minutes. e. Water backwash at 10.0 gpm/ft2 for 2 minutes. f. Drain down to initial level and repeat. 2. After the test, the water level shall be lowered to the top of the filter media. The top of the media shall be inspected and shall have no areas deviating more than plus or minus 1 IN from the average level plane. 3. If the filter underdrain system of any filter fails to meet the above test criteria, the system shall be corrected and retested and the filter underdrain system of the effected filter shall be retested. The Manufacturer shall pay for all corrective action and retesting costs attributable to manufacturing and/or installation oversight deficiencies as determined by the Engineer. The installing contractor will pay for all corrective action and retesting costs attributable to installation problems as determined by the Engineer. G. Water for Testing: See Sections 01 50 00 – Temporary Facilities and Controls. H. Disinfection: Filters shall be disinfected in accordance with Section 33 13 13 – Potable Water Facility Disinfection. I. Services of Manufacturer: 1. Reference Sections 01 61 03 – Common Requirements for Equipment and 01 91 00 – Facility Commissioning for general requirements. 2. Provide the services of a factory certified service engineer specifically trained in the installation, start-up, testing, operation, and maintenance of the equipment specified herein. Such services shall be provided by a representative who is a direct, full-time employee of the Manufacturer. 3. The filter underdrain system manufacturer shall advise, consult, and instruct the installation contractor on installation procedures and adjustments and inspect the equipment during installation as a condition of acceptance of the work. The factory certified service engineer shall be present during the entire filter underdrain system installation effort and when filter media is being placed. 4. The filter underdrain system manufacturer shall be responsible for the initial start-up and testing of the finished filter underdrain installation including media cleaning operations. The factory certified service engineer shall again be present during all filter start-up, testing and media cleaning operations as a condition of acceptance of the work. 5. Services of equipment manufacturer's representative shall include: a. Inspect equipment covered by this Section. b. Supervise adjustments and installation checks. c. Provide test equipment, tools, and instruments necessary to accomplish equipment testing. d. Conduct initial check-out and start-up of equipment, perform operational checks, and supervise acceptance testing. e. Provide a written statement that manufacturer's equipment has been installed properly, started up and is ready for operation by Owner. f. Instruct Owner on operation and maintenance of furnished equipment. BCRUA – Phase 1D WTP Expansion Issued for Bid Filter Underdrain System 46 61 01 - 12 6. Operation and maintenance training shall include the following, at a minimum: a. Theory of operation. b. Process flow description. c. Unit capacity and design criteria. d. Operational troubleshooting. 7. Services of manufacturer’s representative shall be provided for the amount of time specified below. a. Supervision, start-up and testing: 4 days (8 hours/day). b. Instruct Owner on operation and maintenance: 8 hours (2 sessions, 4 hours each). END OF SECTION BCRUA – Phase 1D WTP Expansion Issued for Bid Filter Media 46 61 13 - 1 SECTION 46 61 13 – FILTER MEDIA PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. Filter media. B. Scope of Work: 1. Filter media shall be installed in one (1) existing filter cell as specified herein and detailed on the Drawings. C. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Division 01 – General Requirements. 3. Section 01 91 00 – Facility Commissioning. 4. Division 03 – Concrete. 5. Section 46 61 01 – Filter Underdrain System. 6. Section 46 61 19 – Wash Water Troughs. 1.2 REFERENCE STANDARDS A. American Water Works Association (AWWA): 1. AWWA B100 - Filtering Materials. 2. AWWA B300 – Hypochlorites. B. National Science Foundation (NSF): 1. NSF Standard No. 61 - Indirect Additives, Process Media. 1.3 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Shop Drawings: 1. Product technical data. 2. Filter Media data sheets indicating material, unit weight, effective size, uniformity coefficient and other pertinent data specified or required to evaluate quality for each layer of material. 3. Complete installation and placement procedures. 4. Affidavit of Compliance in accordance with AWWA B100 and NSF No. 61. 5. Results of pre-shipment tests performed by independent testing laboratory. 6. Evidence of Manufacturing Experience. 7. Certification of Quality Control Program. C. Samples: 1. Proper operation of the filters requires careful selection of the relative size of the media. Before Contractor procures media, submit 5-pound samples of each proposed material to BCRUA – Phase 1D WTP Expansion Issued for Bid Filter Media 46 61 13 - 2 Engineer for approval. After submission of samples, Engineer may decide to revise proposed media gradation. Revisions shall be made only by written Engineer approval. D. Certifications and Testing: 1. Section 01 33 00 – Submittal Procedures. 2. Section 01 61 03 – Common Requirements for Equipment: Submittal requirements. 3. Provide the services of a qualified testing laboratory experienced in testing filter media materials to perform the tests specified. 4. Testing laboratory shall be approved by the Engineer. 5. The costs for testing shall be included in proposal. Owner may perform additional testing and Contractor shall permit and assist with sampling as required. 6. The following tests are required: a. Grain Size Analysis, complete with graph of sieve size versus percent passing. b. Acid Solubility. c. Specific Gravity. d. Effective Size and Uniformity Coefficient. e. Hardness (MOH Scale). 1.4 CLOSEOUT SUBMITTALS A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for submittals and operation and maintenance manuals. 1.5 QUALITY ASSURANCE A. Manufacturer Experience: 1. Filter media manufacturer shall have a minimum of 5 years of experience with at least 10 installations in satisfactory operation. B. Pre-Procurement Samples: Reference Samples article in SUBMITTALS section. C. Pre-Shipment Tests: 1. Sampling and testing to be performed by filter media manufacturer in accordance with AWWA B100, prior to shipment of materials. 2. Perform tests on samples obtained directly by the approved testing laboratory in accordance with AWWA B100. 3. Provide certified copies of all tests performed by laboratory. 4. The cost for this testing shall be included in the cost of the media. D. Receipt Tests: 1. Sampling and testing to be performed in accordance with AWWA B100, on material delivered to the site. 2. Samples will be shipped to the testing laboratory by the Engineer. 3. The approved testing laboratory will perform the tests listed in Paragraph 1.5 in accordance with AWWA B100. The cost of this testing shall be included in the cost of the proposal. 4. If the results of the Receipt Tests do not comply with the specifications, the materials must be replaced. BCRUA – Phase 1D WTP Expansion Issued for Bid Filter Media 46 61 13 - 3 E. All filter media shall be certified under ANSI/NSF 61 and suitable for use in potable water filters. 1.6 DELIVERY, STORAGE AND HANDLING A. Reference Section 01 60 00 – Product Requirements. B. Filter media shall not be shipped to the project site until such material is approved by the Engineer. C. Packing and Shipping of Filter Media: 1. Deliver media in new, never-before used, heavy-duty woven, polypropylene, semi-bulk containers treated with UV light inhibitors, having a safety factor of at least 5:1. The containers shall have lifting sleeves for forklift use capable of supporting the entire weight of the full container, and have a bottom discharge spout. 2. The containers shall be clearly marked, including company name, complete material description, lot number, and date of production. 3. Do not ship materials until storage and handling procedures are approved by Owner and delivery has been coordinated with installing contractor. 4. Transport all media on open side trucks/trailers to allow for side unloading by forklift. Material will be unloaded and properly covered or tarped by the installation contractor. 5. Handle media products in accordance with the media manufacturer's written instructions and in a manner to prevent damage. Protect the media from all dust, dirt or deleterious material during packing and shipping operations. PART 2 PRODUCTS 2.1 GENERAL A. Cumulative LID ratio (total depth to effective size, dimensionless units) for the filter media shall be 1372; plus or minus 25. B. Filter media shall meet all requirements of AWWA B100 unless otherwise stated herein. C. Provide additional filter media to account for losses from handling and scraping/skimming. Assume losses from handling and scraping/skimming based on 1 IN sand and 2 IN coal per filter cell. 2.2 ACCEPTABLE MANUFACTURERS A. Anthracite Coal and Silica Sand: 1. Roberts Filter Group. 2. Unifilt Corporation. 3. Xylem Leopold. B. Submit substitutions in accordance with Section 01 25 00. BCRUA – Phase 1D WTP Expansion Issued for Bid Filter Media 46 61 13 - 4 2.3 MATERIALS A. Anthracite Coal: 1. Layer Depth: 42 inches. 2. Effective Size: 1.00 mm plus or minus 0.05 mm. 3. Uniformity Coefficient: Less than or equal to 1.40. 4. Apparent Specific Gravity: 1.65 plus or minus 0.05. 5. Mohs' Hardness Value: over 3.0. 6. Acid Solubility: Less than or equal to 5 percent. 7. Anthracite coal shall be clean, virgin, of deep open pit mine origin and shall not contain dredged or bank material. Media shall be free of visible extraneous material that is not easily separable during normal backwashing and skimming procedures. This includes wood fibers and plant materials. B. Silica Sand: 1. Layer Depth: 6 inches 2. Effective Size: 0.50 mm plus or minus 0.05 mm. 3. Uniformity Coefficient: Less than or equal to 1.40. 4. Specific Gravity: Greater than or equal to 2.60. 5. Acid Solubility: Less than 5 percent. 2.4 SOURCE QUALITY CONTROL A. After delivery to the site, but before placing the media, Engineer may take random test samples of each media and sieve analysis may be performed on each sample by a laboratory selected by Engineer. Failure of the samples to meet the Specifications shall be cause for rejection and Contractor shall remove such media from the site and provide media meeting these Specifications. No plus tolerances shall be allowed on any uniformity coefficients. 2.5 SPARE PARTS A. Furnish 2,000 pounds of filter anthracite to the Owner for inventory in addition to the media shown on the Drawings, plus all additional media required to make up for skimming and backwash losses. Media shall be supplied in waterproof bags which are stamped with the media type and size. PART 3 EXECUTION 3.1 INSTALLATION A. Install products in accordance with manufacturer’s instructions and AWWA B100. B. Anthracite shall be transported, delivered and placed in a careful manner to exclude all dust, dirt, or deleterious material and to prevent physical damage to the particles. C. Each filter basin and underdrain system shall be thoroughly cleaned by sweeping and vacuuming before any media is placed and shall be kept clean throughout the operation. No media shall be placed until the underdrain system manufacturer has certified the system to BCRUA – Phase 1D WTP Expansion Issued for Bid Filter Media 46 61 13 - 5 have been installed and the Preliminary Distribution Tests successfully completed in accordance with Section 46 61 01. D. Do not stand or walk directly on filter media while placing material. E. Wash and scrape sand as required according to AWWA B100. F. After the anthracite has been placed, the bed shall be backwashed successively in order to wash out dirt. Backwashing shall continue until there is no further discoloration. This will require several separate backwashes followed by slow closing of the wash water valve. Final closure of the valve from the opening that gives 10 percent expansion shall extend over at least 30 seconds. G. Following this backwash, the top two inches of anthracite shall be removed and discarded. The final depth of anthracite shall be as shown on the Drawings. Sufficient excess anthracite shall be placed initially to allow for the scraping. The depth of media shall be measured in place after backwashing and filtering for one hour. H. If media are lost from the filters, the Contractor shall bear all expenses for cleanup from all new and existing facilities. 3.2 DISINFECTION A. After placement of filter media, but before the filters are placed into service, the entire depth of filter media and underdrain system in each filter shall be disinfected. Only products approved for disinfection of potable water shall be used. Filter disinfection shall be in accordance with AWWA Standards and as specified in Section 33 13 13 – Potable Water Facility Disinfection, except as modified in the following procedure: 1. With all other filter valves closed, the filter shall be filled with water from the backwash system while simultaneously adding sufficient disinfectant (sodium hypochlorite) to the incoming water to maintain a level of 50 mg/l of free chlorine in the filter box. 2. The backwash valve shall then be closed and the disinfectant allowed to remain in the filter box. The water level shall be maintained at the maximum water level of the filter for not less than 24 hours. The free chlorine residual shall be verified to be at least 25 mg/l in the filter after 24 hours or the filter shall be backwashed and the disinfection procedure shall be repeated. 3. Upon completion of disinfection, the filter contents shall be backwashed to waste to remove all traces of the disinfectant solution. Backwash water shall be disposed of in accordance with applicable regulations. 3.3 FIELD QUALITY CONTROL A. Section 01 40 00 – Quality Requirements. B. Sections 01 61 03 – Common Requirements for Equipment, 01 70 00 – Execution and Closeout Requirements, and 01 91 00 – Facility Commissioning: Testing, Startup, Demonstration, and Training requirements. C. Services of Manufacturer: BCRUA – Phase 1D WTP Expansion Issued for Bid Filter Media 46 61 13 - 6 1. Reference Sections 01 61 03 – Common Requirements for Equipment and 01 91 00 – Facility Commissioning for general requirements. 2. Provide the services of a factory certified service engineer specifically trained in the installation, start-up, testing, operation, and maintenance of the equipment specified herein. Such services shall be provided by a representative who is a direct, full-time employee of the manufacturer. 3. Services of manufacturer’s representative shall be provided as part services specified in Section 46 61 01 – Filter Underdrain System. END OF SECTION BCRUA – Phase 1D WTP Expansion Issued for Bid Wash Water Troughs 46 61 19 - 1 SECTION 46 61 19 – WASH WATER TROUGHS PART 1 GENERAL 1.1 SUMMARY A. Section Includes: 1. Fiberglass reinforced plastic (FRP) wash water troughs. B. Scope of Work: 1. Four (4) wash water troughs shall be installed in one (1) filter cell as detailed on the Drawings. C. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Division 01 – General Requirements. 3. Section 01 91 00 – Facility Commissioning. 4. Division 03 – Concrete. 5. Section 46 61 01 – Filter Underdrain System. 6. Section 46 61 13 – Filter Media. 1.2 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Shop Drawings: 1. Product technical data, including details of fabrication, materials of construction, installation, and leveling data of all items furnished under this Section.. 2. Details of the method of erection of all materials and equipment furnished under this Section. 3. Installation details and written installation instructions, including shipping, storage, protection and handling procedures. 4. Warranty information. 5. Proposed testing and start-up procedures. C. Quality Control Submittals and Certifications: 1. Section 01 33 00 – Submittal Procedures. 2. Section 01 61 03 – Common Requirements for Equipment: Submittal requirements. 1.3 CLOSEOUT SUBMITTALS A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for submittals and operation and maintenance manuals. B. Section 01 91 00 – Facility Commissioning: Closeout Submittal requirements. C. Project Record Documents: Record actual locations and final orientation of equipment. BCRUA – Phase 1D WTP Expansion Issued for Bid Wash Water Troughs 46 61 19 - 2 1.4 QUALITY ASSURANCE A. All components that contact process water shall be ANSI/NSF 61 approved. 1.5 QUALIFICATIONS A. Manufacturer must have, as a minimum, 10 years of experience designing and manufacturing wash water troughs for applications of similar size and flow. 1.6 DELIVERY, STORAGE AND HANDLING A. Section 01 60 00 - Product Requirements: Requirements for transporting, handling, storing, and protecting products. B. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage. C. Store materials according to manufacturer instructions. D. Protection: 1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas. 2. Provide additional protection according to manufacturer instructions 1.7 EXISTING CONDITIONS A. Field Measurements: 1. Proposed wash water troughs will be installed in an existing filter cell intended to accommodate the proposed equipment. Verify dimensions and clearances within the filter cell, including floor level measurement, and coordinate with requirements of the filter underdrain system. Notify the Engineer of any discrepancy before submitting shop drawings for approval. 2. Verify field measurements prior to fabrication. 3. Indicate field measurements on Shop Drawings. 1.8 WARRANTY A. Reference Section 00700 – General Conditions, Article 7.17 for warranty terms. PART 2 PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. FRP wash water troughs: 1. Roberts Filter Group. 2. Warminster Fiberglass. 3. Xylem Leopold. B. Submit requests for substitution in accordance with Section 01 25 00. BCRUA – Phase 1D WTP Expansion Issued for Bid Wash Water Troughs 46 61 19 - 3 2.2 DESIGN REQUIREMENTS A. Each trough shall have a minimum carrying capacity of 3,100 gpm. B. The troughs shall be "U" type design with extended vertical sides. 2.3 MATERIALS AND FABRICATION A. Wash water troughs shall be laminated of fiberglass reinforced polyester resin to a minimum of 3/16-inch thickness. Troughs shall have round bottoms and vertical sides. Top edges of the troughs shall be straight with no more than 1/16-inch deviation from a true plane. Integral longitudinal stiffening ribs shall be provided to assure rigidity. Corrosive resistant spacer rods shall be included to maintain a uniform width over the length of each trough. B. Each trough shall be designed to span the distance as detailed on the Drawings. The troughs shall be designed to support the applied water loads at each location. One end of the trough shall be closed by an integrally molded section at least 1-1/2 times as thick as the main trough with vertical slots to permit leveling. This closed end shall be attached and supported from the wall by means of a fiberglass or Type 316 stainless steel collar and hold down angle as detailed on the Drawings. The collar and hold down angle shall provide for free longitudinal movement of the trough, but shall provide full restraint of vertical or horizontal movement. An integral grouting rib shall be provided at the gullet end to act as a water stop when the trough is grouted into a boxed out opening provided in the gullet wall. Troughs shall be grouted in place after leveling. C. Troughs shall be furnished complete with weir plates having slotted holes 6-inch on center that facilitate a minimum vertical adjustment of 1-inch. The weir plates shall be laminated fiberglass polyester with a 1/4-inch minimum thickness. All necessary bolts, nuts, and washers for attaching the weir plates to the troughs shall be included. D. All exposed supports and hardware shall be Type 316 stainless steel including bolts, nuts, washers, straps, etc., unless specified otherwise herein. PART 3 EXECUTION 3.1 INSTALLATION A. Section 01 61 03 – Common Requirements for Equipment: Installation requirements. B. Install products in accordance with manufacturer’s instructions and under supervision of a manufacturer’s representative. C. Wash water troughs shall be carefully aligned and leveled. 3.2 FIELD QUALITY CONTROL A. Section 01 40 00 – Quality Requirements. BCRUA – Phase 1D WTP Expansion Issued for Bid Wash Water Troughs 46 61 19 - 4 B. Sections 01 61 03 – Common Requirements for Equipment, 01 70 00 – Execution and Closeout Requirements, and 01 91 00 – Facility Commissioning: Testing, Startup, Demonstration, and Training requirements. C. In the completed installation, no variation in elevation greater than 1/16-inch shall exist between any two points on the wash water weir edges. D. Upon completion of the installation, the Engineer may order a full load operating test. Contractor shall furnish all labor and materials required for such tests and correct defects in the fabrication and erection as necessary. Troughs exhibiting excessive deflection or vibration at any wash rate, as determined by the Engineer, shall be removed by the Contractor and replaced with ones of adequate design at no additional cost to the Owner. END OF SECTION BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Circular Gravity Thickener Equipment 46 71 13 - 1 SECTION 46 71 13 – CIRCULAR GRAVITY THICKENER EQUIPMENT (Revised by AD-02) PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Thickener drive mechanism. 2. Influent well. 3. Rake arms and sludge collectors. 4. Access bridge. 5. Control panel. B. Scope of Work: 1. Furnish all labor, materials, equipment, and incidentals required to install, complete and ready for operation, the equipment in the 60-foot diameter Sludge Thickener as shown on the Drawings and specified herein. C. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Division 01 – General Requirements. 3. Section 01 91 00 – Facility Commissioning. 4. Division 03 – Concrete. 5. Division 05 – Metals. 6. Division 09 96 00 – High-Performance Coatings. 7. Section 10 14 00 – Identification for Process Piping and Equipment. 8. Section 26 29 13.01 – Industrial Control Panels. 9. Section 40 05 00 – Common Requirements for Process Piping. 10. Section 40 05 07 – Hangers and Supports for Process Piping. 11. Section 40 05 51 – Common Requirements for Process Valves. 12. Section 40 90 00 – Process Control and Instrumentation Systems – General Provisions. 13. Section 40 90 01 – Instrumentation. 14. Section 40 90 02 – Supervisory Control and Data Acquisition (SCADA) System. 1.2 RFERENCE STANDARDS A. Hydraulic Institute (HI). B. American Society for Testing and Materials (ASTM): 1. ASTM A36 – Standard Specification for Carbon Structural Steel. 2. ASTM A48 – Standard Specification for Gray Iron Castings. 3. ASTM A123 – Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products. 4. ASTM Al48 – Standard Specification for Steel Castings, High Strength, for Structural Purposes. 5. ASTM A153 – Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware. 6. ASTM A276 – Standard Specification for Stainless Steel Bars and Shapes. 7. ASTM A325 – Standard Specification for Structural Bolts, Steel, Heat Treated 120/105 ksi Minimum Tensile Strength. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Circular Gravity Thickener Equipment 46 71 13 - 2 8. ASTM A536 – Standards Specification for Ductile Iron Castings. C. American National Standards Institute (ANSI): 1. ANSI B1.1 – Unified Inch Screw Threads (UN and UNR Thread Form). 2. ANSI B16.1 – Cast Iron Pipe Flanges and Flanged Fittings. 3. ANSI 9 – Load Ratings and Fatigue Life for Ball Bearings. 4. ANSI 11 – Load Ratings and Fatigue Life for Roller Bearings. D. American Gear Manufacturers Association (AGMA): 1. AGMA 9005-D – Lubrication of Industrial Enclosed Gear Drives. 2. AGMA 908-B – Geometry Factors for Determining the Pitting Resistance and Bending Strength of Spur, Helical and Herringbone Gear Teeth. 3. AGMA 1012 – Gear Nomenclature, Definitions of Terms with Symbols. 4. AGMA 2001-D – Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth. 5. AGMA 2004-B – Gear Materials and Heat Treatment Manual. 6. AGMA 6001-D – Design and Selection of Components for Enclosed Gear Drives. 7. AGMA 6010-F – Standard for Spur, Helical, Herringbone and Bevel Enclosed Drives. 8. AGMA 6019-E – Gearmotors Using Spur, Helical, Herringbone, Straight Bevel or Spiral Bevel Gears. 9. AGMA 6034-B – Practice for Enclosed Cylindrical Wormgear Speed Reducers and Gearmotors. E. American Institute of Steel Construction (AISC): 1. Specification for Design, Fabrication and Erection of Structural Steel for Buildings. F. American Iron and Steel Institute (AISI). G. American Welding Society (AWS). H. American Bearing Manufacturers Association (ABMA). I. National Electrical Manufacturers Association (NEMA). 1.3 SUBMITTALS A. Section 01 33 00 – Submittal Procedures: Requirements for submittals. B. Product Data: 1. Submit manufacturer information for system materials and component equipment, including performance characteristics. 2. Include descriptive literature, bulletins, and/or catalogs of the equipment. 3. Include the total weight of the equipment including the weight of the single largest item or component. 4. Provide a complete total bill of materials for all equipment. 5. Motor: a. Complete nameplate data. b. Special features (i.e., space heaters and space heater wattage, corrosion resistant features, etc.). 6. Electrical wiring diagram of each component supplied. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Circular Gravity Thickener Equipment 46 71 13 - 3 C. Shop Drawings: 1. Section 01 61 03 – Common Requirements for Equipment: Shop drawing submittal requirements. 2. Submit drawings showing details of construction, dimensions, weld requirements, and anchor bolt layout for each component of the system. 3. Provide documentation of the AGMA rating of the drive assembly and calculations verifying that the drive meets the specifications. 4. Provide complete description, control diagrams, and schematics of torque overload device. 5. Provide complete description of surface preparation and shop prime painting. 6. Submit detailed instructions on installation requirements, including storage and handling procedures. 7. Submit qualifications for manufacturer. 8. Refer to specification Section 26 29 13.01 - Industrial Control Panels for control panel submittal requirements. Control panels submitted that do not conform to this Section will be returned without review. 9. Project specific control details and electrical schematic and wiring diagrams. 10. Warranty information. D. Source Quality-Control Submittals: 1. Manufacturer's Certificate: Certify that products meet or exceed specified requirements. a. Section 01 33 00 – Submittal Procedures: Supplement 01. 2. Section 01 61 03 – Common Requirements for Equipment: Submittal requirements. 3. Submit results of factory tests of equipment. E. Field Quality-Control Submittals: 1. Section 01 33 00 – Submittal Procedures: Supplements 02 and 03. 2. Section 01 61 03 – Common Requirements for Equipment: Submittal requirements. 3. Section 01 91 00 – Facility Commissioning: Submittal requirements. 4. Indicate results of Contractor-furnished tests and inspections. 5. Certify that equipment has been installed according to manufacturer instructions. 1.4 CLOSEOUT SUBMITTALS A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for Operation and Maintenance Manual. In addition to the requirements of Section 01 70 00, the manual shall include the following at a minimum: 1. Complete parts list cross-referenced to an exploded view assembly drawing. 2. Step-by-step disassembly and reassembly instructions including tolerances and special requirements. 3. Dimensional drawings of all provided equipment. B. Section 01 91 00 – Facility Commissioning: Closeout Submittal requirements. C. Project Record Documents: Record actual locations and final orientation of equipment. 1.5 QUALITY ASSURANCE A. All system components shall be supplied to the Contractor by a single Manufacturer. The equipment shall be manufactured, constructed, and installed in accordance with the best practices and methods and operate satisfactorily when installed as shown on the Drawings. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Circular Gravity Thickener Equipment 46 71 13 - 4 B. Should equipment which differs from these Specifications be offered and determined to be equal to that specified, such equipment shall be acceptable only on the basis that any revisions in the design and/or construction of affected areas, including structure, piping, appurtenant equipment, electric, etc., required to accommodate such a substitution be made at no additional cost to the Owner and be as approved by the Engineer. 1.6 QUALIFICATIONS A. Manufacturer: Company specializing in manufacturing products specified in this Section with minimum ten years' experience. B. Manufacturer shall have supplied circular collection systems 60-feet in diameter and greater, with drives as specified herein, at water treatment plants with successful operation. The manufacturer shall also have a registered professional engineer on staff who has performed structural design of at least 10 circular clarifier mechanisms 60-feet in diameter or greater. A listing of the facilities and a resume of the registered professional engineer shall be submitted. Manufacturers not meeting these experience requirements are not acceptable. 1.7 DELIVERY, STORAGE, AND HANDLING A. Section 01 60 00 - Product Requirements: Requirements for transporting, handling, storing, and protecting products. B. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage. C. Store materials according to manufacturer instructions. D. Protection: 1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas. 2. Provide additional protection according to manufacturer instructions. 1.8 EXISTING CONDITIONS A. Field Measurements: 1. Verify field measurements prior to fabrication. 2. Indicate field measurements on Shop Drawings. 1.9 WARRANTY A. Reference Section 00700 – General Conditions, Article 7.17 for warranty terms. PART 2 - PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. Circular Gravity Thickener Equipment: 1. Evoqua - Envirex. 2. Ovivo. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Circular Gravity Thickener Equipment 46 71 13 - 5 3. WesTech. B. Submit substitutions in accordance with Section 01 25 00. 2.2 GENERAL REQUIREMENTS A. Tag Number: ST1-SC-001. B. Design Criteria: 1. All of the sludge thickener equipment specified herein is intended to be standard equipment for use with aluminum coagulant sludge from a conventional water treatment plant. 2. Sludge thickener equipment shall be installed in a circular concrete tank. 3. Thickener mechanism shall be designated to collect and remove settled solids. 4. Maximum influent sludge flow rate: 700 gpm. 5. Maximum influent solids concentration: 0.5%. 6. Thickened and concentrated settled sludge solids concentration: Up to 5%. 7. Maximum peripheral speed of rake arms and collector scraper blades: 10 ft/min. 8. Thickener Dimensions: a. Inside diameter: 60 feet. b. Side water depth, inboard launder configuration, and floor slope: As shown on the Drawings. 9. Thickener Configuration: a. Side feed and peripheral overflow weir type with a central drive mechanism. Side feed shall convey influent sludge directly into the influent feed well. Flow shall pass under the lower rim of the influent feed well, into the clarification zone, and then discharge over the peripheral overflow weir into the annular inboard discharge launder. b. Center column shall support the entire mechanical drive, collection equipment, and inboard end of the access bridge which spans from the outside wall of the tank. c. Center column turntable shall rotate two attached rake arm assemblies, which sweep the entire tank floor. Collector blades attached to the rake arms shall be arranged to move and clean settled sludge from the tank floor to a sludge hopper surrounding the center support pipe. 2.3 MATERIALS, EQUIPMENT AND FABRICATION A. All equipment shall be assembled in the manufacturer’s shop as far as practical to ensure proper fit of all parts, then match-marked for installation. and disassembled for shipment. All field connections shall be bolted connections, sized and arranged to resist all static, live erection loads. Field welded assembly, except for the bridge splice is not allowed. B. Equipment shall be constructed such that there are no chains, sprockets, bearings, or operating mechanism below the liquid surface or in contact with the liquid. C. All non-submerged structural steel used in fabrication of the equipment shall conform to the requirements of ASTM A36 and be hot-dipped galvanized. Submerged structural steel and steel parts shall be painted carbon steel and have a minimum thickness of 1/4-inch except as specified otherwise. Selection and fabrication of structural steel members shall be in accordance with the latest edition of the AISC Specification for the Design, Fabrication and Erection of Structural Steel for Buildings. All welding shall conform to the latest standards of AWS. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Circular Gravity Thickener Equipment 46 71 13 - 6 D. Drive assembly shall consist of an electric motor connected to a primary helical gear reducer, drive and sprockets with drive chain, if used, an intermediate worm gear reducer, pinion gear, turntable base, and main spur gear, complete with automatic overload activating systems. Drive assembly design shall be based upon 24-hour per day operation for a minimum of 20 years at specified maximum rotational speed. Drive assemblies shall be completely factory assembled and shipped as complete units. Cycloidal reduction units directly coupled to the pinion are also acceptable. 1. Entire drive assembly shall be rated on the basis of a maximum continuous working output torque of not less than 18,000 ft-lbs 17,000 ft-lbs (AD-02). At this torque, all gearing in the drive train shall be rated to the latest AGMA standards with a service factor of 1.5 for both strength and durability. With respect to the main spur gear and companion pinion, the AGMA rating shall be based on a life of 20 years continuous duty for both strength and durability. Drive assembly shall be capable of withstanding a stalled torque of twice the maximum continuous working output torque. At the stalled torque, no components of the drive train or drive platform shall be stressed to a level greater than 90 percent of yield. In addition, the unit shall be of sufficient strength to screed 2 inches of concrete grout in the tank bottom without damage to any of its components. 2. Drive motor shall be either 1,200 or 1,800 rpm, totally enclosed fan cooled (TEFC) for outdoor service and shall conform to the requirements of Section 01 61 03 – Common Requirements for Equipment. Motor shall be rated for a maximum of 1.0 HP and sized such that the nameplate horsepower rating shall not be exceeded if the mechanism operates at the stalled torque. Motors shall be 460VAC/3Ph/60Hz and premium efficiency, severe duty, TEFC construction, class F insulation, industrial type designed for operation in 50 ºC, 100% relative humidity, dusty, and corrosive ambient conditions. a. Anti-condensation heaters shall be provided for motors and shall be cartridge or flexible wrap-around type installed within the motor enclosure adjacent to core iron. Heaters shall be rated for 120VAC/1Ph/60Hz operation and have a heat rating (i.e., wattage) appropriate for the size motor they are protecting. Manufacturer shall coordinate the wattage of the anti- condensation heaters with the size of the control power transformer (CPT) provided and installed as part of the mechanism control panel. The heater wattage and voltage shall be embossed on the motor nameplate. Power leads for the heaters shall be brought out of the motor through the motor lead junction box (i.e., shared box). b. Motor nameplates shall be embossed stainless steel and fastened to the motor frame with stainless steel screws or drive pins. Nameplates shall clearly indicate all of the items of information enumerated in the NEMA Standard MG 1-10.38 or MG 1-20.60, as applicable. 3. Primary helical gear reducer shall be either directly connected geared motor type or be separately connected to the electric motor by a flexible coupling. Gear assemblies used in the primary gear reducers shall conform to AGMA Service Classification II and have a service factor of not less than 1.4. Gears shall be oil lubricated and supported on anti- friction bearings. Oil fill, drain, vent, and level indicator devices shall be provided. Oil level monitoring, drainage and refill shall be easily accomplished from a safe working position on the operating platform and all fittings shall be provided with clear accessibility and work room. The oil drain shall have an extension tube as required to allow collection of drained oil into a container. Arrangements requiring auxiliary oil pumps or recirculating systems are not acceptable. 4. Chain drive, if used, shall have a minimum factor of safety of 4 as applied to the ultimate breaking or transmission strength of the chain with respect to loads transmitted at twice the maximum continuous working output torque rating of the mechanism. Chains shall be steel BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Circular Gravity Thickener Equipment 46 71 13 - 7 roller type. Sprockets shall be fabricated from steel or high test cast-iron. Chain and sprockets shall be enclosed in a weatherproof fabricated Type 316 stainless steel guard provided with service openings. All guard hardware shall be Type 316 stainless steel. 5. Intermediate worm gear or cycloidal reducer shall be secured to the turntable base. The intermediate gear set shall be a cycloidal or cylindrical worm and worm gear. The worm gearing assembly shall be supported on anti-friction roller bearings and operate in an oil bath. Worm gear shall be centrifugally cast bronze or high-test cast-iron and manufactured in one or two parts. If the worm gear consists of two parts (rim and spider), they shall be shouldered, bolted, and doweled for concentricity. Worm shall be hardened ground alloy steel or high-test heat-treated cast iron. Worm gearing shall be enclosed in an ASTM A48 Class 40 high grade cast-iron housing with a removable cover over the worm. Bearings shall be oil lubricated. Output pinion shaft shall be one piece construction with no over- hung loading conditions. Shaft shall be precision aligned and supported by upper and lower taper bearing assemblies machined into the intermediate housing and turntable base. Lower pinion pocket, if used, shall not be a collection point for condensation or drain. Suitable oil fill, drain and oil level indicator devices shall be provided. Oil level monitoring, drainage and refill shall be easily accomplished from a safe working position on the operating platform and all fittings shall be provided with clear accessibility and work room. The oil drain shall have an extension tube as required to allow collection of drained oil into a container. 6. Turntable base shall be bolted to the bridge support system and shall be high-test cast-iron conforming to ASTM A48 Class 40 and substantially thick enough to provide adequate rigidity for proper bearing support. Turntable base shall support the main spur gear and the entire rotating mechanism. The top of the turntable base shall form or support a convenient access platform for the drive mechanism. Turntable base shall have an annular raceway for a ball race upon which the main spur gear rotates. The turntable base shall incorporate a deep oil reservoir to allow sediment to settle away from the ball race and shall have no seals, gaskets, or joints below the oil level to prevent leakage of oil. Turntable base and main spur gear housing shall be constructed such that the balls and insert strip liners, if provided, in the main spur gear and turntable base can be replaced without removing the access bridge and walkway. (AD-02) 7. The ball race, which supports the rotating mechanism, shall have a sufficient diameter to assure stability, without the need of guide shoes and shall be designed for both radial and thrust loads. The ball race shall use alloy steel balls, which shall rotate on renewable hardened steel strip liners, inserted in the turntable base and main spur gear, or rotate on full-contour deep groove raceways. Units utilizing full-contour deep groove raceways in the gear shall provide for replacement of the balls without removing the gear. Balls shall run in an oil bath, which shall be protected by a felt seal and a steel dust shield. Grease lubrication is not permitted. Suitable oil fill, drain and level indicator devices, which can be easily read from the operating platform, shall be provided. Oil level monitoring, drainage and refill shall be easily accomplished from a safe working position on the operating platform and all fittings shall be provided with clear accessibility and work room. The oil drain shall have an extension tube as required to allow collection of drained oil into a container. An automatic condensate drain assembly shall be provided. Manufacturer shall provide all condensate drain piping and accessories required. 8. Main spur gear shall be high-test nodular cast-iron conforming to ASTM A536 with a minimum strength of 80,000 psi, or alloy forged steel conforming to AISI 1050 with a minimum ultimate strength of 120,000 psi, or cast-steel conforming to ASTM A148. Gear shall be driven by either a heat-treated high-strength cast-iron or heat-treated alloy steel BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Circular Gravity Thickener Equipment 46 71 13 - 8 pinion gear keyed to the output shaft of intermediate reducer. Main spur gear shall support the entire load of the rotating collector assembly from the mounting lugs. 9. Gear assemblies used in speed reducers or geared motors shall conform to AGMA Service Classification II. All gear assemblies, including the main spur gear and pinion, used in the drive assembly shall conform to the applicable requirements of the AGMA Standards specified in PART 1 and shall be specially selected for the actual operating speed range of the mechanism. 10. All bearings incorporated within the drive assembly shall be anti-friction type, oil lubricated and conform to the following schedule of minimum rated-life expectancy (B- 10) based on ABMA standards when operating at the maximum continuous working output torque rating of the equipment. a. Main turntable and pinion bearing: B10-200,000 hours. b. Intermediate worm and wheel gearbox bearings: B10-200,000 hours. c. Primary helical and spur speed reducer gearbox bearings: 10-30,000 hours. d. Gearmotor (direct drive): B10-30,000 hours. 11. Load indicating and overload warning device shall be incorporated into the drive assembly. The device shall be actuated by thrust from the worm shaft or rotation of the intermediate reducer against a calibrated spring and shall have an indicating meter, so that the load on the mechanism can be visually monitored from the platform at all times during operation. The indication meter shall provide a visual reading of the “Maximum Continuous Working Output Torque” on a 0 to 100% scale graduated in 10% increments. The assembly enclosure shall be completely weatherproof and provided with access panels for field adjustment or removal of parts when necessary and 120VAC/1Ph/60Hz heaters to prevent condensation. The enclosure for electrical components shall be weatherproof NEMA 4X stainless steel or NEMA 4X cast aluminum (AD-02). Exposed linkage bars are not acceptable. a. Overload warning device shall be pre-set at the factory to allow the transmission of a remote signal in case of impending excessive load. The device shall be set to energize an alarm in the case of impending excessive load over a field adjustable range of 75 to 100% of the maximum continuous working output torque. b. An automatic motor cut off feature shall be incorporated into the function of the overload warning device. Automatic cut off shall occur at 125% of the maximum continuous working output torque and shall be field adjustable from 110 to 140% of the maximum continuous working output torque. Automatic cut off shall energize an alarm at the panel, which shall be transmitted to the plant SCADA system. c. Electrical supply to the overload device shall be 120VAC/1Ph/60Hz. Provide dry contacts, rated 10 Amps at 120VAC for remote control of alarms. Provide one pair of contacts for warning with one normally open and one normally closed contact. Motor amperage sensing devices are not acceptable for torque overload protection. 12. A shear pin device, set for 150% of the maximum continuous working output torque shall be furnished. 13. Sludge collector drive shall be designed for the specified continuous torque rating. Continuous torque shall be defined as the minimum torque at which the sludge collector drive mechanism may operate continuously 24 hours per day, 365 days per year, for 20 years, at the specified maximum sludge collector arm speed. Main gear calculations shall be based upon AGMA 2001-D standards for rating the pitting resistance and bending strength of spur gear teeth. Calculations shall clearly specify the values used for the following design parameters: a. Number of pinions. b. Actual face width BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Circular Gravity Thickener Equipment 46 71 13 - 9 c. Tooth geometry (I and J factors). d. Load distribution factor. e. Allowable contact stress. f. Allowable bending stress. g. Pinion pitch diameter. h. Hardness ratio factor. i. Elastic coefficient. j. Life factor. 14. The load distribution factor shall be determined by the empirical method. Calculations shall include a full description of materials and heat treatment used. Worm gearing shall be designed and rated to equal or exceed the specified continuous torque and life. The basis for rating shall be AGMA Standard 6034-B or other gear design criteria that include design values to be applied for materials used, pressure angle, addendum modifications, and allowable stresses with appropriate re-rate for life cycles required. The following design parameters shall be included in the drive calculations: a. Gear materials, and physical properties. b. Gear pitch or effective diameter. c. Actual face width. d. Tooth pressure angle. e. Number of gear teeth. f. Worm material, heat treatment and finish. g. Number of starts. E. Access bridge and 3-foot-wide walkway as shown on the Drawings shall be half bridge type. The elevation of the access platform shall be a manufacturer recommended distance above the inboard launder weir elevation to eliminate condensation from accumulating in the main spur gear turntable base. Bridge shall be supported at the tank sidewall and center column. Access bridge shall consist of structural trusses, beams and/or channels. Bridge shall be oriented as shown on the Drawings. Access bridge and drive platform (AD-02) Walkway shall be covered with 3/8-inch minimum aluminum checkered plate at least 36-inches wide inside the guardrails. Walkway and bridge shall be capable of withstanding a superimposed loading of 100-pounds per square foot. Deflection of the access bridge under this load shall not exceed 1/360 of the span. A mechanically connected two rail 42-inch-high aluminum guardrail shall be provided along both sides of the walkway and around the perimeter of the center drive platform. Guardrail shall be constructed of 1-1/2-inch Schedule 40 anodized aluminum pipe with Type 316 stainless steel fasteners. A 4-inch-high anodized aluminum toeplate shall be attached to the guardrail using Type 316 stainless steel fasteners. The operating platform at the turntable base shall be skidproof 3/8-inch-thick aluminum checkered plate and shall provide a walkway space at least 3-feet wide on all sides of the drive. Provide neoprene isolation strips between all aluminum materials and steel. The entire access bridge and walkway to the tank sidewall shall be provided by the thickener manufacturer. F. Center support pipe shall support the entire rotating sludge thickener mechanism. Center support pipe shall be constructed from 3/8-inch thick (minimum) painted carbon steel plate reinforced where necessary. Center support pipe shall be constructed such that no portion of the pipe or base plate are stressed beyond the allowable limits set forth AISC specification when the full stall torque load of the drive assembly is applied. 1. Center support pipe shall be mounted to the concrete tank foundation. The thickener manufacturer shall furnish a template to locate anchor bolts for the support pipe base plate. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Circular Gravity Thickener Equipment 46 71 13 - 10 Two 8-inch square or circular bolted inspection and access hatches shall be provided at the base of the support pipe. G. Influent feed well shall be at least 7 feet in diameter and have a minimum projection of 3 inches above the maximum water surface and shall extend at least 5 feet below the water surface. The influent feed well shall be constructed of 3/16-inch (minimum) painted carbon steel plate reinforced with a top ring angle and stiffening angles where necessary, supported from the access bridge. Weir gates or slots complete with baffles shall be provided for the continuous or periodic removal of floating material from inside the influent baffle without allowing short circuiting of the influent liquid. The weir gates or slots shall be accessible from the platform. H. Center drive cage shall be an all-welded box truss constructed of painted carbon steel having a minimum plate thickness of 1/4-inch. Center drive cage shall be fastened to the turntable base and main spur gear assembly with Type 316 stainless steel bolts. The two rake collector arms shall be connected to the center drive cage by rigid bolted connections. The center drive cage shall support and rotate the two rake collector arms. The center drive cage shall have sufficient strength and rigidity such that no member shall be stressed beyond the allowable limits set forth in the AISC specification when the full stalled torque load of the drive assembly is applied at one point at the bottom of one rake collector arm. I. The mechanism shall include two structural painted carbon steel rake collector arms located 180 degrees apart rigidly connected to the center drive cage. The rake collector arms shall be truss construction, either rectangular or triangular, conforming to the slope of the tank floor and shall extend from the center drive cage to the inside face of the outer wall of the tank. Each rake collector arm shall be provided with painted carbon steel blades to scrape the thickened sludge along the tank bottom to the sludge hopper located at the center of the tank. The rake arms and scraper blades shall be arranged to scrape the entire tank bottom twice per revolution of the mechanism. 1. To ensure alignment and connection to the center drive cage, the width of the rake collector arms shall be approximately the same as the center drive cage. The rake collector arms shall be connected to the center drive cage in such a manner that each arm can be easily removed completely or adjusted to conform to the angle of the tank floor when the tank is partially or completely empty. Furnish steel shims as required to adjust rake arm angle. The arms shall not incorporate the use of tie rods or yoke connections. 2. Components of the rake collector arms shall be constructed from 1/4-inch thick (minimum) painted carbon steel plate and angles, suitably reinforced such that no portion of the rake arm is stressed beyond the allowable limits set forth in the AISC specification when the full stall torque load of the drive assembly is applied as a distributed load on one of the rake arms. 3. Sludge hopper shall be furnished with a four-blade scraper assembly. The scraper shall be designed to continuously move accumulated sludge to the sludge withdrawal pipe. The blade settings shall be such that the sludge hopper is scraped four times with each revolution of the mechanism. Each scraper blade shall be rigidly fixed to the drive cage. Each scraper shall be constructed such that no portion of the scraper is stressed beyond the allowable limits set forth in the AISC specification when 100% of the stall torque, applied as a concentrated load, of the drive assembly is applied. 4. Rake collector blades shall have a minimum depth of 9-1/2 inches and shall be stilted construction for maximum thickening. All blades shall be provided with adjustable Type 304 stainless steel squeegees projecting approximately 1-1/2 inches below the bottom of the blade and secured by Type 316 stainless steel bolts and nuts. Each squeegee shall have BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Circular Gravity Thickener Equipment 46 71 13 - 11 a minimum thickness of 20 gauge and be arranged for a 2-inch minimum adjustment in the vertical plane. J. Effluent Weirs: 1. Provide weir plates attached to the peripheral overflow weir wall to control water flow into the annular inboard discharge launder. 2. Weirs shall be 8-inch high by minimum ¼-inch thick fiberglass reinforces polyester resin with support brackets, weir butt plates, and hardware as specified. K. Bolts, Nuts, Washers, and Anchors: 1. Thickener manufacturer shall be responsible for determining the number, size, and location of all anchor bolts to be set in concrete. Anchor bolts, nuts and washers shall be ASTM A276, Type 316 stainless steel or as otherwise specified. Anchor bolts for field tests may be mild steel bolts. Thickener manufacturer shall furnish all anchor bolts. 2. Bolts, nuts, and washers for equipment assembly shall be Type 316 stainless steel. All threads shall be clean cut and shall conform to ANSI Standard B1.1. 3. Mild steel bolts, nuts, and washers may be used only in non-submerged locations and shall be galvanized after being threaded by the hot-dip process in conformance with the ASTM A123 or ASTM A153, as appropriate, unless noted otherwise. 4. All templates for setting anchorage shall be furnished by the thickener manufacturer. 2.4 CONTROL PANEL A. Thickener supplier shall provide a manufactured control panel to power and control the thickener. The supplier shall provide the control system, motor controller, and field devices to safely and completely operate the system. B. Control panel requirements: 1. Control panel shall be UL 508A labeled. 2. Refer to Section 26 29 13.01 - Industrial Control Panels for additional control panel product and fabrication requirements not listed within this specification. 3. Environmental Conditions: a. Temperature: 0-45 degC, outdoor, under direct sunlight. b. Humidity: 0-95%, noncondensing. c. Altitude Rating: Not exceeding 1000 feet. d. Electrical equipment supplied shall be fully rated for the environmental conditions. Derate electrical equipment as required to remain below individual component operating temperature ratings. 4. Manufacturer shall coordinate with Contractor to provide wiring between all system components as required. 5. Power Supply: a. Panel shall require a single 480 V, 60 Hz, 3Ph, 3W power supply. b. Panel Ampacity: 20A. c. Panel Short Circuit Current Rating (SCCR): 42kAIC. d. All other voltages required by system shall be changed from inside the panel, through the use of control power transformers or DC power supplies. 6. Enclosure: a. NEMA 4X rated Type 316 stainless steel. Enclosure shall be suitable for wall mounting. Door(s) shall swing horizontally and shall be held closed with mechanical spring-loaded fasteners. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Circular Gravity Thickener Equipment 46 71 13 - 12 7. At a minimum, the following must be provided with the panel: a. Main circuit protective device (Circuit Breaker or Fuses). b. NEMA rated contactor, minimum Size 1. c. Control power transformer. d. Relays. e. Phase failure relay. f. Terminal and power distribution blocks to connect field wiring connections to panel. No direct termination to relays and motor controllers will be permitted. g. Condensate and breather drain. h. Pushbutton and indication lights. i. Control panel mounted beacon/sounder with silence pushbutton for alarming. j. Thermostatically-controlled panel space heater. k. Refer to Drawings for control schematic. 2.5 FINISHES A. Surface preparation, shop priming, and field painting shall be as specified in Section 09 96 00 – High-Performance Coatings. B. Galvanized steel, aluminum, and stainless steel shall not be painted. 2.6 SPARE PARTS A. Manufacturer shall furnish the following spare parts: 1. One set of rake blade squeegees for all scrapers. 2. One drive chain, if used. 3. One set of heat-treated steel bearing strip liner inserts for main turntable assembly, if used. 4. Ten shear pins. 5. One torque switch (drive control) assembly. 6. Two control power transformer primary fuses. 7. Two control power transformer secondary fuses. 8. Two push-to-test pilot light lenses (two of each color). 9. Provide all special tools required for normal maintenance, including any special equipment required to facilitate drainage or refill of lubricating oils. B. All spare parts shall be suitably packaged or boxed for long-term storage. Each part shall be clearly identified by part description, part number and other pertinent information or data. C. At a minimum, manufacturer shall provide an adequate supply of consumables and calibration materials necessary to operate and maintain the equipment for one year period after Substantial Completion. PART 3 - EXECUTION 3.1 EXAMINATION A. Section 01 70 00 – Execution and Closeout Requirements: Requirements for installation examination. B. Verify layout, type, material, and orientation of connections. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Circular Gravity Thickener Equipment 46 71 13 - 13 3.2 INSTALLATION A. Section 01 61 03 – Common Requirements for Equipment: Installation requirements. B. Installation shall be in strict accordance with the manufacturer's instructions. C. Furnish the required oil and grease for initial operation. The grades of oil and grease shall be in accordance with the manufacturer’s recommendations. D. Install anchor bolts in accordance with the manufacturer’s recommendations and setting drawings. 3.3 FIELD QUALITY CONTROL A. Section 01 40 00 – Quality Requirements. B. Sections 01 61 03 – Common Requirements for Equipment, 01 70 00 – Execution and Closeout Requirements, and 01 91 00 – Facility Commissioning: Testing, Startup, Demonstration, and Training requirements. C. Acceptance Testing: Working under the direction of the manufacturer, field tests shall be performed as follows. 1. A torque test shall be conducted prior to placement of the concrete grout finish on the thickener floor. a. Anchor bolts shall be embedded in the concrete floor at points near the outer portion of the rake arms. Anchor bolts shall be suitable for the loads applied and shall be cut off flush with the rough concrete surface after the tests are completed. Bolts shall be arranged so that a single cable is used at the apex of the cables connecting panel point of one collector arm. A hydraulic cylinder of sufficient capacity and known piston diameter, complete with pressure gauge, shall be connected to the anchor bolts to determine the horizontal load developed. The required gauge reading shall be such that it indicates a force at the anchor bolts, which, when multiplied by the distance from the center of the tank to the anchor bolts, equals twice the specified maximum continuous working output torque. This force shall be maintained for a period of 15 seconds to assure that the equipment is capable of withstanding the required loading under static test conditions (without the drive motor in operation) and to verify or correct the setting of the overload device prior to the actual testing of the equipment with the drive motor. Adjust the overload warning torque setting to specified values. b. After the above test and adjustments and settings to the overload device have been made, the drive motor shall be turned on and the mechanism loaded to overload condition to assure that the mechanism alarms and stops when an overload condition occurs in the tank. c. Alternative methods of producing the test torque may be considered. Submit written details of alternative test procedures for approval. Alternative test methods shall not apply impact loading or uneven loading conditions to the mechanism, which may reduce the life of the equipment. 2. Upon completion of the static and operating torque tests, the mechanism shall be run dry for a period of 8 hours and shall operate without vibration, noise, jamming or overheating. Special attention shall be given during the dry test run to the clearance of the rake scraper blades. BCRUA - Phase 1D WTP Expansion Issued for Bid (Revised by AD-02) Circular Gravity Thickener Equipment 46 71 13 - 14 3. Tests shall be conducted in the presence of the Engineer. 4. In the event that the mechanism fails to pass the above tests, necessary changes shall be made, and the mechanism retested. If the mechanism remains unable to meet test requirements to the satisfaction of the Engineer, it shall be removed and replaced with a satisfactory mechanism at no additional cost to the Owner. D. Services of Manufacturer: 1. Reference Sections 01 61 03 – Common Requirements for Equipment, 01 70 00 – Execution and Closeout Requirements, and 01 91 00 – Facility Commissioning for general requirements. 2. Provide the services of a factory certified service engineer specifically trained in the installation, start-up, testing, operation, and maintenance of equipment specified herein. Such services shall be provided by a representative who is a direct, full-time employee of the manufacturer or their certified representative. 3. Services of equipment manufacturer's representative shall include: a. Inspect equipment covered by this Section. b. Supervise adjustments and installation checks. c. Provide test equipment, tools, and instruments necessary to accomplish equipment testing. d. Conduct initial check-out and start-up of equipment, perform operational checks, and supervise acceptance testing. e. Provide a written statement that manufacturer's equipment has been installed properly, started up and is ready for operation by Owner. f. Instruct Owner on operation and maintenance of furnished equipment. 4. Operation and maintenance training shall include the following, at a minimum: a. Theory of operation. b. Step-by-step start-up and shut-down procedures. c. Step-by-step, “hands-on” assembly and disassembly procedural instructions. d. Replacement part identification and ordering procedures. e. Lubrication procedures, including drain-down and refill procedures. f. Recommended routine maintenance procedures. g. Troubleshooting and diagnostic procedures. h. Instrument adjustment. 5. Services of manufacturer's representative shall be provided for the minimum amount of time specified below. a. Supervision, start up, and testing: 16 hours. b. Instruct Owner on operation and maintenance: 8 hours (2 sessions, 4 hours each). END OF SECTION BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 1 SECTION 46 76 21 - BELT FILTER PRESS (Revised by AD-02 & AD-03) PART 1 - GENERAL 1.1 SUMMARY A. Section Includes: 1. Belt filter press, auxiliary equipment, and accessories. B. Scope of Work: 1. Furnish all labor, materials, equipment and incidentals required and install, test, and make ready for operation one 2-meter effective width belt filter press (SDF-BFP-002) as specified and illustrated on the Drawings. All control panels, valves, and other appurtenances that are required for a complete and operating installation shall be provided. Furnished equipment shall meet all specified performance and mechanical requirements. 2. The proposed belt filter press shall work in conjunction with: a. Existing Belt Filter Press (SDF-BFP-001). b. Proposed Shaftless Screw Conveyors (SDF-SSC-003, SDF-SSC-004, and SDF- SSC-005) specified in Section 41 12 13. The discharge chute of the belt press shall be configured to discharge onto screw conveyor SDF-SSC-003 and the belt press control panel shall control the operation of all three screw conveyors. c. Existing Belt Press Feed Pumps (SDF-BPFP-001 and SDF-BPFP-002). d. Existing Sludge Dewatering Polymer Feed Systems (SDF-PFS-001 and SDF-PFS- 002). 3. The existing Belt Filter Press is a 2.0 meter Ashbrook Two-Belt Klampress with an Extended Gravity Section. 4. If the proposed equipment requires an arrangement or spacing different from that indicated on the Drawings or specified, prepare and submit detailed structural, mechanical, and electrical Drawings and equipment lists showing all necessary changes to accommodate proposed equipment. Drawings and equipment lists shall be signed and sealed by a Professional Engineer licensed in the State of Texas. Such changes, if approved, shall be accomplished at no additional cost to the Owner. The Contractor shall assume the cost of, and responsibility for, satisfactorily accomplishing the necessary structural, mechanical, piping, and electrical changes corresponding to the dimensions and characteristics of the equipment submitted and approved by the Engineer. C. Related Sections: 1. Division 00 – Proposal Requirements, Contract Forms, and Conditions of the Contract. 2. Division 01 – General Requirements. 3. Section 01 91 00 – Facility Commissioning. 4. Division 03 – Concrete. 5. Division 05 – Metals. 6. Section 09 96 00 – High-Performance Coatings. 7. Division 26 – Electrical. 8. Section 26 26 13.01 – Industrial Control Panels. 9. Section 26 29 23 – Low Voltage Variable Frequency Drives. 10. Division 40 – Process Integration. 11. Section 40 90 02 – Supervisory Control and Data Acquisition (SCADA) System. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 2 12. Section 40 90 02.01 – SCADA Loop Descriptions. 13. Section 41 12 13 – Shaftless Screw Conveyors. 1.2 REFERENCE STANDARDS A. American Bearing Manufacturers Association: 1. ABMA 11 - Load Ratings and Fatigue Life for Roller Bearings. B. American Gear Manufacturers Association: 1. AGMA 2001 - Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth. C. American National Standards Institute: 1. ANSI 9 - Load Ratings and Fatigue Life for Ball Bearings. 2. ANSI B16.1 - Cast Iron Pipe Flanges and Flanged Fittings. D. ASTM International: 1. ASTM A36/A36M - Standard Specification for Carbon Structural Steel. 2. ASTM A123/A123M - Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products. E. American Welding Society. F. National Electric Code. G. National Electrical Manufacturers Association: 1. NEMA 250 - Enclosures for Electrical Equipment (1000 Volts Maximum). H. Steel Structures Painting Council: 1. SSPC-SP-10 - Surface Preparation Specification No. 10 Near White Blast Cleaning. 1.3 SUBMITTALS A. Section 01 33 00 - Submittal Procedures: Requirements for submittals. B. Shop Drawings: 1. See Section 01 61 03 – Common Requirements for Equipment shop drawing submittal requirements. 2. Product Data: Submit manufacturer's information for system and component equipment, including electrical characteristics, materials of construction, and coatings. 3. Certified shop and erection drawings showing all important details of construction, sludge feed, wash water, drainage connections, wiring and control diagrams, itemized motor horsepower, dimensions, fasteners, anchor bolts, and other pertinent details. 4. Certified safety factor calculations signed and sealed by a Professional Engineer for structural frame, roller bearings and roller shafts, as well as maximum roller and frame deflection based on maximum design belt tension of 50 PLI (lbs per lineal inch of belt width) or total of 200 PLI for all belts at a belt speed of five (5) meters per minute. 5. General process description, including gravity drainage and low, medium and high pressure stages. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 3 6. Belt system drive details, including typical range of belt tension and recommended belt tension for this application. 7. Belt changing procedures including, the size of the largest component to be removed or lifted and the time (manhours) estimated for a complete belt change. 8. Statement of wash water requirements (flow and pressure). 9. Information on field erection requirements, including total weight of assembled components, weight of the single largest component that will require removal during the life of the unit and gross operating weight. a. For each baseplate, furnish the loads including all horizontal and vertical components as follows: 1) Deadloads due to unit weight empty. 2) Deadloads due to unit weight full of sludge, drain pans full and similar circumstances. 3) Dynamic loads. 4) Sum of Items 2) and 3). 5) Loads exerted during belt changing procedures. 10. Motors: a. Total connected nameplate horsepower and operating horsepower for each belt press motor. 11. Control Panels: a. Dimension and layout details. b. Materials of construction. c. Brand names and catalog literature on all control devices, including: 1) Fused disconnects. 2) Motor starters. 3) Terminal blocks. 4) VFD controllers. 5) Alarm devices. 6) All switches and lights. 7) Timers, relays and related equipment. 8) Programmable Logic Controllers (PLCs). 12. Manufacturer Instructions: Submit detailed instructions on installation requirements, including storage and handling procedures. 13. Manufacturer Experience: Proof of successful operation of equipment of same model and capacity in full-scale operation dewatering similar sludges. Include names of contacts and telephone numbers, date of installation, and model number furnished for three (3) separate installations. 14. Warranty information. C. Source Quality-Control Submittals: 1. Manufacturer's Certificate: Certify that products meet or exceed specified requirements. a. Section 01 33 00 – Submittal Procedures: Supplement 01. 2. Section 01 61 03 – Common Requirements for Equipment: Submittal requirements. 3. Submit results of factory tests and inspections. D. Field Quality-Control Submittals: 1. Section 01 33 00 – Submittal Procedures: Supplements 02 and 03. 2. Section 01 61 03 – Common Requirements for Equipment: Submittal requirements. 3. Section 01 91 00 – Facility Commissioning: Submittal requirements. 4. Acceptance test procedures. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 4 5. Indicate results of Contractor-furnished tests and inspections. 6. Certify that equipment has been installed according to manufacturer instructions. 1.4 CLOSEOUT SUBMITTALS A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for submittals and operation and maintenance manuals. In addition to the requirements of Section 01 70 00, the manual shall include the following at a minimum: 1. Operating and maintenance manuals shall be prepared specifically for this installation and shall include all required cuts, drawings, equipment lists, descriptions, etc. that are required to instruct operating and maintenance personnel. 2. State the manufacturer's ability to furnish repair and maintenance services. Include location of the nearest qualified maintenance repair service representative with a description of their available services, nearest technical sales representative, and location of nearest spare parts inventory. B. Section 01 91 00 – Facility Commissioning: Closeout Submittal requirements. C. Project Record Documents: Record actual locations of installed belt filter press equipment. 1.5 UNIT RESPONSIBILITY AND QUALITY ASSURANCE A. The entire belt filter press system specified shall be provided by the belt filter press supplier in order to ensure coordination and compatibility between all components. B. Contractor shall be responsible for all on-site installation work for the polymer system specified herein. The belt filter press supplier shall be responsible for providing the required technical services to Contractor during the installation of the belt filter press system. C. The belt filter press supplier shall be responsible for furnishing and installing an integrated control panel combining control for all functions of the belt filter press, existing polymer feed system, existing progressing cavity sludge transfer pumps, and three proposed screw conveyors as specified in Section 41 12 13 – Shaftless Screw Conveyors. D. If the installed equipment fails to meet all parameters of specified process performance when properly operated, then the manufacturer shall, at no cost to the Owner, make modifications as required to achieve specified performance, up to and including replacement of installed units. 1.6 QUALIFICATIONS A. Manufacturer Experience: Belt filter press manufacturer shall have a minimum of ten (10) years of experience in constructing specified equipment and shall have a minimum of five (5) similar installations, each having a minimum of 10,000 hours of successful operation. 1.7 DELIVERY, STORAGE, AND HANDLING A. Section 01 60 00 - Product Requirements: Requirements for transporting, handling, storing, and protecting products. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 5 B. Factory assembled parts and components shall not be dismantled for shipment unless permission is received in writing from the Engineer. C. Inspection: Accept materials on Site in manufacturer's original packaging and inspect for damage. D. Store materials according to manufacturer instructions. E. Protection: 1. Protect materials from moisture and dust by storing in clean, dry location remote from construction operations areas. 2. Provide additional protection according to manufacturer instructions. 1.8 EXISTING CONDITIONS A. Field Measurements: 1. Proposed belt filter press system will be installed in the existing Sludge Dewatering Facility and shall fit within existing equipment pad and containment curb. Verify dimensions and clearances within the containment curb and coordinate the installation of the belt filter press with the related work included in the system. Verify equipment supports, structure dimensions, and arrangement and notify the Engineer of any discrepancy before submitting shop and erection drawings for approval. 2. Verify field measurements prior to fabrication. 3. Indicate field measurements on Shop Drawings. 1.9 WARRANTY A. Reference Section 00700 – General Conditions, Article 7.17 for warranty terms. B. Warranty shall include the entire belt filter press system and proposed ancillary sub-systems furnished by the belt filter press Manufacturer. C. Belt filter press bearings shall have a five (5) year warranty on materials and labor. PART 2 - PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. Belt Filter Press: 1. Alfa Laval (Ashbrook Simon-Hartley). 2. Andritz. 3. Komline-Sanderson. B. Filter Belt Wash Station: 1. Appleton Manufacturing. 2. Heinrich Stamm Company. 3. Or approved equal. C. Bearings and housings: 1. FMC Corporation. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 6 2. SKF Industries. 3. Dodge Industrial. 4. Or approved equal. D. Programmable logic controller (PLC): As specified in Section 40 90 02 - Supervisory Control and Data Acquisition (SCADA) System. 2.2 SERVICE CONDITIONS A. The belt filter press system shall function as a complete system to dewater water treatment plant (WTP), aluminum coagulant sludge. The dewatered sludge will be disposed of at a landfill and must consistently meet a paint filter test under all specified operating conditions. B. The WTP treats raw surface water from Lake Travis via a floating pump station moored on the Sandy Creek arm of the lake. Raw water characteristics at the lake surface from monthly data collected between February 2019 and January 2021 are summarized below. 1. Turbidity (NTU): a. Minimum: 1.0. b. Average: 1.8. c. Maximum: 5.7. 2. Temperature (ºC): a. Minimum: 11.7. b. Average: 22.0. c. Maximum: 30.6. 3. pH: a. Minimum: 7.9. b. Average: 8.3. c. Maximum: 8.9. 4. Alkalinity (mg/L): a. Minimum: 151. b. Average: 156. c. Maximum: 161. C. Raw water Total Organic Carbon (TOC) in mg/L from recent historical data: 1. Minimum: 2.7. 2. Average: 3.0. 3. Maximum: 3.5. D. Coagulants used for water treatment: 1. Primary: Aluminum Chlorohydrate. a. Average dose: 14 mg/L. 2. Coagulant aid: Cationic Polymer. a. Average dose: 0.5 mg/L. E. Polymer used for sludge conditioning: 1. SNF Polydyne: Clarifloc A-210P anionic polymer. F. Available Water Supply: 90 gpm maximum at 90 psig. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 7 2.3 PERFORMANCE AND DESIGN CRITERIA A. Tag number: SDF-BFP-002. B. Type: Two belt, extended gravity. C. Minimum effective belt width: 2.0 meters. D. Sludge Type: Conventional WTP as specified in SERVICE CONDITIONS. E. Solids: 1. Feed Concentration: 1 to 3%. 2. Minimum Dewatered Cake: a. 18% with solids ash content greater than 75%. b. 16% with solids ash content greater than 65%, but less than 75%. 3. Minimum Dry Discharge Capacity: 2,100 lbs/hr. 4. Minimum Recovery: 95%. F. Design Hydraulic Loading Rate: 140 gpm at 3% solids. G. Power supply: 460 volt, 60 Hz, 3 phase. H. Maximum connected electrical load: 10 HP. I. Anticipated operation: 8 hrs/day, 4 days/week. J. Sludge Conditioner: 1. Type: In-line, self-cleaning, variable orifice venturi with vortex injection ring. 2. Mixing time: Less than 1.0 seconds at 60 gpm. 2.4 MATERIALS A. General: 1. Materials shall be free from all defects and imperfections that might affect the service ability of the finished product. No used equipment or materials allowed. 2. Materials shall be as follows, unless specified otherwise. B. Structural Frame: ASTM A36 carbon steel or Type 316L stainless steel. C. Belt Support Bars, Rollers, Distribution and Discharge Chutes, Sheet Metal, Drainage Pans, Hydraulic Actuators, Hydraulic Piping and Reservoir: Type 316 stainless steel. D. Discharge Doctor Blade: Type 316 stainless steel, with replaceable polypropylene or UHMWPE doctor blade. E. Plows (Chicanes): HDPE. F. Anchor Bolts, Fasteners, and Hardware: Type 316 stainless steel. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 8 2.5 FABRICATION A. General: 1. Steel plates and shapes shall have a minimum thickness of ¼-inch. 2. Anchor bolts shall be minimum ½-inch diameter. 3. All parts shall be designed to have sufficient strength, stability, and stiffness and to be especially adapted for the conditions of service. 4. All belt filter press units shall be fully assembled in the manufacturer's shop to ensure proper fit of parts. 5. Provide ample room and components for inspection, repairs, and adjustments. 2.6 COMPONENTS A. General: 1. Belt Filter Press shall be a complete dewatering unit and shall consist of, but not be limited to, the following components: a. Structural main frame. b. Gravity dewatering zone. c. First stage low pressure dewatering zone. d. Second stage high pressure/shear dewatering zone. e. Filter and auxiliary belts. f. Rollers. g. Belt wash system. h. Belt alignment system. i. Belt tensioning system. j. Drives. k. Safety guards. l. Discharge blades. m. Drainage system. n. Sludge conditioner. B. Structural Frame: 1. Frame shall be fabricated from steel members into a rigid structure adequately braced to withstand intended loads without vibration or deflection. Fabricated steel frame shall be designed to withstand the maximum stresses imposed on the individual members with a safety factor of 5. Specifically, the maximum actual stress on any member, connection, plate, etc., shall not exceed 20% of the yield strength of the frame material. The maximum stresses imposed on the frame shall include the following: a. Frame, roller, and other component weights. b. Static belt tension due to the belt tensioning system when operated at the maximum pressure developed by the hydraulic system. The tension used for calculations shall be at least 50 lb/lineal-inch of actual belt width. c. Belt tension resulting from the drive motor driving the belts at the highest speed to overcome friction, create shear in the sludge between the belts, and pressure the sludge to dewater it. 2. Manufacturer shall submit calculations on all members indicating compliance with structural requirements. Calculations shall be signed and sealed by a Texas Licensed Professional Engineer. 3. Framework shall be welded and/or bolted construction. No disassembled component, excluding the belt filter frame, shall weigh more than 3,500 pounds. Lifting lugs shall be BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 9 provided as necessary to afford convenient access to maintenance points throughout the belt filter press. All welds shall be continuous. All welds in material other than stainless steel shall be ground smooth. All edges on material other than stainless steel shall be rounded with at least one pass of a grinding wheel. 4. Framework shall ensure absolute plane parallelism of all rolling elements. 5. All steel structural members and plates including interior of hollow tubing, shall be cleaned and coated after fabrication with a high grade hot dip galvanized finish. 6. A structural frame constructed entirely of Type 316L stainless steel instead galvanized steel is acceptable. 7. Structural frame shall be designed for installation on an existing concrete foundation with prepared concrete equipment supports and secured with anchor bolts. Height of equipment supports shall be determined by manufacturer to accommodate belt filter press and auxiliary equipment. The manufacturer shall furnish necessary stainless steel anchor bolts and nuts for installation by the Contractor. 8. Easily removed and replaced side panels shall be provided where necessary to ensure the containment of all liquid and mist within the boundaries of the press frame. Panels shall be fabricated of 16 gauge anodized aluminum or Type 316 stainless steel. 9. Construction shall allow easy access and visual contact with all internal components. 10. Frame disassembly shall not be required for roll removal. 11. Belt filter press manufacturer shall supply platforms, stairs, and guardrails for access to and operation and maintenance of equipment as indicated on the Drawings. Platforms, stairs, and guardrails shall comply with Division 05 specifications. C. Gravity Dewatering Section: 1. Belt filter press shall be furnished with a gravity drainage section to accept sludge from the upstream sludge conditioning system. The gravity drainage section shall include an inlet distribution chute to evenly distribute the conditioned sludge over the entire working width of the moving filter belt. The unit shall be designed to prevent leakage and shall be easily accessible for operation, viewing, cleaning, and adjustment. a. Distribution chute shall allow vertical adjustment for leveling and clearance from belt. 2. Materials in contact with sludge in the distributor area shall be fabricated from Type 316L stainless steel. 3. Conditioned sludge shall be contained on the belt by rubber seals that are replaceable with using special tools. 4. Each gravity drainage section shall be furnished with devices to adequately furrow conditioned sludge to facilitate drainage. Furrowing devices shall be readily removable. There shall be a minimum of ten (10) rows of furrowing devices that can be easily adjusted to create optimal performance with a minimum of eight (8) plows/row. a. Each plow shall be counterweighted, capable of pivoting independently of other plows, and furnished with set collar or clamp to position plow along support rod. b. Mounting: Horizontal rod or angle equipped with handle to allow plows attached to one mounting rod or angle to be lifted from belt when belt filter press is in operation. c. Shoes: Adjustable and replaceable. 5. The use of vacuum assisted drainage sections is not acceptable. 6. In the gravity drainage section, the filter belt shall be supported by Ultra High Molecular Weight (UHMW) polyester strips, a minimum of 2-1/2-inches apart extending the full belt width. The strips shall be supported by a Type 316 stainless steel supporting member. Fiberglass strips are not allowed. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 10 7. All metals in the gravity zone plow and belt support grid/assembly shall be Type 316L stainless steel. 8. The minimum effective drainage area shall be at least 93 square feet for each unit. The effective drainage area shall be calculated as: Area = width x length, where width is defined as the distance between the containment seals of the gravity section and length is defined as the distance from the point of contact of the sludge with the belt at the inlet end to the tangent point of the roll at the end of the zone. D. Pressure Zones: 1. Belt filter press shall be furnished with a two (2) stage pressure zone following the gravity drainage zone. 2. The first stage of the pressure zone shall be a wedge section. Wedge zone is defined as the combined area of the upper and lower filtration areas from the point at which both belts converge to have mutual contact with the sludge cake until the point at which the upper belt reaches the tangent point of the first "S" roll. The minimum allowable area of the wedge zone shall be at least 59 square feet. The effective area shall be calculated as the effective belt width times the roll to media contact length, one side only. The leading opening of the wedge angle shall provide an adjustable opening from 0 to 3-1/2-inches while the press is in operation. The wedge section shall operate without leakage. All metal and support frame work shall be Type 316L stainless steel. Pressure plate type configurations are not acceptable. 3. The second stage of the pressure zone shall consist of an arrangement of a minimum of eight (8) rollers developing an "S" shaped pattern of belt travel. Rollers for the pressure zone shall be cylindrical in shape and constructed as specified. The ends of each shaft shall be equipped with support bearings as specified. The minimum pressure area shall be at least 121 square feet. 4. Pressure zone configuration shall be such that the filtrate is removed from the sludge cake without rewetting the downstream cake. E. Filter Belts: 1. Belts shall be split seam or continuous type. Each belt and connecting splice shall be designed for a minimum tensile strength equal to five (5) times the normal maximum dynamic tension to which the belt is subjected. The splice shall be designed to fail before the belt. 2. Belts shall be seamed and fabricated of monofilament polyester, wear-resistant plastic materials, or combination monofilament polyester and stainless steel material. Nylon belts are not acceptable. The mesh design shall be selected for optimum dewatering of the sludge to be processed with minimum binding of the filter belt. 3. Belt selection shall be as recommended by the manufacturer for the type of sludge and polymer conditioning agent used. 4. Belts shall be designed for ease of replacement with minimum downtime. Belt replacement shall not require disassembly of the equipment. The method of belt change-out shall be demonstrated to show that each belt can be replaced by two WTP employees within two (2) hours. 5. Auxiliary belt systems used in conjunction with filter belts shall be of a material and design to ensure maximum operating life and minimize maintenance. 6. All belts shall be guaranteed to operate for a minimum period of 2000 hours. Minimum belt life shall also cover belts damaged due to defects in manufacture of the press or any of its components and the connection splice. Belts are defined as the belt’s media fabric or conveyor portion on which sludge travels as it is carried through the unit and the belts or BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 11 flexible members that apply pressure and shearing action to the sludge as it travels through the unit. If belt(s) fail within the guarantee period, all equipment and labor necessary to change the belt(s) shall be provided by the manufacturer. F. Roller Assemblies: 1. All rollers shall be of double separated plate stub end shaft or forged end type construction. Stub end shafts and roller heads must be welded in place. Bolted in place stub end roller shafts are not acceptable. All shaft to roller construction shall eliminate any deflection between the shaft and roller. All rollers shall be designed to have a maximum deflection of 0.05-inch at their center when under the maximum design loading. In addition, the actual stress created in the roller due to a belt loading of 200 lb/inch of width shall not exceed 20% of the yield strength of the roller. Maximum loading shall be based on the maximum summation of all forces exerted by the tension on the belts from the belt drive and belt tensioning devices, friction forces, roller mass forces, and the elasticity forces of the belts caused by the inner belt having shorter travel distance than the other belt as the belt and sludge sandwich travel around the roller. Certified calculations shall be submitted stating compliance with the specified maximum loading and deflection. 2. All roller shafts shall be designed per ANSI/ASME B106.1M accounting for reversed bending stress. At a belt tension of 50 lb/linear-inch and belt speed of 10 meters per minute, all rollers shall have a safety factor of 5, based on the yield strength of the material and a safety factor of 4, based on fatigue stress. 3. All carbon steel rollers shall be designed with a minimum of 0.5-inch stub shaft diameter, though journal area shall be a minimum of 2-1/2-inches. All shafts shall be forged steel ASTM A572 Grade 50. 4. Carbon steel roller surfaces shall not be exposed to sludge or moisture. 5. The use of rollers constructed entirely of Type 316L stainless steel instead of carbon steel with protective coatings is acceptable. 6. All rollers shall be coated with a minimum thickness of 25 mil of Rilsan® or 1/4-inch of Buna-N rubber having a 90 shore "A" hardness. Rollers shall be coated up to the point of insertion into the bearing block or have shafts and heads made of Type 316 stainless steel. 7. Rubber coated drive rollers shall enable slip-free transmission of driving torque to the belt. The shaft ends of each drive roller shall be equipped with a support bearing as specified. 8. All perforated rollers shall be Type 316 stainless steel construction. G. Filter Belt Wash System: 1. A belt wash station located inside each belt loop shall be furnished for each belt. Belt wash system shall be suitable for use with filtered, non-potable plant water (PTW). Wash water supply pipe and nozzle assembly shall be housed in a manner that limits the spray pattern to within the wash station housing. Collection and discharge of wash water and filtrate streams shall be separate. The housing and nozzle assembly shall be readily removable. The housing shall be fabricated from Type 316 stainless steel. The housing shall be sealed against the belt with rubber seals. Belts shall be protected from excessive wear from the edges of the wash station housing by replaceable guide surfaces. 2. Each belt wash station shall consist of a minimum of one spray pipe fitted with non-clog nozzles. Nozzle spacing and spray pattern shall provide spray overlap between adjacent nozzles at the belt surface. The spray pipe and nozzles shall be Type 316 stainless steel. Individual nozzles shall be removable. 3. Each belt wash station shall be furnished with an external handwheel. A half-turn of the handwheel shall cause brush bristles to enter each spray nozzle and dislodge any solid particles that have accumulated. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 12 4. Each belt wash station shall be positioned such that washing is performed after the cake has been discharged from the belt. The belt wash station shall extend over the full width of the filter belt. The belt shall be cleaned by the belt wash without blinding. 5. Each belt wash system shall be furnished with a rotameter, pressure gauge, solenoid valve and ball valve for throttling. Each rotameter shall be furnished with shutoff valve and bypass piping to isolate it from the system for cleaning. All wash water piping shall be Schedule 80 PVC or other approved high-strength, corrosion resistant piping. All wash water piping shall be routed to a single point for connection to PTW piping. All wash water piping shall have snap type disconnects or unions to allow removal of wash water headers and piping for maintenance or access to other components of the press. All valves shall comply with applicable Division 40 Specifications. 6. Manual valves and rotameters shall be mounted on the belt filter press frame. Each belt filter shall be provided with a separate discharge connection and piping for wash water and filtrate discharge. Drain piping mounted to the belt press shall be Schedule 80 PVC. 7. Belt wash system shall be designed to operate on a minimum flow of 80 gpm and specified pressure. If required, belt press manufacturer shall supply a booster pump to increase shower water pressure. H. Belt Alignment System: 1. Automatic sensing devices shall be provided for each belt to automatically adjust belts on rollers to assure proper belt alignment while press is operating. 2. Belt alignment devices shall be hydraulically operated and designed to align each belt and locate it centrally on the roller by means of a sensing arm that detects the position of the belt edge. Sensing arm shall operate a Type 316 stainless steel pilot valve, which in turn affects the position of a hydraulic actuator connected to a pivoted belt alignment roller causing the roller to skew from its transverse position. Mechanically link sensing arm to pilot valve to control hydraulic tracking actuator. Alignment system shall provide continuous automatic belt guidance and shall be an integral part of the press. Alignment system shall operate with smooth and slow motions resulting in a minimum of belt travel from side to side. The use of electrical servos is not acceptable. 3. Rollers for the belt alignment system shall be carbon steel with 25 mils thermo-setting nylon coating (Rilsan®) or 1/4-inch minimum thickness Buna-N rubber coating. Rollers constructed entirely of Type 316 stainless steel are also acceptable. Support bearings for these rollers shall be as specified. 4. Hydraulic systems provided with each unit shall include pumps, motors, valves, storage reservoirs, all controls, and stainless steel piping necessary to provide a complete and operational system. 5. All hydraulic lines shall be rigidly supported on the structural frame and properly sized for the intended use with adequate safety factors for the rated pressure. All hydraulic lines shall be woven Type 316L stainless steel. All hydraulic supply and control piping shall be Type 316 stainless steel and supplied by the manufacturer; this shall include all piping between the control panel and belt press. 6. Limit switches: a. Furnish on each side of each belt to detect major misalignment of belt, de-energize all drives, and relay an alarm signal. b. Limit switches to control belt position adjustments are unacceptable. I. Belt Tensioning System: 1. Each belt shall be provided with a hydraulically actuated belt tensioning system that automatically controls adjustments while belt filter press is operating. Design shall be such BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 13 that dewatering pressure is directly proportional to belt tension and adjustments in tension result in immediate changes in dewatering pressure. Manual or electric servo tensioning systems are not acceptable. 2. Belt tensioning system shall be furnished with a local control panel to enable independent adjustments for each belt. Controls shall be calibrated to provide an indication of actual dewatering pressure in pounds per linear-inch at various readings of hydraulic pressure and normal operating limits shall be indicated on the face of the station. Actual dewatering pressure as indicated by the set point selected on the control station shall be maintained automatically despite process changes. 3. Belt tensioning system shall assure parallel movement of the tensioning rollers. Tensioning systems shall have hydraulic pressure rams or pistons on each end of the tension roller or a single ram or piston at the center of each tensioning roller. A parallel torque tube shall be furnished to ensure proper roller alignment during the belt tensioning process. 4. Tensioning system to be able to accommodate maximum belt stretching during useful life of belt. 5. Each belt shall be furnished with one tension roller. Rollers shall be cylindrical in shape and constructed as specified. The shaft ends of each roller shall be equipped with support bearings as specified. 6. Hydraulic systems provided with each unit shall include pumps, motors, valves, storage reservoirs, controls, and piping necessary for a complete and operating system. 7. All hydraulic lines shall be Type 316 stainless steel, rigidly supported on the structural frame, and properly sized for the intended use with adequate safety factors for the pressure rating. 8. Limit switches shall be furnished for each belt with sufficient electrical contacts to de- energize all drives and relay an alarm in the event of failure of the belt tensioning system. J. Drives: 1. Belt drive system shall be capable of variable speed operation controlled from the main control panel. 2. Motors shall be totally enclosed, non-ventilated, inverter duty rated. 3. Each motor shall be furnished with a surface temperature sensor with a rating equal to the specified temperature limit for the motor, which shall be the maximum temperature rating on the motor insulation. Sensor shall send signal to annunciator panel as specified. 4. Motors shall have anti-condensation heaters as specified in Section 01 61 03. 5. Variable frequency drives shall be as specified in Section 26 29 23 and as follows: a. Capable of minimum 1 to 5 speed variation. 6. All drive bearings shall conform to specified requirements. 7. Gear motors shall be rated AGMA Class II and include an AGMA nameplate. 8. Gear reducers shall be totally enclosed, water spray proof, and oil lubricated, with antifriction bearings throughout. Shaft mounted gear reducers shall be rated AGMA Class II. Other helical, spiral bevel, and combination bevel-helical gear reducers shall have a service factor of at least 1.5. Each gear reducer shall have an AGMA nameplate. 9. The nominal input horsepower rating of each gear or speed reducer shall be at least equal to the nameplate horsepower of the drive motor. 10. Drive units shall be designed for 24 hour continuous service. K. Safety Guards: 1. All equipment having exposed moving parts shall have safety guards as required by OSHA Standards. Safety guards shall be made of 10 gauge (0.135-inch diameter) stainless steel wire woven in ¾-inch diamond mesh, or equal, rigidly framed with stainless steel, BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 14 bounded, and mounted in such a manner that they are conveniently removable for servicing equipment. L. Bearings: 1. Comply with ABMA 11. 2. L10 Life: 640,000 hours. 3. The shafts of all rollers shall be equipped with heavy-duty greaseable-type, self-aligning spherical or roller bearings in sealed, splashproof, split case housings. Self-alignment shall occur inside the housing. Housings shall allow changing of bearings without any changes in the factory alignment of the roller. The roller side of the housings shall be triple-sealed and the roller shaft shall have a splash deflector designed to provide adequate sealing from moisture and grime. The outer side of the housings shall be solid and moisture proof. All bearings shall be outboard (externally mounted) bearings and shall be greaseable while the unit is in full operation. Where access platforms are provided adjacent to the belt press, stainless steel tubing shall be provided from the bearing grease point to a central greasing station above the grating. Grease station shall be easily accessible and constructed of Type 316 stainless steel. 4. The L10 bearing life shall be based on ANSI B13.6 when calculated with a belt speed of 10 meters per minute and belt tension of 50 lbs/linear-inch. The L10 bearing life shall be based upon the maximum summation of all forces in all planes applied to the bearings, including but not limited to the applied belt tension, roll weight per inch of roll, force due to drive torque friction forces, roller mass forces, assembly misalignments, and the elasticity forces of the belts caused by the inner belts having shorter travel distance than the outer belt, as the belt and sludge sandwich travels around the roller. A certified statement stating that all bearings comply with the specified requirements for minimum L10 bearing life based on a maximum loadings shall be submitted with shop drawings. 5. Lubrication of bearings shall not be required more frequently than once every six (6) months. M. Sludge Discharge Assembly: 1. Discharge doctor blades shall be provided to scrape dewatered sludge from the belt at intermediate and final discharge rollers. 2. Minimum width: 3 inches wider than belt width. 3. Mounting: a. Furnish stainless-steel blade holder secured in place by means of counterweights or stainless steel spring tension type fasteners. b. Furnish mechanism to adjust position and force of blade against belt. 4. Doctor blades shall be readily removable. Furnish quick release and lock of doctor blade for inspection and servicing. 5. Furnish lifting device to position and hold discharge blades at least 2 inches away from filter belts for blade cleaning. 6. Provide minimum 1/8-inch thick discharge chute to collect and deflect the sludge cake to a sludge conveyor below the discharge. Adequate space shall be provided below the discharge chute for conveyor clearance. N. Filtrate Drainage Pans: 1. Provide drainage pans to collect and discharge sludge filtrate from belts, without splashing and re-wetting downstream cake. 2. Constructed from 12 gauge Type 316 stainless steel and piped separately to drainage basin. 3. Extend minimum 3 inches beyond belt width on both sides. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 15 4. Locate such that moving belts do not contact pans under any conditions. 5. Provide flushing connections to facilitate cleaning. 6. Drainage piping shall be adequately sized for the intended service and rigidly attached to belt press frame. O. Sludge Conditioner: 1. Designed to efficiently mix polymer into sludge and adequately condition sludge for optimum dewatering. 2. Mixer shall be flanged with a cast housing and have an adjustable stainless steel orifice plate with shaft and rubber O-ring seal connected to an externally mounted galvanized steel lever and cast iron counterweight. 3. Open throat area of mixer shall be fully adjustable downward and open automatically to prevent clogging. 4. Mixing energy shall be independently adjustable during operation by moving mixer arm and counterweight. 5. Install upstream of belt press as indicated on the Drawings. P. Emergency Trip Cord System: 1. Encircling sides of belt filter press and supported on main frame. 2. Configured such that pulling on cable at any point will lock OFF switch in open position to immediately interrupt all power to the belt press. 2.7 ELECTRICAL REQUIREMENTS A. Control Panels: 1. Provide main and local control panels to control the belt filter press and auxiliary equipment. Provide main and local control panels to control the belt filter press and auxiliary equipment. Main control panel shall have starters and VFDs for belt drive, hydraulic pump, booster pump and any other belt filter press drive mechanism or valves. Sludge feed pumps, polymer pumps/systems, and conveyors shall be powered by external starters and VFDs. Local control panel shall have interfaces to view and modify sludge feed pump speed, polymer feed pump speed and belt drive speed, and view sludge feed rate. (AD-02) 2. PLC with operator interface terminal (OIT) installed in main panel with ability to connect to WTP SCADA. PLC with operator interface terminal (OIT) installed in main panel with the ability to connect to WTP SCADA. Communication protocol shall be Ethernet IP. PLC shall be ControlLogix. OIT shall be Panelview Plus or equal by Allen Bradley. (AD-02) a. Provide an Uninterruptible Power Supply (UPS) for the PLC. 3. NEMA 250 Type 4X stainless steel enclosure. 4. Single-point 120 Volt, 1 Phase power connection and grounding lug. Single-point 480VAC, 3 Phase, 60A power connection and grounding lug. a. All necessary power conditioning shall be furnished inside the panel for proper operation of the equipment. All necessary power conditioning shall be furnished inside the panel for proper equipment operation. (AD-02) 5. Relay contacts shall be rated 10 amps at 120VAC. 6. Conform to requirements of Section 26 29 13.01 – Industrial Control Panels. 7. Install on access platform adjacent to belt filter press as shown on the Drawings. 8. Control panel shall house main breaker, starters, overloads, variable frequency drive, necessary relays, etc. to enable complete operation of the belt filter press. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 16 9. Devices such as HOA switches and indicating lights shall be mounted on the face of the panel. B. Motors: As specified in this section and Section 01 61 03 - Common Requirements for Equipment. 2.8 CONTROLS AND LOOP DESCRIPTIONS A. Reference Sections 40 90 02 – Supervisory Control and Data Acquisition (SCADA) System and 40 90 02.01 – SCADA Loop Descriptions. B. General: Belt filter press (BFP) operation and control shall be coordinated with several other existing and proposed pieces of equipment provided by others. The BFP manufacturer shall be responsible for providing control (i.e., motor starters, VFDs, indicator lights, selector switches, pushbuttons, etc.) for system equipment at the BFP main control panel. The equipment includes: 1. Existing belt press feed pumps (SDF-BPFP-001 and 002). 2. Existing polymer feed systems (SDF-PFS-001 and 002). 3. Proposed belt filter press (SDF-BFP-002). 4. Existing wash water valve. 5. Proposed screw conveyors (SDF-SSC-003, 004, and 005). C. The BFP manufacturer shall be responsible to provide directions and written instructions, including wiring designations, terminal block numbers, etc. for proper wire terminations. Control wires for the belt press feed pumps, polymer feed units, belt filter press, wash water valve, and screw conveyors shall be terminated in the main control panel. D. Control of the BFP and associated equipment shall be accomplished through the BFP PLC. 1. BFP supplier shall furnish an ethernet cable to run from the BFP control panel PLC to the Process Control SCADA System PLC Ethernet switch to interface with the WTP SCADA network as shown on the Drawings. 2. Controlled equipment signals shall be wired directly to the PLC. PLC discrete outputs shall drive a relay to provide a dry contact to interface with motor starters located in the BFP control panel or the SDF motor control center (by others). 3. Furnish hardwired panel devices and meters for duplicate secondary indication functions and redundant backup machine protection/safety functions. BFP PLC shall be the primary controller for all functions, including those duplicated in hardware. 4. PLC OIT shall provide a display screen and message keypad for control and monitoring of the BFP system and specified auxiliary equipment. Keypad shall have a sealed membrane overlay covering all function keys and numerical keys. OIT shall be menu-driven with automatic fault message windows appearing upon alarm conditions. 5. All monitoring functions available on the BFP system, including monitoring of operator- input control variables, shall be available to the WTP SCADA system as shown on the Contract Drawings. BFP system supplier shall be responsible for coordinating with the Contractor regarding SCADA requirements. E. Proposed Belt Filter Press: 1. P&ID: M-11. 2. PLC-based control functions at the BFP main control panel for auxiliary equipment (existing belt press feed pumps, existing polymer feed system, and proposed screw conveyors) shall include control and operator interface capability, plus pass-through to the WTP SCADA system, for all specified equipment monitoring functions. BFP system BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 17 supplier shall be responsible for reviewing related equipment specifications and coordinating with the Contractor's instrumentation and control supplier to ensure that all functions are properly incorporated into the BFP main control panel. 3. BFP supplier shall coordinate sharing of system and component status information with the Contractor. Provide a PLC I/O register map that identifies registers, addresses, and data types that will enable the SCADA system to properly scan and display the data on SCADA operator work station screens. 4. Data monitored by the WTP SCADA system shall include, but not be limited to the following: a. Equipment alarm conditions, such as FAIL TO START, FAIL TO STOP, Speed DEVIATION, FAIL TO OPEN, FAIL TO CLOSE, Valve position DEVIATION, etc. for all equipment controlled by the BFP PLC. b. Equipment Runtimes (Current and Lifetime) for all motors monitored by the BFP PLC. c. BFP PLC Communications watchdog signal: A watchdog communications timer shall be coordinated with the WTP SCADA system to detect loss of communications between the SCADA system and BFP PLC. In the event of a communications failure, the BFP PLC shall flag all data coming from the SCADA system as OLD (bad quality). d. BFP PLC - PLC Ready. e. BFP PLC - PLC Failure. f. BFP PLC - UPS battery low. g. BFP PLC - AC power failure. h. BFP PLC - DC Power supply failure(s). i. BFP system – Ready. j. BFP - Belt drive running. k. BFP - Belt drive speed. l. BFP - Wash-down pump running. m. BFP - Hydraulic pump running. n. BFP - Pre-wash cycle On. o. BFP - Wash-down cycle On. p. BFP – Belt press feed pump control mode (Speed/Flow). q. BFP - Belt press feed pump # selected. r. BFP - Polymer feed system # selected. s. BFP - Hand/Auto Control. t. BFP - Field local control panel Local/Remote. u. BFP - Emergency Stop Alarm. v. BFP - Sludge flow. w. BFP - Sludge flow totalized (current, previous day). x. BFP - Belt drive failure. y. BFP - Low water pressure. z. BFP - Broken belt. aa. BFP - Low hydraulic pressure. bb. BFP - Belt misaligned. cc. Belt Press Feed Pump (BPFP) – Speed. dd. BPFP – Running. ee. BPFP - Local/Remote. ff. BPFP - Common alarm (Failure, High discharge pressure, Low inlet pressure). gg. Polymer Feed System (PFS) – Speed. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 18 hh. PFS – Running. ii. PFS - Local/Remote. jj. PFS - Common alarm (Failure, High discharge pressure). kk. Shaftless Screw Conveyor (SSC) – Running. ll. SSC - Local/Remote. mm. SSC - Common Alarm (Motor overload, current surge, emergency stop). 5. Provide a communications timer for the WTP SCADA system to detect a communications failure with the BFP control panel PLC. 6. Run times for all motorized equipment shall be totalized in the BFP PLC and made available to the WTP SCADA system with 0.1 (tenth) hour resolution, even if not shown on loop drawings. Two run times shall be calculated: one for overall accumulated run time and the second shall have reset capability by the user via the PLC OIT. 7. All monitored flows shall be totalized in the BFP PLC as daily or cumulative totals. Daily totals shall be reset at midnight and then stored as "Yesterday’s Total Flow". Flow rates and flow totals shall be made available for sharing with the WTP SCADA system. When a valve is closed or a pump is not running, the flow totalizer shall not accumulate values caused by noise or errors in calibration. 8. When a valve is closed or a pump is not running, the associated analog flow signal shall not generate a low flow alarm and it shall be forced to a zero valve. 9. For all analog modulating valves, if the valve is commanded to open or close to a specific position and the position feedback signal deviates from the commanded position by a preset deadband for a preset time period, a valve deviation alarm shall be generated by the BFP PLC and made available for sharing with the WTP SCADA system. 10. For all variable speed pumps, if the pump is commanded to run at a specific speed and the speed feedback signal deviates from the commanded speed by a preset deadband for a preset time period, a speed deviation alarm shall be generated by the BFP PLC and made available for sharing with the WTP SCADA system. 11. BFP PLC shall calculate FAIL TO START and FAIL TO STOP, or FAIL TO OPEN and FAIL TO CLOSE alarm conditions for all equipment it controls. An equipment item shall be considered to FAIL if it is requested to START, STOP, OPEN or CLOSE and the PLC does not receive proper feedback after an adjustable period of time. 12. When any failure occurs, a horn at the BFP control panel shall sound, a beacon on the outside of the SDF building shall be activated, and the appropriate alarm condition shall be indicated. When the ACKNOWLEDGE function at the BFP control panel is initiated, the horn shall silence and the beacon shall be turned off. When the RESET function at the BFP control panel is initiated, the indication of alarm conditions shall be restored to indication of normal operation, if the condition causing the alarm has returned to normal. 13. The assigned BPFP and PFS shall also have speed control at the BFP control panel. Speed control shall be accomplished through a potentiometer capable of providing a 4-20 mA output signal for interface to the speed control devices. BFP manufacturer shall be responsible to coordinate the proper interface requirements. The speed of the BPFP shall also be displayed on the BFP control panel. The input signal to the indicator shall be 4-20 mA DC and calibrated to read GPM. 14. Control of the belts and belt regulator shall be provided at the BFP control panel. Control shall consist of individual LOAD/UNLOAD functions, a controller to regulate pressure, a pressure indicator, and a potentiometer capable of providing a 4-20 mA output signal. Belt speed shall be indicated in feet/minute on the BFP control panel. The input signal to the operator shall be 4-20 mA DC. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 19 15. The OIT shall allow operators to view BFP equipment and instrument status, alarm information, acknowledge, silence and reset alarms, provide manual and automatic operation of the BFP system, enter and adjust control parameters and setpoints, select control modes, select support equipment for use, etc. 16. Status information shown on the OIT shall include, but not be limited to the following: a. Belt Filter Press: SDF-BFP-002: 1) BFP system - Ready, Hand, Auto, Emergency Stopped. 2) BFP - Belt drive running. 3) BFP - Belt drive speed. 4) BFP - Wash-down pump running. 5) BFP - Hydraulic pump running. 6) BFP - Pre-wash cycle on. 7) BFP - Wash-down cycle on. 8) BFP – Belt Press Feed Pump Control mode (Speed/Flow). 9) BFP – Belt press feed pump # selected. 10) BFP - Polymer feed system # selected. 11) BFP - Hand/Auto Control. 12) BFP - Field local control panel Local/Remote. 13) BFP - Emergency Stop Alarm. 14) BFP - Sludge flow. 15) BFP - Sludge flow totalized (current, previous day). 16) BFP - Belt drive failure. 17) BFP - Low water pressure. 18) BFP - Broken Belt. 19) BFP - Low hydraulic pressure. 20) BFP - Belt misaligned. 21) BFP - Low water pressure. b. Assigned Belt Press Feed Pump: SDF-BPFP-001 or 002: 1) BPFP – Speed. 2) BPFP – Running. 3) BPFP - Local/Remote. 4) BPFP - Common alarm (Failure, High discharge pressure, Low inlet pressure). c. Assigned Polymer Feed System: SDF-PFS-001 or 002: 1) PFS – Speed. 2) PFS – Running. 3) PFS - Local/Remote. 4) PFS - Common alarm (Failure, High discharge pressure). d. Shaftless Screw Conveyors: SDF-SSC-003, 004, and 005: 1) SSC - Running. 2) SSC - Local/Remote. 3) SSC - Common alarm (Motor overload, current surge, emergency stop). 17. BFP control panel OIT shall include the following physical hardwired switches and indicators: a. EMERGENCY STOP switch to stop the BFP system. b. ALARM SILENCE and ALARM RESET pushbuttons for silencing and resetting alarms. c. Control Power ON-OFF switch and indication light for provision and indication of control power to the panel. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 20 d. HAND/OFF/AUTO selector switch to determine whether the BFP system control is in hand or manual control mode, automatic control mode, or turned off. e. AUTO-START and AUTO-STOP pushbuttons to enable operator to automatically start and stop the BFP system. PLC shall automatically sequence startup and shutdown of all equipment controlled by the BFP system. F. Proposed Belt Filter Press System Controls: 1. BFP system shall be a stand-alone control system monitored by the WTP SCADA system. There shall be a main control panel and a local control panel for controlling the BFP system. The main control panel shall provide supervisory and automatic control through the panel’s OIT and physical switches. The local control panel at the BFP shall be used by plant operators to adjust BFP controls during startup or for maintenance purposes while running in automatic mode. 2. The PLC shall perform all control actions at the BFP main control panel. To prepare for the BFP system to run, the operator shall make selections from the following equipment and control options: a. Belt Press Feed Pump selection (1, 2, or none). b. Polymer Feed System selection (1, 2, or none). c. Belt Press Feed Pump control mode (Flow or Speed). 3. To run the BFP system in the Hand or Automatic control mode, all equipment controlled by the BFP system must have their Local control panel Local/Remote switches in the Remote position and applicable VFD/MCC Hand/Auto switches in the Auto position. 4. HAND Control Mode: a. Allows the operator to manually control the BFP system equipment (i.e., polymer feed system, belt press feed pumps, and conveyors) from the OIT. All alarm and safety shutdown mechanisms active in the automatic control mode shall remain active in HAND control mode. 5. AUTOMATIC Control Mode: a. Allows the operator to start and stop the BFP System using the OIT or the hardwired AUTO-START and AUTO-STOP buttons on the main control panel. b. Upon receiving an AUTO-START initiation signal, BFP PLC shall sequentially operate all of the equipment within the BFP system train in the appropriate manner. c. Upon receiving an AUTO-STOP initiation signal from the main control panel, the BFP PLC shall sequentially stop all of the equipment within the BFP system train and wash down the BFP belts in the appropriate manner before shutting down the BFP. d. Upon failure of any equipment within the BFP system train, the BFP PLC shall immediately shut down all other equipment within the train. e. BFP PLC shall immediately shut down all equipment in the BFP system train because of the following: 1) The emergency stop button in the BFP panel is pressed. 2) Emergency cord on the BFP is pulled. 3) Low pressure in the wash water line. 4) Assigned belt press feed pump doesn't start or malfunctions. 5) Assigned polymer feed system doesn't start. 6) Screw conveyors do not start or malfunction. 7) Emergency pull cord on a screw conveyor is pulled. 6. Local Control Panel Manual Adjustments: BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 21 a. To adjust BFP system controls at the local control panel, the operator must place the Local/Remote switch in the Local position. While in this position, the operator may: 1) Adjust BFP drive speed. 2) Adjust assigned PFS speed. 3) Enter a flow setpoint to control the speed of the assigned BPFP (Flow mode). 4) Enter a BPFP speed setpoint for the assigned BPFP (Speed mode). b. The Local control panel manual adjustments available shall be made using 1/16 DIN or greater industrial controllers located on local control panel door. Provide four controllers in local control panel, one for each adjustment parameter listed. Controllers shall include 4-20mA input and 4-20mA output signals for communicating with the BFP PLC. Controllers shall be Redlion PXU or equal. c. The local control panel shall include the following mounted to the door: E-Stop mushroom head pushbutton, sludge speed mode and sludge flow mode indicator lights, and Local/Remote selector switch. d. Manual control of individual equipment shall be executed at the BFP control panel OIT and local control panel controllers. (AD-03) G. Existing Belt Press Feed Pumps: 1. P&ID: M-11. 2. Local Manual Control: a. There is a local control panel for each BPFP. To gain local control of a pump, the operator must place the Local/Remote switch in the Local position. While in Local, the operator may start and stop the pump using the Start and Stop pushbuttons. b. The operator may start, stop, and control the speed of a pump at its associated VFD by putting the VFD Hand/Auto switch in the Hand position and using the VFD supplied start/stop and speed controls. 3. Remote Control: a. BPFP local control panel Local/Remote switch must be in the Remote position and the VFD panel Hand/Auto switch must be in the Auto position to allow control from the BFP Control Panel. b. When the BFP System is in the Hand control mode, the operator may start and stop the assigned BPFP using the start and stop pushbutton operators. c. When the BFP System is in Auto control mode, the BFP PLC shall automatically start/stop and control the speed of the assigned BPFP based on the selected control mode. d. In Flow Control Mode, the speed of the assigned BPFP shall be modulated to maintain an operator entered sludge flow setpoint (main control panel OIT or BFP local control panel) to provide a constant sludge flow to the BFP. e. In Speed Control Mode, the speed of the assigned BPFP shall set by the operator from either the main control panel OIT or the BFP local control panel. H. Existing Polymer Feed Systems: 1. P&ID: M-12. 2. Local Manual Control: a. There is a local control panel for each PFS. To gain local control of a feed system, the operator must place the Local/Remote switch in the Local position. While in the local position, the operator may start, stop, and adjust the speed of the unit using the supplied Start and Stop pushbuttons and speed controller. 3. Remote Control: BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 22 a. The assigned PFS Local/Remote switch must be in the Remote position to allow control from the BFP Control panel. b. When the BFP System is in the Hand control mode, the operator may start and stop the assigned PFS using the start and stop pushbutton operators. c. When the BFP System is in Auto control mode, the BFP PLC shall automatically start/stop and control the speed of the assigned PFS as required. I. Proposed Shaftless Screw Conveyors: 1. P&ID: M-11. 2. Local Manual Control: a. There shall be a local control panel for each conveyor. To gain local control of a conveyor, the operator must place the conveyor Local/Remote switch in the Local position. While in the local position, the operator may start and stop the conveyor using the supplied Start and Stop pushbuttons. b. The operator may control a conveyor at the MCC by placing the Hand/Auto switch for the conveyor in the Hand position and using the supplied Start and Stop pushbutton operators. 3. Remote Control: a. The local control station Local/Remote switch must be placed in the Remote position and the MCC Hand/Auto switch must be in the Auto position to allow for remote control of a conveyor from the BFP control panel. b. When the BFP System is in manual control mode, the operator may start and stop the conveyors using the OIT. c. When the BFP System in Auto control mode, the BFP PLC will automatically start and stop the conveyors as required. J. Typical System I/O Signals: 1. Proposed Belt Filter Press (SDF-PLC-BFP02): a. BFP supplier shall determine the I/O signals required to monitor and control the BFP. 2. Existing Belt Press Feed Pumps: a. DO: BPFP - Start/Stop. b. AI: BPFP – Speed. c. AO: BPFP - Speed control. d. DI: BPFP – Running. e. DI: BPFP - Local/Remote. f. DI: BPFP - Common alarm (Failure, High discharge pressure, Low inlet pressure). 3. Existing Polymer Feed Systems: a. AI: PFS – Speed. b. AO: PFS - Speed control. c. DO: PFS - Start/Stop. d. DI: PFS – Running. e. DI: PFS - Local/Remote. f. DI: PFS - Common alarm (Failure, High discharge pressure). 4. Proposed Shaftless Screw Conveyors: a. DO: SSC - Start/Stop. b. DI: SSC – Running. c. DI: SSC - Local/Remote. d. DI: SSC - Common Alarm (Motor overload, current surge, emergency stop). BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 23 2.9 FINISHES A. Surface preparation, shop priming, and field painting shall be as specified in Section 09 96 00 – High-Performance Coatings. B. All iron and steel surfaces shall be blast-cleaned in accordance with SSPC-SP-10 and shop primed in accordance with Section 09 96 00. This excludes galvanized steel. C. Do not paint stainless steel, plastic, and fiberglass surfaces. 2.10 SPARE PARTS A. Belt filter press manufacturer shall furnish the following spare parts: 1. One set of drive chains or belts of each size and type. 2. One set of scraper blades for the discharge end of press. 3. One tension roll scraper blade. 4. One hydraulic repair kit for all steering and tensioning cylinders. 5. Two tapered wedges for containing sludge in the low pressure zone. 6. One complete set of replacement seals for entire press, including distributor, gravity section, wedge zone, and spray housings. 7. One set of filter belts. Type shall be selected after start-up and optimization of the BFP. 8. One set of wash water spray nozzles. 9. One hydraulic pump rebuilt kit. 10. One roller bearing of each type and size. 11. All equipment necessary to change filter belts. 12. Provide all special tools required for normal operation and maintenance. B. All spare parts shall be suitably packaged or boxed for long-term storage. Each part shall be clearly identified by part description, part number and other pertinent information or data. 1. Filter belts shall be packaged to prevent damage or deterioration during storage. During the first year of operation, up to a limit of 2,000 hours of guaranteed belt life and beginning with the start of the warranty period, replace any worn out or broken belts at no cost to the Owner. The spare belts may be used as replacement belts while awaiting shipment of new belts. However, the replacement belts shall be provided by the manufacturer without delay upon notification that spare belts have been installed on the machine. Contractor shall cover costs for shipping replacement belts or return of belts. C. At a minimum, manufacturer shall provide an adequate supply of consumables and calibration materials necessary to operate and maintain the equipment for one year period after Substantial Completion. 2.11 SOURCE QUALITY CONTROL A. Section 01 40 00 - Quality Requirements: Requirements for testing, inspection, and analysis. B. Belt filter press shall be assembled in the manufacturer's shop to ensure proper fitting of parts, then match marked for erection and disassembled as required for shipment. Belt filter press shall be complete with all necessary hydraulic hoses and piping connections. Belt filter press shall ship completely wired with the wiring terminating at terminal boxes supplied by the manufacturer. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 24 C. Provide shop inspection and testing of completed belt filter press. PART 3 - EXECUTION 3.1 EXAMINATION A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for installation examination. B. Verify that facility, piping, and electrical Work are ready to receive belt filter press. 3.2 INSTALLATION A. Reference Section 01 61 03 – Common Requirements for Equipment for general requirements. B. Installation shall be in strict accordance with the manufacturer's instructions. C. Level unit to ensure that belts are level and true. D. Install anchor bolts in accordance with the manufacturer’s recommendations. E. After belt filter press has been set in position and shimmed to the proper elevation, grout space between bottom of the belt filter press bases and concrete equipment pads as required with non- shrink grout as specified in Section 03 30 00 – Cast-In-Place Concrete. 3.3 FIELD QUALITY CONTROL A. Reference Sections 01 40 00 - Quality Requirements, 01 61 03 - Common Requirements for Equipment, 01 70 00 – Execution and Closeout Requirements for inspecting and testing, and Section 01 91 00 – Facility Commissioning. B. Adjusting: 1. After belt filter press has been leveled and set in position, level and align each individual roller assembly. 2. If required, reposition roller assembly bearing housings and shim to attain proper belt tracking. 3. Check control functions and adjust as required. 4. Inspect for proper operation. C. Acceptance Testing: 1. After installation, the belt filter press shall be tested to assure conformance with specified performance criteria. The following tests shall be performed: a. Running test with wash water, but without sludge. b. Operation test using sludge and polymer. c. Final performance test using sludge with polymer. 2. Furnish services of manufacturer's representative experienced in installation of products furnished under this Section to assist in conducting specified acceptance tests. Submit a detailed procedure for each test to the Engineer at least six weeks prior to start of testing. Test procedures shall describe testing methods and schedules. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 25 3. Contractor shall provide all equipment, material, power, chemicals, heat, operating and support personnel, and all other incidentals required to take samples and perform the specified tests. 4. Running Test: a. A test with belt wash water only shall be conducted for belt filter press assembly to assure proper installation of the equipment, piping and electrical work. Test shall include starting belt filter press and operating the belt wash system, automatic belt tracking and tensioning system, and checking to ensure all required interlocks between the belt filter press local and main control panels are functioning properly. Belt filter press and auxiliary system shall operate continuously for a period of at least two hours. 5. Operational Test: a. Prior to the test, make all final adjustments to equipment and perform all required test sequences in order to assure proper operation of equipment. b. After Engineer has agreed that belt filter press and ancillary equipment are in satisfactory operating condition, operational test shall be conducted. c. Operational test shall be conducted for a minimum of four hours. Operational test shall demonstrate satisfactory operation of equipment controlled by the belt filter press main and local control panels. Equipment includes: 1) Existing belt press feed pumps. 2) Existing polymer feed system. 3) All components of the belt filter press. 4) Shaftless screw conveyors. 5) All instrumentation, including speed controllers, indicators, flow meters, totalizers, alarms, status lights, interlocks, and any other component required to ensure satisfactory operation of the BFP system equipment. D. Equipment Acceptance: 1. Acceptance testing shall be subject to conditions of the Contract. 2. In the event that the BFP system fails to pass the above tests, adjust, repair, modify, or replace components failing to perform as specified and rerun tests. 3. Make final adjustments to equipment under direction of manufacturer's representative. E. Services of Manufacturer: 1. Reference Sections 01 61 03 - Common Requirements for Equipment and 01 91 00 – Facility Commissioning for general requirements. 2. Provide the services of a factory certified service engineer specifically trained in the installation, start-up, testing, operation, and maintenance of equipment specified herein. Such services shall be provided by a representative who is a direct, full-time employee of the manufacturer or their certified representative. 3. Services of equipment manufacturer's representative shall include: a. Assist with acceptance testing as specified. b. Inspect equipment covered by this Section. c. Supervise adjustments and installation checks. d. Provide test equipment, tools, and instruments necessary to accomplish equipment testing. e. Conduct initial check-out and start-up of equipment, perform operational checks, and supervise acceptance testing. f. Provide a written statement that manufacturer's equipment has been installed properly, started up and is ready for operation by Owner. BCRUA – Phase 1D WTP Expansion Issued for Bid (Revised by AD-02 & AD-03)Belt Filter Press 46 76 21 - 26 g. Instruct Owner on operation and maintenance of furnished equipment. 4. Operation and maintenance training shall include the following, at a minimum: a. Theory of operation. b. Troubleshooting guidance. c. Step-by-step start-up and shut-down procedures. d. Step-by-step, “hands-on” assembly and disassembly procedural instructions. e. Replacement part identification and ordering procedures. f. Lubrication procedures, including drain-down and refill procedures. g. Recommended routine maintenance procedures. h. Troubleshooting and diagnostic procedures. i. Instrument adjustment. 5. Services of manufacturer's representative shall be provided for the minimum amount of time specified below. a. Supervision, start up, and testing: 60 hours. b. Instruct Owner on operation and maintenance: 8 hours. 3.4 DEMONSTRATION A. Section 01 70 00 - Execution and Closeout Requirements: Requirements for demonstration and training. END OF SECTION