NORTHEAST WRF IMPROVEMENTS PROJECT - 19-0029-UT - BOOK 31
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Book 3
Northeast' RF !mpravements
Project 10 -0029 -UT
Contract Docum3nis &
s p.`,ec►' f icgtion s
Section Ric
Subsection 02220 through
Appendix Page 30
SECTION IVC
NORTHEAST WRF BLEND TANK IMPROVEMENTS
SUPPLEMENTAL TECHNICAL SPECIFICATIONS
(PROJECT No. 19 -0029 -UT)
PREPARED FOR:
BRIGHT AND BEAUTIFUL - BAY TO BEACH
CITY OF CLEARWATER
ENGINEERING DEPARTMENT
100 SOUTH MYRTLE AVENUE
CLEARWATER, FL 33756
PREPARED BY:
ionesEdmundO
Jones Edmunds & Associates, Inc.
324 South Hyde Park Avenue, Suite 250
Tampa, FL 33606
Bid Documents
January 2021
SECTION IVC
SUPPLEMENTAL TECHNICAL SPECIFICATIONS
DIVISION 2 -SITE CONSTRUCTION
02220 DEMOLITION AND MODIFICATIONS
02225 BLEND TANK CLEANING
02230 SITE PREPARATION
02240 DEWATERING
02305 EARTHWORK FOR UTILITIES
02370 EROSION AND SEDIMENTATION CONTROL
02700 PAVING
02920 SEEDING AND SODDING
DIVISION 3 -CONCRETE
03100 CONCRETE FORMWORK
03180 CONCRETE COATING SYSTEM
03200 CONCRETE REINFORCEMENT
03250 CONCRETE JOINTS AND JOINT ACCESSORIES
03300 CAST -IN-PLACE CONCRETE
03360 CONCRETE FINISHES
03600 GROUT
03930 MODIFICATIONS AND REPAIR TO CONCRETE
DIVISION 5 -METALS
05500 METAL FABRICATIONS
DIVISION 9 -FINISHES
09900 PAINTING AND COATING
DIVISION 11 -EQUIPMENT
11000 GENERAL EQUIPMENT REQUIREMENTS
11228 MIXERS
11330 IN-LINE GRINDER
11356 PROGRESSIVE CAVITY PUMPS
DIVISION 13 -SPECIAL CONSTRUCTION
13232 ALUMINUM FLAT COVERS
03720-048-01
August 2019
TABLE OF CONTENTS
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13316 SOFTWARE CONTROL BLOCK DESCRIPTIONS
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13401 PROCESS INSTRUMENTATION AND CONTROLS (PICS)
DIVISION 15 -MECHANICAL
15055 PIPING SYSTEMS -GENERAL
15060 PIPE HANGERS AND SUPPORTS
15075 PROCESS EQUIPMENT, PIPING, AND VALVE IDENTIFICATION
15110 MANUAL, CHECK, AND PROCESS VALVES
15120 POWER -OPERATED VALVE ASSEMBLIES
15121 MISCELLANEOUS PIPE FITTINGS AND ACCESSORIES
15122 FLEXIBLE PIPE COUPLINGS
15125 PIPING APPURTENANCES
15144 PRESSURE TESTING OF PIPING
15155 DUCTILE IRON PIPE AND FITTINGS
15290 PVC PIPE, 3 INCHES AND SMALLER
15860 ODOR CONTROL SYSTEM EQUIPMENT
DIVISION 16 ELECTRICAL
16050 ELECTRICAL -GENERAL PROVISIONS
16110 RACEWAYS AND FITTINGS
16120 WIRES AND CABLES
16130 BOXES
16140 WIRING DEVICES
16150 MOTORS
16160 PANELBOARDS
16170 SAFETY SWITCHES
16370 VARIABLE -SPEED DRIVES
16402 UNDERGROUND SYSTEM
16450 GROUNDING SYSTEM
16460 GENERAL PURPOSE TRANSFORMERS
16500 LIGHTING SYSTEM
16601 LIGHTNING PROTECTION SYSTEM
16921 480 -VOLT MOTOR CONTROL CENTERS
03720-048-01 0 TABLE OF CONTENTS
August 2019
DIVISION 2
SITE CONSTRUCTION
SECTION 02220
DEMOLITION AND MODIFICATIONS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish all labor, materials, equipment, and incidentals
required and demolish, modify, remove, and dispose of work shown on the
Drawings and as specified in this Section.
B. The work includes but is not limited to demolishing, modifying, and removing
existing materials, equipment, or work necessary to install the new work as shown
on the Drawings and as specified in this Section and to connect with existing
work in an approved manner.
C. Demolition, modifications, and removals which may be specified under other
Sections shall conform to requirements of this Section.
D. Demolition and modifications include, but not be limited to, the following:
1. Removal and disposal of existing FRP Sludge Storage and Blend Tank
covers, associated hardware, and appurtenances, while storing and
protecting FRP ducts for future reconnection.
2. Removal and disposal of the contents of the Sludge Storage and Blend
Tanks to clean them in preparation for painting and coating in accordance
with Section 02225, Blend Tank Cleaning.
3. Removal and disposal of the existing radial sludge agitator with associated
diffusers and appurtenances in accordance with Section 02225, Blend
Tank Cleaning.
4. Removal and disposal of the existing dewatering pumps, with associated
canopy, concrete floor, pads, piping, valves, supports, and miscellaneous
items as shown on the Drawings.
5. Removal and disposal of the piping from the Sludge Storage and Blending
Tanks where indicated on the Contract Documents.
6. Removal and Replacement of the existing fiberglass stair treads and
landing.
7. Miscellaneous demolition as shown on the Contract Documents including,
but not limited to, the 6 -inch -high concrete curb and concrete pad to the
extents shown, process air piping above and below grade, grating on the
pipe header trench and piping to the extents shown, and hose bibb.
8. Off-site disposal of excess and unacceptable materials as described below
and in Section 02225, Blend Tank Cleaning.
03720-048-01 02220-1 DEMOLITION AND MODIFICATIONS
August 2019
1.02 RELATED WORK
A. Section 01100, Summary of Work.
B. Section 01330, Submittals and Acceptance.
C. Section 01350, Environmental Protection Procedures.
D. Section 01650, Delivery, Storage, and Handling.
E. Section 01780, Warranties and Bonds.
F. Section 01815, Maintenance of Plant Operation and Sequence of Construction.
G. Section 02225, Blend Tank Cleaning.
1.03 SUBMITTALS
The Contractor shall submit shop drawings in accordance with Section 01330, Submittals and
Acceptance:
A. Submit to the Engineer six copies of proposed methods and operations of
demolition of the structures and modifications before beginning work. Include in
the schedule the coordination of shutoff, capping, and continuation of utility
service as required.
B. Furnish a detailed sequence of demolition and removal work to ensure the
uninterrupted progress of the Owner's operations. The sequence shall be
compatible with sequence of construction and shutdown coordination
requirements.
C. Before beginning demolition work, the Contractor shall complete all
modifications necessary to bypass the affected structure. Actual work shall not
begin until the Engineer has observed and approved the modifications and
authorized beginning the demolition work in writing.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS (NOT USED)
1.06 QUALITY ASSURANCE (NOT USED)
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
03720-048-01 02220-2 DEMOLITION AND MODIFICATIONS
August 2019
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I1.08 DELIVERY, STORAGE, AND HANDLING
1 A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
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1.09 QUALIFICATIONS (NOT USED)
1 1.10 TESTING REQUIREMENTS (NOT USED)
I
1.11 MAINTENANCE (NOT USED)
1.12 RECORD DRAWINGS (NOT USED)
I 1.13 JOB CONDITIONS
O S
1 A. Protection: The Contractor shall conduct the demolition and removal work to
prevent damage or injury to structures, equipment, piping, instrumentation,
I conduit, light fixtures, etc., and occupants of the structures and to adjacent
features which might result from falling debris or other causes, and so as not to
interfere with the use and free and safe passage to and from adjacent structures.
IB. Scheduling: Carryout operations so as to avoid interference with operations and
work in the existing facilities.
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C. Notification: At least 48 hours before beginning demolition or removal, notify the
I Engineer in writing of the proposed schedule of the demolition or removal. The
Owner shall inspect the existing equipment and identify and mark those items
which are to remain the property of the Owner. No removals shall be started
1 without the permission of the Engineer.
D. Conditions of Structures:
I
1. The Owner and the Engineer assume no responsibility for the actual
I 2. condition of the structures to be demolished or modified.
Conditions existing at the time of inspection for bidding purposes will be
maintained by the Owner insofar as practicable. However, variations
1 within a structure may occur before the start of demolition work.
E. Repairs to Damage: The Contractor shall promptly repair damage caused to
1 adjacent facilities by demolition operation when directed by the Engineer and at
no cost to the Owner. Repairs shall be made to a condition at least equal to that
Iwhich existed before construction.
I 03720-048-01 02220-3 DEMOLITION AND MODIFICATIONS
August 2019
F. Traffic Access:
1. The Contractor shall conduct demolition and modification operations and
remove equipment and debris to ensure minimum interference with roads
onsite and to ensure minimum interference with occupied or used
facilities.
2. Special attention is directed towards maintaining safe and convenient
access to the existing facilities by plant personnel and plant associated
vehicles.
1.14 RULES AND REGULATIONS
A. When applicable and as deemed required, the Florida Building Code (latest
edition) or the City shall control the demolition, modification or alteration of the
existing buildings or structures.
B. No building or structure or any part thereof shall be demolished until any required
applicable application has been filed with the Building Inspector and a permit
issued. The fee for this permit shall be the Contractor's responsibility.
1.15 DISPOSAL OF MATERIAL
A. Salvageable material and equipment shall become the property of the Owner. The
Contractor shall dismantle all such items to a size that can be readily handled and
deliver them to a designated storage area.
B. All other material and items of equipment shall become the Contractor's property
and must be removed from the site and disposed of in accordance with the
Federal, State, and local rules and regulations.
C. Storing or selling removed items on the site will not be allowed.
PART 2 PRODUCTS (NOT USED)
PART 3 EXECUTION
3.01 GENERAL
A. All materials and equipment removed from existing work shall become the
property of the Contractor, except for those which the Owner has identified and
marked for the Owner's use. All materials and equipment marked by the Owner to
remain shall be carefully removed so as not to be damaged and shall be cleaned
and stored on or adjacent to the site in a protected place specified by the Engineer
or loaded onto trucks provided by the Owner.
03720-048-01 02220-4 DEMOLITION AND MODIFICATIONS
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B. The Contractor shall dispose of all demolition materials, equipment, debris, and
all other items—except those marked by the Owner to remain—off the site and in
conformance with all existing applicable laws and regulations.
C. Pollution Controls
1. Use water sprinkling, temporary enclosures, and other suitable methods to
limit the amount of dust and dirt rising and scattering in the air to the
lowest practical level. Comply with governing regulations pertaining to
environmental protection.
a. Do not use water when it may create hazardous or objectionable
conditions such as ice, flooding, and pollution.
b. Clean adjacent structures, facilities, and improvements of dust,
dirt, and debris caused by demolition operations. Return adjacent
areas to conditions existing before starting the work.
3.02 STRUCTURAL REMOVALS
A. The Contractor shall remove structures to the lines and grades shown unless
otherwise directed by the Engineer.
B. All demolition debris shall be removed and taken from the site, unless otherwise
approved by the Engineer.
C. After parts or all of slabs and like work which tie into new work or existing work
are removed, the point of junction shall be neatly repaired so as to leave only
finished edges and surface exposed.
3.03 DEMOLITION, REPLACEMENT, AND REPAIR
A. Structural elements shall not be overstressed. The Contractor shall be responsible
for shoring and/or bracing as required and indicated on the Contract Drawings for
adequate structural support as a result of work performed.
B. The shoring and/or bracing shall remain in place until the repair mortar and/or
concrete in each stage has attained design strength.
3.04 CLEAN-UP
A. The Contractor shall remove from the site all debris resulting from the demolition
operations as it accumulates. Upon completion of the work, the Contractor shall
03720-048-01 02220-5 DEMOLITION AND MODIFICATIONS
August 2019
03720-048-01
August 2019
remove all materials, equipment, waste, and debris of every sort and shall leave
the premises clean, neat, and orderly.
END OF SECTION
02220-6 DEMOLITION AND MODIFICATIONS
SECTION 02225
BLEND TANK CLEANING
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Section includes the work necessary for the removal and disposal of tank
contents. This task includes but is not limited to removing, loading, transporting,
and properly disposing of the tank contents including liquid, sludge, scum, rags,
grit, hair, grease, solids and semi-solids off site in accordance with applicable
federal, state, and local regulations.
B. The Section also covers the work necessary to complete the tank cleaning
activities including pressure washing, scraping, rinsing and drying of tank
internals to otherwise prepare the tank for structural inspection.
C. Demolition and removal of the tank aeration and mixing equipment including
aeration grid piping, diffusers, and associated supports, stirring pickets, center
guide shaft and bracket, and electrical wiring and conduit related to the mixers.
1.02 RELATED WORK
A. Section III — General Conditions.
B. Section IV — Technical Specifications.
C. Section IVa — Supplemental Technical Specifications.
D. Section 01815, Maintenance of Plant Operation and Sequence of Construction.
1.03 SUBMITTALS
The Contractor shall submit the following items in accordance with Section III — General
Conditions Article 6.11.1:
A. Before the issuance of the Notice to Proceed, the Contractor shall submit, to the
Engineer for review, a suitable work plan. The work plan shall include, but is not
limited to, the following:
1. Written procedure and time schedule for shut down, cleaning and startup,
including a description of the activities to be performed for each tank and
estimated dates from start and finish of required work on each facility.
2. The proposed procedures for; dewatering; odor control; layout of
equipment and piping; determining partial payment amounts; general
housekeeping; a site health and safety plan; providing needed manpower
03720-048-01 02225-1 BLEND TANK CLEANING
August 2019
and equipment to complete the work in a timely manner; and disposal of
dewatered contents at the disposal site of their choice in accordance with
State and Federal rules.
3. The spill containment plans for both the on-site activities and hauling to
the disposal site. Spills of any nature caused by the Contractor shall be
controlled and cleaned immediately. All spills onsite must be recorded
with volume and actions taken to clean area and reported to the Owner,
Engineer, and FDEP.
4. Photos or videos of the site to document existing condition prior to this
work and after the project is completed.
B. The Contractor or Subcontractor shall submit to the Engineer upon request
certificates signed and dated by each employee certifying that the employee who
will enter the tank has: received training in Confined Space Entry Procedure,
understands the health implications and risks involved, understands the use and
limits of the equipment to be used; and understands engineering and other hazard
control techniques and procedures.
C. Submit to the Owner two copies of proposed methods and operations of
demolition of the structures and modifications before beginning work. Include in
the schedule the coordination of shutoff, capping, and continuation of utility
service as required.
D. Furnish a detailed sequence of demolition and removal work to ensure the
uninterrupted progress of the Owner's operations. The sequence shall be
compatible with the sequence of construction and shutdown coordination
requirements. Additionally, sequence of construction shall be coordinated with
other current projects to avoid conflict.
E. Before beginning demolition work, the Contractor shall coordinate the demolition
work with the Owner, and shall coordinate the modifications necessary to divert
the flow from the affected structure and to maintain plant operations to meet
discharge permit requirements and to the satisfaction of the Owner. Actual work
shall not begin until the Owner has inspected and approved the modifications and
authorized beginning the demolition work in writing.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS (NOT USED)
1.06 QUALITY ASSURANCE (NOT USED)
1.07 WARRANTIES (NOT USED)
03720-048-01 02225-2 BLEND TANK CLEANING
August 2019
1.08 DELIVERY, STORAGE, AND HANDLING (NOT USED)
1.09 QUALIFICATIONS
A. Contractor shall have been in the business of cleaning tanks (and demolishing) for
at least 5 years.
B. Contractor shall be a licensed General Contractor in the state of Florida and
Pinellas County.
C. Contractor shall demonstrate that all employees working on the site have been
trained in Confined Space Entry and have had the requisite refresher training.
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 MAINTENANCE (NOT USED)
1.12 RECORD DRAWINGS (NOT USED)
1.13 JOB CONDITIONS
A. Protection
1. The Contractor shall perform the work in accordance with Section III —
General Conditions Article 6.9 Safety and Protection.
2. The Contractor shall conduct the demolition and removal work to prevent
damage or injury to structures, equipment, piping, instrumentation,
conduit, light fixtures, etc., and occupants of the structures and to adjacent
features that might result from falling debris or other causes, and not
interfere with the use and free and safe passage to and from adjacent
structures.
B. Notification
1. At least 10 business days before beginning demolition or removal, the
Contractor shall notify the Engineer in writing of the proposed schedule of
the demolition or removal. The Owner shall inspect the existing equipment
and identify and mark those items that are to remain on the property of the
Owner. No removals shall be started without the permission of the Owner
and the Engineer.
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August 2019
C. Conditions of Structures
1. The Owner and the Engineer assume no responsibility for the actual
condition of the structures to be repaired or modified.
2. Conditions existing at the time of inspection for bidding purposes will be
maintained by the Owner insofar as practicable. However, variations
within a structure may occur before the start of demolition work.
D. Repairs to Damage
1. The Contractor shall notify the Owner and the Engineer immediately
following any damages to existing facilities.
2. The Contractor shall promptly repair damage caused to adjacent facilities
by demolition operations when directed by the Engineer and at no cost to
the Owner. Repairs shall be made to a condition at least equal to that
which existed before construction.
3. All materials used for repairs shall match existing materials and be of
equal quality or better.
E. Traffic Access
1. The Contractor shall conduct cleaning, demolition and modification
operations and remove equipment and debris to ensure minimum
interference with roads on site and to ensure minimum interference with
occupied or used facilities.
2. Special attention is directed toward maintaining safe and convenient
access to the existing facilities by plant personnel and plant -associated
vehicles.
1.14 RULES AND REGULATIONS
A. The City of Clearwater Public Works shall control the cleaning, demolition,
modification, or alteration of the existing buildings or structures.
B. No building or structure or any part thereof shall be demolished until the
Contractor has obtained a Demolition Permit from the City Building Department.
The City will waive the permit fee.
1.15 DISPOSAL OF MATERIAL
A. All material and equipment removed from existing work shall become the
property of the Contractor and must be removed from the site, except for those
that the Owner has identified and marked for its use. All materials and equipment
marked by the Owner to remain shall be carefully removed so as not to be
03720-048-01
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02225-4 BLEND TANK CLEANING
damaged and shall be cleaned and stored on or adjacent to the site in a protected
place specified by the Engineer or loaded onto trucks provided by the Owner.
B. All demolition debris that is not marked by the Owner shall be removed and
hauled off the site unless otherwise approved by the Owner.
C. Salvageable material and equipment shall become the property of the Owner
unless otherwise as directed by the Engineer or Owner. The Contractor shall
dismantle all such items to a size that can be easily handled and deliver them to a
designated storage area.
D. The Contractor shall dispose of all demolition materials, equipment, debris, and
all other items—except those marked by the Owner to remain—off the site and in
conformance with all existing applicable laws and regulations.
E. Storing or selling removed items on the site shall not be allowed.
PART 2 PRODUCTS (NOT USED)
PART 3 EXECUTION
3.01 GENERAL
A. The Contractor shall coordinate all activities with the Engineer and Owner
personnel before proceeding with work. In situations where the operation of the
plant conflicts with the Contractor's work, the operation of the plant shall take
precedence.
B. The work shall be performed in accordance with the schedule submitted by the
Contractor and approved by the Owner and Engineer.
C. The Contractor shall place his equipment, vehicles, and temporary piping so that it
does not interfere with plant operations or the ongoing construction activities at
the plant.
D. All piping, wiring, adapters, and switches required to connect to the Owner's
water and electric power supply shall be provided by the Contractor. Before
connecting, the Contractor shall coordinate with the Owner. The Contractor shall
provide his own source of electrical power to operate all equipment for the
completion of the work if commercial utility power is not available.
E. Contractor shall conduct work in a way as to minimize odors 24 -hours a day while
emptying and cleaning each tank. Owner and Engineer reserve the right to stop or
postpone the work if odors become objectionable. No additional compensation
03720-048-01 02225-5 BLEND TANK CLEANING
August 2019
will be paid the Contractor because the cleaning work was postponed for
objectionable odors.
F The Contractor shall use the existing manways and access points in the tank to
perform cleaning and follow confined space entry procedures as required to
comply with local and state requirements.
G. The Contractor shall cover and isolate all work areas with disposable plastic
sheeting and strategically place drip pans at pumps, joints, disconnected piping,
tank manholes, clean -outs, drops, etc. to prevent possible contamination and
minimize spills.
H. Pollution Controls
1. The Contractor shall perform the Work in accordance with Section IV —
Technical Specifications — 207 Erosion and Sediment Control. The
Contractor shall prevent any of the storage tank contents from reaching the
storm drains.
2. The Contractor shall use water sprinkling, temporary enclosures, and other
suitable methods to limit the amount of dust and dirt rising and scattering
in the air to the lowest practical level. The Contractor shall comply with
governing regulations pertaining to environmental protection.
a. Do not use water when it may create hazardous or objectionable
conditions such as ice, flooding, and pollution.
b. Clean adjacent structures, facilities, and improvements of dust,
dirt, and debris caused by demolition operations. Return adjacent
areas to conditions existing before starting the work.
3. If it is necessary to remove any abandoned Asbestos Cement (AC) pipe
and/or appurtenances to accommodate the Work, the Contractor must
furnish all permits, labor, material, services, insurance, tools, equipment,
and notifications in accordance with EPA, OSHA, State, and all other
applicable agencies to handle and remove asbestos material.
3.02 SAFETY CONSIDERATIONS
A. The Contractor shall perform the work in accordance with Section III — General
Conditions Article 6.9 Safety and Protection.
B. The Contractor is responsible, at all times, for protecting the health and safety of
his workers. Neither the Engineer nor the Owner will be responsible for any injury
occurring to the Contractor's workers. Neither the Engineer nor the Owner will be
03720-048-01
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02225-6 BLEND TANK CLEANING
responsible for enforcing the Contractor's construction ways and means nor will
they be responsible for enforcing OSHA standards. While conducting cleaning
operations, the Contractor shall always have a superintendent in responsible
charge at the site. This person shall have the authority to make management
decisions pertaining to the project.
C. All Contractors and subcontractors performing work under this Contract must
utilize appropriate protective clothing, equipment, goggles, gloves, face masks,
etc., as necessary to undertake the work in a safe manner.
D. The Contractor shall isolate close, secure, divert, de -energize, lockout and apply
tags -plus applications to all valves, piping and associated equipment as found in
29 CFR 1915.89.
E. Each tank is a confined space and the Contractor is responsible for compliance
with OSHA Confined Space Entry Procedures, as found in 29 CFR Part 1910.146
and 29 CFR 1926 Subpart AA.
F. The Contractor is responsible for providing forced fresh air ventilation and
continuously monitoring the atmosphere inside each confined space to determine
the appropriate level of protection for his personnel during cleaning operations or
Engineer's personnel during an inspection.
3.03 DEWATERING, CLEANING AND DISPOSAL
A. The removal of all contents inside the designated tank including water, sludge,
scum, grit, grease, rags, solids, and semi-solids shall be removed by the
Contractor, whether or not the material is pump -able. The methods necessary to
remove all of the material in the tank shall be determined by the Contractor.
B. The Contractor is responsible for provided inert gas purging, ventilation, supplies,
supervision, electrical power, temporary lighting, backflow prevention devices,
safety equipment, storage, temporary scaffolding, and incidentals required to
conduct the work.
C. The Contractor is responsible for purging each tank with inert gases before the
tank is accessed or contents removed (when applicable).
D. The Contractor is responsible for dewatering the materials removed from the tank
and adding chemicals, as necessary, for odor control to the tank contents to meet
all Federal, State, and Local regulatory requirements.
03720-048-01 02225-7 BLEND TANK CLEANING
August 2019
E. Dewatered sludge shall be stored in a fully covered container or be disposed of
within 24 hours. In no case shall material that is dewatered during the day and not
stored properly remain on site past the end of the same day, defined as 4:00 p.m.
F. The Contractor shall coordinate the location of temporary dewatering facilities
with the Owner.
G. The Contractor is responsible for transportation and disposal of the tank contents
in accordance with local and state regulations. The Contractor shall verify with
City, County, and State officials any load limitations, required by these agencies,
on bridges and access roads to the disposal site. The Contractor shall be
responsible for all costs associated with traffic violations or other claims incurred
as a result of the hauling operations for the duration of the Contract. This includes
ensuring that all loads are within legal limits.
H. The Contractor shall supply copies of weight tickets, waste manifests and bill of
ladings to the Owner in a clear and comprehensive manner.
I. The Contractor is responsible for pressure washing the interior tank walls and
interior mechanical equipment. The Contractor shall also isolate the sludge
withdrawal pipes to prevent debris from entering downstream systems. During
power -washing operations, the Contractor shall be careful not to erode the
concrete surfaces of the existing structure. Any damaged caused to the tank by the
cleaning and removal of contents shall be the responsibility of the Contractor.
J. Water required for dilution, wash down and related purposes will be available
from the Owner's reclaimed water system and provided at current system
pressure. The Owner may also provide the Contractor potable water for cleaning
and wash water applications. If potable water is used, the Contractor is required to
obtain a water meter from the Owner's customer service department.
K. Tank cleaning shall be completed to the satisfaction of the Owner and Engineer
including removing all hardened or calcified deposits and otherwise preparing the
tank for structural inspection.
L. The Contractor is responsible for collecting and disposing of sewage,
contaminated liquids, sludge, scum, grit, grease, rags, solids, and semi-solids, at
local or state -approved treatment facilities.
M. The Contractor is responsible for collecting and disposing of filtrate, wash water
from cleaning, and other refuse material that is produced during the cleaning
operations. The filtrate and wash water may be piped to the head end of the
treatment plant for disposal at a concentration and rate approved by the Owner if
cleaning chemicals are not harmful to the treatment process. The Owner will
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02225-8 BLEND TANK CLEANING
require an analysis of the filtrate or wash water prior to approving its introduction
into the plant process.
N. The Contractor is responsible for preventing and/or abating any spills of tank
contents, cleaning water or other liquids onto the Owner's facility site.
O. The Owner shall approve all cleaning products used by the contractor in cleaning
the tanks and equipment prior to usage. The Owner, at its sole discretion, has the
right to disapprove any cleaning product that it deems harmful to the facility.
P. Contractor shall not allow any residuals, free liquids from the tank, or filtrate from
the dewatering operations to enter storm drains, roadways, waterways, or any
other land, either public or private. In the event that a spill occurs, the Contractor
shall immediately notify the Owner, take the necessary steps to control and clean
the spill under Owner direction, and shall pay any fines levied against the Owner
as a result of the spill. The Contractor shall be responsible for satisfying state
reporting requirements to the Owner, Engineer, and FDEP, and include the Owner
on correspondence related to any onsite spills to ensure proper reporting.
3.04 REMOVAL, REPLACEMENT, AND REPAIR
A. The Contractor shall furnish all labor, materials, equipment, and incidentals
required to remove and dispose of the materials shown in the Drawings and
specified herein:
1. Tank aeration equipment including aeration grid piping, diffusers, and
associated supports.
2. Tank mixing equipment including stirring pickets, center guide shaft and
bracket, supports, and mixer motor.
B. All electrical wiring and conduit related to the mixers shall be removed.
C. The aeration piping penetrating the tank wall shall be cut and capped inside the
tank.
D. Before removing tank cover, the Contractor shall provide engineered temporary
shoring and/or bracing of the hung utilities as regulated.
E. The walkway/bridge must remain in place for the duration of the Work.
F. The Contractor shall remove structures to the lines and grades shown on the
Drawings, unless otherwise directed by the Owner.
03720-048-01 02225-9 BLEND TANK CLEANING
August 2019
G. After parts or all slabs and like work that tie into new work or existing work are
removed, the point of junction shall be neatly repaired so as to leave only finished
edges and surfaces exposed.
H. Structural elements shall not be overstressed. The Contractor shall be responsible
for shoring and/or bracing as required and indicated on the Drawings for adequate
structural support resulting from the work performed.
3.05 CLEAN-UP
A. The Contractor shall remove from the site all debris resulting from cleaning and
demolition operations as it accumulates. Upon completion of the work, the
Contractor shall remove all materials, equipment, waste, and debris of every sort
and shall leave the premises clean, neat, and orderly in a similar or better
condition than what existed prior to start of this work.
B. Contractor shall return any laydown or other work areas to pre -construction
conditions.
END OF SECTION
03720-048-01 02225-10 BLEND TANK CLEANING
August 2019
SECTION 02230
SITE PREPARATION
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish all labor, materials, and equipment required and
perform all site preparation, complete as shown on the Contract Drawings and as
specified in this Section.
B. The Contractor shall obtain all permits required for site preparation before
proceeding with the work, including clearing and tree removal.
C. The areas to be cleared, grubbed, and stripped within public rights-of-way and
utility easements shall be minimized to the extent possible for the scope of
pipeline work and in consideration of the actual means and methods of
construction used. No unnecessary site preparation shall be performed within
these areas.
1.02 RELATED WORK
A. Section 01330, Submittals and Acceptance.
B. Section 01350, Environmental Protection Procedures.
C. Section 01650, Delivery, Storage, and Handling.
D. Section 01780, Warranties and Bonds.
E. Section 02305, Earthwork for Utilities.
F. Section 02920, Seeding and Sodding.
1.03 SUBMITTALS
A. The Contractor shall submit shop drawings in accordance with Section 01330,
Submittals and Acceptance.
B. Submit to the Engineer copies of all permits required before clearing, grubbing,
and stripping work.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS (NOT USED)
1.06 QUALITY ASSURANCE (NOT USED)
03720-048-01 02230-1 SITE PREPARATION
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1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
1.09 QUALIFICATIONS (NOT USED)
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 MAINTENANCE (NOT USED)
1.12 RECORD DRAWINGS (NOT USED)
PART 2 PRODUCTS (NOT USED)
PART 3 EXECUTION
3.01 CLEARING
A. The Contractor shall cut and remove all timber, trees, stumps, brush, shrubs,
roots, grass, weeds, rubbish, and any other objectionable material resting on or
protruding through the surface of the ground.
B. The Contractor shall preserve and protect trees and other vegetation designated on
the Drawings or directed by the Engineer to remain as specified below.
3.02 GRUBBING
A. The Contractor shall grub and remove all stumps, roots in excess of 1-1/2 inches
in diameter, matted roots, brush, timber, logs, concrete rubble, and other debris
encountered to a depth of 18 inches below original grade or 18 inches beneath the
bottom of foundations, whichever is deeper.
B. The Contractor shall refill all grubbing holes and depressions excavated below
the original ground surface with suitable materials and compact to a density
conforming to the surrounding ground surface in accordance with Section 02305,
Earthwork for Utilities.
03720-048-01 02230-2 SITE PREPARATION
August 2019
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3.03 STRIPPING
1 A. The Contractor shall strip topsoil from all areas to be occupied by buildings,
structures, and roadways and all areas to be excavated or filled.
IB. Topsoil shall be free from brush, trash, large stones, and other extraneous
material. Avoid mixing topsoil with subsoil.
1 C. The Contractor shall stockpile and protect topsoil until it is used in landscaping,
loaming, and seeding operations and dispose of surplus topsoil after all work is
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completed.
3.04 DISPOSAL
IA. Dispose of material and debris from sitepreparation p eparatlon operations by hauling such
I materials and debris to an approved offsite disposal area in accordance with
Federal, State, and local rules and regulations. No rubbish or debris of any kind
shall be buried on the site.
1 B. Burning of cleared and grubbed materials or other fires for any reason will not be
permitted.
I3.05 PROTECTION
1 A. Trees and other vegetation designated on the Contract Drawings or directed by the
Engineer to remain shall be protected from damage by all construction operations
I by erecting suitable barriers, guards, and enclosures, or by other approved means.
The Contractor shall conduct clearing operations in a manner to prevent falling
trees from damaging trees and vegetation designated to remain and to the work
I being constructed. The Contractor shall provide for the safety of employees and
others.
1 B. The Contractor shall maintain protection until all work in the vicinity of the work
being protected has been completed.
IC. The Contractor shall not operate heavy equipment or stockpile materials within
the branch spread of existing trees.
ID. The Contractor shall immediately repair any damage to existing tree crowns,
trunks, or root systems. Roots exposed and/or damaged during the work shall
1 immediately be cut off cleanly inside the exposed or damaged area. Treat cut
surfaces with an acceptable tree wound paint and topsoil spread over the exposed
1 root area.
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August 2019
E. When work is completed the Contractor shall remove all dead and downed trees.
Live trees shall be trimmed of all dead and diseased limbs and branches. All cuts
shall be cleanly made at their juncture with the trunk or preceding branch without
injury to the trunk or remaining branches. Cuts over 1 inch in diameter shall be
treated with an acceptable tree wound paint.
F The Contractor shall restrict construction activities to those areas within the limits
of construction designated on the Drawings, within public rights-of-way, and
within easements provided by the Owner. Adjacent properties and improvements
on these properties, public or private, which become damaged by construction
operations shall be promptly restored to their original condition to the full
satisfaction of the property owner.
G. The Contractor shall remove trees damaged beyond saving, through no fault of the
Contractor, as directed by the Engineer.
END OF SECTION
03720-048-01 02230-4 SITE PREPARATION
August 2019
SECTION 02240
DEWATERING
PART 1 GENERAL
1.01 SCOPE OF WORK
A. This Section covers the work necessary to complete the dewatering activities. All
work in this Section shall be done in accordance with the requirements of the
Environmental Resource Permit and Water Use Permit (if required) as issued by
the Southwest Florida Water Management District (SWFWMD).
B. In addition to the requirements listed in this Section, the Contractor shall obtain, if
required, and comply with all requirements of the Generic Permit for the
Discharge of Ground Water From Any Non -Contaminated Site Activity as
described in FAC 62-621-300.
C. Design, furnish, install, test, operate, monitor, and maintain dewatering system of
sufficient scope, size, and capacity to control groundwater flow into excavations
and permit construction to proceed on dry, stable subgrades.
1. Maintain dewatering operations to ensure erosion control, stability of
excavations and constructed slopes, that excavation does not flood, and
that damage to subgrades and permanent structures is prevented.
2. Prevent surface water from entering excavations by grading, dikes, or
other means.
3. Remove dewatering system if no longer needed.
D. The Contractor shall dewater so as to prevent damage to existing work. The
Contractor shall repair or replace damage resulting from the dewatering activities
promptly, remedy environmental damage as approved by the Engineer, and pay
any and all fines levied to Contractor at no additional cost or time to the Owner.
E. The Dewatering Plan shall be signed and sealed by the licensed professional
engineer responsible for its preparation.
F. The Contractor shall design the dewatering system. The Contractor shall be
responsible for obtaining whatever investigations are necessary, before bidding, to
design the dewatering system.
03720-048-01 02240-7 DEWATERING
August 2019
1.02 RELATED WORK
A. Section 01330, Submittals and Acceptance.
B. Section 01350, Environmental Protection Procedures.
C. Section 01650, Delivery, Storage, and Handling.
D. Section 01780, Warranties and Bonds.
1.03 SUBMITTALS
The Contractor shall submit the following in accordance with Section 01330, Submittals and
Acceptance:
A. Before construction, the Contractor shall obtain a dewatering permit from the
SWFWMD as required. At a minimum, the dewatering plan submitted with the
dewatering application shall include the following:
1. Duration of dewatering for each area.
2. Number and size of pumps.
3. Method of dewatering each area.
4. Methods for routing/containing the discharge.
5. Methods of isolating dewatering areas.
6. Time dewatering structure will be in place.
7. Proposed discharge points.
Five copies of the plan shall be submitted to the Engineer for record purposes
only.
B. The Contractor shall be responsible for determining if a Water Use Permit will be
required. If a Water Use Permit is required, it is the Contractor's responsibility to
obtain the required information from the Engineer and Owner to complete the
Water Use Pelinit application to submit with the Dewatering Plan. If a Water Use
Permit is required, the Contractor shall submit five copies of the application to the
Owner/Engineer for submittal purposes only.
C. The Contractor shall be responsible for obtaining a Generic Permit for the
Discharge of Produced Ground Water from any Non -Contaminated Site Activity
as set forth in FDEP Rule 62-621.300(2), FAC. The Contractor shall obtain the
required permit form 62-621.300(2) and the required information from the
Engineer and Owner to complete the Generic Permit for the Discharge of
Produced Ground Water from any Non -Contaminated Site Activity application to
submit with the Dewatering Plan. The Contractor shall submit five copies of the
application to the Owner/Engineer for submittal purposes only.
03720-048-01
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02240-7 DEWATERING
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D. Provide photographs or videotape, sufficiently detailed, of existing conditions of
adjoining properties, facilities, and other construction and site improvements that
might be later misconstrued as damage caused by dewatering operations.
E. Submit Record Drawings at Project closeout identifying and locating utilities and
other subsurface structural, electrical, or mechanical items encountered during
dewatering.
1. Note locations and capping depth of wells and well points.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS (NOT USED)
1.06 QUALITY ASSURANCE
A. Regulatory Requirements: Comply with water disposal requirements of
authorities having jurisdiction.
B. Pre -installation Conference: Conduct conference at the Project site to present and
discuss dewatering means, methods, and monitoring program.
C. Identify a person who shall be present at all times during the execution of this
portion of the Work and who shall be thoroughly familiar with the dewatering
system being installed for this Project, the referenced standards, environmental
and permit requirements, the requirements of this Work, and who shall direct all
work performed under this Section.
D. It shall be the responsibility of the Contractor to determine the water levels before
and during the dewatering work.
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
03720-048-01 02240-7 DEWATERING
August 2019
1.09 QUALIFICATIONS
A. The Contractor shall provide at least one person who shall be present at all times
during the execution of this portion of the Work and who shall be thoroughly
familiar with the dewatering system being installed, the referenced standards, the
requirements of this Work, and who shall direct all work performed under this
Section.
B. The Contractor shall be responsible for determining the water level before
beginning excavation and construction.
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 MAINTENANCE (NOT USED)
1.12 RECORD DRAWINGS (NOT USED)
1.13 PRE-BID INSPECTION AND TESTING
A. Before bidding, the Contractor shall perform a detailed site inspection and, if
desired, obtain the Owner's permission to perform site-specific testing as he
deems necessary to obtain all required information relative to project dewatering
requirements.
B. The Contractor shall include as part of his Bid the total cost of all surface and
subsurface dewatering as required to construct the Project in complete compliance
with the Drawings and these Specifications.
1.14 PROJECT CONDITIONS
A. The Contractor shall not interrupt utilities serving facilities occupied by Owner or
others unless approved by the Owner and Engineer and then only after arranging
to provide temporary utility services according to requirements indicated.
B. Survey adjacent structures and improvements, employing a professional land
surveyor licensed in Florida to establish exact elevations at fixed points to
monitor settlement. Clearly identify monitoring points and reference vertical
datum, and benchmarks. Monitor and record existing initial elevations.
1. During dewatering, regularly resurvey benchmarks, maintaining an
accurate log of surveyed elevations for comparison with original
elevations. Promptly notify the Engineer if changes in elevations occur or
if cracks, sags, or other damage is evident in adjacent construction and
existing structures.
03720-048-01 02240-7 DEWATERING
August 2019
PART 2 PRODUCTS (NOT USED)
PART 3 EXECUTION
3.01 DEWATERING SYSTEM
A. The dewatering system shall be adequate to drain the soils to be excavated to the
extent that the piezometric water level in the construction area is a minimum of
2 feet below the bottom of the excavation, side slopes of excavations, or bottom
of the footings at all times, or as otherwise required to obtain the specified
compaction and installation conditions. Pipeline trenches must be dewatered at
least 18 inches below the trench bottom.
B. If layered soils are encountered, the hydrostatic head in the zone below the
subgrade elevation shall be relieved to prevent uplift.
C. Unless otherwise noted and before any excavating below or within 2 feet above
the groundwater level, a dewatering system shall be placed into operation to lower
water levels to the extent specified previously and then shall be operated
continuously 24 hours a day, 7 days a week, throughout the excavation to
maintain and protect all work until the work has been completed to the
satisfaction of the Engineer.
D. Where used, well points shall be installed in an Engineer -approved manner and in
sufficient numbers to provide the necessary removal of water as stated previously.
Well points and header piping shall be installed so that traffic on public
thoroughfares and site access roads will not be impeded.
E. The Contractor shall be solely responsible for the arrangement, location, and
depths of the dewatering system necessary to accomplish the specified work. The
dewatering system shall stay in full operation until not less than 90% of the total
building load is applied, as will be determined by the Engineer, or until
excavations and trenches have been backfilled and compacted.
F. To prevent excessive noise, exhaust from all pumps and engines shall be silenced
and muffled.
G. Wellpoint or surface water pump discharge shall be controlled to prevent erosion,
undermining, and all other damage and be piped to approved locations.
H. With the Engineer's assistance, the Contractor is responsible for determining what
approvals and permits are required to comply with any and all applicable
regulations and permitting requirements relating to dewatering activities. With the
03720-048-01 02240-7 DEWATERING
August 2019
Engineer's assistance the Contractor shall obtain all necessary approvals and
permits and comply with any and all applicable regulations and permitting
requirements concerning all dewatering activities, including pumpage and
discharge. The Contractor is solely responsible for all costs associated with the
proper implementation of dewatering activities.
I. The Contractor shall perform all dewatering work in strict compliance with
Section 01350, Environmental Protection Procedures, and the Contract Drawings.
J. Excavations shall be kept free from water during the placing of concrete and for
36 hours after or until concrete forms are removed.
K. Protect structures, utilities, sidewalks, pavements, and other facilities from
damage caused by settlement, lateral movement, undermining, washout, and other
hazards created by dewatering operations.
1. Prevent surface water and subsurface or groundwater from entering
excavations, ponding on prepared subgrades, or flooding the site and
surrounding area.
2. Protect subgrades and foundation soils from softening and damage by rain
or water accumulation.
L. Install dewatering system to ensure minimum interference with roads, streets,
walks, and other adjacent occupied and used facilities.
1. Do not close or obstruct streets, walks, or other adjacent occupied or used
facilities without permission from the Owner and authorities having
jurisdiction. Provide alternate routes around closed or obstructed traffic
ways if required by authorities having jurisdiction.
M. Install sufficient dewatering equipment to drain water -bearing strata above and
below the bottom of foundations. If excavating through layered soils, relieve any
potential groundwater hydrostatic head in the zones below to prevent uplift.
1. Open -sump pumping which leads to loss of fines, subgrade softening, and
slope instability shall not be permitted.
N. Dispose of water removed by dewatering in a manner that avoids endangering
public health, property, and portions of work under construction or completed.
Dispose of water in a manner that avoids flooding or accumulation on private
property. Provide sumps, sedimentation tanks, and other flow -control devices as
required by authorities having jurisdiction.
03720-048-01 02240-7 DEWATERING
August 2019
3.02 OBSERVATION WELLS
A. The Contractor shall install observation wells as may be required to record
accurate water levels.
B. The Contractor shall be responsible for maintaining all observation wells and
observing and recording the elevation of the piezometric water levels daily.
C. Wells damaged or destroyed shall be replaced at no additional cost to the Owner.
3.03 CLEANUP
A. Upon completing dewatering elsewhere on the Project, the Contractor shall
remove all equipment and leave the project site in a neat, clean, and acceptable
condition satisfactory to the Owner. Wellpoint holes and excavations shall be
adequately backfilled and compacted to prevent settlement.
END OF SECTION
03720-048-01 02240-7 DEWATERING
August 2019
SECTION 02305
EARTHWORK FOR UTILITIES
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall provide all materials, equipment, labor, and work necessary
to completely construct the project in accordance with the Contract Documents.
This work includes but is not limited to the following:
1. Excavating and removing unsatisfactory materials.
2. Preparing trench foundations.
3. Providing satisfactory material for all trenches as specified and as
required.
4. Obtaining, storing, maintaining, and disposing of materials.
5. Dewatering, shoring, and sheeting.
6. Placing, compacting, testing, final grading, and demolishing subgrade.
7. Performing all other work required by the Contract Documents.
B. The Contractor is responsible for performing all work so as not to damage
existing roadways, facilities, utilities, structures, etc. and shall repair and replace
such damage to equal or better than its original undamaged condition without cost
to the Owner.
C. The Contractor shall examine the site before submitting a bid, taking into
consideration all conditions that may affect the work.
D. The Contractor shall coordinate all additional subsurface investigations and
testing included with this work with the Engineer before performing the
excavation and foundation preparation work. In general, if the Contractor finds
different and unsuitable/unsatisfactory soil conditions during the work, the
Contractor shall notify the Engineer and the Owner immediately.
1.02 RELATED WORK
A. Section 01350, Environmental Protection Procedures.
B. Section 02230, Site Preparation.
C. Section 02240, Dewatering.
03720-048-01 02305-1 EARTHWORK FOR UTILITIES
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1.03 SUBMITTALS
The Contractor shall submit the following shop drawings in accordance with Section 01330,
Submittals and Acceptance:
A. Material Test Reports: From a qualified testing agency indicating and interpreting
test results for compliance of the following with requirements indicated:
1. Classification according to ASTM D2487 of each on-site and borrow soil
material proposed for fill and backfill.
2. Laboratory compaction curve according to ASTM D1557 for each onsite
and borrow soil material proposed for fill and backfill.
B. The Contractor shall submit records before the start of this work. The Contractor
shall verify that the existing conditions are correct as shown on the plans and
mentioned in these Specifications. The Contractor shall note any discrepancies
found immediately and notify the Owner and Engineer.
The records shall include the following:
1. Location of all existing underground utilities, structures, etc. surrounding
the areas to be excavated that may be impacted by the work.
2. Location of test excavations.
3. Location of inspections.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be the latest
revision of any such document in effect at the bid time. The following documents are a part of
this Section. Where this Section differs from these documents, the requirements of this Section
shall apply:
A. OSHA Excavation Safety Standards, 29 CFR 1926, Subpart P
B. Florida Trench Safety Act (90-96, Laws of Florida)
C. American Society for Testing and Materials (ASTM)
1. ASTM D1556/D1556M—Standard Test Method for Density and Unit
Weight of Soil in Place by the Sand -Cone Method.
03720-048-01 02305-2 EARTHWORK FOR UTILITIES
August 2019
2. ASTM D1557—Standard Test Methods for Laboratory Compaction
Characteristics of Soil Using Modified Effort (56,000 ft-lbf/ft3
(2,700 kN-m/m3)).
3. ASTM D2487—Standard Practice for Classification of Soils for
Engineering Purposes (Unified Soil Classification System).
4. ASTM D2937—Standard Test Method for Density of Soil in Place by the
Drive -Cylinder Method.
5. ASTM D3282—Standard Practice for Classification of Soils and Soil -
Aggregate Mixtures for Highway Construction Purposes.
6. ASTM D3740—Standard Practice for Minimum Requirements for
Agencies Engaged in Testing and/or Inspection of Soil and Rock as Used
in Engineering Design and Construction.
7. ASTM D6938—Standard Test Methods for In -Place Density and Water
Content of Soil and Soil -Aggregate by Nuclear Methods (Shallow Depth).
8. ASTM E329—Standard Specification for Agencies Engaged in
Construction Inspection, Testing, or Special Inspection.
D. American Wood Protection Association (AWPA)
1. AWPA C 1—All Timber Products—Preservative Treatment by Pressure
Processes.
2. AWPA C3—Piles – Preservative Treatment by Pressure Processes.
1.06 QUALITY ASSURANCE
A. Geotechnical Testing Agency Qualifications: An independent testing agency
qualified according to ASTM E329 to conduct soil materials and definition
testing, as documented according to ASTM D3740.
B. The Contractor shall do the following:
1. Ensure that excavations provide adequate working space and clearance for
the work to be performed and for installing piping and buried utilities. In
no case shall excavation faces be undercut.
2. Ensure that foundation surfaces are clean and free of loose material of any
kind when pipelines and buried utilities are placed on them.
3. Excavate, trench, and backfill in compliance with applicable requirements
of governing authorities having jurisdiction.
4. Ensure that shoring and sheeting for excavations are designed by a
Florida -registered Professional Engineer and are in accordance with the
Occupational Safety and Health Administration (OSHA) Document 2226,
Safe Working Practices—Excavating and Trenching.
5. Before beginning any excavation or grading, ensure the accuracy of all
survey data indicated on the Contract Drawings and in these Specifications
03720-048-01 02305-3 EARTHWORK FOR UTILITIES
August 2019
and/or as provided. If the Contractor discovers any inaccuracies, errors, or
omissions in the survey data, the Contractor shall immediately notify the
Owner so that proper adjustments can be anticipated or ordered. If the
Contractor begins any excavation or grading, this shall be considered an
acceptance of the survey data by the Contractor, after which time the
Contractor has no claim against the Owner resulting from alleged errors,
omissions, or inaccuracies of the survey data.
6. Ensure that tolerances for excavation are ±0.10 foot to the required line
and to the required grade. Tolerance for compaction of in-place material
shall be ±0.10 foot to the required grade.
7. Ensure that all trench materials derived from the project site and imported
to this site are examined, tested, and classified by an Engineer -approved
soils testing laboratory.
8. Remove unsatisfactory materials and unsuitable materials including muck,
silts, peat, and other loose and very loose compressible soils from
excavations before placing pipe foundation, bedding, and buried utilities.
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
1.09 QUALIFICATIONS (NOT USED)
1.10 PROJECT CONDITIONS
A. Existing Utilities: The Contractor shall not interrupt utilities serving facilities
occupied by the Owner or others unless permitted to do so in writing by the
Engineer and then only after arranging to provide temporary utility services
according to the requirements indicated.
1. Notify the Engineer not less than 2 days in advance of proposed utility
interruptions.
2. Do not proceed with utility interruptions without the Engineer's written
permission.
3. Contact utility -locator service and obtain utility locations for the Project
Area before excavating.
03720-048-01 02305-4 EARTHWORK FOR UTILITIES
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B. The Contractor shall demolish and completely remove from the site existing
underground utilities indicated to be removed. Coordinate with utility companies
to shut off services if lines are active.
1.11 DEFINITIONS
A. Backfill: Soil material or controlled low -strength material used to fill an
excavation.
1. Initial Backfill: Backfill placed beside and over pipe in a trench, including
haunches to support sides of pipe.
2. Final Backfill: Backfill placed over initial backfill to fill a trench.
B. Base Course: The course placed between the subbase course and hot -mix asphalt
paving.
C. Bedding Course: The course placed over the excavated subgrade in a trench
before laying pipe.
D. Borrow Soil: Satisfactory soil imported from off-site for use as fill or backfill.
E. Drainage Course: The course supporting the slab -on -grade that also minimizes
upward capillary flow of pore water.
F. Excavation: Removal of material encountered above subgrade elevations and to
lines and dimensions indicated.
1. Authorized Additional Excavation: Excavation below subgrade elevations
or beyond indicated lines and dimensions as directed by the Engineer.
Authorized additional excavation and replacement material will be paid.
for according to the Contract provisions for unit prices.
2. Bulk Excavation: Excavation more than 10 feet in width and more than
30 feet in length.
3. Unauthorized Excavation: Excavation below subgrade elevations or
beyond indicated lines and dimensions without direction by the Engineer.
Unauthorized excavation, as well as remedial work directed by the
Engineer, shall be without additional compensation.
G. Fill: Soil materials used to raise existing grades.
H. Structures: Buildings, footings, foundations, retaining walls, slabs, tanks, curbs,
mechanical and electrical appurtenances, or other man-made stationary features
constructed above or below the ground surface.
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I. Subgrade: The surface or elevation remaining after completing excavation, or the
top surface of a fill or backfill immediately below subbase, drainage fill, or topsoil
materials.
J. Utilities: On-site underground pipes, conduits, ducts, and cables, as well as
underground services within buildings.
1.12 TESTING REQUIREMENTS
A. The Contractor shall furnish a soil survey for satisfactory material and samples of
materials.
B. Testing for source material, for classification, and for prequalification of material
(on or off site) shall be performed by an independent testing agency retained by
the Contractor and approved by the Engineer.
C. Testing for in-place compacted fill shall be performed by the same independent
testing agency as approved by the Engineer and retained by the Contractor.
D. The number and location of the tests shall be as specified in these Specifications
and as directed by the Engineer during construction.
E. The Contractor shall coordinate activity with the Engineer and the testing agency
to permit testing as directed in the presence of the Engineer.
F. The cost of all testing to achieve specified requirements shall be borne by the
Contractor.
G. The costs of any and all retests due to failure to achieve specified requirements
shall be solely borne by the Contractor and are not reimbursable under this
contract.
H. All materials proposed for use shall be tested as follows:
03720-048-01
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Material
Required Test
Min. No. Tests
Satisfactory
Soil Materials
Soil Classification using
ASTM D2487 (including all
tests contained therein)
One per source of materials to determine
conformance with materials specified in
these Specifications; additional tests
whenever there is any apparent change.
Soil moisture -density
relationship using Modified
Proctor ASTM D1557
One per source of material or apparent
change in material.
02305-6
EARTHWORK FOR UTILITIES
I. Soil materials shall be tested during construction as follows:
Material
Required Test
Min. No. Tests
Satisfactory
Field Density
For each layer of trench bottom subgrade
Soil Material
in-place after
ASTM D1556/D1556M —
Sand Cone Method, or
before addition of soil materials, refill,
bedding, and backfill, and for each 400
compaction
ASTM D6938 -Nuclear
Density Method, or
lineal feet of trench or fraction thereof,
whichever is greater; two tests for each
ASTM D2937 -Drive
drainage, manhole, or wet well structure;
Cylinder Method
additional test whenever there is any
change in native soil, groundwater, or soil
moisture conditions.
J. The approved testing agency shall transmit copies of required laboratory test
results as follows:
1. One copy to the Owner.
2. Two copies to the Engineer.
3. Two copies to the Contractor.
The laboratory test reports shall include, at a minimum, project title; project
location; location of sample; source, time, and date of testing; testing agency's
name, address, and telephone number; and test results. Each test report shall be
signed and sealed by the Professional Engineer representing the testing agency as
specified in these Specifications.
K. The approved testing agency shall transmit copies of field testing results as
follows:
1. One copy to the Owner.
2. Two copies to the Engineer.
3. Two copies to the Contractor.
The field test reports shall include, at a minimum, project title; project location;
location of sample(s) tested; time of testing; date of testing; testing person's full
name; testing agency name, address, and telephone number; and test results.
L. No soil material shall be used until 1) the Engineer has reviewed and approved
test reports and 2) the Contractor submits certification that the soil material
proposed for construction is clean and meets gradation and other parameters
specified in these Specifications.
03720-048-01
August 2019
02305-7 EARTHWORK FOR UTILITIES
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M. At no cost to the Owner, the Contractor shall remove and replace or correct all
materials and work which tests indicate do not conform, in the opinion of the
Engineer, to the requirements of these Specifications.
N. The results of in-place density tests shall be considered satisfactory if the density
in each instance is equal to or greater than the specified density. Soil moisture
content at the time of testing shall conform to requirements of these
Specifications.
O. Where the tests reveal unsatisfactory compaction, the Contractor shall re -
excavate, backfill, recompact, and/or rework the backfill as required to obtain the
required degree of compaction over the entire depth of the excavation.
P. The testing agency shall transmit to the Engineer copies of all testing agency
invoices submitted to the Contractor for payment. Invoices shall clearly indicate
specific services and date and time services are rendered and shall indicate if the
invoiced testing cost is an initial test of the Contractor's work or is a re -test
required due to the Contractor's failure to initially achieve the specified
requirements.
1.13 MAINTENANCE (NOT USED)
1.14 RECORD DRAWINGS (NOT USED)
PART 2 PRODUCTS
2.01 STRUCTURAL MATERIALS
A. Materials used for shoring and bracing, such as sheet piling, uprights, stringers,
and crossbraces, shall be in good serviceable condition. Any timber used shall be
sound and free from large or loose knots.
2.02 TRENCH SOIL MATERIALS
A. Materials used for trench construction shall be free of clumps of clay, rock or
gravel, debris, waste, frozen materials, and other deleterious matter as determined
by the Engineer and shall be satisfactory soil materials as follows:
03720-048-01
August 2019
Area Classification
Soil Materials
In excavations and trenches
Excavated and borrow material that has been sampled,
tested, and approved as "Satisfactory Soil Material."
02305-8
EARTHWORK FOR UTILITIES
B. Satisfactory Soil Materials
1. Soil Classification Groups
Satisfactory soil materials for each trench shall be as follows:
Satisfactory Soil Material (ASTM D3282, Soil Classification Groups)
In-situ Foundation
Bedding, Haunching, and
Initial Backfill
Final Backfill
SW
SP
SW
SP
SW
SP
2. Maximum Particle Size Limitations for Satisfactory Soil Materials
The maximum allowable particle size for satisfactory soil materials within
each trench for each type of utility shall be as follows:
Conduit
Maximum Allowable Particle Size
In-situ
Foundation
Bedding, Haunching,
and Initial Backfill
Final
Backfill
Plastic Pipe (PVC, CPVC, HDPE, etc.)
less than 6 -inch -diameter
See Note 1
1/2 inch
3 inches
Plastic Pipe (PVC, CPVC, HDPE, etc.)
6 -inch -diameter and Larger
See Note 1
3/4 inch
3 inches
Concrete Pipe
Steel Pipe
Ductile Iron Pipe
Fiberglass Pipe
See Note 1
3/4 inch or three
times the wall
thickness, whichever
is less
3 inches
Other Conduit Materials
See Note 2
See Note 2
See Note 2
(1)
There is no requirement when satisfactory undisturbed native soil material is used. Disturbed
portions of the foundation and/or unsatisfactory native soil material shall be replaced with
satisfactory soil materials meeting all the requirements for Bedding.
(2) The maximum allowable particle size shall be in accordance with the manufacturer's written
recommendation.
3. Additional Requirements of Satisfactory Materials
Satisfactory soil materials shall be free of debris, waste, frozen materials,
vegetation, or other deleterious matter. Soils within 4 inches of the exterior
surface of the pipe shall be free of gravel, stones, or other materials which
may abrade the pipe surface.
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C. Unsatisfactory Materials
Unsatisfactory soil materials shall mean ASTM D2487, Soil Classification
Groups GW, GP, GM, GC, SC, CL, ML, OL, CH, MH, OH, and PT and other
highly organic soils and soil materials of any classification that have a moisture
content at the time of compaction beyond the range of 1 percentage point below
and 3 percentage points above the optimum moisture content of the soil material
as determined by moisture -density relations test.
PART 3 EXECUTION
3.01 GENERAL REQUIREMENTS
The Contractor shall do the following:
A. Carefully verify by hand methods the location of all surrounding underground
utilities before performing utility excavations and trenches.
B. Protect utilities to be left in place from damage.
C. Do not interrupt existing utilities serving facilities occupied and used by the
Owner, except when permitted in writing by the Owner.
D. Protect bench marks, survey points, and existing structures, roads, sidewalks,
monitoring wells, paving, curbs, etc. against damage from equipment, vehicular or
foot traffic, settlement, lateral movement, undermining, washout, and all
construction -related activities.
E. Repair and replace damage to existing facilities to equal or better than their
original undamaged condition without cost to the Owner and to the approval of
the Engineer.
F. Excavate and trench in ways that will prevent surface water and subsurface water
from flowing into excavations and will also prevent flooding of the site and
surrounding area.
G. Protect excavations and trenching by shoring, bracing, sheet piling, underpinning,
or other methods as required to prevent cave-ins or loose dirt from falling into
excavations and trenches.
H. Do not operate earth -moving equipment within 5 feet of walls of concrete
structures for depositing or compacting backfill material.
I. Compact the backfill material placed next to concrete walls with hand -operated
tampers or similar equipment that will not damage the structure.
03720-048-01 02305-10 EARTHWORK FOR UTILITIES
August 2019
J. Excavate, fill, backfill, and grade to elevations required by the Contract
Documents.
K. Pile excavated materials suitable for backfill in an orderly manner a sufficient
distance from excavations to prevent overloading, slides, and cave-ins.
L. Do not obstruct access ways, roadways, and plant facilities.
M. Dewater excavations and trenches in accordance with Section 02240, Dewatering.
N. Refer to the Contract Drawings for additional requirements related to earthwork
and protection of existing features.
3.02 TRENCH EXCAVATION
A. Before excavating the trench, the Contractor shall prepare the surface including
clearing and grubbing as specified in Section 206 of the City's Standard Technical
Specifications.
B. The Contractor shall be required to fully comply with all applicable OSHA
Excavation Safety Standards and to abide by them as covered by the most current
version of the Florida Trench Safety Act (90-96, Laws of Florida).
C. The Contractor shall ensure that mechanical equipment used for trench excavation
shall be of a type, design, and construction and shall be so operated that
conduit/utility, when accurately laid to specified alignment, will be centered in the
trench with adequate clearance between the conduit/utility and sidewalls of the
trench. Undercutting the trench sidewall to obtain clearance will not be permitted.
D. The Contractor shall not use mechanical equipment in locations where its
operation would cause damage to trees, buildings, culverts, other existing
property, utilities, structures, etc. above or below ground. In all such locations, the
Contractor shall use hand excavating methods.
E. The Contractor shall not use blasting.
F. The Contractor shall cut trenches sufficiently wide to enable proper installation of
services and to allow for testing and inspection. The Contractor shall also trim and
shape trench bottoms and leave them free of irregularities, lumps, and projections.
Trench width shall be excavated as specified on the Contract Drawings.
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G. The Contractor shall construct trench walls so as to avoid side wall collapse or
sloughing. Trenches shall be either braced or open construction in accordance
with the Contract Documents. No separate payment will be made for any special
procedure used in connection with the excavation.
H. Where sheeting and bracing are not required, the Contractor shall construct trench
walls in the bottom of the excavation as vertical as possible to the maximum
height allowable by OSHA. Trench walls above this height shall be sloped to
guard against side wall collapse or sloughing as specified on the Contract
Drawings.
I. Where sheeting and bracing are required, the sheeting and bracing system shall
meet the requirements in these Specifications.
J. Excavations shall be to the design elevations shown on the Contract Drawings or
as specified, unless unsatisfactory or unsuitable foundation materials are
encountered in the bottom of the excavation. Where unsatisfactory or unsuitable
foundation materials are encountered, this material shall be undercut and removed
as indicated on the Contract Drawings and replaced with satisfactory soil material
meeting all the requirements for Bedding. The lift thicknesses and compaction
requirements for the replacement soil shall also meet the requirements for
Bedding.
K. The Contractor shall be careful not to overexcavate except where necessary to
remove unsatisfactory or unsuitable materials, irregularities, lumps, rock, and
projections. Unnecessary overexcavation shall be replaced as specified in these
Specifications at the Contractor's sole expense.
L. The Contractor shall accurately grade bedding soil materials at the bottoms of the
trenches to provide uniform bearing and support for each section of conduit/utility
at every point along its entire length except where it is necessary to excavate the
bedding for conduit/utility bells (e.g., pipe bells), etc. or for proper sealing of
conduit/utility joints. Abrupt changes in grade of the trench bottom shall be
avoided.
M. The Contractor shall dig bell holes and depressions after the bedding has been
graded to ensure that the conduit/utility rests on the prepared bedding for as much
of its full length as practicable. Bell holes and depressions shall be only of such
length, depth, and width as required to make the joint.
N The Contractor shall do the following:
1. Pile all excavated material in a manner that will not endanger the work or
erode the stormwater management facilities or water courses.
2. Avoid obstructing sidewalks, driveways, and plant facilities.
03720-048-01 02305-12 EARTHWORK FOR UTILITIES
August 2019
3. Leave hydrants, valve pit covers, valve boxes, or other utility controls
unobstructed and accessible.
4. Keep gutters, drainage inlets, natural water courses, and miscellaneous
drainage structures clear or make other satisfactory provisions for their
proper operation.
O. The Contractor shall keep all satisfactory materials that are suitable for use/reuse
in the trench construction separated from unsatisfactory materials.
P. Except where otherwise authorized, indicated, or specified, the Contractor shall
replace, at the Contractor's own expense, all materials excavated below the
bottom of concrete walls, footings, slabs on grade, and foundations with concrete
or flowable fill, as directed by the Engineer.
Q.
03720-048-01
August 2019
The Contractor shall adhere to these Additional Excavation Requirements for
piping:
1. Excavate trenches so that the piping can be laid to the lines, grades, and
elevations indicated on the Contract Drawings.
2. For piping designated to be laid to a minimum cover requirement, grade
trenches to avoid high and low points to the extent practical. Record
Drawings of such pipes shall present top -of -pipe and grade elevations at
all high and low points along each pipe segment, at the end points of each
pipe segments, and at intervals not to exceed 100 feet along each pipe
segment. If, in the opinion of the Engineer, additional air release and/or
vacuum relief valves are required, the Contractor shall install the
additional items as directed by the Engineer.
3. Except at locations specifically indicated otherwise on the Contract
Drawings, the required minimum cover over the top of the pipe from
finished grade for various pipe diameters shall be as follows:
Continue dewatering operations along each pipe segment until the required
minimum cover is provided. During the dewatering operations, the ground
water level in the trench shall remain at all times a minimum of 1 foot
below bottom of trench excavations.
02305-13 EARTHWORK FOR UTILITIES
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Pipe Diameter
48 inch or less
66 inch
72 inch
96 inch
Minimum Cover
3 feet
4 feet
4.5 feet
5 feet
Continue dewatering operations along each pipe segment until the required
minimum cover is provided. During the dewatering operations, the ground
water level in the trench shall remain at all times a minimum of 1 foot
below bottom of trench excavations.
02305-13 EARTHWORK FOR UTILITIES
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R. The Contractor shall adhere to these Additional Excavation Requirements for
Electrical Utilities:
1. Avoid abrupt changes in grade of the trench bottom.
2. The required minimum cover over the top of electrical conduits from
finished grade shall be as follows:
3. The required minimum clearance from the bottom of mat foundations
and/or footings shall be 2 feet. Provide additional cover where necessary
to satisfy the minimum clearance requirement.
4. Provide additional cover depth if necessary to avoid interference of other
cables, ducts, piping, structures, and other utilities.
S. The Contractor shall adhere to this Additional Excavation Requirement for
Appurtenances:
1. Ensure that excavations for valves and similar appurtenances shall be
sufficient to leave at least 12 inches in the clear between the outer surfaces
and the embankment or timber used to hold and protect the walls.
3.03 PROTECTION OF PERSONS AND PROPERTY
A. The Contractor shall do the following:
1. Barricade and post excavations with warning signs for the safety of
persons. Provide warning lights during hours of darkness.
2. Protect structures, utilities, sidewalks, pavements, and other facilities
immediately adjacent to excavations against damage including loading,
settlement, lateral movement, undermining, and washout.
B. Conduct topsoil removal operations to ensure the safety of persons and to prevent
damage to existing structures and utilities, construction in progress, trees and
vegetation to remain standing, and other property.
3.04 SHEETING AND BRACING
A. Where sheeting and bracing are required to support the side walls of the
excavation, the Contractor shall retain a Professional Engineer, registered in
03720-048-01 02305-14 EARTHWORK FOR UTILITIES
August 2019
Electrical Conduits
(Lines less than 5 kV)
Electrical Conduits (Lines
5 kV and up)
Minimum Cover
2 feet
3 feet
3. The required minimum clearance from the bottom of mat foundations
and/or footings shall be 2 feet. Provide additional cover where necessary
to satisfy the minimum clearance requirement.
4. Provide additional cover depth if necessary to avoid interference of other
cables, ducts, piping, structures, and other utilities.
S. The Contractor shall adhere to this Additional Excavation Requirement for
Appurtenances:
1. Ensure that excavations for valves and similar appurtenances shall be
sufficient to leave at least 12 inches in the clear between the outer surfaces
and the embankment or timber used to hold and protect the walls.
3.03 PROTECTION OF PERSONS AND PROPERTY
A. The Contractor shall do the following:
1. Barricade and post excavations with warning signs for the safety of
persons. Provide warning lights during hours of darkness.
2. Protect structures, utilities, sidewalks, pavements, and other facilities
immediately adjacent to excavations against damage including loading,
settlement, lateral movement, undermining, and washout.
B. Conduct topsoil removal operations to ensure the safety of persons and to prevent
damage to existing structures and utilities, construction in progress, trees and
vegetation to remain standing, and other property.
3.04 SHEETING AND BRACING
A. Where sheeting and bracing are required to support the side walls of the
excavation, the Contractor shall retain a Professional Engineer, registered in
03720-048-01 02305-14 EARTHWORK FOR UTILITIES
August 2019
Florida, to design sheeting and bracing. The design shall establish requirements
for sheeting and bracing and shall comply with all applicable codes; authorities
having jurisdiction; and federal, state, and local regulations.
B. The sole responsibility for the design, methods of installation, and adequacy of
sheeting and bracing shall be and shall remain that of the Contractor and the
Contractor's Professional Engineer. The Contractor shall provide all necessary
sheeting and bracing or other procedures as required to ensure safe working
conditions and to protect the excavations.
C. Sheeting and bracing shall consist of braced steel sheet piling, trench box, braced
wood lagging, and soldier beams or other approved methods.
D. The Contractor shall immediately fill and compact voids formed outside the
sheeting. Where soil cannot be properly compacted to fill the void, the Contractor
shall use Class B concrete as backfill at no additional cost to the Owner.
E. The Contractor shall install sheeting outside the required clearances and
dimensions. Sheeting shall be plumb, securely braced, and tied in position.
Sheeting shall be adequate to withstand all pressure to which it may be subjected.
The Contractor shall correct any movement or bulging at no expense to the Owner
so as to provide the necessary clearances and dimensions.
F. The Contractor shall maintain sheeting and bracing in excavations and trenches
for the entire time excavations will be open.
G. The Contractor shall not brace sheeting against pipe being laid. Sheeting shall be
braced so that no concentrated load of horizontal thrust is transmitted to the pipe.
H. Sheeting shall not be withdrawn if driven below the spring line of any pipe. The
Contractor shall cut off tops as indicated on the Contract Drawings and leave
bottoms permanently in place.
3.05 BACKFILLING AND COMPACTION
A. The Contractor shall not backfill trenches until required tests are performed.
B. Trenches improperly backfilled shall be reopened to the depth required for proper
compaction, then refilled and compacted as specified, or the condition shall be
otherwise corrected as directed.
03720-048-01
August 2019
02305-15 EARTHWORK FOR UTILITIES
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C. The Contractor shall perform the following steps to ensure compaction at the
bottom of the trench or excavation before bedding:
1. Remove disturbed native soil material and/or any soils not meeting the
requirement of satisfactory soil material as indicated on the Contract
Drawings.
2. Compact the bottom of the trench excavation (undisturbed native
subsurface soil) to no less than 95% of the Modified Proctor maximum dry
density in accordance with ASTM D1557, before placement of foundation,
bedding, piping, and backfill.
D. To backfill below and around pipe to the spring line of the pipe, the Contractor
shall do the following:
1. Construct foundation and bedding as indicated on the Contract Drawings
before placement of pipe.
2. Install each pipe at proper grade, alignment, and final position.
3. Deposit satisfactory soil material uniformly and simultaneously on each
side of pipe in completed course layers to prevent lateral displacement.
4. Compact under pipe haunches and on each side of pipe to the pipe spring
line as shown on the Contract Drawings to hold the pipe in the proper
position during subsequent pipe backfilling and compaction operations.
5. Construct haunching as indicated on the Contract Drawings.
E. To trench backfill above pipe spring line to finished grade, the Contractor shall do
the following:
1. Deposit satisfactory soil material around and above pipe in uniform layers
as shown on the Contract Drawings.
2. Backfill and compact trenches from the spring line of the pipe to the top of
the trench in completed course layers as shown on the Contract Drawings.
3. Use material previously defined in these Specifications as satisfactory soil
material.
4. Compact by hand or mechanical tampers.
3.06 DISPOSAL OF EXCESS AND WASTE MATERIALS
A. The Contractor shall remove and legally dispose of waste materials, including
excavated material classified as unsatisfactory soil material, trash, and debris from
the property at no additional cost to the Owner.
END OF SECTION
03720-048-01 02305-16 EARTHWORK FOR UTILITIES
August 2019
SECTION 02370
EROSION AND SEDIMENTATION CONTROL
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall take every reasonable precaution throughout construction to
prevent the erosion of soil and the sedimentation of streams, bays, storm systems,
or other water impoundments, ground surfaces, or other property as required by
federal, state, and local regulations.
B. The Contractor shall provide protective covering for disturbed areas upon
suspension or completion of land -disturbing activities. Permanent vegetation shall
be established at the earliest practicable time. Temporary and permanent erosion -
control measures shall be coordinated to ensure economical, effective, and
continuous erosion and siltation control throughout the construction and post -
construction period.
1.02 RELATED WORK
A. Section 01330, Submittals and Acceptance.
B. Section 01650, Delivery, Storage, and Handling.
C. Section 01780, Warranties and Bonds.
D. Section 02920, Seeding and Sodding.
1.03 SUBMITTALS
A. The Contractor shall submit shop drawings in accordance with Section 01330,
Submittals and Acceptance.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be the latest
revision of any such document in effect at the bid time. The following documents are a part of
this Section. Where this Section differs from these documents, the requirements of this Section
shall apply.
A. Florida Department of Transportation (FDOT)
1. FDOT Section 103—Temporary Work Structures.
03720-048-01 02370-1 EROSION AND SEDIMENTATION
August 2019 CONTROL
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2. FDOT Section 104 Prevention, Control, and Abatement of Erosion and
Water Pollution.
3. FDOT Section 530—Riprap.
4. FDOT Section 982—Fertilizer.
5. FDOT Section 985—Geotextile Fabrics.
1.06 QUALITY ASSURANCE (NOT USED)
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
1.09 QUALIFICATIONS (NOT USED)
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 MAINTENANCE (NOT USED)
1.12 RECORD DRAWINGS (NOT USED)
1.13 REGULATORY REQUIREMENTS
A. The Contractor shall prevent damage to properties outside the construction limits
from siltation due to construction of the project and assume all responsibilities to
the affected property owners for correction of damages which may occur. Erosion -
control measures shall be performed conforming to the requirements of and in
accordance with plans approved by applicable state and local agencies and as
specified by the erosion -control portion shown on the Drawings and as required
by these Specifications. The Contractor shall not allow mud and debris to
accumulate in the streets or enter drainage ditches, canals, or waterways. Should
the Contractor pump water from excavations during construction, appropriate
siltation preventative measures shall be taken before the pumped water is
discharged into any drainage ditch, canal, or waterway.
03720-048-01 02370-2 EROSION AND SEDIMENTATION
August 2019 CONTROL
1.14 PRACTICES
The Contractor shall adhere to the following:
A. Avoid dumping soil or sediment into any stream bed, pond, ditch, or watercourse.
B. Maintain an undisturbed vegetative buffer where possible between a natural
watercourse and trenching and grading operations.
C. Avoid equipment crossings of streams, creeks, and ditches where practicable.
1.15 EROSION AND SEDIMENT -CONTROL DEVICES AND FEATURES
A. The Contractor shall construct all devices (silt fences, retention areas, etc.) for
sediment control at the locations required to protect federal, state, and local water
bodies and water courses and drainage systems before beginning to excavate the
site. All devices shall be properly maintained in place until a structure or paving
makes the device unnecessary or until directed to permanently remove the device.
B. The Contractor shall use mulch to temporarily stabilize areas subject to excessive
erosion and to protect seed beds after planting where required.
C. Filter fabric, hay bales, or other approved methods shall be placed and secured
over the grates of each existing inlet, grating, or storm pipe opening near the area
of excavation to prevent silt and debris from entering the storm systems.
D. The Contractor shall use silt fences, hay bales, and floating turbidity barriers as
shown on the plans or as directed by the Owner or Owner's Representative to
restrict movement of sediment from the site.
E. The Contractor shall establish vegetative cover on all unpaved areas disturbed by
the work.
PART 2 PRODUCTS
2.01 GENERAL
A. Open -mesh biodegradable mulching cloth.
B. Fertilizer shall be in accordance with Section 02920, Seeding and Sodding.
C. Lime shall be Dolomitic Agricultural Ground limestone, in accordance with
FDOT Section 982.
03720-048-01 02370-3 EROSION AND SEDIMENTATION
August 2019 CONTROL
D. Grass shall be in accordance with Section 02920, Seeding and Sodding.
E. Silt fence shall consist of non -biodegradable filter fabric (Trevira, Mirafi, etc.), in
accordance with FDOT Section 985, wired to galvanized wire mesh fencing and
supported by wood or metal posts.
F. Floating or staked turbidity barriers as specified in FDOT Section 985 and FDOT
Standard Index 103.
G. Erosion Stone: FDOT Section 530:
1. Sand -Cement Riprap.
2. Concrete Block.
3. Rubble 20 to 300 pounds each.
H. Filter Fabric for placing under Riprap shall meet the requirements of FDOT
Section 985.
I. Baled hay or straw in accordance with FDOT Section 104.
PART 3 EXECUTION
3.01 CLEARING
A. The Contractor shall schedule and perfoinl clearing and grubbing so that
subsequent grading operation and erosion -control practices can follow
immediately after. Excavation, borrow, and embankment operations will be
conducted as a continuous operation. All construction areas not otherwise
protected shall be planted with permanent vegetative cover within 30 working
days after completing active construction.
3.02 STABILIZING
A. The angle for graded slopes and fills shall be no greater than the angle that can be
retained by vegetative cover or other adequate erosion -control devices or
structures. All disturbed areas outside of embankment left exposed will, within
30 working days of completion of any phase of grading, be planted or otherwise
provided with either temporary or permanent ground cover, devices, or structures
sufficient to restrain erosion.
3.03 REGULATORY REQUIREMENTS
A. Whenever land -disturbing activity is undertaken on a tract, a ground cover
sufficient to restrain erosion must be planted or otherwise provided within
03720-048-01 02370-4 EROSION AND SEDIMENTATION
August 2019 CONTROL
30 working days on that portion of the tract upon which further active
construction is to be undertaken.
B. If any earthwork is to be suspended for any reason for longer than 30 calendar
days, the areas involved shall be seeded with vegetative cover or otherwise
protected against excessive erosion during the suspension period. Suspension of
work in any area of operation does not relieve the Contractor of the responsibility
to control erosion in that area.
3.04 VEGETATIVE COVER
A. Preparation of Seedbed shall be in accordance with Section 02920, Seeding and
Sodding.
B. Disturbed areas along embankments shall be permanently seeded with mix
specified in Section 02920, Seeding and Sodding.
C. The Contractor shall mulch all areas immediately after seeding. Mulch shall be
applied and anchored as specified previously in this Section.
3.05 MAINTENANCE
A. The Contractor shall maintain all temporary and permanent erosion -control
measures in functioning order. Temporary structures shall be maintained until
such time as vegetation is firmly established and grassed areas shall be maintained
until completion of the project. Areas which fail to show a suitable stand of grass
or which are damaged by erosion shall be immediately repaired. No additional
payment will be made to the Contractor for re-establishing erosion -control
devices, which may become damaged, destroyed, or otherwise rendered unsuitable
for their intended function during the construction of the project.
B. The Contractor shall remove all silt, sediment, and debris buildup regularly to
maintain functioning storm systems and erosion -control devices.
3.06 REMOVAL OF SEDIMENT CONTROL DEVICES
A. Near completion of the project, when directed by the Engineer, the Contractor
shall dismantle and remove the temporary devices used for sediment control
during construction. All erosion -control devices in seeded areas shall be left in
place until the grass is established. The Contractor shall seed areas around devices
and mulch after removing or filling temporary control devices.
03720-048-01
August 2019
02370-5 EROSION AND SEDIMENTATION
CONTROL
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B. The Contractor shall clean up all areas at the completion of the project.
03720-048-01
August 2019
END OF SECTION
02370-6 EROSION AND SEDIMENTATION
CONTROL
SECTION 02700
PAVING
PART 1 GENERAL
1.01 SCOPE OF WORK
A. This Section covers the work necessary to provide for the construction of all
pavement where indicated on the Drawings.
1.02 SUBMITTALS
The Contractor shall submit shop drawings in accordance with Section 01330, Submittals and
Acceptance:
A. Limerock material submittal is to be made to include liquid limit, plastic index,
gradation, certification regarding deleterious material, limerock bearing ratio
(LBR), Florida Department of Transportation (FDOT) pit number, and other
information as required to indicate performance in accordance with the
specifications.
B. Information regarding asphaltic and Portland cement concrete materials and mix
shall be submitted as required by the referenced FDOT specifications.
1.03 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be the latest
revision of any such document in effect at the bid time, unless otherwise noted. The following
documents are a part of this Section. Where this Section differs from these documents, the
requirements of this Section shall apply.
A. The 2017 editions of the FDOT Standard Specifications for Road and Bridge
Construction (Standard Specifications) and Roadway and Traffic Design
Standards shall be referred to for construction, workmanship, and quality control
as specified with exceptions as noted in this Section.
03720-048-01
August 2019
1. Where the referenced FDOT Specifications cite "the Department," this
shall be modified to "the Owner and/or Engineer" by this contract.
2. The Contractor shall retain an independent testing agency, as approved by
the Engineer, to perform all tests, including tests referenced to be
performed by the Engineer.
02700-1 PAVING
3. Payment for this project is on a Lump -Sum Basis if defined as Lump Sum
on the Bid Form. The FDOT sections defining the Basis of Payment shall
be applied only when unit price work is defined on the Bid Form.
B. American Society of Testing and Materials (ASTM)
1. ASTM D1556/D1556M Standard Test Method for Density and Unit
Weight of Soil in Place by the Sand -Cone Method.
2. ASTM D1557—Standard Test Methods for Laboratory Compaction
Characteristics of Soil Using Modified Effort (56,000 ft-lbf/ft3
(2,700 kN-m/m3)).
3. ASTM D2167—Standard Test Method for Density and Unit Weight of
Soil in Place by the Rubber Balloon Method.
4. ASTM D6938—Standard Test Methods for In -Place Density and Water
Content of Soil and Soil -Aggregate by Nuclear Methods (Shallow Depth).
1.04 QUALITY ASSURANCE
A. The Contractor shall perform field -density tests along the centerline of
construction or as directed by the Engineer and in accordance with the FDOT's
Standard Specifications for Road and Bridge Construction, latest edition.
B. The Contractor shall field check the depth of stabilization and/or limerock at each
road crossing with a pipeline.
C. The Engineer may require additional testing as deemed necessary. The Engineer
shall interpret test results and the Contractor shall perform remedial work as
directed by the Engineer. The Contractor shall provide labor to the Engineer for
help in performing tests and/or checking line and grade at no additional cost to the
Owner.
D. Laboratory maximum dry density of soil mixtures at optimum moisture shall be
determined by ASTM D1557 for subgrade, stabilized subgrade, and limerock base
course.
E. Field density of stabilized subgrade and soils or soil mixtures in fill or backfill
shall be determined by ASTM D1556/D1556M, ASTM D2167, or ASTM D6938
for limerock base course.
F. Bearing value of stabilized subgrade shall be determined by the methods required
for determining LBR according to the FDOT, Standard Specification FM 5-515.
G. Field density of stabilized subbase shall be 98% or greater of the Modified Proctor
maximum dry density, ASTM D1557.
03720-048-01 02700-2 PAVING
August 2019
H. The Engineer shall have sole responsibility for interpreting all test results. The
Contractor shall bear the cost of all retests due to failure to achieve specified
requirements.
PART 2 PRODUCTS
2.01 GENERAL (NOT USED)
2.02 ROCK BASE
A. The following sections of the Standard Specifications shall apply:
1. Section 200-1, Description.
2. Section 200-2, Materials.
2.03 STABILIZING MATERIALS
A. The following sections of the Standard Specifications shall apply:
1. Section 160-1, Description.
2. Section 160-2, Materials.
2.04 PRIME AND TACK COATS FOR BASE COURSES
A. The following sections of the Standard Specifications shall apply:
1. Section 300-1, Description.
2. Section 300-2, Materials.
2.05 ASPHALT
A. The following sections of the Standard Specifications shall apply:
1. Section 334-1, Description.
2. Section 334-2, Materials.
3. Section 334-3, General Composition of Mixture.
4. Section 334-5, Acceptance of the Mixture.
03720-048-01 02700-3 PAVING
August 2019
2.06 CEMENT CONCRETE PAVEMENT
A. The following sections of the Standard Specifications shall apply:
1. Section 350-1, Description.
2. Section 350-2, Materials.
2.07 TRAFFIC STRIPES AND MARKINGS
A. The following sections of the Standard Specifications shall apply:
1. Section 711-1, Description.
2. Section 711-2, Materials.
PART 3 EXECUTION
3.01 EXCAVATION AND EMBANKMENT
A.
The following sections of the Standard Specifications shall apply:
1. Section
2. Section
3. Section
4. Section
5. Section
6. Section
7. Section
8. Section
9. Section
10. Section
11. Section
12. Section
B. Exceptions
03720-048-01
August 2019
120-1, Description.
120-2, Classifications of Excavation.
120-3, Preliminary Soils Investigation.
120-4, Removal of Unsuitable Materials and Existing Roads.
120-5, Disposal of Surplus and Unsuitable Material.
120-6.1, Materials for Borrow.
120-7, Materials for Embankment.
120-8, Embankment Construction.
120-9, Compaction Requirements.
120-10, Acceptance Program.
120-11, Maintenance and Protection of Work.
120-12, Construction.
1. Section 120-4.1, Subsoil Excavation: Unsuitable soils shall be those in
Classifications A-6, A-7, or A-8 in the American Association of State
Highway and Transportation Officials (AASHTO) System.
2. Section 120-4.2, Construction Over Existing Old Road: Where removal of
existing pavement is called for, it shall be removed to the full depth as
indicated in the cross-sections and replaced with new limerock and paving
or other treatment in accordance with the Drawings and details.
3. Section 120-5.3, Disposal of Paving Materials: Disposing of muck on side
slopes shall not apply.
02700-4 PAVING
4. Section 120-9.2.1, General: Laboratory maximum dry density shall be
determined by Modified Proctor, ASTM D1557. Field densities shall be
determined by ASTM D1556/D1556M, ASTM D2167, or ASTM D6938.
All embankments shall be compacted to not less than 95% of the
maximum dry density, as determined by modified Proctor, ASTM D1557.
5. Section 120-12.1, Construction Tolerances: No tolerance greater than
0.1 foot above or below the plan cross-section will be allowed.
3.02 STABILIZING
A. The following sections of the Standard Specifications shall apply:
1. Section 160-3, Construction Methods.
2. Section 160-4, Acceptance Program.
B. Exceptions
1. Section 160-2.4, Granular Subbase: Contractor may not substitute 6 inches
of Granular Subbase for 12 inches of Stabilization unless such substitution
is specifically indicated on the Drawings.
2. Section 160-4.2.1.2, Undertolerance in Bearing Value Requirements: no
undertolerance will be acceptable.
3.03 LIMEROCK BEARING RATIO AND DENSITIES
A. Stabilized finish grade and stabilized shoulders shall have a minimum LBR value
of 40 unless indicated otherwise on the Contract Drawings.
B. Field density of stabilized finished grade shall be a minimum of 98% of the
Modified Proctor maximum dry density as specified in ASTM D1557 to a
minimum depth of 12 inches as shown on the Drawings.
3.04 PRIME AND TACK COATS
A. The following sections of the Standard Specifications shall apply:
03720-048-01
August 2019
1. Section 300-3.1, Pressure Distributor.
2. Section 300-3.2, Sampling Device.
3. Section 300-3.3. Temperature Sensing Device.
4. Section 300-5, Cleaning Base and Protection of Adjacent Work.
5. Section 300-6, Weather Limitations.
6. Section 300-7, Application of Prime Coat.
7. Section 300-8, Application of Tack Coat.
02700-5 PAVING
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3.05 ROCK BASE
A. The following sections of the Standard Specifications shall apply:
1. Section 200-3, Equipment.
1 2. Section 200-4, Transporting Rock.
3. Section 200-5, Spreading Rock.
I 4.
5. Section 200-6, Compacting and Finishing Base.
Section 200-7, Acceptance Program.
6. Section 200-8, Priming and Maintaining.
1 B. Exceptions
1 1. Section 200-7.2.1, Density: The minimum density that will be acceptable
for paved areas will be 98% of the maximum dry density as determined by
Modified Proctor, ASTM D1557.
I2. Section 200-7.3.1.2, Depth and Surface Testing Requirements: Thickness
of base shall be measured at intervals not to exceed 200 feet.
3.06 ASPHALT
1 A. The following sections of the Standard Specifications shall apply:
1. Section 320-6, Preparation of the Mixture.
I2. Section 320-7, Transportation of the Mixture.
3. Section 330-1, Description.
I 4. Section 330-2, Quality Control (QC) Requirements.
5. Section 330-3, Limitations of Operations.
6. Section 330-4, Surface Preparation.
I 7. Section 330-5, Paving Equipment.
8. Section 330-6, Placing Mixture.
9. Section 330-7, Compacting Mixture.
1 10. Section 330-8, Joints.
11. Section 330-9, Surface Requirements.
I12. Section 330-10, Protection of Finished Surface.
3.07 CEMENT CONCRETE PAVEMENTS
A. The following sections of the Standard Specifications shall apply:
' 1. Section 350-3, Equipment.
2. Section 350-4, Subgrade Preparation.
3. Section 350-5, Setting Forms.
4. Section 350-6, Protection from Weather.
' 03720-048-01 02700-6 PAVING
August 2019
5. Section 350-7, Placement of Reinforcement.
6. Section 350-8, Placing Concrete.
7. Section 350-9, Striking -off, Consolidating, and Finishing Concrete.
8. Section 350-10, Final Finish.
9. Section 350-11, Curing.
10. Section 350-12, Joints.
11. Section 350-13, Surface Requirements.
12. Section 350-14, Thickness Determinations.
3.08 PAVEMENT REPAIR
A. At his own expense the Contractor shall repair all damage to pavement as a result
of work under this Contract in a manner satisfactory to the Engineer. Pavement
shall be repaired to match the original surface material thickness and original
grade. However, the asphalt concrete thickness shall not be less than 2 inches. The
repair shall include preparing the subgrade, placing and compacting the applicable
base, priming the limerock base, and placing and maintaining the surface
treatment as specified in this Section.
B. The width of all repairs shall extend at least 12 inches beyond the limit of the
damage and as shown on the Contract Drawings. The edge of the pavement to be
left in place shall be cut to a true edge with a saw or other approved method to
provide a clean edge to abut the repair. The line of the repair shall be reasonably
uniform with no unnecessary irregularities.
3.09 JOINTS
A. General pavement joints within asphalt or concrete driveways and roadways and
where specified or directed by the Engineer, shall be mechanically sawed butt
joints. The edges of asphalt pavement shall be trimmed to straight lines which a
roller can follow or formed.
3.10 TRAFFIC STRIPES AND MARKINGS
A. The following sections of the Standard Specifications shall apply:
03720-048-01
August 2019
1. Section 711-3, Equipment.
2. Section 711-4, Application.
3. Section 711-5, Contractor's Responsibility for Notification.
4. Section 711-6, Protection of Newly Applied Traffic Stripes and Markings.
END OF SECTION
02700-7 PAVING
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SECTION 02920
SEEDING AND SODDING
PART 1 GENERAL
1.01 SCOPE OF WORK
A. This Section includes requirements for the following areas of work:
1. Fine grading.
2. Preparation of areas to receive seeding and sodding.
3. Fertilizing of areas to receive seeding and sodding.
4. Maintenance.
5. Seeding.
6. Hydroseeding.
7. Sodding of new areas to receive seeding and sodding.
8. Mulching.
1.02 RELATED WORK
A. Section 01330, Submittals and Acceptance.
B. Section 01650, Delivery, Storage, and Handling.
C. Section 01780, Warranties and Bonds.
D. Section 02370, Erosion and Sedimentation Control.
1.03 SUBMITTALS
A. The Contractor shall submit shop drawings in accordance with Section 01330,
Submittals and Acceptance.
B. Certificates:
1. Fertilizer, seed, hydroseed, and sod shall be accompanied by certificate
from vendors certifying these items meet the requirements of these
Specifications, stating botanical name, percentage by weight, and
percentage of purity.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be the latest
revision of any such document in effect at the bid time. The following documents are a part of
03720-048-01 02920-1 SEEDING AND SODDING
August 2019
this Section.
shall apply.
A.
B.
C.
D.
Where this Section differs from these documents, the requirements of this Section
FS O-F-241—Fertilizers, Mixed, Commercial.
American Society for Testing and Materials (ASTM)—Equivalent AASHTO
standards may be substituted as approved.
The Florida Department of Transportation (DOT) Standard Specifications for
Road Bridge Construction (Standard Specifications) shall be referred to for both
specific and general standards for materials, construction, workmanship, and
quality control as specified in this Section with exceptions, as noted herein. Note
that any reference in the Standard Specifications to the terms "Department" or
"District Materials Engineer" shall be replaced by the term "Owner."
Section IV, Technical Specifications.
1.06 QUALITY ASSURANCE
A.
The Contractor shall provide seed mixture in containers showing percentage of
seed mix, year of production, net weight, date of packaging, and location of
packaging.
1.07 WARRANTIES
A.
Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
A.
B.
C.
D.
03720-048-01
August 2019
The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
Deliver, store, protect, and handle products to the site and prevent damage from
wetness and weather conditions.
Deliver grass seed mixture in sealed containers. Seed in damaged packaging is not
acceptable.
Deliver fertilizer in waterproof bags showing weight, chemical analysis, and name
of the manufacturer.
02920-2 SEEDING AND SODDING
E. No sod that has been cut for more than 72 hours may be used unless specifically
authorized. A letter of certification from the grassing Contractor as to when the
sod was cut and what type shall be provided to the Engineer upon delivery of the
sod to the job site.
1.09 QUALIFICATIONS (NOT USED)
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 MAINTENANCE
A. Maintenance shall be as indicated under Part 3, Execution, of this Section.
1.12 RECORD DRAWINGS (NOT USED)
1.13 DEFINITIONS
A. Weeds: Weeds include but are not limited to Dandelion, Jimsonweed, Quackgrass,
Horsetail, Morning Glory, Rush Grass, Mustard, Lambsquarter, Chickweed,
Cress, Crabgrass, Canadian Thistle, Nutgrass, Poison Oak, Blackberry, Tansy
Ragqwort, Johnson Grass, Poison Ivy, Nut Sedge, Nimble Will, Bindweed, Bent
Grass, Wild Garlic, Perennial Sorrel, and Brome Grass.
1.14 REGULATORY REQUIREMENTS
A. The Contractor shall comply with regulatory agencies for fertilizer and herbicide
composition.
PART 2 PRODUCTS
2.01 TOPSOIL
A. The Contractor shall provide topsoil from off-site borrow or from project on-site
excavation as approved by the Engineer.
2.02 SEED MIXTURE
A. The Contractor shall comply with the City requirements in Section IV Item 902
and as follows:
1. For sod and seeded areas, fertilize with a complete granular fertilizer on
Bahia and St. Augustine grasses at the rate of 1 pound of nitrogen per
1,000 square feet. Fertilizer shall be commercial grade, mixed granules,
with 30% to 50% of the nitrogen being in slow or controlled release form.
03720-048-01 02920-3 SEEDING AND SODDING
August 2019
The ratio of nitrogen to potash will be 1:1 or 2:1 for complete fertilizer
formulations. Phosphorus shall be no more than one-quarter the nitrogen
level. They shall also contain magnesium and micronutrients
(i.e. manganese, iron, zinc, copper, etc.).
2.03 FERTILIZER FOR SOD
A. The Contractor shall comply with the City requirements in Section IV Item 902.
B. The Contractor shall provide commercial fertilizer of neutral character, with some
elements derived from organic sources, containing not less than 8% phosphoric
acid, 8% potassium, and percentage of nitrogen required to provide less than
1.0 pound of actual nitrogen per 1,000 square feet of area. Provide nitrogen in
form that will be available to the seeded and sodded area during initial period of
growth. The chemical designation shall be 5-10-10.
C. The Contractor shall ensure that the fertilizer is delivered to the site in labeled
bags or containers.
2.04 FERTILIZER FOR SEED
A. The Contractor shall comply with the City requirements in Section IV Item 902.
B. Fertilizer: FS O -F-241, Type I, Grade A; recommended for grass, with 50% of the
elements derived from organic sources, of a proportion necessary to eliminate any
deficiencies of topsoil to the following proportions:
1. Seeded Areas — 5% nitrogen, 10% phosphoric acid, 10% soluble potash.
2.05 WATER FOR SEEDING AND SODDING
A. Water shall be free of acid, alkali, or organic materials and shall have a pH of 7.0
to 8.5. The Contractor shall provide all water needed for grassing by providing
permanent or temporary piping valves and temporary trucks to convey water from
the source to the point of use. The Contractor shall provide any meters required
and pay for water used if the water is taken from a public water system. Water
shall be free of petroleum products, pesticides, and any other deleterious
impurities.
2.06 EROSION -CONTROL FABRIC
A. The Contractor shall provide 70% agricultural straw with 30% coconut fiber
matrix stitches with degradable nettings designed to degrade within 18 months.
Erosion -control anchors shall be as recommended by the manufacturer.
03720-048-01
August 2019
02920-4 SEEDING AND SODDING
2.07 STRAW MULCH
A. Straw mulch shall be used on all newly graded and top -soiled areas sloped 3:1 or
steeper to protect areas against washouts and erosion. Straw mulch shall consist of
threshed straw of oats, wheat, barley, or rye that is free from noxious weeds,
mold, or other objectionable material. The straw mulch shall contain at least 50%
by weight of material that is 10 inches or longer. Straw shall be in an air-dry
condition and suitable for placement with blower equipment.
2.08 TACKIFIER
A. Latex acrylic copolymer shall be Soil Sealant with coalescing agent as
manufactured by Soil Stabilization Products Company, Inc., Merced, CA, or equal
and shall be used as straw mulch tackifier.
PART 3 EXECUTION
3.01 COORDINATION OF WORK
A. The Contractor shall coordinate all work activities to provide for establishing
grass cover at the earliest possible time in the construction schedule to minimize
erosion of topsoil.
3.02 SOIL PREPARATION
Concerning soil preparation, the Contractor shall do the following:
A. Dispose of any existing sod, growth, rocks, or other obstructions which might
interfere with tilling, seeding, sodding, or later maintenance operations. Remove
stones over 1-1/2 inches in any dimensions and sticks, roots, rubbish, and other
extraneous matter. Remove from work area or site: do not stockpile.
B. Till to a depth of not less than 6 inches. Thoroughly loosen and pulverize topsoil.
C. Grade areas to be seeded and sodded to a smooth, even surface with loose,
uniformly firm texture. Roll and rake, remove ridges, and fill depressions to meet
finish grades. Limit fine grading to areas which can be planted in the immediate
future.
D. Moisten prepared areas to be seeded and sodded before planting if the soil is dry.
Water thoroughly and allow the surface to dry off before seeding and sodding. Do
not create a muddy soil condition.
03720-048-01 02920-5 SEEDING AND SODDING
August 2019
E. Restore prepared areas to specified condition if eroded or otherwise disturbed
after the fine grading and before planting.
F. Spread the planting soil mixture to depth required to meet thickness, grades, and
elevations indicated after light rolling and natural settlement. Do not spread if the
material is frozen or if the subgrade is frozen.
G. Preparing Unchanged Grades:
1. Where seeding and sodding in areas that have not been altered or disturbed
by excavating, grading, or stripping operations, prepare soil as follows:
a. Till to a depth of not less than 12 inches.
b. Apply soil amendments and initial fertilizers.
c. Remove high areas and fill in depressions.
d. Till soil to a homogeneous mixture of fine texture, free of lumps,
clods, stones, roots, and other extraneous matter.
H. Allow for a 3 -inch sod thickness in areas to be added next to paving.
I. Before preparing unchanged areas, remove existing grass, vegetation, and turf
Dispose of such material outside of the Owner's property: do not turn over into
soil being prepared for seeding and sodding.
J. Place approximately one-half of the total amount of planting soil required. Work
into the top of the loosened subgrade to create a transition layer and then place the
remainder of the planting soil.
3.03 FERTILIZING FOR SEEDING
A. Seeding: The Contractor shall spread fertilizer uniformly at a rate of 10 pounds
per 1,000 square feet.
B. Apply after smooth raking of topsoil and before roller compaction.
C. Do not apply fertilizer at same time or with same machine as will be used to apply
seed.
D. Mix thoroughly into upper 2 inches of topsoil.
E. Lightly water to aid the dissipation of fertilizer.
03720-048-01
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02920-6 SEEDING AND SODDING
3.04 SEEDING
A. Apply seed at the rate designated on the schedule evenly in two intersecting
directions. Rake in lightly.
B. Do not seed areas in excess of that which can be mulched on the same day.
C. Do not sow immediately following rain, when ground is too dry, or during windy
periods.
D. Roll seeded area with appropriate equipment to achieve seed embedment and soil
compaction.
E. Apply water with a fine spray immediately after each area has been mulched.
Saturate to 4 inches of soil.
3.05 HYDRO -SEEDING
A. Apply seeded slurry with a hydraulic seeder at the rate designated on schedule
evenly in two intersecting directions.
B. Do not hydro -seed area in excess of that which can be mulched on the same day.
C. Apply water with a fine spray immediately after each area has been mulched.
Saturate to 4 inches of soil.
3.06 SEED PROTECTION
A. When seeding is complete, apply straw mulch at a rate of 4,000 pounds/acre.
Apply tackifier as required.
B. Cover seeded slopes where grade is 4 inches per foot or greater with erosion
fabric. Roll fabric onto slopes without stretching or pulling.
C. Lay fabric smoothly on surface, bury top end of each section in 6 -inch -deep
excavated topsoil trench. Provide a 2- to 4 -inch overlap of adjacent rolls. Backfill
the trench and rake smooth, level with the adjacent soil.
D. Secure outside edges and overlaps in accordance with the manufacturer's
recommendations.
E. Lightly dress slopes with topsoil to ensure close contact between fabric and soil.
03720-048-01
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02920-7 SEEDING AND SODDING
F. At the sides of ditches, lay fabric laps in direction of water flow. Lap ends and
edges a minimum of 6 inches.
3.07 SODDING NEW AREAS
When sodding new areas, the Contractor shall do the following:
A. Before laying sod, contact the Engineer to observe soil preparation work. Lay sod
within 24 hours of the time of stripping. Do not plant dormant sod or if the ground
is frozen.
B. Lay sod to form a solid mass with tightly fitted joints. Butt ends and sides of sod
strips; do not overlap. Stagger to offset joints in adjacent courses. Employ
installation methods to avoid damage to subgrade or sod. On slopes install the sod
with an overlap that allows water to flow over the adjacent strip and not under it.
Tamp or roll lightly to ensure contact with subgrade. Work sifted soil into minor
cracks between pieces of sod; remove excess to avoid smothering adjacent grass.
C. Anchor sod on slopes greater than 3:1 with wood pegs as required to prevent
slippage.
D. Water sod thoroughly with a fine spray immediately after planting.
3.08 RECONDITIONING SEEDED AND SODDED AREAS
The Contractor shall ensure that seeded and sodded areas are properly reconditioned by doing the
following:
A. Recondition seeded and sodded areas that are damaged by work operations,
including storage of materials or equipment and movement of vehicles. Also
recondition seeded and sodded areas where settlement or washouts occur or where
minor regrading is required. Recondition other existing seeded and sodded areas
where indicated.
B. Provide fertilizer, topsoil, seed, or sod amendments as specified for new seeded
and sodded areas and as required to provide satisfactory reconditioning. Provide
new planting soil as required to fill low spots and meet new finish grades.
C. Cultivate bare and compacted areas thoroughly to provide a good deep planting
bed.
D. Remove diseased or unsatisfactory seeded and sodded areas; do not bury into soil.
Remove topsoil containing foreign materials resulting from operations including
03720-048-01
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02920-8 SEEDING AND SODDING
oil drippings, stone, gravel, and other construction materials. Replace with new
topsoil.
E. Where substantial seeding and sodding remains (but is thin), mow, rake, aerate if
compacted, fill low spots, remove humps and cultivate soil, fertilize, and seed.
Remove weeds before seeding or, if extensive, apply selective chemical weed
killers as required. Apply a seedbed mulch, if required, to maintain moist
condition.
F. Water newly planted areas and keep moist until new grass is established.
3.09 PROTECTION
A. The Contractor shall erect barricades, warning signs, and fencing to protect newly
planted areas from traffic. Maintain barricade fencing and warning signs
throughout the maintenance period until project is substantially completed.
3.10 MAINTENANCE
To maintain the seeded and sodded area, the Contractor shall do the following:
A. Mow sod to a height of 2 inches as soon as there is enough top growth to cut with
a mower. Remove no more than 40% of grass leaf growth in initial or subsequent
mowing. Do not delay mowing until grass blades bend over and become matted.
B. Maintain grass growth by watering, fertilizing, weeding, mowing, trimming, and
other operations such as rolling, re -grading, and replanting as required to establish
a smooth, acceptable seeding and sodding, free from eroded or bare areas.
C. Remove weeds by pulling or chemical treatment.
D. Perform maintenance until the date of final completion of project.
E. Apply the second fertilizer application after the first mowing and when grass is
dry. Use fertilizer which will provide not less than 1.0 pound of actual nitrogen
per 1,000 square feet of seeded and sodded areas.
F. Replant bare areas using the same materials specified for seeded and sodded areas.
G. Watering: Provide and maintain temporary piping, hoses, and watering equipment
as required to convey water from water sources and to keep seeded and sodded
areas uniformly moist as required for proper growth. Do not apply more than
1 inch of water per week to sustain grass growth.
03720-048-01 02920-9 SEEDING AND SODDING
August 2019
H. Lay out temporary watering system and arrange watering schedule to avoid
walking over muddy areas. Use equipment and water to prevent puddling and
water erosion and displacing seed or mulch (if any).
I. Apply water in sufficient quantities and as often as seasonal conditions require to
keep the grassed areas moist.
J. Provide supplemental water and irrigation to sod areas when the rainfall is not
adequate to maintain soil moisture necessary for growth of the grass. The
Contractor is responsible for determining the quantities of water required and
when to irrigate. This obligation shall remain in full force and effect until final
acceptance of the work by the Owner and shall be provided at no additional cost
to the Owner.
The Owner, at its discretion, may relieve the Contractor of this obligation at such
time as the Owner is able to provide irrigation if available. This action, however,
does not relieve the Contractor of the provisions and guarantees set forth in the
Contract Documents.
3.11 ACCEPTANCE OF SEEDED OR SODDED AREAS
A. When seeding or sodding work, including maintenance, is substantially complete,
the Engineer and the Owner will, upon request, observe to determine satisfactory
growth and acceptability:
1. The term "Satisfactory Growth" as used in this Section is defined as even
plant growth in healthy condition without bare spots larger than 1 square
foot in seeded areas and without bare spots in sodded areas. Bare spots in
sodded areas shall be resodded. The Contractor shall maintain all grassed
and sodded areas until satisfactory growth has been demonstrated at
project final completion. If the subsequent stand of grass is found
contaminated with weeds or other obnoxious or undesirable growth, the
Contractor shall eliminate such undesirable growth at the Contractor's own
expense.
B. The Contractor shall re -plant rejected work and continue specified maintenance
until the work is accepted by the Engineer and the Owner and found to be
acceptable.
C. Sodded areas will be acceptable provided requirements, including maintenance,
have been complied with and a healthy, well -rooted, even -colored, viable seeded
or sodded area is established, free of weeds, open joints, bare areas, and surface
irregularities.
03720-048-01 02920-10 SEEDING AND SODDING
August 2019
3.12 CLEANUP
A. The Contractor shall promptly remove soil and debris created by seeding and
sodding work from paved areas. Clean wheels of vehicles before they leave the
site to avoid tracking soil onto surfacing of roads, walks, or other paved areas.
03720-048-01
August 2019
END OF SECTION
02920-11 SEEDING AND SODDING
DIVISION 3
CONCRETE
SECTION 03100
CONCRETE FORMWORK
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish all labor, materials, equipment, and incidentals
required to design, install, and remove formwork for cast -in-place concrete as
shown on the Drawings and as specified in this Section.
B. Secure to forms as required or set for embedment as required all miscellaneous
metal items, sleeves, reglets, anchor bolts, inserts, and other items furnished under
other sections and required to be cast into concrete or approved in advance by the
Engineer.
1.02 RELATED WORK
A. Section 03200, Concrete Reinforcement.
B. Section 03250, Concrete Joints and Joint Accessories.
C. Section 03300, Cast -In -Place Concrete.
D. Section 03600, Grout.
1.03 SUBMITTALS
A. The Contractor shall submit shop drawings in accordance with Section 01330,
Submittals and Acceptance:
1. Form release agent.
2. Form ties.
B. Samples
1. Demonstrate to the Engineer on a designated area of the concrete
substructure exterior surface that the form release agent will not adversely
affect concrete surfaces to be painted, coated, or otherwise finished and
will not affect the forming materials.
2. Certify that the form release agent is suitable for use in contact with
potable water after 30 days (non-toxic and free of taste and odor).
1.04 WORK SEQUENCE (NOT USED)
03720-048-01 03100-1 CONCRETE FORMWORK
August 2019
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be in
accordance with the currently effective Florida Building Code (FBC). The following documents
are a part of this Section. Where this Section differs from these documents, the requirements of
this Section shall apply.
A. American Concrete Institute (ACI)
1. ACI 301—Specifications for Structural Concrete.
2. ACI 318—Building Code Requirements for Structural Concrete and
Commentary.
3. ACI 347R—Guide to Formwork for Concrete.
B. American Plywood Association (APA)
1. Material grades and designations as specified.
C. Where reference is made to one of the above standards, the revision in effect at
the time of bid opening shall apply.
1.06 QUALITY ASSURANCE (NOT USED)
1.07 WARRANTIES (NOT USED)
1.08 DELIVERY, STORAGE, AND HANDLING (NOT USED)
1.09 QUALIFICATIONS (NOT USED)
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 WEATHER CONSTRAINTS (NOT USED)
1.12 SYSTEM DESCRIPTION
A. General: Architectural Concrete is wall, slab, beam, or column concrete which
will have surfaces exposed to view in the finished work. It includes similar
exposed surfaces in water -containment structures from the top of walls to 2 feet
below the normal water surface in open tanks and basins.
B. Formwork shall be designed and erected in accordance with the requirements of
ACI 301 and ACI 318 and as recommended in ACI 347R and shall comply with
all applicable regulations and codes. The design shall consider any special
requirements due to the use of plasticized and/or retarded set concrete.
03720-048-01 03100-2 CONCRETE FORMWORK
August 2019
PART 2 PRODUCTS
2.01 GENERAL
A. The use of a manufacturer's name and model or catalog number is to establish the
standard of quality and general configurations desired.
2.02 MATERIALS
A. Forms for cast -in-place concrete shall be made of wood, metal, or other approved
material. Construct wood forms of sound lumber or plywood of suitable
dimensions and free from knotholes and loose knots. Where used for exposed
surfaces, dress and match boards. Sand plywood smooth and fit adjacent panels
with tight joints. Metal forms may be used when approved by the Engineer and
shall be of an appropriate type for the class of work involved. All forms shall be
designed and constructed to provide a flat, uniform concrete surface requiring
minimal finishing or repairs.
B. Wall Foims
1. Forms for all exposed exterior and interior concrete walls shall be
"Plyform" exterior -grade plywood panels manufactured in compliance
with the APA and bearing the trademark of that group or an equal
acceptable to the Engineer. Provide B grade or better veneer on all faces to
be placed against concrete during forming. The class of material and
grades of interior plies shall be of sufficient strength and stiffness to
provide a flat, unifonn concrete surface requiring minimal finishing and
grinding.
2. All joints or gaps in forms shall be taped, gasketed, plugged, and/or
caulked with an approved material so that the joint will remain watertight
and will withstand placing pressures without bulging or creating surface
patterns.
C. Rustication strips shall be at the location and shall conform to the details shown
on the Drawings. Moldings for chamfers and rustications shall be milled and
planed smooth. Rustications and corner strips shall be of a nonabsorbent material,
compatible with the form surface, and fully sealed on all sides to prohibit the loss
of paste or water between the two surfaces.
03720-048-01 03100-3 CONCRETE FORMWORK
August 2019
D. Column Forms
1. Rectangular columns shall be formed as specified for wall forms. All
corners shall have a 3/4 -inch chamfer unless otherwise noted on the
Drawings.
E. Form Release Agent
1. Coat all forming surfaces in contact with concrete using an effective, non-
staining, non -residual, water-based, bond -breaking form coating unless
otherwise noted. Form release agents used in potable water containment
structures shall be suitable for use in contact with potable water and shall
be non toxic and free of taste or odor.
F. Form Ties
03720-048-01
August 2019
1. Form ties encased in concrete other than those specified in the following
paragraphs shall be designed so that after removal of the projecting part no
metal shall remain within 1-1/2 inches of the face of the concrete. The part
of the tie to be removed shall be at least 1/2 inch diameter or be provided
with a wood or metal cone at least 1/2 inch diameter and 1-1/2 inches
long. Form ties in concrete exposed to view shall be the cone washer type.
2. Form ties for exposed exterior and interior walls shall be as specified in
the preceding paragraph except that the cones shall be of approved wood
or plastic.
3. Flat bar ties for panel forms, if used, shall have plastic or rubber inserts
having a minimum depth of 1-1/2 inches and sufficient dimensions to
permit proper patching of the tie hole.
4. Ties for liquid containment structures shall have an integral waterstop that
is tightly welded to the tie.
5. Common wire shall not be used for form ties.
6. Alternate form ties consisting of tapered -through bolts at least 1 inch
diameter at the smallest end or through bolts that use a removable tapered
sleeve of the same minimum size may be used at the Contractor's option.
Obtain the Engineer's acceptance of the system and spacing of ties before
ordering or purchase forming. Clean, fill, and seal the form tie hole with
non -shrink cement grout. The Contractor shall be responsible for
watertightness of the form ties and any repairs needed.
03100-4 CONCRETE FORMWORK
PART 3 EXECUTION
3.01 GENERAL
A. Forms shall be used for all cast -in-place concrete, including sides of footings.
Forms shall be constructed and placed so that the resulting concrete will be of the
shape, lines, dimensions, and appearance indicated on the Drawings.
B. Forms for walls shall have removable panels at the bottom for cleaning,
inspection, and joint surface preparation. Forms for walls of considerable height
shall have closable intermediate inspection ports. Tremies and hoppers for placing
concrete shall be used to allow concrete inspection, prevent segregation, and
prevent the accumulation of hardened concrete on the forms above the fresh
concrete.
C. Molding, bevels, or other types of chamfer strips shall be placed to produce
blockouts, rustications, or chamfers as shown on the Drawings or as specified in
this Section. Chamfer strips shall be provided at horizontal and vertical projecting
corners to produce a 3/4 -inch chamfer. Rectangular or trapezoidal moldings shall
be placed in locations requiring sealants where specified or shown on the
Drawings. Sizes of moldings shall conform to the sealant manufacturer's
recommendations.
D. Forms shall be sufficiently rigid to withstand construction loads and vibration and
to prevent displacement or sagging between supports. Construct forms so that the
concrete will not be damaged by their removal. The Contractor shall be entirely
responsible for the adequacy of the forming system.
E. Before form material is reused, all surfaces to be in contact with concrete shall be
thoroughly cleaned, all damaged places repaired, all projecting nails withdrawn,
and all protrusions smoothed. Reuse of wooden forms for other than rough finish
will be permitted only if a "like new" condition of the form is maintained.
3.02 FORM TOLERANCES
A. Forms shall be surfaced, designed, and constructed in accordance with the
recommendations of ACI 347R and shall meet the following additional
requirements for the specified finishes:
1. Formed Surface Exposed to View: Edges of all form panels in contact
with concrete shall be flush within 1/16 inch and forms for plane surfaces
shall be such that the concrete will be planed within 3/16 inch in 4 feet.
Forms shall be tight to prevent the passage of mortar, water, and grout.
The maximum deviation of the finish wall surface at any point shall not
03720-048-01 03100-5 CONCRETE FORMWORK
August 2019
exceed 1/4 inch from the intended surface as shown on the Drawings.
Form panels shall be arranged symmetrically and in an orderly manner to
minimize the number of seams.
2. Foiined surfaces not exposed to view or buried shall meet requirements of
Class "C" Surface in ACI 347R.
3. Formed rough surfaces including mass concrete, pipe encasement,
electrical duct encasement, and other similar installations shall have no
minimum requirements for surface smoothness and surface deflections.
The overall dimensions of the concrete shall be plus or minus 1 inch.
3.03 FORM PREPARATION
A. Wood forms in contact with the concrete shall be coated with an effective release
agent before the forms are installed.
B. Steel forms shall be thoroughly cleaned and mill scale and other ferrous deposits
shall be sandblasted or otherwise removed from the contact surface for all forms,
except those used for surfaces receiving a rough finish. All forms shall have the
contact surfaces coated with a release agent.
3.04 REMOVAL OF FORMS
A. The Contractor shall be responsible for all damage resulting from removing the
forms. Forms and shoring for structural slabs or beams shall remain in place in
accordance with ACI 301 and ACI 347R. Form removal shall conform to the
requirements specified in Section 03300, Cast -In -Place Concrete, and a curing
compound applied.
3.05 INSPECTION
A. The Engineer on site shall be notified when the forms are complete and ready for
inspection at least 6 hours before the proposed concrete placement.
B. Failure of the forms to comply with the requirements specified in this Section or
to produce concrete complying with requirements of this Section shall be grounds
for rejection of that portion of the concrete work. Rejected work shall be repaired
or replaced as directed by the Engineer at no additional cost to the Owner. Such
repair or replacement shall be subject to the requirements of this Section and
approval of the Engineer.
END OF SECTION
03720-048-01 03100-6 CONCRETE FORMWORK
August 2019
SECTION 03180
CONCRETE COATING SYSTEM
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish and install all labor, materials, equipment, and incidentals required to
supply and install the concrete coating system on the interior surfaces of the
Sludge Storage and Blend Tanks as indicated in the Contract Documents.
1.02 10 -YEAR LIMITED WARRANTY
A. Manufacturer shall provide a 10 -year limited warranty for coating system.
1.03 REFERENCES
A. American Society for Testing and Materials (ASTM)
1. ASTM D4258—Standard Practice for Surface Cleaning Concrete for
Coating.
2. ASTM D4259—Standard Practice for Abrading Concrete.
3. ASTM D4263—Standard Test Method for Indicating Moisture in
Concrete by the Plastic Sheet Method.
4. ASTM D4414—Standard Practice for Measruement of Wet Film
Thickness by Notch Gages.
5. ASTM D4541 Standard Test Method for Pull -Off Strength of Coatings
Using Portable Adhesion Testers.
6. ASTM D4787—Standard Practice for Continuity Verification of Liquid or
Sheet Linings Applied to Concrete Substrates.
B. NACE International (NACE)
1. NACE SP0188—Discontinuity (Holiday) Testing of New Protective
Coatings on Conductive Substrates.
C. Steel Structures Painting Council (SSPC)
1. SSPC PA-9—Measurement of Dry Coating Thickness Using Ultrasonic
Gages.
2. SSPC SP-1—Solvent Cleaning.
3. SSPC SP-7/NACE No. 4—Brush-Off Blast Cleaning.
4. SSPC SP-10/NACE No. 2—Near-White Blast Cleaning.
03720-048-01 03180-1 CONCRETE COATING SYSTEM
August 2019
5. SSPC SP-12/NACE No. 5—Surface Preparation and Cleaning of Metals.
6. SSPC SP-13/NACE No. 6—Surface Preparation of Concrete.
D. International Concrete Repair Institute (ICRI)
1. ICRI CSP-2—Standard Guidelines – Grinding.
2. ICRI CSP-6—Standard Guidelines – Medium Scarification.
1.04 SUBMITTALS
A. Submit for review, complete detailed shop drawings for all materials furnished
under this Section.
B. The manufacturer of the coating system shall furnish an affidavit attesting to the
successful use of its material as a coating for concrete structures for a minimum
period of 5 years in wastewater conditions recognized as corrosive or otherwise
detrimental to concrete.
C. Name, address, and detailed qualifications of the applicator to which the
Contractor intends to award the work under this Section. Qualifications shall
include, but not be limited to, a list of installations that are currently in service
and documentation that the firm is currently a qualified applicator of the proposed
materials by the supplier or manufacturer.
PART 2 PRODUCTS
2.01 COATING SYSTEMS
A. The coating system shall be one of the systems as described in the Contract
Documents and outlined below.
03720-048-01
August 2019
1. Green Monster Liner
a. Cementitious Surfacer shall be Green Monster Liner 30 and shall
be applied at a minimum of 1/2 inch thickness and as required to
bring the existing structure up to original thickness.
b. Apply primer in accordance with the manufacturer's requirements.
c. Apply one coating of Green Monster Liner 30 at a minimum DFT
of 125 mils.
2. Sauereisen – Sewergard 210
a. Cementitious Surfacer shall be Sauereisen Underlayment
No. F-121 and shall be applied at a minimum of 1/2 inch thickness
03180-2 CONCRETE COATING SYSTEM
and as required to bring the existing structure up to original
thickness.
b. Apply one coating of Sewergard 210T on surfaces at a minimum
DFT of 125 mils.
c. Apply one coating of Sewergard 210G on surfaces at a minimum
DFT of 20 mils.
3. SpectraShield
a. Apply SpectraShield at a minimum of 1/2 inch thickness and as
required to bring the existing structure up to original thickness.
b. Apply coating of SpectraShield in accordance with the
manufacturer's requirements.
B. The coating system shall be applied by a qualified applicator trained in handling,
mixing and application of the material including the required surface cleaning and
preparation. The applicator shall have a minimum of 5 years of experience
installing the product and shall be approved for installation by the manufacturer.
A list of references of projects in Florida using the specified coating system shall
be provided to the City and Engineer for review.
PART 3 EXECUTION
3.01 GENERAL
A. Before any work being performed the Contractor shall notify the owners of any
property that may be affected by the construction.
B. Surface preparation shall be performed in accordance with Manufacturer's
requirements and at a minimum shall remove all deteriorated materials, dirt, oil,
grease, and all other bond inhibiting materials from the surface by dry mechanical
means, i.e. - sandblasting, grinding, etc, as approved by the Engineer.
C. Where existing reinforcement is exposed the reinforcement shall be cleaned of all
rust and coated with a corrosion inhibitor as recommended by the coating
Manufacturer.
D. Installation, curing and testing shall be performed in accordance with the
Manufacturer's specifications and requirements.
E. In all cases where coating work must be performed in a non -flow condition the
Contractor shall be responsible for coordinating and facilitating all flow diversion
and bypass pumping during the coating operation.
03720-048-01
August 2019
03180-3 CONCRETE COATING SYSTEM
F. New Portland cement concrete structures shall have endured a minimum of
28 days since manufacture before commencing coating installation. Should earlier
coating be required, coating product manufacturer shall recommend specifications
including appropriate cure assessment testing and use of specialty primers and
sealers.
3.02 REPAIRS AND SURFACE PREPARATION
A. Excessive debris, sediment, root intrusion or other foreign materials which may
impact the effectiveness of the surface preparation process shall be removed
before the commencement thereof.
B. Offset structural components, lids, covers, frames, etc. shall be repaired, replaced,
or reset before the commencement of surface preparation.
C. External soil/fill voids shall be remediated and/or stabilized by replacement or
injection of stabilizing grout as determined appropriate by the Engineer.
D. Oils, grease, incompatible existing coatings, waxes, form release, curing
compounds, efflorescence, sealers, salts, or other contaminants which may affect
the performance and adhesion of the coating to the substrate shall be removed in
accordance with SSPC-SP 1 — Solvent Cleaning.
E. Choice of surface preparation method(s) should be per the coating manufacturer's
recommendation which shall be based upon the condition of the structure and
concrete or masonry surface, potential contaminants present, access to perform
work, and the required cleanliness and profile of the prepared surface to receive
the repair and/or coating product(s).
F. Surface preparation method shall be abrasive blasting.
03720-048-01
August 2019
1. SSPC SP-13/NACE No. 6 Surface Preparation of Concrete.
2. ASTM D4258, Standard Practice for Surface Cleaning Concrete for
Coating, and ASTM D4259, Standard Practice for Abrading Concrete.
3. ICRI Technical Guideline No. 03732 Selecting and Specifying Concrete
Surface Preparation for Sealers, Coatings, and Polymer Overlays.
4. NACE/SSPC Standards for the surface preparation of steel.
03180-4 CONCRETE COATING SYSTEM
G. Whichever method(s) are used, they shall be performed in a manner that provides
a uniform, sound, clean, and neutralized surface suitable for the specified coating
product(s).
1. Resulting surface profile of the prepared concrete substrate shall be (as
described in ICRI Technical Guideline No. 03732):
a. For application of cementitious materials: At least an ICRI CSP -2.
b. For application of coating products: At least an ICRI CSP -2.
2. Concrete and/or mortar damaged by corrosion, chemical attack or other
means of degradation shall be removed so that sound substrate remains:
a. In conditions where severe chemical/microbiological attack has
occurred the prepared substrate shall exhibit a pH of 8-12.
Additional cleaning and/or contaminated substrate removal may be
required to achieve the specified pH level.
H. At the time of the recoating, the amount of flash rust shall be no greater than "No
Flash Rust" as defined in SSPC-SP 12.
I. Before the application of the coating product repairs shall be completed to ensure
the following:
03720-048-01
August 2019
1. All inflow and infiltration shall be eliminated by use of appropriate repair
material(s), such as hydraulic cements and/or chemical grouts.
2. All repairs to joints, pipe seals, steps, mechanical penetrations, benches,
inverts, pipes or other appurtenances to be coated shall be completed and
repaired surfaces prepared according to this Section.
a. Benches or other horizontal surfaces shall have adequate slope
(1 inch rise per lineal foot minimum) to minimize the retention of
debris following surcharge.
b. Inverts or flow channels shall be smooth without lips, rough edges,
or other features which may cause debris to collect; contoured to
minimize turbulent flow; and be sloped to promote adequate flow
from the inlet(s) to the outlet pipe.
c. All joints, pipe seals, steps, or other penetrations shall be sealed
against inflow, infiltration, and exfiltration and be adequately
filled, smoothed, and contoured to promote monolithic coating
application.
03180-5
CONCRETE COATING SYSTEM
J. Areas where reinforcing steel has been exposed shall be repaired in accordance
with the Project Engineer's recommendations, as shown on the Drawings and at
the minimum all exposed steel shall be prepared before coating with the coating
product specified or other approved primer as specified by the coating product
manufacturer.
3.03 FIELD QUALITY CONTROL AND TESTING
A. The Contractor shall give the City and Engineer a minimum of 3 days advance
notice of the start of any field surface preparation work or coating application
work, and a minimum of 7 days advance notice of the start of any surface
preparation work.
B. The Contractor shall furnish, until final acceptance of such coatings, inspection
devices in good working condition for the detection of holidays and measurement
of dry -film thicknesses of protective coatings. Dry -film thickness gages shall be
made available for the City's and Engineer's use at all times while coating is
being done, until final acceptance of such coatings. The Contractor shall furnish
the services of a trained operator of the holiday detection devices until the final
acceptance of such coatings.
C. Coating system thickness shall be inspected to ensure compliance with the
specifications herein.
1. During application a wet film thickness gauge, meeting ASTM D4414,
Standard Practice for Measurement of Wet Film Thickness by Notched
Gages, shall be used. Measurements shall be taken, documented, and
attested to by the Contractor for submission to the Owner.
2. After the coating product(s) have cured in accordance with manufacturer
recommendations, coating system thickness may be measured according
to SSPC-PA 9, Measurement of Dry Coating Thickness Using Ultrasonic
Gages.
D. High voltage holiday detection for coating systems installed in corrosive
environments, when it can be safely and effectively employed, shall be performed
to ensure monolithic protection of the substrate. After the coating product(s) have
cured in accordance with manufacturer recommendations, all surfaces shall be
inspected for holidays in accordance with NACE SP0188, Discontinuity
(Holiday) Testing of New Protective Coatings on Conductive Substrates, or
ASTM D4787, Standard Practice for Continuity Verification of Liquid or Sheet
Linings Applied to Concrete Substrates. All detected holidays shall be marked
03720-048-01 03180-6 CONCRETE COATING SYSTEM
August 2019
and repaired according to the coating product(s) manufacturer's
recommendations.
1. Test voltage shall be a minimum of 100 volts per mil of coating system
thickness.
2. Detection of a known or induced holiday in the coating product shall be
confirmed to ensure proper operation of the test unit.
3. All areas repaired shall be retested following cure of the repair material(s).
4. In instances where high voltage holiday detection is not feasible a close
visual inspection shall be conducted, and all possible holidays shall be
marked and repaired as described above.
5. Documentation of areas tested, equipment employed, results, and repairs
made shall be submitted to the Owner/Engineer by the Contractor.
E. Visual inspection shall be made by the City, the Engineer, or their representative.
Any deficiencies in the finished coating affecting the performance of the coating
system or the operational functionality of the structure shall be marked and
repaired according to the recommendations of the coating product(s)
manufacturer.
F. Inspection by the City, the Engineer, their representative, or the waiver of
inspection of any particular portion of the Work, shall not relieve the Contractor
of its responsibility to perform the work in accordance with these Specifications.
G. Before demobilization from the site, the Contractor shall remove all construction
debris, stabilize any spill areas and wash roadway areas affected by the work.
H. Inspection by the Owner shall be scheduled after the work is complete, and again
within the warranty period.
END OF SECTION
03720-048-01 03180-7 CONCRETE COATING SYSTEM
August 2019
SECTION 03200
CONCRETE REINFORCEMENT
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish all labor, materials, equipment, and incidentals
required and install all concrete reinforcement complete as shown on the
Drawings and as specified in this Section.
B. Furnish only all deformed steel reinforcement required to be entirely built into
concrete masonry unit construction.
1.02 RELATED WORK
A. Section 03100, Concrete Formwork.
B. Section 03250, Concrete Joints and Joint Accessories.
C. Section 03300, Cast -In -Place Concrete.
D. Section 03600, Grout.
1.03 SUBMITTALS
A. The Contractor shall submit shop drawings in accordance with Section 01330,
Submittals and Acceptance:
1. Reinforcing steel. Placement drawings shall conform to the
recommendations of ACI SP -66. All reinforcement in a concrete
placement shall be included on a single placement drawing or cross
referenced to the pertinent main placement drawing. The main drawing
shall include the additional reinforcement (around openings, at corners,
etc.) shown on the standard detail sheets. Bars to have special coatings
and/or to be of special steel or special yield strength are to be clearly
identified.
2. Bar bending details. The bars shall be referenced to the same identification
marks shown on the placement drawings.
3. Schedule of all placements to contain synthetic reinforcing fibers. The
amount of fibers per cubic yard to be used for each of the placements shall
be noted on the schedule. The name of the manufacturer of the fibers and
the product data shall be included with the submittal.
03720-048-01 03200-1 CONCRETE REINFORCEMENT
August 2019
B. The Contractor shall submit test reports, in accordance with Section 01330,
Submittals and Acceptance, of each of the following items:
1. Certified copy of mill test on each steel proposed for use showing the
physical properties of the steel and the chemical analysis.
2. Welder's certification. The certification shall be in accordance with
AWS D 1.4/D 1.4M when welding of reinforcement is required.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be in
accordance with the currently effective Florida Building Code (FBC). The following documents
are a part of this Section. Where this Section differs from these documents, the requirements of
this Section shall apply.
A. American Society for Testing and Materials (ASTM)
1. ASTM A615/A615M Standard Specification for Deformed and Plain
Carbon -Steel Bars for Concrete Reinforcement.
2. ASTM A704/A704M—Standard Specification for Welded Steel Plain Bar
or Rod Mats for Concrete Reinforcement.
3. ASTM A706/A706M—Standard Specification for Deformed and Plan
Low -Alloy Steel Bars for Concrete Reinforcement.
4. ASTM A767/A767M—Standard Specification for Zinc -Coated
(Galvanized) Steel Bars for Concrete Reinforcement.
5. ASTM A775/A775M—Standard Specification for Epoxy -Coated Steel
Reinforcing Bars.
6. ASTM A884/A884M—Standard Specification for Epoxy -Coated Steel
Wire and Welded Wire Reinforcement.
7. ASTM A934/A934M—Standard Specification for Epoxy -Coated
Prefabricated Steel Reinforcing Bars.
8. ASTM A996/A996M—Standard Specification for Rail -Steel and Axle -
Steel Deformed Bars for Concrete Reinforcement.
9. ASTM A1064/A1064M—Standard Specification for Carbon -Steel Wire
and Welded Wire Reinforcement, Plain and Deformed for Concrete.
B. American Concrete Institute (ACI)
1. ACI 301—Specifications for Structural Concrete.
2. ACI 318—Building Code Requirements for Structural Concrete and
Commentary.
3. ACI SP-66—ACI Detailing Manual.
03720-048-01 03200-2 CONCRETE REINFORCEMENT
August 2019
C. Concrete Reinforcing Steel Institute (CRSI)
1. Manual of Standard Practice.
D. American Welding Society (AWS)
1. AWS D1.4/A1.4M—Structural Welding Code — Reinforcing Steel.
1.06 QUALITY ASSURANCE
A. Provide services of a manufacturer's representative, with at least 2 years
experience in the use of the reinforcing fibers for a preconstruction meeting and
assistance during the first placement of the material.
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
B. Reinforcing steel shall be substantially free from mill scale, rust, dirt, grease, or
other foreign matter.
C. Reinforcing steel shall be shipped and stored with bars of the same size and shape
fastened in bundles with durable tags, marked in a legible manner with waterproof
markings showing the same "mark" designations as those shown on the submitted
Placing Drawings.
D. Reinforcing steel shall be stored off the ground and kept free from dirt, oil, or
other injurious contaminants.
1.09 QUALIFICATIONS (NOT USED)
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 WEATHER CONSTRAINTS (NOT USED)
03720-048-01
August 2019
03200-3 CONCRETE REINFORCEMENT
PART 2 PRODUCTS
2.01 MATERIALS
A. Materials shall be new, of domestic manufacture, and shall comply with the
following material specifications.
B. Deformed Concrete Reinforcing Bars: ASTM A615/A615M, Grade 60 deformed
bars.
C. Concrete Reinforcing Bars required on the Drawings to be Welded:
ASTM A706/A706M.
D. Welded Steel Wire Fabric: ASTM A1064/A1064M. Provide in flat sheets.
E. Welded Deformed Steel Wire Fabric: ASTM A1064/A1064M.
F. Welded Plain Bar Mats: ASTM A704/A704M and ASTM A615/A615M
Grade 60 plain bars.
G. Fabricated Deformed Steel Bar Mats: ASTM A1064/A1064M and
ASTM A615/A615M Grade 60 deformed bars.
H. The following alternate materials are allowed:
1. ASTM A615/A615M Grade 60 may be used for ASTM A706/A706M
provided the following requirements are satisfied:
a. The actual yield strength of the reinforcing steel based on mill
tests shall not exceed the specified yield strength by more than
18,000 psi. Retests shall not exceed this value by more than an
additional 3,000 psi.
b. The ratio of the actual ultimate tensile strength to the actual tensile
yield strength of the reinforcement shall not be less than 1.25.
c. The carbon equivalency (CE) of bars shall be 0.55 or less.
I. Reinforcing Steel Accessories
1. Plastic Protected Bar Supports: CRSI Bar Support Specifications, Class 1
Maximum Protection.
2. Stainless Steel Protected Bar Supports: CRSI Bar Support Specifications,
Class 2 Moderate Protection.
03720-048-01 03200-4 CONCRETE REINFORCEMENT
August 2019
3. Precast Concrete Block Bar Supports: CRSI Bar Support Specifications,
Precast Blocks. Blocks shall have equal or greater strength than the
surrounding concrete.
4. Steel Protected Bar Supports: #4 Steel Chairs with plastic or rubber tips.
J. Tie Wire
1. Tie Wires for Reinforcement shall be 16 -gauge or heavier, black annealed
wire, or stranded wire.
K. Mechanical reinforcing steel butt splices shall be positive connecting taper
threaded -type employing a hexagonal coupler such as Lenton rebar splices as
manufactured by Erico Products Inc., Solon, OH, or equal. They shall meet all
ACI 318 Building Code requirements. Bar ends must be taper threaded with
coupler manufacturer's bar threader to ensure proper taper and thread engagement.
Bar couplers shall be torqued to the manufacturer's recommended value.
1. Unless otherwise noted on the Drawings, mechanical tension splices shall
be designed to produce a splice strength in tension or compression of not
less than 125% of the ASTM -specified minimum yield strength of the
rebar.
2. Compression -type mechanical splices shall provide concentric bearing
from one bar to the other bar and shall be capable of developing the
ultimate strength of the rebar in compression.
L. Fiber Reinforcement
1. Synthetic reinforcing fiber for concrete shall be 100% polypropylene
collated, fibrillated fibers as manufactured by Fibermesh Company of
Synthetic Industries Inc., Chattanooga, TN, Fibermesh or equal. Fiber
length and quantity for the concrete mix shall be in strict compliance with
the manufacturer's recommendations as approved by the Engineer.
2.02 FABRICATION
A. Fabrication of reinforcement shall be in compliance with the CRSI Manual of
Standard Practice.
B. Bars shall be cold bent. Bars shall not be straightened or rebent.
C. Bars shall be bent around a revolving collar having a diameter of not less than that
recommended by the ACI 318.
03720-048-01
August 2019
03200-5 CONCRETE REINFORCEMENT
D. Bar ends that are to be butt spliced, placed through limited diameter holes in
metal, or threaded shall have the applicable end(s) saw cut. Such ends shall
terminate in flat surfaces within 1-1/2 degrees of a right angle to the axis of the
bar.
PART 3 EXECUTION
3.01 INSTALLATION
A. Surface condition, bending, spacing, and tolerances of placement of reinforcement
shall comply with the CRSI Manual of Standard Practice. The Contractor shall be
solely responsible for providing an adequate number of bars and maintaining the
spacing and clearances shown on the Drawings.
B. Except as otherwise indicated on the Drawings, the minimum concrete cover of
reinforcement shall be as follows:
1. Concrete cast against and permanently exposed to earth: 3 inches.
2. Concrete exposed to soil, water, sewage, sludge and/or weather: 2 inches
(including bottom cover of slabs over water or sewage).
3. Concrete not exposed to soil, water, sewage, sludge, and/or weather:
a. Slabs (top and bottom cover), walls, joists, shells, and folded plate
members: 1 inch.
b. Beams and columns (principal reinforcement, ties, spirals, and
stirrups): 1-1/2 inches.
C. Reinforcement which will be exposed for a considerable length of time after being
placed shall be coated with a heavy coat of neat cement slurry.
D. No reinforcing steel bars shall be welded either during fabrication or erection
unless specifically shown on the Drawings or specified in this Section or unless
prior written approval has been obtained from the Engineer. All bars that have
been welded, including tack welds, without such approval shall be immediately
removed from the work. When welding of reinforcement is approved or called
for, it shall comply with AWS D1.4/D1.4M.
E. Reinforcing steel interfering with the location of other reinforcing steel, conduits,
or embedded items may be moved within the specified tolerances or one bar
diameter, whichever is greater. Greater displacement of bars to avoid interference
shall only be made with the approval of the Engineer. Do not cut reinforcement to
03720-048-01 03200-6 CONCRETE REINFORCEMENT
August 2019
install inserts, conduits, mechanical openings, or other items without the prior
approval of the Engineer.
F. Securely support and tie reinforcing steel to prevent movement during concrete
placement. Secure dowels in place before placing concrete.
G. Reinforcing steel bars shall not be field bent except where shown on the Drawings
or specifically authorized in writing by the Engineer. If authorized, bars shall be
cold bent around the standard diameter spool specified in the CRSI. Do not heat
bars. Closely inspect the reinforcing steel for breaks. If the reinforcing steel is
damaged, replace, Cadweld, or otherwise repair as directed by the Engineer. Do
not bend reinforcement after it is embedded in concrete unless specifically shown
otherwise on the Drawings.
3.02 REINFORCEMENT AROUND OPENINGS
A. Unless specific additional reinforcement around openings is shown on the
Drawings, provide additional reinforcing steel on each side of the opening
equivalent to one half of the cross sectional area of the reinforcing steel
interrupted by an opening. The bars shall have sufficient length to develop bond at
each end beyond the opening or penetration.
3.03 SPLICING OF REINFORCEMENT
A. Splices designated as compression splices on the Drawings, unless otherwise
noted, shall be 30 bar diameters but not less than 12 inches. The lap splice length
for column vertical bars shall be based on the bar size in the column above.
B. Tension lap splices shall be provided at all laps in compliance with ACI 318.
Splices in adjacent bars shall be staggered. Class A splices may be used when
50% or less of the bars are spliced within the required lap length. Class B splices
shall be used at all other locations.
C. Splicing of reinforcing steel in concrete elements noted to be "tension members"
on the Drawings shall be avoided whenever possible. However, if required for
constructability, splices in the reinforcement subject to direct tension shall be
welded to develop, in tension, at least 125% of the specified yield strength of the
bar. Splices in adjacent bars shall be offset the distance of a Class B splice.
D. Install wire fabric in as long lengths as practicable. Wire fabric from rolls shall be
rolled flat and firmly held in place. Splices in welded -wire fabric shall be lapped
in accordance with the requirements of ACI 318 but not less than 12 inches. The
spliced fabrics shall be tied together with wire ties spaced not more than 24 inches
on center and laced with wire of the same diameter as the welded wire fabric. Do
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August 2019
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not position laps midway between supporting beams or directly over beams of
continuous structures. Offset splices in adjacent widths to prevent continuous
splices.
E. Mechanical reinforcing steel splicers shall be used only where shown on the
Drawings. Splices in adjacent bars shall be offset by at least 30 bar diameters.
Mechanical reinforcing splices are only to be used for special splice and dowel
conditions approved by the Engineer.
3.04 ACCESSORIES
A. Determine, provide, and install accessories such as chairs, chair bars, and the like
in sufficient quantities and strength to adequately support the reinforcement and
prevent its displacement during the erection of the reinforcement and the
placement of concrete.
B. Use precast concrete blocks where the reinforcing steel is to be supported over
soil.
C. Stainless steel bar supports or steel chairs with stainless-steel tips shall be used
where the chairs are set on forms for a concrete surface that will be exposed to
weather, high humidity, or liquid (including bottom of slabs over liquid -
containing areas). Use of galvanized or plastic -tipped metal chairs is permissible
in all other locations unless otherwise noted on the Drawings or specified in this
Section.
D. Alternate methods of supporting top steel in slabs, such as steel channels
supported on the bottom steel or vertical reinforcing steel fastened to the bottom
and top mats, may be used if approved by the Engineer.
3.05 INSPECTION
A. In no case shall any reinforcing steel be covered with concrete until the
installation of the reinforcement, including the size, spacing, and position of the
reinforcement has been observed by the Engineer and the Engineer's release to
proceed with the concreting has been obtained. The Engineer shall be given ample
prior notice of the readiness of placed reinforcement for observation. The forms
shall be kept open until the Engineer has finished his/her observations of the
reinforcing steel.
END OF SECTION
03720-048-01 03200-8 CONCRETE REINFORCEMENT
August 2019
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SECTION 03250 '
CONCRETE JOINTS AND JOINT ACCESSORIES
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish all labor, materials, equipment, and incidentals
required and install accessories for concrete joints as shown on the Drawings and
as specified in this Section.
1.02 RELATED WORK
A. Section 03100, Concrete Formwork.
B. Section 03200, Concrete Reinforcement.
C. Section 03300, Cast -In -Place Concrete.
D. Section 03360, Concrete Finishes.
E. Section 03600, Grout.
F. Section 05500, Metal Fabrications.
1.03 SUBMITTALS
A. The Contractor shall submit shop drawings in accordance with Section 01330,
Submittals and Acceptance:
03720-048-01
August 2019
1. Standard waterstops: Product data, including catalogue cut, technical data,
storage requirements, splicing methods, and conformity to ASTM
standards.
2. Special waterstops: Product data, including catalogue cut, technical data,
location of use, storage requirements, splicing methods, installation
instructions, and confoiiuity to ASTM standards.
3. Premolded joint fillers: Product data, including catalogue cut, technical
data, storage requirements, installation requirements, location of use, and
conformity to ASTM standards.
4. Bond breaker: Product data, including catalogue cut, technical data,
storage requirements, installation requirements, location of use, and
conformity to ASTM standards.
5. Expansion joint dowels: Product data on the complete assembly, including
dowels, coatings, lubricants, spacers, sleeves, expansion caps, installation
requirements, and conformity to ASTM standards.
6. Compressible joint filler: Product data, including catalogue cut, technical
data, storage requirements, installation requirements, location of use, and
conformity to ASTM standards.
03250-1 CONCRETE JOINTS AND JOINT ACCESSORIES
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7. Bonding agents: Product data, including catalogue cut, technical data,
storage requirements, product life, application requirements, and
conformity to ASTM standards.
B. Certifications
1. Certification that all materials used within the joint system are compatible
with each other.
2. Certification that materials used in the construction of joints are suitable
for use in contact with potable water 30 days after installation.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be in
accordance with the currently effective Florida Building Code (FBC). The following documents
are a part of this Section. Where this Section differs from these documents, the requirements of
this Section shall apply.
A. American Society for Testing and Materials (ASTM)
1. ASTM A675/A675M Standard Specification for Steel Bars, Carbon,
Hot -Wrought, Special Quality, Mechanical Properties.
2. ASTM C881/C881M—Standard Specification for Epoxy -Resin -Base
Bonding Systems for Concrete.
3. ASTM C 1059/C 1059M Standard Specification for Latex Agents for
Bonding Fresh to Hardened Concrete.
4. ASTM D1751—Standard Specification for Preformed Expansion Joint
Filler for Concrete Paving and Structural Construction (Nonextruding and
Resilient Bituminous Types).
5. ASTM D1752—Standard Specification for Preformed Sponge Rubber
Cork and Recycled PVC Expansion Joint Fillers for Concrete Paving and
Structural Construction.
B. US Army Corps of Engineers (CRD)
1. CRD C572—Specifications for Polyvinylchloride Waterstop.
1.06 QUALITY ASSURANCE (NOT USED)
03720-048-01 03250-2 CONCRETE JOINTS AND JOINT ACCESSORIES
August 2019
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1.07 WARRANTIES 1
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
1.09 QUALIFICATIONS (NOT USED)
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 WEATHER CONSTRAINTS (NOT USED)
PART 2 PRODUCTS
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2.01 GENERAL ,
A. The use of the manufacturer's name and model or catalog number is to establish
the standard of quality and general configuration desired.
B. All materials used together in a given joint (bond breakers, backer rods, joint
fillers, sealants, etc.) shall be compatible with one another. Coordinate selection
of suppliers and products to ensure compatibility. Under no circumstances shall
asphaltic bond breakers or joint fillers be used in joints receiving sealant.
C. All chemical sealant type waterstops shall be products specifically manufactured
for the purpose for which they will be used and the products shall have been
successfully used on similar structures for more than 5 years.
2.02 MATERIALS
A. Premolded Joint Filler
1. Premolded joint filler structures: Self -expanding cork, premolded joint
filler shall conform to ASTM D1752, Type III. The thickness shall be
3/4 inch unless shown otherwise on the Drawings.
2. Premolded joint filler sidewalk and roadway concrete pavements or where
fiber joint filler is specifically noted on the Drawings: The joint filler shall
be asphalt impregnated fiber board conforming to ASTM D1751.
Thickness shall be 3/4 inch unless otherwise shown on the Drawings.
03720-048-01 03250-3 CONCRETE JOINTS AND JOINT ACCESSORIES
August 2019
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B. Bond Breaker
1. Bond breaker tape shall be an adhesive -backed glazed butyl or
polyethylene tape which will satisfactorily adhere to the premolded joint
filler or concrete surface as required. The tape shall be the same width as
the joint.
2. Except where tape is specifically called for on the Drawings, bond breaker
for concrete shall be either bond breaker tape or a nonstaining type bond
prevention coating such as Williams Tilt -up Compound by Williams
Distributors Inc.; Silcoseal 77, by SCA Construction Supply Division,
Superior Concrete Accessories, or equal.
C. Bonding Agent
1. Epoxy bonding agent shall be a two -component, solvent -free, moisture -
insensitive, epoxy -resin material conforming to ASTM C881/C881M,
Type II. The bonding agent shall be Sikadur 32 Hi Mod by Sika
Corporation of Lyndhurst, NJ; Concressive Liquid (LPL) by Master
Builders of Cleveland, OH; or equal. Acrylic may be used if approved by
the Engineer.
D. Compressible Joint Filler
1. The joint filler shall be a non -extruded watertight strip material use to fill
expansion joints between structures. The material shall be capable of
being compressed at least 40% for 70 hours at 68°F and subsequently
recovering at least 20% of its original thickness in the first half hour after
unloading. Compressible joint filler shall be Evasote 380 E.S.P, by E Poxy
Industries, Inc., Ravena, NY, Sikaflex 1 a by Sika, or equal.
PART 3 EXECUTION
3.01 INSTALLATION
A. Construction Joints
1. Make construction joints only at locations shown on the Drawings or as
approved by the Engineer. Any additional or relocation of construction
joints proposed by the Contractor must be submitted to the Engineer for
written approval.
2. Additional or relocated joints should be located where they least impair
the strength of the member. In general, locate joints within the middle
third of spans of slabs, beams, and girders. However, if a beam intersects a
03720-048-01 03250-4 CONCRETE JOINTS AND JOINT ACCESSORIES
August 2019
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girder at the joint, offset the joint a distance equal to twice the width of 1
the member being connected. Locate joints in walls and columns at the
underside of floors, slabs, beams, or girders and at tops of footings or floor
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slabs. Do not locate joints between beams, girders, column capitals, or
drop panels and the slabs above them. Do not locate joints between
brackets or haunches and walls or columns supporting them. 1
3. All joints shall be perpendicular to the main reinforcement. Continue
reinforcing steel through the joint as indicated on the Drawings. When
joints in beams are allowed, provide a shear key and inclined dowels as
approved by the Engineer.
4. Provide sealant grooves for joint sealant where indicated on the Drawings.
5. At all construction joints and at concrete joints designated on the
Drawings to be "roughened," uniformly roughen the surface of the
concrete to a full amplitude (distance between high and low points or side
to side) of approximately 1/4 inch to expose a fresh face. Thoroughly
clean joint surfaces of loose or weakened materials by waterblasting or
sandblasting and prepare for bonding.
6. Provide waterstops in all wall and slab construction joints in liquid
containment structures and at other locations shown on the Drawings.
7. Keyways shall not be used in construction joints unless specifically shown
on the Drawings or approved by the Engineer.
B. Expansion Joints
03720-048-01
August 2019
1. Do not extend through expansion joints, reinforcement, or other embedded
metal items that are continuously bonded to concrete on each side of joint.
2. Position premolded joint filler material accurately. Secure the joint filler
against displacement during concrete placement and compaction. Place
joint filler over the face of the joint, allowing for sealant grooves as
detailed on the Drawings. Tape all joint filler splices to prevent intrusion
of mortar. Seal expansion joints as shown on the Drawings.
3. Expansion joints shall be 3/4 inch wide unless otherwise noted on the
Drawings.
4. Where indicated on the Drawings, install smooth dowels at right angles to
expansion joints. Align dowels accurately with finished surface. Rigidly
hold in place and support during concrete placement. Unless otherwise
shown on the Drawings, apply oil or grease to one end of all dowels
through expansion joints. Provide plastic expansion caps on the lubricated
ends of expansion dowels.
5. Provide center -bulb -type waterstops in all wall and slab expansion joints
in liquid containment structures and at other locations shown on the
Drawings.
03250-5 CONCRETE JOINTS AND JOINT ACCESSORIES
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C. Contraction Joints
03720-048-01
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1. Provide sealant grooves, sealants, and waterstops at contraction joints in
slabs on grade or walls as detailed. Provide waterstops at all wall and slab
contraction joints in water containment structures and at other locations
shown on the Drawings.
2. Contraction joints may be sawed if specifically approved by the Engineer.
If contraction joint grooves are sawed, properly time the saw cutting with
the time of the concrete set. Start cutting as soon as the concrete has
hardened sufficiently to prevent aggregates from being dislodged by the
saw. Complete cutting before shrinkage stresses have developed
sufficiently to induce cracking. No reinforcing shall be cut during
sawcutting.
3. Extend every other bar of reinforcing steel through contraction joints or as
indicated on the Drawings. Where specifically noted on the Drawings,
coat the concrete surface with a bond breaker before placing new concrete
against it. Avoid coating reinforcement or waterstops with bond breaker at
these locations.
END OF SECTION
03250-6 CONCRETE JOINTS AND JOINT ACCESSORIES
SECTION 03300
CAST -IN-PLACE CONCRETE
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish all labor and materials required and install cast -in-
place concrete complete as shown on the Drawings and as specified in this
Section.
1.02 RELATED WORK
A. Section 03100, Concrete Formwork.
B. Section 03200, Concrete Reinforcement.
C. Section 03250, Concrete Joints and Joint Accessories.
D. Section 03360, Concrete Finishes.
E. Section 03600, Grout.
1.03 SUBMITTALS
A. The Contractor shall submit shop drawings in accordance with Section 01330,
Submittals and Acceptance:
1. Sources of cement, pozzolan, and aggregates.
2. Material Safety Data Sheets (MSDS) for all concrete components and
admixtures.
03720-048-01
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3. Air entraining admixture. Product data, including catalogue cut, technical
data, storage requirements, product life, recommended dosage,
temperature considerations, and conformity to ASTM standards.
4. Water -reducing admixture. Product data, including catalogue cut,
technical data, storage requirements, product life, recommended dosage,
temperature considerations, and conformity to ASTM standards.
5. High -range water -reducing admixture (plasticizer). Product data, including
catalogue cut, technical data, storage requirements, product life,
recommended dosage, temperature considerations, retarding effect, slump
range, and conformity to ASTM standards. Identify proposed locations of
use.
03300-1 CAST -IN-PLACE CONCRETE
6. Concrete mix for each formulation of concrete proposed for use, including
constituent quantities per cubic yard, water-cementitious materials ratio,
concrete slump, type, and manufacturer of cement. Provide either a. or b.
below for each mix proposed:
a. Standard deviation data for each proposed concrete mix based on
statistical records.
b. The curve of water-cementitious materials ratio versus concrete
cylinder strength for each formulation of concrete proposed based
on laboratory tests. The cylinder strength shall be the average of
the 28 -day cylinder strength test results for each mix. Provide
results of 7- and 14 -day tests if available.
7. Sheet curing material. Product data, including catalogue cut, technical
data, and conformity to ASTM standard.
8. Liquid curing compound. Product data, including catalogue cut, technical
data, storage requirements, product life, application rate, and conformity
to ASTM standards. Identify proposed locations of use.
B. Samples
1. Fine and coarse aggregates if requested by the Engineer.
C. Test Reports
1. Fine aggregates—sieve analysis, physical properties, and deleterious
substance.
2. Coarse aggregates—sieve analysis, physical properties, and deleterious
substances.
3. Cements—chemical analysis and physical properties for each type.
4. Pozzolans—chemical analysis and physical properties.
5. Proposed concrete mixes—compressive strength, slump, and air content.
D. Certifications
1. Certify that admixtures used in the same concrete mix are compatible with
each other and with the aggregates.
2. Certify that admixtures are suitable for use in contact with potable water
after 30 days of concrete curing.
3. Certify that the curing compound is suitable for use in contact with potable
water after 30 days (non-toxic and free of taste or odor).
03720-048-01 03300-2 CAST -IN-PLACE CONCRETE
August 2019
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be in
accordance with the currently effective Florida Building Code (FBC). The following documents
are a part of this Section. Where this Section differs from these documents, the requirements of
this Section shall apply.
A. American Society for Testing and Materials (ASTM)
1. ASTM C31/C31M—Standard Practice for Making and Curing Concrete
Test Specimens in the Field.
2. ASTM C33/33M—Standard Specification for Concrete Aggregates.
3. ASTM C39/C39M Standard Test Method for Compressive Strength of
Cylindrical Concrete Specimens.
4. ASTM C42/C42M—Standard Test Method for Obtaining and Testing
Drilled Cores and Sawed Beams of Concrete.
5. ASTM C94/C94M—Standard Specification for Ready -Mixed Concrete.
6. ASTM C143/C143M Standard Test Method for Slump of Hydraulic -
Cement Concrete.
7. ASTM C 150/C 150M—Standard Specification for Portland Cement.
8. ASTM C171—Standard Specification for Sheet Materials for Curing
Concrete.
9. ASTM C173/C173M—Standard Test Method for Air Content of Freshly
Mixed Concrete by the Volumetric Method.
10. ASTM C231/C231M—Standard Test Method for Air Content of Freshly
Mixed Concrete by the Pressure Method.
11. ASTM C260/C260M—Standard Specification for Air -Entraining
Admixtures for Concrete.
12. ASTM C309—Standard Specification for Liquid -Membrane Forming
Compounds for Curing Concrete.
13. ASTM C494/C494M—Standard Specification for Chemical Admixtures
for Concrete.
14. ASTM C618—Standard Specification for Coal Fly Ash and Raw or
Calcined Natural Pozzolan for Use in Concrete.
15. ASTM C 1017/C 1017M—Standard Specification for Chemical
Admixtures for Use in Producing Flowing Concrete.
B. American Concrete Institute (ACI)
03720-048-01
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1. ACI 304R—Guide for Measuring, Mixing, Transporting, and Placing
Concrete.
2. ACI 305R—Guide to Hot Weather Concreting.
03300-3 CAST -IN-PLACE CONCRETE
3. ACI 306.1—Standard Specification for Cold Weather Concreting.
4. ACI 318—Building Code Requirements for Structural Concrete and
Commentary.
5. ACI 350—Code Requirements for Environmental Engineering Concrete
Structures and Commentary.
1.06 QUALITY ASSURANCE
A. Reinforced concrete shall comply with ACI 318; the recommendations of
ACI 350; and other stated requirements, codes, and standards. The most stringent
requirement of the codes, standards, and this Section shall apply when conflicts
exist.
B. Only one source of cement and aggregates shall be used on any one structure.
Concrete shall be uniform in color and appearance.
C. Thirty days before placing concrete, the Contractor shall discuss with the
Engineer the sources of individual materials and batched concrete proposed for
use. Discuss placement methods, waterstops, and curing. Propose methods of hot
and cold weather concreting as required. Before placing any concrete containing a
high -range water -reducing admixture (plasticizer), the Contractor, accompanied
by the plasticizer manufacturer, shall discuss with the Engineer the properties and
techniques of batching and placing plasticized concrete.
D. If, during the progress of the work, it is impossible to obtain concrete of the
required workability and strength with the materials being furnished, the Engineer
may order such changes in proportions or materials, or both, as may be necessary
to obtain the desired properties. All changes so ordered shall be made at the
Contractor's expense.
E. If, during the progress of the work, the materials from the sources originally
accepted change in characteristics, the Contractor shall, at his/her expense, make
new acceptance tests of aggregates and establish new design mixes.
F. The Contractor shall furnish testing of the following materials to verify
conformity with this Section and the stated ASTM Standards:
1. Fine aggregates for conformity with ASTM C33/C33M—sieve analysis,
physical properties, and deleterious substances.
2. Coarse aggregates for conformity with ASTM C33/C33M—sieve analysis,
physical properties, and deleterious substances.
3. Cements for conformity with ASTM C 150/C 150M—chemical analysis
and physical properties.
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4. Pozzolans for conformity with ASTM C618—chemical analysis and
physical properties.
5. Proposed concrete mix designs—compressive strength, slump, and air
content.
G. A firm providing field testing and inspection services will be approved by the
Owner. The cost of such work, except as specifically stated otherwise, shall be
paid by the Contractor and reimbursed by the Owner under the Concrete Testing
Allowance.The following items shall be tested by the Owner to verify conformity
with this Section:
1. Concrete placements—compressive strength (cylinders), compressive
strength (cores), slump, and air content.
2. Other materials or products that may come under question.
H. All materials incorporated in the work shall conform to accepted samples.
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
The Contractor shall adhere to the requirements specified in Section 01650, Delivery, Storage,
and Handling, for storing and protecting the items specified in this Section:
A. Cement: Store in weathertight buildings, bins, or silos to provide protection from
dampness and contamination and to minimize warehouse set.
B. Aggregate: Arrange and use stockpiles to avoid excessive segregation or
contamination with other materials or with other sizes of like aggregates. Build
stockpiles in successive horizontal layers not exceeding 3 feet in thickness.
Complete each layer before the next is started. Do not use frozen or partially
frozen aggregate.
C. Sand: Arrange and use stockpiles to avoid contamination. Allow sand to drain to a
uniform moisture content before using. Do not use frozen or partially frozen
aggregates.
D. Admixtures: Store in closed containers to avoid contamination, evaporation, or
damage. Provide suitable agitating equipment to ensure uniform dispersion of
ingredients in admixture solutions which tend to separate. Protect liquid
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admixtures from freezing and other temperature changes which could adversely
affect their characteristics.
E. Pozzolan: Store in weathertight buildings, bins, or silos to provide protection from
dampness and contamination.
F. Sheet Curing Materials: Store in weathertight buildings or off the ground and
under cover.
G. Liquid Curing Compounds: Store in closed containers.
1.09 QUALIFICATIONS (NOT USED)
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 WEATHER CONSTRAINTS (NOT USED)
PART 2 PRODUCTS
2.01 GENERAL
A. The use of the manufacturer's name and model or catalog number is for the
purpose of establishing the standard of quality and general configuration desired.
B. Like items of materials shall be the end products of one manufacturer in order to
provide standardization for appearance, maintenance, and manufacturer's service.
2.02 MATERIALS
A. Materials shall comply with this Section and any applicable State or local
requirements.
B. Cement: Domestic Portland cement complying with ASTM C 150/C 150M. Air
entraining cements shall not be used. The brand of cement shall be subject to
approval by the Engineer and one brand shall be used throughout the Work. The
following cement type(s) shall be used:
1. Class A,B,C,D Concrete Type II with the addition of fly ash resulting in
C3A being below 5% of total cementitious content, Type III limited to 5%
C3A or Type V.
C. Fine Aggregate: Washed inert natural sand conforming to the requirements of
ASTM C33/C33M.
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D. Coarse Aggregate: Well -graded crushed stone or washed gravel conforming to
the requirements of ASTM C33/C33M. Grading requirements shall be as listed in
ASTM C33/C33M Table 2 for the specified coarse aggregate size number. Limits
of Deleterious Substances and Physical Property Requirements shall be as listed
in ASTM C33/C33M Table 3 for severe weathering regions. Size numbers for the
concrete mixes shall be as shown in Table 1 in this Section.
E. Water: Potable water free from injurious amounts of oils, acids, alkalis, salts,
organic matter, or other deleterious substances.
F. Admixtures: Admixtures shall be free of chlorides and alkalis (except for those
attributable to water). When it is required to use more than one admixture in a
concrete mix, the admixtures shall be from the same manufacturer. Admixtures
shall be compatible with the concrete mix, including other admixtures, and shall
be suitable for use in contact with potable water after 30 days of concrete curing.
1. Air -Entraining Admixture: The admixture shall comply with
ASTM C260/C260M. Proportioning and mixing shall be in accordance
with the manufacturer's recommendations.
2. Water -Reducing Agent: The admixture shall comply with
ASTM C494/C494M, Type A. Proportioning and mixing shall be in
accordance with the manufacturer's recommendations.
3. High -Range Water -Reducer (Plasticizer): The admixture shall comply
with ASTM C494/C494M, Type F, and shall result in non -segregating
plasticized concrete with little bleeding and with the physical properties of
low water/cement ratio concrete. The treated concrete shall be capable of
maintaining its plastic state in excess of 2 hours. Proportioning and mixing
shall be in accordance with the manufacturer's recommendations.
4. Admixtures causing retarded or accelerated setting of concrete shall not be
used without written approval from the Engineer. When allowed, the
admixtures shall be retarding or accelerating water -reducing or high -range
water -reducing admixtures.
G. Pozzolan (Fly Ash) shall be Class F fly ash complying with ASTM C618 except
that the Loss on Ignition (LOI) shall be limited to 3% maximum.
H. Sheet Curing Materials. Waterproof paper, polyethylene film, or white burlap
polyethylene sheeting all complying with ASTM C171.
I. Liquid Curing Compound. Liquid membrane forming curing compound shall
comply with the requirements of ASTM C309, Type 1 D (clear or translucent
with fugitive dye) and shall contain no wax, paraffin, or oil. The curing compound
shall be approved for use in contact with potable water after 30 days according to
NSF 61 (non-toxic and free of taste or odor).
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2.03 MIXES
A. An independent testing laboratory acceptable to the Owner engaged by and at the
expense of the Contractor shall develop mix designs and testing.
B. Select proportions of ingredients to meet the design strength and materials limits
specified in Table 1 and to produce concrete having proper placability, durability,
strength, appearance, and other required properties. Proportion ingredients to
produce a homogenous mixture that will readily work into corners and angles of
forms and around reinforcement without permitting materials to segregate or
allowing excessive free water to collect on the surface.
C. The design mix shall be based on standard deviation data of prior mixes with
essentially the same proportions of the same constituents or, if such data are not
available, be developed by a testing laboratory acceptable to the Engineer and
engaged by and at the expense of the Contractor. Mixes based on standard
deviation shall be accepted based on the modification factors for standard
deviation tests contained in ACI 318. The water content of the concrete mix,
determined by laboratory testing, shall be based on a curve showing the relation
between water cementitious ratio and 7- and 28 -day compressive strengths of
concrete made using the proposed materials. The curves shall be determined by
four or more points, each representing an average value of at least three test
specimens at each age. The curves shall have a range of values sufficient to yield
the desired data, including the specified design strengths as modified below,
without extrapolation. The water content of the concrete mixes to be used, as
deteliuined from the curve, shall correspond to strengths 16% greater than the
specified design strengths. The resulting mix shall not conflict with the limiting
values for maximum water cementitious ratio and net minimum cementitious
content as specified in Table 1.
D. Compression Tests: Provide testing of the proposed concrete mix or mixes to
demonstrate compliance with the specified design strength requirements in
conformity with the paragraph above.
E. Entrained air, as measured by ASTM C231/C231M, shall be as shown in Table 1.
1. If the air -entraining agent proposed for use in the mix requires testing
methods other than ASTM C231/C231M to accurately determine air
content, make special note of this requirement in the admixture submittal.
F. Slump of the concrete as measured by ASTM C 143/C 143M shall be as shown in
Table 1. If a high -range water -reducer (plasticizer) is used, the slump indicated
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shall be that measured before plasticizer is added. Plasticized concrete shall have
a slump ranging from 7 to 10 inches.
G. Proportion admixtures according to the manufacturer's recommendations. Two or
more admixtures specified may be used in the same mix provided that the
admixtures in combination retain full efficiency and have no deleterious effect on
the concrete or on the properties of each other.
TABLE 1
CONCRETE MIX REQUIREMENTS
Class
Design
Strength (1)
Cement (2) Fine
Aggregate (2)
Coarse
Aggregate (3)
Cementitious
Content (4)
C 150/C 150M
A
2,500
Type II C33/C33M
57
440 min.
C 150/C 150M
B
3,000
Type II C33/C33M
57
480 min.
C 150/C 150M
C
4,000
Type II C33/C33M
57
560 min.
C 150/C 150M
D
5,000
Type II C33/C33M
57
600 min.
Class
W/C Ratio
Fly Ash AE Range WR (7)
HRWR (8)
Slump Range
(5)
(6)
(inches)
A
0.62 max.
-- 3.5 to 5 Yes
*
1 to 4
B
0.54 max.
-- 3.5 to 5 Yes
*
1 to 3
C
0.44 max.
20to25% 3.5to5 Yes
*
3to5
D
0.40 max.
-- 3.5 to 5 Yes
*
3 to 5
NOTES:
(1) Minimum compressive strength in psi at 28 days.
(2) ASTM designation.
(3) Size Number in ASTM C33/C33M.
(4) Cementitious content in lbs/cu yd.
(5) W/C is Water-Cementitious ratio by weight.
(6) AE is percent air -entrainment.
(7) WR is water -reducer admixture.
(8) HRWR is high -range water -reducer admixture.
* HRWR used at the Contractor's option.
PART 3 EXECUTION
3.01 MEASURING MATERIALS
A. Concrete shall be composed of Portland cement, fine aggregate, coarse aggregate,
water, and admixtures as specified and shall be produced by a plant acceptable to
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the Engineer. All constituents, including admixtures, shall be batched at the plant
except a high -range water -reducer may also be added in the field.
B. Measure materials for batching concrete by weighing in conformity with and
within the tolerances given in ASTM C94/C94M except as otherwise specified.
Scales shall have been certified by the local Weights and Measures official within
1 year of use.
C. Measure the amount of free water in fine aggregates within 0.3% with a moisture
meter. Compensate for varying moisture contents of fine aggregates. Record the
number of gallons of water as batched on printed batching tickets.
D. Admixtures shall be dispensed either manually using calibrated containers or
measuring tanks or by an automatic dispenser approved by the manufacturer of
the specific admixture.
1. Charge air entraining and chemical admixtures into the mixer as a solution
using an automatic dispenser or similar metering device.
2. Inject multiple admixtures separately during the batching sequence.
3.02 MIXING AND TRANSPORTING
A. Concrete shall be ready mixed concrete produced by equipment acceptable to the
Engineer. No hand mixing will be permitted. Clean each transit mix truck drum
and reverse drum rotation before the truck proceeds under the batching plant.
Equip each transit mix truck with a continuous, nonreversible, revolution counter
showing the number of revolutions at mixing speeds.
B. Ready mix concrete shall be transported to the site in watertight agitator or mixer
trucks loaded not in excess of their rated capacities as stated on the name plate.
C. Keep the water tank valve on each transit truck locked at all times. Any addition
of water must be directed by the Engineer. Added water shall be incorporated by
additional mixing of at least 35 revolutions. All added water shall be metered and
the amount of water added shall be shown on each delivery ticket.
D. All central plant and rolling stock equipment and methods shall comply with
ACI 318 and ASTM C94/C94M.
E. Select equipment of size and design to ensure continuous flow of concrete at the
delivery end. Metal or metal lined non -aluminum discharge chutes shall be used
and shall have slopes not exceeding 1 vertical to 2 horizontal and not less than
1 vertical to 3 horizontal. Chutes more than 20 feet long and chutes not meeting
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slope requirements may be used if concrete is discharged into a hopper before
distribution.
F. Retempering (mixing with or without additional cement, aggregate, or water) of
concrete or mortar which has reached initial set will not be permitted.
G. Handle concrete from mixer to placement as quickly as practicable while
providing concrete of required quality in the placement area. Dispatch trucks from
the batching plant so they arrive at the work site just before the concrete is
required, thus avoiding excessive mixing of concrete while waiting or delays in
placing successive layers of concrete in the forms.
H. Furnish a delivery ticket for ready -mixed concrete to the Engineer as each truck
arrives. Each ticket shall provide a printed record of the weight of cement and
each aggregate as batched individually. Use the type of indicator that returns for
zero punch or returns to zero after a batch is discharged. Clearly indicate the
weight of fine and coarse aggregate, cement and water in each batch, the quantity
delivered, the time any water is added, and the numerical sequence of the
delivery. Show the time of day batched and time of discharge from the truck.
Indicate the number of revolutions of the truck mixer.
I. Temperature and Mixing Time Control
1. In cold weather, do not allow the as -mixed temperature of the concrete
and concrete temperatures at the time of placement in the forms to drop
below 40°F.
2. If water or aggregate has been heated, combine water with aggregate in
the mixer before cement is added. Do not add cement to mixtures of water
and aggregate when the temperature of the mixture is greater than 90°F.
3. In hot weather, cool ingredients before mixing to maintain temperature of
the concrete below the maximum placing temperature of 90°F. If
necessary, substitute well -crushed ice for all or part of the mixing water.
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4. The maximum time interval between adding mixing water and/or cement
to the batch and placing concrete in the forms shall not exceed the values
shown in Table 2.
TABLE 2
MAXIMUM TIME TO DISCHARGE OF CONCRETE
Air or Concrete Temperature
(whichever is higher)
Maximum Time
80 to 90°F (27 to 32°C)
70 to 79°F (21 to 26°C)
40 to 69°F (5 to 20°C)
45 minutes
60 minutes
90 minutes
J. If an approved high -range water -reducer (plasticizer) is used to produce
plasticized concrete, the maximum time interval shall not exceed 90 minutes.
3.03 CONCRETE APPEARANCE
A. Concrete mix showing either poor cohesion or poor coating of the coarse
aggregate with paste shall be remixed. If this does not correct the condition, the
concrete shall be rejected. If the slump is within the allowable limit but excessive
bleeding, poor workability, or poor finishability are observed, changes in the
concrete mix shall be obtained only by adjusting one or more of the following:
1. The gradation of aggregate.
2. The proportion of fine and coarse aggregate.
3. The percentage of entrained air within the allowable limits.
B. Concrete for the work shall provide a homogeneous structure which, when
hardened, will have the required strength, durability, and appearance. Mixtures
and workmanship shall be such that concrete surfaces, when exposed, will require
no finishing. When concrete surfaces are stripped, the concrete, when viewed in
good lighting from 10 feet away, shall be pleasing in appearance and at 20 feet
shall show no visible defects.
3.04 PLACING AND COMPACTING
A. Placing
1. The Contractor shall verify that all formwork completely encloses
concrete to be placed and is securely braced before placing concrete.
Remove ice, excess water, dirt, and other foreign materials from forms.
Confirm that reinforcement and other embedded items are securely in
place. Have a competent workman at the location of the placement who
can ensure that reinforcing steel and embedded items remain in designated
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locations while concrete is being placed. Sprinkle semi -porous subgrades
or forms to eliminate suction of water from the mix. Seal extremely
porous subgrades in an approved manner.
2. Deposit concrete as near its final position as possible to avoid segregation
due to rehandling or flowing. Place concrete continuously at a rate which
ensures the concrete is being integrated with fresh plastic concrete. Do not
deposit concrete that has partially hardened or has been contaminated by
foreign materials or on concrete that has hardened sufficiently to cause
formation of seams or planes of weakness within the section. If the section
cannot be placed continuously, place construction joints as specified or as
approved.
3. Pumping of concrete will be permitted. Use a mix design and aggregate
sizes suitable for pumping and submit for approval.
4. Remove temporary spreaders from forms when the spreader is no longer
useful. Temporary spreaders may remain embedded in concrete only when
made of galvanized metal or concrete and if prior approval has been
obtained.
5. Do not place concrete for supported elements until concrete previously
placed in the supporting element (columns, slabs, and/or walls) has
reached adequate strength.
6. Where surface mortar is to form the base of a finish, especially surfaces
designated to be painted, work coarse aggregate back from forms with a
suitable tool to bring the full surface of the mortar against the form.
Prevent the formation of excessive surface voids.
7. Slabs
a. After suitable bulkheads, screeds, and jointing materials have been
positioned, the concrete shall be placed continuously between
construction joints beginning at a bulkhead, edge form, or corner.
Each batch shall be placed into the edge of the previously placed
concrete to avoid stone pockets and segregation.
b. Avoid delays in casting. If there is a delay in casting, the concrete
placed after the delay shall be thoroughly spaded and consolidated
at the edge of that previously placed to avoid cold joints. Concrete
shall then be brought to correct level and struck off with a
straightedge. Bullfloats or darbies shall be used to smooth the
surface, leaving it free of humps or hollows.
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c. Where slabs are to be placed integrally with the walls below them,
place the walls and compact as specified. Allow 1 hour to pass
between placement of the wall and the overlying slab to permit
consolidation of the wall concrete. Keep the top surface of the wall
moist so as to prevent cold joints.
8. Formed Concrete
a. Place concrete in forms using tremie tubes and taking care to
prevent segregation. Bottoms of tremie tubes shall preferably be in
contact with the concrete already placed. Do not permit concrete to
drop freely more than 4 feet. Place concrete for walls in 12- to
24 -inch lifts, keeping the surface horizontal. If plasticized concrete
is used, the maximum lift thickness may be increased to 7 feet and
the maximum free fall of concrete shall not exceed 15 feet.
9. Underwater concreting shall be performed in conformity with the
recommendations of ACI 304R. The tremie system shall be used to place
underwater concrete. Tremie pipes shall be in the range of 8 to 12 inches
in diameter and be spaced at not more than 16 feet on centers nor more
than 8 feet from an end form. Where concrete is being placed around a
pipe, there shall be at least one tremie pipe on each side of each pipe.
Where the tremie system is not practical, direct pumped concrete for
underwater placement may be used subject to approval of the system,
including details, by the Engineer.
B. Compacting
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1. Consolidate concrete by vibration, puddling, spading, rodding, or forking
so that concrete is thoroughly worked around reinforcement, embedded
items, and openings and into corners of forms. Puddling, spading, etc.,
shall be continuously performed along with vibration of the placement to
eliminate air or stone pockets that may cause honeycombing, pitting, or
planes of weakness.
2. All concrete shall be placed and compacted with mechanical vibrators.
The number, type, and size of the units shall be approved by the Engineer
in advance of placing operations. No concrete shall be ordered until
sufficient approved vibrators (including standby units in working order)
are on the job.
3. A minimum frequency of 7,000 rpm is required for mechanical vibrators.
Insert vibrators and withdraw at points from 18 to 30 inches apart. At each
insertion, vibrate sufficiently to consolidate concrete, generally from 5 to
03300-14 CAST -IN-PLACE CONCRETE
15 seconds. Do not over vibrate so as to segregate. Keep a spare vibrator
on the site during concrete placing operations.
4. Concrete Slabs: Concrete for slabs less than 8 inches thick shall be
consolidated with vibrating screeds; slabs 8 to 12 inches thick shall be
compacted with internal vibrators and (optionally) with vibrating screeds.
Vibrators shall always be placed into concrete vertically and shall not be
laid horizontally or laid over.
5. Walls and Columns: Internal vibrators (rather than form vibrators) shall be
used unless otherwise approved by the Engineer. In general, for each
vibrator needed to consolidate the batch at the point of discharge, one or
more additional vibrators must be used to densify, homogenize, and
perfect the surface. The vibrators shall be inserted vertically at regular
intervals through the fresh concrete and slightly into the previous lift, if
any.
6. Amount of Vibration: Vibrators are to be used to consolidate properly
placed concrete but shall not be used to move or transport concrete in the
forms. Vibration shall continue until:
a. Frequency returns to normal.
b. Surface appears liquefied, flattened, and glistening.
c. Trapped air ceases to rise.
d. Coarse aggregate has blended into the surface but has not
disappeared.
3.05 CURING AND PROTECTION
A. The Contractor shall protect all concrete work against injury from the elements
and defacements of any nature during construction operations.
B. Curing Methods
1. Curing Methods for Concrete Surfaces: Cure concrete to retain moisture
and maintain specified temperature at the surface for a minimum of 7 days
after placement. Curing methods to be used are as follows:
a. Water Curing: Keep entire concrete surface wet by ponding,
continuous sprinkling, or by covering with saturated burlap. Begin
wet cure as soon as concrete attains an initial set and maintain wet
cure 24 hours a day.
b. Sheet Material Curing: Cover entire surface with sheet material.
Securely anchor sheeting to prevent wind and air from lifting the
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sheeting or entrapping air under the sheet. Place and secure sheet
as soon as initial concrete set occurs.
c. Liquid Membrane Curing: Apply over the entire concrete surface
except for surfaces to receive additional concrete. Curing
compound shall NOT be placed on any concrete surface where
additional concrete is to be placed, where concrete sealers or
surface coatings are to be used, or where the concrete finish
requires an integral floor product. Curing compound shall be
applied as soon as the free water on the surface has disappeared
and no water sheen is visible, but not after the concrete is dry or
when the curing compound can be absorbed into the concrete.
Application shall be in compliance with the manufacturer's
recommendations.
2. Specified applications of curing methods.
a. Slabs for Water Containment Structures: Water curing only.
b. Slabs on Grade and Footings (not used to contain water): Water
curing, sheet material curing, or liquid membrane curing.
c. Structural Slabs (other than water containment): Water curing or
liquid membrane curing.
d. Horizontal Surfaces that Will Receive Additional Concrete,
Coatings, Grout, or Other Material that Requires Bond to the
Substrate: Water curing.
e. Formed Surfaces: None if nonabsorbent forms are left in place
7 days. Water cure if absorbent forms are used. Sheet cured or
liquid membrane cured if forms are removed before 7 days.
Exposed horizontal surfaces of formed walls or columns shall be
water cured for 7 days or until next placement of concrete.
f. Concrete Joints: Water cured or sheet material cured.
C. Finished surfaces and slabs shall be protected from the direct sunlight to prevent
checking and crazing.
D. Cold Weather Concreting:
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1. Cold weather is defined as a period when the average daily outdoor
temperature drops below 40°F for more than 3 successive days. The
average daily temperature shall be calculated as the average of the highest
and the lowest temperature from midnight to midnight.
2. Cold weather concreting shall conform to ACI 306.1 and the additional
requirements specified in this Section. Temperatures at the concrete
placement shall be recorded at 12 -hour intervals (minimum).
03300-16 CAST -IN-PLACE CONCRETE
3. The Contractor shall discuss a cold weather work plan with the Engineer.
The discussion shall encompass the methods and procedures proposed for
use during cold weather, including producing, transporting, placeing,
protecting, curing, and monitoring the temperature of the concrete. The
procedures to be implemented upon abrupt changes in weather conditions
or equipment failures shall also be discussed. Cold weather concreting
shall not begin until the work plan is acceptable to the Engineer.
4. During periods of cold weather, concrete shall be protected to provide
continuous warm, moist curing (with supplementary heat when required)
for a total of at least 350 degree-days of curing.
a. Degree-days are defined as the total number of 24-hour periods
multiplied by the average daily air temperature at the surface of the
concrete (e.g., 5 days at an average 70°F = 350 degree-days).
b. To calculate the weighted average daily air temperature, sum
hourly measurements of the air temperature in the shade at the
surface of the concrete taking any measurement less than 50°F as
0°F. Divide the sum thus calculated by 24 to obtain the weighted
average temperature for that day.
5. Salt, manure, or other chemicals shall not be used for protection.
6. The protection period for concrete being water cured shall not be
terminated during cold weather until at least 24 hours after water curing
has been terminated.
E. Hot Weather Concreting
1. Hot weather is defined as any combination of high air temperatures, low
relative humidity, and wind velocity which produces a rate of evaporation
estimated in accordance with ACI 305R, approaching or exceeding
0.2 lb/sq ft/hr).
2. Concrete placed during hot weather shall be batched, delivered, placed,
cured, and protected in compliance with the recommendations of
ACI 305R and the additional requirements specified in this Section.
a. Temperature of concrete being placed shall not exceed 90°F and
every effort shall be made to maintain a uniform concrete mix
temperature below this level. The temperature of the concrete shall
be such that it will cause no difficulties from loss of slump, flash
set, or cold joints.
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b. All necessary precautions shall be taken to deliver the concrete
promptly, to place the concrete promptly upon its arrival at the job,
and to provide vibration immediately after placement.
c. The Engineer may direct the Contractor to immediately cover
plastic concrete with sheet material.
3. The Contractor shall discuss with the Engineer a work plan describing the
methods and procedures proposed for concrete placement and curing
during hot weather. Hot weather concreting shall not begin until the work
plan is acceptable to the Engineer.
3.06 REMOVAL OF FORMS
A. Except as otherwise specifically authorized by the Engineer, forms shall not be
removed before the concrete has attained a strength of at least 30% of its specified
design strength, nor before reaching the following number of degree-days of
curing (whichever is longer):
TABLE 3
MINIMUM TIME TO FORM REMOVAL
Forms for:
Degree -Days:
Beams and slabs
Walls and vertical surfaces
500
100
(See definition of degree-days in Paragraph 3.05D.)
B. Shores shall not be removed until the concrete has attained at least 70% of its
specified design strength and also sufficient strength to support safely its own
weight and construction live loads.
3.07 INSPECTION AND FIELD TESTING
A. The batching, mixing, transporting, placing, and curing of concrete shall be
subject to the inspection of the Engineer at all times. The Contractor shall advise
the Engineer of his/her readiness to proceed at least 24 hours before each concrete
placement. The Engineer will inspect the preparations for concreting, including
the preparation of previously placed concrete, the reinforcing steel and the
alignment, and the cleanliness and tightness of formwork. No placement shall be
made without inspection and acceptance by the Engineer.
B. In compliance with ASTM C31/C31M, the Engineer (or inspector) will take sets
of field -control cylinder specimens during the work. The number of sets of
concrete test cylinders taken of each class of concrete placed each day shall not be
03720-048-01 03300-18 CAST -IN-PLACE CONCRETE
August 2019
less than one set per day, nor less than one set for each 150 cu yd of concrete, nor
less than one set for each 5,000 sq ft of surface area for slabs or walls.
1. A "set" of test cylinders consists of four cylinders: one to be tested at
7 days and two to be tested and their strengths averaged at 28 days. The
fourth may be used for a special test at 3 days or to verify strength after
28 days if the 28 -day test results are low.
2. When the average 28 -day compressive strength of the cylinders in any set
falls below the specified design strength or below proportional minimum
7 -day strengths (where proper relation between 7- and 28 -day strengths
have been established by tests), proportions, water content, or temperature
conditions shall be changed to achieve the required strengths.
C. The Contractor shall cooperate in testing by allowing free access to the work for
the selection of samples, providing an insulated closed curing box for specimens,
affording protection to the specimens against injury or loss through the
operations, and furnishing material and labor required for taking concrete cylinder
samples. The cost of taking and shipping specimens will be paid for by the
Contractor and reimbursed by the Owner under the Concrete Testing Allowance.
Curing boxes shall be acceptable to the Engineer.
D. In accordance with ASTM C143/C143M, slump tests will be made in the field
immediately before placing the concrete. If the slump is greater than the specified
range, the concrete shall be rejected.
E. Air Content: Air content shall be tested for on fresh concrete samples. Air content
for concrete made of ordinary aggregates having low absorption shall be tested for
in compliance with either the pressure method complying with
ASTM C231/C231M or by the volumetric method complying with
ASTM C173/C173M. If lightweight aggregates or aggregates with high
absorptions are used, the latter test method shall be used.
F. The Engineer may have cores taken from any questionable area in the concrete
work such as construction joints and other locations as required for determining
concrete quality. The results of tests on such cores shall be the basis for accepting,
rejecting, or determining the continuation of concrete work.
G. The Contractor shall cooperate in obtaining cores by allowing free access to the
work and permitting the use of ladders, scaffolding, and such incidental
equipment as may be required. Repair all core holes. The work of cutting and
testing the cores will be at the expense of the Contractor. Work found to be
acceptable will be reimbursed under the Concrete Testing Allowance.
03720-048-01 03300-19 CAST -IN-PLACE CONCRETE
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3.08 FAILURE TO MEET REQUIREMENTS
A. Should the strengths shown by the test specimens made and tested in compliance
with the previous provisions fall below the values given in Table 1, the Engineer
shall have the right to require changes in proportions outlined to apply to the
remainder of the work. Furthermore, the Engineer shall have the right to require
additional curing on those portions of the structure represented by the test
specimens which failed. The cost of such additional curing shall be at the
Contractor's expense. If such additional curing does not give the strength required
as evidenced by core and/or load tests, the Engineer shall have the right to require
strengthening or replacing those portions of the structure that fail to develop the
required strength. The cost of all such core borings and/or load tests and any
strengthening or concrete replacement required because strengths of test
specimens are below those specified shall be entirely at the expense of the
Contractor. In such cases of failure to meet strength requirements, the Contractor
and Engineer shall confer to determine what adjustment, if any, can be made in
compliance with sections titled "Strength" and "Failure to Meet Strength
Requirements" of ASTM C94/C94M. The "purchaser" referred to in
ASTM C94/C94M is the Contractor in this Section.
B. When the tests on control specimens of concrete fall below the specified strength,
the Engineer will permit check tests for strengths to be made by means of typical
cores drilled from the structure in compliance with ASTM C42/C42M and
ASTM C39/C39M. In the case of cores not indicating adequate strength, the
Engineer, in addition to other recourses, may require, at the Contractor's expense,
load tests on any one of the slabs, beams, piles, caps, and columns in which such
concrete was used. Tests need not be conducted until concrete has aged 60 days.
C. Should the strength of test cylinders fall below 60% of the required minimum
28 -day strength, the concrete shall be rejected and shall be removed and replaced.
3.09 PATCHING AND REPAIRS
A. This Section is intended to require quality work, including adequate forming and
proper mixing, placing, and curing of concrete so completed concrete surfaces
will require no patching.
B. Defective concrete and honeycombed areas as determined by the Engineer shall
be repaired as specified by the Engineer.
C. As soon as the forms have been stripped and the concrete surfaces exposed, fins
and other projections shall be removed; recesses left by the removal of form ties
shall be filled; and surface defects which do not impair structural strength shall be
03720-048-01
August 2019
03300-20 CAST -IN-PLACE CONCRETE
repaired. Clean all exposed concrete surfaces and adjoining work stained by
leakage of concrete to the approval of the Engineer.
D. Immediately after removal of forms remove plugs and break off metal ties as
required by Section 03100, Concrete Formwork. Promptly fill holes upon
stripping as follows: moisten the hole with water, followed by a 1/16 -inch brush
coat of neat cement slurry mixed to the consistency of a heavy paste. Immediately
plug the hole with a 1 -to -1.5 -mixture of cement and concrete sand mixed slightly
damp to the touch (just short of "balling"). Hammer the grout into the hole until
dense and an excess of paste appears on the surface in the form of a spiderweb.
Trowel smooth with heavy pressure. Avoid burnishing.
E. When patching exposed surfaces, employ the same source of cement and sand as
used in the parent concrete. Adjust color if necessary by adding proper amounts of
white cement. Rub lightly with a fine Carborundum stone at an age of 1 to 5 days
if necessary to bring the surface down with the parent concrete. Exercise care to
avoid damaging or staining the virgin skin of the surrounding parent concrete.
Wash thoroughly to remove all rubbed matter.
3.10 SCHEDULE
A. The following (Table 4) are the general applications for the various concrete
classes and design strengths:
03720-048-01
August 2019
TABLE 4
CONCRETE SCHED
Class
Design Strength
(psi)
Description
A
2,500
Concrete fill and duct
encasement
B
3,000
Concrete overlay slabs and
pavements
C
4,000
Walls, slabs on grade,
suspended slab and beam
systems, columns, grade
beams, and all other
structural concrete
D
5,000
Prestressed concrete
END OF SECTION
03300-21 CAST -IN-PLACE CONCRETE
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SECTION 03360
CONCRETE FINISHES
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish all labor, materials, equipment, and incidentals
required and finish cast -in-place concrete surfaces as shown on the Drawings and
as specified in this Section.
1.02 RELATED WORK
A. Section 03100, Concrete Formwork.
B. Section 03300, Cast -In -Place Concrete.
C. Section 03600, Grout.
1.03 SUBMITTALS
The Contractor shall submit shop drawings in accordance with Section 01330, Submittals
and Acceptance:
A. Concrete sealer. Confirmation that the sealer is compatible with additionally
applied coatings shall also be submitted.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be in
accordance with the currently effective Florida Building Code (FBC). The following documents
are a part of this Section. Where this Section differs from these documents, the requirements of
this Section shall apply.
A. American Society for Testing and Materials (ASTM)
1. ASTM C33/C33M—Standard Specification for Concrete Aggregates.
03720-048-01 03360-1 CONCRETE FINISHES
August 2019
1.06 QUALITY ASSURANCE
A. Finishes
1. For concrete which will receive additional applied finishes or materials,
the surface finish specified is required for the proper application of the
specified manufacturer's products. Where alternate products are approved
for use, determine if changes in finishes are required and provide the
proper finishes to receive these products.
2. Changes in finishes made to accommodate products different from those
specified shall be performed at no additional cost to the Owner. Submit
the proposed new finishes and their construction methods to the Engineer
for approval.
B. Services of Manufacturer's Representative
1. Upon 72 hours notification, make available at no extra cost to the Owner
the services of a qualified field representative of the manufacturer of the
curing compound, sealer, or hardener to instruct the user on the proper
application of the product under prevailing job conditions.
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
1.09 QUALIFICATIONS (NOT USED)
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 WEATHER CONSTRAINTS (NOT USED)
PART 2 PRODUCTS
2.01 MATERIALS
A. Chemical hardener shall be Lapidolith by Sonneborn; Hornolith by A.C. Horn;
Penalith by W.R. Meadows or equal fluosilicate base material.
03720-048-01
August 2019
03360-2 CONCRETE FINISHES
B. Concrete sealer shall be "MasterKure CC 180 WB", by Master Builders
Solutions, Shakopee, MN or equal.
PART 3 EXECUTION
3.01 FORMED SURFACES
A. Forms shall not be removed before the requirements of Section 03300, Cast -In -
Place Concrete, have been satisfied.
B. Exercise care to prevent damaging edges or obliterating the lines of chamfers,
rustications, or corners when removing the forms or performing any other work
adjacent to such chamfers, rustications, or corners.
C. Clean all exposed concrete surfaces and adjoining work stained by leakage of
concrete.
D. Rough Form Finish
1. Immediately after stripping forms and before concrete has changed color,
carefully remove all fins and projections.
2. Promptly fill holes left by tie cones and defects as specified in
Section 03300, Cast -In -Place Concrete.
E. Rubbed Finish
1. Immediately upon stripping forms and before the concrete has changed
color, carefully remove all fins. While the wall is still damp, apply a thin
coat of medium -consistency neat cement slurry by bristle brushes to
provide a bonding coat within all pits, air holes, or blemishes in the parent
concrete. Avoid coating large areas with the slurry at one time.
2. Before the slurry has dried or changed color, apply a dry (almost crumbly)
grout proportioned by volume and consisting of 1 part cement to
1-1/2 parts of clean masonry sand having a fineness modulus of
approximately 2.3 and complying with the gradation requirements of
ASTM C33/C33M for such a material. Grout shall be uniformly applied
by damp pads of coarse burlap approximately 6 -inch square used as a
float. Scrub grout into the pits and air holes to provide a dense mortar in
all imperfections.
3. Allow the mortar to partially harden for 1 or 2 hours depending on the
weather. If the air is hot and dry, keep the wall damp during this period
using a fine, fog spray. When the grout has hardened sufficiently so it can
be scraped from the surface with the edge of a steel trowel without
03720-048-01 03360-3 CONCRETE FINISHES
August 2019
damaging the grout in the small pits or holes, cut off all that can be
removed with a trowel. (Note: Grout allowed to remain on the wall too
long will harden and will be difficult to remove.)
4. Allow the surface to dry thoroughly and rub it vigorously with clean dry
burlap to completely remove any dried grout. No visible film of grout
shall remain after this rubbing. The entire cleaning operation for any area
must be completed the day it is started. Do not leave grout on surfaces
overnight. Allow sufficient time for grout to dry after it has been cut off
with the trowel so it can be wiped off clean with the burlap.
5. On the day after the repair of pits, air holes, and blemishes, the walls shall
again be wiped off clean with dry, used pieces of burlap containing old
hardened mortar which will act as a mild abrasive. After this treatment,
there shall be no built-up film remaining on the parent surface. If,
however, such a film is present, a fine abrasive stone shall be used to
remove all such material without breaking through the surface film of the
original concrete. Such scrubbing shall be light and sufficient only to
remove excess material without changing the texture of the concrete.
6. A thorough wash down with stiff bristle brushes shall follow the final
bagging or stoning operation. No extraneous materials shall remain on the
surface of the wall. The wall shall be sprayed with a fine fog spray
periodically to maintain a continually damp condition for at least 3 days
after the application of the repair grout.
F. Abrasive Blast Finish
03720-048-01
August 2019
1. Coordinate with Rubbed Finish application. Do not begin until Rubbed
Finish operation is complete or before concrete has reached minimum
7 -day strength. The Rubbed Finish application may be deleted by the
Engineer if the unfinished concrete surface is of superior quality. Apply
the abrasive blast finish only where indicated on the Drawings.
2. Prepare a sample area a minimum of 4 feet high by 16 feet wide. Blast
Finish as directed by the Engineer on a portion of new wall construction
which will not be exposed in the final work. The sample area shall contain
a variety of finishes obtained with different nozzles, nozzle pressures, grit
materials, and blasting techniques for selection by the Engineer. Final
accepted sample shall remain exposed until all Blast Finish operations are
complete.
3. The Blast Finish operation shall meet all regulatory agency requirements.
The Blast Finish contractor shall be responsible for obtaining all required
permits and/or licenses.
03360-4 CONCRETE FINISHES
1
4. Perform abrasive blast finishing in as continuous an operation as possible,
using the same work crew to maintain continuity of finish on each surface
or area of work. Maintain patterns or variances in depths of blast as
present on the accepted sample.
5. Use an abrasive grit of proper type and gradation as well as equipment and
technique to expose aggregate and surrounding matrix surfaces as follows:
a. Medium: Generally expose coarse aggregate 1/4 -inch to 3/8 -inch
reveal.
6. Abrade blast corners and edge of patterns carefully, using back-up boards,
to maintain uniform comer or edge line. Determine type of nozzle, nozzle
pressure, and blasting techniques required to match the Architect's
samples.
7. Upon completing the Blast Finish operation, thoroughly flush finished
surfaces with clean clear water to remove residual dust and grit. Allow to
air dry until curing of concrete is complete.
8. After the concrete has cured for a minimum of 28 days, apply a clear
acrylic sealer as directed by the manufacturer.
3.02 FLOORS AND SLABS
A. Floated Finish
1. Machine Floating
a. Screed floors and slabs with straightedges to the established grades
shown on the Drawings. Immediately after final screeding sprinkle
a dry cement/sand shake in the proportion of two sacks of Portland
cement to 3501b of coarse natural concrete sand evenly over the
surface at the rate of approximately 500 lb/1,000 square feet of
floor. Do not sprinkle neat, dry cement on the surface.
b. The application of the cement/sand shake may be eliminated at the
discretion of the Engineer if the base slab concrete exhibits
adequate fattiness and homogeneity and the need is not indicated.
When the concrete has hardened sufficiently to support the weight
of a power float without the float's digging into or disrupting the
level surface, thoroughly float the shake into the surface with a
heavy revolving disc -type power compacting machine capable of
providing a 200-1b compaction force distributed over a 24 -inch -
diameter disc.
03720-048-01 03360-5 CONCRETE FINISHES
August 2019
c. Start floating along walls and around columns and then move
systematically across the surface leaving a matte finish.
d. The compacting machine shall be the "Kelly Power Float with
Compaction Control" as manufactured by Kelley Industries of SSP
Construction Equipment Inc., Pomona, CA, or equal. Troweling
machines equipped with float (shoe) blades that are slipped over
the trowel blades may be used for floating. Floating with a
troweling machine equipped with normal trowel blades will not be
permitted. The use of any floating or troweling machine which has
a water attachment for wetting the concrete surface during
finishing will not be permitted.
2. Hand Floating
a. In lieu of power floating, small areas may be compacted by hand
floating. The dry cement/sand shake previously specified shall be
used unless specifically eliminated by the Engineer. Screed the
floors and slabs with straightedges to the established grades shown
on the Drawings. While the concrete is still green but sufficiently
hardened to support a finisher and kneeboards with no more than
1/4 -inch indentation, wood float to a true, even plane with no
coarse aggregate visible. Use sufficient pressure on the wood floats
to bring moisture to the surface.
3. Finishing Tolerances
a. Level floors and slabs to a tolerance of plus or minus 1/8 inch
when checked with a 10 -foot straightedge placed anywhere on the
slab in any direction. Where drains occur, pitch floors to drains
such that no low spots are left undrained. Failure to meet either of
the above requirements shall be cause for removal, grinding, or
other correction as directed by the Engineer.
B. Broom Finish
1. Screed slabs with straightedges to the established grades indicated on the
Drawings. When the concrete has stiffened sufficiently to maintain small
surface indentations, draw a stiff bristle broom lightly across the surface in
the direction of drainage or, in the case of walks and stairs, perpendicular
to the direction of traffic to provide a non -slip surface.
03720-048-01 03360-6 CONCRETE FINISHES
August 2019
C. Steel Trowel Finish
1. Finish concrete as specified in Article 3.04. Then, hand steel trowel to a
perfectly smooth hard even finish free from high or low spots or other
defects.
D. Concrete Sealer
1. Prepare and seal surfaces indicated on the room finish schedule to receive
a sealer as follows:
a. Finish concrete as specified in the preceding paragraphs and in
accordance with the Schedule in Article 3.05.
b. Newly Placed Concrete: Surface must be sound and properly
finished. Surface is application ready when it is damp but not wet
and can no longer be marred by walking workmen.
c. Newly Cured Bare Concrete: Level any spots gouged out by
trades. Remove all dirt, dust, droppage, oil, grease, asphalt, and
foreign matter. Cleanse with caustics and detergents as required.
Rinse thoroughly and allow to dry so that the surface is no more
than damp and not wet.
d. Aged Concrete: Restore surface soundness by patching, grouting,
filling cracks and holes, etc. Surface must also be free of any dust,
dirt, and other foreign matter. Use power tools and/or strippers to
remove any incompatible sealers or coatings. Cleanse as required
following the procedure indicated under cured concrete.
e. Methods: Apply sealer to form a continuous, uniform film by
spray, soft bristle pushbroom, long nap roller, or lambswool
applicator. Ordinary garden -type sprayers, using neoprene hose,
are recommended for best results.
f. Applications: For curing only, apply the first coat evenly and
uniformly as soon as possible after final finishing at the rate of
200 to 400 square feet per gallon. Apply the second coat when all
trades are completed and the structure is ready for occupancy at the
rate of 400 to 600 square feet per gallon.
g. To meet guarantee and to seal and dustproof, two coats are
required. For sealing new concrete, both coats shall be applied full
strength. On aged concrete, when renovating, dustproofing, and
sealing, the first coat should be thinned 10 to 15% with reducer in
accordance with the manufacturer's directions.
03720-048-01 03360-7 CONCRETE FINISHES
August 2019
3.03 CONCRETE RECEIVING CHEMICAL HARDENER
A. After 28 days minimum concrete cure, apply chemical hardener in three
applications to a minimum total coverage of the undiluted chemical of 100 square
feet per gallon and in accordance with the manufacturer's recommendations as
reviewed.
3.04 APPROVAL OF FINISHES
A. All concrete surfaces, when finished, will be inspected by the Engineer.
B. Surfaces which in the opinion of the Engineer are unsatisfactory shall be
refinished or reworked.
C. After finishing horizontal surfaces, regardless of the finishing procedure
specified, the concrete shall be cured in compliance with Section 03300, Cast -In -
Place Concrete, unless otherwise directed by the Engineer.
3.05 SCHEDULE OF FINISHES
A. Concrete shall be finished as specified either to remain as natural concrete or to
receive an additional applied finish or material under another section.
B. Concrete for the following conditions shall be finished as noted on the Drawings
and as further specified in this Section:
1. Concrete to Receive Dampproofing: Rough form finish. See
Paragraph 3.01D.
2. Concrete Not Exposed to View and Not Scheduled to Receive an
Additional Applied Finish or Material: Rough form finish. See
Paragraph 3.01D.
3. Exterior Vertical Concrete Above Grade Exposed to View: Rubbed finish.
See Paragraph 3.O1E.
4. Interior Vertical Concrete Exposed to View Except in Water Containment
Areas: Rubbed finish. See Paragraph 3.O1E.
5. Vertical Concrete in Water Containment Areas. Rubbed finish on
exposed surfaces and extending to 2 feet below normal operating water
level: Rough form finish on the remainder of submerged areas. See
Paragraphs 3.01E and 3.01D.
6. Interior and Exterior Underside of Concrete Exposed to View: Rubbed
finish. See Paragraph 3.O1E.
7. Exterior surfaces exposed to view and indicated to have an abrasive blast
finish. See Paragraph 3.01F.
03720-048-01 03360-8 CONCRETE FINISHES
August 2019
8. Interior or Exterior Horizontal Concrete not Requiring Floor Hardener or
Sealer: Floated finish. See Paragraph 3.02A.
9. Concrete for Exterior Walks and Interior and Exterior Stairs: Broomed
finish perpendicular to direction of traffic. See Paragraph 3.02B.
10. Concrete Slabs On Which Process Liquids Flow or In Contact with
Sludge: Steel trowel finish. See Paragraph 3.02C.
11. Concrete to Receive Hardener: See Paragraph 3.02D.
12. Concrete tank bottoms to be covered with grout: See Section 03600,
Grout.
END OF SECTION
03720-048-01 03360-9 CONCRETE FINISHES
August 2019
SECTION 03600
GROUT
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish all labor, materials, equipment, and incidentals
required and install grout complete as shown on the Drawings and as specified in
this Section.
1.02 RELATED WORK
A. Section 03100, Concrete Formwork.
B. Section 03200, Concrete Reinforcement.
C. Section 03250, Concrete Joints and Joint Accessories.
D. Section 03300, Cast -In -Place Concrete.
E. Section 05500, Metal Fabrications.
1.03 SUBMITTALS
A. The Contractor shall submit shop drawings in accordance with Section 01330,
Submittals and Acceptance:
1. Commercially manufactured nonshrink cementitious grout. The submittal
shall include catalog cuts, technical data, storage requirements, product
life, working time after mixing, temperature considerations, conformity to
required ASTM standards, and Material Safety Data Sheet.
2. Commercially manufactured nonshrink epoxy grout. The submittal shall
include catalog cuts, technical data, storage requirements, product life,
working time after mixing, temperature considerations, conformity to
required ASTM standards, and Material Safety Data Sheet.
3. Cement grout. The submittal shall include the type and brand of the
cement, the gradation of the fine aggregate, product data on any proposed
admixtures, and the proposed mix of the grout.
4. Concrete grout. The submittal shall include data as required for concrete
as delineated in Section 03300, Cast -In -Place Concrete, and for fiber
reinforcement as delineated in Section 03200, Concrete Reinforcement.
This includes the mix design, constituent quantities per cubic yard, and the
water/cement ratio.
B. Laboratory Test Reports: Submit laboratory test data as required under
Section 03300, Cast -In -Place Concrete, for concrete to be used as concrete grout.
03720-048-01 03600-1 GROUT
August 2019
C. Certifications: Certify that commercially manufactured grout products and
concrete grout admixtures are suitable for use in contact with potable water after
30 days curing.
D. Qualifications: Grout manufacturers shall submit documentation that they have at
least 10 years experience in the production and use of the proposed grouts which
they will supply.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be in
accordance with the currently effective Florida Building Code (FBC). The following documents
are a part of this Section. Where this Section differs from these documents, the requirements of
this Section shall apply.
A. American Society for Testing and Materials (ASTM)
1. ASTM C33/C33M—Standard Specification for Concrete Aggregates.
2. ASTM C 150/C 150M—Standard Specification for Portland Cement.
3. ASTM C531—Standard Test Method for Linear Shrinkage and
Coefficient of Thermal Expansion of Chemical -Resistant Mortars, Grouts,
Monolithic Surfacings, and Polymer Concretes.
4. ASTM C579—Standard Test Methods for Compressive Strength of
Chemical -Resistant Mortars, Grouts, Monolithic Surfacings, and Polymer
Concretes.
5. ASTM C827/C827M—Standard Test Method for Change in Height at
Early Ages of Cylindrical Specimens of Cementitious Mixtures.
6. ASTM C1107/C 1107M—Standard Specification for Packaged Dry,
Hydraulic -Cement Grout (Nonshrink).
7. ASTM D695—Standard Test Method for Compressive Properties of Rigid
Plastics.
B. US Army Corps of Engineers Standard (CRD)
1. CRD C-621—Corps of Engineers Specification for Non -Shrink Grout.
03720-048-01 03600-2 GROUT
August 2019
1.06 QUALITY ASSURANCE
A. Pre -installation Conference
1. Well in advance of grouting, the Contractor shall hold a pre -installation
meeting to review the requirements for surface preparation, mixing,
placing, and curing procedures for each product proposed for use. Parties
concerned with grouting shall be notified of the meeting at least 10 days
before its scheduled date.
13. Services of Manufacturer's Representative
1. A qualified field technician of the nonshrink grout manufacturer,
specifically trained in installing the products, shall attend the pre-
installation conference and shall be present for the initial installation of
each type of nonshrink grout. Additional services shall also be provided as
required to correct installation problems.
C. Field Testing
1. All field testing and inspection services required shall be provided by the
Owner. The Contractor shall assist in the sampling of materials and shall
provide any ladders, platforms, etc., for access to the work. The methods
of testing shall comply in detail with the applicable ASTM Standards.
2. The field testing of concrete grout shall be as specified for concrete in
Section 03300, Cast -In -Place Concrete.
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
B. Deliver materials to the jobsite in original, unopened packages, clearly labeled
with the manufacturer's name, product identification, batch numbers, and printed
instructions.
C. Store materials in full compliance with the manufacturer's recommendations.
Total storage time from the date of manufacture to the date of installation shall be
03720-048-01
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03600-3 GROUT
limited to 6 months or the manufacturer's recommended storage time, whichever
is less.
D. Material which becomes damp or otherwise unacceptable shall be immediately
removed from the site and replaced with acceptable material at no additional
expense to the Owner.
E. Nonshrink-cement-based grouts shall be delivered as preblended, prepackaged
mixes requiring only the addition of water.
F. Nonshrink epoxy grouts shall be delivered as premeasured, prepackaged, three -
component systems requiring only blending as directed by the manufacturer.
1.09 QUALIFICATIONS
A. The grout manufacturer shall have a minimum of 10 years experience in the
production and use of the type of grout proposed for the work.
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 WEATHER CONSTRAINTS (NOT USED)
1.12 DEFINITIONS
A. Nonshrink Grout: A commercially manufactured product that does not shrink in
either the plastic or hardened state, is dimensionally stable in the hardened state,
and bonds to a clean base plate.
PART 2 PRODUCTS
2.01 GENERAL
A. The use of a manufacturer's name and product or catalog number is to establish
the standard of quality desired.
B. To standardize appearance, like materials shall be the products of one
manufacturer or supplier.
2.02 MATERIALS
A. Nonshrink Cementitious Grout
1. Nonshrink cementitious grouts shall meet or exceed the requirements of
ASTM C 1107/C 1107M, Grades B or C and CRD C-621. Grouts shall be
03720-048-01 03600-4 GROUT
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Portland -cement based, contain a pre -proportioned blend of selected
aggregates and shrinkage compensating agents, and shall require only the
addition of water. Nonshrink cementitious grouts shall not contain
expansive cement or metallic particles. The grouts shall exhibit no
shrinkage when tested in conformity with ASTM C827/C827M.
a. General purpose nonshrink cementitious grout shall conform to the
standards stated above and shall be SikaGrout 212 by Sika Corp.;
Set Grout by Master Builders, Inc.; Gilco Construction Grout by
Gifford Hill & Co.; Euco NS by The Euclid Chemical Co.; NBEC
Grout by U. S. Grout Corp.; or equal.
b. Flowable (Precision) nonshrink cementitious grout shall conform
to the standards stated above and shall be Masterflow 928 by
Master Builders, Inc.; Hi Flow Grout by the Euclid Chemical Co.;
SikaGrout 212 by Sika Corp.; Supreme Grout by Gifford Hill &
Co.; Five Star Grout by U. S. Grout Corp.; or equal.
B. Nonshrink Epoxy Grout
1. Nonshrink epoxy based grout shall be a pre -proportioned, three -
component, 100% solids system consisting of epoxy resin, hardener, and
blended aggregate. It shall have a compressive strength of 14,000 psi in
7 days when tested in conformity with ASTM D695 and have a maximum
thermal expansion of 30x10-6 when tested in conformity with
ASTM C531. The grout shall be Ceilcote 648 CP by Master Builders Inc.;
Five Star Epoxy Grout by US Grout Corp.; Sikadur 42 Grout Pak by Sika
Corp.; High Strength Epoxy Grout by the Euclid Chemical Co.; or equal.
C. Cement Grout
1. Cement grouts shall be a mixture of one part Portland cement conforming
to ASTM C 150/C 150M, Types I, II, or III and 1 to 2 parts sand
conforming to ASTM C33/C33M with sufficient water to place the grout.
The water content shall be sufficient to impart workability to the grout but
not to the degree that it will allow the grout to flow.
D. Concrete Grout
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1. Concrete grout shall conform to the requirements of Section 03300, Cast -
In -Place Concrete, except as specified in this Section. It shall be
proportioned with cement, coarse and fine aggregates, water, water
reducer, and an air -entraining agent to produce a mix having an average
strength of 2,900 psi at 28 days, or 2,500 psi nominal strength. Coarse
aggregate size shall be 3/8 inch maximum. Slump should not exceed
03600-5 GROUT
5 inches and should be as low as practical yet still retain sufficient
workability.
2. Synthetic reinforcing fibers as specified in Section 03200, Concrete
Reinforcement, shall be added to the concrete grout mix at the rate of
1.5 lb of fibers per cubic yard of grout. Fibers shall be added from the
manufacturer's premeasured bags and according to the manufacturer's
recommendations in a manner which will ensure complete dispersion of
the fiber bundles as single monofilaments within the concrete grout.
E. Water
1. Potable water, free from injurious amounts of oil, acid, alkali, organic
matter, or other deleterious substances.
PART 3 EXECUTION
3.01 PREPARATION
A. Grout shall be placed over cured concrete which has attained its full design
strength unless otherwise approved by the Engineer.
B. Concrete surfaces to receive grout shall be clean and sound, free of ice, frost, dirt,
grease, oil, curing compounds, laitance and paints, and free of all loose material
or foreign matter which may affect the bond or performance of the grout.
C. Roughen concrete surfaces by chipping, sandblasting, or other mechanical means
to ensure bond of the grout to the concrete. Remove loose or broken concrete.
Irregular voids or projecting coarse aggregate need not be removed if they are
sound, free of laitance, and firmly embedded into the parent concrete.
1. Air compressors used to clean surfaces in contact with grout shall be the
oilless type or equipped with an oil trap in the air line to prevent oil from
being blown onto the surface.
D. Remove all loose rust, oil, or other deleterious substances from metal
embedments or bottom of baseplates before installing the grout.
E. Concrete surfaces shall be washed clean and then kept moist for at least 24 hours
before the placing of cementitious or cement grout. Saturation may be achieved
by covering the concrete with saturated burlap bags, using a soaker hose, flooding
the surface, or other method acceptable to the Engineer. Upon completion of the
24-hour period, visible water shall be removed from the surface before grouting.
An adhesive bonding agent should only be used in lieu of surface saturation when
approved by the Engineer for each specific location of grout installation.
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F Epoxy -based grouts do not require the saturation of the concrete substrate.
Surfaces in contact with epoxy grout shall be completely dry before grouting.
G. Construct grout forms or other leak -proof containment as required. Forms shall be
lined or coated with release agents recommended by the grout manufacturer.
Forms shall be of adequate strength, securely anchored in place, and shored to
resist the forces imposed by the grout and its placement.
1. Forms for epoxy grout shall be designed to allow the formation of a
hydraulic head and shall have chamfer strips built into forms.
H. Level and align the structural or equipment bearing plates in accordance with the
structural requirements and the recommendations of the equipment manufacturer.
Equipment shall be supported during alignment and installation of grout by shims,
wedges, blocks, or other approved means. The shims, wedges, and blocking
devices shall be prevented from bonding to the grout by appropriate bond
breaking coatings and removed after grouting unless otherwise approved by the
Engineer.
3.02 INSTALLATION—GENERAL
A. The Contractor shall mix, apply, and cure products in strict compliance with the
manufacturer's recommendations and this Section.
B. Have sufficient manpower and equipment available for rapid and continuous
mixing and placing. Keep all necessary tools and materials ready and close at
hand.
C. Maintain temperatures of the foundation plate, supporting concrete, and grout
between 40 and 90°F during grouting and for at least 24 hours after or as
recommended by the grout manufacturer, whichever is longer. Take precautions
to minimize differential heating or cooling of baseplates and grout during the
curing period.
D. Take special precautions for hot weather or cold weather grouting as
recommended by the manufacturer when ambient temperatures and/or the
temperature of the materials in contact with the grout are outside of the 60 and
90°F range.
E. Install grout in a manner which will preserve the isolation between the elements
on either side of the joint where grout is placed in the vicinity of an expansion or
contraction joint.
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F Reflect all existing underlying expansion, contraction, and construction joints
through the grout.
3.03 INSTALLATION—CEMENT GROUTS AND NONSHRINK CEMENTITIOUS
GROUTS
A. Mix in accordance with the manufacturer's recommendations. Do not add cement,
sand, pea gravel, or admixtures without prior approval by the Engineer.
B. Avoid mixing by hand. Mixing in a mortar mixer (with moving blades) is
recommended. Pre -wet the mixer and empty excess water. Add premeasured
amount of water for mixing, followed by the grout. Begin with the minimum
amount of water recommended by the manufacturer and then add the minimum
additional water required to obtain workability. Do not exceed the manufacturer's
maximum recommended water content.
C. Placements greater than 3 inches deep shall include the addition of clean, washed
pea gravel to the grout mix when approved by the manufacturer. Comply with the
manufacturer's recommendations for the size and amount of aggregate to be
added.
D. Place grout into the designated areas in a manner which will avoid segregation or
entrapment of air. Do not vibrate grout to release air or to consolidate the
material. Placement should proceed in a manner which will ensure the filling of
all spaces and provide full contact between the grout and adjoining surfaces.
Provide grout holes as necessary.
E. Place grout rapidly and continuously to avoid cold joints. Do not place cement
grouts in layers. Do not add additional water to the mix (retemper) after initial
stiffening.
F. Just before the grout reaches its final set, cut back the grout to the substrate at a
45° angle from the lower edge of the bearing plate unless otherwise approved by
the Engineer. Finish this surface with a wood float (brush) finish.
G. Begin curing immediately after form removal, cutback, and finishing. Keep grout
moist and within its recommended placement temperature range for at least
24 hours after placement or longer if recommended by the manufacturer. Saturate
the grout surface by use of wet burlap, soaker hoses, ponding, or other approved
means. Provide sunshades as necessary. If drying winds inhibit the ability of a
given curing method to keep grout moist, erect wind breaks until wind is no
longer a problem or curing is finished.
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3.04 INSTALLATION—NONSHRINK EPDXY GROUTS
A. Mix in accordance with the procedures recommended by the manufacturer. Do
not vary the ratio of components or add solvent to change the consistency of the
grout mix. Do not overmix. Mix full batches only to maintain proper proportions
of resin, hardener, and aggregate.
B. Monitor ambient weather conditions and contact the grout manufacturer for
special placement procedures to be used for temperatures below 60 or above 90°F.
C. Place grout into the designated areas in a manner which will avoid trapping air.
Placement methods shall ensure the filling of all spaces and provide full contact
between the grout and adjoining surfaces. Provide grout holes as necessary.
D. Minimize "shoulder" length (extension of grout horizontally beyond base plate).
In no case shall the shoulder length of the grout be greater than the grout
thickness.
E. Finish grout by puddling to cover all aggregate and provide a smooth finish.
Break bubbles and smooth the top surface of the grout in conformity with the
manufacturer's recommendations.
F. Epoxy grouts are self curing and do not require the application of water. Maintain
the formed grout within its recommended placement temperature range for at least
24 hours after placing, or longer if recommended by the manufacturer.
3.05 INSTALLATION—CONCRETE GROUT
A. Screed underlying concrete to the grade shown on the Drawings. Provide the
surface with a broomed finish, aligned to drain. Protect and keep the surface clean
until placement of concrete grout.
B. Remove the debris and clean the surface by sweeping and vacuuming all dirt and
other foreign materials. Wash the tank slab using a strong jet of water. Flushing
debris into tank drain lines will not be permitted.
C. Saturate the concrete surface for at least 24 hours before placing the concrete
grout. Saturation may be maintained by ponding, by the use or soaker hoses, or by
other methods acceptable to the Engineer. Remove excess water just before
placing the concrete grout. Place a cement slurry immediately ahead of the
concrete grout so that the slurry is moist when the grout is placed. Work the slurry
over the surface with a broom until it is coated with approximately 1/16- to
1/8 -inch -thick cement paste.
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D. Place concrete grout to final grade using the scraper mechanism as a guide for
surface elevation and to ensure that high and low spots are eliminated. Unless
specifically approved by the equipment manufacturer, mechanical scraper
mechanisms shall not be used as a finishing machine or screed.
E. Provide grout contraction joints as indicated on the Drawings.
F. Finish and cure the concrete grout as specified for cast -in-place concrete.
3.06 SCHEDULE
A. The following list indicates where the particular types of grout are to be used:
1. General purpose nonshrink cementitious grout: Use at all locations where
nonshrink grout is called for on the plans except for base plates greater
than 3 feet wide by 3 feet long and, except for the setting of anchor rods,
anchor bolts or reinforcing steel in concrete.
2. Flowable nonshrink cementitious grout: Use under all base plates greater
in area than 3 feet by 3 feet. Use at all locations indicated to receive
flowable nonshrink grout by the Drawings. The Contractor, at his/her
option and convenience, may also substitute flowable nonshrink grout for
general purpose nonshrink cementitious grout.
3. Nonshrink epoxy grout: Use for setting anchor rods, anchor bolts, and
reinforcing steel in concrete and for all locations specifically indicated to
receive epoxy grout.
4. Cement grout: Cement grout may be used for grouting incidental base
plates for structural and miscellaneous steel such as post base plates for
platforms, base plates for beams, etc. It shall not be used when nonshrink
grout is specifically called for on the Drawings or for grouting primary
structural steel members such as columns and girders.
5. Concrete grout: Use for overlaying the base concrete under scraper
mechanisms of clarifiers to allow more control in placing the surface
grade.
END OF SECTION
03720-048-01 03600-10 GROUT
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SECTION 03930
MODIFICATIONS AND REPAIR TO CONCRETE
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish all labor, materials, equipment, and incidentals
required and cut, remove, repair, or otherwise modify parts of existing concrete
structures or appurtenances as shown on the Drawings and as specified in this
Section. Work under this Section shall also include bonding new concrete to
existing concrete.
1.02 RELATED WORK
A. Section 02220, Demolition and Modifications.
B. Section 03100, Concrete Formwork.
C. Section 03200, Concrete Reinforcement.
D. Section 03250, Concrete Joints and Joint Accessories.
E. Section 03300, Cast -In -Place Concrete.
F. Section 03600, Grout.
G. Section 05500, Metal Fabrications.
1.03 SUBMITTALS
A. The Contractor shall submit shop drawings in accordance with Section 01330,
Submittals and Acceptance.
B. Submit to the Engineer, in accordance with Section 01330, Submittals and
Acceptance, a Schedule of Demolition and the detailed methods of demolition to
be used at each location.
C. Submit the manufacturer's technical literature on all product brands proposed for
use to the Engineer for review. The submittal shall include the manufacturer's
installation and/or application instructions.
D. When substitutions for acceptable brands of materials specified in this Section are
proposed, submit brochures and technical data of the proposed substitutions to the
Engineer for approval before delivery to the project.
1.04 WORK SEQUENCE (NOT USED)
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03930-1 MODIFICATIONS AND REPAIR TO CONCRETE
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1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be in
accordance with the currently effective Florida Building Code (FBC). The following documents
are a part of this Section. Where this Section differs from these documents, the requirements of
this Section shall apply.
A. American Society for Testing and Materials (ASTM)
1. ASTM C881/C881M—Standard Specification for Epoxy -Resin -Base
Bonding Systems for Concrete.
2. ASTM C882/C882M—Standard Test Method for Bond Strength of
Epoxy -Resin Systems Used with Concrete by Slant Sheer.
3. ASTM D570—Standard Test Method for Water Absorption of Plastics.
4. ASTM D638—Standard Test Method for Tensile Properties of Plastics.
5. ASTM D695—Standard Test Method for Compressive Properties of Rigid
Plastics.
6. ASTM D732—Standard Test Method for Shear Strength of Plastics by
Punch Tool.
7. ASTM D790—Standard Test Methods for Flexural Properties of
Unreinforced and Reinforced Plastics and Electrical Insulating Materials.
8. ASTM G3—Standard Practice for Conventions Applicable to
Electrochemical Measurements in Corrosion Testing.
1.06 QUALITY ASSURANCE
A. No existing structure or concrete shall be shifted, cut, removed, or otherwise
altered until the Engineer so authorizes.
B. When removing materials or portions of existing structures and when making
openings in existing structures, all precautions shall be taken and all necessary
barriers, shoring and bracing, and other protective devices shall be erected to
prevent damage to the structures beyond the limits necessary for the new work,
protect personnel, control dust, and prevent damage to the structures or contents
by falling or flying debris. Unless otherwise permitted, shown, or specified, line
drilling will be required in cutting existing concrete.
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
B. Manufacturer Qualifications: The manufacturer of the specified products shall
have a minimum of 10 years experience in the manufacture of such products and
03720-048-01 03930-2 MODIFICATIONS AND REPAIR TO CONCRETE
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shall have an ongoing program of training, certifying, and technically supporting
the Contractor's personnel.
C. Contractor Qualifications: The Contractor shall complete a program of instruction
in the application of the approved manufacturer's material specified in this
Section and provide certification from the manufacturer attesting to their training
and status as an approved applicator.
D. Furnish a notarized certificate stating that the materials meet the requirements of
this Section and have the manufacturer's current printed literature on a specified
product.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
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B. Deliver the specified products in original, unopened containers with the
manufacturer's name, labels, product identification, and batch numbers.
C. Store and condition the specified product as recommended by the manufacturer.
1.09 QUALIFICATIONS (NOT USED)
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 WEATHER CONSTRAINTS (NOT USED)
PART 2 PRODUCTS
2.01 MATERIALS
A. General
1. Materials shall comply with this Section and any state or local regulations.
B. Epoxy Bonding Agent
1. General
a. The epoxy bonding agent shall be a two -component, solvent -free,
asbestos -free moisture -insensitive epoxy -resin material used to
bond plastic concrete to hardened concrete complying with the
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requirements of ASTM C881/C881M, Type II, and the additional
requirements specified in this Section.
2. Material
a. Properties of the cured material:
(1) Compressive Strength (ASTM D695): 8,500 psi minimum
at 28 days.
(2) Tensile Strength (ASTM D638): 4,000 psi minimum at
14 days.
(3) Flexural Strength (ASTM D790 Modulus of Rupture):
6,300 psi minimum at 14 days.
(4) Shear Strength (ASTM D732): 5,000 psi minimum at
14 days.
(5) Water Absorption (ASTM D570 2 -hour boil): 1.0%
maximum at 14 days.
(6) Bond Strength (ASTM C882/C882M) Hardened to Plastic:
1,500 psi minimum at 14 days moist cure.
(7) Effective Shrinkage: Passes Test.
(8) Color: Gray.
3. Approved manufacturers include Sika Corporation, Lyndhurst, NJ,
Sikadur 32, Hi Mod; Master Builder's, Cleveland, OH, Concresive Liquid
(LPL); or equal.
C. Epoxy Paste
1. General
a. Epoxy Paste shall be a two -component, solvent -free, asbestos -free,
moisture -insensitive epoxy -resin material used to bond dissimilar
materials to concrete such as setting railing posts, dowels, anchor
bolts, and all threads into hardened concrete and shall comply with
the requirements of ASTM C881/C881M, Type I, Grade 3 and the
additional requirements specified in this Section. It may also be
used to patch existing surfaces where the glue line is 1/8 inch or
less.
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2. Material
a. Properties of the cured material:
(1) Compressive Properties (ASTM D695): 10,000 psi
minimum at 28 days.
(2) Tensile Strength (ASTM D638): 3,000 psi minimum at
14 days. Elongation at Break 0.3% minimum.
(3) Flexural Strength (ASTM D790 Modulus of Rupture):
3,700 psi minimum at 14 days.
(4) Shear Strength (ASTM D732): 2,800 psi minimum at
14 days.
(5) Water Absorption (ASTM D570): 1.0% maximum at
7 days.
(6) Bond Strength (ASTM C882/C882M): 2,000 psi at 14 days
moist cure.
(7) Color: Concrete grey.
3. Approved manufacturers include:
a. Overhead applications: Sika Corporation, Lyndhurst, NJ, Sikadur
Hi Mod LV 31; Master Builders, Inc., Cleveland, OH, Concresive
1438; or equal.
b. Sika Corporation, Lyndhurst, NJ, Sikadur Hi Mod LV 32; Master
Builders, Inc., Cleveland, OH, Concresive 1438; or equal.
D. Non -Shrink Precision Cement Grout, Non -Shrink Cement Grout, Non -Shrink
Epoxy Grout and Polymer Modified mortar are included in Section 03600, Grout.
E. Adhesive -capsule -type anchor system shall be equal to the HVA adhesive
Anchoring System by Hilti Fastening Systems, Tulsa, OK. The capsule shall
consist of a sealed glass capsule containing premeasured amounts of a polyester
or vinylester resin, quartz sand aggregate, and a hardener contained in a separate
vial in the capsule.
F. Acrylic Latex Bonding Agent
G. Crack Repair Epoxy Adhesive
1. General
a. Crack Repair Epoxy Adhesive shall be a two -component, solvent -
free, moisture -insensitive epoxy -resin material suitable for crack
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grouting by injection or gravity feed. It shall be formulated for the
specific size of opening or crack being injected.
b. All concrete surfaces containing potable water or water to be
treated for potable use that are repaired by the epoxy adhesive
injection system shall be coated with an acceptable epoxy coating
approved by the FDA for use in contact with potable water.
2. Material
a. Properties of the cured material
(1) Compressive Properties (ASTM D695): 10,000 psi
minimum at 28 days.
(2) Tensile Strength (ASTM D638): 5,300 psi minimum at
14 days. Elongation at Break 2 to 5%.
(3) Flexural Strength (ASTM D790 Modulus of Rupture):
12,000 psi minimum at 14 days (gravity); 4,600 psi
minimum at 14 days (injection)
(4) Shear Strength (ASTM D732): 3,700 psi minimum at
14 days.
(5) Water Absorption (ASTM D570 2 -hour boil): 1.5%
maximum at 7 days.
(6) Bond Strength (ASTM C882/C882M): 2,400 psi at 2 days
dry; 2,000 psi at 14 days dry plus 12 days moist.
(7) Effective Shrinkage: Passes Test.
3. Approved manufacturers include:
a. For standard applications: Sika Corporation, Lyndhurst, NJ,
Sikadur Hi Mod; BASF, Masterinject 1500, or equal.
b. For very thin applications: Sika Corporation, Lyndhurst, NJ,
Sikadur Hi Mod LV; Master Builders Inc., Cleveland, OH,
Concresive 1468 or equal.
H. Polymer -Modified Portland Cement Mortar (Vertical and Overhead Surfaces)
1. The polymer -modified Portland cement mortar shall be a two -component,
polymer -modified, Portland cement fast -setting, non -sag mortar with a
migrating corrosion inhibitor.
2. Component A shall be a liquid polymer emulsion of an acrylic copolymer
base and additives. It shall have a particle size of less than 0.1 micron.
3. Component A shall contain an organic, migrating corrosion inhibitor,
which has been independently proven to reduce corrosion in concrete via
ASTM G3 (half -cell potential tests). The corrosion inhibitor shall not be
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calcium nitrate and shall have a minimum of 7 years of independent field
testing to document performance on actual construction projects.
4. Component B shall be a blend of selected Portland cements, specially
graded aggregates, admixtures for controlling setting time, water reducers
for workability, and accelerators.
5. The ratio of Component A: Component B shall be 1:5:2 by weight.
6. The polymer -modified Portland cement mortar shall be placeable from
1/8- to 1 -1/2 -inch depth per lift.
7. Aggregate to extend the polymer -modified Portland cement mortar shall
be a minus 1/2- or 3/8 -inch clean, well -graded, saturated surface dry
material having low absorption and high density in conformance with the
manufacturer's requirements.
8. Approved manufacturers include Sika Corporation, Lyndhurst, NJ —
Sikatop 123 plus.
I. Polymer -Modified Portland Cement Mortar (Horizontal Surfaces)
1. The polymer -modified Portland cement mortar shall be a two -component,
polymer -modified, Portland cement fast -setting, non -sag mortar with a
migrating corrosion inhibitor.
2. Component A shall be a liquid polymer emulsion of an acrylic copolymer
base and additives. It shall have a particle size of less than 0.1 micron.
3. Component A shall contain an organic, migrating corrosion inhibitor,
which has been independently proven to reduce corrosion in concrete via
ASTM G3 (half -cell potential tests). The corrosion inhibitor shall not be
calcium nitrate and shall have a minimum of seven tests. The corrosion
inhibitor shall not be calcium nitrate and shall have a minimum of 7 years
of independent field testing to document performance on actual
construction projects.
4. Component B shall be a blend of selected Portland cements, specially
graded aggregates, admixtures for controlling setting time, water reducers
for workability, and accelerators.
5. The ratio of Component A: Component B shall be 1:7:2 by weight.
6. The polymer -modified Portland cement mortar shall be placeable from a
1/8 -inch to 1 -inch depth per lift.
7. Aggregate to extend the polymer -modified Portland cement mortar shall
be a minus 1/2- or 3/8 -inch clean, well -graded, saturated surface dry
material having low absorption and high density in conformance with the
manufacturer's requirements.
8. Approved manufacturers include Sika Corporation, Lyndhurst, NJ,
Sikatop 122 plus.
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PART 3 EXECUTION
3.01 GENERAL
A. In all cases where concrete is repaired in the vicinity of an expansion joint or
contraction joint the repairs shall be made to preserve the isolation between
components on either side of the joint.
B. When drilling holes for dowels/bolts at new or existing concrete, drilling shall
stop if rebar is encountered. As approved by the Engineer, the hole location shall
be relocated to avoid rebar. Rebar shall not be cut without prior approval by the
Engineer. Where possible, rebar locations shall be identified before drilling using
"rebar locators" so that drilled hole locations may be adjusted to avoid rebar
interference.
3.02 CONCRETE REMOVAL
A. Concrete designated to be removed to specific limits as shown on the Drawings or
directed by the Engineer shall be done by line drilling at limits followed by
chipping or jack hammering as appropriate in areas where concrete is to be taken
out. Remove concrete in such a manner that surrounding concrete or existing
reinforcing to be left in place and existing in-place equipment is not damaged.
Sawcutting at limits of concrete to be removed shall only be done if indicated on
the Drawings or after obtaining written approval from the Engineer.
B. Where existing reinforcing is exposed due to saw cutting/core drilling and no new
material is to be placed on the sawcut surface, a coating or surface treatment of
epoxy paste shall be applied to the entire cut surface to a thickness of 1/4 inch.
C. In all cases where the joint between new concrete or grout and existing concrete
will be exposed in the finished work, except as otherwise shown or specified, the
edge of concrete removal shall be a 1 -inch -deep saw cut on each exposed surface
of the existing concrete.
D. Concrete specified to be left in place which is damaged shall be repaired by
approved means to the satisfaction of the Engineer.
E. The Engineer may from time to time direct the Contractor to make additional
repairs to existing concrete. These repairs shall be made as specified or by such
other methods as may be appropriate.
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3.03 CONNECTION SURFACE PREPARATION '
A. Connection surfaces shall be prepared as specified below for concrete areas
requiring patching, repairs, or modifications as shown on the Drawings, specified
in this Section, or as directed by the Engineer.
B. Remove all deteriorated materials, dirt, oil, grease, and all other bond -inhibiting
materials from the surface by dry mechanical means, i.e. sandblasting, grinding,
etc., as approved by the Engineer. Be sure the areas are not less than 1/2 inch
deep. Irregular voids or surface stones need not be removed if they are sound, free
of laitance, and firmly embedded into parent concrete, subject to the Engineer's
final inspection.
C. If reinforcing steel is exposed, it must be mechanically cleaned to remove all
contaminants, rust, etc., as approved by the Engineer. If half of the diameter of the
reinforcing steel is exposed, chip out behind the steel. The distance chipped
behind the steel shall be a minimum of 1/2 inch. Reinforcing to be saved shall not
be damaged during the demolition operation.
D. Reinforcing from existing demolished concrete which is shown to be incorporated
in new concrete shall be cleaned by mechanical means to remove all loose
material and products of corrosion before proceeding with the repair. It shall be
cut, bent, or lapped to new reinforcing as shown on the Drawings and provided
with 1 -inch minimum cover all around.
E. The following are specific concrete surface preparation "methods" to be used
where called for on the Drawings, specified in this Section, or as directed by the
Engineer.
1. Method A: After the existing concrete surface at connection has been
roughened and cleaned, thoroughly moisten the existing surface with
water. Brush on a 1/16 -inch layer of cement and water mixed to the
consistency of a heavy paste. Immediately after applying the cement paste,
place new concrete or grout mixture as detailed on the Drawings.
2. Method B: After the concrete surface has been roughened and cleaned,
apply an epoxy bonding agent at connection surface. The field preparation
and application of the epoxy bonding agent shall comply strictly with the
manufacturer's recommendations. Place new concrete or grout mixture to
limits shown on the Drawings within time constraints recommended by
the manufacturer to ensure bond.
3. Method C: Drill a hole 1/4 inch larger than the diameter of the dowel. The
hole shall be blown clear of loose particles and dust just before installing
epoxy. The drilled hole shall first be filled with [epoxy paste], then
dowels/bolts shall be buttered with paste and inserted by tapping. Unless
03720-048-01 03930-9 MODIFICATIONS AND REPAIR TO CONCRETE
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otherwise shown on the Drawings, deformed bars shall be drilled and set
to a depth of 10 bar diameters and smooth bars shall be drilled and set to a
depth of 15 bar diameters. If not noted on the Drawings, the Engineer will
provide details regarding the size and spacing of dowels.
4. Method D: Combination of Methods B and C.
5. Method E: The capsule anchor system shall be set in existing concrete by
drilling holes to the required depth to develop the full tensile and shear
strengths of the anchor material being used. The anchor bolts system shall
be installed according to the manufacturer's recommendation in holes
sized as required. The anchor stud bolt, rebar, or other embedment item
shall be tipped with a double 45° chamfered point, securely fastened into
the chuck of all rotary percussion hammer drill and drilled into the
capsule -filled hole. The anchor may be installed in horizontal, vertical,
and overhead positions.
3.04 GROUTING
A. Grouting shall be as specified in Section 03600, Grout.
3.05 CRACK REPAIR
A. Cracks on horizontal surfaces shall be repaired by gravity feeding crack sealant
into cracks according to the manufacturer's recommendations. If cracks are less
than 1/16 -inch thick they shall be pressure injected.
B. Cracks on vertical surfaces shall be repaired by pressure injecting crack sealant
through valves sealed to the surface with crack repair epoxy adhesive according to
the manufacturer's recommendations.
3.06 CONCRETE SURFACE REPAIR AND/OR EXPOSED REINFORCING REPAIR
A. All loose, unsound (delaminated), and deteriorated concrete shall be removed by
mechanical means.
B. Saw cut the perimeter of unsound (delaminated) concrete to form a rectangle with
straight edges to a depth of 3/4 inch or to the top of the reinforcing, whichever is
shallower. Do not cut reinforcing unless otherwise noted.
C. Chip concrete substrate to obtain a surface profile with new fractured -aggregate
surface.
D. The depth of repair shall be not less than the performance criteria of the specific
product used.
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E. Where reinforcing steel with active corrosion is encountered, the procedure shall
be as follows:
1. Remove all contaminants and rust from exposed reinforcing steel.
2. When half of the diameter of the rebar is exposed, chip out behind the
reinforcing steel, 1 inch minimum.
3. The distance chipped behind the rebar shall be equal to or exceed the
minimum placement depth of the material to be used or as indicated on the
Drawings.
4. Bars shown to remain in place which are found to have lost more than
15% class sectional area due to corrosion or which are damaged by the
concrete removal process so that their cross-sectional area has been
reduced by more than 15% shall be replaced with new bars.
F. Cracks encountered in the substrate in the area of the patch area shall be treated as
approved by the Engineer.
G. Substrate may be dry or damp but free of standing water.
H. Remove dust, laitance, and any foreign particles.
I. Spray apply mixed epoxy resin adhesive on the prepared area to receive the
Portland cement mortar or concrete in strict compliance with the manufacturer's
recommendations.
J. While the adhesive coat is still wet (before it is tack -free to the touch) apply
polymer -modified cement. The edges shall be vertical and straight.
K. For applications greater than 1 inch in depth, apply polymer -modified cement in
lifts. Score the top lifts of each lift to produce a roughened surface before
applying the next lift. Allow the lift to reach final set before proceeding with the
next lift. Adhesive coat shall be applied between each lift.
3.07 INSPECTION
A. At the completion of all repairs, the Contractor, Engineer, and Installers of the
material used on the repairs shall inspect the work.
03720-048-01
August 2019
END OF SECTION
03930-11 MODIFICATIONS AND REPAIR TO CONCRETE
DIVISION 5
METALS
1
SECTION 05500 1
METAL FABRICATIONS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. This Section includes the following:
1. Loose bearing and leveling plates.
2. Shelf and relieving angles.
3. Miscellaneous framing and supports.
4. Stair nosings.
5. Gratings.
B. Products furnished, but not installed, under this Section include the following:
1. Anchor bolts, steel pipe sleeves, and wedge -type inserts indicated to be
cast into concrete or built into unit masonry.
1.02 RELATED WORK
A. Section 01330, Submittals and Acceptance.
B. Section 01650, Delivery, Storage, and Handling.
C. Section 01780, Warranties and Bonds.
1.03 SUBMITTALS
The Contractor shall submit shop drawings in accordance with Section 01330, Submittals and
Acceptance:
A. Product Data: For the following:
1. Non -slip aggregates and non -slip -aggregate surface finishes.
2. Prefabricated building columns.
3. Metal nosings and treads.
4. Paint products.
5. Grout.
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.
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2. Provide templates for anchors and bolts specified for installation under
other sections.
3. For installed products indicated to comply with design loads, include
structural analysis data signed and sealed by the qualified professional
engineer responsible for their preparation.
C. Samples for Verification: For each type and finish of extruded nosing.
D. Mill Certificates: Signed by the manufacturers of stainless-steel sheet certifying
that products furnished comply with requirements.
E. Welding certificates.
F. Qualification Data: Florida Professional Engineering Registration certificate.
1.04 WORK SEQUENCE
A. The Contractor shall coordinate the installation of anchorages for metal
fabrications. 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 the Project site in time for installation.
B. The Contractor shall coordinate the installation of steel weld plates and angles for
casting into concrete that are specified in this Section but required for work of
another section. Deliver such items to the Project site in time for installation.
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be in
accordance with the currently effective Florida Building Code (FBC). The following documents
are a part of this Section. Where this Section differs from these documents, the requirements of
this Section shall apply.
A. American National Standards Institute (ANSI)
1. ANSUASC A14.3—Ladders – Fixed – Safety Requirements.
B. American Society for Testing and Materials (ASTM)
1. ASTM A27/A27M—Standard Specification for Steel Castings, Carbon,
for General Application.
2. ASTM A36/A36M—Standard Specification for Carbon Structural Steel.
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3. ASTM A47/A47M—Standard Specification for Ferritic Malleable Iron
Castings.
4. ASTM A48/A48M—Standard Specification for Gray Iron Castings.
5. ASTM A53/A53M—Standard Specification for Pipe, Steel, Black and
Hot -Dipped, Zinc -Coated, Welded and Seamless.
6. ASTM A123/A123M—Standard Specification for Zinc (Hot -Dip
Galvanized) Coatings on Iron and Steel Products.
7. ASTM A153/A153M—Standard Specification for Zinc Coating (Hot -Dip)
on Iron and Steel Hardware.
8. ASTM A276/A276M—Standard Specification for Stainless Steel Bars and
Shapes.
9. ASTM A307—Standard Specification for Carbon Steel Bolts, Studs, and
Threaded Rod 60,000 PSI Tensile Strength.
10. ASTM A489—Standard Specification for Carbon Steel Eyebolts.
11. ASTM A500/A500M—Standard Specification for Cold -Formed Welded
and Seamless Carbon Steel Structural Tubing in Rounds and Shapes.
12. ASTM A563—Standard Specification for Carbon and Alloy Steel Nuts.
13. ASTM A653/A653M—Standard Specification for Steel Sheet, Zinc -
Coated (Galvanized) or Zinc -Iron Alloy -Coated (Galvannealed) by the
Hot -Dip Process.
14. ASTM A666—Standard Specification for Annealed or Cold -Worked
Austenitic Stainless Steel Sheet, Strip, Plate, and Flat Bar.
15. ASTM A780/A780M—Standard Practice for Repair of Damaged and
Uncoated Areas of Hot -Dip Galvanized Coatings.
16. ASTM A786/A786M—Standard Specification for Hot -Rolled Carbon,
Low -Alloy, High -Strength Low -Alloy, and Alloy Steel Floor Plates.
17. ASTM B108/B108M—Standard Specification for Aluminum -Alloy
Permanent Mold Castings.
18. ASTM B209—Standard Specification for Aluminum and Aluminum -
Alloy Sheet and Plate.
19. ASTM B221—Standard Specification for Aluminum and Aluminum -
Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes.
20. ASTM B633—Standard Specification for Electrodeposited Coatings of
Zinc on Iron and Steel.
21. ASTM C 1107/C 1107M—Standard Specification for Packaged Dry,
Hydraulic -Cement Grout (Nonshrink).
22. ASTM Di187/D 1187M—Standard Specification for Asphalt -Base
Emulsions for Use as Protective Coatings for Metal.
23. ASTM E488/E488M—Standard Test Methods for Strength of Anchors in
Concrete Elements.
24. ASTM F436/F436M—Standard Specification for Hardened Steel Washers
Inch and Metric Dimensions.
25. ASTM F593—Standard Specification for Stainless Steel Bolts, Hex Cap
Screws, and Studs.
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August 2019
26. ASTM F594—Standard Specification for Stainless Steel Nuts.
27. ASTM F836M—Standard Specification for Style 1 Stainless Steel Metric
Nuts (Metric).
28. ASTM F879—Standard Specification for Stainless Steel Socket Button
and Flat Countersunk Head Cap Screws.
29. ASTM F1554—Standard Specification for Anchor Bolts, Steel, 36, 55,
and 105-ksi Yield Strength.
30. ASTM F3125/F3125M—Standard Specification for High Strength
Structural Bolts, Steel and Alloy Steel, Heat Treated, 120 ksi (830 MPa)
and 150 ksi (1,040 MPa) Minimum Tensile Strength, Inch and Metric
Dimensions.
C. American Society of Mechanical Engineers (ASME)
1. ASME B18.2.1—Square, Hex, Heavy Hex, and Askew Head Bolts and
Hex, Heavy Hex, Hex Flange, Lobed Head, and Lag Screws (Inch Series).
2. ASME B18.6.1—Wood Screws (Inch Series).
3. ASME B18.6.3—Machine Screws, Tapping Screws, and Metallic Drive
Screws (Inch Series).
4. ASME B18.6.7M—Metric Machine Screws.
5. ASME B 18.21.1—Washers: Helical Spring -Lock, Tooth Lock, and Plain
Washers (Inch Series).
6. ASME B18.21.2M—Lock Washers (Metric Series).
7. ASME B18.22M—Metric Plain Washers.
D. American Welding Society (AWS)
1. AWS D1.1/D1.1M-
2. AWS D1.2/D1.2M-
3. AWS D1.3/D1.3M-
4. AWS D1.6/D1.6M—
Structural Welding Code –
Structural Welding Code –
Structural Welding Code –
Structural Welding Code –
Steel.
Aluminum.
Sheet Steel.
Stainless Steel.
E. Environmental Protection Agency (EPA)
1. EPA Method 24—Surface Coatings.
F. Federal Regulations (FR)
1. 40 CFR 59—National Volatile Organic Compound Emission Standards
for Consumer and Commercial Products.
G. National Association of Architectural Metal Manufacturers (NAAMM)
1. NAAMM MBG 531—Metal Bar Grating Manual.
05500-4
03720-048-01
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METAL FABRICATIONS
H. Society for Protection Coatings (SSPC)
1. SSPC-PAI—Shop, Field, and Maintenance Painting of Steel.
2. SSPC-SP6/NACE No. 3—Commercial Blast Cleaning.
3. SSPC-SP1O/NACE No. 2—Near-White Blast Cleaning.
4. SSPC-Paint 20—Zinc-Rich Coating Inorganic and Organic.
5. SSPC-Paint 29—Zinc Dust Sacrificial Primer, Performance -Based.
6. SSPC-Zone 1A—Interior, Normally Dry.
7. SSPC-Zone 1B Exterior, Normally Dry.
1.06 QUALITY ASSURANCE
A. Welding: Qualify procedures and personnel according to the following:
1. AWS D 1.1 /D 1.1 M, Structural Welding Code – Steel.
2. AWS D1.2/D1.2M, Structural Welding Code – Aluminum.
3. AWS D1.3/D1.3M, Structural Welding Code – Sheet Steel.
4. AWS D1.6/D1.6M, Structural Welding Code – Stainless Steel.
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
1.09 QUALIFICATIONS (NOT USED)
1.10 PROJECT REQUIREMENTS
A. Structural Performance of Ladders: The Contractor shall provide ladders capable
of withstanding the effects of loads and stresses within limits and under
conditions specified in ANSUASC A14.3.
B. Thermal Movements: Provide exterior metal fabrications that allow for thermal
movements resulting from the following maximum change (range) in ambient and
surface temperatures by preventing buckling, opening of joints, overstressing of
components, failure of connections, and other detrimental effects. Base
03720-048-01 05500-5 METAL FABRICATIONS
August 2019
engineering calculation on surface temperatures of materials due to both solar
heat gain and nighttime -sky heat loss.
1. Temperature Change (Range): 120°F, ambient; 180°F, material surfaces.
1.11 PROJECT CONDITIONS
A. Field Measurements: The Contractor shall verify actual locations of walls and
other construction contiguous with metal fabrications by field measurements
before fabrication and indicate measurements on shop drawings.
1. Established Dimensions: Where field measurements cannot be made
without delaying the Work, establish dimensions and proceed with
fabricating metal fabrications without field measurements. Coordinate
wall and other contiguous construction to ensure that actual dimensions
correspond to established dimensions.
2. Provide allowance for trimming and fitting at site.
PART 2 PRODUCTS
2.01 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.
2.02 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.
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2.03 FERROUS METALS
A. Steel Plates, Shapes, and Bars: ASTM A36/A36M.
1. Unless noted otherwise, steel that is not stainless steel shall be galvanized
with a G90 coating conforming to ASTM A123/A123M.
B. Stainless -Steel Sheet, Strip, Plate, and Flat Bars: ASTM A666, Type 316L.
C. Stainless -Steel Bars and Shapes: ASTM A276/A276M, Type 316L.
D. Steel Tubing: ASTM A500/A500M, cold -formed steel tubing.
E. Steel Pipe: ASTM A53/A53M, standard weight (Schedule 40), unless another
weight is indicated or required by structural loads.
2.04 ALUMINUM ALLOY PRODUCTS
A. Aluminum Sheet Plates: Conforming to ASTM B209.
B. Aluminum Extrusions: Conforming to ASTM B221.
C. Aluminum Castings: Conforming to ASTM B108/B108M.
2.05 FASTENERS
A. General: For all exterior applications and where fastening aluminum, provide
Type 304 stainless-steel fasteners. Provide hot -dipped galvanized fasteners in all
other applications in accordance with ASTM A153/A153M unless noted
otherwise on the Project Specifications or Contract Drawings. Select fasteners for
type, grade, and class required.
B. High -Strength Bolts and Nuts: ASTM F3125/F3125M with heavy hex nuts
ASTM A563 and hardened carbon -steel washers ASTM F436/F436M.
C. Steel Bolts and Nuts: Regular hexagon -head bolts, ASTM A307, Grade A; with
hex nuts, ASTM A563 (ASTM A563M); and, where indicated, flat washers.
D. Stainless -Steel Bolts and Nuts: Regular hexagon -head annealed stainless-steel
bolts, nuts, and flat washers; ASTM F593 for bolts and ASTM F594 for nuts,
Alloy Group A4.
E. Stainless Steel Socket Button and Flat Countersunk Head Cap Screws: ASTM
F879.
F. Anchor Bolts: ASTM F 1554, Grade 36.
03720-048-01 05500-7 METAL FABRICATIONS
August 2019
G. Eyebolts: ASTM A489.
H. Machine Screws: ASME B18.6.3 (ASME B18.6.7M).
I. Lag Bolts: ASME B18.2.1.
J. Wood Screws: Flat head, ASME B18.6.1.
K. Plain Washers: Round, ASME B18.22.1 (ASME B18.22M).
L. Lock Washers: Helical, spring type, ASME B18.21.1 (ASME B18.21.2M).
M. Expansion Anchors: Anchor bolt and sleeve assembly with ability to sustain,
without failure, a load equal to six times the load imposed when installed in unit
masonry and four times the load imposed when installed in concrete, as
determined by testing according to ASTM E488/E488M conducted by a qualified
independent testing agency.
1. Material for Anchors in Interior Locations: Carbon -steel components zinc -
plated to comply with ASTM B633, Class Fe/Zn 5.
2. Material for Anchors in Exterior Locations: Alloy Group (A4) stainless-
steel bolts complying with ASTM F593 and nuts complying with
ASTM F594 (ASTM F836M).
2.06 MISCELLANEOUS MATERIALS
A. Welding Rods and Bare Electrodes: Select according to AWS specifications for
metal alloy welded.
B. Shop Primers: Provide primers that comply with Division 9.
C. Zinc -Rich Primer: Complying with SSPC-Paint 20 or SSPC-Paint 29 and
compatible with topcoat.
1. Use primer with a VOC content of 3.5 lb/gal or less when calculated
according to 40 CFR 59, Subpart D (EPA Method 24).
2. Available Products:
a. Benjamin Moore & Co.; Epoxy Zinc -Rich Primer CM18/19.
b. Carboline Company; Carbozinc 621.
c. ICI Devoe Coatings; Catha-Coat 313.
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d. International Coatings Limited; Interzinc 315 Epoxy Zinc -Rich
Primer.
e. PPG Architectural Finishes, Inc.; Aquapon Zinc -Rich
Primer 97-670.
f. Sherwin-Williams Company (The); Corothane I GalvaPac Zinc
Primer.
g. Tnemec Company, Inc.; Tneme-Zinc 90-97.
D. Bituminous Paint: Cold -applied asphalt emulsion complying with
ASTM D1187/D1187M.
E. Galvanizing Repair Paint: High -zinc -dust -content paint for regalvanizing welds in
steel, complying with SSPC-Paint 20.
F. Nonshrink, Metallic Grout: Factory -packaged, ferrous -aggregate grout complying
with ASTM C 1107/C 1107M, specifically recommended by the manufacturer for
heavy-duty loading applications.
G. Nonshrink, Nonmetallic Grout: Factory -packaged, nonstaining, noncorrosive,
nongaseous grout complying with ASTM C 1107/C 1107M. Provide grout
specifically recommended by the manufacturer for interior and exterior
applications.
2.07 FABRICATION, GENERAL
A. Shop Assembly: Preassemble items in the shop to the 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, unless otherwise indicated. Remove sharp
or rough areas on exposed surfaces.
C. Form bent -metal corners to the smallest radius possible without causing grain
separation or otherwise impairing work.
D. Form exposed work true to line and level with accurate angles, 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.
03720-048-01 05500-9 METAL FABRICATIONS
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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.
F. Form exposed connections with hairline joints, flush and smooth, using concealed
fasteners where possible. Where exposed fasteners are required, use Phillips flat-
head (countersunk) screws or bolts, unless otherwise indicated. Locate joints
where least conspicuous.
G. Fabricate seams and other connections that will be exposed to weather so as 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 the type indicated and 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 inch by 1-1/2 inches
with a minimum 6 -inch embedment and 2 -inch hook, not less than
8 inches from ends and corners of units and 24 inches o.c., unless
otherwise indicated.
2.08 GRATINGS
Floor gratings shall be designed to withstand a live load of 250 pounds per square foot for the
span indicated, with a maximum deflection of L/240 in locations as shown in the Contract
Drawings.
A. Gray Cast Iron -Gratings: Conforming to ASTM A48/A48M.
B. Metal Plank Gratings: Non -slip type, aluminum conforming to ASTM B209, 6061
T6, and steel conforming to ASTM A653/A653M, G90 galvanized.
C. Metal Bar Gratings: Conforming to NAAMM MBG 531.
D. Aluminum grating material shall be aluminum alloy 6063-T6 with a mill finish.
Cross bars shall be attached to the bearing bars with interlocked swaged joints.
The grating shall be Type BS by IKG Borden, Houston, TX; Type 19 SG -4 by
Ohio Gratings, Inc., Canton, OH; Type 19S4 by Seidelhuber Metal Products, San
Carlos, CA; or equal.
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2.09 PATTERNED FLOOR PLATES
Floor plates shall be designed to withstand a live load of 250 pounds per square foot for the span
indicated with a maximum deflection of L/240 in locations shown in the Contract Drawings.
A. Steel floor plates conforming to ASTM A786/A786M, minimum 14 gauge, and
with G90 galvanized coating.
B. Aluminum Flood Plate: Conforming to ASTM B209, 6061 T6.
2.10 MISCELLANEOUS METAL FABRICATIONS
A. Loose Bearing and Leveling Plates: Flat, free from warps or twists, and of the
required thickness and bearing area. Drill plates to receive anchor bolts and for
grouting as required. Galvanize after fabrication.
B. Shelf and Relieving Angles:
1. Fabricate from steel angles of sizes indicated and for attachment to
concrete framing. Provide slotted holes to receive 3/4 -inch bolts, spaced
not more than 6 inches from ends and not more than 24 inches o.c., unless
otherwise indicated.
2. For cavity walls, provide vertical channel brackets to support
shelf/relieving angles from back-up masonry and concrete. Align
expansion joints in angles with indicated control and expansion joints in
cavity wall exterior wythe.
3. Galvanize shelf angles.
4. Furnish wedge -type concrete inserts, complete with fasteners, to attach
shelf angles to cast -in-place concrete or masonry.
C. Miscellaneous Framing and Supports:
03720-048-01
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1. Provide steel framing and supports for applications indicated that are not a
part of structural steel framework as required to complete the Work.
2. Fabricate units to sizes, shapes, and profiles indicated and required to
receive other adjacent construction retained by framing and supports.
Fabricate from structural steel shapes, plates, and steel bars of welded
construction using mitered joints for field connection. Cut, drill, and tap
units to receive hardware, hangers, and similar items.
3. Galvanize miscellaneous framing and supports in all locations.
05500-11 METAL FABRICATIONS
D. Cast -Metal Nosings:
1. Fabricate units of material, sizes, and configurations indicated. If not
indicated, provide cast-iron units with an integral abrasive finish. Furnish
in lengths as required to accurately fit each opening or conditions.
a. Cast units with an integral abrasive grit consisting of silicon
carbide.
2. Provide anchors for embedding units in concrete, either integral or applied
to units, as standard with the manufacturer.
3. Apply black asphaltic coating to concealed bottoms, sides, and edges of
cast-iron units set into concrete.
E. Corner Guards: Stainless steel; Thickness: Minimum 1/16 inch.
2.11 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.
2.12 STEEL AND IRON FINISHES
A. Galvanizing: Hot -dip galvanize items as indicated to comply with applicable
standard listed below:
1. ASTM A123/A123M, for galvanizing steel and iron products.
2. ASTM A153/A153M, for galvanizing steel and iron hardware.
B. Preparation for Shop Priming: Prepare uncoated ferrous -metal surfaces to comply
with minimum requirements indicated below for SSPC surface preparation
specifications and environmental exposure conditions of installed metal
fabrications:
1. Exteriors (SSPC Zone 1B) and Items Indicated to Receive Zinc -Rich
Primer: SSPC-SP 6/NACE No. 3.
2. Interiors (SSPC Zone 1A): SSPC-SP 10/NACE No. 2.
C. Shop Priming: Apply shop primer to uncoated surfaces of metal fabrications,
except those with galvanized finishes and those to be embedded in concrete,
sprayed -on fireproofing, or masonry, unless otherwise indicated. Comply with
03720-048-01 05500-12 METAL FABRICATIONS
August 2019
SSPC-PA 1, Paint Application Specification No. 1: Shop, Field, and Maintenance
Painting of Steel, for shop painting.
1. Stripe paint corners, crevices, bolts, welds, and sharp edges.
2.13 STAINLESS STEEL FINISHES
A. Remove tool and die marks and stretch lines or blend into finish.
B. Dull Satin Finish: No. 6.
C. When polishing is completed, passivate and rinse surfaces. Remove embedded
foreign matter and leave surfaces chemically clean.
PART 3 EXECUTION
3.01 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 bolts, wood screws, and other connectors.
03720-048-01
August 2019
05500-13 METAL FABRICATIONS
1
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 a heavy
coat of bituminous paint.
3.02 INSTALLING BEARING AND LEVELING PLATES
A. The Contractor shall clean concrete and masonry bearing surfaces of
bond -reducing materials and roughen to improve bond to surfaces. Clean the
bottom surface of bearing plates.
B. Set loose leveling and bearing plates on wedges or other adjustable devices. After
the bearing members have been positioned and plumbed, tighten the anchor bolts.
Do not remove wedges or shims, but if they are protruding cut off flush with the
edge of the bearing plate before packing with grout.
1. Use non -shrink, metallic grout in concealed locations where not exposed
to moisture; use non -shrink, nonmetallic grout in exposed locations, unless
otherwise indicated.
2. Pack grout solidly between bearing surfaces and plates to ensure that no
voids remain.
3.03 ADJUSTING AND CLEANING
The Contractor shall do the following:
A. Touchup Painting: Immediately after erection, clean field welds, bolted
connections, and abraded areas. Paint uncoated and abraded areas with the same
material as used for shop painting to comply with SSPC-PA-1 for touching up
shop -painted surfaces.
1. Apply by brush or spray to provide a minimum 2.0 -mil dry -film thickness.
B. Touchup Painting: Cleaning and touchup painting of field welds, bolted
connections, and abraded areas of shop paint are specified in Division 9, Finishes.
C. Galvanized Surfaces: Clean field welds, bolted connections, and abraded areas
and repair galvanizing to comply with ASTM A780/A780M.
END OF SECTION
03720-048-01 05500-14 METAL FABRICATIONS
August 2019
DIVISION 9
FINISHES
SECTION 09900
PAINTING AND COATING
PART 1 GENERAL
1.01 SCOPE OF WORK
A. This Section includes materials for and application of painting and coating
systems for the following surfaces:
1. Submerged metal.
2. Exposed metal.
3. Buried metal.
4. Exposed PVC.
5. Concrete and masonry.
6. Metal in contact with concrete.
B. It does not include coating steel water tanks and reservoirs.
1.02 RELATED WORK
A. Section 01330, Submittals and Acceptance.
B. Section 01650, Delivery, Storage, and Handling.
C. Section 01780, Warranties and Bonds.
D. Division 3, Concrete.
E. Division 11, Equipment.
F. Section 15075, Process Equipment, Piping, and Valve Identification.
1.03 SUBMITTALS
A. The Contractor shall submit shop drawings in accordance with Section 01330,
Submittals and Acceptance.
B. Submit manufacturer's data sheets showing the following information:
03720-048-01
August 2019
1. Percent solids by volume.
2. Minimum and maximum recommended dry -film thickness per coat for
prime, intermediate, and finish coats.
3. Recommended surface preparation.
4. Recommended thinners.
5. Statement verifying that the specified prime coat is recommended by the
manufacturer for use with the specified intermediate and finish coats.
09900-1 PAINTING AND COATING
6. Application instructions including recommended equipment and
temperature limitations.
7. Curing requirements and instructions.
C. Submit color swatches.
D. Submit certificate identifying the type and gradation of abrasives used for surface
preparation.
E. Submit material safety data sheets for each coating.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be the latest
revision of any such document in effect at the bid time. The following documents are a part of
this Section. Where this Section differs from these documents, the requirements of this Section
shall apply.
A. American Society for Testing and Materials (ASTM)
03720-048-01
August 2019
1. ASTM A780/A780M—Standard Practice for Repair of Damaged and
Uncoated Areas of Hot -Dip Galvanized Coatings.
2. ASTM C501—Standard Test Method for Relative Resistance to Wear of
Unglazed Ceramic Tile by the Taber Abraser.
3. ASTM D520—Standard Specification for Zinc Dust Pigment.
4. ASTM D522/D522M—Standard Test Methods for Mandrel Bend Test of
Attached Organic Coatings.
5. ASTM D1002—Standard Test Method for Apparent Shear Strength of
Single -Lap -Joint Adhesively Bonded Metal Specimens by Tension
Loading (Metal -to -Metal).
6. ASTM D2240—Standard Test Method for Rubber Property – Durometer
Hardness.
7. ASTM D2697—Standard Test Method for Volume Nonvolatile Matter in
Clear or Pigmented Coatings.
8. ASTM D3734—Standard Specification for High -Flash Aromatic
Naphthas.
9. ASTM D4060—Standard Test Method for Abrasion Resistance of Organic
Coatings by the Taber Abraser.
10. ASTM D4138—Standard Practices for Measurement of Dry Film
Thickness of Protective Coating Systems by Destructive, Cross -Sectioning
Means.
09900-2 PAINTING AND COATING
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
11. ASTM D4258—Standard Practice for Surface Cleaning Concrete for
Coating.
12. ASTM D4260—Standard Practice for Liquid and Gelled Acid Etching of
Concrete.
13. ASTM D4261—Standard Practice for Surface Cleaning Concrete Masonry
Units for Coating.
14. ASTM D4263 Standard Test Method for Indicating Moisture in
Concrete by the Plastic Sheet Method.
15. ASTM D4787—Standard Practice for Continuity Verification of Liquid or
Sheet Linings Applied to Concrete Substrates.
16. ASTM D6386—Standard Practice for Preparation of Zinc (Hot -Dip
Galvanized) Coated Iron and Steel Product and Hardware Surfaces for
Painting.
17. ASTM D7091—Standard Practice for Nondestructive Measurement of
Dry Film Thickness of Nonmagnetic Coatings Applied to Ferrous Metals
and Nonmagnetic, Nonconductive Coatings Applied to Non -Ferrous
Metals.
18. ASTM E84—Standard Test Method for Surface Burning Characteristics of
Building Materials.
B. National Association of Corrosion Engineers International (NACE)
1. NACE SP0188—Discontinuity (Holiday) Testing of New Protective
Coatings on Conductive Substrates.
C. Steel Structure Painting Council (SSPC)
1. SSPC PA-1—Shop, Field, and Maintenance Painting of Steel.
2. SSPC PA-2—Procedure for Determining Conformance to Dry Coatings
Thickness.
3. SSPC
4. SSPC
5. SSPC
6. SSPC
7. SSPC
8. SSPC
9. SSPC
10. SSPC
11. SSPC
ning.
eaning.
leaning.
—White Metal Blast Cleaning.
Commercial Blast Cleaning.
—Brush -Off Blast Cleaning.
—Near -White Blast Cleaning.
Cleaning to Bare Metal.
—Surface Preparation of Concrete.
SP -1 --Solvent Clea
SP-2—Hand Tool Cl
SP-3—Power Tool C
SP-5/NACE No. 1
SP-6/NACE No. 3—
SP-7/NACE No. 4
SP-10/NACE No. 2
SP-11—Power Tool
SP-13/NACE No. 6
D. U.S. Department of Defense (MIL)
03720-048-01
August 2019
1. MIL-P-21035—Paint High Zinc Dust Content, Galvanizing Repair
(Metric).
09900-3 PAINTING AND COATING
1.06 QUALITY ASSURANCE (NOT USED)
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
1.09 QUALIFICATIONS (NOT USED)
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 MOCK-UP (NOT USED)
1.12 PROJECT REQUIREMENTS (NOT USED)
PART 2 MATERIALS
2.01 PAINTING AND COATING SYSTEMS
The following index lists the various painting and coating systems by service and generic type:
PAINT COATINGS SYSTEM INDEX
No.
Title
Generic Coating
Submerged Metal Coating Systems
6.
Submerged Metal, Raw Sewage or Grit Slurries
Epoxy resin/ceramic
7.
Submerged Metal, Potable or Nonpotable Water
Epoxy
Exposed or Submerged Metal Coating Systems (NOT USED)
Exposed Metal Coating Systems
10.
Exposed Metal, Corrosive Environment
High -build epoxy (two -
coat with polyurethane
topcoat
14.
Exposed Metal, Atmospheric Environment
Urethane
18.
Exposed Metal, Organic Zinc Primer for Shop Coating and
Field Touch -Up
Organic zinc
03720-048-01
August 2019
09900-4
PAINTING AND COATING
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
PAINT COATINGS SYSTEM INDEX
No.
Title
Generic Coating
Buried Metal Coating Systems
21.
Buried Metal
Epoxy
24.
Buried Metal
Corrosion -resisting
grease
Concrete and Masonry Coating Systems
31.
Exposed Concrete and Masonry, Corrosive Environment
Epoxy
32.
Exposed Concrete and Masonry, Atmospheric Weathering
Environment
Acrylic
33.
Submerged Concrete, Raw Water or Raw Sewage
Vinyl ester
34.
Concrete Floors, Wet Environment
Epoxy
PVC, CPVC, and FRP Coating Systems
41.
PVC, Ultraviolet Exposure, and Color Coding
Polyurethane
Coating Systems for Miscellaneous Metals
51.
Insulate Aluminum (Insulation) from Concrete and Carbon
Steel
Bituminous
52.
Exposed Metal, Galvanized Steel and Aluminum
Synthetic resin
54.
Aluminum Insulation from Concrete and Carbon Steel
Epoxy
55.
Repair of Galvanized Steel Surfaces
Cold galvanizing
compound
Plaster, Wood, Masonry, and Drywall Coating Systems (NOT USED)
Coating System for Fusion Epoxy -Coated Steel Surfaces (NOT USED)
Exterior Architectural Coatings and Finishes (NOT USED)
Interior Architectural Coatings and Finishes (NOT USED)
High -Temperature Coatings (NOT USED)
These systems are specified in detail in the following Paragraphs. For each coating, the required
surface preparation, prime coat, intermediate coat (if required), topcoat, and coating thicknesses
are described. Mil thicknesses shown are minimum dry -film thicknesses.
A. Submerged Metal Coating Systems
03720-048-01
August 2019
1. System No. 6—Submerged Metal, Raw Sewage or Grit Slurries:
a. Type: Two -component epoxy resin/ceramic having 100% volume
solids and having the following characteristics:
Tensile shear adhesion (ASTM D1002):
2,500 psi (min)
Shore D hardness (minimum):
85
Abrasion resistance (ASTM D4060):
0.8 mg (max) loss
per 1,000 cycles
09900-5
PAINTING AND COATING
b. Service Conditions: For use as a lining for pump volutes, pump
impellers, piping, valves, and heat exchanger tubes subject to
severe abrasion service.
c. Surface Preparation: Solvent clean per SSPC-SP1 to remove
contaminants from the surface. Abrasive blast per SSPC-SP-10,
Near White Metal Blast Cleaning.
d. Coating System: Apply two coats (each a different color) to a
minimum thickness of 10 mils per coat. Minimum total coating
thickness shall be 20 mils. Product: THORTEX Cerami-Tech C.R.
as applied by Western Industrial Technology, Inc., Fullerton,
California, or Paragon Industries, Horsham, Pennsylvania;
Belzona 1341; or equal.
2. System No. 7—Submerged Metal, Potable or Nonpotable Water:
a. Type: Epoxy: 100% sbv Polyamine Epoxy with near "0" VOC.
b. Service Conditions: For use with structures, valves, piping, or
equipment immersed in potable or nonpotable water.
c. Surface Preparation: Solvent clean per SSPC-SP 1 to remove
contaminants from the surface. Abrasive blast per SSPC SP -10,
Near Abrasive White Metal Blast Cleaning.
d. Coating System: Apply the manufacturer's recommended number
of coats to attain the specified minimum coating thickness.
Products: Devoe Bar -Rust 233H; Tnemec N140; Sherwin-
Williams Tank Clad HS B62-80 Series/B60V80; PPG
AQUAPON® LT NSF Low Temperature Epoxy Coatings 95-172;
Carboline Super Hi -Gard 891; Ameron 395; International
Interline 785HS; Wisconsin Protective Coating Corp. Plasite 7133
or 9133, Keysite 740, Scotchkote 306, or equal; 20 mils total.
Color of topcoat: white. Each coat shall be a different color than
the one preceding it. Tnemec Series N140 Pota-Pox Plus
Polyamidoamine epoxy at 6.0 to 8.0 mils/coat. Apply two coats.
Total system should not exceed 17 mils.
B. Exposed Metal Coating Systems
03720-048-01
August 2019
1. System No. 10 Exposed Metal, Corrosive Environment:
a. Type: High -build epoxy finish coat having a minimum volume
solids of 60%, with an inorganic zinc prime coat and a pigmented
polyurethane finish coat having a minimum 52% sbv.
09900-6 PAINTING AND COATING
03720-048-01
August 2019
b. Service Conditions: For use with metal structures or pipes
subjected to water condensation, chemical fumes such as hydrogen
sulfide, salt spray, and chemical contact.
c. Surface Preparation: Solvent clean per SSPC-SP1 to remove
contaminants from the surface. Abrasive blast per SSPC-SP-10,
Near White Metal Blast Cleaning.
d. Prime Coat: Self -curing, two -component inorganic zinc -rich
coating recommended by the manufacturer for overcoating with a
high -build epoxy finish coat. Minimum zinc content shall be
12 pounds per gallon. Apply to a thickness of 3 mils. Products:
Tnemec Series 90-97; Devoe Catha-Coat 304 or 304V;
International Interzinc 180HS; Ameron 9HS; Carboline 11 HS;
Sherwin-Williams Zinc -Clad II Plus, B69VZ12/B69VZ13/B69D11
at 2.5 to 4.0 mils DFT; PPG METALHIDE® 28 Inorganic Zinc -
Rich Primer 97 — 672, or equal.
e. Intermediate Coat: Tnemec Series 104; ICI Devoe Devran 224 HS;
International Interguard 760HS; Ameron 385; Carboline 888 or
890; Sherwin-Williams Macropoxy 646 B58-600/B58V600 at 4.0
to 8.0 mils DFT; PPG PITT -GUARD® Direct -to -Rust Epoxy
Mastic Coating 97-145 Series, or equal; 5 mils. Film thickness 5.0
to 8.0 mils/coat. Minimum solids by volume should be 82%.
f. Finish Coat: Two -component pigmented acrylic or aliphatic
polyurethane, minimum 70% sbv recommended by the
manufacturer for overcoating a high -build epoxy coating. Apply to
a thickness of at least 2 mils. Products: Tnemec Series 1075; ICI
Devoe Devthane 379; International Interline 990HS; Ameron 450
HS; Carboline 134 HG; Sherwin-Williams Hi -Solids Polyurethane
B65-300 Series/B60V30 at 2.5 to 4.0 mils DFT; PPG
PITTHANE® Ultra -Gloss Urethane Enamel 95-812 Series; or
equal.
2. System No. 14 Exposed Metal, Atmospheric Environment:
a. Type: Single component, moisture -cured, micaceous iron oxide
(MIO), urethane having a minimum volume solids of 61% and
having a minimum MIO content of 4 pounds per gallon, with a
zinc -rich primer and a moisture cured, MIO, aliphatic acrylic
urethane topcoat.
b. Service Conditions: For use with exposed metal structures or
piping subjected to continuous water condensation, salt spray, and
chemical fumes, such as moist hydrogen sulfide.
c. Prime Coat: Single -component, zinc -rich, moisture cured urethane
having a minimum zinc content of 80% in the dry film. Apply one
coat of Wasser MC -Zinc or Sherwin-Williams Corothane I Galva
09900-7 PAINTING AND COATING
Pac Zinc Primer B65A11 at 3.0 to 4.0 mils DFT to a minimum
thickness of 3 mils. Tnemec Series 1 Aromatic Polyurethane
primer.
d. Intermediate Coats: Apply one coat of Wasser MC-Ferrox B or
Sherwin-Williams Corothane I Ironox B B65A11 at 3.0 to 5.0 mils
DFT and one coat of Wasser MC -CR or Sherwin-Williams
Corothane I MIO -Aluminum B65S14 at 2.0 to 3.0 mils DFT to a
minimum dry -film thickness of 4 mils per coat. Color of first coat:
brown/gray. Color of second coat: white.
e. Finish Coat: Single -component, moisture -cured, MIO, aliphatic
urethane having a minimum volume solids of 50%. Apply one coat
of Wasser MC-Shieldcoat or Sherwin-Williams Aliphatic, B65-10
Series at 2.5 to 3.5 mils DFT. Ferrox A to a minimum thickness of
3 mils. Tnemec Series 1074 or Tnemec Series 1075, catalyzed
Aliphatic Acrylic polyurethane.
3. System No. 18—Exposed Metal, Organic Zinc Primer for Shop Coating
and Field Touch -Up:
a. Type: Organic zinc primer having a minimum zinc content of
14 pounds per gallon.
b. Service Conditions: For use as a shop -applied primer or field
touch-up primer over inorganic zinc prime coatings on exposed
metal.
c. Surface Preparation: Solvent clean per SSPC-SP1 to remove
contaminants from the surface. Abrasive blast per SSPC-SP-10,
Near White Metal Blast Cleaning.
d. Coating: Coating shall be of the two- or three -component
converted epoxy, epoxy phenolic, or urethane type. Products:
Tnemec 90-97; International Interzinc 308; Ameron 68HS; ICI
Devoe 313; Carboline 859; Sherwin-Williams Zinc -Clad III HS
B69A100/B69D11/B69D11 at 3.0 to 5.0 mils DFT; PPG
DurethaneTM MCZ 97-679; or equal. Applied to a minimum dry -
film thickness of 3 mils. Organic zinc primer shall be
manufactured by the prime coat manufacturer.
C. Buried Metal Coating Systems
03720-048-01
August 2019
1. System No. 21—Buried Metal:
a. Type: High solids Cycloaliphatic Amine epoxy or phenolic epoxy
having minimum volume solids of 80% (ASTM D2697).
b. Service Conditions: Buried metal, such as valves, flanges, bolts,
nuts, structural steel, and fittings.
09900-8 PAINTING AND COATING
c. Surface Preparation: Solvent clean per SSPC-SP1 to remove
contaminants from the surface. Abrasive blast per SSPC-SP-10,
Near White Metal Blast Cleaning.
d. Coating System: Apply three or more coats of Ameron 400;
Tnemec 104 HS (6.0 to 8.0 mils per coat); ICI Devoe Bar -
Rust 233H; Carboline 890LT; Sherwin-Williams Tank Clad HS
B62-80 Series/B60V80 Series at 5.0 to 8.0 mils/coat or equal;
30 mils total. Maximum thickness of an individual coating shall
not exceed the manufacturer's recommendation.
2. System No. 24—Buried Metal:
a. Type: Corrosion -resisting grease.
b. Service Conditions: Buried metal, such as bolts, bolt threads, tie
rods, and nuts.
c. Surface Preparation: Solvent clean per SSPC-SP1 to remove
contaminants from the surface. Power Tool Clean per SSPC-SP3
as a minimum. Abrasive blasting per SSPC-SP-6, Commercial
Blast Cleaning is preferred.
d. Coating: NO -OX -ID GG -2 as manufactured by Sanchem, Inc.
Apply to a minimum thickness of 1/4 inch.
D. Concrete and Masonry Coating Systems
03720-048-01
August 2019
1. System No. 31—Exposed Concrete and Masonry, Corrosive Environment:
a. Type: Polyamide-cured epoxy having a minimum volume solids of
53%. If the service is splash and spillage then use the existing
updated system.
b. Service Conditions: Concrete and masonry exposed to corrosive
atmospheres, such as hydrogen sulfide gas, chlorine gas, or
chlorinated effluent sprays in wastewater treatment plants.
c. Surface Preparation: In accordance with Article 3.04. Clean to an
ICRI CSP 5 standard. If using for splash and spillage surface,
preparation can be brush off abrasive blasting.
d. Prime Coat: Epoxy filler compound or epoxy masonry filler having
a minimum solids volume of 60%. Apply one coat to fill voids,
pores, and cracks. Products: Tnemec 54-660, International Intercryl
320WB, Amerlock 400 BF, ICI Devoe Devran 265 BHF, Sentry
610, Sherwin-Williams Kem Cati-Coat HS B42W400/B42V401 at
10.0 to 20.0 mils DFT, or equal. For surfacing, use Tnemec Series
218 MortarClad applied to 1/4 -inch. For greater depressions use
Tnemec Series 63-1500 or Tnemec Series 219 MortarCast.
09900-9 PAINTING AND COATING
03720-048-01
August 2019
e. Intermediate Coat: One coat of Tnemec 104 (6.0 to 8.0 mils per
coat); International Interguard 760HS; Amerlock 400; ICI Devoe
Bar -Rust 233 H; Carboline 890; Sherwin-Williams Macropoxy 646
B58-600 Series/B58V600 at 5.0 to 8.0 mils DFT; or equal.
f. Finish Coat: Two coats of Tnemec 104 (use 6.0 to 8.0 mils per
coat); International Interguard 760HS; Amerlock 400; ICI Devoe
Bar -Rust 233 H; Carboline 890; Sherwin-Williams Macropoxy 646
B58-600 Series/B58V600 at 4.0 to 8.0 mils DFT; or equal.
2. System No. 32 Exposed Concrete and Masonry, Atmospheric
Weathering Environment:
a. Type: Acrylic enamel or acrylic latex having a minimum volume
solids of 36%.
b. Service Conditions: Exposed concrete or masonry exposed to
normal sunlight and weathering.
c. Surface Preparation: In accordance with Article 3.04.
d. Prime Coat: Water -borne acrylic or cementitious acrylic emulsion
having a minimum solids volume of 40%. Apply one coat of
Carboline "Flexide" Masonry Block Filler to fill all voids, pores,
and cracks; ICI Devoe Bloxfill 4000; Amerlock 400 BF; Tnemec
54-562 Masonry Filler single component epoxy; International
Intercryl 320WB; Sherwin-Williams Heavy Duty Block Filler
B42W46 at 10.0 to 18.0 mils DFT; PPG SPEEDHIDE® Int/Ext
Acrylic Masonry Block Filler 6-15; or equal.
e. Finish Coat: Two coats of Carboline 3350, two coats of ICI Devoe
4208; two coats of Ameron 220; two coats Tnemec Series 6 at 2.0
to 3.0 mils per coat; two coats of International Intercryl 530WB
520; Sherwin-Williams Metalatex Semi -Gloss B42 series at 2.0 to
4.0 mils DFT/coat; two coats of PPG Int/Ext Semi -Gloss Acrylic
Metal Finish 7-374 Series; or equal. Apply to a thickness of 2 mils
per coat.
3. System No. 33—Submerged Concrete, Raw Water or Raw Sewage:
a. Type: Vinyl -ester -finish coat system. Minimum resin content in the
finish coat system shall be 29% by weight. The vinyl -ester -finish
coat system shall be formulated with an abrasion -resistant pigment
to provide no more than an average 60 -mg weight loss when run on
a Taber Abraser using a CS -17 wheel, 1,000 -gram weight on
1,000 cycles.
09900-10 PAINTING AND COATING
b. Service Conditions: Concrete submerged in raw water or raw
sewage and structures containing moist hydrogen sulfide such as
manholes and sewage pumping station wet wells.
c. Surface Preparation: In accordance with Article 3.04.
d. Prime Coat – Surfacer:
(1) Apply epoxy or vinyl ester filler and surfacer to fill in
depressions. Products: Plasite 9029; Tnemec
Series 120-5003 (apply Tnemec 120-5002 primer at 10 to
15 mils wet to facilitate application of the 120-5003
surfacer); or Sherwin Williams Corobond Vinyl Ester
Primer, B88C10/B88R99 at 3.5 to 4.5 mils DFT.
(2) Apply prime coat with trowel or squeegee so that exposed
aggregate is covered and the surface is level with the
surrounding concrete.
e. Finish Coats: Apply three or more coats to a total thickness of
40 mils minimum. Maximum thickness of any single coat shall not
exceed 15 mils. Observe manufacturer's recommended recoating
time between coats. Products: Plasite 4007; Tnemec 120-5001
Vinester; or Sherwin-Williams Magnalux 304,
921 -W -304/531-0-006/970-C-949 at 14.0 to 16.0 DFT.
4. System No. 34—Concrete Floors, Wet Environment:
a. Type: Cycloaliphatic Amine Epoxy higher solids material of no
less than 80% sbv.
b. Service Conditions: Concrete floors subject to pedestrian traffic or
exposure to water splashing from pump seal water, cleaning, etc.
c. Surface Preparation: In accordance with Article 3.04.
d. Coating System: Two coats of Ameron 400; two coats of ICI
Devoe 233 H; two coats of Tnemec Series104; two coats of
International Interguard 760HS; two coats of Carboline 890; two
coats of Sherwin-Williams Macropoxy 646 B58-600 Series/
B58V600 at 5.0 to 8.0 mils DFT; PPG PITT -GUARD® Rapid
Coat Direct -to -Rust Epoxy Coating 95-2400; or equal. Apply to a
minimum dry -film thickness of 5 mils per coat. Broadcast glass
beads, Tnemec Series 211-0212, into a finish for a non -slip finish.
03720-048-01 09900-11 PAINTING AND COATING
August 2019
E. PVC, CPVC, and FRP Coating System
1. System No. 41—PVC, Ultraviolet Exposure, and Color Coding:
a. Type: Epoxy primer with minimum volume solids of 54% and a
pigmented polyurethane enamel having a minimum volume solids
of 66%.
b. Service Conditions: Color coding of PVC exposed to sunlight.
c. Surface Preparation: Clean the surface per SSPC SP -1, Solvent
Cleaning. Then, lightly abrade the surface with medium -grain
sandpaper.
d. Prime Coat: One coat of Tnemec Series N69 Epoxoline;
International 7510; Ameron 385; ICI Devoe Devran 224 HS;
Sherwin-Williams Macropoxy 646 B58 Series/B58V600 at 5.0 to
8.0 mils DFT; Carboline 888 or 890; PPG PITT -GUARD® Direct -
to -Rust Epoxy Mastic Coating 97-145 Series; or equal. Apply to a
minimum dry -film thickness of 4 mils.
e. Finish Coat: One coat of Tnemec Series 1075; International
Interthane 990HS; Ameron 450 HS; ICI Devoe Devran 379;
Carboline 134 HG; Sherwin-Williams Hi -Solids Polyurethane
B65-300 Series/B60V30 at 3.0 to 4.0 mils DFT; PPG
PITTHANE® Ultra -Gloss Urethane Enamel 95-812 Series; or
equal. Apply to a minimum dry -film thickness of 3 mils.
F. Coating Systems for Miscellaneous Metals
1. System No. 51—Insulate Aluminum (Insulation) from Concrete and
Carbon Steel:
a. Type: Bituminous paint having a minimum volume solids of 68%
coal -tar pitch based.
b. Service Conditions: Coat areas of aluminum grating, stairs,
structural members, or aluminum fabrications, in contact with
concrete or carbon steel with this system.
c. Surface Preparation: Solvent or steam clean in accordance with
SSPC SP -1; do not use alkali cleaning. Then dust blast. Option to
hand or power scarify.
d. Prime Coat: Apply synthetic resin or epoxy primer to metal surface
before finish coats. Products: International Intervinux
VTA528/529, or equal. No primer required for Carboline or
Tnemec.
e. Finish Coat: Carboline Super Service Black; Tnemec 46-465;
International Intertuf 100; or equal. Apply two coats to a minimum
dry -film thickness of 8.0 to 12.0 mils/coat.
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August 2019
03720-048-01
August 2019
2. System No. 52—Exposed Metal, Galvanized Steel and Aluminum:
a. Type: Synthetic resin or epoxy primer.
b. Service Conditions: Coat galvanized steel and aluminum surfaces
with this system before applying topcoat.
c. Surface Preparation of Galvanized Steel: Surfaces shall be flat with
no protrusions. Remove high spots and tears in the galvanizing
with hand and power grinders. Comply with ASTM D6386,
Paragraph 5.2.1. Do not remove the galvanized coating below the
specified thickness. Solvent clean galvanized surfaces in
accordance with ASTM D6386, Paragraph 5.3.2. Then sweep blast
as in ASTM D6386, Paragraph 5.4.1. Use one of the abrasive
materials described in ASTM D6386, Paragraph 5.4.1. Surface
preparation for weathered and partially weathered galvanized steel
shall be in accordance with ASTM D6386, Paragraphs 6 and 7.
Apply prime coating within 1 hour of the surface preparation.
d. Surface Preparation of Aluminum: Solvent clean or steam clean
aluminum surfaces as specified in SSPC SP -1; do not use alkali
cleaning. Then dust blast and follow with a chemical conversion
coating per MIL -C-5541, Class 1A.
e. Prime Coat: Tnemec Series N69 2.5 to 3.5 mils; Ameron 385; ICI
Devoe Devran 224 HS; Carboline Rustbond Penetrating Sealer SG;
Sherwin-Williams Macropoxy 646 B58-600 Series/B58V600 at 5.0
to 8.0 mils DFT; PPG PITT -GUARD® Direct -to -Rust Epoxy
Mastic Coating 97-145 Series; or equal. Apply to a minimum
thickness of 4 mils.
f. Intermediate and Finish Coats: Epoxy polyurethane as described in
System No. 10. Do not include the inorganic zinc prime coat
described in that system.
3. System No. 54—Aluminum Insulation from Concrete and Carbon Steel:
a. Type: High -solids epoxy or phenolic epoxy having minimum
volume solids of 80% (ASTM D2697).
b. Service Conditions: Coat areas of aluminum grating, stairs,
structural members, or aluminum fabrications in contact with
concrete or carbon steel with this system.
c. Surface Preparation: Solvent or steam cleaning as specified in
SSPC SP -1; do not use alkali cleaning. Then dust blast.
d. Coating System: Apply three or more coats of Ameron 400;
Tnemec 135; ICI Devoe Bar -Rust 233H; Sherwin-Williams
Macropoxy B58-600 Series/B58V600 at 5.0 to 8.0 mils DFT; PPG
PITT -GUARD® Direct -to -Rust Epoxy Mastic Coating 97-145
09900-13 PAINTING AND COATING
Series; or equal; 30 mils total. Maximum thickness of an individual
coating shall not exceed the manufacturer's recommendation.
4. System No. 55—Repair of Galvanized Steel Surfaces:
a. Type: Cold galvanizing compound consisting of paint containing
oils, solvents, and zinc dust and complying with MIL -P-21035.
Minimum metallic zinc content in the cured coating shall be 90%.
b. Service Conditions: Repair of damaged galvanized coatings on
steel surfaces.
c. Surface Preparation: Clean damaged surfaces in accordance with
SSPC SP -1, Solvent Cleaning and SP -11, Power Tool Cleaning to
Bare Metal.
d. Coating System: Apply Z.R.C. Galvanizing Compound; RAMCO
Specialty Products "Zinckit"; NuWave "Galv-Match-Plus";
Devcon "Cold Galvanizing"; Clearco "Cold Galvanizing Spray";
Tnemec Series 90-1K97; or equal; to a minimum dry -film
thickness of 3 mils. Apply as specified in ASTM A780/A780M,
Annex A2.
G. Abrasives for Surface Preparation
03720-048-01
August 2019
1. Abrasives used for preparation of ferrous (excluding stainless steel)
surfaces shall be one of the following:
a. 16- to 30- or 16- to 40 -mesh silica sand or mineral grit.
b. 20- to 40 -mesh garnet.
c. Crushed iron slag, 100% retained on No. 80 mesh.
d. SAE Grade G-40 or G-50 iron or steel grit.
2. Abrasives used for preparation of stainless steel surfaces shall be 20- to
40 -mesh silicon carbide or aluminum oxide.
3. Abrasives used for preparation of copper and aluminum surfaces shall be
one of the following:
a. Crushed slag, 80 to 100 mesh.
b. Very fine silica sand, 80 to 100 mesh.
4. Abrasives used for preparation of concrete and masonry surfaces shall be
16- to 30- or 16- to 40 -mesh silica sand.
09900-14
PAINTING AND COATING
5. In the above gradations, 100% of the material shall pass through the first
stated sieve size and 100% shall be retained on the second stated sieve
size.
H. Organic Zinc Primer for Field Touch -Up and Shop Coating
1. Where shop -applied inorganic zinc primers cannot be used because of
volatile organic compound (VOC) regulations, the organic zinc primer
described in System No. 18 may be substituted for the specified inorganic
zinc primers.
PART 3 EXECUTION
3.01 WEATHER CONDITIONS
A. Do not paint in the rain, wind, snow, mist, or fog or when steel or metal surface
temperatures are less than 5°F above the dew point.
B. Do not apply paint when the relative humidity is above 85%.
C. Do not paint when temperature of metal to be painted is above 120°F.
D. Do not apply alkyd, inorganic zinc, silicone aluminum, or silicone acrylic paints if
air or surface temperature is below 40°F or expected to be below 40°F within
24 hours.
E. Do not apply epoxy, acrylic latex, and polyurethane paints on an exterior or
interior surface if air or surface temperature is below 60°F or expected to drop
below 60°F in 24 hours.
3.02 SURFACE PREPARATION PROCEDURES
A. Remove oil and grease from metal surfaces in accordance with SSPC SP -1. Use
clean cloths and cleaning solvents and wipe dry with clean cloths. Do not leave a
film or greasy residue on the cleaned surfaces before abrasive blasting.
Powerwashing with a biodegradable degreaser is also acceptable.
B. Remove weld spatter and weld slag from metal surfaces and grind smoothly rough
welds, beads, peaked corners, and sharp edges including erection lugs in
accordance with SSPC SP -2 and SSPC SP -3. Grind 0.020 inch (minimum) off the
weld caps on pipe weld seams. Grind outside sharp corners, such as the outside
edges of flanges, to a minimum radius of 1/4 inch.
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09900-15 PAINTING AND COATING
C. Do not abrasive blast or prepare more surface area in one day than can be coated
in one day; prepare surfaces and apply coatings the same day. Remove sharp
edges, burrs, and weld spatter. Prime all areas before rust bloom forms and within
the same day.
D. Do not abrasive blast PVC, CPVC, or FRP piping or equipment. Do not abrasive
blast epoxy- or enamel -coated pipe that has already been factory coated, except to
repair scratched or damaged coatings.
E. For carbon steel, do not touch the surface between the time of abrasive blasting
and the time the coating is applied. Apply coatings within 2 hours of blasting or
before any rust bloom forms.
F. Surface preparation shall conform to the SSPC specifications as follows:
Solvent Cleaning
SP -1
Hand Tool Cleaning
SP -2
Power Tool Cleaning
SP -3
White Metal Blast Cleaning
SP -5
Commercial Blast Cleaning
SP -6
Brush -Off Blast Cleaning
SP -7
Pickling
SP -8
Near -White Blast Cleaning
SP -10
Power Tool Cleaning to Bare Metal
SP -11
Surface Preparation and Cleaning of Steel and Other Hard
Materials by High- and Ultrahigh -Pressure Water Jetting
Before Recoating
SP -12
Surface Preparation of Concrete
SP -13
G. Wherever the words "solvent cleaning," "hand tool cleaning," "wire brushing," or
"blast cleaning" or similar words are used in these Specifications or in the paint
manufacturer's specifications, they shall be understood to refer to the applicable
SSPC (Steel Structure Painting Council), surface preparation specifications listed
above.
H. Dust blasting is defined as cleaning the surface through the use of very fine
abrasives, such as siliceous or mineral abrasives, 80 to 100 mesh. Apply a fine
etch to the metal surface to clean the surface of any contamination or oxide and to
provide a surface profile for the coating.
I. Brush-off blasting of concrete and masonry surfaces is defined as opening
subsurface holes and voids and etching the surface for a coating to bond.
03720-048-01 09900-16 PAINTING AND COATING
August 2019
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J. For carbon steel surfaces, after abrasive blast cleaning, the height of the surface
profile shall be 2 to 3 mils. Verify the surface profile by measuring with an
impresser tape acceptable to the Owner's Representative. Perform a minimum of
one test per 100 square feet of surface area. Testing shall be witnessed by the
Owner's Representative. The impresser tape used in the test shall be permanently
marked with the date, time, and locations where the test was made. Test results
shall be promptly presented to the Owner's Representative.
K. Do not apply any part of a coating system before the Owner's Representative has
reviewed the surface preparation. If coating has been applied without this review,
if directed by the Owner's Representative, remove the applied coating by abrasive
blasting and reapply the coat in accordance with this Specification.
3.03 ABRASIVE BLAST CLEANING
A. Use dry abrasive blast cleaning for metal surfaces. Do not use abrasives in
automatic equipment that have become contaminated. When shop or field blast
cleaning with handheld nozzles, do not recycle or reuse blast particles.
B. After abrasive blast cleaning and before coating is applied, dry clean surfaces to
be coated by dusting, sweeping, and vacuuming to remove residue from blasting.
Apply the specified primer or touch-up coating within an 8 -hour working day. Do
not apply coating over damp or moist surfaces. Reclean any blast -cleaned surface
not coated within the 8 -hour period before applying primer or touch-up coating.
C. Keep the area of the work in a clean condition and do not permit blasting particles
to accumulate and constitute a nuisance or hazard.
D. During abrasive blast cleaning, prevent damage to adjacent coatings. Schedule
blast cleaning and coating so that dust, dirt, blast particles, old coatings, rust, mill
scale, etc., will not damage or fall upon wet or newly coated surfaces.
3.04 PREPARATION OF CONCRETE AND MASONRY SURFACES TO BE COATED
A. Surface preparation of concrete and masonry surfaces shall be in accordance with
SSPC SP-13/NACE 6, Division 3, Concrete, and the following.
B. Do not apply coating until concrete has cured at least 30 days at 75°F and a
minimum 50%. Finish concrete surfaces in accordance with Section 03360,
Concrete Finishes. Do not use curing compound on surfaces that are to be coated.
C. Concrete and masonry surfaces on which coatings are to be applied shall be of
even color, gray or gray -white. The surface shall have no pits, pockets, holes, or
03720-048-01
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09900-17 PAINTING AND COATING
sharp changes of surface elevation. Scrubbing with a stiff -bristle fiber brush shall
produce no dusting or dislodging of cement or sand. Sprinkling water on the
surface shall produce no water beads or standing droplets. Concrete and masonry
shall be free of laitance and slick surfaces.
D. Detergent clean the concrete or masonry surface with Trisodium Phosphate in
accordance with ASTM D4258. Then sandblast surfaces (brush-off blast). Floor
slabs may be acid etched as specified in ASTM D4260 in lieu of sandblasting.
After sandblasting, wash surfaces with water to remove dust and salts in
accordance with ASTM D4258 or D4261. The grain of the concrete surface to
touch shall not be rougher than that of No. 10 mesh sand. Use International
Concrete Repair Institute (ICRI) standards for concrete and masonry surface
preparation.
E. Before coating concrete, plaster, and masonry with System No. 31, 33, or 34
determine the presence of capillary moisture in accordance with ASTM D4263,
except as modified below. Tape a 4 -foot -by -4 -foot sheet of polyethylene plastic to
the concrete surface to be coated. Allow the plastic sheet to remain in place at
least 24 hours. After the specified time has elapsed, remove the plastic sheet and
visually examine both the underside of the plastic sheet and the concrete surface
beneath it. There shall be no indication of moisture on either surface. If moisture
is indicated, allow additional curing time for the concrete and then retest. Provide
one test sheet for every 500 square feet of concrete surface to be coated. For walls,
provide one test sheet for each 10 feet (or fraction thereof) of vertical rise in all
elevations starting within 12 inches of the floor or base slab.
F. Acceptance criteria for concrete surfaces shall be in accordance with
SSPC SP-13/NACE No. 6, Table 1, "Severe Service."
G. Do not apply coatings to concrete when the concrete is outgassing. Apply coatings
only when the concrete surface temperature is stable, not rising. Apply concrete
coatings when the temperature is falling to reduce the potential of outgassing.
3.05 COATING STAINLESS STEEL
A. Solvent clean in accordance with SSPC SP -1. Solvents and cleaning solutions
shall contain less than 200 mg/L of halogens. Then abrasive blast to give a surface
profile of 2.0 to 3.0 mils. Refer to the coatings for the correct surface profile. Use
coatings that are low in chloride content.
B. Do not apply inorganic zinc primers to stainless steel if such primers are specified
in the painting system required. Apply only the intermediate and finish coats in
such cases.
03720-048-01 09900-18 PAINTING AND COATING
August 2019
3.06 PROCEDURES FOR ITEMS HAVING SHOP -APPLIED PRIME COATS
A. After applying primer to surfaces, allow coating to cure for a minimum of 2 hours
before handling to minimize damage.
B. When loading for shipment to the project site, use spacers and other protective
devices to separate items to prevent damaging the shop -primed surfaces during
transit and unloading. If wood spacers are used, remove wood splinters and
particles from the shop -primed surfaces after separation. Use padded chains or
ribbon binders to secure the loaded items and minimize damage to the shop -
primed surfaces.
C. Cover shop -primed items 100% with protective coverings or tarpaulins to prevent
deposition of road salts, fuel residue, and other contaminants in transit.
D. Handle shop -primed items with care during unloading, installation, and erection
operations to minimize damage. Do not place or store shop -primed items on the
ground or on top of other work unless the ground or work is covered with a
protective covering or tarpaulin. Place shop -primed items above the ground upon
platforms, skids, or other supports.
3.07 FIELD TOUCH-UP OF SHOP -APPLIED PRIME COATS
A. Remove oil and grease surface contaminants on metal surfaces in accordance with
SSPC SP -1. Use clean rags wetted with a degreasing solution, rinse with clean
water, and wipe dry.
B. Remove dust, dirt, salts, moisture, chalking primers, or other surface contaminants
that will affect the adhesion or durability of the coating system. Use a high-
pressure water blaster or scrub surfaces with a broom or brush wetted with a
solution of Trisodium Phosphate, detergent, and water. Before applying
intermediate or finish coats to inorganic zinc primers, remove any soluble zinc
salts that have formed by scrubbing with a stiff bristle brush. Rinse scrubbed
surfaces with clean water.
C. Remove loose or peeling primer and other surface contaminants not easily
removed by the previous cleaning methods in accordance with SSPC SP -7/
NACE No. 4. Take care that the remaining primers are not damaged by the blast
cleaning operation. The remaining primers shall be firmly bonded to the steel
surfaces with blast -cleaned edges feathered.
D. Remove rust, scaling, or primer damaged by welding or during shipment, storage,
and erection in accordance with SSPC SP-10/NACE No. 2. Take care that the
remaining primers are not damaged by the blast cleaning operation. Areas smaller
03720-048-01 09900-19 PAINTING AND COATING
August 2019
than 1 square inch maybe prepared in accordance with SSPC SP -11. The
remaining primers shall be firmly bonded to the steel surfaces with cleaned edges
feathered.
E. Use repair procedures on damaged primer that protect adjacent primer. Blast
cleaning may require the use of lower air pressure, smaller nozzles and abrasive
particle sizes, short blast nozzle distance from surface, shielding, and/or masking.
F. After abrasive blast cleaning of damaged and defective areas, remove dust, blast
particles, and other debris by dusting, sweeping, and vacuuming; then apply the
specified touch-up coating.
G. Surfaces that are shop primed with inorganic zinc primers shall receive a field
touch-up of organic zinc primer as specified in System No. 18 to cover scratches
or abraded areas.
H. Other surfaces that are shop primed shall receive a field touch-up of the same
primer used in the original prime coat.
3.08 PAINTING SYSTEMS
A. All materials of a specified painting system, including primer, intermediate, and
finish coats, shall be produced by the same manufacturer. Thinners, cleaners,
driers, and other additives shall be as recommended by the paint manufacturer for
the particular coating system.
B. Deliver paints to the jobsite in the original, unopened containers.
3.09 PAINT STORAGE AND MIXING
A. Store and mix materials only in areas designated for that purpose by the Owner's
Representative. The area shall be well ventilated, with precautionary measures
taken to prevent fire hazards. Post "No Smoking" signs. Storage and mixing areas
shall be clean and free of rags, waste, and scrapings. Tightly close containers after
each use. Store paint at an ambient temperature from 50°F to 100°F.
B. Prepare multiple -component coatings using all of the contents of the container for
each component as packaged by the paint manufacturer. Do not use partial
batches. Do not use multiple -component coatings that have been mixed beyond
their pot life. Provide small quantity kits for touch-up painting and for painting
other small areas. Mix only the components specified and furnished by the paint
manufacturer. Do not intermix additional components for reasons of color or
otherwise, even within the same generic type of coating.
03720-048-01
August 2019
09900-20 PAINTING AND COATING
3.10 PROCEDURES FOR THE APPLICATION OF COATINGS
A. Conform to the requirements of SSPC PA -1. Follow the recommendations of the
coating manufacturer, including the selection of spray equipment, brushes, rollers,
cleaners, thinners, mixing, drying time, temperature and humidity of application,
and safety precautions.
B. Stir, strain, and keep coating materials at a uniform consistency during
application. Power mix components. For multiple component materials, premix
each component before combining. Apply each coating evenly, free of brush
marks, sags, runs, and other evidence of poor workmanship. Use a different shade
or tint on succeeding coating applications to indicate coverage where possible.
Finished surfaces shall be free from defects or blemishes.
C. Do not use thinners unless recommended by the coating manufacturer. If thinning
is allowed, do not exceed the maximum allowable amount of thinner per gallon of
coating material. Stir coating materials at all times when adding thinner. Do not
flood the coating material surface with thinner before mixing. Do not reduce
coating materials more than is absolutely necessary to obtain the proper
application characteristics and to obtain the specified dry -film thicknesses.
D. Remove dust, blast particles, and other debris from blast cleaned surfaces by
dusting, sweeping, and vacuuming. Allow ventilator fans to clean airborne dust to
provide good visibility in working area before applying coating. Remove dust
from coated surfaces by dusting, sweeping, and vacuuming before applying
succeeding coats.
E. Apply coating systems to the specified minimum dry -film thicknesses as
determined in accordance with SSPC PA -2.
F. Apply primer immediately after blast cleaning and before any surface rusting
occurs, or any dust, dirt, or any foreign matter has accumulated. Before applying
coating, re -clean surfaces that have surface colored or become moist by blast
cleaning.
G. Apply a brush coat of primer on welds, sharp edges, nuts, bolts, and irregular
surfaces before applying the primer and finish coat. Apply the brush coat before
and in conjunction with the spray coat application. Apply the spray coat over the
brush coat.
H. Before applying subsequent coats, allow the primer and intermediate coats to dry
for the minimum curing time recommended by the manufacturer. In no case shall
the time between coats exceed the manufacturer's recommendation.
03720-048-01
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09900-21 PAINTING AND COATING
I. Each coat shall cover the surface of the preceding coat completely and there shall
be a visually perceptible difference in applied shade or tint of colors.
J. Applied coating systems shall be cured at 75°F or higher for 48 hours. If
temperature is lower than 75°F, curing time shall be in accordance with printed
recommendations of the manufacturer, unless otherwise allowed by the Owner's
Representative.
K. Assembled parts shall be disassembled sufficiently before painting or coating to
ensure complete coverage by the required coating.
3.11 SURFACES NOT TO BE COATED
A. Do not paint the surfaces listed below unless otherwise noted in the drawings or in
other sections. Protect the following surfaces during the painting of adjacent
areas:
1. Concrete walkways.
2. Mortar -coated pipe and fittings.
3. Stainless steel.
4. Metal letters.
5. Glass.
6. Roofing.
7. Fencing.
8. Copper tubing, red brass piping, and PVC piping except where such piping
occurs in rooms where the walls are painted, or required for color coding.
9. Electrical fixtures except for factory coatings.
10. Nameplates.
11. Grease fittings.
12. Brass and copper, submerged.
13. Fiberglass items, unless specifically required in the FRP specifications.
14. Aluminum handrail, stairs, and grating.
15. Insulated pipe.
3.12 PROTECTION OF SURFACES NOT TO BE PAINTED
A. Remove, mask, or otherwise protect hardware, lighting fixtures, switch plates,
aluminum surfaces, machined surfaces, couplings, shafts, bearings, nameplates on
machinery, and other surfaces not intended to be painted. Provide drop cloths to
prevent paint materials from falling on or marring adjacent surfaces. Protect
working parts of mechanical and electrical equipment from damage during surface
preparation and painting process. Mask openings in motors to prevent paint and
other materials from entering the motors.
03720-048-01
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09900-22
PAINTING AND COATING
3.13 SURFACES TO BE COATED
A. The exact coating to be applied in any location is not designated by the descriptive
phrases in the coating system titles such as "corrosive environment," "buried
metal," or "submerged metal." Coat surfaces with the specific coating systems as
described below:
1. Coat mechanical equipment, such as pumps and mixers, as described in
the various mechanical equipment specifications. The color of the finish
coat shall match the color of the connecting piping.
2. Coat aboveground and exposed piping or piping in vaults and structures as
described in the various piping specifications and as shown in the piping
schedule in the Contract Drawings. The color of the finish coat shall be as
shown in the Piping Schedule in the Contract Drawings.
3. Coat submerged steel and ductile iron piping as specified in System No. 7.
4. Paint pumps, gear reducers, and motors the same color as the connected
piping.
5. Coat valves as described the same as the adjacent piping. Aboveground
valves, or valves in vaults and structures, shall match the color of the
connecting piping.
6. Coat Sludge Storage and Blend Tank Interiors in accordance with
Specification 03180, Concrete Coating Systems
7. Paint Sludge Storage and Blend Tank Exteriors as specified in System
No. 32.
8. Coat concrete surfaces where shown in the drawings. System No. 33 on
submerged concrete surfaces unless otherwise shown in the drawings.
9. Coat aluminum surfaces in contact with concrete as specified in System
No. 54.
10. Coat buried flanges, nuts, and bolts unless they are stainless steel, valves,
flexible pipe couplings, exposed rebar in thrust blocks, and valve boxes as
specified in System No. 21 or as specified in the particular specifications
for the above items. Coat buried bolt threads, tie bolt threads, and nuts as
specified in System No. 24.
11. Coat exposed indoor galvanized electrical conduit as specified in System
No. 52. Color of finish coat shall be OSHA Safety Orange unless specified
elsewhere.
3.14 DRY -FILM THICKNESS TESTING
A. Measure coating thickness specified for carbon steel surfaces with a magnetic -
type dry -film thickness gauge in accordance with SSPC PA -2. Measure coating
thickness specified for stainless steel, aluminum, and copper surfaces with an
eddy -current type thickness gauge in accordance with ASTM D7091. Provide
certification that the gauge has been calibrated by a certified laboratory within the
03720-048-01 09900-23 PAINTING AND COATING
August 2019
past 6 months. Provide dry -film thickness gauge as manufactured by Mikrotest or
Elcometer.
B. Test the finish coat of metal surfaces (except zinc primer and galvanizing) for
holidays and discontinuities with an electrical holiday detector, low -voltage, wet -
sponge type. Provide measuring equipment. Provide certification that the gauge
has been calibrated by a certified laboratory within the past 6 months. Provide
detector as manufactured by Tinker and Rasor or K -D Bird Dog.
C. Measure coating thickness specified for concrete or masonry surfaces in
accordance with ASTM D4138. Test the finish coat of concrete and masonry
surfaces in accordance with NACE SP0188 or ASTM D4787. Patch coatings at
the points of thickness measurement or holiday detection.
D. Check each coat for the correct dry -film thickness. Do not measure within 8 hours
after application of the coating.
E. For metal surfaces, make five separate spot measurements (average of three
readings) spaced evenly over each 100square feet of area (or fraction thereof) to
be measured. Make three readings for each spot measurement of either the
substrate or the paint. Move the probe or detector a distance of 1 to 3 inches for
each new gauge reading. Discard any unusually high or low reading that cannot be
repeated consistently. Take the average (mean) of the three readings as the spot
measurement. The average of five spot measurements for each such 100 -square -
foot area shall not be less than the specified thickness. No single spot
measurement in any 100 -square -foot area shall be less than 80% nor more than
120% of the specified thickness. One of three readings which are averaged to
produce each spot measurement may underrun by a greater amount as defined by
SSPC PA -2.
F. For concrete surfaces, make five separate spot measurements spaced evenly over
each 100 square feet of area (or fraction thereof) to be measured. The average of
five spot measurements for each such 100 -square -foot area shall not be less than
the specified thickness. No single spot measurement in any 100 -square -foot area
shall be less than 80% nor more than 120% of the specified thickness.
G. Perform tests in the presence of the Owner's Representative.
3.15 REPAIR OF IMPROPERLY COATED SURFACES
A. If the item has an improper finish color or insufficient film thickness, clean and
topcoat the surface with the specified paint material to obtain the specified color
and coverage. Sandblast or power -sand visible areas of chipped, peeled, or
abraded paint, feathering the edges. Then prime and finish the coat in accordance
03720-048-01
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09900-24 PAINTING AND COATING
with the Specifications. The work shall be free of runs, bridges, shiners, laps, or
other imperfections.
3.16 CLEANING
A. During the work, remove discarded materials, rubbish, cans, and rags at the end of
each day's work.
B. Thoroughly clean brushes and other application equipment at the end of each
period of use and when changing to another paint or color.
C. Upon completion of painting work, remove masking tape, tarps, and other
protective materials, using care not to damage finished surfaces.
END OF SECTION
03720-048-01 09900-25 PAINTING AND COATING
August 2019
DIVISION 11
EQUIPMENT
SECTION 11000
GENERAL EQUIPMENT REQUIREMENTS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. This Section specifies general work requirements regarding the products and
execution services that are specified in the Division 11 Sections incorporated in
the Contract Documents. The requirements specified shall apply to all of the
Division 11 Sections, unless noted otherwise.
1.02 RELATED WORK
A. Other sections in the Contract Documents contain work that is related to the
general work requirements specified in this Section. This related work includes
but is not limited to the following sections:
1. Division III, General Conditions.
2. Section 01330, Submittals and Acceptance.
3. Section 01650, Delivery, Storage, and Handling.
4. Section 01755, Equipment Testing and Startup.
5. Section 01820, Training.
6. Section 09900, Painting and Coating.
7. Division 11, Equipment.
8. Division 13, Special Construction.
9. Section 15125, Piping Appurtenances.
10. Division 16, Electrical.
1.03 SUBMITTALS
The Contractor shall submit shop drawings in accordance with Section 01330, Submittals and
Acceptance:
A. The submittal contents for equipment, instrumentation, controls, and
appurtenances specified in the Division 11 Sections shall contain the general
information listed below. Additional submittal requirements are contained in the
Division 11 Sections.
03720-048-01
August 2019
1. A list and description of all deviations from the Contract Documents.
2. A list of equipment and components on each drawing with each product
identified by legend reference. Include product name, manufacturer, and
model number.
11000-1
GENERAL EQUIPMENT REQUIREMENTS
3. Completely dimensioned plan, elevations and cross-sections of system
equipment and sub -assemblies.
4. Shop and erection drawings showing details, anchor bolt locations, and
field connections.
5. Manufacturer's equipment installation instructions.
6. Descriptive literature, technical bulletins, and catalog data sheets for all
equipment and purchased sub -components.
7. Installation, operation, maintenance and start-up procedures.
8. Total equipment weight (while operating).
9. Drive mechanism torque rating and bearing life rating.
10. Motor data and catalog information.
11. Submit complete electrical drawings, schematics, and interconnecting
wiring diagrams and schedules for the equipment control system,
instrumentation, and control panel(s) showing numbered wiring terminals
in the control panel conforming to NEMA ICS -1-101. Identify field device
terminals, wire number, wire sizes, control and power wire types, and
interfaced elements.
12. Control panel construction and panel layout drawings.
13. Complete technical literature for all factory -applied paint systems. Clearly
indicate the components to be coated and the corresponding paint system.
14. Manufacturers' descriptive literature, product specifications, and
published details.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS (NOT USED)
1.06 QUALITY ASSURANCE
A. Requirements of Regulatory Agencies: The Contractor shall comply with
construction requirements of State, County, and other local political subdivision
specifications as may exceed the requirements of the codes, standards, and
approving bodies referenced in this Section.
1. NFPA Standards: The Contractor shall comply with requirements of the
National Fire Protection Association (NFPA) Standards referenced in the
various Specifications Sections and as directly appropriate to the work and
workmanship.
2. Electrical Requirements: The Contractor shall comply with requirements
for both the Underwriters' Laboratories, Inc. (UL) Listings, Labels, and
Approvals and the National Electrical Manufacturers' Associations
(NEMA) Stamps or Seals as applicable to electrical equipment or
apparatus forming parts of the Mechanical Equipment.
03720-048-01 11000-2 GENERAL EQUIPMENT REQUIREMENTS
August 2019
B. Certificates and Permits: Upon completion of work and before final payment, the
Contractor shall furnish to the Engineer formal certification of final inspections
from authorities having jurisdiction over the work in this project and secure
required permits, if any, from such authorities. Additionally, the Contractor shall
prepare any detailed diagrams and drawings that are required by those authorities
having jurisdiction over the work of this project at no additional cost to the
Owner.
C. Source Quality Control: Products used throughout these Specifications and as
indicated on the Drawings shall be from companies having established reputations
in the manufacture of the particular materials, equipment, or apparatus specified.
Such products may be of their own make or products of others for which they
assume full responsibility when used in finished products which are not
manufactured completely by them and with replacement parts available.
D. Products: The equipment specified in the Division 11 Sections was based on the
latest models that were available from the specified equipment manufacturers at
the time the Contract Documents were developed. If any equipment models
specified in the Division 11 Sections have been discontinued or will be
discontinued within 1 year after the bid date, the Contractor shall furnish and
install the latest and most recent equipment model at no additional cost to the
Owner.
E. For each category of materials and equipment (Products) specified in the
Division 11 Sections, the Contractor shall provide Products of the same
manufacturer and type.
F. Equipment Selection: The Contractor may furnish equipment of higher electrical
characteristics, physical dimensions, capacities, and ratings provided such
proposed equipment is approved by the Engineer in writing. Upon receiving the
Engineer's approval to provide such equipment, the Contractor shall furnish the
connecting mechanical and electrical services including but not limited to circuit
breakers, conduit, increased control panel enclosure size, motors, bases, and any
other electrical equipment needed to accommodate the higher electrical
characteristics at no additional cost to the Owner.
G. If minimum energy ratings or efficiencies of equipment are specified in
Division 11, Equipment, the Contractor shall furnish and install equipment that
meets or exceeds the specified design and commissioning requirements (no
exceptions) as determined by the Engineer.
H. All the equipment specified in the Contract Documents shall be standard units of
proven ability as manufactured by a competent organization that is fully
experienced, reputable and qualified in the manufacture of the equipment to be
03720-048-01
August 2019
11000-3
GENERAL EQUIPMENT REQUIREMENTS
furnished. The equipment shall be designed, constructed, and installed in
accordance with the best practice and methods and shall operate satisfactorily
when installed.
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
1.09 QUALIFICATIONS
A. The manufacturer of each piece of equipment described in the Division 11
Sections shall meet the following requirements, unless noted otherwise:
1. Have a record of operation, manufacturing and servicing the items
specified in the Division 11 Sections for a minimum of 10 years before the
Bid Date.
2. Have a minimum of five installations of equipment similar to that
specified in this Section at municipal wastewater treatment facilities in
Florida before the bid date.
3. Have been in business for at least the 10 consecutive years before the Bid
Date.
B. If the equipment manufacturer that the Contractor proposes to furnish and install
the equipment described in the Division 11 Sections does not meet these
qualifications and is not specified in the Contract Documents, the Engineer
reserves the right to reject the equipment from this manufacturer for use on this
project. Any costs incurred by the Contractor as a result of providing equipment
from a manufacturer that does not meet the qualifications described in this Section
shall not be incurred by the Owner.
C. The Contractor shall furnish documentation that the manufacturer meets these
qualifications as part of the submittals specified in Section 01330, Submittals and
Acceptance.
1.10 TESTING REQUIREMENTS (NOT USED)
03720-048-01 11000-4 GENERAL EQUIPMENT REQUIREMENTS
August 2019
1.11 MAINTENANCE
A. Spare Parts
1. The Contractor shall furnish the spare parts specified in the Division 11
Sections. The Contractor shall also submit a list of recommended spare
parts, special tools, and lubricants for each equipment item. The list shall
include contact information for local sources for supply of all parts and
professional service.
1.12 SYSTEM DESCRIPTION (NOT USED)
1.13 OPERATION AND MAINTENANCE (O&M) MANUALS
A. O&M Manuals shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01830, Operations and Maintenance Manuals.
1.14 PATENTS AND LICENSES (NOT USED)
PART 2 PRODUCTS
2.01 MOTORS
A. All motors identified in Division 11 Sections shall be furnished and installed
under Division 11, Equipment, and in accordance with Division 16, Electrical.
2.02 CONTROLS
A. General
03720-048-01
August 2019
1. All control panels specified in the Division 11 Sections shall be furnished
and installed under Division 11, Equipment, and in accordance with
Divisions 13, Special Construction, and 16, Electrical.
2. The Contractor shall furnish and install controls designed to operate on
120 -volt, single-phase, 60 Hertz electric service unless otherwise
specified. The Contractor shall furnish and install 120 -volt step-down
voltage transformers as specified in Division 16, Electrical, in each control
panel as required.
3. The Contractor shall furnish and install elapsed time meters in each
control panel for each piece of motor -driven equipment being controlled
by that control panel. All elapsed -time meters shall be furnished and
installed in accordance with Division 16, Electrical.
11000-5
GENERAL EQUIPMENT REQUIREMENTS
4. All control panels shall be furnished with a main circuit breaker to
enable/disable electric service to the panelboard.
5. All control panels that will annunciate a local and/or remote alarm shall be
furnished with an ALARM ACKNOWLEDGE reset pushbutton switch
(momentary contact) wired to each alarm contact.
6. All indicating lamps in each control panel shall be furnished in accordance
with the color -coded scheme:
a. ON indicating lamps: Red.
b. OFF indicating lamps: Green.
c. Alarm indicating lamps: Amber.
d. POWER ON indicating lamp: White.
7. Provide a heater inside of each control panel enclosure to prevent
condensation. Heater size shall be in accordance with the equipment
manufacturer's recommendations.
8. The face of each control panel shall be installed so it is facing north
whenever possible or provided with a sunshield when not possible.
2.03 FLOAT SWITCHES
A. Float switches shall be of the suspended type with polypropylene or PVC body.
Units shall have an integral electrical cable with two #19 AWG stranded
conductors. Switches shall be pilot duty, normally open or normally closed, as
required for application. Switches shall be suitable for use with intrinsically safe
circuits. Each switch shall be supported from an AISI Type 316 stainless steel
cable support bracket with individual stainless steel Kellems grip strain relief
supports. Each switch shall be provided with sufficient cable length to extend
from the float switch to the final termination point at the pump control panel with
an additional 18 inches of looped cable. The float switch cables shall be bundled
to an AISI Type 316 stainless steel cable with heavy-duty nylon strap wire ties.
The upper end of the stainless steel cable shall be attached to the cable support
bracket and the lower end attached to a 5 -pound (minimum) cable weight. The
cable weight shall be firmly attached to the cable and shall be constructed of
noncorrosive metal and/or materials. Float switches and cables shall be
intrinsically safe when used in classified locations.
03720-048-01
August 2019
11000-6
GENERAL EQUIPMENT REQUIREMENTS
2.04 EQUIPMENT ANCHORING SYSTEMS
A. All anchoring systems including, but not limited to, expansion anchors, adhesive
anchors, anchor bolts, cinch anchors, and screws that are required to install the
equipment and appurtenances specified in the Division 11 Sections shall be AISI
Type 316 stainless steel unless noted otherwise. The Contractor shall furnish and
install all equipment anchoring systems in accordance with Section 05500, Metal
Fabrications.
2.05 EQUIPMENT NAMEPLATES
A. The Contractor shall provide engraved laminated phenolic nameplates with white
legend and black field that provides the following information for each piece of
equipment described in the Division 11 Sections.
1. Equipment Description (i.e., Mixer, Truck Off -Loading Pump No 1, etc).
2. Equipment Identification Label No. as shown on the Contract Drawings.
B. Letter height on each nameplate shall not be less than 3/4 -inch. Nameplates shall
be factory drilled for fasteners. Secure nameplates to equipment or nearby wall
using AISI Type 304 stainless steel fasteners. The locations of each nameplate
shall be coordinated with the Owner and approved by the Owner before their
installation.
C. The Contractor shall obtain the Engineer's approval for the nameplate information
for each equipment item described in the Division 11 Sections before ordering
these nameplates from the manufacturer.
2.06 PRESSURE GAUGE ASSEMBLIES - PUMPING UNITS
A. General: The Contractor shall provide a pressure gauge assembly as specified in
Section 15125, Piping Appurtenances, on the suction and discharge piping of the
pumping units specified in the Division 11 Sections. The intent of the Drawings is
not to show the locations of every pumping unit pressure gauge. Rather, the
Contractor shall mount each pressure gauge as close to the pump suction and
discharge connections as possible, but so as not to impede the operation and
maintenance of the pressure gauge assembly, pumping unit, and valves installed
on the pumping unit suction and discharge piping. Coordinate the location of all
pressure gauge assemblies with the Owner before installation.
03720-048-01
August 2019
11000-7 GENERAL EQUIPMENT REQUIREMENTS
PART 3 EXECUTION
3.01 INSTALLATION
A. General: The Contractor shall install the equipment in accordance with the
manufacturer's instructions and recommendations and approved submittals at
the locations shown on the Drawings. If the equipment locations shown on the
Drawings are in conflict with the manufacturer's recommendations or will
interfere with the installation or operation of any other item indicated in the
Contract Documents, the Contractor shall immediately notify the Owner and
Engineer before they relocate this equipment and provide the necessary
appurtenances to install the equipment in accordance with the manufacturer's
recommendations at no additional cost to the Owner. The Contractor shall not
install any equipment at locations not in accordance with the Contract Documents
or approved submittals.
B. The Contractor shall install equipment, slabs, walls level and plumb, parallel and
perpendicular to other building and components in exposed interior spaces, unless
otherwise shown on the Drawings.
C. The Contractor shall apply an anti -seize compound to threaded fasteners of
equipment components that require removal, replacement, or adjustment as part of
any maintenance or inspection procedure.
D. The Contractor shall furnish and install the required oil and grease for initial
operation in accordance with the manufacturer's recommendations.
E. Provide means of oil lubrication for bearings and other metallic parts in sliding
contact. Use alemite industrial -type fittings except where otherwise specified. The
Contractor shall also perform the following work:
1. Locate lubrication points on equipment readily accessible without the
necessity of removing covers, plates, housings or guards, or without
creating safety hazards at installed equipment elevations.
2. The Contractor shall exhaust pressure -lubricated units to the atmosphere
to prevent excessive greasing.
3. The Contractor shall extend grease fittings to locations that are readily
accessible to the Owner. The Contractor shall coordinate the location of
these grease fittings with the Owner before their installation.
F. The Contractor shall furnish and apply touch-up paint to any equipment's factory
painting finish that is chipped or damaged during installation. All factory -finish
touch-up paint shall be mutually compatible with the factory finish on the
03720-048-01
August 2019
11000-8
GENERAL EQUIPMENT REQUIREMENTS
equipment and shall be furnished by the manufacturer of the equipment to be
touched up in the field.
G. If equipment mounting heights are not shown on the Drawings, the Contractor
shall install that piece of equipment to provide the maximum amount of headroom
(defined as the distance from the bottom of the structure to the top of finished
floor or grade), as possible. In such an instance, the Contractor shall obtain the
Engineer's approval for this mounting location before installing that piece of
equipment in the field.
H. The Contractor shall furnish and install all mechanical equipment to facilitate
service, maintenance, and repair or replacement of the equipment components.
The Contractor shall connect equipment for ease of disconnecting, with minimum
interference to other installations.
3.02 FIELD TESTING
A. General: The Contractor shall provide services of a factory -authorized service
representative to perform, approve, and certify the field testing specified in this
Section. Field testing shall generally consist of performing the pre -startup and
startup tests as specified in the Division 11 Sections and the final mechanical
performance test specified in this Section. The Contract Documents may require
the Contractor to perform factory testing on equipment items before the Engineer
approves their use for this project. The Contractor shall refer to the Division 11
Sections regarding equipment shop testing requirements.
B. The Contractor shall adhere to the following requirements regarding the field
testing to be provided for this project:
03720-048-01
August 2019
1. The service representative shall be employed by the manufacturer of the
equipment specified at the time field testing is being performed. The
service representative shall be authorized by the factory to perform the
field testing specified in Division 11, Equipment. Upon request by the
Engineer, the Contractor shall submit a letter from a company officer of
the equipment manufacturer stating that the service representative
performing the field testing is authorized by the manufacturer.
2. Before scheduling each field test with the equipment manufacturer, the
Contractor shall coordinate with the Owner and Engineer to obtain a list of
dates that both parties would be available to attend the testing. The
Contractor shall notify the Owner and Engineer of the field testing dates
no less than 14 calendar days before the date of the field test.
3. If directed by the Engineer, the Contractor shall perform a second pre -
startup and/or startup test, in accordance with the procedures specified in
the Division 11 Sections, at no additional cost to the Owner if the original
11000-9
GENERAL EQUIPMENT REQUIREMENTS
pre -startup and/or startup test did not pass because of any work that was
deemed by the Engineer to be non-compliant with the Contract Documents
and/or manufacturer's recommendations.
4. The Contractor shall only perform startup testing after the Contractor has
reached Substantial Completion for the project as defined in the
Agreement and General Conditions.
5. The Contractor shall furnish, install, and remove any temporary piping,
valves, appurtenances, and equipment necessary to perform the pre -startup
and startup testing to the Engineer's satisfaction.
6. All field testing shall be performed Monday through Friday at the project
site, unless otherwise approved by the Owner.
7. The duration that the manufacturer's representative is required to be
onsite to perform the pre -startup and startup training is specified in the
Table 11000-1, Equipment Testing and Training Requirements.
C. Operating Costs
1. Costs for Pre -startup and Startup Testing: The Contractor shall include in
the Contract Price the following operating costs for satisfactorily
completing the Initial Mechanical Performance Tests on equipment being
tested:
a. Lubricating grease.
b. Lubricating oils.
c. Such other materials or utilities not specifically identified in this
Section but required to conduct the pre -startup and startup testing.
d. Portable diesel power generation sets and diesel fuel as needed for
lighting, portable tools, and furnishing electrical to any temporary
pumping units used to transfer reclaimed water to each treatment
or storage structure for startup testing. The Owner will provide
reclaimed water for testing at their discretion.
2. Costs for Final Mechanical Performance Tests: The Owner will pay for
the operating costs for the Final Mechanical Performance Test, except for
the Contractor's personnel needed to perform and supervise this testing as
specified in this Section.
D. The intent of the field testing for each equipment item specified in the Division 11
Sections is provided in this Section. If the individual equipment field testing
procedures specified in the Division 11 Sections are not sufficient to obtain a
Manufacturer's Certification or to demonstrate compliance with the Contract
03720-048-01
August 2019
11000-10
GENERAL EQUIPMENT REQUIREMENTS
03720-048-01
August 2019
Documents, the Contractor shall perform these additional field test procedures at
no additional cost to the Owner.
1. Pre -startup Testing: Upon the Contractor's completion of the installation
and adjustment of the equipment; the Contractor, with his own forces and
with the manufacturer's representative(s), shall demonstrate to the
Engineer's satisfaction that the equipment has been furnished and installed
in accordance with the Contract Documents and the manufacturer's
recommendations.
a. The Contractor shall repair any equipment items that do not pass
the pre -startup test, as identified by the Engineer and/or
manufacturer's representative, to the satisfaction of the Engineer
before performing the startup testing for that equipment.
2. Startup Testing: Upon successful completion of the pre -startup testing, the
Contractor shall demonstrate that the mechanical performance and
controls of each equipment item, when operated in accordance with the
design intent indicated by the Contract Documents, are satisfactory to the
Owner and Engineer.
a. Startup testing shall be performed with each equipment item and
associated treatment structure simulated under similar operating
conditions as the final mechanical performance testing specified in
this Section. For equipment that will operate while being
submerged as shown on the Drawings, the Contractor shall fill the
respective treatment structure to its maximum water surface with
reclaimed water for wastewater systems and perform startup
testing while that equipment is submerged. The Contractor shall
not use wastewater to fill any treatment structures for startup
testing.
b. After the startup testing procedures specified in the Division 11
Sections have been completed to the satisfaction of the Engineer,
the Contractor shall operate that equipment for one successful
continuous 72 -hour period without assistance from the Owner as a
condition of startup testing. If the equipment needs to be taken out
of service for repair during this 72 -hour period because it not
operating in accordance with the intent of the Contract Documents,
this operating period shall cease. A new operating period will not
begin until the equipment has been operating in accordance with
the Contract Documents and manufacturer's recommendations for
at least 72 consecutive hours. The Contractor shall furnish any
additional supervision or provisions necessary to verify that each
11000-11
GENERAL EQUIPMENT REQUIREMENTS
03720-048-01
August 2019
equipment item was successfully operated during this 72 -hour
operating period.
c. Upon completion of the startup test, the Contractor shall dewater
each treatment and storage structure in accordance with local and
State regulations and in a manner that is satisfactory to the Owner
and Engineer.
3. Final Mechanical Performance Testing: The Contractor shall perform
final mechanical performance testing of the equipment specified in the
Division 11 Sections once the following conditions have been satisfied:
a. The Contractor has successfully completed the pre -startup and
startup testing requirements specified in the Division 11 Sections.
b. The Contractor has performed the training services specified in this
Section.
c. The Contractor has procured all of the required permits for each
building and treatment structure within the project site.
d. The Engineer has received and approved all of the manufacturer's
certifications of compliance, warranties, and operation and
maintenance manuals for all required items as specified in the
Contract Documents.
e. The intent of the final mechanical performance test is for the entire
facility to be operated by the Owner for a continuous 30 -day
period while the facility is receiving and treating raw sewage or
raw water. During this 30 -day testing period the Contractor shall
furnish personnel who shall be on-site as needed and available at
all times 24 hours per day during the final mechanical performance
test. Personnel shall be competent in the troubleshooting and repair
of the equipment and related electrical and mechanical systems
specified in the Contract Documents. The Contractor's electricians
and mechanical technicians shall be on-site as needed (minimum
8 hours/week) and available 24 hours per day to assist with this
testing. If the final mechanical performance testing needs to be
stopped and suspended due to equipment not operating in
accordance with the design intent of the Contract Documents as
determined by the Engineer, the following conditions shall apply:
(1) The Contractor shall repair and troubleshoot these items
immediately at no additional cost to the Owner.
11000-12
GENERAL EQUIPMENT REQUIREMENTS
(2) The 30 -day period for the final mechanical performance
testing will start over (i.e., be reset to zero hours).
f. Upon restarting the final mechanical performance testing, the
Contractor shall furnish the appropriate personnel defined above
on-site as needed and available (minimum 8 hours/week) for
24 hours per day during the 30 -day period at no additional cost to
the Owner even though the total duration of the final mechanical
performance testing (including restarts), may exceed 30 days.
g.
The final mechanical performance test shall end when the Engineer
determines that all of the equipment and related systems are
operating in accordance with the design intent of the Contract
Documents and all deficiencies that hinder the normal day-to-day
operation of the facility have been corrected to the satisfaction of
the Engineer. The Engineer shall notify the Contractor in writing
when the final mechanical performance testing has been
successfully completed.
3.03 TRAINING SERVICES
A. Upon completion of the pre -startup and startup testing and before the final
mechanical performance testing, the manufacturer of the equipment specified in
the Divisions 11, Equipment, 13, Special Construction, 15, Mechanical, and 16,
Electrical, shall provide an authorized representative to train the Owner's
personnel in the operation and maintenance of the equipment. Training shall be
provided in accordance with Section 01820, Training, and as specified in each
section. The representative shall provide additional onsite startup and
troubleshooting services during this training upon request by the Engineer or
Owner while performing these training services. The duration of the training
services for each equipment item are specified in the Table 11000-1, Equipment
Testing and Training.
B. The Contractor shall conduct two separate training sessions for all items discussed
in this document: one for the morning staff (7:00 A.M.) and one for the afternoon
staff (2:00 P.M.).
3.04 MANUFACTURER'S CERTIFICATIONS OF COMPLIANCE
A. Upon successful completion of the pre -startup testing, startup testing, and training
services specified in this Section, as required in Table 11000-1, Equipment
Testing and Training Requirements, the Contractor shall obtain the equipment
manufacturer's certification that the equipment specified in the respective
Division 11 Sections has been installed, adjusted, and tested in accordance with
03720-048-01
August 2019
11000-13
GENERAL EQUIPMENT REQUIREMENTS
the manufacturer's recommendations. The Contractor shall furnish the Engineer
with Manufacturer's Certificates of Compliance and Equipment Manufacturer's
Certificate of Installation Testing and Instruction for each specified equipment
item before performing the final mechanical performance testing specified in this
Section.
Table 11000-1 Equipment Testing and Training Requirements
(Hours below stipulate the duration the manufacturer's representative is required be on site to perform the
required pre -startup and starting testing, final mechanical performance testing, and training services
specified in the listed sections. See Note 1.)
Section
Equipment Name
Pre -Startup
Testing (3)
Startup
Testing
(3)
Final Mechanical
Performance
Testing (4)
Training
(4)5
O
11228
Mixers
4 hours
4 hours
4 hours
8 hours
11330
In -Line Grinder
4 hours
4 hours
4 hours
8 hours
11356
Progressive Cavity Pumps
8 hours
8 hours
8 hours
16 hours
13232
Aluminum Flat Covers
2 hours
2 hours
2 hours
4 hours
Notes:
1.
If difficulties occur in operating the equipment due to the manufacturer's fabrication or the Contractor's
installation, additional service shall be provided at no change in Contract Price or Time.
2. All times listed above exclude travel time to and from the project site.
3. The Pre -Startup and Startup testing may be combined within a single trip if the manufacturer's
representative determines that the equipment is properly installed by the Contractor in accordance with the
Contract Documents and the manufacturer's recommendations: However, these services shall not be
combined with the Final Mechanical Performance Testing and Training; a separate trip(s) shall be
conducted to accomplish these services.
4. The Final Mechanical Performance Testing and Training may be combined within a single trip but shall not
be combined with the Pre -Startup and Startup testing. Training shall be conducted in accordance with
Section 01820, Training.
5. The Contractor shall conduct two separate training sessions for all items discussed in this document: one
for the morning staff (7:00 A.M.) and one for the afternoon staff (2:00 P.M.). The reflected training hours
are the total combined between both of these sessions.
03720-048-01
August 2019
11000-14
GENERAL EQUIPMENT REQUIREMENTS
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
MANUFACTURER'S CERTIFICATE OF COMPLIANCE
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 in accordance with Manufacturer's recommendations.
Inspected, checked, and adjusted.
Serviced with proper initial lubricants.
Electrical and mechanical connection meet quality and safety standards.
All applicable safety equipment has been properly installed.
Comments:
System has been performance tested, and meets or exceeds specified
performance requirements (when complete system of one manufacturer).
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 his equipment, and (iii) authorize the 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:
By Manufacturer's Authorized Representative:
03720-048-01
August 2019
11000-15
(Authorized Signature)
GENERAL EQUIPMENT REQUIREMENTS
OWNER
PROJECT
EQUIPMENT MANUFACTURER'S CERTIFICATE OF
INSTALLATION TESTING AND INSTRUCTION
CONTRACT NO.
Jones Edmunds No.
EQUIPMENT SPECIFICATION SECTION
EQUIPMENT DESCRIPTION
I , Authorized representative of
(Print Name)
hereby CERTIFY that
(Print Manufacturer's Name)
(Print equipment name and model with serial No.)
Installed for the subject project has have been installed in a satisfactory manner, has have been
satisfactorily tested, is/are ready for operation, and that Owner assigned operating personnel have
been suitably instructed in the operation, lubrication, and care of the units on Date:
Time:
CERTIFIED BY: DATE:
(Signature of Manufacturer's Representative)
OWNER'S ACKNOWLEDGEMENT OF MANUFACTURER'S INSTRUCTION
I/We the undersigned, authorized representatives of the
and/or Plant Operating Personnel have received classroom and hands on instruction on the
operation, lubrication, and maintenance of the subject equipment and am are prepared to assume
normal operational responsibility for the equipment:
DATE:
DATE:
DATE:
END OF SECTION
03720-048-01 11000-16 GENERAL EQUIPMENT REQUIREMENTS
August 2019
SECTION 11228
MIXERS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish all labor, materials, equipment, and incidents
required and unload, install, place in operation, and field test mixers, motors,
gearboxes, local control panels and isolator in the Sludge Storage and Blend
Tanks. Each mixer unit shall be specifically designed to provide sufficient mixing
to the Sludge Storage and Blend Tanks.
B. All mixers for the Sludge Storage and Blend Tanks shall be provided from one
manufacturer.
C. These Specifications are intended to generally describe what is required but do
not cover all details, which will vary with the requirements of the equipment
application. The Specifications are, however, intended to cover furnishing, shop
testing, delivery, unloading, on-site storage, complete installation, and field
testing of all materials, equipment, and appurtenances for the complete mixing
system as specified in this Section, whether specifically mentioned in these
Specifications or not.
1.02 RELATED WORK
Other Specifications in the Contract Documents contain work related to the general work
requirements specified in this Section. This related work includes but is not limited to the
following sections:
A. Section 01330, Submittal and Acceptance.
B. Section 01650, Delivery, Storage, and Handling.
C. Section 01755, Equipment Testing and Startup.
D. Section 01780, Warranties and Bonds.
E. Section 01785, Record Documents.
F. Section 01815, Maintenance of Plant Operation and Sequence of Construction.
G. Section 01820, Training.
H. Section 01830, Operations and Maintenance Manuals.
I. Section 09900, Painting and Coating.
J. Division 3, Concrete Work.
K. Division 16, Electrical.
L. Section 16150, Motors.
03720-048-01 11228-1 MIXERS
August 2019
1.03 SUBMITTALS
A. The Contractor shall submit shop drawings in accordance with Section 01330,
Submittals and Acceptance.
B. The Contractor shall submit to the Engineer copies of all materials required to
establish compliance with this Section. Submittals shall include at least the
following:
1. Descriptive literature, bulletins, catalog cuts, and drawings for the
equipment including minimum submergence requirements.
2. Materials of construction, specifications, grade, or type.
3. Coating information.
4. Identify each mixer by tag number to which the catalog data and detail
sheets pertain.
5. Certified shop and installation drawings showing all details of
construction, dimensions, and anchor bolt requirements.
6. Shaft size and material.
7. Mixer body size, type, and material.
8. Complete bill of materials for the equipment.
9. 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.
10. The weight of each component: motor, gearbox, shafting, and impeller.
11. The total weight of the complete assembled mixer.
12. Dynamic torque and moment.
13. Complete motor data including size, make, type, and characteristics of the
electric motor along with wiring diagram.
14. A list of manufacturer's recommended spare parts to be supplied
15. Design calculation demonstrating that specified performance requirements
are met.
16. Control panel drawing and wiring diagrams.
C. Test Reports to be Submitted:
1. Description of test procedures and equipment.
2. Copies of all test results, as specified in Parts 2 and 3 of this Section.
D. Complete operation and maintenance instructions shall be furnished for all
equipment specified in this Section in accordance with Division 1, General
Requirements.
E. The Contractor shall submit the manufacturer's Certificate of Installation,
Testing, and Instruction as specified in Division 1, General Requirements.
03720-048-01
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1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be the latest
revision of any such document in effect at the bid time. The following documents are a part of
this Section. Where this Section differs from these documents, the requirements of this Section
shall apply.
A. American Iron and Steel Institute (AISI)
B. American Bearing Manufacturers Association (ABMA)
C. American Gear Manufacturers Associations, Inc. (AGMA), where applicable or
equivalent DIN -ISO standards.
1. AGMA 6013—Standard for Industrial Enclosed Gear Drives.
D. American Society for Testing and Materials (ASTM)
E. American Welding Society (AWS)
F. Anti -friction Bearing Manufacturer's Association (AFBMA)
G. International Organization for Standardization (ISO), where applicable
H. National Electrical Code (NEC)
I. National Electrical Manufacturers Association (NEMA)
J. Occupational Safety and Health Administration (OSHA)
K. The Society of Protective Coatings (SSPC)
L. Underwriter's Laboratory (UL)
1.06 QUALITY ASSURANCE
A. The Contractor shall provide quality assurance measures for the items specified in
this Section in accordance with this Section and Section 11000, General
Equipment Requirements.
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August 2019
1.07 WARRANTIES
A. Warranties shall be in accordance with Section 01780, Warranties and Bonds, and
as specified herein.
B. Warranty Period: All equipment supplied under this Section shall be warranted by
the manufacturer for at least 3 years, 6 months, following initial shipments from
its factory or 3 years following start-up and testing, whichever occurs first.
C. The equipment shall be warranted to be free from defects in workmanship, design,
and materials. If any part of the equipment fails during the warranty period, the
failed component shall be replaced and the unit(s) restored to service at no
expense to the Owner.
D. The manufacturer's warranty period shall run concurrently with the Contractor's
warranty period. No exception to this provision shall be allowed.
1.08 DELIVERY, STORAGE AND HANDLING
A. The Contractor shall adhere to the requirements specified in the Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
B. All equipment and 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.
C. The equipment shall be delivered on site as fully assembled as transportation
allows. Factory -assembled parts and components shall not be dismantled for
shipment unless permission is received in writing from the Engineer.
D. Finished iron or steel surfaces not painted shall be properly protected to prevent
rust and corrosion.
E. Each box or package shall be properly marked to show its net weight in addition
to its contents.
F. Finished surfaces of all exposed openings shall be protected by wooden blanks,
strongly built, and securely bolted thereto.
G. Finished iron or steel surfaces shall be painted in accordance with Section 09900,
Painting and Coating.
03720-048-01
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11228-4 MIXERS
H. Care shall be taken to avoid supporting or lifting the mixers in a manner that will
place excessive stress on parts or shafts that are not designed to support the
weight of the unit. The mixer assembly shall be lifted by eyebolts provided in the
top of motor drive or by slings.
1.09 QUALIFICATIONS
A. The Contractor shall assume full responsibility for the satisfactory installation and
operation of the entire mixers, gearboxes, and motors as specified.
B. All the equipment specified under this Section shall be furnished by a single
manufacturer and shall be standard units of proven ability as manufactured by a
competent organization that 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 the best practice and shall operate
satisfactory when installed.
C. All equipment furnished under this Section shall be new and unused and shall be
the standard products of manufacturers with a successful record of manufacturing
and servicing the similar equipment for a minimum of 5 years.
D. The manufacturer shall be fully responsible for the design, arrangement, and
operation of all connected rotating components of the assembled mixer unit to
ensure that neither harmful nor damaging vibration occurs during operation. The
design shall include all supporting frames and fabrication steel base plate for
mounting the unit to the existing structure.
E. Any additional equipment necessary for the proper operation of the proposed
installation not specifically mentioned in these Specifications or shown on the
Drawings shall be furnished and installed.
1.10 TESTING REQUIREMENTS
A. Testing shall be performed as specified in Part 2 and Part 3 of these
Specifications.
1.11 MAINTENANCE
A. Spare Parts
1. The Contractor shall furnish the following spare parts in clearly identified
containers, labeled for easy identification without opening the packaging
and suitably protected for long-term storage in humid environment.
03720-048-01 11228-5 MIXERS
August 2019
2. For the two mixers, provide each:
a. One service kit with lip seals, O -rings, and shim sets.
b. One spare motor per mixer.
c. One spare gearbox per mixer.
d. Additional spare parts shall be provided in accordance with the
recommendations of equipment manufacturers.
B. Special Tools
1. One shaft clamp for each shaft size.
2. The Contractor shall furnish one set of all special tools required for normal
operation and maintenance of the equipment.
C. Tools shall be furnished in a suitable steel case, clearly and indelibly marked on
the exterior to indicate the equipment for which the tools are intended.
1.12 SYSTEM DESCRIPTION
A. The Contractor shall provide two mixers at the Northeast Water Reclamation
Facility (NEWRF). The mixers should be installed in each of the two Sludge
Storage and Blend Tanks (one mixer in the North Sludge Storage and Blend Tank
and one mixer in the South Sludge Storage and Blend Tank) as shown on the
Contract Drawings.
B. The mixer shall be adequately designed to mix sludge completely within the
Sludge Storage and Blend Tanks with geometry, volume, and side -water depth
shown in the Contract Drawing and as specified herein. Variation in the blended
sludge shall be less than 10% over the range of the side -water depth. The mixer
shall consist of a complete assembly of drive unit, gear box, shaft, seals, impeller,
base plate, and all other necessary components and accessories. The mixer shall
be specifically designed and furnished to meet the requirements specified herein
these Project Specifications and as shown in the Contract Documents.
C. All equipment specified and to be furnished and installed in this Section is
intended to be standard for mixing based on this application.
D. The mixer units required under this Section shall be complete, including the
motor, speed reducer, shaft, impeller, and base plate with proper alignment of the
unit. All parts shall be so designed and proportioned as to have lateral strength,
stability, and stiffness and to be especially adapted for the operational conditions
and the properties of the sludge to be mixed.
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E. Equipment furnished under this Section shall be designed for a municipal
wastewater treatment plant environment in which the equipment is exposed to the
atmosphere. The equipment shall be designed for humid atmospheric conditions
in West -Central Florida and shall be designed for continuous operation; 24 hours
per day, 365 days per year.
1.13 OPERATION AND MAINTENANCE (O&M) MANUALS
A. The manufacturer shall provide Operation and Maintenance manuals for the
specific equipment with appropriate model numbers and motor data specific for
this project. Operations and Maintenance Manuals shall be in accordance
Section III — General Conditions, and Section 01830, Operations and Maintenance
Manuals.
1.14 PATENTS AND LICENSES (NOT USED)
PART 2 PRODUCTS
2.01 PERFORMANCE AND DESIGN REQUIREMENTS
A. The mixing equipment is used to mix the contents of the Sludge Storage and
Blend Tanks with mixers as shown on the Contract Drawings.
B. Each mixer shall operate independently and shall be controlled from the as shown
in the Contract Documents and specified in these Project Specifications. The
mixers shall be constant speed units designed to operate continuously.
C. Northeast Water Reclamation Facility
03720-048-01
August 2019
1. Tank Volumes
Number of Sludge Storage and Blend Tanks
2
Tank Dimensions
40 ft diameter x 18 ft height
Side Water Depth
4 ft — 16 ft
Sludge % TS
4-6%
Tank Finished Floor (Elevation)
57.73 ft
Minimum Operating Level (Elevation)
58.73 ft
Maximum Operating Level (Elevation)
74.23 ft
Normal Sludge Level (Elevation varies)
62.73 to 68.73 ft
Tank Volume -Full
150,000 gallons
Tank Volume — Normal Operation
35,000 to 95,000 gallons
11228-7
MIXERS
2. Performance Criteria
Sludge Storage and Blend Tank Mixer Design
Rotational Speed
<45 rpm
Average Bottom Velocity
>3.0 ft/s
Motor
40 hp
Voltage/Ph/Hz
460/3/60
Nominal Motor Speed
1,800 rpm
Service Factor
<2
Bearing Life
>100,000 L10
D. The mixer manufacturer and model shall be the following:
1. Invent Environmental Technologies, Inc., Model HCM/2500-44-40.0hp.
2.02 MATERIALS AND EQUIPMENT
A. Invent Environmental Technologies
1. Mixer Design and Construction:
a. Each mixer assembly shall consist of a dry installed heavy-duty
speed reducer with hollow stainless steel shaft, electric motor, base
plate, and hyperbolic mixing body.
b. Mixers shall be capable of handling biological activated sludge
with a solids concentration from 4 to 6%, with a Sludge Volume
Index (SVI) of 80 mL/g or greater and shall be designed to prevent
settlement in the tanks and to re -suspend biological material on the
tank bottom. The mixer shall be capable of mixing the mixed
liquor without introduction of air.
c. The mixer shall be designed as a vertical shaft mixer, with a dry
installed motor. During operation the mixer shall not generate any
upward forces on the bridge construction.
d. The mixer shall have a steady stationary flow pointed downward
parallel to the mixer shaft, the highest speeds and turbulent
fluctuations shall be produced in the bottom area. No separation
vortex shall appear on the water surface.
e. Mixer shall be equipped with a bottom guide to allow the mixer to
operate at tank -empty -to -full operating condition.
2. Gear Drive:
a. The drives for the mixers shall be SEW Eurodrive (or approved
equal), parallel shaft helical geared motors and have a high-quality
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corrosion protection coating, robust weather protective hood and
filled with synthetic oil.
b. The gear shall be rated for a long bearing service life and for
adverse operating conditions. The driving shaft shall be mounted in
a hollow shaft and secured by means of a nut. The torque shall be
transmitted by a feather key connection. The hollow shaft shall be
capped.
c. The gearbox shall be built as a parallel helical gear shaft with the
following requirements:
(1) A calculated lifetime L10 of the bearings of approximately
100,000 hours.
(2) High quality protection against corrosion.
(3) Covered hollow shaft.
(4) Service factor of greater 1.5.
d. The gearbox housing shall be cast iron covered with a high-quality
Standard 053 coating having a thickness of at least 6 mils. The
gear box shall be connected to the mounting base using a flange
connection with stainless steel nuts and bolts.
3. Motor:
a. Unless otherwise noted in this Section motors shall be in
accordance with Section 16150, Motors.
b. Motor shall be a three-phase squirrel cage motor with helical gear
having the following specifications:
(1) The motor shall be SEW or approved equal.
(2) Squirrel cage induction for operation on 460 volt, three-
phase, 60 Hz current. Synchronous speed shall not exceed
1,800 rpm. The motor shall be of the totally enclosed, fan -
cooled type suitable for outdoor operation having NEMA
Class F insulation and Class B temperature rise at full load,
a service factor of 1.5, rated for 40°C ambient temperature.
(3) Motors shall have a weather protection hood and be
suitable for operation in a moisture -laden atmosphere. The
conduit boxes shall be gasketed with neoprene or
equivalent material, so as to prevent moisture from entering
the stator through the conduit box. Condensation drains
shall be suitable positioned in the lower external surface, so
03720-048-01 11228-9 MIXERS
August 2019
that nay accumulation of moisture can drain from the
complete motor housing.
(4) Increased protection of the winding against humidity and
acid.
(5) Inner corrosion protection of motor.
(6) High-quality protective varnishing against corrosion.
(7) Protection type IP66.
(8) ISO -Class F.
(9) Provide 120VAC motor space heaters and motor
bi-metallic thermostats.
4. Mounting Base: The mounting base of the mixer shall consist of a gear
base plate mounted on rubber buffers connected permanently to the bridge
by AISI Type 316 stainless steel bolted connection. The gear plate shall be
designed as a distortion -proof steel structure with an impact -proof
powder -coated surface. The plate shall be able to be leveled using
threaded bolts which adjust in height. The rubber buffers/isolator shall
absorb starting -up jolts, prevent any transfer of vibrations to the bridge
and constitute the galvanic separation of the mixer from its surroundings.
The mounting base shall be supplied with a fastening set with AISI
Type 316 stainless steel anchor bolts for connecting to the bridge as shown
in the Contract Drawings.
5. Shaft: The drive shaft of the mixer shall be made from AISI Type 316 and
resistant to most chemicals and wastewater. The top end of the shaft shall
be a steel tappet for the connection to the gear hollow shaft. At the lower
end there shall be a flange. The mixer body shall include a flanged
screwed connection. The manufacturer shall field verify shaft length with
the Contractor during shop drawing submittal.
6. Hyperboloid Mixer Body: The hyperboloid mixer body shall be a
streamlined stress -free body without any mounted or fitted parts. The
transport ribs which accelerate the flow shall be integrated in the mixer
body and be made of top quality, fiberglass reinforced plastic. The mixer
body shall be coated with a gel coat and polished surface.
7. Bolts and Hardware: All base plates, assembly bolts, nuts, washers,
fasteners shall be AISI Type 316 stainless steel as specified.
2.03 SHOP PAINTING
A. Before exposure to weather and shop painting, all surfaces shall be thoroughly
cleaned, dry, and free from all mill scale, rust, grease, dirt, and other foreign
matter.
03720-048-01
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11228-10 MIXERS
B. The mixers, base plates, and gear boxers shall be prepared and shop -primed in
accordance with Division 9. Primer shall be compatible with the finish paint
specified in Section 09900, Painting and Coating.
C. All nameplates shall be properly protected during painting.
D. Gears and other similar surfaces not to be painted shall be given a heavy shop
coat of grease or other suitable rust -resistant coating. This coating shall be
maintained as necessary to prevent corrosion during storage and erection and shall
be satisfactory to the Engineer up to the time of the final acceptance test.
2.04 SHOP TESTING
A. The Engineer shall have the right to inspect, test, or witness tests of all materials
or equipment to be furnished under this Section before shipment from the point of
manufacture.
B. The Engineer shall be notified in writing before initial shipment in ample time so
that arrangement can be made for an inspection.
C. The mixers shall be factory/shop tested in accordance with the approved testing
procedures to ensure that the quality of materials used in the manufacture of the
mixers and workmanship conforms to the specified requirements.
2.05 CONTROL PANELS
A. A NEMA 4X, 316 stainless control panel shall be provided for each mixer. The
panels shall be deadfront construction with inner door, 3 -point door latch and
include a, UL 508a label as an assembly with a SCCR rating of 14 kA minimum.
B. Panels shall include a main circuit breaker and branch breaker for controls and
receptacle. Panels will include a solid-state soft type starter rated for 50°C,
manufactured by either Square -D or Allen-Bradley. All internal wiring shall be
copper, rated at 600V and identified at each end.
C. The panels will include an inner door with the following NEMA 4X rated
devices:
1. Lockable Safety Disconnect Switch.
2. Hand -off -Auto.
3. Elapse Time Meter.
4. Running Indicator.
5. Stop Indicator.
03720-048-01 11228-11 MIXERS
August 2019
6. Mixer Trouble Indicator (high amperage/motor overload).
7. Alarm Reset.
D. The panels shall include dry contacts for use by the remote SCADA system as
follows:
1. Mixer Run.
2. Mixer Fail (high amperage/motor overload).
3. Mixer in Hand.
4. Mixer in Auto.
5. Reset Position.
E. The panels shall include an internal 480 -volt surge protection rated a minimum of
50kA/mode.
PART 3 EXECUTION
3.01 INSTALLATION
A. Installation of the mixer, motor, shaft, associated equipment and accessories, and
supports shall be in strict accordance with the manufacturer's instructions and
recommendations in the locations shown on the Contract Drawings. The required
grade lubricant for initial operation shall be furnished in accordance with the
manufacturer's recommendations. Mounting, leveling, any required calibration,
and anchor bolting shall be installed in accordance with the manufacturer's
recommendations.
B. The Contractor shall submit a certificate from the manufacturer stating that the
installation of the equipment is satisfactory; that the equipment is ready for
operation; and that the operating personnel have been suitably instructed in the
operation, lubrication, and care of each unit.
C. The Contractor shall make all adjustments to each unit as directed by the
equipment manufacturer before placing the unit in operation.
3.02 FIELD PAINTING
A. Field painting is specified in Division 9. The primer and paint used in the shop
shall be products of the same manufacturer as the field paint to ensure
compatibility.
B. All nameplates shall be properly protected during painting.
03720-048-01
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11228-12 MIXERS
3.03 FIELD TESTING
A. Before testing, each mixer shall be checked by the manufacturer's technical
representative for lubrication, alignment, and rotation. The manufacturer's
technical representative shall notify the Contractor and the Engineer of anything
in the installation that affects the manufacturer's guarantee. The Contractor shall
make the adjustment based on manufacturer's recommendation. The
manufacturer's representative shall provide certification that each mixer is
rotating in the right direction and is ready for testing.
B. The test runs of the mixers shall be undertaken with water in the tanks filled to the
peak water elevations shown on the Drawings. The test runs on the mixers shall
determine acceptable running noise, speed, and rotational direction.
C. In the event of improper installation, the Contractor shall correct the Work and re-
test the mixers at no additional cost to the Owner. The manufacturer will provide
certification that the improper installation has been corrected.
D. The Contractor shall perform testing on blended sludge concentration after the
installation is complete and the plant is in operation. The Contractor shall furnish
all labor, materials, laboratory testing, and equipment required for the test. The
cost of the testing shall be included in the Contract Price. The blended sludge test
shall be conducted as follows in the tank when it is full and without additional
sludge flowing into the tank:
1. Sludge concentration test shall be conducted at blended sludge
concentrations of 4 to 6% in the tanks. The SVI shall be greater than
80 mL/g.
2. The test shall be conducted in both tanks, and the tests shall demonstrate
that a uniform concentration of the blended Sludge is achieved.
Uniformity shall be defined as plus or minus 10% of the arithmetic
average of blended sludge total suspended solids concentration for all
samples taken.
3. Nine samples shall be taken in each tank. The sample location shall be
selected by the Engineer and shall be spaced horizontally based on the
location of the access hatches on the tank covers and equally spaced
vertically within the tank. The maximum depth at which any sample shall
be taken shall be a minimum of 6 inches above the floor level. In addition,
samples shall be taken a minimum of 12 inches from the tank wall.
Samples shall be tested at an independent laboratory approved by the
Engineer. The tests will be conducted without flow into the tank. The cost
for the laboratory shall be borne by the Contractor.
4. If requested by the Engineer, the Contractor shall collect additional
samples to be tested by the Owner's laboratory for verification.
03720-048-01 11228-13 MIXERS
August 2019
5. If the average of the samples fail to meet the specified requirements, the
Contractor and the manufacturer shall make all necessary modifications to
correct the problem and re -test at no additional cost to the Owner. If
necessary, the Contractor shall replace the non-performing mixer(s) at no
additional cost to the Owner.
3.04 TRAINING SERVICES
A. The manufacturer technical representative shall be on site to perform training
services in accordance with Section 01820, Training, and Table 11000-1,
Equipment Testing and Training Requirements, in Section 11000, General
Equipment Requirements.
3.05 CERTIFICATION
A. The Contractor shall provide a written certification from the manufacturer
certifying that the equipment has been properly installed according to the Contract
Drawings, Project Specifications, and manufacturer's instructions and that the
equipment is operating normally.
3.06 MANUFACTURER'S SERVICES
A. The equipment manufacturer shall furnish the services of a competent and
experienced factory representative who has complete knowledge of proper
installation, operation, and maintenance of the equipment for not less than what is
specified in Table 11000-1, Equipment Testing and Training Requirements, in
Section 11000, General Equipment Requirements, to inspect the installed
equipment, perform an initial test run and startup testing, conduct final
performance testing, and provide operation and maintenance instructions to the
plant personnel. The number of trips is determined by the construction schedule
and as necessary to meet the requirements of these Project Specifications.
B. If there are difficulties in operating the equipment due to manufacturer's design or
fabrication, additional service shall be provided at no cost to the Owner.
END OF SECTION
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SECTION 11330
IN-LINE GRINDER
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish and install inline electric grinders. The equipment
shall be as described in this Section and as shown on the Drawings. The
Contractor shall be responsible for equipment installation according to the
recommendations of the supplier and in compliance with all OSHA, local, state,
and federal codes and requirements.
B. These Specifications are intended to give a general description of what is required
but do not cover all details in installing, testing, and operating the equipment.
1.02 RELATED WORK
A. Division 3, Concrete.
B. Section 09900, Painting and Coating.
C. Division 15, Mechanical.
D. Division 16, Electrical.
1.03 SUBMITTALS
A. The Contractor shall submit shop drawings in accordance with Section 01330,
Submittals and Acceptance.
B. The Contractor shall submit to the Engineer copies of all materials required to
establish compliance with this Section. Submittals shall include at least the
following:
03720-048-01
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1. Certified shop and erection drawings showing all important details of
construction, dimensions, and anchor bolt locations.
2. Descriptive literature, bulletins, and /or catalogs of the equipment.
3. Data on the characteristics and performance of the equipment.
4. Complete wiring diagrams and elementary or control schematics,
including coordination with other electrical control devices.
5. A complete total bill of materials of all equipment.
6. A list of the manufacturer's recommended spare parts to be supplied in
addition to those specified in Article 1.07, with the manufacturer's current
price for each item.
7. Complete motor data.
11330-1 IN-LINE GRINDER
C. Test reports to be submitted shall include at least the following:
1. Description of test procedures and equipment.
2. Copies of all test results, as may be specified in this Section.
D. Complete operating and maintenance instructions shall be furnished for all
equipment specified in this Section and in accordance with the General
Conditions and Division 1, General Requirements.
E. The Contractor shall submit the manufacturer's certificate of installation, testing,
and instruction.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be the latest
revision of any such document in effect at the bid time. The following documents are a part of
this Section. Where this Specification Section differs from these documents, the requirements of
this Section shall apply.
A. Design, manufacturing, and assembly of elements of the products specified in this
Section shall be in accordance with the standards listed below:
1. American Gear Manufacturing Association (AGMA)
2. American Society for Testing and Materials (ASTM)
a. ASTM A36 Standard Specification for Carbon Steel Plate.
b. ASTM A536-84—Standard Specification for Ferritic Ductile Iron
Castings.
c. ASTM A126—Standard Specification for Gray Iron Castings for
Valves, Flanges, and Pipe Fittings.
d. ASTM B.16—Standard Specification for Class 40 Grey Iron
Castings.
e. ASTM D429—Standard Test Methods for Rubber Property—
Adhesion to Rigid Substrates.
3. American Iron and Steel Institute (AISI)
a. AISI 316—Stainless Steel.
b. AISI 304—Stainless Steel.
03720-048-01 11330-2 IN-LINE GRINDER
August 2019
c. AISI 4130 Heat Treated Alloy Steel.
d. AISI 4140—Heat Treated Hexagon Steel.
B. Controllers shall, as applicable, meet the requirements of the following
Regulatory Agencies:
1. National Electrical Manufacturer's Association (NEMA) Standards
2. National Electrical Code (NEC)
3. Occupational Health and Safety Administration (OSHA)
4. Underwriters Laboratory (UL and cUL)
1.06 QUALITY ASSURANCE
A. Qualified suppliers shall have a minimum of 5 years' experience at manufacturing
two -shafted grinding equipment, inclined augers, and motor controls with a
minimum of 25 installations with similar equipment. The supplier shall provide a
list of names and dates of installations for verification by the Engineer or the
Owner's Representative.
B. The supplier shall provide the services of factory -trained representative to check
the installation and to start up the electric grinder. The factory representative shall
have complete knowledge of proper installation, operation, and maintenance of
equipment supplied. The representative shall inspect the final installation and
supervise a start-up test of the equipment.
C. If there are difficulties in operating the equipment due to the manufacturer's
fabrication or the Contractor's installation, additional services shall be provided at
no change in contract price or time.
1.07 WARRANTIES
A. Warranties shall be in accordance with Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
B. All parts shall be properly protected so that no damage or deterioration will occur
during the delay from the time of shipment until installation is completed and the
units and equipment are ready for operation.
03720-048-01
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11330-3 IN-LINE GRINDER
C. All equipment and parts must be properly protected against any damage during
storage at the site.
D. Factory -assembled parts and components shall not be dismantled for shipment
unless permission is received in writing from the Engineer.
E. Finished surfaces of all exposed pump openings shall be protected by wooden
blanks, strongly built and securely bolted.
F. Finished iron or steel surfaces not painted shall be properly protected to prevent
rust and corrosion.
1.09 QUALIFICATIONS
A. All the equipment specified under this Section shall be furnished by a single
manufacturer and shall be standard units of proven ability as manufactured by a
competent organization which 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 the best practice and methods and
shall operate satisfactorily when installed.
B. All equipment furnished under this Section shall be new and unused and shall be
the standard products of manufacturers having a successful record of
manufacturing and servicing the equipment and systems specified in this Section
for a minimum of 5 years.
1.10 TESTING REQUIREMENTS
A. Testing shall be in accordance with Part 3, Execution.
1.11 MAINTENANCE
A. The Contractor shall furnish the following spare parts in clearly identified
containers, labeled for easy identification without opening the packaging and
suitably protected for long-term storage in humid environment. At a minimum,
the spare parts shall include:
B. For the two grinders provide each:
1. Three cutters.
2. Three spacers.
3. One gasket kit.
4. One set of fuses for each fuse type.
03720-048-01 11330-4 IN-LINE GRINDER
August 2019
5. Additional spare parts shall be provided in accordance with the
recommendations of equipment manufacturers.
C. Furnish one set of all special tools required for normal operation and maintenance
of the equipment. Tools shall be furnished in a suitable case, clearly and indelibly
marked on the exterior to indicate the equipment for which the tools are intended.
D. Furnish lubrication in accordance with Section 11000, General Equipment
Requirements.
1.12 SYSTEM DESCRIPTION
A. The Contractor shall provide two in-line grinders at the Northeast Water
Reclamation Facility (NEWRF). The grinders should be installed near the two
Sludge Storage and Blend Tanks (one grinder south of the Blend Tank on the 6 -
inch blended sludge line upstream of the anaerobic digester feed pumps and one
grinder east of the Blend Tank on the 6 -inch thickened primary sludge and
thickened waste activated sludge — combined thickened sludge — upstream of the
tee that enters the Blend Tank) as shown on the Contract Drawings.
B. The grinder shall be adequately designed to grind sludge completely within the
blended sludge and combined thickened sludge lines with the layout, pipe size,
and distances from pumps and fittings as shown in the Contract Drawings and as
specified herein.
C. The pumps which feed the sludge into the grinder may operate intermittently
throughout the day (i.e. 45 minutes on, 15 minutes off, every hour). Grinder shall
be capable of running without positive flow through the pipe during these periods.
D. The grinder shall consist of motor, cutting stack with tooth cutters, mechanical
seals, and motor controller. The grinder shall be specifically designed and
furnished to meet the requirements specified herein these Project Specifications
and as shown in the Contract Documents.
E. All equipment specified and to be furnished and installed in this Section is
intended to be standard for grinding based on this application.
F. The grinder units required under this Section shall be complete, including the
motor, cutting stack with tooth cutters, mechanical seals, and motor controller. All
parts shall be so designed and proportioned as to have strength, stability, and
endurance to be especially adapted for the operational conditions and the
properties of the sludge to be grinded.
03720-048-01
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11330-5 IN-LINE GRINDER
G. Equipment furnished under this Section shall be designed for a municipal
wastewater treatment plant environment in which the equipment is exposed to the
atmosphere. The equipment shall be designed for humid atmospheric conditions
in West -Central Florida and shall be designed for intermittent operation; 365 days
per year.
1.13 OPERATION AND MAINTENANCE (O&M) MANUALS
A. The Contractor shall provide O&M Manuals for the electric grinder that are
tailored to fit the training during start-up. The submittal shall reflect data that
match the equipment provided and shall be in accordance with General
Conditions, Supplementary Conditions, and Specification Section 01830,
Operations and Maintenance Manuals.
1.14 PATENTS AND LICENSES (NOT USED)
PART 2 PRODUCTS
2.01 PERFORMANCE AND DESIGN REQUIREMENTS
A. The grinder equipment is used to grind the contents within the line carrying
thickened primary sludge and thickened waste activated sludge (combined
thickened sludge) as well as the line carrying blended sludge as shown on the
contract Drawings.
B. Each grinder shall operate independently and shall be controlled as shown in the
Contract Documents and specified in these Project Specifications. The grinder
shall be constant speed units designed to operate intermittently, 365 days/year.
C. Performance Criteria
Number of Grinders
2
Pipe Size
6 -inch
Flow Rate
50-150 gpm
Pressure Drop
0.1 psi — 0.2 psi
Sludge % Total Solids Maximum
4-6%
Motor
3 HP (2.2 KW)
Voltage/Ph/Hz
460/3/60
Nominal Motor Speed
1,800 rpm
Service Factor
1.15
Minimum Efficiency at Full Load
87.5%
Power Factor at Full Load
78%
D. The grinder manufacturer and model shall be the following:
1. JWC Muffin Monster Model 30004T-1206
03720-048-01 11330-6
August 2019
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2.02 MATERIALS AND EQUIPMENT
A. GENERAL
1. The equipment covered by these Specifications is intended to be
equipment of proven ability as manufactured by reputable concerns having
long experience in the production of such equipment. The equipment
furnished shall be designed, constructed, and installed in accordance with
the best practice and methods and shall operate satisfactorily when
installed as shown on the Drawings.
2. All parts shall be so designed and proportioned as to have liberal strength
and stiffness and to be especially adapted for the work to be done. Ample
room and facilities shall be provided for inspection, repairs, and
equipment.
B. Each unit of equipment shall be identified with stainless steel nameplates giving
the name of the manufacturer. Name plate information shall include equipment
model number, serial number, supplier's name, and location.
2.03 GRINDERS
A. The grinders shall be Model No. 30004T-1206 by JWC Environmental or
Engineer -approved equal.
B. The grinder shall be provided in an in-line assembly.
C. The grinder shall include cutters, spacers, shafts, bearings and seals, cutter stack
adjustment port, reducer, and motor.
D. The grinder shall be of two -shaft design and be capable of continuous operation,
processing wet or dry. Grinders designed with cutter and spacer cartridges rather
than individual cutters and spacers shall not be acceptable.
E. Two -shaft design shall consist of two parallel shafts alternately stacked with
individual intermeshing cutters and spacers positioned on the shaft to form a
helical pattern. The two shafts shall counter -rotate with the driven shaft operating
at a portion of the drive shaft speed.
F. Grinder construction shall be as follows:
1. Individual Cutters and Spacers:
a. The cutting chamber shall be sized appropriately for a 6 -inch pipe.
03720-048-01 11330-7 IN-LINE GRINDER
August 2019
b. Individual cutters and spacers shall be AISI 4130 heat-treated alloy
steel, surface ground for uniformity and through -hardened to a
minimum 45 to 50 Rockwell C.
c. The inside configuration of both the individual cutters and the
individual spacers shall be hexagonal so as to fit the shafts with a
total clearance not to exceed 0.015 inch (0.38 mm) across the flats
to ensure positive drive and minimize wear on the cutters.
d. Cutter configuration shall consist of 13 -tooth cam cutters. To
maintain particle size, the height of the tooth shall not exceed
1/2 inch (13 mm) above the root diameter. Cutter to cutter root
diameter overlap shall be not less than 1/16 inch (1.6 mm) or
greater than 1/4 inch (6 mm) to maintain the best possible cutting
efficiency while incurring the least amount of frictional losses.
e. The cutters shall exert a minimum force at the tooth tip of
1,830 lb/hp (10,921 N/kW) during momentary load peaks.
2. Shafts:
a. Grinder drive and drive shafts shall be made of AISI 4140 heat-
treated hexagon steel with a tensile strength rating of not less than
149,000 psi (1,027 kPa).
b. Each hexagonal shaft shall measure a nominal 2 inches (51 mm)
across parallel surfaces.
3. Main Housing and Covers:
a. Grinder end housings shall be cast of A536-84 ductile iron with a
cast -in-place flow deflector, designed to protect the bushings while
guiding particles directly into the cutting chamber.
4. Shaft Bearings and Seals:
a. The radial and axial loads of the cutter shafts shall be borne by
sealed, oversized, deep -groove ball bearings at each end.
b. The bearings shall be protected by a combination of a replaceable
and independent tortuous path device and mechanical seals.
c. Face materials shall be of tungsten carbide to tungsten carbide.
d. O -rings shall be made of Buna-N elastomers.
e. Products requiring continuous or occasional lubrication or flushing
shall not be accepted.
f. The mechanical seal shall be rated at 90 psi (620 kPa) continuous
duty by the seal supplier.
g. The bearings shall be housed in a replaceable cartridge that
supports and aligns the bearings and seals and protects the shafts
03720-048-01 11330-8 IN-LINE GRINDER
August 2019
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and end housings. The seal elements shall be independent of the
stack height; therefore, cutter stack tightness shall not affect seal
performance. The seal elements shall maintain their factory -set
preload independent of the cutter stack tightness.
h. Seals shall meet required pressure rating regardless of cutter stack
fit. The seal cartridge shall provide seal protection against axial
loading on shafts and bearings during shaft deflection.
i. Each seal element shall be positively locked to its corresponding
rotating or static cartridge element. This positive lock on the seal
elements is critical to long seal life in applications where grit or
other abrasive materials are present.
5. Reducer:
a. The speed reducer shall be a grease -filled planetary -type of reducer
with a 500% shock load capability. The reduction ratio shall be
29:1
b. The input shaft of the reducer shall be directly coupled to the
motor using a three-piece coupling, and the output shaft of the
reducer shall be directly coupled with the grinder using a two-piece
coupling.
6. Motor:
a. The motor shall be 3 hp (2.2 kW), TEFC 1, 1,750 rpm,
208-230/460 volts, three phase, 60 Hz.
b. Motor service factor shall be 1.15, the efficiency factor not less
than 87.5% at full load, and the power factor not less than 78% at
full load.
c. The motor shall provide two terminals for the connection of
positive temperature coefficient (PTC) thermistor sensors. PTC
sensors shall be embedded in the motor stator windings to monitor
winding temperature.
2.04 CONTROL PANEL
A. The controller shall provide independent control of the grinder; it shall be
Standard UL/cUL listed Model PC2200 and shall be rated for 3 hp, 460 volts,
three phase, 60 Hz. It shall include an IEC starter with over -current protection,
jam -sensing current transformer and micro -PLC. The panel shall be UL rated for
14 kAIC fault current.
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August 2019
B. The controller shall be equipped with ON-OFF/RESET-REMOTE three position
selector switch.
1. In the ON position, the grinder will run.
2. In the OFF/RESET position the grinder will not run.
3. In the REMOTE position the grinder will start and stop as controlled by a
remotely -located dry contact.
4. The grinder will only be reset by switching the ON-OFF/RESET-
REMOTE selector switch to the OFF/RESET position.
5. Provide incoming power lighting and surge protection at a minimum of
50kA/mode.
C. Control Devices
1. NEMA 4X pilot devices will be mounted on the enclosure front panel
door.
2. The controller will have indicator lights for POWER ON, RUN, and
FAIL.
3. Indicator lights will be LED type pilot lights. Lights and the selector
switch will be heavy duty NEMA 4X type.
4. Control transformer will be protected by two primary fuses and one
secondary fuse. The 120 -volt secondary fuse shall have one leg grounded.
5. Contacts will be included for grinder RUN and FAIL signal outputs. The
contracts will be rated two amperes.
6. Provide alarm and equipment status for remote monitoring by the SCADA
system.
D. Motor Starter
1. Starter will be a full -voltage reversing type with 120 -volt operating coils.
2. Forward and reverse contactors on the starters will have both mechanical
and electrical interlocks.
3. Overload relays will be adjustable so that the range selected includes the
full load amperes rating and service factor.
E. Safety Features
03720-048-01
August 2019
1. When a grinder jam condition occurs in the grinder ON or REMOTE
mode, the controller shall stop the grinder, reverse the grinder rotation,
and clear the obstruction. If the jam is cleared, the controller will return
the grinder to normal operation.
a. Up to two additional reversing cycles may occur within
30 seconds.
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b. After three total reversing cycles, the controller shall automatically
de -energize the grinder motor and activate a fail indicator and fail
contact.
2. If a power failure occurs while the grinder is running, operation will
resume when power is restored.
3. If a power failure occurs while the grinder is in a fail condition, the fail
indicator will reactivate when power is restored.
4. The controller shall provide overload protection for the motor through an
overload relay mounted directly on the grinder motor starter.
5. Short-circuit protection shall be provided by a properly -sized circuit
breaker or set of fuses installed with the equipment.
6. Controller reset will only be available from the local panel controls.
PART 3 EXECUTION
3.01 INSTALLATION
A. Installation shall be in strict accordance with the manufacturer's instructions and
recommendation and in the locations shown on the Drawings. Installation shall
include furnishing the required oil and grease for initial operation. The grades of
oil and grease shall be in accordance with the manufacturer's recommendations.
Anchor bolts shall be set in accordance with the manufacturer's
recommendations.
B. Supply all anchor bolts, temporary lift equipment, power, water, labor, and all
other incidentals required for the proper installation of the grinder.
3.02 PAINTING
A. Painting and coating of all equipment, motors, and associated appurtenances shall
be in accordance with Section 09900, Painting and Coating, and Section 11000,
General Equipment Requirements, and as described herein.
B. Before exposure to weather and before shop painting, all surfaces shall be
thoroughly cleaned, dry, and free from all mill/scale, rust, grease, dirt, and other
foreign matter.
C. Gears, bearing surfaces, and other similar surfaces not referenced in
Section 09900, Painting and Coating, painted shall be given a suitable rust -
03720 -048-01 11330-11 IN-LINE GRINDER
August 2019
resistant coating. This coating shall be maintained as necessary to prevent
corrosion during periods of storage and installation up to the time of the final
acceptance.
D. All nameplates shall be properly protected during painting.
3.03 TESTING
A. Equipment testing shall be in accordance with Section 01450, Testing,
Section 11000, General Equipment Requirements, and as described herein.
B. After equipment has been completely installed and working under the direction of
the manufacturer, the Contractor shall conduct, in the presence of the Owner and
Engineer, such tests as are necessary to indicate that the installation is performing
to the standards indicated in the Specifications.
C. If the equipment performance does not meet the Specifications, corrective
measures shall be taken, or defective equipment shall be removed and replaced
with equipment that satisfies the conditions specified.
D. Submit six copies of certified test results upon satisfactory completion of testing.
END OF SECTION
03720-048-01 11330-12 IN-LINE GRINDER
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SECTION 11356
PROGRESSIVE CAVITY PUMPS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish all labor, materials, and incidentals required to
provide the self -priming, positive displacement progressive cavity pumping units
and appurtenances specified in this Section and shown on the Contract Drawings.
1. Truck Off -Loading Station: Two progressive cavity pumps.
2. Anaerobic Digester Feed Pump Station: Two progressive cavity pumps.
3. Dewatering Feed Pump Station: Four progressive cavity pumps.
B. All equipment shall be installed, adjusted, tested, and placed in operation in strict
accordance with this Section and the manufacturer's recommendations.
C. Each pumping unit shall be designed and constructed to operate satisfactorily with
minimum noise, vibration, and cavitation, and reasonable long service life when
operated continuously or intermittently for waste activated sludge in an outdoor
environment.
D. Each unit shall be furnished with motor of adequate size to start each progressive
cavity pump that has not been in service for 90 days.
E. Only one pump manufacturer shall be selected for the three pump stations.
1.02 RELATED WORK
A. Section 01000, Project Requirements.
B. Section 01330, Submittals and Acceptance.
C. Section 01650, Delivery, Storage, and Handling.
D. Section 01755, Equipment Testing and Startup.
E. Section 01780, Warranties and Bonds.
F. Section 01820, Training.
G. Section 01830, Operations and Maintenance Manuals.
H. Section 03600, Grout.
I. Section 09900, Painting and Coating.
J. Section 11000, General Equipment Requirements.
K. Division 13, Special Construction: Instrumentation work, unless as otherwise
specified in this Section.
L. Section 15125, Piping Appurtenances.
03720-048-01 11356-1 PROGRESSIVE CAVITY PUMPS
August 2019
M. Division 16, Electrical.
N. Section 16150, Motors.
1.03 SUBMITTALS
The Contractor shall submit shop drawings in accordance with Section 01330, Submittals and
Acceptance:
A. Certified shop and erection drawings showing all important details of
construction, dimensions, and anchor bolt locations.
B. Descriptive literature, bulletins, and/or catalogs of the equipment.
C. Complete master wiring diagrams and elementary or control schematics drawings,
including coordination with other electrical control devices such as the pump
control system, shall be furnished for approval before proceeding with
manufacturing. Drawings should show such details that are necessary to facilitate
interconnections with other equipment. Standard pre-printed sheets or drawings
simply marked to indicate applicability to this Contract will not be acceptable.
Refer to the Electrical and Instrumentation Drawings for the control wiring
diagrams for the pump motors.
D. A complete bill of materials of all equipment.
E. A list of the manufacturer's recommended spare parts to be supplied in addition to
those specified in this Section, with the manufacturer's current price for each
recommended spare part item. Include gaskets, packing, etc. on the list. If
bearings are applicable, list bearings by the bearing manufacturer's name and
corresponding numbers.
F. Complete motor data.
G. Test reports to be submitted: Tests shall be conducted at a minimum of five points
along the pump performance curve on the actual pumping units to be furnished.
All equipment tested by the pump manufacturer shall certify to its compliance
with the project requirements. Curves and other information shall be submitted on
8 -1/2 -inch -by -11 -inch sheets at as large a scale as is practical. Curves shall be
plotted from zero flow at shut-off head to pump capacity at minimum specified
head:
1. Certified factory test results of each pumping unit in accordance with the
standards of the Hydraulic Institute.
2. Factory -tested, certified, and guaranteed pump performance curves
showing the specified requirements for head/capacity, brake horsepower,
03720-048-01 11356-2 PROGRESSIVE CAVITY PUMPS
August 2019
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pump efficiency, speed of rotation, and NPSHR for each pumping unit.
Characteristics of pumps furnished may have a tolerance of 1% percent
below or 5% above the head and capacity of the specified requirements.
H. The Contractor shall submit the Manufacturer's Certificate of Installation, Testing,
and Instruction as specified in Division 1.
I. If it is not possible to comply with certain requirements of this Specification,
include in submittals a complete description of all requirements not complied
with.
J. The Contractor shall submit a signed letter from an authorized representative of
the pump manufacturer certifying that each pumping unit will not clog or bind on
the solids typically found in the application specified in this Section.
K. If the Contractor deviates from the piping layout as shown on the Contract
Drawings, the Contractor shall submit scaled piping drawings showing locations
and dimensions to and from fittings, valves, tanks, equipment, structures, and
related appurtenances. Provide scaled drawings to a minimum scale of 1 inch
equals 10 feet. Provide details to minimum scale of 1/8 inch equals 1 foot.
Elevations shall correspond to reference vertical elevation datum shown or
provided for this project.
L. Provide wiring and control panel drawings related to the alarming systems.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be the latest
revision of any such document in effect at the bid time. The following documents are a part of
this Section. Where this Section differs from these documents, the requirements of this Section
shall apply.
A. American Bearing Manufacturers Association (ABMA)
B. American Gear Manufacturers' Association (AGMA)
C. American Iron and Steel Institute (AISI)
D. American National Standards Institute (ANSI)
03720-048-01 11356-3 PROGRESSIVE CAVITY PUMPS
August 2019
E. American Society for Testing and Materials (ASTM)
1. ASTM A48—Standard Specification for Gray Iron Castings.
F. American Society of Mechanical Engineers (ASME)
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.
G. American Welding Society (AWS)
H. National Electrical Manufacturer's Association (NEMA)
1. NEMA MG 1—Motors and Generators.
2. NEMA MG 1-12.58.1—Standardized Method for Testing.
I. Institute of Electrical and Electronics Engineers (IEEE)
1. IEEE 112—Standard Test Procedure for Polyphase Induction Motors and
Generators.
2. IEEE 117—Standard Test Procedure for Thermal Evaluation of Systems
of Insulating Materials for Random -Wound AC Electric Machinery.
1.06 QUALITY ASSURANCE
A. The Contractor shall provide quality assurance measures for the items specified in
this Section in accordance with this Section and Section 11000, General
Equipment Requirements.
B. Modifications to the manufacturer's standard design may be required to meet
these Specifications. Equipment not complying with the mechanical, electrical,
and material integrity established by these Specifications will not be acceptable as
determined by the Engineer.
C. All of the equipment, accessories, and controls specified in this Section shall be
furnished by a single manufacturer and shall be standard units of proven ability as
manufactured by a competent organization that is fully experienced, reputable,
and qualified in the manufacture of the equipment to be furnished.
03720-048-01 11356-4 PROGRESSIVE CAVITY PUMPS
August 2019
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, and in this Section for storing and protecting the
equipment specified in this Section.
B. The pumps shall be shipped to the jobsite complete with the motor, local wiring,
control, equipment base, and anchor bolts and other appurtenances as specified
pre-installed. Spare parts shall be shipped loose and ready for installation at the
location shown on the Contract Drawings.
1.09 QUALIFICATIONS
A. The manufacturer(s) of the equipment specified in this Section shall meet the
qualifications specified in Section 11000, General Equipment Requirements.
Additionally, the pump manufacturer shall meet the following qualifications that
supersede the requirements specified in Section 11000, General Equipment
Requirements:
1. The manufacturer shall have a minimum of five installations in Florida
that are similar to the pumping equipment specified in this Section. The
Engineer shall reserve the right to determine if previous installations by
the manufacturer are similar to the pumping equipment specified in this
Section.
2. The Contractor shall submit a list of no fewer than 10 reference
installations of pumps in identical service applications to those specified in
this Section. At least five of the reference installations provided shall be of
the exact model pump specified in this Section. References shall be pumps
that have been in continuous service for at least 3 years from the Bid Date.
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 MAINTENANCE
A. The Contractor shall furnish the following spare parts for each pump in clearly
identified containers, labeled for easy identification without opening the
packaging and suitably protected for long-term storage in a humid environment.
03720-048-01 11356-5 PROGRESSIVE CAVITY PUMPS
August 2019
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B. For the eight progressive cavity pumps, provide each: 1
1. One stator assembly with TSE sensor sleeves.
2. One set of universal joint assemblies.
3. One of each set of mechanical seals.
4. One rotor.
1.12 SYSTEM DESCRIPTION
A. The pumping equipment specified in this Section shall be designed to pump
activated sludge from three stations to their respectively locations:
1. Truck Off -Loading Pumps
a. Shall be used to pump sludge from the Truck Off -Loading Station
to the Sludge Storage and Blend Tanks.
2. Anaerobic Digester Feed Pumps
a. Shall be used to pump sludge from the Sludge Storage and Blend
Tanks to the Anaerobic Digester.
3. Dewatering Feed Pumps
a. Shall be used to pump sludge from the Sludge Storage and Blend
Tanks to the Dewatering Building.
B. Equipment furnished under this Section shall be designed for a municipal
wastewater treatment plant environment in which the equipment is exposed to the
atmosphere. The equipment shall be designed for humid atmospheric conditions
in West -Central Florida.
1.13 OPERATIONS AND MAINTENANCE (O&M) MANUALS
A. O&M Manuals shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01830, Operations and Maintenance Manuals.
1.14 PATENTS AND LICENSES (NOT USED)
1.15 SPECIAL CONSIDERATIONS (NOT USED)
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PART 2 PRODUCTS
2.01 PERFORMANCE AND DESIGN REQUIREMENTS
A. Equipment Identification Labels (Number)
1. Truck Off -Load Pumps: 101-P-1 and 101-P-2.
2. Anaerobic Digester Feed Pumps: 102-P-1, 102-P-2, and (future) 102-P-3.
3. Dewatering Feed Pumps: 103-P-1, 103-P-2, 103-P-3, and 103-P-4.
B. Service Conditions
1. Percent Solids: 6%.
2. Design Specific Gravity: 1.00-1.02.
3. Apparent Viscosity: 300-1000 CP.
4. Average Solids Size: 0.25 inch.
5. pH: 5-9.
6. Design Pumping Temperature: 68°F -84°F.
Unit Designation
Truck Off-
Loading Pumping
Station
Anaerobic Digester
Feed Pumping
Station
Dewatering Feed
Pumping Station
Number of Units
2
2
4
Total Head at Primary
Design Condition (feet)
28
88
100
Capacity at Primary
Design Condition (gpm)
500
100
150
Total Head at Secondary
Design Condition (feet)
-
67
57
Capacity at Secondary
Design Condition (gpm)
-
20
50
Discharge Diameter
6 -inch
6 -inch
6 -inch
Maximum RPM at
Design Point
350
175
125
Drive
Constant -Speed
VFD
VFD
C. Acceptable Manufacturers:
1. Seepex, Inc.
2. Moyno, Inc.
3. Engineer approved equal.
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2.02 EQUIPMENT
A. The pumping equipment specified in this Section shall in general consist of the
following components:
1. Pump Case.
2. Rotor.
3. Stator.
4. Drive Train:
a. Universal Joint.
b. Drive Shafts.
5. Motor.
6. Isolation Ring with Pressure Switch and Gauge.
B. Pump Casing:
1. The pump body shall be thick-walled ASTM A48 cast iron. All cast parts
will be smooth and free of sandholes, blowholes, and other defects.
C. Rotor and Stator:
1. Each pump shall employ a single -helix convoluted rotor operating in a
double -helix convoluted stator.
2. The convolutions shall be configured to form a cavity between the rotor
and stator progressing from the pump inlet to pump discharge outlet with
the operation of the rotor. The fit between the rotor and stator at the point
of contact shall compress the stator material sufficiently to form sufficient
sealing to prevent leakage of sludge.
3. The rotor shall be provided with the following coating or plating systems:
a. Chrome Plating or Ductile Coating: a minimum of 0.010 -inch
thickness with a minimum Rockwell hardness of 57-60 Rc.
4. The stator material shall be a single piece medium-high acrylonitrile
Buna-N rubber with a minimum Durometer hardness (Shore A) of 70-76.
03720-048-01 11356-8 PROGRESSIVE CAVITY PUMPS
August 2019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5. The stator seals shall be designed to prevent the material being pumped
from contacting the stator metal tube or bonding adhesive.
D. Drive Train
1. Rotor shall be driven by heavy duty drive train. Rotor shall be joined by
means of connecting rod with sealed pin type universal joints at each end.
U -joints shall be factory lubricated with oil and completely sealed from
abrasive fluids being pumped.
2. Drive shaft shall be of solid drive shaft design.
E. Motor:
1. Unless otherwise noted in this Section motors shall be in accordance with
Section 16150, Motors.
2. The motors shall meet the following:
Unit Designation
Truck Off-
Loading Pumping
Station
Anaerobic Digester
Feed Pumping
Station
Dewatering
Feed Pumping
Station
Max. Motor Power
(HP)
25
10
15
Voltage
230/460
230/460
230/460
Phase
3
3
3
Hz
60
60
60
3. All motors shall be adequately sized to start each progressive cavity pump
that has not been in service for 90 days.
4. Each pump motor shall be designed to withstand up to 15 separate pump
starts per hour.
5. Acceptable manufacturers:
a. Baldor.
b. US Motors.
c. WEG.
d. Engineer Approved Equal.
F. Accessories
1. Run Dry Protection: The stator shall be fitted with a temperature sensor
sleeve and thermistor sensor with relay. The controller shall monitor the
stator temperature and activate a shutdown and alarm sequence if the
03720-048-01 11356-9 PROGRESSIVE CAVITY PUMPS
August 2019
stator temperature reaches the adjustable limit on the controller. The
controller shall include a manual local and remote reset function. Input to
the controller shall be 1x115VAC/60 Hz. The panel shall be NEMA 4X
316 stainless steel, UL labeled as an assembly. Panel minimum size shall
be 12 inches x 12 inches x 6 inches. The controller shall relay to the
remote SCADA system a "high temperature alarm".
2. Over Pressure Protection: Each pump unit shall be supplied with a
silicone -filled isolation ring with a dual -mounted gauge and dual -point
pressure switch (high pressure alarm, and high -high pressure shut -down).
The pressure ranges for the switch and gauge shall be selected specifically
for each specified service. The isolation ring shall be mounted between
ANSI flanges, be sized according to the discharge pipe as shown on the
Drawings and be constructed with a carbon steel body and fittings with a
Buna N sleeve. The switch shall be SPDT, NEMA 4 with 316 stainless
steel enclosure.
2.03 PAINTING
A. Equipment shall be provided with the manufacturer's recommended shop and
field coating systems for severe -duty services rated for outdoor exposure in the
State of Florida.
PART 3 EXECUTION
3.01 INSTALLATION
A. The Contractor shall install the equipment specified in this Section in accordance
with Section 11000, General Equipment Requirements, and in accordance with
the manufacturer's recommendations.
B. Install the equipment in the locations as shown on the Contract Drawings and in
accordance with the manufacturer's published instructions and recommendations
and the approved shop drawings. Installation shall include furnishing the required
oil and grease for initial operation. The grades of oil and grease shall be in
accordance with the manufacturer's recommendations.
C. All anchor bolts and fasteners shall be AISI Type 316 stainless steel and shall be
furnished by the pump manufacturer.
D. Adjust pump assemblies so that the motors are properly aligned, plumb, and level
with the pumps and all interconnecting shafts and couplings.
E. Provide non -shrink grout for pump installation in accordance with Section 03600,
Grout.
03720-048-01
August 2019
11356-10 PROGRESSIVE CAVITY PUMPS
F. All strain from the attached piping shall be eliminated from the pumps, and any
evidence of pump or motor misalignment, noisy operation, or other signs of
improper setting shall be corrected by the Contractor using the means specified in
this Section at no additional cost to the Owner. Care during storage, installation,
and lubrication shall be in strict accordance with the manufacturer's
recommendations.
3.02 FIELD TESTING
A. The Contractor shall provide the services of a factory -authorized service
representative to perform, approve, and certify the pre -startup testing and startup
testing specified in this Section. The service representative shall be certified and
employed by the manufacturer of the equipment specified in this Section. All field
testing shall be provided in accordance with Section 11000, General Equipment
Requirements.
1. The factory -authorized service representative shall be onsite to perform
the field-testing services specified for one 8 -hour day, excluding travel
time.
2. Pre -Startup Testing: The factory -authorized service representative shall
perform the pre -startup testing specified in this Section in accordance with
Section 11000, General Equipment Requirements.
3. Startup Testing: The factory -authorized service representative shall
perform the startup testing specified in this Section in accordance with
Section 11000, General Equipment Requirements.
4. Final Mechanical Performance Testing: The Contractor shall perform final
mechanical performance testing for this equipment in accordance with
Section 11000, General Equipment Requirements.
3.03 TRAINING SERVICES
A. The manufacturer technical representative shall be on site to perform training
services in accordance with Section 01820, Training, and Table 11000-1,
Equipment Testing and Training Requirements.
B. An authorized representative of the pump manufacturer shall instruct
representatives of the Owner in startup, operation, and maintenance procedures.
The Contractor shall procure the services of the pump manufacturer's
representative for on the project site training service in accordance with
Table 11000-1 in Section 11000, General Equipment Requirements. The
manufacturer's services specified represent an absolute minimum acceptable level
of service and are not intended to limit the responsibilities of the Contractor to
comply with all requirements of the Contract Documents. The Contractor shall
03720-048-01 11356-11 PROGRESSIVE CAVITY PUMPS
August 2019
procure, at no additional cost to the Owner, all services required to comply with
these requirements, including additional or extended trips to the job site by the
manufacturer's representative.
3.04 MANUFACTURER'S CERTIFICATION OF COMPLIANCE
A. The Contractor shall furnish a Manufacturer's Certification of Compliance for the
equipment specified in this Section in accordance with Section 11000, General
Equipment Requirements.
END OF SECTION
03720-048-01 11356-12 PROGRESSIVE CAVITY PUMPS
August 2019
DIVISION 13
SPECIAL CONSTRUCTION
SECTION 13232
ALUMINUM FLAT COVERS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish all labor, materials, and equipment to provide a
complete, installed system of fixed and removable, custom fit, flat aluminum
cover over the Sludge Storage Tank. The Tank Cover System includes cover
panels, structural supports, and attaching hardware. The cover shall be fully
engineered, substantially airtight, aluminum cover structure comprised of panels
and beams.
B. All equipment shall be installed, adjusted, and tested in strict accordance with this
Section and the manufacturer's recommendations.
C. The manufacturer shall field -verify all dimensions before fabrication of
components.
1.02 RELATED WORK
A. Section 01330, Submittals and Acceptance.
B. Section 01650, Delivery, Storage, and Handling.
C. Section 01780, Warranties and Bonds.
D. Section 01785, Record Documents.
E. Section 01830, Operations and Maintenance Manuals.
F. Section 11000, General Equipment Requirements.
1.03 SUBMITTALS
The Contractor shall submit shop drawings in accordance with Section 01330, Submittals and
Acceptance:
A. Shop Drawings: Submit for approval the following:
03720-048-01
August 2019
1. Manufacturer's literature, illustrations, specifications, and engineering
data.
2. Dimensioned drawings showing layout, final installation, fabrication
methods, assembly, accessories, and installation details.
3. Setting drawings, templates, and directions for the installation of anchor
bolts and other anchorages.
13232-1 ALUMINUM FLAT COVERS
4. Deviations from Drawings and Specifications.
5. Proof of qualifications (See Article 1.06A).
B. Computations and Certifications:
1. Complete structural calculations showing the governing stresses in all
members and connections and detailed shop drawings. Preliminary
drawings shall be stamped by the cover Manufacturer's Professional
Engineer. Final Drawings and calculations shall bear the stamp of
Professional Engineer registered in the State of Florida.
2. Manufacturer's standard guarantee (see Article 1.06A).
3. A letter of certification signed and sealed by a Professional Engineer
registered in the State of Florida confirming that the aluminum cover is in
full compliance with the Contract Drawings and Project Specifications
including any testing provisions included therein.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be the latest
revision of any such document in effect at the bid time. The following documents are a part of
this Section. Where this Section differs from these documents, the requirements of this Section
shall apply.
A. Aluminum Association
B. American Welding Society (AWS)
1. AWS D1.2/D1.2M—Structural Welding Code — Aluminum.
C. Florida Building Code
D. National Environmental Balancing Bureau (NEBB)
1. Procedural Standards for Testing, Adjusting and Balancing of
Environment System.
E. Uniform Building Code (UBC)
03720-048-01 13232-2 ALUMINUM FLAT COVERS
August 2019
1.06 QUALITY ASSURANCE
A. Fabrication and Workmanship
1. Workmanship: The quality of workmanship shall be equal to the best
general practice in modern structural fabrication shops. Workmanship,
fabrication, and shop connections shall be in accordance with the latest
edition of AWS D1.2/D1.2M.
2. Preparation for Welding: All components to be welded shall be free of
dirt, grease, and other contaminants and shall fit up properly for sound
welding. Surfaces to be welded may not be cut with oxygen. Sawing,
shearing, or machining may be used.
3. Welding Procedures: All welding shall be with an inert gas shield arc
process. Machine settings shall be developed with test welds of the same
material, alloy, and geometry as the work pieces, and samples will be
tested destructively.
B. The Contractor shall provide quality assurance measures for the items specified in
this Section in accordance with this Section and Section 11000, General
Equipment Requirements.
C. All of the equipment, accessories, and other appurtenances specified in this
Section shall be furnished by a single manufacturer and shall be standard units of
proven ability as manufactured by a competent organization that is fully
experienced, reputable, and qualified in the manufacture of the equipment to be
furnished.
1.07 WARRANTIES (NOT USED)
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section and in strict accordance with the manufacturer's instructions and
recommendations.
1.09 QUALIFICATIONS
A. Manufacturer's Qualifications: Manufacturer shall be a company specialized in
providing engineered aluminum covers for wastewater treatment tanks/troughs for
at least 10 years with a minimum of five successful and similar installations in
Florida. These installations shall be similar in square footage and design to this
project. When requested by the Engineer, submit written evidence to show
03720-048-01
August 2019
13232-3 ALUMINUM FLAT COVERS
experience qualifications and adequacy of plant capability and facilities for
performance of contract requirements.
B. Erector: Regularly engaged for at least 10 years in the erection of aluminum
covers for wastewater treatment tanks.
C. Welders: Qualified and licensed within the past 2 years in accordance with AWS.
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 MAINTENANCE (NOT USED)
1.12 SYSTEM DESCRIPTION (NOT USED)
1.13 OPERATION AND MAINTENANCE (O&M) MANUALS (NOT USED)
A. O&M Manuals shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01830, Operations and Maintenance Manuals.
1.14 PATENTS AND LICENSES (NOT USED)
1.15 SPECIAL CONSIDERATOINS (NOT USED)
PART 2 PRODUCTS
2.01 DESIGN CRITERIA
A. Except as otherwise specified or shown, all design, materials, joints, connections,
and workmanship shall conform to the Uniform Building Code (UBC), the
Florida Building Code, and the Aluminum Association.
B. Design a flat cover to withstand the cover dead load plus equipment dead load
plus the following live load conditions:
1. The structure is in a hurricane -prone region. Wind loading shall be in
accordance with the applicable Florida Building Code:
a. Base wind speed shall be 155 mph.
b. Importance factor shall be in accordance with Industrial Standards.
2. Span: The clear span length of the cover shall be as noted on the Contract
Drawings.
03720-048-01 13232-4 ALUMINUM FLAT COVERS
August 2019
03720-048-01
August 2019
3. Radius: The radius of the cover shall be as noted on the Contract
Drawings
4. The flat cover shall be a clear span structure, designed to be self-
supporting from its periphery on the concrete tank walls. The cover shall
span under the existing bridge structure and must stay within the
4 3/4 -inch spacing between the top of the tank and the bottom of the
existing bridge structure. The cover shall not be designed to bear any
structural weight on the existing bridge nor flash to the bridge structure.
5. The flat cover shall not have any support beams below the decking that
exceed the 2 -foot -6 -inch freeboard (from the top of the tank wall to the
liquid level) inside the tankage placing any cover support beams in direct
contact with the liquid inside the tank.
6. The flat cover shall provide a means to remove four panel sections as
shown on the Contract Drawings for ease of maintenance and removal of
the mixers and impellers. The overall clear and unobstructed opening after
panel and beam removal shall accommodate the direct dead lift of a
10 -foot -6 -inch -diameter impeller on the mixer shaft without tilting or
turning the angle of the shaft or impeller. The cover system surrounding
this opening shall maintain the design stress, concentrated live load,
distributed design live load, and deflection requirements of this
specification when these panels and beams are removed for mixer
maintenance.
7. The removable panel sections shall be labeled to clearly indicate how to
remove and reinstall the sections during maintenance and removal of the
mixer and impellers.
8. Concentrated Live Load: The structural components shall be designed to
support a 400 -pound load on a 6 -inch -x -6 -inch area located anywhere on
the surface of the structure without permanently deforming the tested area.
9. Distributed Design Live Load and Deflection: All structural components
shall be designed to support the dead weight of the structure, plus a live
load of 50 pounds per square foot of surface. The maximum deflection of
any component under this load shall not exceed L/240 of the span of that
component. In no event shall the dead load deflection exceed the rise of
any component to avoid surface ponding.
10. Design Stresses: All allowable design stresses in structural aluminum shall
be in accordance with the Specifications for Aluminum Structures for
building -type structures by the Aluminum Association.
13232-5 ALUMINUM FLAT COVERS
1
11. Skid Resistance: The cover shall possess an integral non-skid surface, and
no exposed area of cover system wider than 1 inch shall be without ribs/
non-skid surface. The aluminum -decking surface of the structure shall be
Hallsten's Deck Slat or Engineer -approved equal, which is ribbed to
provide an aggressively non-skid surface. The edges of adjacent deck slats
shall double interlock so that the slats shall act together. The decking
surface shall be manufactured from alloy 6061-T6. The manufacturer of
the non-skid surface shall demonstrate in writing satisfactory performance
for a minimum of 10 years in the wastewater industry for the intended
purpose. This surface shall not be achieved by the use of paint, adhesive
tapes, sand blasting, or any other means other than an extruded process.
12. Chemical Resistance: Panels shall be fabricated entirely of 6061-T6
corrosion -resistant aluminum extrusions. Every panel to beam connection
shall be chemical resistant and will not weaken or corrode and will
interlock. A mechanical and replaceable Santoprene seal shall isolate the
cover perimeter from the concrete wall. No foam tape or caulk shall be
allowed.
13. Configuration: The surface -mount aluminum cover shall land on the
surface of the existing concrete as shown on the Contract Drawings and on
ledger angle where applicable. The cover shall be composed of panels and
beams. All panels shall interlock with the adjoining beam and panels
without the use of threaded fasteners. Uplift of each panel will be resisted
with the use of an integral latch system. The weight of an individual panel
shall not exceed 150 pounds. Each removable panel shall be easy to
remove without disruption of adjacent panels, and the lifting force
required shall not exceed the dead weight of the panel.
2.02 DETAILS OF CONSTRUCTION
A. Manufacturer: Provide a flat cover as designed and fabricated by one of the
following:
1. Hallsten.
2. Or Engineer -approved equal per Article 2.03 of this Section.
B. Flat Coved Dimensions: The flat cover shall conform to the dimensions shown on
the Contract Drawings.
03720-048-01 13232-6 ALUMINUM FLAT COVERS
August 2019
C. General:
1. The flat cover shall be a clear span structure, designed to be self-
supporting from its periphery on concrete tank walls.
2. The edges of each panel shall be interconnected as to prevent slippage or
disengagement under design conditions.
3. Provide gasket material such that all connections to the concrete structure
are substantially airtight. Provide gasket material such that all connections
between adjacent aluminum cover panels are substantially airtight. Gasket
material shall be as specified below.
4. Provide the flat cover with access hatches, as shown on the Contract
Drawings.
5. Provide openings for odor control ductwork and air piping inlet for each
tank cover in accordance with the details of the Contract Drawing and at
locations shown on the Contract Drawings.
6. No welding or thermal cutting of aluminum structural members, supports,
or connections will be permitted in the field.
D. Materials:
1. Aluminum: All aluminum used in the fabrication of the cover shall be
alloy 6061-T6. All plate shall be alloy 6061-T6. Material shall be new and
of top quality.
2. Welding Electrodes: Welding shall be with electrodes of an alloy, which
shall produce welds with strength and corrosion -resistant characteristics
compatible to the base metal.
3. Fasteners: All fasteners between aluminum components shall be stainless
steel or structural plastic. Aluminum shall be isolated from dissimilar
materials by means of a stainless steel spacer or an elastomeric isolator.
Beams and panels shall be fastened to concrete using stainless steel drill in
place anchor bolts.
4. Steel Accessories: No carbon steel components shall be used.
5. Seals: A mechanical and replaceable Santoprene seal shall isolate the
cover perimeter from dissimilar materials such as concrete and steel. No
foam tape or caulk shall be allowed for isolation of cover system.
6. Access Hatch Panels: Access to any location under the cover shall be
gained through integral gear hinged access hatches. The Access Hatch
Panels shall have the identical properties as the rest of the aluminum cover
including loads, deflection, and slip resistance specifications. The access -
hinged panels shall be the full panel width. The length of the access panel
shall be clearly indicated on the submittal drawings and in accordance
with the Contract Drawings. Hinged panel components including hinges,
decking, and lifting handles shall be extruded 6061-T6. While in the
closed position, the hatches will be completely flush and therefore pose no
03720-048-01 13232-7 ALUMINUM FLAT COVERS
August 2019
tripping hazard. In the open position, the panel shall lie flat on the cover
and will not need a hold -open device.
7. Pipe penetration kits shall be provided as shown on the Drawings for all
locations where liquid piping penetrates the plane of the cover.
8. Duct penetration kits shall be provided as shown on the Drawings for the
location on each tank where the odor -control ducting intersects with the
cover.
9. A small 18 -inch square hatch shall be provided on each tank cover to
facilitate the Contractor -provided float switch and transducer for liquid
level sensing.
10. A penetration kit shall be provided on each tank cover to accommodate the
level transducer for liquid level sensing.
11. Handles: Handles shall be an integral flush -mounted aluminum and
incorporated into the non-skid deck slat.
12. Anchor Bolts: Furnish anchor bolts and nuts of Series 316 stainless steel,
of ample size and strength for the purpose intended, sized by the
equipment manufacturer.
2.03 ENGINEER'S PRE -APPROVAL OF ALTERNATE COVERS
A. The Manufacturer of an alternate cover system shall submit a pre -approval
submittal package to the Engineer at least 14 days before the Bid Date. Only
approved alternates listed by addendum will be acceptable. The following
information and supporting documentation shall be provided to the Engineer.
B. Shop Drawings: Submit for approval the following:
1. Manufacturer's literature, illustrations, specifications, and engineering
data.
2. Complete detailed drawings showing the proposed cover system,
fabrication methods, assembly, accessories, and installation details.
3. Setting drawings, templates, and directions for the installation of anchor
bolts and other anchorages.
4. Deviations from Drawings and Specifications.
5. Proof of qualifications (see Paragraph 1.09A).
C. Computations:
1. Complete structural calculations showing the governing stresses in all
members and connections, and detailed shop drawings. Preliminary
drawings shall be stamped by a Professional Engineer registered in
Florida.
2. Manufacturer's standard guarantee.
03720-048-01 13232-8 ALUMINUM FLAT COVERS
August 2019
3. A letter of certification signed and sealed by a Professional Engineer
registered in Florida confirming that the aluminum cover is in full
compliance with the Plans and Specifications including any testing
provisions included therein.
PART 3 EXECUTION
3.01 INSTALLATION
A. All preparation to the existing concrete tank for installation of the cover shall be
in strict accordance with the manufacturer's recommendations so as not to
damage the existing concrete tank and to allow for proper install of the cover.
B. The flat cover shall be erected in strict accordance with the manufacturer's
instructions by the manufacturer skilled and experienced in the erection of
aluminum structures and covers.
C. The manufacturer shall field -verify all dimensions before fabrication of
components.
D. Ensure an initial substantially airtight/watertight installation of the structure by
establishing and adhering to a uniform method of applying the prescribed torque
to the strut cover bolt fasteners.
E. Properly align the cover, ensuring that they are plumb and level. Field re -
fabrication of structural components of panels will not be accepted. Forcing of the
structure to make it fit during construction is expressly forbidden and not
acceptable.
F. The cover manufacturer shall install the aluminum cover with certified crews
from the factory who regularly install tank covers. Installation shall not be
subcontracted nor handled by the Contractor. Installation by the manufacturer
shall ensure installation of the cover according to the required windload standards
according to the Florida Building Code. The manufacturer shall certify the
installation in writing after the installation is completed and the certification shall
be signed and sealed by a Professional Engineer in Florida.
3.02 TESTING
A. The manufacturer technical representative shall be on site to perform training
services in accordance with Section 01820, Training, and Table 11000-1,
Equipment Testing and Training Requirements.
03720-048-01 13232-9 ALUMINUM FLAT COVERS
August 2019
B. Loads: After installation, the cover structure shall be tested for conformance with
the deflection limits. A load of 400 pounds shall be placed as directed by the
Engineer, and the maximum deflection created by the load shall be measured.
C. Prequalified Shop Testing:
1. The manufacturer shall perform a prequalified shop air tightness test and
certification for the cover components proposed. This test shall be
performed in accordance with the "Procedural Standards for Testing,
Adjusting and Balancing of Environment System" as published by the
National Environmental Balancing Bureau (NEBB) on cover components
of no less than 80 square feet. Said test shall be conducted and witnessed
by a NEBB-certified technician.
2. A report of the test shall be prepared by the certified technician and shall
be sealed with the NEBB seal. The report shall include a description and
illustration of the test components and test apparatus and a report of the
results.
3. The cover shall maintain an air intrusion leakage rate not to exceed
0.2 cfm per square foot at an applied negative pressure of 0.2 inch of water
column for 5 minutes.
END OF SECTION
03720-048-01 13232-10 ALUMINUM FLAT COVERS
August 2019
SECTION 13316
SOFTWARE CONTROL BLOCK DESCRIPTIONS
PART 1 GENERAL
1.01 SCOPE
A. This Section provides functional descriptions of the computer software
requirements for the Process and Instrumentation and Control System (PICS) as
indicated in specifications and on the drawings. These descriptions are intended to
provide an overview of the operating concept of the plant process equipment
rather than describing in detail every operating feature, I/O point, or required set -
point.
B. The Supplier shall provide all PLC and Human Machine Interface (HMI)
programming, and graphic configuration as required for completely functional
system in accordance with the contract documents.
03720-048-01
August 2019
1. Programming: The PICS Supplier shall configure and program all
hardware and network and communications devices required for an
operating system plus any testing software required for the factory test.
The PICS Supplier is responsible for by programming the Plant SCADA
System and Plant Control Work Station (PCWS) and all other plant
systems PLCs.
2. Control Hierarchy: Several levels and modes of operational control will
exist for the system. Operators will have the ability to monitor and control
equipment via local manual controls at the equipment, or via the local
PLC Operator Interface Terminal (OIT) and through the SCADA
computers. The selection of these operational modes will be made
available through the use of hardwired and/or software selector switches.
a. Manual Control (Local): Hardwired local switches Local -Off -
Remote (LOR) (or as shown on plans and noted in detailed loop
descriptions) provide selection of Local Manual control, or Remote
Manual control (via PLCOIT or via SCADA) control of the
equipment. All equipment equipped with Local Manual
LOCAL/OFF/REMOTE (LOR) switches in LOCAL will override
all Remote PLC and SCADA control. This mode is intended
primarily for maintenance functions and is not intended for normal
process control operation. When the local switch is in REMOTE,
the device is under computer (PLC and/or SCADA) control.
13316-1 SOFTWARE CONTROL BLOCK DESCRIPTION
EMI
b. Computer Control: When the equipment LORswitch is placed in
the REMOTEposition, equipment will be controlled by the PLC in
either the REMOTE AUTO or REMOTE MANUAL mode (via a
software switch on the PLCOIT or SCADA screen).
c. REMOTE MANUAL: The Operator can remotely control
equipment through software Start/Stop commands and where
applicable, speed controlusing software switching on the PLC OIT
or via SCADA screen. The Start/Stop Command shall be wired as
one discrete output and programmed as maintained RUN
command.
d. REMOTE AUTO: Control is accomplished via PLC or SCADA
automatic control logic strategy.
e. While in the REMOTE AUTO mode, SCADA and PLCOIT
MANUAL commands are not executed by the PLC control logic.
C. Programming of control logic and configuration of the EXISTING CONTROL
SYSTEM with new process graphical screens — HMI software is part of the Work
and shall be the responsibility of the PICS Supplier.
D. Control System: The Instrumentation and Control System shall apply to all
systems described in this Section. Attached PLC I/O tabulations are for reference.
The PICS Supplier and CONTRACTOR shall confirm in the field the existing
physical PLC wiring before adding or removing wiring.
PART 2 PRODUCTS
2.01 GENERAL
A. The descriptions are applicable to the software specified in Section 13401,
Process Instrumentation and Controls (PICS).
PART 3 EXECUTION
3.01 PLC PROGRAMMING FUNCTIONAL REQUIREMENTS
A. The following paragraphs describe general configuration tasks that are required
for the system PLC(s). These tasks shall be programmed in the applicable PLC.
Each PLC may have multiple instances of each of these tasks or may have no
instances of some or all of these tasks. The input/output lists (located in these
documents as specified in Section 13401, Process Instrumentation and Controls
[PICS]) and detailed equipment control descriptions (included herein) should be
referenced to determine the requirements for each PLC.
03720-048-01 13316-2 SOFTWARE CONTROL BLOCK DESCRIPTION
August 2019 EMI
B. PLC or HMI requirements detailed here will not be repeated in the individual
control loop descriptions but are required.
C. The following paragraphs cover functional requirements of the software, which
are generic and may or may not be related to any specific control loop. The
requirements apply to both the local OITs and SCADA computers. Control
functionality will be identical for all sites.
D. Abbreviations: The following abbreviations are used in the control descriptions:
1.
AM
Auto -Manual
2.
HOA
Hand -Off -Auto
3.
LR
Local -Remote
4.
LOR
Local -Off -Remote
5.
RS
Run -Stop
6.
OC
Open -Close
7.
OSC
Open -Stop -Close
8.
00
On -Off
9.
PV
Process Variable
10.
SP
Set Point (variable)
E. Available Process Values: All generated process alarm, equipment status, and
process variable values associated with a particular PLC shall be available at its
OIT and also on SCADA HMI including remote displays (PCWS). Refer to HMI
specification for additional requirements.
F. Flow Totalized Values: Flow values shall be integrated, totalized, and stored in
the PLC registers so the values displayed on the OIT and SCADA computers will
be identical.
1. For each flow meter whose analog "flow" signal is monitored by a PLC or
for any calculated flow signal utilized for process control and monitoring,
internal flow totalization shall be accumulated by the respective PLC. The
flow totalization routine shall utilize floating point variables to accomplish
the flow integration.
2. Two flow totals shall be accumulated and accessible from the PLC. The
current 24-hour period total, the previous 24-hour period total shall be
calculated and stored. The 24-hour total shall reset at midnight.
3. The flow total values shall be displayed on the OIT.
G. System Failure: Failure of a PLC shall result in safe shutdown of associated
process equipment. Interposing relays shall be provided where required to assure
that equipment will revert to its fail-safe condition. Failure of any PLC or its
communication shall be alarmed.
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H. Rack/Module Configuration: The rack and module definitions for each PLC, as
well as the PLC communications configuration shall be completely configured to
allow proper addressing of all field connected I/O points. This shall include
configuration of any remote input/output (RIO) racks.
PLC Database Definition: The PLC database will include both field I/O points
and internally generated points required for programming. All field I/O points and
internal programming points shall be fully defined according to database naming
conventions approved by ENGINEER and OWNER. As a minimum, each
database point shall be provided with a tag name, engineering unit, alarm
parameters, and description. Internally generated points (calculations) and set -
point variables shall be provided as required whether specified in the control
descriptions or not. All process and timer set points shall be Operator adjustable
from the OIT.
J. Analog Scaling: Each analog input and output will be appropriately scaled in
engineering units for use in internal PLC programming and monitoring by the
OIT and remote SCADA computers.
K. Equipment Runtimes: For each equipment item whose "run" status is monitored
by a PLC, an internal equipment runtime shall be accumulated by the respective
PLC. The runtime procedure will monitor the status of the equipment "run"
contact and, when the equipment is running, increment a software timer that
maintains equipment runtime to within a one -minute resolution. The timer shall
stop incrementing, but not reset, when the "run" contact indicates that the
equipment is not running. The timer value shall increment an hour counter that
maintains a floating-point value representing the equipment run time in hours and
tenths of hours. The counter value shall be available for display on the OIT and
SCADA computer. A manual reset of the runtime value shall be available at the
OIT for personnel at the supervisor level and above.
L. Equipment Starts: For each equipment item whose "run" status is monitored by a
PLC, an internal equipment number of `Starts' shall be accumulated by the
respective PLC. The runtime procedure will monitor the status of the equipment
"run" contact and, when the equipment is running, increment a software counter
that maintains equipment `starts'. The counter value shall be available for display
on the OIT and SCADA computer. A manual reset of the value shall be available
at the HMIfor personnel at the supervisor level and above.
M. Change -of -State Alarms: While equipment is controllable from the PLC (IN
REMOTE), discrete output commands shall be compared to their respective
process feedback status signal (where available) to verify proper execution. If the
feedback status does not match the most recent output command (after an
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adjustable time delay), an alarm message shall be displayed on the HMlcomputer
and transmitted to SCADA. The alarm shall remain energized until the proper
discrete condition is sensed and until the operator resets the alarm.
N. Equipment Availability: In general, equipment with PLC control has been
provided with a local HOA, HOR, LR, or LOR selector switch that transfers
control to the PLC. The PLC shall monitor the position of this local selector
switch to determine if the equipment is available for PLC control. If more than
one `switch' or availability condition exists, the `switches' shall be series hard-
wired such that a single signal shall indicate that the equipment is available for
PLC control. If the equipment is not available, the PLC program shall not attempt
to implement remote manual or automatic status changes for the equipment. The
PLC program may, however, need to implement special routines if equipment
unavailability affects a sequence (as described in the detailed equipment
descriptions).
1. Upon:
a. Transmitter Failure: Analog signal less than 2 mA or greater than
22 mA.
b. Pump/Motor Failure: The PLC shall automatically remove its Call -
to -Run and if applicable, set its analog set -point value to a
minimum value.
c. An alarm shall be generated on any failure.
O. Maintained/Momentary Outputs: The need for maintained or momentary control
outputs shall be determined from the input/output listing and the electrical
schematics. In general, equipment with only one PLC control output point
indicated in the I/O list shall be programmed for a maintained control output.
Equipment with two (or more) control outputs shall be programmed for
momentary outputs as required. Provisions shall be made, in either case, to
remove the active state (start, open, forward, initiate, etc.) control output when an
equipment failure is sensed or when the equipment transitions from available to
unavailable (local switch change).
P. Power Failure: A utility power failure is detected by the PLC UPS running from
battery power.
1. Upon detection of utility power failure:
a. A power failure alarm is generated.
2. All PLC controlled equipment is turned off until main power has been
restored for 30 seconds.
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Q.
3. Upon power restoration for 30 seconds:
a. A power restored alarm is generated.
b. Devices will remain in their current configuration. Note that an
equipment REMOTE AUTO / REMOTE MANUAL mode may be
altered during the power outage if designated in the detailed
control strategy.
c. All devices will require Operator intervention (via OIT or
SCADA) to restart the equipment when not in REMOTE AUTO
mode.
d. All devices over 20 HP shall be stagger -started according to
control strategy details.
e. Control strategy details shall provide additional (if required)
actions to occur upon power restoration.
Manual/Auto Bumpless Transfer: Unless otherwise indicated in the equipment
control descriptions, equipment changes from automatic to manual control shall
be bumpless. Equipment running or stopped in automatic mode shall remain
running or stopped when manual mode is selected.
R. PLC Peer to Peer Ethernet Communications: Each PLC shall monitor peer -peer
PLC communications required for process control of an equipment system
distributed among multiple RTUs/PLCs.Communications failures shall be
detected, alarmed, and acted upon in accordance with detailed strategy
requirements.
S. PLC Low Battery: An alarm shall be generated on PLC low memory low battery
detection.
T. PLC Generated Alarms: Alarms from each PLC shall be logged into the OIT
alarm log table and displayed as described below. This requirement will not be
restated in the individual control loop descriptions.
U. Instrument Calibration: Provide the ability to place all field instruments in a
CALIBRATE mode at the SCADA system or OIT. The PLC will hold last value
of the field instrument to allow the plant to operate.
V. PLC Out of Service mode: An alarm shall be generated on SCADA system when
the PLC is taken out of service.
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3.02 OIT FUNCTIONAL REQUIREMENTS
A. The following paragraphs describe general configuration tasks that are required
for the OIT and related software.
1. Database: The system database, including field I/O and internal points
shall be established according to the database point naming conventions
approved by OWNER. Database generation for field I/O shall include all
required coordination with PLC level addresses. All calculated totals,
averages, daily totals, etc. calculated by the PLC in Section 3.01 of this
Section shall be displayed on the OIT.
2. Alarms: Complete system alarming shall be configured. This shall include
configuration of graphical alarm displays, and configuration of audible
alarms as available. All process or system alarms shall appear on a
dedicated alarm summary screen.
a. For LOW or LOW -LOW analog or discrete alarms which do not
apply if the associated equipment is not operating, provisions shall
be made to prevent generation of these alarms. This shall include
alarms such as low amperage alarms for pumps that are not
running. This may also include low flows or pressures when
associated pumps are not operating (this will only apply if periodic
operation of the equipment is considered normal).
b. All alarms/events shall be time stamped when displayed or printed.
Unacknowledged alarms shall not automatically clear from the
alarm summary if they return to normal before being
acknowledged.
B. Manual Entry of Data: The OIT shall allow manual entry data of all ENGINEER
and OWNER designated set -points, and process control variables. These variables
shall be password protected as indicated in the control descriptions.
3.03 EQUIPMENT CONTROL AND CONTROL MODE OVERVIEW
A. The following paragraphs explain the general format and control modes that are
used in the detailed equipment descriptions. These paragraphs apply to the
attached, project specific, equipment control descriptions included herein.
B. Descriptions for control are included in the detailed equipment control
descriptions. They are provided primarily for overview information and guidance
to show intent for the PICS Supplier. The PICS Supplier are responsible for all
03720-048-01
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detailed programming requirements for safe and proper operation of the
equipment provided by them under all conditions.
1. PICS Supplierand ultimately the CONTRACTOR shall be responsible for
all coordination issues between their systems to insure they work together
in a seamless operation.
3.04 DETAILED EQUIPMENT CONTROL DESCRIPTIONS
A. The following paragraphs describe functional requirements for various software
control blocks in the control system. These descriptions are intended to provide an
overview of the operational concept for the facilities, rather than describing in
detail every operating feature, requirement, or interlock. The programmer is to
provide a functioning system, including failure recovery, whether completely or
explicitly stated in the control descriptions.
B. Introduction: The purpose of the control strategy is to provide a detailed
description of the control, monitoring and alarm functional requirements
associated with each process loop for the plant control system (PCS) to operate all
the processes associated for the operation of the facility.
C. The process loop number is determined by the ISA tag name. The Control
Strategy Description Table in Section 3.04.G of this Section provides a cross-
reference between the process loop and the associated control strategy.
D. Each control strategy is divided into sections:
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1. Overview: This Section provides a basic performance description as an
introductory guide.
2. Monitoring and Control: This Section provides required equipment
operation status, current process variable measurements, totaling process
variable measurements, and active equipment control mode status that are
to be monitored (`Monitor' does not include alarms):
a. Equipment operation status includes OPEN or CLOSED position;
ON or OFF; and LOW, HIGH or OFF. (OFF is also referred to
`READY' in the electrical schematics wiring diagrams.)
b. Current process variable measurements include level, pressure,
c. Totaling process variable measurements include daily, monthly,
and annual total measurements; as well as, equipment (pumps)
cumulative runtimes for daily, weekly, monthly and yearly
runtimes.
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d. Active equipment control mode status includes REMOTE selected
in the field; MANUAL or AUTO selected from the control system
interface; PID controller's set point and output; operator entered
parameters for control algorithms (such as dosage, timers, etc.);
current sequence steps.
e. Local (Manual) Display/Control: For equipment and valves that
have Local Control Stations (LCS), Local Control Panels (LCP) or
Motor Control Panels (MCPs), the Local/Off/Remote (L/O/R)
hand switches dictates where the equipment or valves are
controlled. In LOCAL Mode, the control is from the LCS, LCP or
MCP via Open/Close pushbuttons or Start/Stop pushbuttons and
also speed potentiometers.
3. Remote Control:
a. Manual: In this mode the LCS or LCP must be in REMOTE Mode
REMOTE MANUAL Mode — control is forwarded to the OIT.
Equipment and valves do not operate automatically but must be
"pulsed" open/close (for valves and slide gates) or equipment
started/stopped manually. Typical POP-UP graphic templates shall
be utilized for all valves, slide gates, pumps, equipment, etc.
b. Auto: Same as Remote Manual Control except: In REMOTE
AUTO Mode — control of equipment and valves are controlled
automatically from the PLC as defined below:
(1) Control: This Section provides required modes of
equipment operation, mathematical algorithms,
proportional -integral -derivative (PID) controller, and
sequencing steps. This Section assumes the equipment is
placed in AUTO or REMOTE (from the field). If the
equipment is not in REMOTE then the described controls
are disabled and the equipment is not available for the OIT.
The OIT shall alert the operator defining the problem area
or piece of equipment Not -In -Auto Mode or that is not
functioning properly.
4. Transfer: This Section provides the functional requirements of transferring
from one control mode to another control mode. For example, bumpless
transfer is the ability to seamlessly go from one mode to another mode
without interrupting the equipment operation.
a. Active equipment control mode status includes AUTO or
REMOTE selected in the field; MANUAL or AUTO selected from
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the control system interface; PID controller's set point and output;
operator entered parameters for control algorithms (such as dosage,
timers, etc.); current sequence steps.
5. Interlock: This Section provides required control interaction between two
or more devices and override functions to protect equipment and process
performance under normal operations. It also provides the necessary
action to be taken if E -STOP is activated. `Interlocks' do not include
override actions caused by field generated alarms, equipment or
instrument failure, and total plant or area power outage.
6. Alarms:
a. Alarm: This Section provides required annunciation, control action
and priority of field generated alarms, logic generated alarms, and
logic generated warnings. Logic generated alarms and warnings
are identified in the control strategy. These alarms include:
(1) OOR Analog Input: For all analog inputs, issue an Out of
Range (OOR) alarm if an analog input is outside of the 4 to
20 mA range for 30 seconds.
(2) FAIL -to -CLOSE: If a CLOSE command is issued and there
is no CLOSE status feedback to indicate valve has reached
full closed position within 45 seconds or the CLOSE status
is not present while valve is commanded to CLOSED
position, then issue a FAIL -to -CLOSE alarm.
(3) FAIL -to -OPEN: If an OPEN command is issued and there
is no OPEN status feedback to indicate valve has reached
full open position within 45 seconds or the OPEN status is
not present while valve is commanded to OPEN position,
then issue a FAIL -to -OPEN alarm.
(4) FAIL -to -RUN: If a START command is issued and there is
no ON status feedback to indicate device has started within
45 seconds or the ON status is not present while device is
running, then issue a FAIL -to -RUN alarm.
(5) FAIL -to -STOP: If a STOP command is issued and there is
still an ON status feedback after 45 seconds from issuing a
STOP command, then issue a FAIL -to -STOP alarm.
(6) FEEDBACK FAILURE: A PID controller modulates a
valve position or pump speed to maintain a process set
point under AUTO mode and the controller's feedback
used to determine off set from set point is ± 5% from the
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set point for 45 seconds then issue a FEEDBACK
FAILURE alarm.
(7) FORCE OVERRIDE: A failure condition occurs that
requires the control logic to override a calculated value
used for controlling a device such as valve position or
pump speed, etc.
(8) NO STANDBY AVAILABLE: The control strategy has a
`duty' and `standby' or Lead/Lag service operation under
AUTO mode and there is only one pump available for
AUTO control then issue a NO STANDBY AVAILABLE
warning.
(9) TRACKING FAILURE: A variable speed device or
modulating valve is commanded to a speed or position
percentage and the feedback from the drive tachometer or
actuator positioner is + 5% from the commanded speed or
position for 45 seconds then issue a TRACKING
FAILURE alarm.
(10) POWER OUTAGE FORCED STOP: The equipment was
running under PLC control in MANUAL mode prior to loss
of power and due to the power outage, the equipment was
stopped. Issue a POWER OUTAGE FORCED STOP alarm
upon this condition.
7. Fault Mode: This Section provides the functional control requirements in
the event that there is an equipment or instrument failure. An equipment
failure is defined as the inability to control or monitor a device placed
under REMOTE control due to an alarm condition. An instrument failure
is defined as the inability to monitor a device due to an alarm condition.
8. Power Outage: This Section provides functional control requirements in
the event of a loss of power and the functional control requirements upon
power restoration. This Section assumes a power outage to be detected by
the transfer of normal to generator power for all processes.
E. HMI Generated Alarms: In addition, alarm priority levels are assigned a number
from 1 to 4. The numbers are categorized by the urgency of the alarm condition
and are as follows:
03720-048-01
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Priority
Description
1
Human safety in Danger/Chemical Spill Potential/Toxic
Gas Leak.
2
Equipment or system failure; or interlock to shutdown
equipment to prevent mechanical damage.
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Priority
Description
3
Control override to prevent jeopardizing process
performance or possible mechanical damage.
4
Warning of potential problem effecting process
performance or possible mechanical damage.
F. Control System Overview:
1. Tanks
a. Name: North Biosolids Blending Tank.
b. Name: South Dewatering Storage Tank.
c. Name: Primary Anaerobic Digester.
2. Sludge Valve Station
a. Name: Thickened Primary Sludge Valve to Digester Equipment
No. 102 -AC -3.
b. Name: Thickened Waste Activated Sludge Valve to Digester
Equipment No. 102 -AC -1.
c. Name: Thickened Primary Sludge Valve to Combined Thickened
Sludge Equipment No. 102 -AC -4.
d. Name: Thickened Waste Activated Sludge Valve to Combined
Thickened Sludge Equipment No. 102 -AC -2.
3. Pumps
a. Name: Truck Off -Loading Pumps Equipment No. 101-P-1 and
101-P-2.
b. Name: Digester Feed Pumps Equipment No. 102-P-1 and 102-P-2.
c. Name: Dewatering Feed Pumps Equipment No. 103-P-1, 103-P-2,
103-P-3, and 103-P-4.
d. Name: Existing Truck Off -Loading Pump Station (Backup
Operations).
4. System Description — Normal Operation
a. Tank Status: Normal Operation will utilize the North Tank for
Biosolids Blending and the South Tank for Dewatering Storage.
The North Biosolids Blending Tank will receive the following for
blending and discharge to the Primary Anerobic Digester:
I (1) East Plant WRF thickened WAS sludge loads using the
Truck Off -Loading Pump Station (101-P-1 and 101-P-2).
1
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(2)
(3)
Existing WRF scum pump station and feed piping.
Combined Thickened Sludge Piping (Thickened WAS and
Thickened Primary Sludge).
b. The South Dewatering Storage Tank will receive daily discharge
of anerobic digested sludge from the Primary Anaerobic Digester
for temporary storage and mixing prior to dewatering by centrifuge
and/or belt filter presses.
5. Sludge Valve Station Status: The Sludge Valve Station actuators will be
set by the operator as follows:
a. Normally close the valve actuators to the Digester (102 -AC -3 and
102 -AC -1) and normally open the valves to the Combined
Thickened Sludge (102 -AC -4 and 102 -AC -2). This will direct the
Thickened Primary Sludge from the new Salnes Filters and the
Thickened Waste Activated Sludge from the existing WAS
Thickeners into a single Combined Thickened Sludge Line that
feeds to the North Biosolids Blend Tank.
6. Pump Logic Status and Alarm Annunciation:
a. The Truck Off -Loading Pumps will receive the following alarms:
(1) The North Biosolids Blending Tank High Level.
b. The Digester Feed Pumps will receive the following alarms:
(1) The North Biosolids Blending Tank Low Level.
(2) The Primary Anaerobic Digester High Level.
c. The Dewatering Feed Pumps will receive the following alarms:
(1) The South Dewatering Storage Tank Low Level.
d. The Dewatering Equipment (Centrifuge and/or Belt Filter Press —
Shutdown Alarm).
7. System Description — South Dewatering Tank Maintenance (Backup
Operation Mode):
a. Tank Status: The Operator will select the North Tank for operation
as the Dewatering Storage Tank. There will be no Biosolids
Blending Tank in operation under this mode and Thickened
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Primary and Thickened WAS biosolids will be sent to the primary
anerobic digester using the Sludge Valve Station. The East Plant
WRF Thickened WAS truck off-loading will be done at the
Existing East WRF Thickened WAS Pump Station will pump
thickened WAS from the East WRF tanker trucks directly into the
Primary Anaerobic Digester.
b. Sludge Valve Station Status: The Sludge Valve Station actuators
will be set by the operator to open position for the valves to the
Digester (102 -AC -3 and 102 -AC -1) and the operator will set to
close position for the valves to the Combined Thickened Sludge
(102 -AC -4 and 102 -AC -2) piping to the North Sludge Blend Tank.
These valve settings will direct the Thickened Primary Sludge and
the Thickened Waste Activated Sludge directly into the Primary
Anerobic Digester.
c. Pump Logic Status:
(1) The Truck Off -Loading Pump Station at the Blend Tanks
will not operate while in Maintenance Operation with the
North Tank used as the Dewatered Sludge Storage Tank.
(2) The Existing East WRF Thickened WAS Pump Station will
be used for East Plant WRF thickened WAS truck off-
loading to feed directly into the Digester and will receive
the following alarms:
(3)
(a) The Primary Anaerobic Digester High Level.
(b) Shut -down the Existing East WRF Thickened WAS
Pump Station.
The Digester Feed Pumps will not operate while the North
Tank is used for the Dewatering Storage Tank, and the
South Tank is out of service for maintenance.
(4) The Dewatering Feed Pumps will receive the following
alarms:
(a) North Tank Low Level to protect the Dewatering
Feed Pumps from pumping dry.
(b) The Dewatering Equipment (centrifuge and belt
filter press) — Shut Down Alarm.
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8. System Description — North Blend Tank Maintenance (Backup Operation
Mode):
a. Tank Status: The Operator will select the South Tank for operation
as the Biosolids Blend Tank. The North Biosolids Blend Tank will
be out of service for maintenance and there will be no Sludge
Dewatering Tank in operation under this mode and anerobic
digested sludge will be sent directly from the Primary Anaerobic
Digester directly to the suction side of the Dewatering Feed
Pumps. The South Biosolids Blending Tank will receive the
following for blending and discharge to the Primary Anerobic
Digester: East Plant WRF thickened WAS sludge loads using the
Truck Off -Loading Pump Station (101-P-1 and 101-P-2), the
existing WRF scum pump station and feed piping, and the
Combined Thickened Sludge Piping (Thickened WAS and
Thickened Primary Sludge).
b. Sludge Valve Station Status: The Sludge Valve Station actuators
will be set by the operator as follows: normally close the valve
actuators to the Digester (102 -AC -3 and 102 -AC -1) and normally
open the valves to the Combined Thickened Sludge (102 -AC -4 and
102 -AC -2). This will direct the Thickened Primary Sludge from
the new Salnes Filters and the Thickened Waste Activated Sludge
from the existing WAS Thickeners into a single Combined
Thickened Sludge Line that feeds to the South Biosolids Blend
Tank.
c. Primary Anaerobic Digester — Manual Valve Adjustments:
Operators will open and close the following valves located in the
lower level gallery of the Anaerobic Digester to feed anerobic
digested sludge directly to the suction piping of the Dewatering
Feed Pump Station: Open 6 -inch Plug Valve (107-V-1) and Close
6 -inch Plug Valves (107-V-2) and (107-V-4) to allow digested
sludge to be transferred from the existing digester supernatant
transfer (6-DTS) line into the 6 -inch waste sludge (6 -WS) line. The
existing 6 -WS line becomes the new 8 -inch anaerobic sludge pipe
(8-inch-ADIG-1) that feeds the Storage and Blend Tanks.
9. Pump Logic Status and Alarm Annunciation:
a. The Truck Off -Loading Pumps will receive the following alarms:
(1) The South Biosolids Blending Tank High Level.
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b. The Digester Feed Pumps will receive the following alaiiiis:
(1) The South Biosolids Blending Tank Low Level.
(2) The Primary Anaerobic Digester High Level.
c. The Dewatering Feed Pumps will receive the following alarms:
(1) Primary Anaerobic Digester Low Level.
(2) The Dewatering Equipment (Centrifuge and/or Belt Filter
Press — Shutdown Alarm).
G. Introduction to Control Description: The purpose of the control strategy is to
provide a detailed description of the control, monitoring and alarm functional
requirements associated with each process loop for the Plant's control system
(PCS) to operate the following processes:
No.
Control Strategy Description
100
Diversion Valves
200
Sludge Storage
300
Sludge Dewatering Feed System
400
Digester Feed System
500
Truck Loading
1. Diversion Valves:
a. The four (4) diversion valves 102 -AC -1, 2, 3, and 4 shall be
controlled manually from the SCADA system or locally. The
sequence of operations shall be as follows:
(1) Local Control:
(a) The operator sets the LOCAL/REMOTE selector
switch at the respective actuator to the LOCAL
position.
(b) The operator sets the OPEN/OFF/CLOSED in the
desired position.
(c) Status:
i. Open.
ii. Closed.
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(d) Alarms:
i. Actuator High Torque.
(e) Interlocks:
i. None.
(0 Historical:
i. Record position, time stamp all status and
alarms.
(2) Remote Control:
(a) The operator sets the LOCAL/REMOTE selector
switch at the respective actuator to the REMOTE
position.
(b) The operator sets the HMI actuator to the desired
position.
(c) Status:
i. Open.
ii. Closed.
(d) Alarms:
i. Actuator High Torque.
ii. No Flow.
(e) Interlocks:
i. Confirm Tank Levels.
ii. Confirm Grinder 110-G-1 Operation.
iii. Confirm Flow.
(0 Historical:
i. Record position, time stamp all status and
alarms.
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2. Sludge Storage:
a. One vertical Hyperboloid-body ragless type impeller mixer will be
located in each of the North Biosolids Blend Tank and South
Sludge Dewatering Tanks. The mixers will be controlled by
Manufacturer's Control Panel located at each unit. Tank mixers are
single speed with continual operation. Each mixer will have a local
panel with H/O/A switch. In Automatic (A) the mixer runs based
on input from SCADA. In Hand the unit is operated locally by
Operations Staff.
b. The two sludge storage tanks 110-T-1 and 110-T-2 with mixers
110-M-1 and 110-M-2 shall be monitored and controlled from the
SCADA system or locally. The sequence of operations shall be as
follows:
(1) Mixer Local Manual:
(a) The operator sets the HAND/OFF/REMOTE
selector switch at the respective mixer to the HAND
position.
(b) Status:
i. Mixer Run.
ii. Mixer in Hand.
(c) Alarms:
i. Mixer Trouble.
(d) Interlocks:
i. None.
(e) Historical:
i. Record run time, status, and alarms.
(2) Mixer Remote Control:
(a) The operator sets the HAND/OFF/REMOTE
selector switch at the respective mixer to the
REMOTE position.
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(b) The operator sets the HMI, ON/OFF selector switch
to the desired position.
(c) Status:
i. Mixer Run.
ii. Mixer in Remote.
(d) Alarms:
i. Mixer Trouble.
(e) Interlocks:
i. Confirm Tank Levels.
(f) Historical:
i. Record run time, status, and alarms.
(3) Storage Tanks:
(a) The SCADA system shall monitor each sludge
storage tank.
(b) Status:
i. Tank Level.
(c) Alarms:
i. Tank Impeding High Level (Operator
Adjustable).
ii. Tank Impeding Low Level (Operator
Adjustable).
iii. Tank Emergency High Level (Float).
iv. Tank Impeding Low Level (Float).
(d) Interlocks:
i. Close Fill Valve on High Level.
ii. Shut Down Pumps on Low Level.
03720-048-01 13316-19 SOFTWARE CONTROL BLOCK DESCRIPTION
August 2019 EMI
(e) Historical:
i. Record level, status, and alarms.
3. Sludge Dewatering Feed System:
a. A total of four progressing cavity pumps, three dedicated and one
back-up, are proposed. The pumps will be controlled with Variable
Frequency Drives (VFDs) to allow the pump to handle variations
in sludge flows. The VFD will be controlled by the selected
dewatering system chosen for that pump (Centrifuge Control Panel
(CP); Belt Filter Press No. 1 CP or Belt Filter Press No. 2 CP). The
Operators Staff will manually select and operate which pumps will
be used with which dewatering system. Any of the progressing
cavity pumps will be capable of pumping to any of the dewatering
processes (Belt Filter Press No. 1, Belt Filter Press No. 2, or
Centrifuge) through manual manipulation of the valves and
selection on the HMIs of each dewatering system control panel.
The four (4) sludge dewatering feed pumps 103-P-1,2,3,4 shall be
monitored and controlled from the SCADA system or locally. The
sequence of operations shall be as follows:
(1) Local VFD Manual:
(a) The operator sets the LOCAL/REMOTE selector
switch at the respective VFD to the LOCAL
position.
(b) The operator sets the HAND/OFF/REMOTE
selector switch at the motor to the REMOTE
position.
(c) The operator at the VFD sets the ON/OFF selector
switch in the desired position.
(d) Status:
i. Pump Run.
ii. Pump in REMOTE.
iii. Pump Speed.
iv. Pump in HAND.
03720-048-01 13316-20 SOFTWARE CONTROL BLOCK DESCRIPTION
August 2019 EMI
03720-048-01
August 2019
(e) Alarms:
i. VFD Trouble.
ii. Motor High Temp.
iii. Pump High Temp.
iv. Pump High Pressure.
(f) Interlocks:
i. Off position at motor HOA will not allow
pump to start.
(g) Historical:
i. Record run time, status, and alarms.
(2) Local Manual at Motor:
(a) The operator sets the LOCAL/REMOTE selector
switch at the respective VFD to the REMOTE
position.
(b) The operator sets the HAND/OFF/REMOTE
selector switch at the motor to the HAND position.
Pump will start a preset speed programed at the
VFD.
(c) Status:
i. Pump Run.
ii. Pump in REMOTE.
iii. Pump Speed.
iv. Pump in HAND.
(d) Alarms:
i. VFD Trouble.
ii. Motor High Temp.
iii. Pump High Temp.
iv. Pump High Pressure.
(e) Interlocks:
i. In REMOTE at VFD.
13316-21 SOFTWARE CONTROL BLOCK DESCRIPTION
EMI
(f) Historical:
i. Record run time, status, and alarms.
(3) Remote Control at Dewatering Equipment:
(a) The operator sets the LOCAL/REMOTE selector
switch at the respective VFD to the REMOTE
position.
(b) The operator sets the HAND/OFF/REMOTE
selector switch at the motor to the REMOTE
position.
(c) Status:
i. Pump Run.
ii. Pump in REMOTE.
iii. Pump Speed.
iv. Pump in REMOTE.
(d) Alarms:
i. VFD Trouble.
ii. Motor High Temp.
iii. Pump High Temp.
iv. Pump High Pressure.
(e) Interlocks:
i. OFF position of field selector switches will
not allow pump to start.
ii. If the liquid level in the Sludge Storage
(Primary) and Blend Tank is at the Low
Level the pump will be turned off and a
signal will be initiated indicating that the
pump was turned off due to the low liquid
level in the Sludge Storage and Blend Tank.
This will signal an alarm to the selected
dewatering system control panel to shut-
down due to low tank level.
iii. The dewatering feed pumps will only be
controlled as called for by the selected and
03720-048-01 13316-22 SOFTWARE CONTROL BLOCK DESCRIPTION
August 2019 EMI
03720-048-01
August 2019
associated dewatering equipment specific
for each pump (Belt Filter Press No. 1, Belt
Filter Press No. 2, and Centrifuge).
iv. If there is a failure at the respective belt
filter press or centrifuge: the pumps will
immediately turn-off.
v. The dry running protection devices or high
pressure equipped by the manufacturer will
also be able to turn the pumps off.
(f) Historical:
i. Record run time, status, and alarms.
4. Digester Feed System:
a. The Anaerobic Digester Feed Pump Station consists of two
progressing cavity pumps, one primary and one back-up, with
space for one additional pump in the future. The pumps will be
controlled with SCADA and Variable Frequency Drives (VFDs) to
allow the operations staff to set the daily blended sludge volume
and flow (gpm) to feed to the Primary Anaerobic Digester. The
blended sludge flow and rate feed to the Digester will be measured
by a magnetic flow meter. The goal is to provide continuous feed
of blended sludge to the anerobic digester over a 24-hour period to
eliminate foaming, improve volatile solids destruction /
stabilization, and increase digester gas production. The operations
staff will choose the daily volume of blended sludge to be pumped
the Primary Anaerobic Digestor and select the corresponding
24-hour Digester Feed Pump flow rate and operating times to be
set and then the pump will be automatically controlled by the
SCADA system. The SCADA will record the flow rate (gpm),
daily volume of blended sludge pumped (gallons) and shut-off the
pump when the selected daily volume is reached. The pump will
automatically re -start and stop each day to pump the selected
sludge volume. The two sludge dewatering feed pumps
102-P-1 and 2 shall be monitored and controlled from the SCADA
system or locally. The sequence of operations shall be as follows:
(1) Local VFD Manual:
(a) The operator sets the LOCAL/REMOTE selector
switch at the respective VFD to the LOCAL
position.
13316-23 SOFTWARE CONTROL BLOCK DESCRIPTION
EMI
03720-048-01
August 2019
(b) The operator sets the HAND/OFF/REMOTE
selector switch at the motor to the REMOTE
position.
(c) The operator at the VFD sets the ON/OFF selector
switch in the desired position.
(d) Status:
i. Pump Run.
ii. Pump in REMOTE.
iii. Pump Speed.
iv. Pump in HAND.
(e) Alarms:
i. VFD Trouble.
ii. Motor High Temp.
iii. Pump High Temp.
iv. Pump High Pressure.
(f) Interlocks:
i. Off position at motor HOA will not allow
pump to start.
(g) Historical:
i. Record run time, status, and alarms.
(2) Local Manual at Motor:
(a) The operator sets the LOCAL/REMOTE selector
switch at the respective VFD to the REMOTE
position.
(b) The operator sets the HAND/OFF/REMOTE
selector switch at the motor to the HAND position.
Pump will start a preset speed programed at the
VFD.
13316-24 SOFTWARE CONTROL BLOCK DESCRIPTION
EMI
1
(c) Status: 1
i. Pump Run.
ii. Pump in REMOTE.
iii. Pump Speed.
iv. Pump in HAND.
(d) Alarms:
i. VFD Trouble.
ii. Motor High Temp.
iii. Pump High Temp.
iv. Pump High Pressure.
(e) Interlocks:
i. In REMOTE at VFD.
(f) Historical:
i. Record run time, status, and alarms.
(3) Remote Control from SCADA:
(a) The operator sets the LOCAL/REMOTE selector
switch at the respective VFD to the REMOTE
position.
(b) The operator sets the HAND/OFF/REMOTE
selector switch at the motor to the REMOTE
position.
(c) Operations staff selects which Tank (North
Biosolids Blend Tank (Primary) or South
Dewatering Storage Tank (Backup) will act as the
Biosolids Blank Tank).
(d) Operations staff selects which pump will operate
and number of pumps in-service.
(e) Operations staff inputs/ selects daily volume of
blended sludge to pump to Primary Anaerobic
Digester (gallons/day) — Range: 40,000 to
100,000 gals/day.
03720-048-01 13316-25 SOFTWARE CONTROL BLOCK DESCRIPTION
August 2019 EMI
1
(f) SCADA calculates a 24-hour pump flow rate
(gpm) — e.g.: 60,000 gals/day _ 1,440 min/day =
42 gals/min.
(g)
Based on pump curve and allowable minimum
pump speed input during integrations, SCADA
calculates pump speed (rpm) and selected drive
speed (Hz). Operator accepts or giving option to
select a set a different operating speed (rpm).
(h) Status:
i. Pump Run.
ii. Pump in REMOTE.
iii. Pump Speed.
iv. Pump in REMOTE.
(i) Alarms:
i. VFD Trouble.
ii. Motor High Temp.
iii. Pump High Temp.
iv. Pump High Pressure.
v. Anaerobic Digester High Level..
(j) Interlocks:
i. OFF position of any field selector switches
will not allow pump to start.
ii. Low Level Sludge Storage and Blend Tank
Shut Off (Depending on Tank In -Service.
iii. The dry running protection devices or high
pressure equipped by the manufacturer will
also be able to turn the pumps off.
iv. High or High -High Primary Anaerobic
Digester Tank Level Shut Off (Existing
SCADA monitoring and recording signal).
(k) Historical:
i. Record run time, status, and alarms.
03720-048-01 13316-26 SOFTWARE CONTROL BLOCK DESCRIPTION
August 2019 EMI
ii. Flow from Flow Meter:
a. Total Gallons per Day (gpm/day) —
Blended Sludge Pumped to Primary
Anaerobic Digester.
b. Flow rate set in SCADA and flow
rate measured (gpm).
c. Pump start / stop times to pump
selected daily sludge volume (as
applicable if pump needs to start and
stop ever hour to pump low flow
volumes at allowable minimum
pump speed.
d. Continuously monitor and record
tank level (feet) and volume
(gallons) in the North Biosolids
Blend Tank and South Dewatering
Tank.
5. Truck Loading:
a. A total of two progressing cavity pumps, one primary and one
back-up, are proposed. Pumps are constant speed and will have a
local control station at the pumps to allow truck haulers to
Start/Stop pumps. The local station will be integrated into the
SCADA system for monitoring, alarm annunciation and recording.
The pump will be operated based on Start/Stop push buttons at the
local control station. An HMI installed at the local control station
will allow monitoring of a magnetic flow meter integrated into the
SCADA system will record total volume, in gallons per event (date
and time) discharged from the trucks. The total volume, time, and
date of each off-loading will be recorded and saved in the SCADA
system as well as displayed at the HMI. If Sludge Blend Tank is at
high level as determined by the ultrasonic level control in the tank,
the off-loading authorization will not be granted, and the pump
will not be able to be turned on and the HMI will display "Tank at
High Level Contact Operations Staff'. The sequence of operation
is as follows:
(1) Local MCC Manual:
(a) The operator sets the HAND/OFF/REMOTE
selector switch at the motor control center to the
HAND position.
03720-048-01 13316-27 SOFTWARE CONTROL BLOCK DESCRIPTION
August 2019 EMI
(b) The operator sets the HAND/OFF/REMOTE
selector switch at the motor to the HAND position.
(c) Status:
i. Pump Run.
ii. Pump in REMOTE.
(d) Alarms:
i. Motor High Temp.
(e) Historical:
i. Record run time, status, and alarms.
(2) Local Manual at Motor:
(a) The operator sets the HAND/OFF/REMOTE
selector switch at the motor control center to the
HAND position.
(b) The operator sets the HAND/OFF/REMOTE
selector switch at the motor to the HAND position.
(c) Status:
i. Pump Run.
ii. Pump in REMOTE.
(d) Alarms:
i. Motor High Temp.
(e) Historical:
i. Record run time, status, and alarms.
(3) Remote Control at Truck Loading:
(a) The operator sets the HAND/OFF/REMOTE
selector switch at the motor control center to the
REMOTE position.
03720-048-01 13316-28 SOFTWARE CONTROL BLOCK DESCRIPTION
August 2019 EMI
(b) The operator sets the HAND/OFF/REMOTE
selector switch at the motor to the REMOTE
position.
(c) Operations staff selects which pump is in-service.
(d) Operations staff selects which Tank is in-service
(Primary -North Blend Tank).
(e) Status:
i. Pump Run.
ii. Pump in MCC REMOTE.
iii. Pump Speed.
iv. Pump in Motor REMOTE.
(f) Alarms:
i. Motor High Temp.
ii. Pump High Temp.
iii. Pump High Pressure.
(g) Interlocks:
i. OFF position of field selector switches will
not allow pump to start.
ii. Start /Stop push button to be controlled by
Truck Hauler for pump start operation and
stop button to be pushed when truck is
empty.
iii. Lock -out if Sludge Storage and Blend Tank
has insufficient volume based on tank high
level annunciation and notification on HMI
Screen.
iv. Locks -out after a specified elapse time
(adjustable by plant staff only).
v. Pump off and lock -out if liquid level reaches
the high -high level in the Sludge Storage
and Blend Tank.
03720-048-01 13316-29 SOFTWARE CONTROL BLOCK DESCRIPTION
August 2019 EMI
vi. Magnetic Flow Meter and Indicating
Transmitter (FE/FIT 500) to read the
following:
a. Truck Off -Load Event: Event No. /
Gallons Per Truck Off -Load (Gals)/
Date/Time.
b. Totalizer: Gallons.
vii. Tank Levels for North Blend and South
Dewatering Storage Tanks (LIT 201 and
LIT 202.
(h) Historical:
i. Record run time, status. and alarms
ii. Flow Gallons Per Truck Off -Load (Gals)/
Date/Time.
3.05 ATTACHMENTS
A. Attachments listed below, following "END OF SECTION," are part of this
Section.
1. Table 13316-1, PLC -PB I/O Schedule.
2. Table 13316-2, PLC -DG I/O Schedule.
END OF SECTION
03720-048-01 13316-30 SOFTWARE CONTROL BLOCK DESCRIPTION
August 2019 EMI
Table 13316-1
PLC -PB I/O Schedule
1
Table 13316-1
PLC -PB I/O SCHEDULE
scription
ISA
Tag
Type
Signal
Range/
N.O. Status
Units/
N.C. Status
Field Wiring
Specification Section
Responsible for
Signal Source
Remarks
ISA Signal
Source Design.
Signal Source
Device
ocess 200 Blend Tanks
xer#1 Run Status
YIQR-201
DI
Form C
Stopped
Running
YS -201
200-LCP-1
11228
EVT, CRT, DRT,DSC
Mixer#1 Trouble
YAR -2018
DI
Form C
Normal
Alarm
YS -2018
200-LCP-1
11228
EVT
Mixer#1 In Auto
ZS -201
DI
Form C
Normal
Auto
ZS -201
200-LCP-1
11228
EVT
xer#1 In Hand
ZS -201B
DI
Form C
Normal
Hand
ZS -201B
200-LCP-1
11228
EVT
xer#1 Motor Fail
EUIR-201
DI
Form C
Normal
Alarm
ES -201
200-LCP-1
11228
EVT
xer#1 Command
YCC-201
DO
Form C
Normal
Open
YS -201
PLC -PB
13401
North Blend Tank Level
LI -201
Al
4-20mA
0-30
ft.in
LT -201
LIT -201
13401
EVT
Orth Blend Tank High Level
LAH-201
DI
Form C
Normal
Alarm
LSH -201
LSH -201
13401
EVT
Orth Blend Tank Low Level
LAL-201
DI
Form C
Normal
Alarm
LSL-201
LSL-201
13401
EVT
xer #2 Run Status
YIQR-202
DI
Form C
Stopped
Running
YS -202
200-LCP-1
11228
EVT, CRT, DRT,DSC
xer#2 Trouble
YAR -202B
DI
Form C
Normal
Alarm
YS -2028
200-LCP-1
11228
EVT
er #2 In Auto
ZS -202
DI
Form C
Normal
Auto
ZS -202
200-LCP-1
11228
EVT
er#2 In Hand
ZS -202B
DI
Form C
Normal
Hand
ZS -202B
200-LCP-1
11228
EVT
Mixer #2 Motor Fail
EUIR-202
DI
Form C
Normal
Alarm
ES -202
200-LCP-1
11228
EVT
Mixer#2 Command
YCC-202
DO
Form C
Normal
Open
YS -202
PLC -PB
13401
uth Blend Tank Level
LI -202
Al
4-20mA
0-30
ft.in
LT -202
LIT -202
13401
EVT
South Blend Tank High Level
LAH-202
DI
Form C
Normal
Alarm
LSH -202
LSH -202
13401
EVT
South Blend Tank Low Level
LAL-202
DI
Form C
Normal
Alarm
LSL-202
LSL-202
13401
EVT
nder#1 Run Status
YIQR-110A
ENET
ENET
Stopped
Running
YS -110A
110-LCP-1
11330
EVT, CRT, DRT,DSC
finder#1 Trouble
YAR -110B
ENET
ENET
Normal
Alarm
YS -110B
110-LCP-1
11330
EVT
Grinder#1 In Auto
ZS -110A
ENET
ENET
Normal
Auto
ZS -110A
110-LCP-1
11330
EVT
Grinder#1 In Hand
ZS -1108
ENET
ENET
Normal
Hand
ZS -110B
110-LCP-1
11330
EVT
finder#1 Motor Fail
EUIR-110A
ENET
ENET
Normal
Alarm
ES -110A
110-LCP-1
11330
EVT
ocess 300 Dewatering Feed Pumps
Feed Pump #1 Run Status
YIQR-301
ENET
ENET
Stopped
Running
YS -301
VFD
16370
EVT, CRT, DRT, DSC
Feed Pump #1 VFD Manual
ZS -301A
ENET
ENET
Normal
Manual
ZS -301A
VFD
16370
EVT
ed Pump #1 VFD Remote
ZS -301B
ENET
ENET
Normal
Remote
ZS -301B
VFD
16370
EVT
ed Pump #1 VFD Trouble
YA-301A
ENET
ENET
Normal
Alarm
YS -301A
VFD
16370
EVT
ed Pump #1 Motor High Temperature
TAH -301
ENET
ENET
Normal
Alarm
TS -301
VFD
11356
EVT
Feed Pump #1 Motor Overload
EUA -301
ENET
ENET
Normal
Alarm
ES -301
VFD
16370
EVT
Feed Pump #1 Speed Feedback
SI -301
ENET
ENET
0-100
%
SR -301
VFD
16370
MN, MX,MA
ed Pump #1 Speed Control
SC -301
ENET
ENET
0-100
%
ST -301
VFD
13401
MN, MX,MA
ed Pump 81 Run Command
YC -301
ENET
ENET
Start
Stop
YS -301
VFD
13401
EVT
-ed Pump #1 Pressure
PA -301
ENET
ENET
0-25
psi
PS -301
VFD
11356
MN, MX,MA
Feed Pump #1 Temperature
TI -301
ENET
ENET
0-200
F
TS -301
VFD
11356
MN, MX,MA
Feed Pump #1 Local Em. Stop
ZS -301C
DI
Form C
Normal
Stop
ZS -301C
HS -301
16050
EVT
ed Pump#1 Local Remote
ZS -301D
DI
Form C
Normal
Remote
ZS -301D
HS -301
16050
EVT
ed Pump #2 Run Status
YIQR-302
ENET
ENET
Stopped
Running
YS -302
VFD
16370
EVT, CRT, DRT, DSC
ed Pump #2 VFD Manual
ZS -302A
ENET
ENET
Normal
Manual
ZS -302A
VFD
16370
EVT
Feed Pump #2 VFD Remote
ZS -302B
ENET
ENET
Normal
Remote
ZS -302B
VFD
16370
EVT
Feed Pump #2 VFD Trouble
YA-302A
ENET
ENET
Normal
Alarm
YS -302A
VFD
16370
EVT
ed Pump #2 Motor High Temperature
TAH -302
ENET
ENET
Normal
Alarm
TS -302
VFD
11356
EVT
ed Pump #2 Motor Overload
EUA -302
ENET
ENET
Normal
Alarm
ES -302
VFD
16370
EVT
ed Pump #2 Speed Feedback
SI -302
ENET
ENET
0-100
%
SR -302
VFD
16370
MN, MX,MA
Feed Pump #2 Speed Control
SC -302
ENET
ENET
0-100
%
ST -302
VFD
13401
MN, MX,MA
Feed Pump #2 Run Command
YC -302
ENET
ENET
Start
Stop
YS -302
VFD
13401
EVT
ed Pump #2 Pressure
PA -302
ENET
ENET
0-25
psi
PS -302
VFD
11356
MN, MX,MA
ed Pump #2 Temperature
TI -302
ENET
ENET
0-200
F
TS -302
VFD
11356
MN, MX,MA
ed Pump #2 Local Em. Stop
ZS -302C
DI
Form C
Normal
Stop
ZS -302C
HS -302
16050
EVT
Feed Pump #2 Local Remote
ZS -302D
DI
Form C
Normal
Remote
ZS -302D
HS -302
16050
EVT
ed Pump #3 Run Status
YIQR-303
ENET
ENET
Stopped
Running
YS -303
VFD
16370
EVT, CRT, DRT, DSC
ed Pump #3 VFD Manual
ZS -303A
ENET
ENET
Normal
Manual
ZS -303A
VFD
16370
EVT
ed Pump #3 VFD Remote
ZS -303B
ENET
ENET
Normal
Remote
ZS -303B
VFD
16370
EVT
-ed Pump #3 VFD Trouble
YA-303A
ENET
ENET
Normal
Alarm
YS -303A
VFD
16370
EVT
Feed Pump #3 Motor High Temperature
TAH -303
ENET
ENET
Normal
Alarm
TS -303
VFD
11356
EVT
F -ed Pump #3 Motor Overload
EUA -303
ENET
ENET
Normal
Alarm
ES -303
VFD
16370
EVT
ed Pump #3 Speed Feedback
SI -303
ENET
ENET
0-100
%
SR -303
VFD
16370
MN, MX,MA
ed Pump #3 Speed Control
SC -303
ENET
ENET
0-100
%
ST -303
VFD
13401
MN, MX,MA
d Pump #3 Run Command
YC -303
ENET
ENET
Start
Stop
YS -303
VFD
13401
EVT
Feed Pump #3 Pressure
PA -303
ENET
ENET
0-25
psi
PS -303
VFD
11356
MN, MX,MA
Feed Pump #3 Temperature
TI -303
ENET
ENET
0-200
F
TS -303
VFD
11356
MN, MX,MA
ed Pump #3 Local Em. Stop
ZS -303C
DI
Form C
Normal
Stop
ZS -303C
HS -303
16050
EVT
ed Pump #3 Local Remote
ZS -303D
DI
Form C
Normal
Remote
ZS -303D
HS -303
16050
EVT
Feed Pump #4 Run Status
YIQR-304
ENET
ENET
Stopped
Running
YS -304
VFD
16370
EVT, CRT, DRT, DSC
Feed Pump #4 VFD Manual
ZS -304A
ENET
ENET
Normal
Manual
ZS -304A
VFD
16370
EVT
ed Pump #4 VFD Remote
ZS -304B
ENET
ENET
Normal
Remote
ZS -304B
VFD
16370
EVT
ed Pump #4 VFD Trouble
YA-304A
ENET
ENET
Normal
Alarm
YS -304A
VFD
16370
EVT
pd Pump #4 Motor High Temperature
TAH -304
ENET
ENET
Normal
Alarm
TS -304
VFD
11356
EVT
eed Pump #4 Motor Overload
EUA -304
ENET
ENET
Normal
Alarm
ES -304
VFD
16370
EVT
Feed Pump #4 Speed Feedback
SI -304
ENET
ENET
0-100
%
SR -304
VFD
16370
MN, MX,MA
1
13316 - SOFTWARE CONTROL BLOCK DESCRIPTIONS
13316-1
Table 13615-1
PLC -PB I/O SCHEDULE
Description
ISA
Tag
Type
Signal
Range/
N.O. Status
Units/
N.C. Status
Field Wiring
Specification Section
Responsible for
Signal Source
Remarks
ISA Signal
Source Design.
Signal Source
Device
Feed Pump #4 Speed Control
SC -304
ENET
ENET
0-100
%
ST -304
VFD
13401
MN, MX,MA
Feed Pump #4 Run Command
YC -304
ENET
ENET
Start
Stop
YS -304
VFD
13401
EVT
Feed Pump #4 Pressure
PA -304
ENET
ENET
0-25
psi
PS -304
VFD
11356
MN, MX,MA
Feed Pump #4 Temperature
TI -304
ENET
ENET
0-200
F
TS -304
VFD
11356
MN, MX,MA
Feed Pump #4 Local Em. Stop
ZS -304C
DI
Form C
Normal
Stop
ZS -304C
HS -304
16050
EVT
Feed Pump #4 Local Remote
ZS -304D
DI
Form C
Normal
Remote
ZS -304D
HS -304
16050
EVT
Valve 130 -ZS -1 Open Status
ZI-301
DI
Form C
Normal
Open
ZSC-301
130 -ZS -1
15110
EVT
Valve 130 -ZS -1 Closed Status
ZO-301
DI
Form C
Normal
Closed
ZSO-301
130 -ZS -1
15110
EVT
Valve 130 -ZS -2 Open Status
ZI-302
DI
Form C
Normal
Open
ZSC-302
130 -ZS -2
15110
EVT
Valve 130 -ZS -2 Closed Status
ZO-302
DI
Form C
Normal
Closed
ZSO-302
130 -ZS -2
15110
EVT
Valve 130 -ZS -3 Open Status
ZI-303
DI
Form C
Normal
Open
ZSC-303
130 -ZS -3
15110
EVT
Valve 130 -ZS -3 Closed Status
ZO-303
DI
Form C
Normal
Closed
ZSO-303
130 -ZS -3
15110
EVT
Valve 130 -ZS -4 Open Status
ZI-304
DI
Form C
Normal
Open
ZSC-304
130 -ZS -4
15110
EVT
Valve 130 -ZS -4 Closed Status
ZO-304
DI
Form C
Normal
Closed
ZSO-304
130 -ZS -4
15110
EVT
Valve 130 -ZS -5 Open Status
ZI-305
DI
Form C
Normal
Open
ZSC-305
130 -ZS -5
15110
EVT
Valve 130 -ZS -5 Closed Status
ZO-305
DI
Form C
Normal
Closed
ZSO-305
130 -ZS -5
15110
EVT
Valve 130 -ZS -6 Open Status
ZI-306
DI
Form C
Normal
Open
ZSC-306
130 -ZS -6
15110
EVT
Valve 130 -ZS -6 Closed Status
ZO-306
DI
Form C
Normal
Closed
ZSO-306
130 -ZS -6
15110
EVT
Valve 130 -ZS -7 Open Status
ZI-307
DI
Form C
Normal
Open
ZSC-307
130 -ZS -7
15110
EVT
Valve 130 -ZS -7 Closed Status
ZO-307
DI
Form C
Normal
Closed
ZSO-307
130 -ZS -7
15110
EVT
Valve 130 -ZS -8 Open Status
ZI-308
DI
Form C
Normal
Open
ZSC-308
130 -ZS -8
15110
EVT
Valve 130 -ZS -8 Closed Status
ZO-308
DI
Form C
Normal
Closed
ZSO-308
130 -ZS -8
15110
EVT
Valve 130 -ZS -9 Open Status
ZI-309
DI
Form C
Normal
Open
ZSC-309
130 -ZS -9
15110
EVT
Valve 130 -ZS -9 Closed Status
ZO-309
DI
Form C
Normal
Closed
ZSO-309
130 -ZS -9
15110
EVT
Valve 130 -ZS -9 Open Status
ZI-310
DI
Form C
Normal
Open
ZSC-310
130 -ZS -10
15110
EVT
Valve 130 -ZS -9 Closed Status
ZO-310
DI
Form C
Normal
Closed
ZSO-310
130 -ZS -10
15110
EVT
Process 400 Digester Feed Pumps
Feed Pump #1 Run Status
YIQR-401
ENET
ENET
Stopped
Running
YS -401
VFD
16370
EVT, CRT, DRT, DSC
Feed Pump #1 VFD Manual
ZS401A
ENET
ENET
Normal
Manual
ZS -401A
VFD
16370
EVT
Feed Pump #1 VFD Remote
ZS -401B
ENET
ENET
Normal
Remote
ZS -401B
VFD
16370
EVT
Feed Pump #1 VFD Trouble
YA-401A
ENET
ENET
Normal
Alarm
YS -401A
VFD
16370
EVT
Feed Pump #1 Motor High Temperature
TAH -401
ENET
ENET
Normal
Alarm
TS -401
VFD
11356
EVT
Feed Pump #1 Motor Overload
EUA -401
ENET
ENET
Normal
Alarm
ES -401
VFD
16370
EVT
Feed Pump #1 Speed Feedback
SI -401
ENET
ENET
0-100
%
SR -401
VFD
16370
MN, MX,MA
Feed Pump #1 Speed Control
SC -401
ENET
ENET
0-100
%
ST -401
VFD
13401
MN, MX,MA
Feed Pump #1 Run Command
YC -401
ENET
ENET
Start
Stop
YS -401
VFD
13401
EVT
Feed Pump #1 Pressure
PA -401
ENET
ENET
0-25
psi
PS -401
VFD
11356
MN, MX,MA
Feed Pump #1 Temperature
TI -401
ENET
ENET
0-200
F
TS -401
VFD
11356
MN, MX,MA
Feed Pump#1 Local Em. Stop
ZS -401C
DI
Form C
Normal
Stop
ZS -401C
HS -401
16050
EVT
Feed Pump #1 Local Remote
ZS -401D
DI
Form C
Normal
Remote
ZS -401 D
HS -401
16050
EVT
Feed Pump #2 Run Status
YIQR402
ENET
ENET
Stopped
Running
YS -402
VFD
16370
EVT, CRT, DRT, DSC
Feed Pump #2 VFD Manual
ZS -402A
ENET
ENET
Normal
Manual
ZS -402A
VFD
16370
EVT
Feed Pump #2 VFD Remote
ZS -402B
ENET
ENET
Normal
Remote
ZS -402B
VFD
16370
EVT
Feed Pump #2 VFD Trouble
YA-402A
ENET
ENET
Normal
Alarm
YS -402A
VFD
16370
EVT
Feed Pump #2 Motor High Temperature
TAH -402
ENET
ENET
Normal
Alarm
TS -402
VFD
11356
EVT
Feed Pump #2 Motor Overload
EUA -402
ENET
ENET
Normal
Alarm
ES -402
VFD
16370
EVT
Feed Pump #2 Speed Feedback
SI -402
ENET
ENET
0-100
%
SR -402
VFD
16370
MN, MX,MA
Feed Pump #2 Speed Control
SC -402
ENET
ENET
0-100
%
ST -402
VFD
13401
MN, MX,MA
Feed Pump #2 Run Command
YC -402
ENET
ENET
Start
Stop
YS -402
VFD
13401
EVT
Feed Pump #2 Pressure
PA -402
ENET
ENET
0-25
psi
PS -402
VFD
11356
MN, MX,MA
Feed Pump #2 Temperature
TI -402
ENET
ENET
0-200
F
TS -402
VFD
11356
MN, MX,MA
Feed Pump #2 Local Em. Stop
ZS402C
DI
Form C
Normal
Stop
ZS -402C
HS -402
16050
EVT
Feed Pump #2 Local Remote
ZS -402D
DI
Form C
Normal
Remote
ZS402D
HS -402
16050
EVT
Digester Flow
FIQR-400
Al
4-20mA
0-600
gpm/MGD
FIT400
FIT -400
13401
MN, MX, HH, LL
Grinder #2 Run Status
YIQR-410A
ENET
ENET
Stopped
Running
YS -410A
410-LCP-1
11330
EVT, CRT, DRT,DSC
Grinder#2 Trouble
YAR410B
ENET
ENET
Normal
Alarm
YS -410B
410-LCP-1
11330
EVT
Grinder#2 In Auto
ZS410A
ENET
ENET
Normal
Auto
ZS410A
410-LCP-1
11330
EVT
Grinder#2 In Hand
ZS -410B
ENET
ENET
Normal
Hand
ZS410B
410-LCP-1
11330
EVT
Grinder#2 Motor Fail
EUIR-410A
ENET
ENET
Normal
Alarm
ES -410A
410-LCP-1
11330
EVT
Process 500 Truck Loading Pumps
Loading Pump #1 Run Status
YIQR-501
DI
ENET
Stopped
Running
YS -501
MCC
16921
EVT, CRT, DRT, DSC
Loading Pump #1 MCC Manual
ZS -501A
DI
ENET
Normal
Manual
ZS -501A
MCC
16921
EVT
Loading Pump #1 MCC Remote
ZS -501B
DI
ENET
Normal
Remote
ZS -501B
MCC
16921
EVT
Loading Pump #1 MCC Trouble
YA-501A
DI
ENET
Normal
Alarm
YS -501A
MCC
16921
EVT
Loading Pump #1 Run Command
YC -501
DO
ENET
Start
Stop
YS -501
MCC
13401
EVT
Loading Pump #1 Pressure
PA -501
DI
ENET
0-25
psi
PS -501
MCC
11356
MN, MX,MA
Loading Pump #1 Temperature
TI -501
DI
ENET
0-200
F
TS -501
MCC
11356
MN, MX,MA
Loading Pump #1 Local Em. Stop
ZS -501C
DI
Form C
Normal
Stop
ZS -501C
HS -501
16050
EVT
Loading Pump#1 Local Remote
ZS -501D
DI
Form
Normal
Remote
ZS -501D
HS -501
16050
EVT
Loading Pump #2 Run Status
YIQR-502
DI
ENET
Stopped
Running
YS -502
MCC
16921
EVT, CRT, DRT, DSC
Loading Pump #2 MCC Manual
ZS -502A
DI
ENET
Normal
Manual
ZS -502A
MCC
16921
EVT
Loading Pump #2 MCC Remote
ZS -502B
DI
ENET
Normal
Remote
ZS -502B
MCC
16921
EVT
Loading Pump #2 MCC Trouble
YA-502A
DI
ENET
Normal
Alarm
YS -502A
MCC
16921
EVT
Loading Pump #2 Run Command
YC -502
DO
ENET
Start
Stop
YS -502
MCC
13401
EVT
13316 - SOFTWARE CONTROL BLOCK DESCRIPTIONS
13316-2
1
1
1
1
1
1
Table 13615-1
PLC -PB I/O SCHEDULE
ascription
ISA
Tag
Type
Signal
Range/
N.O. Status
Units/
N.C. Status
Field Wiring
Specification Section
Responsible for
Signal Source
Remarks
ISA Signal
Source Design.
Signal Source
Device
ading Pump #2 Pressure
PA -502
DI
ENET
0-25
psi
PS -502
MCC
11356
MN, MX,MA
ading Pump #2 Temperature
TI -502
DI
ENET
0-200
F
TS -502
MCC
11356
MN, MX,MA
ading Pump #2 Local Em. Stop
ZS -502C
DI
Form C
Normal
Stop
ZS -502C
HS -502
16050
EVT
Loading Pump #2 Local Remote
ZS -502D
DI
Form C
Normal
Remote
ZS -502D
HS -502
16050
EVT
uck Loading Flow
FIQR-500
Al
4-20mA
0-600
gpm/MGD
FIT -400
FIT -400
13401
MN, MX, HH, LL
ii, ck Driver Start Comand
YC -503A
DI
Form C
Normal
Start
YS -503A
101-LCP-3
13401
i uck Driver Stop Comand
YC -503B
DI
Form C
Normal
Stop
YS -503B
101-LCP-3
13401
nfirm all I/O locations with the Contractor and approved shop drawings
fore submitting l&C for review and approvals
vide 10% spare I/O of each type including
programming services typical for status or alarm for all spare DI,
ocess indication, trending and historical database
typical spare Al, and typical interlocking for all spare DO, plus
ransmit for all spare AO. Wire all spares to field terminal block.
1
1
1
1
1
1
1
1
1
1
1
1
13316 - SOFTWARE CONTROL BLOCK DESCRIPTIONS
Abbreviations:
MCC Motor Control Center
MA
DT
CT
DRT
CRT
Form C
EVT
SSS
PM
Daily Average
Daily Flow Total
Continuous Flow Total
Daily Run Time
Continuous Run Time
Dry Contact Form C"
Log Events of Status Change
Solid State Starter
Power Meter
MX
MN
HH
LL
DI
DO
Al
AO
SD
Daily Maximum
Daily Minimum
High Limit Alarm
Low Limit Alarm
Discrete Input
Discrete Output
Analog Input
Analog Output
Smoke Detector
BTCP
GCP
EFD
DSC
PU
LSW
ENET
LPMR
DTCP
LCP
13316-3
Table 13316-2
PLC -DG I/O Schedule
En N-- — N MN r EN MN M r-- = s ---
Table 13316-2
PLC -DG I/O SCHEDULE
Description
ISA
Tag
Type
Signal
Range/
N.O. Status
Units/
N.C. Status
Field Wiring
Specification Section
Responsible for
Signal Source
Remarks
ISA Signal
Source Design.
Signal Source
Device
Process 100 Flow Diversion
Control Valve 102 -AC -1 Open Run Status
ZSOR-100A
DI
Form C
Normal
Open
ZS -100A
102 -AC -1
15120
EVT
Control Valve 102 -AC -1 Close Run Status
ZSCR-100A
DI
Form C
Normal
Closed
ZS --100A
102 -AC -1
15120
EVT
Control Valve 102 -AC -1 "In Remote"
ZSR -100A
DI
Form C
Normal
In Remote
ZS -100A
102 -AC -1
15120
EVT
Control Valve 102 -AC -1 Failure
WAIR-100A
DI
Form C
Normal
Alarm
WS -100A
102 -AC -1
15120
EVT
Control Valve 102 -AC -1 Command
YCO-100A
DO
Form C
Normal
Open
YS -100A
102 -AC -1
13401
Control Valve 102 -AC -2 Open Run Status
ZSOR-100B
DI
Form C
Normal
Open
ZS -100B
102 -AC -2
15120
EVT
Control Valve 102 -AC -1 Close Run Status
ZSCR-100B
DI
Form C
Normal
Closed
ZS --100B
102 -AC -2
15120
EVT
Control Valve 102 -AC -2 "In Remote"
ZSR -100B
DI
Form C
Normal
In Remote
ZS -100B
102 -AC -2
15120
EVT
Control Valve 102 -AC -2 Failure
WAIR-100B
DI
Form C
Normal
Alarm
WS -100B
102 -AC -2
15120
EVT
Control Valve 102 -AC -2 Command
YCO-100B
DO
Form C
Normal
Open
YS -100B
102 -AC -2
13401
Control Valve 120 -AC -3 Open Run Status
ZSOR-100C
DI
Form C
Normal
Open
ZS -100C
102 -AC -3
15120
EVT
Control Valve 120 -AC -3 Close Run Status
ZSCR-100C
DI
Form C
Normal
Closed
ZS --100C
102 -AC -3
15120
EVT
Control Valve 120 -AC -3 "In Remote"
ZSR -100C
DI
Form C
Normal
In Remote
ZS -100C
102 -AC -3
15120
EVT
Control Valve 120 -AC -3 Failure
WAIR-100C
DI
Form C
Normal
Alarm
WS -100C
102 -AC -3
15120
EVT
Control Valve 120 -AC -3 Command
YCO-100C
DO
Form C
Normal
Open
YS -100C
102 -AC -3
13401
Control Valve 120 -AC -4 Open Run Status
ZSOR-100D
DI
Form C
Normal
Open
ZS -100D
102 -AC -4
15120
EVT
Control Valve 120 -AC -4 Close Run Status
ZSCR-100D
DI
Form C
Normal
Closed
ZS --100D
102 -AC -4
15120
EVT
Control Valve 120 -AC -4 "In Remote"
ZSR -100D
DI
Form C
Normal
In Remote
ZS -100D
102 -AC -4
15120
EVT
Control Valve 120 -AC -4 Failure
WAIR-100D
DI
Form C
Normal
Alarm
WS -100D
102 -AC -4
15120
EVT
Control Valve 120 -AC -4 Command
YCO-100D
DO
Form C
Normal
Open
YS -100D
102 -AC -4
13401
Diversion #1 Flow
FIQR-100
Al
4-20mA
0-1000
gpm/MGD
FIT -100
FIT -100
13401
MN, MX, HH, LL
Confirm all I/O locations with the Contractor and approved shop drawings
before submitting I&C for review and approvals
Provide 10% spare I/O of each type including
programming services typical for status or alarm for all spare DI,
process indication, trending and historical database
for typical spare Al, and typical interlocking for all spare DO, plus
retransmit for all spare AO. Wire all spares to field terminal block.
13316 - SOFTWARE CONTROL BLOCK DESCRIPTIONS
Abbreviations:
MCC Motor Control Center
MA Daily Average
DT Daily Flow Total
CT Continuous Flow Total
DRT Daily Run Time
CRT Continuous Run Time
Form C Dry Contact Form C*
EVT Log Events of Status Change
SSS Solid State Starter
MX
MN
HH
LL
DI
DO
Al
AO
SD
Daily Maximum
Daily Minimum
High Limit Alarm
Low Limit Alarm
Discrete Input
Discrete Output
Analog Input
Analog Output
Smoke Detector
BTCP
GCP
EFD
DSC
PU
LSW
ENET
LPMR
DTCP
13316-2
SECTION 13401
PROCESS INSTRUMENTATION AND CONTROLS (PICS)
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall perform all work necessary to furnish, install, commission,
test, document, and start up the instrumentation and control (I&C) system,
including modifying the existing I&C system. The Contractor shall provide all
materials, labor, equipment, incidentals, and services required for a complete and
operational system.
B. The Contractor shall acquire the services of a single, experienced I&C system
provider specifically trained in the type of equipment to be provided. The provider
shall assume responsibility for satisfactory operation of the process I&Cs as an
integrated system.
1.02 RELATED WORK
A. The provisions of all other sections of the Specifications are fully applicable to
this Section as if incorporated in this Section.
B. The Contractor shall be responsible for coordinating work with the Owner and
Subcontractors.
1.03 SUBMITTALS
The Contractor shall submit shop drawings in accordance with Section 01330, Submittals and
Acceptance:
A. Provide shop drawings for all equipment, field panels (FPs), and enclosures.
03720-048-01
August 2019
1. At a minimum the Drawings shall show the fabrication design, internal
equipment arrangement, internal wiring, and external wiring connections.
2. Provide panel elementary diagrams. The diagrams shall show all control
functions, power distribution, switched analog signals, and auxiliary
devices such as relays, alarms, fuses, lights, fans, etc.
3. Provide power requirement (voltages, currents, phases) and heat
dissipation (maximum Btu/hr) summary for all panels.
4. Panel connection drawings shall show ISA wire tags.
5. Provide any needed installation details to adequately define the installation
of panels and field components.
13401-1
PROCESS INSTRUMENTATION AND CONTROLS (PICS)
EMI
B. Provide loop diagrams for each specified loop. The loop diagrams shall meet the
minimum requirements of ISA 5.4. Loop diagram(s) shall show the wiring and/or
piping for all major components, resistors, diodes, DC power supplies, shield
terminations, tubing, piping, valving, test taps, and other appurtenances for
process connections. Each analog diagram shall tabulate loop impedances. An
individual loop shall be shown on a diagram divided into three areas for
identifying element locations: panel face, back -of -panel, and field. Loop diagrams
shall be on 8 -1/2 -x -11 -inch or 11 -x -17 -inch drawings.
1. Provide an operation description for each loop.
C. Provide electrical interconnection diagrams showing all component and panel
connection/terminal identification numbers and external wire numbers. These
diagrams shall include all intermediate terminations (e.g., at terminal junction
blocks and motor control centers).
1. The interconnection diagrams shall be coordinated with other suppliers
and the electrical subcontractor. The electrical subcontractor shall review
and approve the diagrams before any submission to the Engineer.
2. The diagrams, device designations, and symbols shall be in accordance
with NEMA ICS 1-101.
D. The Contractor shall submit a complete list of materials and equipment to be
incorporated in the work to the Engineer within 30 days after Award of Contract.
1. The list shall include catalog numbers, cut sheets, diagrams, and other
descriptive data required to demonstrate conformance with the
Specifications. Partial lists will not be acceptable.
2. The basis of acceptance will be the manufacturer's published ratings for
the equipment. The manufacturer shall be regularly engaged in the
manufacture of the products specified.
E. The Contractor shall submit testing procedures, test reports, and a training
program.
03720-048-01
August 2019
1. Provide a test procedure outline, example operational report, and example
functional test procedures and schedules.
2. Provide a factory test report.
3. Provide an operational acceptance report. The report shall contain a
completed status sheet for each loop. Each sheet shall be signed off on by
the Contractor's field crew. The report shall be reviewed, verified, and
signed off on by the Contractor.
4. Provide a training program and schedule.
13401-2 PROCESS INSTRUMENTATION AND CONTROLS (PICS)
EMI
F. Each submittal shall be complete, neat, orderly, and bound with a table of contents
and section divider tabs.
G. Each submittal shall include but not be limited to the requirements described in
this Section.
H. Or equal materials or products may be submitted for approval. Submissions shall
be accompanied with adequate data to demonstrate equality. Equality of materials
or products shall be the decision of the Engineer.
I. Each submittal shall be accompanied by a cover letter describing any exceptions
or deviations from the Specifications. Cover letters addressing resubmitted
materials shall also describe any changes which have been made since the
previous submittal and include a brief response to the Engineer's comments.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be the latest
revision of any such document in effect at the bid time. The following documents are a part of
this Section. Where this Section differs from these documents, the requirements of this Section
shall apply.
A. American Society for Testing and Materials (ASTM)
B. American National Standards Institute (ANSI)
1. ANSUTIA 568-C.2—Balance Twisted -Pair Telecommunications Cabling
and Components.
C. International Electrotechnical Commission (IEC)
1. IEC 61935—Specification for the Testing of Balanced and Coaxial
Information Technology Cabling – Part 1: Installed Balanced Cabling as
specified in ISO/IEC 11810 and Related Standards.
D. International Organization of Standardization (ISO)
03720-048-01
August 2019
1. ISO/IEC TR 24750:2007—Information Technology – Assessment and
Mitigation of Installed Balanced Cabling Channels in order to Support of
10GBASE-T.
13401-3
PROCESS INSTRUMENTATION AND CONTROLS (PICS)
EMI
E. International Society of Automation (ISA)
1. ISA 5.1—Instrumentation Symbols and Identification (NRC ADOPTED).
2. ISA 5.4 Instrument Loop Diagrams.
3. ISA 20—Specification Forms for Process Measurement and Control
Instruments, Primary Elements and Control Valves.
4. ISA 50.00.01—Compatibility of Analog Signals for Electronic Industrial
Process Instruments.
5. ISA RP7.1—Pneumatic Control Circuit Pressure Test.
6. ISA RP55.1—Hardware Testing of Digital Process Computers.
F. National Electrical Manufacturers Association (NEMA)
1. NEMA ICS-1—Industrial Control and Systems General Requirements.
G. National Institute of Standards and Technology (NIST)
H. Underwriter's Laboratories, Inc. (UL)
1.06 QUALITY ASSURANCE
A. SCADA Integrators shall be City approved including: McKim & Creed,
Commerce Controls, Curry Controls, and Revere Controls.
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
B. All work, equipment, and materials supplied shall be warranted against defective
design, materials, and workmanship for 1 year. The warranty period shall begin at
the time of project completion and acceptance by the Owner.
C. The warranty shall cover replacement equipment and/or repair, including labor,
travel time and miscellaneous expenses, at no cost to the Owner for the full
warranty period.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
03720-048-01 13401-4 PROCESS INSTRUMENTATION AND CONTROLS (PICS)
August 2019 EMI
B. Deliver materials and equipment with the manufacturer's tags and labels and UL
labels intact. Deliver packaged material in the manufacturer's original, unopened
containers bearing the manufacturer's name, brand, and UL label.
C. Throughout this Contract the Contractor shall provide suitable protection for
materials and equipment against loss or damage and the effects of weather and the
construction environment. The Contractor shall be responsible for the condition of
materials and equipment until the acceptance of equipment by the Owner.
D. Before installation, store material and equipment indoors in a dry, clean location.
Handle and store to avoid damage. Heat storage areas that contain items subject to
corrosion under damp conditions.
E. Turn off power to panels and equipment and close and cover CPs and equipment
during any dusty construction to prevent degrading the operation or service life.
F. Follow the manufacturer's installation instructions explicitly, unless otherwise
indicated. Wherever any conflict arises between the manufacturer's instructions
and these Contract Documents, follow the Engineer's decision at no additional
cost to the Owner. Keep a copy of the manufacturer's installation instructions on
the job site and available for review at all times.
G. Keep the premises free of waste material or rubbish. Before final inspection and
testing and upon completion of the work, remove materials, scraps, and debris
from the premises and from the interior and exterior of all devices and equipment.
H. Touch up scratches, scrapes, or chips in interior and exterior surfaces of devices
and equipment with finishes matching as nearly as possible the type, color, and
consistency of the original finish.
1.09 RECORD DRAWINGS
A. Record Drawings shall be submitted in accordance with Section 01785, Record
Documents, and this Section.
B. The Contractor shall provide one set of Record Drawings on CD or DVD in
AutoCAD "DWG" or "DXF" format, consisting of the following:
03720-048-01
August 2019
1. Process and instrumentation diagrams.
2. Loop diagrams.
3. Panel elementary diagrams.
4. Interconnecting wiring diagrams.
13401-5
PROCESS INSTRUMENTATION AND CONTROLS (PICS)
EMI
1.10 SYSTEM DESCRIPTION
A. The general arrangement of the instruments, controls, and monitoring systems are
shown on the Drawings and specified in this Section. The location of all
transmitters, controllers, recorders, indicators, etc., shall be as shown on the
Drawings and/or as indicated in this Section. The Contractor shall be responsible
for all detail installation drawings showing wiring and shall be responsible for
furnishing all devices required for a complete and functioning system.
1.11 OPERATION AND MAINTENANCE (O&M) MANUAL
A. O&M Manuals shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01830, Operations and Maintenance Manuals.
B. Before final acceptance of this project, the Contractor shall submit an O&M
Manual to the Engineer for all components provided under this Section. The
manual shall comply with the following:
1. The literature shall have sufficiently detailed descriptions and figures to
facilitate the operation, removal, installation, adjustment, calibration, and
maintenance of each component to the printed circuit board level.
2. The manual shall include internal wiring and piping diagrams.
Termination designations and wire and pipe numbers shall be clearly
shown. Diagrams, device designations, and symbols shall be in accordance
with NEMA ICS 1-101.
3. The manual shall include an updated set of the manufacturer's literature,
data sheets, loop descriptions of operations, drawings corrected in
accordance with shop drawing review comments and Record Drawing
modifications and components parts list.
4. Instructions and parts lists shall have been prepared for the specific
equipment furnished.
5. List of suppliers and/or service shops that can provide parts and
accessories and equipment repair for the components provided under this
Section. The list shall include a contact name, telephone number, and
address.
C. The general arrangement of the instruments, controls, and monitoring systems is
shown on the Drawings and specified in this Section. The location of all
transmitters, controllers, recorders, indicators, totalizers, etc., shall be as shown on
the Drawings and/or as indicated in this Section. The Contractor shall be
responsible for all detail installation drawings showing wiring and shall be
responsible for furnishing all devices required for a complete and functioning
system.
03720-048-01
August 2019
13401-6 PROCESS INSTRUMENTATION AND CONTROLS (PICS)
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1.12 PATENTS AND LICENSES (NOT USED)
1.13 MANUFACTURER'S LITERATURE
A. The Contractor shall provide descriptive literature for all equipment provided
under this Section. The literature shall include major components, electrical
devices, panel materials, panel components, panel paints and colors, mechanical
devices, equipment tags, tubing, valves, fittings, fasteners, and appurtenances.
This descriptive literature shall include catalog information, external wiring
information, dimensional data, and mounting requirements.
B. Provide data (specification) sheets for all equipment and components. Provide a
separate data sheet for each major component. The data sheets shall show the
"component name," tag numbers, quantities, specific catalog/ordering numbers,
specific features, and special options.
C. Provide a components parts list with exact and complete (including options and
accessories) manufacturer's part number. Group the list by the component name
used in these Specifications. Group each component type by tag number used in
these Specifications. Components without tag numbers shall be grouped by the
manufacturer's part number.
D. Provide a list of recommended spares, spare parts, and expendables with tag
number, part number, unit pricing, and total purchase cost.
E. Provide storage requirements for all components provided under this Section.
1.14 CERTIFICATION/DOCUMENTATION
A. The instrument system supplier(s) shall verify the calibration and operation of all
control, instrumentation, and telemetry components and shall present written
certification of the operation.
1.15 PERMITS AND FEES
A. The Contractor shall obtain all necessary permits, licenses, and inspections
required for the work of this Section and pay all charges incidental to these
permits, licenses, and inspections. The Contractor shall deliver to the Engineer all
certificates of inspection and licenses issued by authorities having jurisdiction.
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PROCESS INSTRUMENTATION AND CONTROLS (PICS)
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1.16 ABBREVIATIONS AND ACRONYMS
A. ASD: Adjustable Speed Drive.
B. CA: Calculated Analog.
C. CP: Control Panel.
D. CPU: Central Processing Unit.
E. CS: Computer Subsystem.
F. FDT: Factory Demonstration Test.
G. FP: Field Panel.
H. HMI: Human/Machine Interface.
I. ISA: International Society of Automation.
J. I&C: Instrumentation and Control.
K. IPS: Instrument and Panel Subsystem.
L. I/O: Inputs and Outputs.
M. LAN: Local Area Network.
N. MCC: Motor Control Center.
O. OIU: Operator Interface Unit.
P. OIT: Operator Interface Terminal.
Q. O&M: Operation and Maintenance.
R. ORT: Operational Readiness Test.
S. PAT: Performance Acceptance Test.
T. PC: Personal Computer.
U. PICS: Process I&C System.
V. P&ID: Piping and Instrument Drawing.
W. PLC: Programmable Logic Controller.
X. RIO: Remote Input/Output.
Y. RTU: Remote Terminal Unit.
Z. SCADA: Supervisory Control and Data Acquisition.
AA. TSP: Twisted Shielded Pairs.
BB. UPS: Uninterruptable Power Supply.
CC. VFD: Variable Speed Drive (see ASD).
DD. WAN: Wide Area Network.
EE. WiFi: Wireless.
1.17 DEFINITIONS
A. Enclosure: CP, console, cabinet, or instrument housing.
B. Instructor Day: 8 hours of actual instruction time.
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C. Software: Programs or configuration data for digital devices, stored in read-only
memory, programmable read-only memory, read/write memory, disk, tape, or
other electronic storage device. Types of software are defined as follows:
1. Standard Software: Packages that are independent of the project on which
they are used. Standard software includes Operating Systems, Office
Suites, and the Process Monitoring and Control software.
2. Application Software: Code or configuration of the standard software to
provide functions unique to this project.
D. Rising/Falling: Terms used to define actions of discrete devices about their set
points.
1. Rising: Contacts close when an increasing process variable rises through
set point.
2. Falling: Contacts close when a decreasing process variable falls through
set point.
E. Analog Signals, Current Type:
1. 4 to 20 mA DC signals conforming to ISA S50.1.
2. Unless otherwise indicated for specific PICS Subsystem components, use
the following ISA 50.1 options:
a. Transmitter Type: Number 2, two -wire.
b. Transmitter Load Resistance Capacity: Class L.
c. Fully isolated transmitters and receivers.
F. Analog Signals, Voltage Type: 1 to 5 volts DC within panels where a common
high precision -dropping resistor is used.
G. Discrete Signals: Two -state logic signals using 24 VDC or 120VAC sources as
indicated.
H. Pulse Frequency Signals:
03720-048-01
August 2019
1. Direct current pulses whose repetition rate is linearly proportional to
process variable.
2. Pulses generated by contact closures or solid-state switches as indicated.
3. Power source less than 30 VDC.
13401-9
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I. Special Signals: Other types of signals used to transmit analog and digital
information between field elements, transmitters, receivers, controllers, and digital
devices.
J. Instrument Tag Numbers: A shorthand tag number notation is used in the Loop
Specifications. For example: 10-PI-2(A/B).
Notation
Explanation
10
Unit process/Loop designation.
PI
ISA designator for Pressure Indicator.
(2)
Unit designation; alphanumeric designation of same process
types in a given loop; -1, -2 in this example.
(A/B)
Component designation; Alphanumeric designation of same
component type within a process; -A, -B in this example.
In this example, 10-PI-(2)(A/B) is shorthand for:
10 -PI -1-A, 10 -PI -1-B, 10 -PI -2-A, 10 -PI -2-B.
K. Activity Completion: The following is a list of key activities and their completion
criteria:
1. Administrative Submittals: Reviewed and accepted.
2. Shop Drawings: Reviewed and approved.
3. Quality Control Submittals: Reviewed and accepted.
4. Tests (Except ORT): Tests have been completed and required test
documentation has been accepted.
a. ORT: ORT has been completed and the Engineer has spot-checked
associated test forms and checklists in field.
b. Hardware Delivery: Hardware has been delivered to site and
inventoried by the Owner.
c. Ready for Operation: ORT has been completed.
L. PICS Substantial Completion: Prerequisites for Substantial Completion for each
stage of work include:
03720-048-01
August 2019
1. PICS Submittals have been accepted or approved, as specified.
2. PICS Subcontractor has successfully completed PAT.
3. Owner training plan is on schedule.
4. Spares, expendables, and test equipment have been delivered to the
Owner.
13401-10 PROCESS INSTRUMENTATION AND CONTROLS (PICS)
EMI
M. PICS Acceptance: When the Engineer issues a written notice of acceptance, the
following prerequisites shall have been met:
1. PICS Certificate of Substantial Completion for both stages of work.
2. Punch -list items completed.
3. Final revisions to O&M manuals accepted.
4. Maintenance service agreements for PICS accepted by the Owner.
PART 2 PRODUCTS
2.01 MANUFACTURERS
A. The manufacturer(s) and/or supplier(s) shall have regularly engaged in the
manufacture of major components and/or assembly or I&C systems of the type
and scope required for this project for a minimum of 5 years.
B. It is recognized that one manufacturer may not make all the equipment required
and specified under this Section. The Contractor shall be responsible for ensuring
that the various manufacturers and equipment suppliers' products are coordinated
and are compatible so that the equipment performs the specified functions. The
Contractor shall ensure that they are fully aware and understand the requirements
of the system.
2.02 GENERAL EQUIPMENT REQUIREMENTS
A. All components and items of equipment that are necessary, whether indicated or
not, to affect the required functions and performance shall be provided. In general,
and unless otherwise noted, corrosion -resistant materials such as 316 stainless
steel shall be used. Working pressures, spans, and other ratings shall be selected to
best fit the application. All like equipment shall be by the same manufacturer.
B. Whenever any material or product is indicated by patent or proprietary name, by
name of manufacturer, or by catalog number, such specifications shall be deemed
to be used to establish a standard of quality to expand the description of the
material or product desired. Materials and products equal to the named material or
product may be provided unless specifically noted otherwise.
C. All equipment furnished under this Section shall be new and unused and shall be
the standard product of a manufacturer having a minimum of 5 years successful
experience in the manufacture of the equipment. Wherever possible, equipment
items having the same or similar rated capacity or function shall be identical.
Equipment shall be of the manufacturer's latest proven design.
03720-048-01
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D. The design of the instrumentation and control system is based on the equipment
and components specified in this Section. If more than one manufacturer is noted,
the first named is the basis for design where there are differences. If the
Contractor selects equipment which changes the design basis, the Contractor shall
obtain approval from the Engineer and make all approved changes at no additional
cost to the Owner.
E. Electrical Transient Protection: All I&C equipment shall be equipped with
suitable surge -arresting devices to protect the equipment from damage due to
electrical transients induced in the interconnecting lines by lightning discharges or
by nearby electrical devices.
1. Voltage surge and transient protectors for both power and analog field
circuits shall be provided on the field end and destination end of the
circuits.
a. Analog circuits shall be protected by DEHN or Phoenix
suppressors.
b. All instrument 120 -volt power and signal circuits shall be protected
by DEHN or Phoenix suppressor.
2. The devices shall be connected to the system ground. The total resistance
of the ground circuit from the device to the driven ground rod shall not
exceed 0.1 ohm.
F. Signal Characteristics
1. Analog signals shall be 4-20 mA DC and shall conform to the
compatibility requirements of ISA 50.1. Unless otherwise noted, circuits
shall be Type 2 two -wire. Transmitters shall have a load -resistance
capability conforming to Class L. Transmitters and receivers shall be fully
isolated.
2. Discrete signals are two -state logic signals of two types. Control signals
shall use 120 -VAC sources. Alarm signals that interface directly with an
annunciator shall use less than 30-VDC sources. All alarm signals shall be
"normally open, close to alarm" isolated contacts rated for 5 amperes at
120 VAC and 2 amperes at 30 VDC.
G. Environmental Conditions
03720-048-01
August 2019
1. Unconditioned air: 20 °F to 105 °F, 10% to 100% humidity, subject to
wash down or rain, corrosive (assume marine salts and H2S as a
minimum), and nonhazardous. Enclosures shall be NEMA 4X.
2. Other conditions as noted or approved.
13401-12
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H. Nameplates, Name Tags, and Service Legends: All field- and panel -mounted
components provided under this Section shall be provided with permanently
mounted name tags bearing the entire ISA tag number of the component.
1. Panel -mounted tags shall be engraved plastic. Field -mounted tags shall be
stamped 16 -gauge 316 stainless steel with 3/16 -inch -high characters.
2. Nameplates shall be inscribed to identify the component listed and
mounted near a panel -face -mounted instrument.
3. Service legends shall be integrally mounted on a panel -mounted
instrument. Unless otherwise noted, service legends shall be engraved with
the functional explanation.
4. Nameplates and service legends shall be engraved, rigid, laminated plastic
plates attached to enclosure with stainless steel screws maintaining NEMA
rating of enclosure. Unless otherwise noted, plate color shall be black with
3/16 -inch -high white lettering. Panel nameplates shall have 1/2 -inch -high
lettering.
Colors and Inscriptions: Unless otherwise noted, the following inscription and
color code shall be used for all push buttons and indicating light lenses: ON, red;
OFF, green; OPEN, green; CLOSED, red; AUTO, white; MANUAL, yellow;
START, red; STOP, green; RESET, red; TEST, black; ACKNOWLEDGE, green;
and READY, blue. All unused or non -inscribed buttons shall be black.
1. Lettering shall be black on white, amber, or yellow. Lettering shall be
white on black, red, blue, or green.
J. Relays
03720-048-01
August 2019
1. Analog signal switching relays shall be provided for switching 4-20 mA or
1-5 VDC signals. The relays shall have double -throw dry circuit contacts
in a break -before -make configuration rated for 15 VA minimum. The
relays shall be sealed to prevent dust, dirt, or moisture contamination.
Relays shall be UL recognized and shall be Potter and Brumfield KUP or
KUL Series or Struthers -Dunn Series 219.
2. Control circuit switching relays shall be rated for not less than 2 amperes
at 120 VAC or 28 VDC.
3. All relay connections shall have a screw terminal interface with the wiring.
Terminals shall have a permanent, legible identification and shall be
mounted so that terminal identifications are clearly visible, and the
terminals are readily accessible.
4. Intrinsically save relays shall be UL approved, solid state, dual channel,
din rail mounted, Crouse Hinds Series MTL7700.
13401-13
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K. Power Supplies: Provide DC power supplies as required to power instruments
requiring external DC power.
1. Power supplies shall convert 120 -VAC power to DC power of the
appropriate voltage(s) with sufficient voltage regulation and ripple control
to ensure that the instruments being supplied can operate within their
required tolerances.
2. Output overvoltage and overcurrent protective devices shall be provided
with the power supply to protect the instruments from damage due to
power supply failure and to protect the power supply from damage due to
external failure.
3. Each power supply shall be provided with a NEMA 1 enclosure for
mounting within other enclosures. Power supplies shall be mounted so that
dissipated heat does not adversely affect other components.
L. Wiring: All electrical wiring and wiring identification shall be in accordance with
the applicable requirements of Division 16, Electrical.
03720-048-01
August 2019
1. Wires shall be 600 -volt class, PVC insulated stranded copper.
2. Wiring for 120 -volt circuits and signals shall be sized as required for the
current to be carried, but not smaller than 14 AWG if enclosed in sheet
metal raceway or plastic wiring duct. Wiring for signal circuits shall be
TSP not smaller than 16 AWG. Analog signals shall be separated from any
power wiring by at least 6 inches.
3. All interconnecting wires to other enclosures shall be terminated at
numbered terminal blocks. All external connections shall be to numbered
terminal blocks. All connections for future functions shall be wired to
numbered blocks.
a. Terminal blocks shall be grouped to keep circuits of different
voltages separate. Provide sufficient terminal blocks for all
functions required, all spare annunciator points, and all spare
conductors plus 15% spare.
b. Terminal blocks shall be one-piece molded plastic blocks with
screw-type terminals and barriers rated for 300 volts. Terminals
shall be double sided and supplied with removable covers that
prevent accidental contact with live circuits. Terminals shall have
permanent and legible identification and be clearly visible with
protective cover removed.
c. Wires shall be terminated at the terminal blocks with crimp -type,
pre -insulated, ring -tongue lugs. Lugs shall be the appropriate size
13401-14 PROCESS INSTRUMENTATION AND CONTROLS (PICS)
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for the size of the terminal block screws and the size and number
of wires terminated.
4. All analog signal wiring shall be TSP with tie points at terminal blocks.
Provide external dropping resistors or diodes to allow an instrument to be
removed from the loop without opening the circuit.
5. Shields shall be interconnected within each loop at terminals. Shield wires
shall be dressed with heat -shrink tubing. Ground signal shields at CPs only
(not field devices).
6. Enclosures shall conform to the National Electrical Manufacturer's
Association, NEMA -4X, unless otherwise noted. Construction shall be of
316 stainless steel unless otherwise noted. Aluminum construction shall
use 5052 H-32 aluminum alloy and shall provide for noncontact of
dissimilar metals. Minimum metal thickness shall be 14 gauge. Where
practical, enclosures shall be manufactured by Hoffman or H.F. Cox.
a. Doors shall be rubber gasketed with a continuous hinge.
b. Panels mounted outside or in unheated areas shall be provided with
thermostatically controlled heaters that will maintain the inside
panel temperature above 40° F.
c. Panels shall be sized to adequately dissipate heat generated by
equipment in or on the panel.
d. Provide a breaker -protected 120 -volt, 15 -amp duplex receptacle in
the panel.
M. Operator Interface Terminals
1. Terminals (OIT) shall be microprocessor -based, flat panel, touchscreen
type. The unit shall have data entry capabilities and shall include a
password security function. The unit shall be connected to the plant
network and shall display status, alarm, and diagnostic information. The
OIT shall:
a.
b.
c.
d.
e.
f.
g•
h.
i.
03720-048-01
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Display Size:
Color Scale
Pixels
Brightness
CPU
Dot Pitch
System Memory
Flash Memory
RS232 & RS485 Port
13401-15
9.0 -inch
65,536 colors
800 x 600 (HI -Res TFT)
260 cd/ m^2
500 Hz Fanless
0.267 mm x 0.267 mm
356 MBytes DRAM
256 MBytes
Yes
PROCESS INSTRUMENTATION AND CONTROLS (PICS)
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j. USB Port Types A and B
k. Ethernet Port 10/100 Base -T
1. Power 24 VDC, 20W
m. Temperature 0 to 50 Deg C
n. Enclosure NEMA 4/4X
o. Manufacturer PanelView Plus 7
N. Ethernet Switches
1. Ethernet switch, 6 RJ45 ports, 10/100/1000 Mbps on all RJ45 ports, two
multi -mode SC -D ports, 1 Gbps full duplex, auto negotiation (RJ45),
autocrossing function, with signal contact and QoS, extended temperature
range.
2. Interface 1 Ethernet (RJ45) ports 6 (RJ45 ports). Connection method RJ45
Ethernet in RJ45 twisted pair Transmission speed 10/100/1000 MBit/s.
Interface 2 Fiber optic interface with 2 (SC multi -mode). Connection
method shall be SC Transmission physics multi -mode fiberglass.
Transmission speed shall be 1000 MBit/s (full duplex). Transmission
length shall be 220 m (Fiberglass 62.5/125) 550 m (Fiberglass 50/125).
Wavelength 850 nm Interface 4 Potential -free signaling contact with
connection method as plug-in/screw connection via COMBICON.
3. Phoenix Contact SFN 6GT/2SX.
O. Programmable Logic Controller (PLC)
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1. The PLC CPU shall be as manufactured by Allen-Bradley CompactLogix
with built-in Ethernet network.
2. Each discrete input module shall accept up to sixteen (16) 120Vac input
signals received from devices such as pushbuttons, selector switches,
pressure switches, temperature switches, or limit switches and converts
them into voltage logic levels that can be processed by the controller. Input
signals shall be wired in two groups of eight signals per module. Each
group of eight points shall be protected by a .16 amp external indicating
fuse block. Each input shall be optically isolated and protected with a red
LED to indicate the presence of the 24Vdc power (circuit closed
indication). A green LED shall be provided to indicate the presence of the
I/O module supply voltage of each group. Discrete input modules shall be
as manufactured by Allen-Bradley.
3. Each discrete output module shall provide eight relay switched, 120Vac
output signals that can drive loads up to 1 amp such as relays, starters, and
solenoid valves. The outputs shall be optically isolated from the system.
Output signals shall be field wired in two groups of four outputs per
module. Each group of four points shall be protected by an external .16A
indicating fuse block. Each output shall be isolated and provided with a
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red LED to indicate the output is turned "on". A green LED shall be
provided to indicate the presence of the required 24Vdc supply voltage.
External, panel mounted, 10Amp, interposing relays shall be provided for
interfacing to control devices that are external to the local control panel or
to devices that exceed the rating of the output module. Where LED type
status indicators are used, a loading resister shall be installed to prevent
leakage current from keeping the lamps falsely lit. Discrete input modules
shall be as manufactured by Allen-Bradley.
4. Analog input modules shall be eight channels with opto-isolation. Inputs
shall accept 4-20mA DC signals. Input shall be set for Unipolar with
Offset and Extended Resolution mode to detect loss of signal or low input
indication. Resolution shall be 11 -bit plus sign with a 10 ms conversion
time. The four points shall be protected by an external .16A indicating fuse
block. A green LED shall be provided to indicate the presence of the
required 24Vdc supply voltage. A second green LED shall be provided to
indicate the module is healthy. Removal of any panel -mounted devices
shall not interrupt the input signals to the PLC. Analog values shall
continue to function properly. Inputs shall be provided for Flow and Level.
Analog input modules shall be as manufactured by Allen-Bradley
5. Analog Output Module shall be eight channels with opto-isolation.
Outputs shall drive 4-20mA DC signals. Output shall be set for Unipolar
with Offset and Extended Resolution mode to detect loss of signal or low
input indication. Resolution shall be 11 -bit plus sign with a 10 ms
conversion time. The four points shall be protected by an external .16A
indicating fuse block. A green LED shall be provided to indicate the
presence of the required 24Vdc supply voltage. A second green LED shall
be provided to indicate the module is healthy. Removal of any panel -
mounted devices shall not interrupt the input signals to the PLC. Analog
values shall continue to function properly. Outputs shall be provided for
VFD speed pacing. Analog output modules shall be as manufactured by
Allen-Bradley.
2.03 INSTRUMENTATION
A. Water meter
1. Flow Element -Magnetic Meter
a. Tags:
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ISA Designation
Line Size (Inches)
Service
FE/FIT-100
6
Sludge
FE/FIT-500
6
Sludge
FE/FIT-400
4
Sludge
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03720-048-01
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b. Flow element shall be of the electromagnetic type using the pulsed
DC -type coil excitation principle with high preamp input
impedance. The flow measuring system, consisting of flow
element, transmitter, and appurtenances, shall have an overall
accuracy of 1% of rate with a 10:1 turndown for all flows resulting
from pipe velocities of 1 to 33 feet per second. The system shall
operate on 120 -volt (10%), 60 -Hz power. The unit shall have a
zero -stability feature, thereby eliminating the need to stop flow to
check zero alignment.
c. The flow element shall be of watertight, NEMA 4 construction,
unless otherwise noted. The meter shall consist of a 316 stainless-
steel meter tube, 150 -pound ANSI carbon steel raised face flanges,
Teflon liner, and 316 stainless-steel electrodes, unless otherwise
noted. Electrodes shall be either flush or bullet -nose type. Meters
4 inches and smaller with Teflon liners shall be wafer -style design.
Suitable covers shall be provided for flow element ends to protect
the tube liner during shipment. The unit shall be furnished with
grounding rings or shall be provided with built-in grounding
electrodes.
d. The remote flow transmitter shall be indicating, both flow rate and
totalized flow, and suitable for pipe stand mounting, with integral
indicators and totalizers furnished. The transmitter output shall be
a 4 to 20mA DC signal in linear proportion to flow and shall drive
loads with impedances in the range of 0 to 800 ohms without load
adjustments for a 24VDC supply. Output span and zero shall be
manually adjustable. Both transmitter and primary element shall be
powered from the same 120 -volt, 60 -Hz source.
e. Sufficient special cable(s) shall be provided for interconnection
between the flow element and the transmitter. Cable(s) shall
facilitate both signal and power for the flow element (120 -volt,
60 -Hz power will be made available at the transmitter).
f. For each size of flow tube, provide one spool piece with identical
laying length and flanges. Provide lifting rings on each spool piece
to facilitate the replacement of a flow tube by the spool piece.
13401-18 PROCESS INSTRUMENTATION AND CONTROLS (PICS)
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g.
Provide stainless steel sunshield and transient surge protection for
the incoming 120VAC and DC signals as manufactured by DEHN
or Phoenix series. Transient surge protection shall be mounted in a
stainless steel box.
h. The manufacturer of the flow meter shall be Rosemount, ABB or
Sparling.
B. Level Meter
1. Flow Element -Floats
a. Tags:
03720-048-01
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ISA Designation
Service
LE/LSH-201
Sludge
LE/LSL-201
Sludge
LE/LSH-202
Sludge
LE/LSL-202
Sludge
2. Type:
a. Tilting float actuation.
b. SPDT non -mercury switch.
c. Polypropylene casing.
3. Operation:
a. Function: To produce a contact output at a predetermined liquid
level.
b. Operating Principle: A sealed switch encased in a weighted float
freely suspended from a cable is actuated by the tilting motion of
the float when it is displaced by the liquid level.
Functional:
a. Output: Form C (SPDT) hermetically sealed non -mercury switch,
rated 6 amps at 250 volts ac.
5. Physical:
a. Float: Hermetically sealed, molded polypropylene casing.
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b. Cable: Three -conductor No. 19 AWG PVC jacketed.
c. Mounting: Cable suspended by waterproof compression connector.
6. Performance:
a. Angular operating Differential 20 degrees.
b. Vertical operating Differential 1/2 -inch.
7. Manufacturer:
a. Float switch shall be Roto -Float, 3- or 4 -wire, or equal.
8. Accessories:
a. Support bracket with adjustable clamp for setting switch height.
b. NEMA 4X junction box.
C. Level Meter
03720-048-01
August 2019
ISA Designation
Service
LE/LIT-201
Sludge
LE/LIT-202
Sludge
Unit shall be ultrasonic type, continuous level measuring system
consisting of level element, transmitter, and cable for connection from
level element to transmitter.
2. Level element shall be ultrasonic type transducer. Transducer shall be of
waterproof construction with operating range of -20 to +50 degrees C at
1 atmosphere, unless otherwise noted. Transducer shall be furnished with
4 -inch PVC blind flange for mounting where shown or noted.
3. Transmitter shall contain solid state programmable controls to operate
transducer provide pump controls, totalizer and to provide a 4 to 20 mA dc
output signal in linear proportion to the level being sensed. Transmitter
shall be provided with high contrast 4 -digit 18mm LCDs display and five
LEDs to indicate alarm conditions. Transmitter scale range shall be as
noted. Transmitters for storage tank shall be characterized for the storage
tank shape. Transmitter shall be mounted in a NEMA 4X enclosure, unless
otherwise noted, suitable for mounting as noted or shown.
4. Level system shall have an overall accuracy of plus or minus 0.25% of full
scale and shall operate on 120 -volt, 50/60 -Hz power.
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5. Transmitter shall provide five discrete outputs, adjustable over the entire
scale range. At the noted set point, unit shall transfer SPDT contacts which
shall be rated for 5 amperes, continuous, at 120V ac. Set points shall be
screwdriver adjustable from inside the enclosure and shall be repeatable
within plus or minus 1/4 percent of full scale.
6. Interconnecting cable between transducer and transmitter shall be
furnished with the unit with length as shown.
7. Provide transient surge protection for the incoming 120VAC and DC
signals
8. Unit shall be Milltronics "HydroRanger".
PART 3 EXECUTION
3.01 GENERAL
A. The Contractor shall lay out the work and be responsible for necessary lines,
levels, elevations, and measurements. Installations shall comply with the
applicable requirements of Division 16, Electrical. The Drawings indicate the
extent and general arrangement of the components. The Contractor shall
familiarize himself with work of other trades engaged in the construction. Exact
routing of raceways, piping, and locations of equipment may be governed by
structural conditions and obstructions. The Contractor shall coordinate the details
of equipment shop drawings for connections to equipment furnished by others.
This is not to be construed to permit redesigning systems.
3.02 INSTALLATION
A. The Contractor shall comply with referenced standards, National Electrical Code
(NEC), National Electrical Safety Code, local codes, and rules and regulations of
local agencies having jurisdiction. The size of conductors, circuit breakers, motor
controllers, and protective devices indicated or specified shall meet all
requirements of the NEC.
3.03 INSTALLER QUALIFICATIONS
A. The installer shall be acceptable to the manufacturer and/or supplier of the I&C
systems. The installer shall have a minimum of 5 years of experience installing
I&C systems of a similar type and scope.
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3.04 WORKMANSHIP
A. General
1. Install materials and equipment in a workmanlike manner using craftsmen
skilled in the particular trade. Provide work which has a neat and finished
appearance.
2. Coordinate the work with the Owner, the Engineer, and the work of other
trades to avoid conflicts, errors, delays, and unnecessary interference.
B. Electrical Power and Signal Wiring
1. Control and signal wiring in enclosures and racks shall be restrained by
plastic ties or ducts. Hinge wiring shall be secured at each end so that any
bending or twisting will be around the longitudinal axis of the wire and the
bend area shall be protected with a sleeve.
2. Arrange wiring neatly, cut to proper length, and remove surplus wire.
Provide abrasion protection for any wire bundles which pass through holes
or across edges of sheet metal.
3. Use the manufacturer's recommended tool with the proper sized anvil for
all crimp terminations. No more than one wire shall be terminated in a
single crimp lug and no more than two lugs shall be installed on a single -
screw terminal.
4. Wiring shall not be spliced or tapped except at device terminals or
terminal blocks. All devices with pig -tail wiring shall terminate on
terminal blocks within or near the device.
5. All materials, equipment, and workmanship shall be subject to inspection
at any time by the Engineer. The Contractor shall correct any work,
materials, or equipment not in accordance with these Contract Documents
or found to be deficient or defective. Corrections shall be made in a
manner satisfactory to the Engineer at no additional cost to the Owner.
3.05 TESTING
A. General: All elements of the I&C system shall be tested to demonstrate that the
total system satisfies all of the requirements of this Specification.
03720-048-01
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1. All testing materials and equipment shall be provided by the Contractor.
Where it is not practical to test with real process variables, the Contractor
shall provide a suitable means of simulation. These simulation techniques
shall be acceptable to the Engineer.
2. The Contractor shall have an updated set of Drawings and Specifications,
a master copy of approved test procedures, and the master copy of current
test failures and solutions to test failures.
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3. Testing will not to be considered complete until all portions of the test
have been approved by the Engineer. If a test or a portion of a test fails to
the point where it needs to be rescheduled, the additional testing cost shall
be borne by the Contractor.
B. Factory Testing: The components shall be tested with simulated I/O at the factory.
Factory tests shall generally conform to the applicable sections of ISA RP55.1.
The Engineer and/or Owner shall be notified of when and where the testing is to
take place and given the option to attend and observe the testing.
C. Operational Acceptance Testing: The objective of these tests is to demonstrate
that each portion of the I&C system is ready for operation.
1. All components of the system shall be checked for proper installation,
adjusted, and calibrated on a loop -by -loop basis.
2. All elements shall be checked to verify that they have been properly
installed and that all terminations have been made correctly. All pneumatic
tubing shall be tested in accordance with ISA procedure RP7.1.
3. All discrete elements and systems shall have their set points adjusted and
shall be checked for proper operation.
4. All continuous elements and systems shall have three-point calibrations
performed. All controller tuning constants shall be adjusted to preliminary
settings.
5. The Contractor shall prepare operational acceptance test status report
sheets for each loop listing the checks and adjustments performed and the
calibration points actually set. Copies of completed status report sheets
shall be submitted before final acceptance.
D. Functional Acceptance Testing: The objective of these tests is to demonstrate that
the I&C system is operating and complying with the specified performance
requirements.
03720-048-01
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1. Each loop function shall be demonstrated to the Engineer in accordance
with approved test procedures. Each loop shall be signed off by the
Contractor and the Engineer upon satisfactory completion.
2. A test date may be set after the testing submittal has been approved and
pre-test training has been completed.
3. No modifications shall be made to the system during the functional
acceptance test period except as required to maintain Owner operations.
The test shall not interrupt normal operations unless approved by the
Owner.
4. If a test fails to produce the expected results, the Contractor will need to
respond quickly to determine the cause and take corrective action.
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Construction shall not interfere with the tests unless approved by the
Engineer.
5. All failed tests shall be retested until the result complies with the
Specifications and/or is acceptable to the Engineer and Owner.
6. At the end of the test, a punch list will be provided to the Contractor. The
Contractor shall then determine the cause of the failure, correct the
deficiency, and report to the Engineer why the test failed and the corrective
action taken. The Engineer will then determine if the function needs to be
retested and determine any other tests which may be required.
7. Within 10 working days from the end of a test period or retest period, a
formal punch list will be transmitted to the Contractor. The Contractor
shall submit a single test report for the test period and reschedule retesting
if needed. Retesting shall be scheduled for not less than 1 week after the
Engineer receives the test report and the retest dates shall be acceptable to
all.
3.06 ON-SITE SUPERVISION
A. The Contractor shall provide factory -trained, onsite service engineers to supervise
and coordinate installation, adjustment, testing, training, and startup of the I&C
system.
B. The Contractor shall provide startup and testing assistance by engineers and
programmers as required to thoroughly check all of the equipment and perform all
operational and functional tests required.
C. The service engineer shall be specifically trained on the type of equipment
specified and shall advise the Contractor in the location and method of installing
special cable, mounting, pipe, and wiring of one of each type of device. The
service engineer shall supervise the calibration, commissioning, and initial start-
up of the I&C system. A signed and dated calibration sticker shall be affixed to
each device.
3.07 TRAINING
A. The Contractor shall provide a minimum of two8-hour days on-site training for
the Owner's O&M personnel at the job site before functional acceptance testing.
B. The training program shall include classroom and field instruction by experienced
and knowledgeable technicians and engineers on the O&M of the I&C elements,
components, and systems provided.
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3.08 FUNCTIONAL DESCRIPTIONS
A. Functional Descriptions shall be in accordance with Section 13316, Software
Control Block Descriptions.
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END OF SECTION
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DIVISION 15
MECHANICAL
SECTION 15055
PIPING SYSTEMS—GENERAL
PART 1 GENERAL
1.01 SCOPE OF WORK
A. This Specification describes responsibilities and requirements for Piping Systems
including the following:
1. Labor, materials, tools, equipment, and services to be furnished in
accordance with the provisions of the Contract Documents. The materials
to be used for the piping systems shown in the Drawings are listed by
service in the Piping Schedule, included in the Contract Drawings.
2. Coordination of work with other trades.
3. Furnishing and installing all supplementary or miscellaneous items,
appurtenances, and devices incidental to or necessary for a sound, secure,
and complete installation, although such work is not specifically indicated.
4. Furnishing Record Drawings and documents for piping systems.
1.02 RELATED WORK
A. Section 01300, Contract Administration.
B. Section 01330, Submittals and Acceptance.
C. Section 01650, Delivery, Storage, and Handling.
D. Section 01780, Warranties and Bonds.
E. Section 01785, Record Documents.
F. Section 01830, Operations and Maintenance Manuals.
G. Section 02305, Earthwork for Utilities.
H. Section 09900, Painting and Coating.
I. Section 15075, Process Equipment, Piping, and Valve Identification.
J. Section 15144, Pressure Testing of Piping.
K. Section 15155, Ductile Iron Pipe and Fittings.
L. Section 15290, PVC Pipe, 3 Inches and Smaller.
1.03 SUBMITTALS
The Contractor shall submit the following in accordance with Section 01330, Submittals and
Acceptance:
A. If the Contractor deviates from the piping layout as shown on the Contract
Drawings, the Contractor shall submit scaled piping drawings showing locations
and dimensions to and from fittings, valves, tanks, equipment, structures, and
related appurtenances. Provide scaled drawings to a minimum scale of 1 inch
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15055-1 PIPING SYSTEMS—GENERAL
equals 10 feet. Provide details to minimum scale of 1/8 inch equals 1 foot.
Elevations shall correspond to reference vertical elevation datum shown or
provided for this project.
B. Copies of any manufacturer's written directions regarding material handling,
delivery, storage, and installation.
C. Record piping drawings shall meet the requirements of Section 01300, Contract
Administration, and Section 01785, Record Documents. During the work, the
Contractor shall maintain accurate, up-to-date Record Drawings of piping systems
installed in the project, including pre-existing piping discovered, relocated, or at
locations other than as originally shown on the Drawings. When the work is
completed and accepted by the Owner and the Engineer, the Contractor shall
submit Record Drawings in accordance with Section 01785, Record Documents.
The Contractor shall identify complete location, elevations, and description of
piping systems. Piping systems and fittings are to be identified from three points
on structures and/or stationary appurtenances.
D. Submit copies of forms documenting required field pressure testing work and
results.
E. Submit welding certificate copies.
F. Submit certified copies of mill test reports for bolts and nuts, including coatings if
specified. Provide recertification by an independent domestic testing laboratory
for materials originating outside of the United States.
G. Submit manufacturer's data sheet for gaskets supplied showing dimensions and
bolting recommendations.
H. Support Systems:
1. Drawings of each piping system locating each support, guide, and anchor.
2. Identify support, guide, and anchor type by catalog number and shop/
Contract Drawing detail number
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be the latest
revision of any such document in effect at the bid time. The following documents are a part of
this Section. Where this Section differs from these documents, the requirements of this Section
shall apply.
03720-048-01 15055-2 PIPING SYSTEMS—GENERAL
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A. American Society for Testing and Materials (ASTM)
1. ASTM A183—Specification for Carbon Steel Track Bolts and Nuts.
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—Specification for Carbon and Alloy Steel Nuts for
Bolts for High -Pressure and High -Temperature Service.
4. ASTM A307 Specification for Carbon Steel Bolts, Studs, and Threaded
Rod 60,000 psi Tensile Strength.
5. ASTM D1330—Standard Specification for Rubber Sheet Gaskets.
6. ASTM F467—Standard Specification for Nonferrous Nuts for General
Use.
B. American Society of Mechanical Engineers (ASME)
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 B16.21—Nonmetallic Flat Gaskets for Pipe Flanges.
4. ASME B18.2.1—Square, Hex, Heavy Hex, and Askew Head Bolts and
Hex, Heavy Hex, Hex Flange, Lobed Head, and Lag Screws (Inch Series).
5. ASME B18.2.2—Nuts for General Applications: Machine Screw Huts,
Hex, Square, Hex Flange, and Coupling Nuts (Inch Series).
6. ASME B31.1—Power Piping.
7. ASME B31.3—Process Piping.
8. ASME BPVC—Boiler and Pressure Vessel Code.
C. American Water Works Association (AWWA)
1. AWWA C111/A21.11—Rubber-Gasket Joints for Ductile -Iron Pressure
Pipe and Fittings.
2. AWWA C207—Steel Pipe Flanges for Waterworks Service, Sizes
4 Inches Through 144 Inches (100 mm Through 3,600 mm).
D. Manufacturers Standardization Society of the Valve and Fittings Industry (MSS)
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1. MSS SP 58—Pipe Hangars and Supports – Material, Design,
Manufacture, Selection, Application, and Installation.
E. NSF International (NSF)
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1. NSF 61—Drinking Water System Components – Health Effects.
15055-3 PIPING SYSTEMS—GENERAL
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1.06 QUALITY ASSURANCE (NOT USED)
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
B. The Contractor shall protect the pipe from kinks, cuts, end damage, and other
defects when transporting all piping. Binding and tie -down methods shall not
damage or deflect the pipes in any way. Pipe damaged during shipment shall be
rejected.
C. Pipe shall be stored on level ground, preferably turf or sand, free of sharp objects
that could damage the pipe. Stacking of any pipe shall be limited to a height that
will not cause excessive deformation of the lower layers of pipe under anticipated
temperature conditions. When necessary due to ground conditions, the pipe shall
be stored on wooden sleepers, spaced suitably and of such widths to not allow
deformation of the pipe at the point of contact with the sleeper or between
supports. Pipe shall not be removed from storage until bedding or sub -grade work
is complete and ready to receive the pipe.
D. The joined pipe shall be handled in such a manner that the pipe is not damaged by
dragging it over sharp and cutting objects. Ropes, fabric, or rubber -protected
slings and straps shall be used when handling pipe. Chains, cables, or hooks
inserted into the pipe ends shall not be used. Two slings spread apart shall be used
for lifting each length of pipe. Pipe or fittings shall not be dropped. Slings for
handling joined pipe shall not be positioned at socket -welded joints. Sections of
the pipes with cuts and gouges shall be removed and the ends of the pipe rejoined.
In accordance with the pipe manufacturer's written instructions, the Contractor
shall repair all pipe with damaged linings and pipe exterior coatings that have
been damaged before the pipe is installed.
E. The Contractor shall cover all pipe stored on the site with canvas or other opaque
material to protect it from sunlight. Provide air circulation under the covering.
F. The Contractor shall inspect all pipe, fittings, and other accessories upon delivery
and during the work. Any defective or damaged materials found during field
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15055-4 PIPING SYSTEMS—GENERAL
inspection or during tests shall be removed from the site and replaced by, and at
the expense of, the Contractor.
G. The interior of all pipe, fittings, and other accessories shall be kept free from dirt
and foreign matter at all times. Fittings shall be drained and stored in a manner
that will protect them from damage by freezing.
H. Gaskets shall be placed in a cool location out of direct sunlight. Gaskets shall not
come in contact with petroleum products. Gaskets shall be used on a first -
delivered -to -site and first -to -be -installed rotation basis. Mechanical joint glands,
bolts, and washers shall be handled and stored in a manner that will ensure proper
use with respect to types and sizes.
1.09 QUALIFICATIONS (NOT USED)
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 MAINTENANCE (NOT USED)
1.12 OPERATIONS AND MAINTENANCE (O&M) MANUALS
A. O&M Manuals shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01830, Operations and Maintenance Manuals.
1.13 DEFINITIONS OF BURIED, EXPOSED, AND SUBMERGED PIPING
A. Buried piping is piping buried in soil, beneath a structure and/or encased in
concrete. Where an exterior pipe coating is specified to be factory- or field -
applied, the Contractor shall provide the coating up to the penetration of a
structure. Piping encased in concrete does not require an exterior coating other
than what is factory furnished.
B. Exposed piping is piping in any of the following conditions or locations:
1. Visible piping above ground.
2. Visible piping inside buildings, vaults, or other structures.
3. Visible piping in underground concrete trenches or galleries that are
accessible.
C. Submerged piping is considered to be all piping within a liquid holding tank.
D. Concealed piping is piping above grade that is not visible or accessible and is
contained within building walls, attics, floor spaces, pipe chases, pipe galleries, or
structures.
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1.14 SYSTEM DESIGN REQUIREMENTS
A. General
1. The Project Specifications and Contract Drawings are not all inclusive of
explicit piping details; provide piping for intended use in compliance with
laws and regulations, including ASME B31.1 Code (Power Piping).
2. Pressure ratings and materials specified represent minimum acceptable
standards for piping systems.
3. Piping Systems: Suitable for the services specified and intended.
4. Piping shall be color coded in accordance with the Florida Department of
Environmental Protection requirements.
B. Support Systems
1. The absence of pipe supports and details on the Contract Drawings shall
not relieve the Contractor of responsibility for sizing and providing
supports for this project.
2. Select and design within the specified spans and component requirements.
3. Comply with requirements of MSS SP 58, Pipe Hangers and Supports —
Materials, Design, and Manufacture.
4. Criteria for structural design and selection of pipe support system
components:
a. Dead loads imposed by the weight of the pipes filled with water,
within specified spans and component requirements, plus any
insulation.
b. Safety factor: Minimum of 5.
5. Design, size, and space support anchoring devices, including anchor bolts,
inserts, and other devices used to anchor the support, to withstand the
shear and pullout loads imposed by loading and spacing on each particular
support.
a. Piping smaller than 30 inches: Supports are shown only where
specific types and locations are required; additional pipe supports
may be required and are to be provided and installed by the
Contractor at no additional cost to the Owner.
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C. Adapters
1. No attempt has been made to show all adapters, spool pieces, reducers,
bushings, or other fittings required to accommodate the connection of
pipes, fittings, and valves of various joint design and sizes throughout the
project. The Contractor is completely responsible for providing, at his
expense, all adapters, reducers, sleeves, spool pieces, restraints, and other
fittings and appurtenances necessary for connection and restraint of pipe
(for the same pipe material of or a transition of pipe materials), valves,
fittings, and appurtenances throughout the project, which shall be
constructed of appropriate materials, coated and lined to match the
materials, coatings, and linings specified for the connected components.
All adapters, reducers, sleeves, spool pieces, and other fittings shall be
coated and lined in accordance with the specifications for each individual
pipe system.
D. Unions
1. No attempt has been made to show all unions required for the project. The
Contractor shall provide unions at all connections of threaded pipe to
installed equipment unless deleted by the Engineer, in writing, at certain
locations. The unions shall meet or exceed the quality of materials,
pressure rating, service, and painting requirements of connected piping.
PART 2 PRODUCTS
2.01 PIPING SYSTEM GENERAL REQUIREMENTS SCHEDULE
A. Unless noted otherwise in the Contract Drawings, piping system materials,
fittings, and appurtenances are subject to requirements of the individual
Specifications for the piping systems.
2.02 PIPING SCHEDULE
A. A piping schedule (flow stream identification) listing the piping identification
abbreviations, piping materials, operating pressures, field test pressures, lining
systems, and color coding as identified and provided on the Contract Drawings.
In project locations where the piping system material referenced on the piping
schedule is not appropriate, the required piping material is indicated on the
Contract Drawings. Materials called out in the Contract Drawings shall govern
over materials stated in the piping schedule.
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2.03 THREAD FORMING FOR STAINLESS STEEL BOLTS
A. Form threads for stainless steel bolts by rolling, not by cutting or grinding.
2.04 BOLTS AND NUTS FOR FLANGES FOR DUCTILE IRON PIPE FLANGES
A. Bolts, washers, and nuts for pipe installed indoors, outdoors above and below
ground, and in vaults and structures shall be as specified in Section 15155, Ductile
Iron Pipe and Fittings.
B. Unless specified elsewhere, bolts, washers, and nuts for submerged Class 150
flanges shall be Type 304 stainless steel conforming to ASTM A193/A193M
(Grade B8) for bolts and ASTM A194/A194M (Grade 8) for nuts. Fit shall be
Class 2A conforming to ASME B1.1 when connecting to cast-iron valves having
body bolt holes.
2.05 BOLTS AND NUTS FOR TYPE 304 STAINLESS STEEL PIPE FLANGES
A. Bolts, washers, and nuts for flanges shall be Type 304 stainless steel conforming
to ASTM A193/A193M, Grade B8, for bolts and ASTM A194/A194M, Grade 8,
for nuts.
2.06 BOLTS AND NUTS FOR TYPE 316 STAINLESS-STEEL PIPE FLANGES
A. Bolts, washers, and nuts for flanges shall be Type 316 stainless steel conforming
to ASTM A193/A193M, Grade B8, for bolts and ASTM A194/A194M, Grade 8,
for nuts.
2.07 BOLTS AND NUTS FOR PVC, CPVC, AND PVDF PIPE FLANGES
A. Bolts for piping in sodium hypochlorite service shall be made of titanium, in
accordance with ASTM F467, Grade Til, Ti2, or Ti7. Nuts and washers shall
conform to ASTM F467 and shall be made of titanium.
B. Bolts, washers, and nuts in chemical service other than sodium hypochlorite shall
be Type 304 stainless steel conforming to ASTM A193/A193M, Grade B8, for
bolts and ASTM A194/A194M, Grade 8, for nuts, unless specified elsewhere.
C. Unless specified elsewhere, bolts, washers, and nuts for buried and submerged
flanges and flanges located outdoors above ground or in vaults and structures shall
be Type 304 stainless steel conforming to ASTM A193/A193M, Grade B8, for
bolts and ASTM A194/A194M, Grade 8, for nuts.
03720-048-01 15055-8 PIPING SYSTEMS—GENERAL
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D. The Contractor shall provide a washer under each nut and under each bolthead.
Washers shall be of the same material as the nuts.
2.08 BOLTS AND NUTS FOR STEEL PIPE FLANGES
A. Unless specified elsewhere, bolts, washers, and nuts for Class 150 flanges
(including AWWA C207, Class D) located indoors, outdoors above ground, in
vaults, and in structures shall be carbon steel, ASTM A307, Grade B. Bolts,
washers, and nuts for buried service shall also be hot -dipped galvanized.
B. Unless specified elsewhere, bolts, washers, and nuts for submerged Class 150
flanges shall be Type 304 stainless steel conforming to ASTM A193/A193M
(Grade B8) for bolts and ASTM A194/A194M (Grade 8) for nuts. Fit shall be
Class 2A in accordance with ASME B1.1 when connecting to cast-iron valves
having body bolt holes.
2.09 LUBRICANT FOR STAINLESS STEEL BOLTS AND NUTS
A. Anti -seize thread lubricant shall be applied to the thread portion of all (above
grade and below grade) stainless steel bolts (stainless steel tie rods, etc.) during
assembly. Anti -seize lubricant shall be chloride free and shall be nongalling NSF
approved. Anti -seize thread lubricant shall be Jet -Lube "Nikal," John Crane
"Thred Gard Nickel," Never-Seez "Pure Nickel Special," or Permatex "Nickel
Anti -Seize."
2.10 FLANGE GASKETS FOR STEEL, DUCTILE IRON, AND STAINLESS STEEL PIPE
A. Flange gaskets shall be in accordance with AWWA C207, except as modified in
this Section. Gaskets shall be ring type. All gasket material shall be suitable for
the fluid being conveyed and shall be resistant to free chlorine concentrations up
to 10 mg/L. All gasket material shall be rated to the surge pressures listed in the
pipe schedule. Gaskets shall be EPDM or an approved equal.
2.11 FLANGE GASKETS FOR DUCTILE -IRON PIPE AND FITTINGS IN RAW SEWAGE
A. Gaskets shall be full face, 1/8 inch thick, Buna-N having a Brinell Hardness of
55 to 65 durometer. Gaskets shall be suitable for a water pressure of 200 psi at a
temperature of 250°F. Gaskets shall have "nominal" pipe size inside diameters,
not the inside diameters indicated in ASME B16.21. Provide Garlock Style 9122
or equal. The Contractor shall verify that the gaskets are compatible with all
chemicals being used.
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2.12 FLANGE GASKETS FOR PVC AND CPVC PIPE
A. Gaskets for flanged joints shall be full faced, 1/8 inch thick, having a Brinell
Hardness of 50 to 70 durometer A. Gasket material shall be EPR unless noted or
specified otherwise. Gasket material for sodium hypochlorite service shall be
Viton ETP unless noted or specified otherwise. Gaskets shall be compatible with
the fluids conveyed.
2.13 FLANGE GASKETS FOR PVDF PIPE
A. Gaskets for flanged joints shall be full faced, 5/64 inch thick (minimum), made of
Teflon -bonded EPDM or PVDF-bonded EPDM. The EPDM shall have a Brinell
Hardness of 65 to 70 Durometer "A." Gaskets shall be suitable for a fluid
temperature range of -40°F to +210°F and compatible with the fluids conveyed.
2.14 FLANGE GASKETS FOR STAINLESS-STEEL PIPE IN CHEMICAL SERVICE (NOT
USED)
2.15 LOCATOR WIRE AND DETECTABLE MARKING TAPE
A. All 2 -inch and larger buried piping shall be laid with two insulated, 12 -gauge
minimum AWG, THWN strand copper wires tied to the nonmetallic pipe at 18
inches on center for location purposes.
B. All 2 -inch and larger buried piping shall be laid with underground detectable
caution tape, 2 -inch tape for a maximum of 12 -inch depth and 6 -inch tape for a
maximum of 24 -inch depth. Tape shall be placed a minimum of 1 foot above the
top of pipe.
C. Marking tape shall be as detailed herein and also in accordance with
Section 15075, Process Equipment, Piping, and Valve Identification.
PART 3 EXECUTION
3.01 PREPARATION
A. Field Alignment:
03720-048-01
August 2019
1. The piping shown on the Contract Drawings is generally indicative of the
work, with symbols and notations provided for clarity. However, the
Contract Drawings are not an exact representation of all conditions
involved; therefore, install piping to suit actual field conditions and
measurements as approved by the Engineer. No extra compensation will
15055-10 PIPING SYSTEMS—GENERAL
be made for work due to differences between indicated and actual
dimensions.
2. The Contractor shall install all adapters, fittings, flanged connections,
closures, restrained joints, etc. not specified but necessary for a complete
installation acceptable to the Engineer.
3. The Contract Drawings do not indicate all adapters, fittings, spool pieces,
bushings, unions, supports, hangers, and other items required to
accommodate the installing and connecting of pipe, fittings, valves, and
equipment of various joint designs and sizes. Provide such required items
of appropriate designs, materials, coatings, and linings acceptable to the
Engineer.
4. An extensive network of underground piping, duct, conduit, direct -buried
conductors, and related structures of various sizes, materials, alignments,
age, and function exist within the project site. Conclusive information
concerning these facilities is not available. Consequently, the design of
new piping indicated on the Contract Drawings is approximate. Adjust
alignment, fitting, valve, and joint locations as required and as approved
by the Engineer to accommodate and protect existing facilities and provide
the intended functionality of new piping.
3.02 FIELD LAYOUT AND MODIFICATIONS
A. Unless directed otherwise, the Contractor shall be responsible for setting
construction layout stakes and/or offsets required to complete the designated
work. The Contractor shall ensure that those stakes and/or offsets are protected
and any re -staking required for any reason including work stoppage shall be
included in the bid price and no additional compensation to the Contractor will be
made.
B. The Engineer has the right to make any modifications the Engineer deems
necessary due to field conditions, conflicts with other utilities, or to protect other
properties.
3.03 PIPE PRODUCTS INSPECTION
A. The Contractor shall obtain from the pipe manufacturer a certificate of inspection
to the effect that the pipe, fittings, gaskets, glands, bolts, and nuts supplied for this
Contract have been inspected at the plant and that they meet the requirements of
these specifications. The Contractor shall submit these certificates to the Engineer
before installing the pipe materials. The Contractor shall visually inspect all pipe
and fittings at delivery and before they are lowered into the trench to be installed.
Pipe or fittings that do not conform to these Specifications or have been damaged
in any manner will be rejected and the Contractor must remove them immediately.
The entire product of any plant may be rejected when, in the opinion of the
03720-048-01
August 2019
15055-11 PIPING SYSTEMS—GENERAL
1
Engineer, the methods or quality assurance and uniformity of manufacturer fail to
secure acceptable and uniform pipe products or where the materials used produce
inferior pipe products.
3.04 REMOVAL OF EXISTING PIPE AND FITTINGS
A. Pipe, fittings, and valves specifically identified on the Contract Drawings to be
removed or replaced from service shall be physically taken out of the ground. The
limits of pipe to be removed shall be specifically called for in the plans or shall be
approved in writing by the Engineer. Any other removal not specifically called for
shall be approved in writing and shall be considered incidental to construction of
other items in the contract and the Contractor will not receive compensation for
such work.
13. When removing pipe and fittings, the Contractor shall excavate a trench wide
enough to dislodge the pipe from the surrounding soil and long enough to be able
to handle the pipe and fittings without causing any damage to nearby utilities,
structures, or adjacent property.
C. The removed pipe, fitting, and appurtenances will become the Contractor's
property unless noted otherwise in the Contract Drawings or specified elsewhere
to become the property of the Owner, and the Contractor shall be responsible for
proper disposal and any required permits for disposal.
D. Regarding pipe remaining in the ground subsequent to removal of connected pipe
or pipe fittings, the remaining buried pipes, openings, and fittings shall be plugged
or capped as approved by the Engineer.
E. Pipe that will be abandoned in place shall be plugged or capped as approved by
the Engineer.
3.05 BURIED PIPING AND PIPE FITTINGS
A. Trenching and backfilling for all pipe and fittings shall also be in accordance with
Section 02305, Earthwork for Utilities.
B. Installation:
03720-048-01
August 2019
1. Inspect all piping for defects and remove all lumps or excess coatings
before installation. The inside of the mechanical joint and outside of plain -
end pipe shall be cleaned before joining pipe. Caution shall be taken to
prevent damage to the pipe during lowering into the trench. Remove all
foreign matter that has entered the pipe during storage and installation.
The Contractor shall cover the pipe ends during installation to prevent
15055-12 PIPING SYSTEMS GENERAL
debris from entering the pipe. No debris, tools, clothing, or other material
shall be placed in the pipe.
2. After being placed in the trench, the pipe shall be brought to the proper
line and grade by compacting the approved backfill material under it,
except at the bell end. Joint deflection shall not exceed 75% of the
manufacturer's limit.
3. The Contractor shall install temporary water -tight plugs on the pipe ends
during the time that the pipe is in the trench but no work is in progress. If
there is water in the trench upon beginning work, this plug shall remain in
place until the trench has been pumped dry, unless otherwise approved by
the Engineer, the Engineer's Representative, or the Owner's
Representative.
4. Buried carbon steel bolts and nuts shall be coated in accordance with
Section 09900, Painting and Coating, System No. 21.
5. Coat threaded portions of stainless steel bolts and nuts with lubricant
before assembly.
6. Restrained plugs or caps shall be inserted into all buried dead-end pipes,
tees, or crosses. Provide blind flanges for all flanged exposed piping.
Restrained plugs and caps installed for pressure testing shall be fully
secured and blocked to withstand the test pressure.
7. Where plugging is required because of contract division or phasing for
later connection, the ends of such lines shall be equipped with a suitable
cast-iron or ductile -iron plug/cap or blind flange with or without a blowoff
cock, as shown on the Drawings. Installation or removal of such plugging
shall be considered incidental to the work and the Contractor shall not be
compensated by the Owner for performing this work.
3.06 FLANGED JOINTS FOR EXPOSED PIPE AND FITTINGS
A. When bolting flanged joints, the Contractor shall avoid restraint on the opposite
end of the pipe or fitting, which would prevent uniform gasket compression or
which would cause unnecessary stress in the flanges. One flange shall be free to
move in any direction while the flange bolts are being tightened. Bolts shall be
tightened gradually and at a uniform rate to ensure uniform compression of the
gasket, in accordance with pipe and fitting manufacturer's recommendations.
B. Coat threaded portions of stainless steel bolts and nuts with lubricant before
assembly.
3.07 PIPING CONNECTIONS TO PUMPS AND OTHER EQUIPMENT
A. When connecting to pumps and equipment, the Contractor shall ensure that piping
stresses are not transmitted to the pump and equipment. All connecting pipe shall
be permanently supported and aligned so that accurate matching of bolt holes and
03720-048-01
August 2019
15055-13 PIPING SYSTEMS—GENERAL
uniform contact over the entire surface of pump flanges are obtained before any
bolts are installed in the flanges or pipe is threaded into pump and equipment. In
addition, pump connection piping shall be free to move parallel to its longitudinal
center line while the bolts are being tightened.
1. Pumps and equipment shall be leveled, aligned, and wedged into a
position that will fit the connecting pipe, but shall not be grouted until the
initial fitting and alignment of the pump and equipment may be shifted on
its foundation if necessary to properly install the connecting pipe. Each
pump and piece of equipment shall, however, be grouted before final
bolting of the connecting piping.
2. After final alignment and bolting, the pump and equipment connections
shall be tested for applied piping stresses by loosening the flange bolts
which, if the piping is properly installed, should result in no movement of
the piping relative to the pump or opening of the pump connection joints.
If any movement is observed, the piping shall be loosened and re -aligned
as required and then the flanges bolted back together. The flange bolts then
shall be loosened and the process repeated until no movement is observed.
3. All carbon steel bolts and nuts shall be coated with the same exterior
coating applied to the piping system.
3.08 ANCHORING AND RESTRAINING
A. Thrust blocks shall be used in new lines and shall be limited to areas in which a
new fitting has been installed in an existing line where field restraining joints are
not feasible or when directed by the Engineer.
3.09 FLUSHING, CLEANING, TESTING AND INSPECTION OF PIPING
A. See Section 15144, Pressure Testing of Piping, for the requirements of pipe
flushing, cleaning, pressure testing, and inspection requirements.
3.10 SPECIAL REQUIREMENTS AND PIPING SPECIALTIES
A. Welding:
1. Use only certified welders meeting procedures and performance outlined
in Section IX of the ASME BPVC and other codes and requirements in
accordance with local building and utility requirements. Submit Welder's
certificates to the Engineer for the project record before beginning any
welding on the project. The Welder must be certified for all positions (flat,
vertical, and overhead).
03720-048-01 15055-14 PIPING SYSTEMS GENERAL
August 2019
2. Have all welds conform to highest industrial practice in accordance with
ASME B31.1 and ASME B31.3 or other codes and requirements in
accordance with local building and utility requirements.
3.11 PIPE COLOR CODING
A. The pipe color shall be as identified on the Pipe Schedule in the Contract
Drawings. The Contractor shall coordinate with the Engineer and the Owner to
generate a list of acceptable pipe colors for exposed piping systems. Where color -
coding is achieved by painting exterior surfaces of the piping systems, painting
shall be provided in accordance with Section 09900, Painting and Coating. On
applicable pipes, color shall be in accordance with FDEP color -coding
requirements and Recommended Standards for Wastewater Facilities
2014 Edition.
03720-048-01
August 2019
END OF SECTION
15055-15 PIPING SYSTEMS—GENERAL
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1 SECTION 15060
PIPE HANGERS AND SUPPORTS
1
PART 1 GENERAL
1.01 SCOPE OF WORK
1 A. This Section includes requirements for materials and installation of pipe hangers
and supports, including accessory items such as anchor bolts and screws, pipe
1 spiders, neoprene isolation pads, cable trays for hoses, and drip guards.
1.02 RELATED WORK
A. Section 01330, Submittals.
B. Section 01650, Delivery, Storage, and Handling.
C. Section 01780, Warranties and Bonds.
D. Section 05500, Metal Fabrications.
' E. Section 09900, Painting and Coating.
F. Division 15, Mechanical.
1.03 SUBMITTALS
The Contractor shall submit shop drawings in accordance with Section 01330, Submittals and
1 Acceptance:
A. Provide line drawings of each piping system to the scale shown on the Contract
Drawings, locating each support or hanger. Identify each type of hanger or
support by the manufacturer's catalog number or figure.
' B. Provide installation drawings and manufacturer's catalog information on each type
of hanger and support used. Clearly indicate the actual pipe outside diameter (not
' just nominal pipe size) that is used for the hangers and supports.
' C. Submit layout drawings for the drip guards, showing dimensions and thicknesses.
Show design of seam or joint where field connections will be made between
sections and pieces of drip guards.
D. Submit a certificate listing the type of resin to be used, describing the
manufacturer's brand name or designation, composition, and characteristics.
' 1.04 WORK USED)
SEQUENCE Q (NOT
1
' 03720-048-01 15060-1 PIPE HANGERS AND SUPPORTS
January 2021
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be the latest
revision of any such document in effect at the bid time. The following documents are a part of
this Section. Where this Section differs from these documents, the requirements of this Section
shall apply.
A. American Society for Testing and Materials (ASTM)
1. ASTM A36/A36M—Standard Specification for Carbon Structural Steel.
2. ASTM A47/A47M—Standard Specification for Ferritic Malleable Iron
Castings.
3. ASTM A48/A48M—Standard Specification for Gray Iron Castings.
4. ASTM A153/A153M—Standard Specification for Zinc Coating (Hot -Dip)
on Iron and Steel Hardware.
5. ASTM A194/A194M—Standard Specification for Carbon and Alloy Steel
Nuts for Bolts for High Pressure or High Temperature Service, or Both.
6. ASTM A276/A276M—Standard Specification for Stainless Steel Bars and
Shapes.
7. ASTM A307—Standard Specification for Carbon Steel Bolts, Studs, and
Threaded Rod 60,000 psi Tensile Strength.
8. ASTM A575—Standard Specification for Steel Bars, Carbon, Merchant
Quality, M -Grades.
9. ASTM A576—Standard Specification for Steel Bars, Carbon, Hot -
Wrought, Special Quality.
10. ASTM A635/A635M—Standard Specification for Steel, Sheet and Strip,
Heavy -Thickness Coils, Hot -Rolled, Alloy, Carbon, Structural, High -
Strength Low -Alloy, and High -Strength Low -Alloy with Improved
Formability, General Requirements for.
11. ASTM A1011/A1011M—Standard Specification for Steel, Sheet and
Strip, Hot -Rolled, Carbon, Structural, High -Strength Low -Alloy, High -
Strength Low -Alloy with Improved Formability, and Ultra -High Strength.
12. ASTM D256—Standard Test Methods for Determining the Izod
Pendulum Impact Resistance of Plastics.
13. ASTM E84—Standard Test Method for Surface Burning Characteristics
of Building Materials.
14. ASTM F593—Standard Specification for Stainless Steel Bolts, Hex Cap
Screws, and Studs.
15. ASTM F594—Standard Specification for Stainless Steel Nuts.
B. American Society of Mechanical Engineers (ASME)
03720-048-01
January 2021
1. ASME B31.1—Power Piping.
15060-2 PIPE HANGERS AND SUPPORTS
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C. Manufacturer's Standardization Society
1. MSS SP-58—Pipe Hangers and Supports – Materials, Design,
Manufacture, Selection, Application, and Installation.
1.06 QUALITY ASSURANCE
A. All hangers, supports, and appurtenances shall conform to the latest applicable
requirements of ASME B31.1, except as supplemented or modified by the
requirements of this Section.
B. All hangers, supports, and appurtenances shall be of approved standard design
where possible and shall be adequate to maintain the supported load in proper
position under all operating conditions. The minimum working factor of safety for
all supporting equipment, with the exception of springs, shall be five times the
ultimate tensile strength of the material, assuming 10 feet of water -filled pipe
being supported.
C. All pipe and appurtenances connected to equipment shall be supported so as to
prevent any strain being imposed on the equipment. When manufacturers have
indicated requirements that piping loads shall not be transmitted to their
equipment, the Contractor shall submit certification stating that such requirements
have been complied with.
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
B. All supports and hangers shall be crated, delivered, and uncrated to protect against
any damage.
C. All parts shall be properly protected so that no damage or deterioration shall occur
during a prolonged delay from the time of shipment until installation is
completed.
D. Finished iron or steel surfaces not galvanized or painted shall be properly
protected to prevent rust and corrosion.
03720-048-01 15060-3 PIPE HANGERS AND SUPPORTS
January 2021
1.09 QUALIFICATIONS (NOT USED)
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 MAINTENANCE (NOT USED)
1.12 OPERATIONS AND MAINTENANCE (O&M) MANUALS (NOT USED)
PART 2 PRODUCTS
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2.01 GENERAL 1
A. Not all pipe supports or hangers required are shown on the Drawings. The
Contractor shall provide pipe supports for every piping system installed. Support
piping by pipe support where it connects to pumps or other mechanical
equipment.
B. The Contractor shall ensure that pipe support and hanger components shall
withstand the dead loads imposed by the weight of the pipes, fittings, and valves
(all filled with water) plus valve actuators and any insulation and shall have a
minimum safety factor of 5 based on the material's ultimate strength.
C. All of the equipment specified in this Section is intended to support the various
types of pipe and piping systems. The details shown on the Drawings are intended
to indicate the generally desired methods of support under normal conditions. The
Contractor shall develop final details and any details associated with special
conditions not already covered to meet the system conditions specified in the
respective Pipe Sections of Division 15, Mechanical.
D. All pipe and tubing shall be supported as required to prevent significant stresses
in the pipe of tubing material, valves, fittings, and other pipe appurtenances and to
support and secure the pipe in the intended position and alignment. All supports
shall be designed to adequately secure the pipe against excessive dislocation due
to thermal expansion and contraction, internal flow forces, and all probable
external forces such as equipment, pipe, and personnel contact. Any structural
steel members required to brace any piping from excessive dislocation shall
conform to the applicable requirements of Section 05500, Metal Fabrications, and
shall be furnished and installed under this Section.
E. Hangers and supports shall be spaced in accordance with ASME B31.1 except
that the maximum unsupported span shall not exceed 10 feet unless otherwise
specified in this Section.
03720-048-01
January 2021
15060-4 PIPE HANGERS AND SUPPORTS
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F. Where flexible couplings are required at equipment, tanks, etc., the end opposite
to the piece of equipment, tank, etc., shall be rigidly supported.
G. All pipe and appurtenances connected to the equipment shall be supported so as to
prevent any strain from being imposed on the equipment or piping system.
H. All rods, clamps, hangers, inserts, anchor bolts, brackets, and components for
interior pipe supports shall be furnished with galvanized finish, hot -dipped, or
electro -galvanized coated, except where field welding is required. Interior clamps
on plastic pipe shall be plastic coated. Supports for copper pipe shall be copper
plated or shall have a 1/16 -inch plastic coating. All rods, clamps, hangers, inserts,
anchor bolts, brackets, and components for exterior pipe and pipe within outdoor
structures shall be of AISI Type 316 stainless steel.
L Supports shall be sufficiently close together so that the sag of the pipe is within
limits that will permit drainage and avoid excessive bending stresses from
concentrated loads between supports.
J. All un -insulated non-metallic piping such as PVC, CPVC, etc., shall be protected
from local stress concentrations at each support point. Protection shall be
provided by galvanized steel protection shields or other method as approved by
the Engineer. Where pipes are bottom supported 180°, arc shields shall be
furnished. Where 360° arc support is required, such as U bolts, protection shields
shall be provided for the entire pipe circumference. Protection shields shall have
an 18 -gauge minimum thickness, not be less than 12 inches in length, and be
securely fastened to pipe with stainless steel or galvanized metal straps not less
than 1/2 -inch wide.
K. All insulated pipe shall be furnished with a rigid foam insulating saddle at each
pipe support location as specified under respective pipe insulation. Provide
galvanized protection shields as specified in Paragraph 2.O1J above at each
location.
L. Where pipe hangers and supports come in contact with copper piping, provide
protection from galvanic corrosion by wrapping pipe with 1/16 -inch -thick
neoprene sheet material and galvanized protection shield or copper -plated or
PVC -coated hangers and supports.
M. Pipe supports shall be provided as follows:
1. Cast-iron and ductile -iron piping shall be supported at a maximum support
spacing of 10 feet with a minimum of one support per pipe section at the
joints.
03720-048-01 15060-5 PIPE HANGERS AND SUPPORTS
January 2021
2. Steel and stainless steel piping 2-1/2 inches or larger diameter shall be
supported at a maximum support spacing of 10 feet with a minimum of
one support per pipe section at the joints.
3. Support spacing for steel and stainless piping 2 inches and smaller
diameter and copper tubing shall not exceed 5 feet.
4. Supports for multiple PVC plastic piping shall be continuous wherever
possible. Individually supported PVC pipes shall be supported as
recommended by the manufacturer except that support -spacing shall not
exceed 3 feet. Multiple, suspended, horizontal plastic PVC pipe runs shall,
where possible, be supported by ladder -type cable trays such as the
Electray Ladder by Husky-Burndy; Cable Tray by Enduro Composite
Systems; the Globetray by the Metal Products Division of United States
Gypsum or equal. Ladder shall be of FRP construction. Rung spacing shall
be 12 inches. Tray width shall be approximately 6 inches for single runs
and 12 inches for double runs. Ladder -type cable trays shall be furnished
complete with all hanger rods, rod couplings, concrete inserts, hanger
clips, etc., required for a complete support system. Individual plastic pipes
shall be secured to the rungs of the cable tray by strap clamps, or fasteners
similar to Globe, Model M -CAC; Husky-Burndy, Model SCR; or equal.
Spacing between clamps shall not exceed 9 feet. The cable trays shall
provide continuous support along the length of the pipe. Individual
clamps, hangers, and supports in contact with plastic PVC pipe shall
provide firm support but not so firm as to prevent longitudinal movement
due to thermal expansion and contraction.
5. All vertical pipes shall be supported at each floor or at intervals of not
more than 12 feet by approved pipe collars, clamps, brackets, or wall rests
and at all points necessary to ensure rigid construction.
6. Pipe supports shall not induce point loadings, but shall distribute pipe
loads evenly along the pipe circumference.
7. Supports shall be provided at changes in direction and elsewhere as shown
on the Drawings or as specified in this Section. No piping shall be
supported from other piping or from metal stairs, ladders, and walkways,
unless specifically directed or authorized by the Engineer.
8. Pipe supports shall be provided to minimize lateral forces through valves,
both sides of split -type couplings, and sleeve -type couplings and to
minimize all pipe forces on pump housings. Pump housings shall not be
used to support connecting pipes.
9. Effects of thermal expansion and contraction of the pipe shall be
accounted for in the pipe support selection and installation.
N. Any required pipe support for which the supports specified in this Section are not
applicable shall be fabricated or constructed from standard structural steel shapes
and concrete and anchor hardware similar to items previously specified in this
Section and shall be subject to the approval of the Engineer.
03720-048-01 15060-6 PIPE HANGERS AND SUPPORTS
January 2021
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2.02 HANGER AND SUPPORT SYSTEMS
A. Pipe hangers and supports shall be as manufactured by Anvil, Unistrut, Cooper
B -Line, Aikinstrut, Superstrut, or equal.
B. Pipe hangers and supports shall comply with MSS SP -58 for the standard types
referenced on the Drawings. The Contractor shall construct special hangers and
supports if detailed in the Drawings. Type numbers for standard hangers and
supports shall be in accordance with MSS SP -58 as listed below:
03720-048-01
January 2021
Type
Number
Description
Manufacturer and Model
(or Equal)
1
Adjustable steel clevis
Anvil Fig. 590 or 260, B -Line B3100
or B3102
3
Steel double -bolt pipe clamp
Anvil Fig. 295A or 295H, B -Line
B3144 or B3144A
4
Steel pipe clamp (pipes smaller than
3 inches)
Anvil Fig. 212, B -Line B3140
4
Steel pipe clamp (pipes 3 inches and
larger)
Anvil Fig. 216, B -Line 3142
5
Pipe hanger
B -Line B6690
6
Adjustable swivel pipe ring
Anvil Superstrut 714, Anvil Fig. 104
7
Adjustable steel band hanger
B -Line B3172
8
Extension pipe or riser clamp
Anvil Fig. 261, B -Line B5573
9
Adjustable band hanger
Anvil Fig. 97
10
Adjustable swivel ring band hanger
Anvil Fig. 70, B -Line B3170 NF
11
Split pipe ring with adjustable
turnbuckle
Anvil Fig. 108, B -Line B3173
13
Steel turnbuckle
Anvil Fig. 230, B -Line B3202
14
Steel clevis
Anvil Fig. 299, B -Line B3201
15
Swivel turnbuckle
Anvil Fig. 114, B -Line B3224
16
Malleable iron socket
Anvil Fig. 110R, B -Line B3222
17
Steel weldless eye nut
B -Line B3200
18
Steel or malleable iron concrete insert
Anvil Fig. 281, Superstrut 452
19
Top beam C-clamp
Anvil Fig. 92, B -Line B3033
20
Side I-beam or channel clamp
Anvil Fig. 14 or 217
21
Center I-beam clamp
Anvil Figure 134
22
Welded attachment type
Anvil Fig. 66 B -Line B3083
23
C-clamp
Anvil Fi . 86, B -Line B3036L
24
U -bolt
Anvil Fig. 137, B -Line B3188
26
Clip
Anvil Fig. 262, B -Line B3180
28
Steel I-beam clamp with eye nut
Anvil Fig. 228
29
Steel wide flange
Anvil Fig. 228 clamp with eye nut
30
Malleable iron beam clamp with
extension piece
Superstrut CM -754, B -Line B3054
31
Light welded steel bracket
Anvil Fig. 194, B -Line B3063
32
Medium welded steel bracket
Anvil Fig. 195, B -Line B3066
33
Heavy welded steel bracket
Anvil Fig. 199, B -Line B3067
15060-7
PIPE HANGERS AND SUPPORTS
Type
Number
Description
Manufacturer and Model
(or Equal)
34
Side beam bracket
Anvil Fig. 202, B -Line B3062
36
Pipe saddle support
Anvil Fig. 258, B -Line B3095
37
Pipe stanchion saddle
Anvil Fig. 259, B -Line B3090
38
Adjustable pipe saddle support
Anvil Fig. 264, B -Line B3093/B3089
39
Steel pipe covering
Anvil Fig. 160, 161, 162, 163, 164, or
165; Superstrut A 789; B -Line
B3160/B3165
40
Insulation protection shield
Anvil Fig. 167, B -Line B3151
41
Single pipe roll
Anvil Fig. 171, B -Line B3114
43
Adjustable roller hanger with swivel
Anvil Fig. 181, B -Line B3110
44
Pipe roll, complete
Anvil Fig. 271, B -Line B3117SL
C. General: Unless specified elsewhere or shown in the Contract Drawings, pipe
hangers and supports shall be 304 stainless steel and shall match the number,
type, location, and capacity of the existing supports.
D. Offset Pipe Clamp.
E. Anvil Figure 103, Cooper B -Line B3148, or equal. Material shall be Type 316
stainless steel unless otherwise noted.
2.03 MISCELLANEOUS PIPE SUPPORTS AND HANGERS
A. Pipe Anchor Chair: Anvil Figure 198 or equal.
B. One Hole Clamp: Anvil Figure 126 or equal.
C. Roller Chair: Anvil Figure 175 or equal.
2.04 STEEL CHANNEL FRAMING SYSTEM
A. Steel channel frames shall be 1-5/8 inches wide by 1-5/8 or 3-1/4 inches high by
12 -gauge metal thickness, unless otherwise shown on the Drawings. Material
shall conform to ASTM A36/A36M, A1011/A1011M (Grade 33 minimum), or
A653 unless stainless steel is indicated on the Drawings. Stainless steel shall be
Type 304. One side of the channel shall have a continuous open slot with inturned
clamping ridges. Maximum allowable stress under any combination of applied
uniformly distributed loads and concentrated loads shall not exceed those
recommended in the AISC or AISI. Deflection shall not exceed 1/240 of span.
The Contractor shall use multiple back-to-back channels to achieve these criteria
if single channels are not sufficient. Products: Unistrut P1000 or P5000 Series,
B -Line B11 or B22 Series, or equal.
03720-048-01 15060-8 PIPE HANGERS AND SUPPORTS
January 2021
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B. Steel channels shall be hot -dipped galvanized according to ASTM A153/A153M.
C. Nuts shall be machined and case hardened. The Contractor shall provide
rectangular nuts with the ends shaped to permit a quarter turn crosswise in the
framing channel. Provide two serrated grooves in the nut to engage the inturned
edges of the channel.
D. Pipe clamps (including attachment screws and nuts) shall be Unistrut P1100 or
P2000 Series, B -Line B2000 Series, or equal. Material shall be Type 304 stainless
steel.
E. Hanger rods for trapezes shall be carbon steel (ASTM A36/A36M, A575, or
A576) unless stainless steel is indicated on the Contract Drawings. Stainless-steel
hanger rod material shall comply with ASTM A276/A276M, Type 304.
F. Accessory fittings and brackets shall be the same material as the channel or
trapeze. Provide coating on carbon steel fittings and brackets as specified for the
channels and frames.
1. Flat Plate Fittings: Unistrut P1065, P1066, P1925; Superstrut AB -206,
AB -207; or equal.
2. Post Bases: Unistrut P2072A, Superstrut AP -232, or equal.
3. 90° Brackets: Unistrut P1326, P1346; Superstrut AB -203; or equal.
4. Rounded -End Flat Plate Fittings: Unistrut P2325, Superstrut X-240, or
equal.
G. Parallel pipe clamps shall be Unistrut P1563 through P1573, Superstrut AB -719,
or equal. Material shall be Type 304 stainless steel.
2.05 FIBERGLASS -REINFORCED PLASTIC (FRP) CHANNEL FRAMING SYSTEM
A. FRP pipe hangers and supports shall be Aickinstrut, Inc. or equal.
B. Material properties shall be as follows:
03720-048-01
January 2021
Longitudinal Direction
Ultimate Tensile (psi)
37,500 minimum
Ultimate Compressive (psi)
35,000 minimum
Ultimate Flexural (psi)
37,500 minimum
Tensile Modulus (psi) x 10**6
3.00 minimum
Flexural Modulus (psi) x 10**6
2.00 minimum
Ultimate Shear Strength (psi)
6,000 minimum
Ultimate Bearing Stress (psi)
35,000 minimum
Izod Impact (ASTM D256) ft-lb/inch notch
30 minimum
15060-9
PIPE HANGERS AND SUPPORTS
Longitudinal Direction
Transverse Direction
Ultimate Tensile (psi)
10,000 minimum
Ultimate Compressive (psi)
20,000 minimum
Ultimate Flexural (psi)
14,000 minimum
Tensile Modulus (psi) x 10**6
1.0 minimum
Compressive Modulus (psi) x 10**6
1.4 minimum
Flexural Modulus (psi) x 10**6
1.0 minimum
Ultimate Shear Strength (psi)
5,500 minimum
Ultimate Bearing Stress (psi)
35,000 minimum
Izod Impact, ft -lb notch
5 minimum
Hardness
Barcol Test
50 minimum
C. Glass -fiber -reinforced composites and plastic products shall have a flame spread
rating of 25 or less when tested in accordance with ASTM E84.
D. Channel framing shall be 1-5/8 inches deep by 1-5/8 inches wide and shall be
made using vinylester resin equal to Ashland Derakane 411, Ashland Hetron 922,
or Reichhold Dion 9800. It shall have a nexus polyester surfacing veil over 100%
of the surface which, along with a filler system, will protect against degradation
from ultraviolet light. Channel shall be supplied with integral notches 1 inch on
center. Notches shall be located on the interior flange to prevent slippage of pipe
clamps and fittings after installation. In place of notched channel, unnotched
channel may be used if the vertical channel sections supporting the horizontal
piping are provided with stop lock hardware at each pipe clamp to prevent
slippage. Channel framing shall be Aickinstrut G.R.P. Type V 2000 series or
equal.
E. Channel framing connections shall be made with vinylester glass fiber composite
nuts, bolts, all threaded rods, channel fittings, bases, and hanger assemblies. Nut,
bolts, and rods shall be Aickinstrut 4200 series, Strut Tech PVCG, or equal.
Channel fittings shall be Aickinstrut 2800 style or equal.
F. Load-bearing pipe clamps and nonload-bearing pipe straps shall be nonmetallic
and nonconductive and shall be made by the injection -molding process using
polyurethane -base resin. Pipe clamps and straps shall be Aickinstrut 3100 Series
or equal.
G. Clevis hangers shall be made with vinylester glass fiber and be Aickinstrut
1500 Series or equal.
H. Hanger rods for trapezes shall be carbon steel (ASTM A36/A36M, A575, or
A576) unless stainless steel or FRP is indicated on the Contract Drawings.
Stainless steel hanger rod material shall comply with ASTM A276/A276M,
Type 304. FRP hanger rod shall be by Aickinstrut, StrutTech, or equal.
03720-048-01 15060-10 PIPE HANGERS AND SUPPORTS
January 2021
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2.06 PIPE SPIDERS
A. Cooper B -Line B3281 to 3286, Superstrut S-794 or equal.
2.07 WAFFLE ISOLATION PADS
A. Mason Type "W;" Machinery Installation Systems "Unisorb" Type S, SB, F, or
FB; or equal. Provide minimum 1/4 -inch thickness.
2.08 NEOPRENE ISOLATING SLEEVES FOR METAL PIPE 6 INCHES AND SMALLER
A. Unistrut P2600, B -Line "Vibrocushion," or equal.
2.09 ANCHOR BOLTS AND SCREWS
A. Anchor bolts and screws for attaching pipe supports and hangers to walls, floors,
ceilings, and roof beams shall be Type 316 stainless steel, ASTM A276/A276M
or F593. Nuts shall be Type 316 stainless steel, ASTM A194/A194M, Grade 8M,
or ASTM F594, Type 316 stainless steel.
PART 3 EXECUTION
3.01 PIPE HANGER AND WALL SUPPORT SPACING
A. The Contractor shall install pipe hangers and wall supports on horizontal and
vertical runs at the spacing shown or detailed on the Contract Drawings. Provide
hanger rods (for horizontal runs) and wall supports of the sizes shown or detailed
on the Contract Drawings. If no spacing or rod sizes are given on the Contract
Drawings or in the Project Specifications for a particular piping system, use the
following:
03720-048-01
January 2021
1. Pipe Hanger and Wall Support Spacing for Steel and Ductile -Iron Pipe
(Section 15155, Ductile Iron Pipe and Fittings):
Pipe Size
(inches)
Maximum Support or Hanger
Spacing (feet)
Minimum Rod Size
(inches)
3/8 and smaller
4
3/8
1/2 through 1
6
3/8
1-1/4 through 2
8
3/8
2-1/2 and 3
10
1/2
3-1/2 and 4
10
5/8
6
12
3/4
8
12
7/8
IO and 12
14
7/8
15060-11
PIPE HANGERS AND SUPPORTS
Pipe Size
(inches)
Maximum Support or Hanger
Spacing (feet)
Minimum Rod Size
(inches)
14 and 16
16
1
18
15
1
20 through 24
9
1
30
6
1
B. Pipe Hanger or Wall Support Spacing for PVC Pipe (Section 15290, PVC Pipe,
3 Inches and Smaller):
Pipe Size
(inches)
Maximum Support or Hanger
Spacing
(feet)
Minimum Rod Size
(inches)
3/4
4
3/8
1
4
3/8
1-1/2
5
3/8
2
5
3/8
2-1/2
5
1/2
3
6
1/2
C. For piping services not described, the Contractor shall provide hangers and
supports according to MSS SP -58 and SP -69.
D. The Contractor shall provide bracing for piping 8 inches and smaller that is
installed on hangers or trapezes according to MSS SP -127, except provide lateral
bracing at maximum 10 -foot center -to -center spacings. Provide sway bracing for
hangers for piping larger than 8 inches as detailed on the Contract Drawings.
3.02 PIPE SUPPORT SPACING FOR SUPPORTS ON TOP OF SLABS OR GRADE
A. The Contractor shall install pipe supports on horizontal runs at the spacing shown
or detailed on the Contract Drawings. Provide supports of the type shown or
detailed on the Contract Drawings. If no spacings are given on the Contract
Drawings or in the Project Specifications for a particular piping system, use the
following:
03720-048-01
January 2021
1. Pipe Support Spacing for Steel and Ductile -Iron Pipe (Section 15155,
Ductile Iron Pipe and Fittings:
Pipe Size
(inches)
Maximum Support Spacing
(feet)
3/8 and smaller
4
1/2 through 1
6
1-1/4 through 2
8
2-1/2 and 3
10
3-1/2 and 4
10
6
12
15060-12
PIPE HANGERS AND SUPPORTS
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Pipe Size
(inches)
Maximum Support Spacing
(feet)
8
12
10 and 12
14
14 and 16
16
18
16
20 through
24
18
30
18
B. Pipe support spacing for other pipe materials shall be the same as described in
Article 3.01 of this Section.
3.03 INSTALLING PIPE HANGERS AND SUPPORTS
The Contractor shall do the following:
A. Provide separate hangers or supports at each valve. Provide one hanger or support
around each end of the valve body or on the adjacent connecting pipe within one
pipe diameter of the valve end. Provide additional hangers or supports to relieve
eccentric loadings imposed by offset valve actuators.
B. Provide separate hangers or supports at each pipe elbow, tee, or fitting. Provide
separate hangers or supports on both sides of each nonrigid joint or flexible pipe
coupling.
C. Adjust pipe hangers according to MSS SP -89, Paragraph 10.6.
D. Install leveling bolts beneath support baseplates. Provide 3/4 -inch -thick grout pad
beneath each base.
E. Install piping without springing, forcing, or stressing the pipe or any connecting
valves, pumps, and other equipment to which the pipe is connected.
3.04 INSTALLING STEEL AND FRP CHANNEL FRAMES
A. The Contractor shall use 1 -5/8 -inch -high channel frames, unless 3 -1/4 -inch is
needed, to provide clearance from walls. Use multiple back-to-back channels if
additional clearance is needed.
3.05 INSTALLING NEOPRENE ISOLATING SLEEVES
A. The Contractor shall install a sleeve around each metal pipe 6 inches and smaller
at the point of bearing or contact with the pipe hanger or support.
03720-048-01 15060-13 PIPE HANGERS AND SUPPORTS
January 2021
3.06 PAINTING AND COATING
The Contractor shall do the following regarding painting and coating:
A. Grind the welds of fabricated steel pipe supports smooth, prepare surface by
sandblasting, and apply coating system in accordance with Section 09900,
Painting and Coating.
B. Paint exposed metallic pipe hangers and supports to match the color of the
adjacent wall using System No. 52 in accordance with Section 09900, Painting
and Coating. If the adjacent wall is not painted, paint the hangers and supports to
match color code of the largest pipe on the support.
C. Coat submerged pipe hangers and supports in accordance with Section 09900,
Painting and Coating.
D. Coat FRP pipe hangers and supports exposed to direct sunlight with System
No. 41 in accordance with Section 09900, Painting and Coating. FRP pipe
hangers and supports that are hidden from direct sunlight need not be coated.
03720-048-01
January 2021
END OF SECTION
15060-14 PIPE HANGERS AND SUPPORTS
SECTION 15075
PROCESS EQUIPMENT, PIPING, AND VALVE IDENTIFICATION
PART 1 GENERAL
1.01 SCOPE OF WORK
A. This Section includes requirements for materials and installation of markers,
labels, and signs for pipes, tanks, and valves; for mechanical equipment; for
hazardous materials warnings; and for miscellaneous plant services.
1.02 RELATED WORK
A. Section 01330, Submittals and Acceptance.
B. Section 01650, Delivery, Storage, and Handling.
C. Section 01780, Warranties and Bonds.
1.03 SUBMITTALS
A. The Contractor shall submit shop drawings in accordance with Section 01330,
Submittals and Acceptance.
B. The Contractor shall submit an ID schedule for the piping, valves, equipment,
tanks, and any signs required for this project for review and acceptance by the
Engineer. This schedule shall be in a formatted list that is easy to follow and
categorized in a logical manner.
C. The Contractor shall submit manufacturer's catalog data and descriptive literature
describing materials, colors, letter size, and size of labels.
D. The locations of each nameplate shall be coordinated with the Engineer and
Owner and approved by the Engineer and Owner before their installation.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS (NOT USED)
1.06 QUALITY ASSURANCE (NOT USED)
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
03720-048-01
August 2019
15075-1 PROCESS EQUIPMENT, PIPING, AND
VALVE IDENTIFICATION
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
1.09 QUALIFICATIONS (NOT USED)
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 MAINTENANCE (NOT USED)
1.12 OPERATIONS AND MAINTENANCE (O&M) MANUALS
A. O&M Manuals shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01830, Operations and Maintenance Manuals.
PART 2 PRODUCTS
2.01 LABELS FOR PIPING
A. The Contractor shall provide 4" stenciled labels using weather- and UV -resistant
acrylic. Labels shall include the direction of flow, Pipe Size, and Pipe
Abbreviation in accordance with the Pipe Schedule on the Drawings.
2.02 LABELS FOR VALVES
A. The Contractor shall provide each valve listed on the Tag Number list with an
identification tag. The tag shall be 3 -inch diameter circular aluminum or stainless
steel: W. H. Brady, Seton Name Plate Corp, or Engineer approved equal. Tags
shall have 1/8 -inch cast in black -filled letters. The Contractor shall provide
fiberglass tags for chemical system valves. The valve identification shall be as
shown in the mechanical details of the Contract Drawings and include the valve
size, flow stream, valve type, and direction and number of turns to open. The
Contractor shall submit the valve tag label schedule for review by the Engineer in
accordance with Paragraph 1.03.B of this Specification.
2.03 HOSE BIBB SIGNS—UNSAFE WATER
A. The Contractor shall provide a rigid sign labeled "DO NOT DRINK" and "NO
BEBER" for each hose bibb. Size and lettering shall conform to OSHA
requirements. Signs shall be Seton Nameplate Company 20 -gauge baked enamel,
minimum size 7 inches by 3 inches; Brady B-120 Fiber -Shield fiberglass,
minimum size 7 inches by 3 inches, 1/8 inch thick; or equal.
03720-048-01 15075-2 PROCESS EQUIPMENT, PIPING, AND
August 2019 VALVE IDENTIFICATION
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2.04 LABELS FOR MECHANICAL EQUIPMENT
A. The Contractor shall provide a label for each installed pump, mixer, grinder, flow
meter, or other piece of mechanical equipment as part of this Project. The label
shall show the equipment name and tag number as shown on the Tag Number list
or on the Contract Drawings. Labels shall be 1-1/2 inches (minimum) by 4 inches
(minimum) brass, aluminum, or 1/8 -inch -thick fiberglass tags.
B. Provide fiberglass tags for chemical system equipment: Brady B-120 Fiber -
Shield, Seton Style 2065, or equal. Contractor shall submit the mechanical
equipment label schedule for review by the Engineer in accordance with
Paragraph 1.03.B of this Specification.
2.05 LABELS FOR TANKS
A. Signs shall be weather- and UV -resistant. Labels shall be Brady B-946, Seton
Name Plate Corporation PSPL, or equal. Minimum size shall be 7 inches by
10 inches. Provide a sign on each quadrant of the tank bearing the tank tag
number and the name and purpose of the liquid stored (e.g. "South Dewatering
Storage Tank and North Biosolids Blend Tank).
B. All applicable tanks shall be properly labeled for safety with signs stating,
"Permit Required Confined Space". Signs shall be clearly visible and placed at all
access points to the tank including manways and tank hatches.
2.06 HAZARDOUS MATERIALS WARNING AND DANGER SIGNS (NOT USED)
2.07 UNDERGROUND PLASTIC WARNING TAPE FOR METAL PIPE
A. The Contractor shall provide permanent, bright -colored, continuous -printed
plastic tape intended for direct burial service, not less than 6 inches wide by
3.5 mils thick. Tape shall be as detailed herein and also in accordance with
Section 15055, Piping Systems—General. Provide tape with printing that most
accurately indicates the type of service of buried pipe. Provide the following
colored tape for the various piping services:
03720-048-01
August 2019
Service
Color
Service
Color
Cable TV
Orange
Water
Blue
Gas
Yellow
Sewer
Green
Electric
Red
Chemical
Yellow
Telephone
Orange
Reclaimed Water
Violet
15075-3 PROCESS EQUIPMENT, PIPING, AND
VALVE IDENTIFICATION
2.08 UNDERGROUND DETECTABLE METALLIC PIPE WARNING TAPE
A. The Contractor shall provide permanent, bright -colored, continuous -printed tape
consisting of an aluminum or steel foil sheathed in a plastic laminate, not less than
2 inches wide by 3 mils thick. Tape shall be as detailed herein and also in
accordance with Section 15055, Piping Systems—General. Provide tape with
printing that most accurately indicates the type of buried service. Provide the
following colored tape for the various piping services:
Service
Color
Service
Color
Cable TV
Orange
Water
Blue
Gas
Yellow
Sewer
Green
Electric
Red
Chemical
Yellow
Telephone
Orange
Reclaimed Water
Violet
PART 3 EXECUTION
3.01 INSTALLING PIPE LABELS
A. The Contractor shall provide a stenciled label and flow arrow at each connection
to pumps or other mechanical equipment, at wall boundaries, at tees and crosses,
and at 20 -foot centers on straight runs of piping.
3.02 INSTALLING VALVE AND EQUIPMENT LABELS
A. The Contractor shall attach labels to the valve or piece of equipment with
Type 304 or 316 stainless steel chains unless otherwise noted. For sodium
hypochlorite and hydrofluosilicic acid use thermoplastic chains to attach labels.
B. The Contractor shall attach valve labels to the valve handwheels. If the valve has
no handwheel, attach the label to the valve by tying the tag wire or chain around
the operating shaft or nut.
C. Installation of the valve collar with identification disk shall be in accordance with
the Contract Drawings.
3.03 INSTALLING MISCELLANEOUS SIGNS
A. The Contractor shall attach miscellaneous signs according to the sign
manufacturer's recommendations and in accordance with OSHA requirements.
3.04 INSTALLING WALL AND DOOR SIGNS
A. Attach to walls and doors using epoxy adhesive.
03720-048-01
August 2019
15075-4 PROCESS EQUIPMENT, PIPING, AND
VALVE IDENTIFICATION
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3.05 INSTALLING UNDERGROUND PLASTIC WARNING TAPE FOR METAL PIPE
A. During backfilling of each exterior underground piping system, the Contractor
shall install continuous underground -type plastic line marker directly over buried
line at 6 to 8 inches above the top of the pipe. Where multiple small lines are
buried in common trench and do not exceed overall width of 16 inches, install a
single line marker.
3.06 INSTALLING UNDERGROUND DETECTABLE METALLIC PIPE WARNING
TAPE
A. The Contractor shall install tape 12 to 18 inches below finished ground surface
directly over buried pipelines. Where multiple small pipelines are buried in a
common trench and do not exceed an overall width of 16 inches, install a single
marker tape.
END OF SECTION
03720-048-01 15075-5 PROCESS EQUIPMENT, PIPING, AND
August 2019 VALVE IDENTIFICATION
SECTION 15110
MANUAL, CHECK, AND PROCESS VALVES
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish all labor, materials, equipment, and incidentals
required and install complete and ready for operation all valves as shown in the
Drawings and as specified in this Section. All valves shall be complete with all
necessary manual actuators, valve boxes, extension stems, and floor stands, which
are required for proper valve operation and completion of the work.
1. All valves shall be of the sizes shown in the Drawings. All equipment of
the same type shall be from one manufacturer, unless authorized in writing
by the Engineer.
2. The valves shall include but not be limited to the following:
a. Air Valves.
b. Ball Valves.
c. Check Valves.
d. Gate Valves.
e. Globe and Angle Valves.
f. Plug Valves.
1.02 RELATED WORK
A. Section 01330, Submittals and Acceptance.
B. Section 01650, Delivery, Storage, and Handling.
C. Section 01780, Warranties and Bonds.
D. Section 01830, Operations and Maintenance Manuals.
E. Section 09900, Painting and Coating.
F. Section 15055, Piping Systems—General.
G. Section 15120, Power -Operated Valve Assemblies.
H. Section 15144, Pressure Testing of Piping.
I. Section 15155, Ductile Iron Pipe and Fittings.
03720-048-01 15110-1 MANUAL, CHECK, AND PROCESS VALVES
August 2019
1.03 SUBMITTALS
The Contractor shall submit shop drawings in accordance with Section 01330, Submittals and
Acceptance:
A. Product technical submittal data shall contain the following information and data:
1. Acknowledgment that products submitted meet requirements of standards
referenced.
2. Manufacturer's installation instructions.
3. Manufacturer's operation and maintenance manuals.
4. Data of valves, actuators, and accessories:
a. Pressure and temperature rating.
b. Materials of construction, with ASTM reference and grade.
c. Linings and coatings.
d. Dimensions and weight.
e. Flow coefficient.
f. Actuators and accessories details.
g. Manufacturer's product brochure, cut -sheets, and parts diagrams.
B. Dimensions and orientation of valve actuators as installed on the valves. Show
location of internal stops for gear actuators. State differential pressure and fluid
velocity used to size actuators. For worm -gear actuators, state the radius of the
gear sector in contact with the worm and state the handwheel diameter.
C. The following test reports: Performance Tests; Leakage Tests; Hydrostatic Tests;
and Proof -of -Design Tests as applicable or required.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be the latest
revision of any such document in effect at the bid time. The following documents are a part of
this Section. Where this Section differs from these documents, the requirements of this Section
shall apply.
A. American Petroleum Institute (API)
1. API SPEC 6D—Specification for Pipeline and Piping Valves.
03720-048-01 15110-2 MANUAL, CHECK, AND PROCESS VALVES
August 2019
2. API SPEC 6FA—Specification for Fire Test for Valves.
3. API STD 594—Check Valves: Flanged, Lug, Wafer and Butt -Welding.
4. API STD 607—Fire Test for Quarter -turn Valves and Valves Equipped
with Nonmetallic Seats.
B. American Society for Testing of Materials (ASTM)
03720-048-01
August 2019
1. ASTM A36/A36M—Standard Specification for Carbon Structural Steel.
2. ASTM A47/A47M—Standard Specification for Ferritic Malleable Iron
Castings.
3. ASTM A48/A48M—Standard Specification for Gray Iron Castings.
4. ASTM A105/A105M—Standard Specification for Carbon Steel Forgings
for Piping Applications.
5. ASTM A108—Standard Specification for Steel Bar, Carbon and Alloy,
Cold -Finished.
6. ASTM A126—Standard Specification for Gray Iron Castings for Valves,
Flanges, and Pipe Fittings.
7. ASTM A148/A148M—Standard Specification for Steel Castings, High
Strength, for Structural Purposes.
8. ASTM A181/A181M Standard Specification for Carbon -Steel Forgings,
for General -Purpose Piping.
9. 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.
10. ASTM A193/A193M—Standard Specification for Alloy -Steel and
Stainless Steel Bolting for High Temperature or High Pressure Service and
Other Special Purpose Applications.
11. ASTM A 194/A194M—Standard Specification for Carbon Steel, Alloy
Steel, and Stainless Steel Nuts for Bolts for High Pressure or High
Temperature Service, or Both.
12. ASTM A216/A216M—Standard Specification for Steel Castings, Carbon,
Suitable for Fusion Welding, for High -Temperature Service.
13. ASTM A240/A240M—Standard Specification for Chromium and
Chromium -Nickel Stainless Steel Plate, Sheet, and Strip for Pressure
Vessels and for General Applications.
14. ASTM A269/A269M—Standard Specification for Seamless and Welded
Austenitic Stainless Steel Tubing for General Purpose.
15. ASTM A276/A276M—Standard Specification for Stainless Steel Bars and
Shapes.
16. ASTM A313/A313M—Standard Specification for Stainless Steel Spring
Wire.
17. ASTM A322—Standard Specification for Steel Bars, Alloy, Standard
Grades.
15110-3 MANUAL, CHECK, AND PROCESS VALVES
18. ASTM A351/A351M—Standard Specification for Castings, Austenitic,
for Pressure -Containing Parts.
19. ASTM A395/A395M—Standard Specification for Ferritic Ductile Iron
Pressure -Retaining Castings for Use at Elevated Temperatures.
20. ASTM A436—Standard Specification for Austenitic Gray Iron Castings.
21. ASTM A439/A439M—Standard Specification for Austenitic Ductile Iron
Castings.
22. ASTM A449—Standard Specification for Hex Cap Screws, Bolts and
Studs, Heat Treated, 120/105/90 ksi Minimum Tensile Strength, General
Use.
23. ASTM A479/A479M—Standard Specification for Stainless Steel Bars and
Shapes for Use in Boilers and Other Pressure Vessels.
24. ASTM A494/A494M Standard Specification for Castings, Nickel and
Nickel Alloy.
25. ASTM A516/A516M—Standard Specification for Pressure Vessel Plates,
Carbon Steel, for Moderate- and Lower -Temperature Service.
26. ASTM A536—Standard Specification for Ductile Iron Castings.
27. ASTM A564/A564M—Standard Specification for Hot -Rolled and Cold -
Finished Age -Hardening Stainless Steel Bars and Shapes.
28. ASTM A582/A582M Standard Specification for Free -Machining
Stainless Steel Bars.
29. ASTM A666—Standard Specification for Annealed or Cold -Worked
Austenitic Stainless Steel Sheet, Strip, Plate, and Flat Bar.
30. ASTM A743/A743M Standard Specification for Castings, Iron -
Chromium, Iron -Chromium -Nickel, Corrosion Resistant, for General
Application.
31. ASTM A744/A744M—Standard Specification for Castings, Iron -
Chromium -Nickel, Corrosion Resistant, for Severe Service.
32. ASTM A890/A890M—Standard Specification for Castings, Iron -
Chromium -Nickel -Molybdenum Corrosion -Resistant, Duplex
(Austenitic/Ferritic) for General Application.
33. ASTM B16/B16M—Standard Specification for Free -Cutting Brass Rod,
Bar and Shapes for Use in Screw Machines.
34. ASTM B21/B21M—Standard Specification for Naval Brass Rod, Bar, and
Shapes.
35. ASTM B61—Standard Specification for Steam or Valve Bronze Castings.
36. ASTM B62—Standard Specification for Composition Bronze or Ounce
Metal Castings.
37. ASTM B98/B98M—Standard Specification for Copper -Silicon Alloy
Rod, Bar and Shapes.
38. ASTM B99/B99M—Standard Specification for Copper -Silicon Alloy
Wire for General Applications.
39. ASTM B127—Standard Specification for Nickel -Copper Alloy
(UNS N04400) Plate, Sheet, and Strip.
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40. ASTM B 148 Standard Specification for Aluminum -Bronze Sand
Castings.
41. ASTM B 150/B 150M—Standard Specification for Aluminum Bronze Rod,
Bar, and Shapes.
42. ASTM B164—Standard Specification for Nickel -Copper Alloy Rod, Bar,
and Wire.
43. ASTM B 169/B 169M—Standard Specification for Aluminum Bronze
Sheet, Strip, and Rolled Bar.
44. ASTM B 193—Standard Test Method for Resistivity of Electrical
Conductor Materials.
45. ASTM B371/B371M—Standard Specification for Copper -Zinc -Silicon
Alloy Rod.
46. ASTM B427—Standard Specification for Gear Bronze Alloy Castings.
47. ASTM B443—Standard Specification for Nickel -Chromium -
Molybdenum -Columbium Alloy (UNS N06625) and Nickel -Chromium -
Molybdenum -Silicon Alloy (UNS N06219) Plate, Sheet, and Strip.
48. ASTM B446—Standard Specification for Nickel -Chromium -
Molybdenum -Columbium Alloy (UNS N06625), Nickel -Chromium -
Molybdenum -Silicon Alloy (UNS N06219), and Nickel -Chromium -
Molybdenum -Tungsten Alloy (UNS N06650) Rod and Bar.
49. ASTM B462—Standard Specification for Forged or Rolled UNS N06030,
UNS N06022, UNS N06035, UNS N06200, UNS N06059, UNS N10362,
UNS N06686, UNS N08020, UNS N08367, UNS N10276, UNS N10665,
UNS N10675, UNS N10629, UNS N08031, UNS N06045, UNS N06025,
UNS R20033 Alloy Pipe Flanges, Forged Fittings, and Valves and Parts
for Corrosive High -Temperature Service.
50. ASTM B463—Standard Specification for UNS N08020 Alloy Plate,
Sheet, and Strip.
51. ASTM B472—Standard Specification for Nickel Alloy Billets and Bars
for Reforging.
52. ASTM B584—Standard Specification for Copper Alloy Sand Castings for
General Applications.
53. ASTM B763/B763M—Standard Specification for Copper Alloy Sand
Castings for Valve Applications.
54. ASTM D1248—Standard Specification for Polyethylene Plastics
Extrusion Materials for Wire and Cable.
55. ASTM D1784—Standard Specification for Rigid Poly (Vinyl Chloride)
(PVC) Compounds and Chlorinated Poly (Vinyl Chloride) (CPVC)
Compounds.
56. ASTM D1785—Standard Specification for Poly (Vinyl Chloride) (PVC)
Plastic Pipe, Schedules 40, 80, and 120.
57. ASTM D2000—Standard Classification System for Rubber Products in
Automotive Applications.
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58. ASTM D3222 -Standard Specification for Unmodified Poly (Vinylidene
Fluoride) (PVDF) Molding Extrusion and Coating Materials.
59. ASTM D4101 -Standard Classification system and Basis for
Specification for Polypropylene Injection and Extrusion Materials.
60. ASTM F441/F441M-Standard Specification for Chlorinated Poly (Vinyl
Chloride) (CPVC) Plastic Pipe, Schedules 40 and 80.
61. ASTM F467 -Standard Specification for Nonferrous Nuts for General
Use.
62. ASTM F468 Standard Specification for Nonferrous Bolts, Hex Cap
Screws, Socket Head Cap Screws, and Studs for General Use.
C. American Society of Mechanical Engineers (ASME)
1. ASME B1.20.1 -Pipe Threads, General Purpose (Inch).
2. ASME B1.20.7 -Hose Coupling Screw Threads (Inch).
3. ASME B16.1 -Gray Iron Pipe Flanges and Flanged Fittings Classes 25,
125, and 250.
4. ASME B16.5 Pipe Flanges and Flanged Fittings NPS 1/2 through
NPS 24 Metric/Inch Standard.
5. ASME B16.10 -Face -to -Face and End -to -End Dimensions of Valves.
6. ASME B16.11 Forged Fittings, Socket -Welding and Threaded.
7. ASME B16.18 -Cast Copper Alloy Solder Joint Pressure Fittings.
8. ASME B 16.24 -Cast Copper Alloy Pipe Flanges, Flanged Fittings, and
Valves Classes 150, 300, 600, 900, 1500, and 2500.
9. ASME B16.34 -Valves Flanged, Threaded and Welding End.
10. ASME B 16.42 -Ductile Iron Pipe Flanges and Flanged Fittings
Classes 150 and 300.
11. ASME B 16.47 -Large Diameter Steel Flanges NPS 26 through NPS 60
Metric/Inch Standard.
12. ASME B36.10 -Welded and Seamless Wrought Steel Pipe.
D. American Society of Safety Engineers (ASSE)
1. ASSE 1011 -Performance Requirements for Hose Connection Vacuum
Breakers.
E. American Water Works Association (AWWA)
03720-048-01
August 2019
1. AWWA C 110/A21.10 -Ductile -Iron and Gray -Iron Fittings.
2. AWWA C111/A21.11-Rubber-Gasket Joints for Ductile -Iron Pressure
Pipe and Fittings.
3. AWWA C115/A21.15-Flanged Ductile -Iron Pipe with Ductile -Iron or
Gray -Iron Threaded Flanges.
15110-6 MANUAL, CHECK, AND PROCESS VALVES
4. AWWA C207—Steel. Pipe Flanges for Waterworks Service, Sizes 4 -Inch
through 144 -Inch (100 mm through 3,600 mm).
5. AWWA C500 Metal -Seated Gate Valves for Water Supply Service.
6. AWWA C504—Rubber-Sealed Butterfly Valves.
7. AWWA C507—Ball Valves 6 -Inch through 60 -Inch (150 mm through
1,500 mm).
8. AWWA C508—Swing-Check Valves for Waterworks Service, 2 -Inch
through 48 -Inch (50 mm through 1,200 mm) NPS.
9. AWWA C509—Resilient-Seated Gate Valves for Water Supply Service.
10. AWWA C512—Air Release, Air/Vacuum, and Combination Air Valves
for Water and Wastewater Service.
11. AWWA C515—Reduced-Wall, Resilient -Seated Gate Valves for Water
Supply Service.
12. AWWA C550—Protective Interior Coatings for Valves and Hydrants.
13. AWWA C606—Grooved and Shouldered Joints.
14. AWWA C800—Underground Service Line Valves and Fittings.
F. Fluid Controls Institute (FCI)
1. FCI 70-2—Control Valve Seat Leakage.
G. Manufacturers Standardization Society (MSS)
1. MSS SP-61—Pressure Testing of Valves.
2. MSS SP-67—Butterfly Valves.
3. MSS SP-68—High Pressure Butterfly Valves with Offset Design.
4. MSS SP-81—Stainless-Steel or Stainless -Steel -Lined, Bonnetless, Knife
Gate Valves with Flanged Ends.
5. MSS SP -83 --Class 3000 and 6000 Pipe Unions, Socket Welding and
Threaded (Carbon Steel, Alloy Steel, Stainless Steels, and Nickel Alloys).
6. MSS SP -108 Resilient -Seated Cast Iron Eccentric Plug Valves.
H. National Fluid Power Association (NFPA)
1. NFPA T3.6.7—Fluid Power Systems and Products – Square Head
Industrial Cylinders – Mounting Dimensions.
2. NFPA T3.6.68—Fluid Power – Square Head Cylinders – Determination of
the Static Failure Pressure Rating of Pressure Containing Components.
I. NSF International (NSF)
1. NSF 61—Drinking Water System Components – Health Effects.
03720-048-01 15110-7 MANUAL, CHECK, AND PROCESS VALVES
August 2019
1.06 QUALITY ASSURANCE (NOT USED)
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
B. All valves, unless otherwise directed, shall be loaded and unloaded by lifting, and
under no circumstances shall valves be dropped, skidded, or rolled. Valves shall
not be stacked or placed under pipe, fittings, or other valves in such a manner that
damage could result.
C. Slings, hooks, or tongs used for lifting shall be padded in such a manner as to
prevent damage to exterior surface or interior linings and valve components. If
any part of the coating, lining, or components is damaged, the repairs or
replacement shall be made by the Contractor at his expense and in a manner
satisfactory to the Engineer before attempting to install such valves.
D. Only new valves will be allowed for installation and shall be stored in a manner to
prevent damage and be kept free of dirt, mud, or other debris.
1.09 QUALIFICATIONS
A. All of the valves shall be products of well-established firms which are fully
experienced, reputable, have been selling this product for a minimum of 10 years,
and are qualified in the manufacture of the particular product furnished. The
valves shall be designed, constructed, and installed in accordance with the
requirements and procedures of applicable AWWA standards and shall comply
with these Specifications as applicable.
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 MAINTENANCE (NOT USED)
1.12 OPERATIONS AND MAINTENANCE (O&M) MANUALS
A. O&M Manuals shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01830, Operations and Maintenance Manuals.
03720-048-01 15110-8 MANUAL, CHECK, AND PROCESS VALVES
August 2019
1.13 VALVE TYPE CLASSIFICATIONS
A. Air Valves (Type 100 series):
1. Type 140: Air Valves for Sewage Services, Air Release.
B. Ball Valves (Type 200 series)
1. Type 220: Regular Port Threaded Stainless Steel Ball Valves, 2 Inches and
Smaller.
C. Check Valves (Type 400 series):
1. Type 430: Ductile -Iron Swing -Flex Check Valves, 2 Inches through
36 Inches.
D. Gate Valves (Type 600 series):
1. Type 652: Stainless -Steel Gate Valves, 2 Inches through 6 Inches.
E. Globe and Angle Valves (Type 700 series):
1. Type 710: Bronze Angle Hose Valves, 1 Inch through 3 Inches.
2. Type 720: Bronze Hose Bibbs, 1/2 Inch through 1 Inch.
F. Plug Valves (Type 900 series):
1. Type 902: Eccentric Plug Valves, 4 Inches through 12 Inches.
2. Type 920: Cast -Iron Non -Lubricated Eccentric Plug Valves, 4 Inches and
Larger.
PART 2 PRODUCTS
2.01 GENERAL
A. Valves are identified in the Drawings by size and type number. For example, a
callout of 36V300 refers to a 36 -inch -diameter Type 300 valve. A Type 300 valve
is a flanged, rubber -seated butterfly valve that is 4 inches through 72 inches for
exposed service.
B. All valves shall be complete with all necessary geared actuators, chainwheels and
chains, handwheeis, levers, valve bonnets, valve boxes, extension stems,
operating nuts, and T -handle wrenches, which are required for proper valve
03720-048-01
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operating and completing of the work included under this Section. Renewable
parts including discs, packing, and seats shall be of types specified in this Section
and acceptable by valve manufacturer for the intended service. All units shall
have the name of the manufacturer and the size of the valve cast on the body or
bonnet or shown on a permanently attached stainless-steel plate in raised
embossed letters. All isolation valves shall be suitable for the intended service
with bubble -tight shutoff to flow in either direction.
C. Bronze or brass components in contact with water shall comply with the
following requirements:
Constituent
Content
Zinc
7% maximum
Aluminum
2% maximum
Lead
8% maximum
Copper + Nickel + Silicon
83% minimum
D. Valves and valve operators shall be factory prepared and primed and field finish
coated in accordance with Section 09900, Painting and Coating.
2.02 VALVE ACTUATORS
A. The valve actuator shall be an integral part of a valve. The valve actuator shall be
provided, installed, and adjusted by the valve manufacturer. Actuator mounting
arrangements shall facilitate operation and maintenance and shall be determined
by the valve manufacturer unless indicated otherwise on the Drawings or directed
by the Engineer.
B. All valves shall open counter clockwise as viewed from the top. Unless otherwise
required by the Owner, the direction of rotation of the wheel or wrench nut to
open each valve shall be to the left (counterclockwise). Each valve body or
actuator shall have the word "Open" cast on it and an arrow indicating the
direction to open.
C. Actuators shall clearly indicate valve position and an adjustable stop shall be
provided to set closing torque. All exposed nuts, bolts, and washers shall be AISI
Type 304 stainless steel. Unless noted otherwise, valves shall be equipped with
the following manual actuators:
03720-048-01
August 2019
1. Exposed Valves 6 Inches and Smaller: Removable lever or handwheel
actuators.
2. Exposed Valves 8 Inches and Larger: Geared actuators with handwheels.
15110-10 MANUAL, CHECK, AND PROCESS VALVES
3. Buried or Submerged Valves 6 Inches and Smaller: 2 -inch -square
operating nuts (with valve bonnets, valve boxes, and extension stems as
required) and T -handle wrench.
4. Buried or Submerged Valves 8 Inches and Larger: Geared actuators with
2 -inch -square operating nuts (with valve bonnets, valve boxes, and
extension stems as required) and wrench.
D. Levers or handwheels shall be provided to actuate the valves where the valves are
within 6 feet and 7 inches from finished grade or the operating floor. Handwheels
shall be constructed of ductile -iron. Levers and handwheels shall be coated in
accordance with Section 09900, Painting and Coating. Handwheel diameters for
traveling nut actuators shall not exceed 8 inches for valves 12 inches and smaller
and shall not exceed 12 inches for valves 20 inches and smaller.
E. Chainwheel and guide actuators shall be provided for all exposed valves installed
with their centerlines more than 6 feet and 9 inches above finished grade.
Chainwheels shall be cast-iron with stainless-steel stem, clip, and pins. The
actuating chain shall be AISI Type 304 stainless steel. Stainless-steel chain
baskets shall also be provided with these units. Chainwheels shall be coated in
accordance with Section 09900, Painting and Coating.
Chainwheels and guides shall be Clow Figure F-5680, DeZurik Series W or
LWG, Stockham, or equal.
F. Gear actuators for valves 8 inches through 20 inches shall be of the worm -and -
gear or of the traveling -nut type. Gear actuators for valves 24 inches and larger
shall be of the worm -and -gear type. Gear actuators for motorized valves shall be
of the worm -and -gear type, regardless of size.
1. Gear actuators should be designed assuming that the differential pressure
across the valves is equal to the test pressure of the connecting piping and
assuming a line fluid temperature range of 33°F to 125°F, unless
otherwise required in the detailed valve specifications.
2. Gear actuators shall be enclosed and oil lubricated with seals provided on
shafts to prevent entry of dirt and water into the actuator. Gear actuators
for valves aboveground or in vaults and structures shall have handwheels.
The actuators for valves in exposed service shall contain a dial indicating
the position of the valve disc or plug.
3. Traveling nut and worm -and -gear actuators shall be of the totally enclosed
design and proportioned to permit operation of the valve under full
differential pressure rating of the valve with a maximum pull of 80 pounds
on the handwheel or crank. Stop -limiting devices shall be provided in the
actuators in the open and closed positions. Actuators shall be of the self-
locking type to prevent the disc or plug from creeping. Design actuator
03720-048-01 15110-11 MANUAL, CHECK, AND PROCESS VALVES
August 2019
components between the input and the stop -limiting devices to withstand
without damage a pull of 200 pounds for handwheel or chainwheel
actuators and an input torque of 300 foot-pounds for operating nuts when
operating against the stops.
4. The self-locking worm gear shall be a one-piece design of gear bronze
material (ASTM B427; or ASTM B584, Alloy C86200) that is accurately
machine cut. Actuators for eccentric and lubricated plug valves may
use ductile -iron gears provided the gearing is totally enclosed with
spring-loaded rubber lip seals on the shafts. The worm shall be hardened
alloy steel (ASTM A322, Grade G41500 or G41400; or
ASTM A148/A148M, Grade 105-85) with thread ground and polished.
Support worm -gear shafts at each end by ball or tapered roller bearings.
The reduction gearing shall run in a proper lubricant. The handwheel
diameter shall be no more than twice the radius of the gear sector in
contact with the worm. Worm -gear actuators shall be Limitorque
Model HBC, EIM Series W, or equal.
G. For buried or submerged service, provide watertight shaft seals and watertight
valve and actuator cover gaskets. Provide totally enclosed actuators designed for
buried or submerged service.
H. All buried valves shall have non -rising stems. All buried valves 3 feet below
grade or deeper as measured at the valve centerline shall be furnished with an
operator stem extension to extend the operating nut within 6 inches from the top
of the valve box cover.
I. Motorized Valves shall be in accordance with Section 15120, Power -Operated
Valve Assemblies.
2.03 VALVE END CONNECTIONS
A. Provide valve end connections conforming to connected piping and as shown in
the Drawings. Generally, all buried valves shall be mechanical joint type end
connectors. Exposed valves shall be screwed -end, socket -weld end, or flanged to
conform to adjacent exposed connected piping system.
B. Comply with the following standards:
03720-048-01
August 2019
1. Threaded: ASME B1.20.1.
2. Flanged: ASME B16.1 Class 125 unless other noted or AWWA C207.
3. Mechanical (gland) Type: AWWA C111.
4. Soldered: ASME B16.18.
15110-12 MANUAL, CHECK, AND PROCESS VALVES
C. Nuts, Bolts, and Washers: Wetted or internal to be bronze or stainless-steel.
Exposed to be zinc or cadmium -plated.
D. Epoxy Interior Coating: Provide epoxy coating for all interiors of ferrous valve
body surfaces in accordance with AWWA C550. Coatings shall be NSF -approved
for valves in all potable water piping services. Coatings shall not be required for
stainless-steel valve interiors.
2.04 VALVE BOXES
A. All buried valves 2 -inch size and larger shall be equipped with a standard cast-
iron roadway valve box. Valve boxes shall be of the slip or sliding type with a
round lid marked "Sewer" for wastewater and a square lid marked "Reclaimed
Water" for reclaimed water valves. The box shall be designed to prevent transfer
of the surface loads directly to the valve or piping. Valve boxes must have a
minimum adjustable range of 12 inches and a minimum inner diameter of
6 inches. All valve boxes and lids shall be produced from grey cast-iron
conforming to the latest revision of specification for grey iron castings,
ASTM A48, Class 20A -25A. All castings shall be true and free of holes and shall
be cleaned according to good foundry practice, chipped and ground as needed to
remove fins and rough places on castings. Valve boxes have to be rated to sustain
FDOT H-20 loadings and have a minimum depth of 8 inches. The valve box lid
shall fit flush in the top of the box without forcing and shall not rock, tip, or rattle.
B. Provide debris cap as required in the Contract Drawings.
C. Coat buried cast-iron pieces as specified in Section 09900, Painting and Coating,
System No. 21 or with fusion -bonded epoxy.
D. Valve boxes shall be as manufactured by Tyler Pipe, Geneco, Star Pipe Products,
or equal.
2.05 EXTENSION STEMS
A. Where the depth of the valve is such that its centerline is more than 4 feet below
grade, provide operating extension stems to bring the operating nut to a point
6 inches below the surface of the ground and/or box cover. Where the valve is
submerged, provide operating extension stems to bring the operating nut to
6 inches above the water surface. Extension stems shall be Type 316 stainless
steel, solid core, and shall be complete with 2 -inch -square operating nut. The
connections of the extension stems to the operating nuts and to the valves shall
withstand without damage a pull of 300 foot-pounds.
03720-048-01
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B. Extension stem diameters shall be as tabulated below:
Valve Size
(inches)
Minimum Extension
Stem Diameter
(inches)
2
3/4
3,
4
7/8
6
1
8
1-1/8
10,
12
1-1/4
14
1-3/8
16,
18
1-1/2
20,
24,
30,
36
1-3/4
42, 48, 54
2
C. Provide buried valves or valves located inside manholes or vaults with valve
boxes cast in the manhole or vault roof with a valve position indicator designed to
fit standard 5 -1/4 -inch valve boxes. The indicators shall show valve position and
the direction and number of turns required to fully open (or close). All internal
gearing shall be sealed. Ship each unit ready for field installation complete with
valve box cast-iron adapter, capscrews, guide bushing, position indicator, flexible
washer, centering plate, and 2 -inch AWWA nut. Valve box and indicator shall be
provided by the valve manufacturer. Indicators shall be Westran Position
Indicator, Pratt Diviner, or equal.
2.06 FLOOR STANDS
A. When required by the installations, provide floor stands for the operation of
valves. Floor stands shall be of the nonrising stem, indicating type, complete with
steel extension stems, couplings, handwheels, stem guide brackets, and special
yoke attachments as required by the valves and recommended and supplied by
the stand manufacturer. Floor stands shall be cast-iron base type: Clow,
Figure F-5515; Bingham and Taylor; Stockham; or equal. Handwheels shall
turn counterclockwise to open the valves.
B. Provide Type 316 stainless-steel anchor bolts.
C. Provide Type 316 stainless-steel extension stems for valves in exposed service.
Provide Type 316 stainless-steel stems for valves in submerged service.
D. Provide adjustable stem guide brackets for extension stems. The bracket shall
allow valve stems to be set over a range of 2 to 36 inches from walls. Provide
bushings drilled to accept up to 2 -inch -diameter stems. Base, arm, and clamp shall
be Type 316 stainless-steel. Bushing shall be bronze (ASTM B584, Alloy C86400
or C83600). Bolts, nuts, screws, and washers (including wall anchor bolts) shall
03720-048-01 15110-14 MANUAL, CHECK, AND PROCESS VALVES
August 2019
be Type 316 stainless steel. Provide slots in the bracket to accept 3/4 -inch bolts
for mounting the bracket to the wall. Products: Trumbull Industries, Inc.,
Adjustable Stem Guide or equal.
2.07 BOLTS, NUTS, AND GASKETS FOR FLANGED VALVES
A. Bolts, nuts, and gaskets for flanged valves shall be as described in Section 15055,
Piping Systems—General.
2.08 PAINTING AND COATING
A. Coat metal valves located aboveground or in vaults and structures the same as the
adjacent piping. If the adjacent piping is not coated, coat valves as specified in
Section 09900, Painting and Coating, System No. 10. Apply the specified prime
and finish coat at the place of manufacture. The finish coat shall match the color
of the adjacent piping. Coat handwheels the same as the valves.
B. Coat buried metal valves at the place of manufacture as specified in
Section 09900, Painting and Coating, System No. 21.
C. Coat submerged metal valves, stem guides, extension stems, and bonnets at the
place of manufacture as specified in Section 09900, Painting and Coating, System
No. 7.
D. Line the interior metal parts of metal valves 4 inches and larger, excluding seating
areas and bronze and stainless-steel pieces, as specified in Section 09900,
Painting and Coating, System No. 6. Apply lining at the place of manufacture.
E. Coat floor stands as specified in Section 09900, Painting and Coating, System
No. 10.
F. Test the valve interior linings and exterior coatings at the factory with a low -
voltage (22.5 to 80 volts, with approximately 80,000 -ohm resistance) holiday
detector, using a sponge saturated with a 0.5% sodium chloride solution. The
lining shall be holiday free.
G. Measure the thickness of the valve interior linings as specified in Section 09900,
Painting and Coating. Repair areas having insufficient film thickness as specified
in Section 09900, Painting and Coating.
03720-048-01 15110-15 MANUAL, CHECK, AND PROCESS VALVES
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2.09 AIR VALVES (TYPE 100 SERIES)
A. General Description:
1. All valves shall meet or exceed all applicable provisions of the latest
revision of AWWA C512, Standard for Air -Release, Air/Vacuum, and
Combination Air Valves for Waterworks Service. All valves for drinking
water services shall comply with NSF 61. Design pressure is 150 psig.
Valves shall be operable for water temperatures of above freezing to
125°F.
2. All valves shall consist of a float or a float assembly. Valves shall be
identified properly in plates attached permanently on the valve body. The
body and cover shall be cast-iron ASTM A126, Class B, or
ASTM A48/A48M, Class 35. Valves 3 inches and smaller shall have
threaded ends. Valves 4 inches and larger shall have flanged ends.
Threaded ends shall comply with ASME B1.20.1. Flanges shall comply
with ASME B16.1, Class 125. All flanges shall be flat faced.
3. The float shall be Type 304 or 316 Stainless -Steel. For valves with inlet
sizes less than 4 inches, the float shall be able to withstand a collapse
pressure of 1,000 psig. For inlet sizes 4 inches and larger, the float shall
be capable of withstanding collapse pressures of 750 psig. Trim shall be
Type 304 or 316 Stainless -Steel. The valve seat shall be of EPDM or other
rubber materials applicable to wastewater and sludge. The valve seat shall
be easily removed and replaced in the field.
4. Drain/test ports on all valves with inlet size 1 inch or larger shall have two
1/2 -inch NPT minimum plugged ports, one near the bottom of the valve
body and the other near the top of the valve. The plug shall be of bronze,
ASTM B584, Alloy C83600.
B. Type 140—Air Valves for Sewage Services, Air Release:
1. Type 140 air valves for sewage service shall have elongated cylindrical
chambers. All valves shall provide the following: 1/2 -inch clearance
around the float in the chamber; minimum size 1/2 -inch isolation valve
and quick -disconnect couplings at the valve venting for back-flushing;
blowoff port and valve at the bottom of the chamber; and inlet valve at
the valve inlet. A back-flushing assembly shall be provided for all valves.
The back-flushing assembly shall consist of an inlet shutoff valve, a flush
valve, a clear water inlet valve, rubber supply hose, and quick -disconnect
couplings. Type 140 valves shall be air -release valves. Valves shall be
APCO 450 Series, Val -Matic Model 49ABW, or equal.
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2.10 BALL VALVES (TYPE 200 SERIES)
A. Type 220—Regular Port Threaded Stainless Steel Ball Valves, 2 Inches and
Smaller:
1. Stainless-steel ball valves 2 inches and smaller shall be rated at a
minimum pressure of 1,500 psi WOG at a temperature of 100°F. Valve
body, ball, and stem shall be Type 316 stainless-steel,
ASTM A276/A276M or ASTM A351. Seat and seals shall be reinforced
PTFE. Valves shall have plastic -coated lever actuators. Valves shall have
screwed ends (ASME B1.20.1) and nonblowout stems. Valves shall be
Flowserve Marpac B780 Series, Apollo 76-100 Series, or approved equal.
2.11 CHECK VALVES (TYPE 400 SERIES)
A. Type 430 Ductile -Iron Swing -Flex Check Valves, 2 Inches through 36 inches:
03720-048-01
August 2019
1. The valve body and cover shall be constricted of ASTM A536
Grade 65-45-12 ductile -iron. The disc shall be precision -molded Buna-N,
ASTM D2000 Class BG. A screw-type backflow actuator shall be
provided to allow opening of the valve during no -flow conditions. Buna-N
seals shall be used to seal the stainless-steel stem in a bronze bushing. The
backflow device shall be of the rising -stem type to indicate position. A
stainless-steel T -handle shall be provided for ease of operation. The valve
shall be designed for a minimum working pressure of 150 psi. The
manufacturer's name, initials, or trademark and also the size of the valve,
working pressure, and direction of flow shall be directly cast on the body.
Swing check valves shall exceed the minimum requirements of
AWWA C508 with a heavy-duty body of ductile -iron with integral
flanges, faced and drilled in accordance with ASME B16.1 Class 125.
Bolts, nuts, washers, etc., shall be 316 stainless-steel. The valve body shall
be the full waterway type. The disk arm shall be ductile -iron or steel,
suspended from and keyed to a stainless-steel shaft, which is completely
above the waterway and supported at each end by heavy bronze bushings.
The shaft shall rotate freely without the need for external lubrication. The
shaft shall be sealed where it passes through the body by means of a
stuffing box and adjustable packing. Simple 0 -ring shaft seals are not
acceptable. The valve interior shall be painted with epoxy coating by the
valve manufacturer in accordance with AWWA C550. The check valve
shall be Val -Matic Swing -Flex check valve, or approved equal.
15110-17 MANUAL, CHECK, AND PROCESS VALVES
1
2.12 GATE VALVES (TYPE 600 SERIES)
1
1
1
1
1
1
1
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A. Type 652—Stainless-Steel Gate Valves, 2 inches through 6 inches:
1. Stainless-steel gate valves 2 inches through 6 inches shall be of the wedge
type, Class 150 with rising stem and handwheel. The bonnet shall be of
the bolted type. Ends shall be flanged in accordance with ASME B16.5.
Materials of construction shall be as follows:
Component
Material
Specification
Body, bonnet, yoke, and
wedge
Stainless-steel
ASTM A351,
Grade CF8M
Stem and gland follower
Stainless-steel
ASTM A276/A276M,
Type 316
Handwheel
Malleable iron
ASTM A47/A47M
Nuts and bolts
Stainless-steel
ASTM A1941A194M,
Grade 818F or
ASTM A193/A193M,
Grade 88
Packing
Teflon
--
2. Valves shall be Powell Figure 1832, Crane/Alloyco Figure 90, or equal.
2.13 GLOBE AND ANGLE VALVES (TYPE 700 SERIES)
A. Type 710—Bronze Angle Hose Valves, 1 Inch through 3 Inches:
1. Angle -type hose valves 1 inch through 3 inches shall be brass or bronze
(ASTM B62 or ASTM B584, Alloy C83600) body with rising or non -
rising stem, composition disc, and bronze or malleable iron handwheel.
The stem shall be bronze, ASTM B62, ASTM B584 (Alloy C83600), or
ASTM B584 (Alloy C87600). Valves shall have a cold -water service
pressure rating of at least 150 psi. Provide cap and chain with valve.
Threads on the valve outlet shall be American National Standard fire hose
coupling screw thread. Valves shall be Nibco T -301-W, Powell Figure 151
with nipple adapter, Crane 17TF with hose nipple adapter, or approved
equal.
B. Type 720—Bronze Hose Bibbs, 1/2 -Inch through 1 Inch:
1. Hose bibbs 1/2 inch, 3/4 inch, and 1 inch shall be all bronze (ASTM B62
or ASTM B584, Alloy C83600) with rising or non -rising stem,
composition disc, bronze or malleable iron handwheel, and bronze stem
03720-048-01 15110-18 MANUAL, CHECK, AND PROCESS VALVES
August 2019
(ASTM B99/B99M, Alloy C65100; ASTM B371/B371M, Alloy C69400;
or ASTM B584, Alloy C87600). Packing shall be PTFE or graphite.
Valves shall have a pressure rating of at least 125 psi for cold -water
service. Threads on valve outlets shall be American National Standard fire
hose coupling screw thread (ASME B1.20.7). Provide atmospheric
vacuum breaker conforming to ASSE 1011 and IAPMO code. Valves
shall be manufactured by Nibco or approved equal.
2.14 PLUG (TYPE 900 SERIES)
A. Plug and Seating Design for Eccentric Plug Valves (910 and 920): Eccentric plug
valves shall comply with MSS SP -108 and the following. Provide a rectangular
plug design, with an associated rectangular seat. Provide bidirectional seating
design. The valve shall seat with the rated pressure upstream and downstream of
the closed plug. Provide geared actuators sized for bidirectional operation.
B. For Types 910 and 920 eccentric plug valves, the metallic portion of the plug
shall be one-piece design and shall be without external reinforcing ribs which
result in a space between the rib and the main body of the plug through which
water can pass. Valves shall be repackable without any disassembly of valve or
actuator. The valve shall be capable of being repacked while under the design
pressure in the open position. Nowhere in the valve or actuators shall the valve
shaft be exposed to iron -on -iron contact. Sleeve bearings shall be stainless-steel in
valve sizes 20 inches and smaller and bronze or stainless-steel in valve sizes
24 inches and larger. Provide enclosed worm -gear actuators for valves 6 inches
and larger.
C. Rubber compounds shall have less than 2% volume increase when tested in
accordance with ASTM D471 after being immersed in distilled water at a
temperature of 73.4°F ±2°F for 70 hours.
D. Where indicated on the Contract Drawings, Plug Valves shall be equipped with
valve position indicators. Indicators shall have NEMA 4X enclosures, 2 NPT
conduit connections, 2 SPDT mechanical switches, and external visual indicator.
Indicators shall not exceed 16 amp rating. Indicators shall be as manufactured by
Assured Automation, YF Series, or engineer -approved equal.
E. Type 902—Eccentric Plug Valves, 4 Inches through 12 Inches:
1.
03720-048-01
August 2019
Eccentric plug valves 4 inches through 12 inches shall be non -lubricated
type. Minimum pressure rating shall be 175 psi. Bodies shall be cast-iron
in accordance with ASTM A126, Class B. Ends shall be flanged,
Class 125 in accordance with ANSI B16.1. Plugs shall be stainless-steel,
cast-iron (ASTM A126, Class B), or ductile -iron (ASTM A536,
15110-19 MANUAL, CHECK, AND PROCESS VALVES
Grade 65-45-12) with Buna-N facing. Valve body seats shall be Type 304
or 316 stainless-steel or have a raised welded -in overlay at least 1/8 -inch
thick of not less than 90% nickel. Body capscrews and bolts and nuts shall
be Type 316 stainless-steel. Packing shall be butadiene -filled Teflon.
Provide 100% port area. Valves shall be DeZurik PEC Note: DeZurik PET
is 100% port, Clow F-5412, Val -Matic "Cam -Centric," Milliken
"Millcentric" Figure 601, Pratt `Ballcentric," or approved equal.
F. Type 920—Cast-Iron Non -Lubricated Eccentric Plug Valves, 4 Inches and
Larger:
03720-048-01
August 2019
1. Plug valves 4 inches and larger shall be of the non -lubricated eccentric
type with resilient faced plugs and shall be furnished with flanges or
mechanical joint end connections to match connecting piping and as
shown in the Drawings. Flanged valves shall be 125-1b flanges and faced
and drilled to the ASME B16.1, 125-1b standard. Mechanical joint ends
shall conform to AWWA C111. Valve bodies shall be of ASTM A126
Class B cast-iron. Valves shall be furnished with a welded overlay seat of
not less than 90% pure nickel. Seat area shall be raised, with raised surface
completely covered with weld to ensure that the plug face contacts only
nickel. Screwed -in seats shall not be acceptable. The plug shall have a
cylindrical seating surface eccentrically offset from the center of the plug
shaft. The interference between the plug face and body seat, with the plug
in the closed position, shall be externally adjustable in the field with the
valve in the line under pressure. Plugs shall be resilient faced with Hycar
(Acrylonitrile -Butadiene) or Buna N, formulated and constructed to be
suitable for use with wastewater. Minimum port areas shall be 80% of full
pipe flow area. Valves shall have sleeve -type metal bearings and shall be
of sintered, oil -impregnated, permanently lubricated Type 316 ASTM.
Nonmetallic bearings shall not be acceptable. Valve shaft seals shall be of
the multiple V -ring type or U -cup type and shall be externally adjustable
and replaceable without removing the bonnet or actuator from the valve
under pressure. Valves using 0 -ring seals or non-adjustable packing shall
not be acceptable. All exposed nuts, bolts, springs, washers, and other
fasteners shall be 300 -series stainless-steel. Valve working pressure
ratings shall be a minimum of 150 psi. Each valve shall be given a
hydrostatic and seat test with certified copies of proof -of -design test
reports as outlined in AWWA C504, Section 5.5. Plug valves shall be
DeZurik PEC Series, Henry Pratt Company "Ballcentric" Series, or
approved equal.
15110-20 MANUAL, CHECK, AND PROCESS VALVES
1
PART 3 EXECUTION 1
3.01 JOINTS
A. Bolt holes of flanged valves shall straddle the horizontal and vertical centerlines
of the pipe run to which the valves are attached. Clean flanges by wire brushing 1
before installing flanged valves. Clean flange bolts and nuts by wire brushing,
lubricate threads with oil and graphite, and tighten nuts uniformly and
progressively. If flanges leak under pressure testing, loosen or remove the nuts
and bolts, reseat or replace the gasket, reinstall or retighten the bolts and nuts, and
retest the joints. Joints shall be watertight.
B. Clean threaded joints by wire brushing or swabbing. Apply Teflon joint
compound or Teflon tape to pipe threads before installing threaded valves. Joints 1
shall be watertight.
C. Install lug -type valves with separate hex head machine bolts at each bolt hole and
each flange (two bolts per valve bolt hole).
D. Install grooved -end couplings for valves in accordance with Section 15055,
Piping Systems—General.
3.02 INSTALLING EXPOSED VALVES
A. Unless otherwise indicated in the Drawings, install valves in horizontal runs of 1
pipe having centerline elevations 4 feet 6 inches or less above the floor with their
operating stems vertical. Install valves in horizontal runs of pipe having centerline
elevations between 4 feet 6 inches and 6 feet 9 inches above the floor with their
operating stems horizontal.
B. Install valves on vertical runs of pipe that are next to walls with their stems
horizontal, away from the wall. Valves on vertical runs of pipe that are not located
next to walls shall be installed with their stems horizontal, oriented to facilitate 1
valve operation.
3.03 INSTALLING BURIED VALVES 1
A. Connect the valve, coat the flanges, apply tape wrapping or polyethylene
encasement as required on the Drawings, and place and compact the backfill to
the height of the valve stem.
B. Place block pads under the extension pipe to maintain the valve box vertical
during backfilling and repaving and to prevent the extension pipe from contacting
the valve bonnet. 1
03720-048-01 15110-21 MANUAL, CHECK, AND PROCESS VALVES
August 2019
C. Mount the upper slip pipe of the extension in midposition and secure with backfill
around the extension pipe. Pour the concrete ring allowing a depression so the
valve box cap will be flush with the pavement surface.
D. Install debris cap as close as possible under the cast-iron cover without interfering
with the cover operation. Trim flexible skirt to provide a smooth contact with the
interior or the extension pipe.
3.04 INSTALLING EXTENSION STEM GUIDE BRACKETS
A. Install extension stem guide brackets at 6- to 8 -foot centers. Provide at least two
support brackets for stems longer than 10 feet, with one support near the bottom
of the stem and one near the top.
3.05 FIELD COATING BURIED VALVES
A. Coat flanges of buried valves and the flanges of the adjacent piping and the bolts
and nuts of flanges and mechanical joints, as specified in Section 09900, Painting
and Coating, System No. 24.
B. Wrap buried metal valves 6 inches and larger with polyethylene sheet as specified
in Section 15155, Ductile Iron Pipe and Fittings.
3.06 VALVE LEAKAGE AND FIELD TESTING
A. Test valves for leakage at the same time that the connecting pipelines are tested.
See Section 15144, Pressure Testing of Piping, for pressure testing requirements.
Protect or isolate any parts of valves, actuators, or control and instrumentation
systems whose pressure rating is less than the pressure test. Valves shall show
zero leakage. Repair or replace any leaking valves and retest.
B. Operate manual valves through three full cycles of opening and closing. Valves
shall operate from full open to full close without sticking or binding. Do not
backfill buried valves until after verifying that valves operate from full open to
full closed. If valves stick or bind or do not operate from full open to full closed,
repair or replace the valve and repeat the tests.
C. Test gear actuators through three full cycles from full -open to full -close without
binding or sticking. The pull required to operate handwheel- or chainwheel-
operated valves shall not exceed 80 pounds. The torque required to operate valves
having 2 -inch AWWA nuts shall not exceed 150 foot-pounds. If actuators stick or
bind or if pulling forces and torques exceed the values stated previously, repair or
03720-048-01 15110-22 MANUAL, CHECK, AND PROCESS VALVES
August 2019
replace the actuators and repeat the tests. Operators shall be lubricated in
accordance with the manufacturer's recommendations before operating.
03720-048-01 15110-23 MANUAL, CHECK, AND PROCESS VALVES
August 2019
Date of Installation
WATER SERVICE CARD
Contract Drawing Number
Service Line Size (inches)
Length of Water Service Line (feet)
Meter Size (inches)
Name
House/Business Address or Location:
Phone #
GPS coordinate @ main
GPS coordinate @ meter
Confirm Photos are attached
Installation Foreman
Service Layout
Provide a brief sketch of the installed configuration. Indicate lengths, depths of the water service,
and show three ties to meter box and to corporation stop:
Depth @ Main (feet)
Depth @ stub out (feet)
Contractor Signature Resident Observer Signature
(Rev 2 — 15 Oct 2006)
03720-048-01 15110-24 MANUAL, CHECK, AND PROCESS VALVES
August 2019
ISOLATION VALVE CARD
Date of Installation
Contract Drawing Number
Closest Street Address to Valve or Location of Valve
Size of Valve (inches)
Circle Type of Valve: Gate Butterfly
GPS Coordinate @ Valve
Installation Foreman
Confirm Photos are attached
Isolation Valve Layout
Provide a brief sketch of the installed configuration. Show depths of the water line and show
three ties to the isolation valve:
Depth @ Main (feet)
Contractor Signature Resident Observer Signature
(Rev 2 —15 Oct 2006)
03720-048-01 15110-25 MANUAL, CHECK, AND PROCESS VALVES
August 2019
Date of Installation
FIRE HYDRANT CARD
Contract Drawing Number
Closest Street Address to Fire Hydrant or Location of Fire Hydrant
Length of Hydrant Line (feet)
List any offset fittings required.
List Utilities requiring offset fittings
GPS coordinate @ main
GPS coordinate @ Hydrant
Installation Foreman
Confirm Photos are attached
Fire Hydrant Layout
Provide a brief sketch of the installed configuration. Indicate lengths, depths of the water line
and hydrant, offset fittings, and show three ties to the fire hydrant isolation valve:
Depth @ Main (feet)
Depth @ hydrant (feet)
Contractor Signature Resident Observer Signature
(Rev 2 — 15 Oct 2006)
END OF SECTION
03720-048-01 15110-26 MANUAL, CHECK, AND PROCESS VALVES
August 2019
SECTION 15120
POWER -OPERATED VALVE ASSEMBLIES
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish all labor, materials, equipment, and incidentals
required to install complete and ready for operation power operated valve
assemblies shown in the Drawings and as specified in this Section. The power
operated valve assemblies shall consist of valves with electric motor multi -turn
actuators with valve -stem mounted worm -gear actuators for exposed valve
actuation service, extension stems and extension bonnets with worm -gear
actuators for buried valve actuation service, controls for local and remote
operation, and accessories required for manual and automatic valve operation.
B. All valves shall be of the type specified in Section 15110, Manual, Check, and
Process Valves. All valve and actuator combinations of the same type shall be
from one manufacturer, unless authorized in writing by the Engineer.
C. The power operated valve assemblies shall be provided by the valve
manufacturer/supplier. Valves shall be as specified in Section 15110, Manual,
Check, and Process Valves. The complete power operated valve assemblies shall
be assembled at the valve factory for performance testing. The completed
assemblies for each valve shall be shipped to the job site completely assembled
and ready for installation including actuator, actuator controls, valve with
mechanical worm -gear actuator, and extension stem assemblies as required.
1.02 RELATED WORK
A. Related Specifications for work required for this Section:
1. Section 01330, Submittals and Acceptance.
2. Section 01650, Delivery, Storage, and Handling.
3. Section 01780, Warranties and Bonds.
4. Section 01830, Operations and Maintenance Manuals.
5. Section 09900, Painting and Coating.
6. Section 13401, Process Instrumentation and Controls (PICS).
7. Section 15055, Piping Systems—General.
8. Section 15110, Manual, Check, and Process Valves.
03720-048-01 15120-1 POWER -OPERATED
August 2019 VALVE ASSEMBLIES
1.03 SUBMITTALS
A. The Contractor shall submit shop drawings in accordance with the requirements
of Section 01330, Submittals and Acceptance, and Section 15110, Manual,
Check, and Process Valves.
B. The Contractor shall submit the following:
1. Actuator manufacturer's catalog data showing motor actuator parts and
materials of construction, referenced by AISI, ASTM, SAE, or CDA
specification and grade. Indicate motor actuator dimensions, weights, and
coatings.
2. The minimum and maximum torque required to open and close each
motor -actuated valve supplied for this project.
3. Certified factory performance test records for each assembly.
4. Motor data including nameplate data, insulation type, duty rating, and
torque output at duty rating.
5. Electrical schematic drawings and interconnecting wiring diagrams for
external monitoring and controls.
6. Catalog data, brochures, drawings for valves, worm -gear actuators, bonnet
extensions, shaft extensions, and other accessories.
7. Catalog data, drawings, diagrams for the complete assembly including
drawings of each assembly, and dimensions of extension bonnets from
center line of valve to center line of electric motor actuator.
8. Control descriptions for local and remote controls including opening and
closing (speed) times, and valve positions for open/close control duties.
Control requirements are described in other sections listed in Article 1.02
of this Section.
9. Site storage, protection, and installation requirements and procedures.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS (NOT USED)
1.06 QUALITY ASSURANCE (NOT USED)
1.07 WARRANTIES
A. Warranties shall be in accordance with Section 01780, Warranties and Bonds.
03720-048-01 15120-2 POWER -OPERATED
August 2019 VALVE ASSEMBLIES
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, and Section 15110, Manual, Check, and Process
Valves, for the items specified in this Section.
1.09 QUALIFICATIONS
A. All power -operated valve assemblies shall be products of well-established valve
manufacturers which are fully experienced, reputable, have been furnishing power
operated valve assemblies including field servicing and start-up for a minimum of
10 years. The valves shall be designed, constructed, and installed in accordance
with the requirements and procedures of AWWA C540 and other applicable
AWWA standards and shall comply with these Specifications as applicable.
1.10 MAINTENANCE
A. The Contractor shall furnish the following spare parts for each actuator in clearly
identified containers, labeled for easy identification without opening the
packaging and suitably protected for long-term storage in a humid environment.
B. For the four motorized actuators, provide each:
1. One set of shear pins
2. One set of gear assemblies
3. One Set of couplings
4. Additional spare parts shall be provided in accordance with the
recommendations of equipment manufacturers.
1.11 OPERATIONS AND MAINTENANCE (O&M) MANUALS
A. O&M Manuals shall be in accordance with General Provisions, Special
Provisions, and Section 01830, Operations and Maintenance Manuals.
PART 2 PRODUCTS
2.01 GENERAL
A. All valves furnished under this Section shall conform to the requirements
specified in Section 15110, Manual, Check, and Process Valves.
B. All worm -gear actuators shall conform to the requirements for respective valve
series number (types) as specified in Section 15110, Manual, Check, and Process
Valves.
03720-048-01 15120-3 POWER -OPERATED
August 2019 VALVE ASSEMBLIES
C. All power -operated valve assemblies shall be furnished with all necessary
operating appurtenances which are required for the proper completion of the work
specified in this Section and as specified in Section 15110, Manual, Check, and
Process Valves, including but not limited to:
1. Valve -Stem and Extension Bonnet Mounted Worm -Gear Type Actuators.
2. Extension Stems.
3. Actuator Support Floor Stands (if required).
4. Extension Bonnets.
5. Electric Motor Actuator Mounted to Worm -Gear Actuators with Manual
Handwheel Operator and Local Control.
D. Power operated valve assemblies designated to be furnished with bonnet
extensions shall have bonnet extensions and shaft extensions lengths to provide
the electric motor actuator centerline at 48 inches above the concrete maintenance
slab, as shown in the Contract Drawings.
2.02 VALVES
A. Process Identification Numbers:
1. West TWAS Valve: 104-V-1.
2. East TWAS Valve: 104-V-2.
3. West TPSL Valve: 105-V-1.
4. East TPSL Valve: 105-V-1.
B. Plug Valves (Flanged -End Connection) V902: As shown in the Contract
Drawings and as specified under Section 15110, Manual, Check, and Process
Valves.
2.03 ELECTRIC MOTOR ACTUATORS
A. Number of Electric Actuators: Four.
B. The actuators shall be electric motor gear train type consisting of motor controls,
gearbox, geared limit switches, torque switches, and manual override handwheel
with declutching lever and worm -gear actuator suitable for multi -turn valve
operation. The actuators shall be capable of producing no less than 1-1/2 times the
required minimum operating torque. The actuators shall be of the self-locking
type and shall operate the valve from fully opened to fully closed positions, or the
reverse, in approximately 40 seconds.
03720-048-01
August 2019
15120-4 POWER -OPERATED
VALVE ASSEMBLIES
C. The electric motor actuators shall be sized for the following process conditions:
Valve Location/Designation
Valve Size
Duty Function
West TWAS Valve (104-V-1)
6"
Open/Close
East TWAS Valve (104-V-2)
6"
Open/Close
West TPSL Valve (105-V-1)
6"
Open/Close
East TPSL Valve (105-V-2)
6"
Open/Close
D. The actuators shall comply with AWWA C540, except as modified herein. Output
capacity of motors shall be sufficient to open or close the valve against the
maximum differential pressure when the voltage is 10% above or below normal at
the specified service conditions. Motors shall have Class F or H insulation system.
Provide motor with torque output (at duty rating) that exceeds the requirements of
the following paragraphs including the safety factor.
E. Design the actuator to move valves from fully closed to fully open in the time
specified in the subsection on "Service Conditions."
F. Provide the following integral to the actuator: reversing, magnetic starter, three
overloads (one in each ungrounded leg) or two motor thermal cutouts, 120 -volt
control power transformer, LOCAL/STOP/REMOTE selector switch
(maintained), OPEN -STOP -CLOSE selector switch (spring return to center), and
OPEN/CLOSED status indicator lights.
G. Provide dry contact for remote indication of the actuator status and alarm
conditions as follows:
1. Mode of operation (LOCAL/REMOTE).
2. Actuator FAIL.
3. Valve FAIL.
4. OPEN/CLOSE Status.
H. The actuator shall operate (i.e., move full open or full closed) upon receipt of a
remote contact. The actuator operation shall be mutually exclusive (i.e., operate
only upon receipt of a remote OPEN or remote CLOSED command).
I. The actuator shall include provisions for Emergency Shutdown (ESD) operation,
initiated by a remote contact. ESD operation shall either maintain the existing
valve position or position the valve either full OPEN or full CLOSED, as
preconfigured. This command shall override any command, local or remote.
03720-048-01
August 2019
15120-5 POWER -OPERATED
VALVE ASSEMBLIES
1
1
1
1
1
1
1
1
1
1
1
1
1
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1
J. Establish an Actuator FAIL alarm whenever any of the following conditions are
active, as a minimum:
1. Battery LOW.
2. Loss of Power.
3. HIGH Motor Temp.
K. Establish a Valve FAIL Alarm whenever any of the following conditions are
active, as a minimum:
1. Valve Jammed (High torque on stops).
2. Valve Stalled (High torque off stops).
L. Provide a separate (remote) enclosure with local/remote selector switch, stop -
open -close push buttons, and open and closed indicator lights for motor actuators
over 6 feet 6 inches above the floor or deck in lieu of integral controls.
M. Do not use external conduit for wiring any components within the actuator.
N. Gear actuators shall be totally enclosed and factory -grease packed or oil
lubricated. The power gearing shall consist of helical gears of heat-treated steel.
Worm gears shall be alloy bronze accurately cut with a hobbing machine. Worm
shall be hardened steel alloy. Design gears for 24-hour continuous service with an
AGMA rating of 1.50.
O. Position switches shall be integrally geared to the actuator and shall be adjustable
and capable of actuation at any point between fully opened and fully closed
positions. The position switches shall operate while the actuator is either in
manual or in motor operation. Provide motor actuators with position switches
capable of being separately used to provide remote indication of end of travel in
each direction and to stop motion at the end of travel in each direction.
P. Provide two individually adjustable torque switches to protect the valve and
motor against overload in the opening and closing directions. To prevent
hammering, the torque switch shall not reclose until the valve is made to travel in
the opposite direction.
Q.
Provide a manually operated handwheel that shall not rotate during electrical
operation. If electrical power is interrupted, handwheel operation shall be
activated by a hand lever attached to the mechanism. While the valve is operated
manually, the motor shall not rotate. After electrical power is restored, the
handwheel shall automatically disengage. Design the handwheel diameter so that
hand operation will not damage the valve.
03720-048-01 15120-6 POWER -OPERATED
August 2019 VALVE ASSEMBLIES
R. The position switch and torque switch contacts shall be capable of interrupting at
least 0.2 -ampere inductive load at 125 -volt d -c or 6 -ampere inductive load at
120 -volt a -c.
S. Provide a lost -motion device for open/close operation to permit the motor to reach
full speed before the load is applied. Provide lost -motion action for manual
operation also. Do not provide lost -motion device for modulating applications.
T. Motor shall de -energize if a stall occurs when attempting to unseat a jammed
valve.
U. Provide a time delay to prevent instant reversal of the actuator motor.
V. Provide terminal connections for external remote controls fed from an internal
24 -volt or 120 -volt supply.
W. Provide a main disconnect NEMA 4X SS rated 15 -ampere 3 -pole, 480 -volt non-
fused to be mounted on the valve assembly.
X. Acceptable Electric Motor Actuator Manufacturer
1. FlowServe Limitorque L120 Series.
2. Rotork Controls IQ Series (Open/Close).
3. Or approved equal.
PART 3 EXECUTION
3.01 STORAGE AND/OR INCOMPLETE INSTALLATION BEFORE START-UP
A. Power -operated valve assemblies delivered to the site, stored, and/or installed
outside exposed to the weather or temperatures below 40 degrees F before
permanent installation and start-up, shall be protected according to the actuator
manufacturer's recommended procedures for exposure and extended storage.
3.02 FACTORY ASSEMBLY
A. Factory mount the electric motor actuator and controls on worm -gear valve
operator extension bonnet with extension stem to valve and furnish and transport
the completely assembled power -operated valve assembly to the site.
3.03 FACTORY ADJUSTMENTS AND TESTS
A. The valve manufacturer shall mount and adjust the electric motor actuator and
accessories on each valve and operate each power -operated valve assembly before
03720-048-01 15120-7 POWER -OPERATED
August 2019 VALVE ASSEMBLIES
shipment. Adjust limit switch position and torque switches. Measure and record
motor current at maximum torque tripping point and actuator output speed.
3.04 PAINTING AND COATING
A. Finish coat the power -operated valve assembly the same color as piping.
3.05 FIELD INSTALLATION
A. Install the power operated valve assemblies in accordance with the manufacturer's
instructions. Keep assemblies dry, closed, and sealed to prevent internal moisture
damage during construction. Power -operated valve assemblies shall not be stored
or placed in direct contact with the ground before installation. Provide additional
hangers and supports for assemblies to prevent eccentric loads bearing on the
valve and adjacent piping system.
3.06 FIELD TESTING
A. Test shall simulate a typical valve load. Test motor actuators and record the
following:
1. Current at maximum torque setting.
2. Torque at maximum torque setting.
3. Flash test voltage.
4. Actuator output speed and open to closed, and closed to open operating
times.
B. Test motor actuators as installed by measuring the current drawn (in amperes) by
each motor for unseating, seating, and running conditions. The measured current
shall not exceed the current measurement recorded during the factory
performance test.
C. If the measured current drawn exceeds the factory performance test value, provide
a larger motor or gear drive or adjust the actuator so that the measured amperage
does not exceed the factory value.
D. Ensure that limit switches are placed at their correct settings. Open and close
valves twice and ensure that limit switches are functioning properly.
E. Provide a performance test certificate with results of the tests stated above. In
addition, include details of this specification including gear ratios for both manual
and automatic drive, closing direction, wiring diagram code number, and all other
field test measurements.
03720-048-01 15120-8 POWER -OPERATED
August 2019 VALVE ASSEMBLIES
3.07 FIELD SERVICE
A. The Contractor shall provide the services of the power -operated valve assembly
manufacturer's representatives for the power -operated valve assemblies specified
herein.
B. The representative shall be present at the project site for the following listed
services in the fomu of two trips to the site for an 8 -hour -day of service per trip:
1. Inspection of the installation of the assemblies, functional testing, and
certification that the assemblies have been installed and tested in
accordance with the manufacturer's recommendations and this Section.
Manufacturer's certification of proper installation shall be received and
acknowledged by the Engineer before the plant startup.
2. Plant Startup and Training of the Owner in the operation and maintenance
of the equipment.
3.08 CERTIFICATION
A. Provide written certification from the power -operated valve assembly supplier
that the assemblies have been properly installed and factory and field tested
according to the Contract Documents and manufacturer's recommendations and
that the equipment is operating normally. Make all necessary corrections and
adjustments including but not limited to parts, labor, or freight at no additional
cost to the Owner.
END OF SECTION
03720-048-01 15120-9 POWER -OPERATED
August 2019 VALVE ASSEMBLIES
SECTION 15121
MISCELLANEOUS PIPE FITTINGS AND ACCESSORIES
PART 1 GENERAL
1.01 SCOPE OF WORK
A. This Section describes requirements for materials and installation of
miscellaneous piping specialties, such as quick -connect couplings.
1.02 RELATED WORK (NOT USED)
A. Section 01330, Submittals and Acceptance.
B. Section 01650, Delivery, Storage, and Handling.
C. Section 01780, Warranties and Bonds.
D. Section 01830, Operations and Maintenance Manuals.
1.03 SUBMITTALS
The Contractor shall submit shop drawings in accordance with Section 01330, Submittals and
Acceptance:
A. Submit manufacturer's catalog data and descriptive literature showing dimensions
and materials of construction by ASTM reference and grade. Show coatings.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be the latest
revision of any such document in effect at the bid time. The following documents are a part of
this Section. Where this Section differs from these documents, the requirements of this Section
shall apply.
A. American Society for Testing and Materials (ASTM)
1. ASTM A36/A36M—Standard Specification for Carbon Structural Steel.
2. ASTM A240/A240M—Standard Specification for Chromium and
Chromium -Nickel Stainless Steel Plate, Sheet, and Strip for Pressure
Vessels and for General Applications.
3. ASTM A513/A513M—Standard Specification for Electric -Resistance -
Welded Carbon and Alloy Steel Mechanical Tubing.
4. ASTM A536—Standard Specification for Ductile Iron Castings.
03720-048-01 15121-1 MISCELLANEOUS PIPE FITTINGS
August 2019 AND ACCESSORIES
5. ASTM A635/A635M—Standard Specification for Steel, Sheet and Strip,
Heavy -Thickness Coils, Hot -Rolled, Alloy, Carbon, Structural, High -
Strength Low -Alloy, and High -Strength Low -Alloy with Improved
Formability, General Requirements for.
6. ASTM C219—Standard Terminology Relating to Hydraulic Cement.
7. ASTM D2000—Standard Classification System for Rubber Products in
Automotive Applications.
B. American Society of Mechanical Engineers (ASME)
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 SA36—Carbon Steel Shapes, Plates, and Bars of Structural
Quality for Use in Riveted, Bolted, or Welded Construction.
4. ASME SA675—Carbon Steel Middle Ring or Sleeve.
C. American Water Works Association (AWWA)
1. AWWA C111/A21.22—Rubber-Gasket Joints for Ductile -Iron Pressure
Pipe and Fittings.
2. AWWA C213—Fusion-Bonded Epoxy Coatings and Linings for Steel
Water Pipe and Fittings.
3. AWWA C219—Bolted Sleeve -Type Couplings for Plain -End Pipe.
D. American Iron and Steel Institute (AISI)
1. AISI C1012—Hard-Drawn Low -Carbon Steel.
1.06 QUALITY ASSURANCE (NOT USED)
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
1.09 QUALIFICATIONS (NOT USED)
03720-048-01 15121-2 MISCELLANEOUS PIPE FITTINGS
August 2019 AND ACCESSORIES
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 MAINTENANCE (NOT USED)
1.12 OPERATIONS AND MAINTENANCE (O&M) MANUALS
O&M Manuals shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01830, Operations and Maintenance Manuals.
PART 2 PRODUCTS
2.01 METALLIC QUICK -CONNECT COUPLINGS
A. Type 6: Quick -connect couplers shall be female-coupler/female-thread type with
locking handles. Provide dust plug and security chain with each coupler. Bodies
and locking handles shall be Type 316 stainless steel. The gasket shall be Teflon.
Couplers shall be CIVACON Kamlok 633 -D/634 -A, Evertite, or equal.
B. Type 8: Quick -connect couplers shall be male-adapter/150 lb ASME Flange type.
Provide dust cap and security chain with each coupler. Bodies and locking
handles shall be Type 316 stainless steel. The gasket shall be Teflon. Adapters
shall be CIVACON Kamlock 733 LDS/634-B, Evertite, or equal.
C. Type 10: Quick -connect couplers shall be male-adapter/hose-shank type. Provide
dust cap with each coupler. Bodies and dust caps shall be Type 316 stainless steel.
The gasket shall be Teflon. Adapters shall be CIVACON Kamlok 633 -E/634 -B,
Evertite, or equal.
PART 3 EXECUTION
3.01 INSTALLING QUICK -CONNECT COUPLINGS
A. Attach to piping in accordance with the relevant piping specification.
3.02 INSTALLING COUPLINGS
A. Pipe for use with flexible couplings shall have plain ends as specified in the
respective pipe sections in Division 15, Mechanical.
B. Alloy steel bolts and nut for flanged joints shall be made with high-strength, low -
alloy Cor -Ten bolts, nuts, and washers. Cor -Ten for mechanical joints shall be
made with mild corrosion resistant alloy steel bolts and nuts. All exposed bolts
03720-048-01
August 2019
15121-3 MISCELLANEOUS PIPE FITTINGS
AND ACCESSORIES
shall be painted the same color as the pipe. All joints to be wrapped with 8 -mil
color -coded poly wrap.
C. Before sleeve -type couplings are installed, the pipe ends shall be cleaned
thoroughly for a distance of 8 inches. Soapy water may be used as a gasket
lubricant. A follower and gasket, in that order, shall be slipped over each pipe to a
distance of about 6 inches from the end, and the middle ring shall be placed on the
substantial completion date unless otherwise requested by the Owner.
D. Mechanical joints shall be made in the standard manner. Valve stems shall be
vertical in all cases. Set cast-iron box as shown on the Drawings. Boxes shall have
sufficient bracing to maintain alignment during backfilling. Knobs on cover shall
be parallel to pipe. Remove any sand or undesirable fill from valve box after
installation. Extend tracing wire outside of valve box extension pipe and enter at
valve box.
E. Thoroughly clean oil, scale, rust, and dirt from the pipe to provide a clean seat for
the gasket.
F. Wipe gaskets clean before installations.
G. Lubricate flexible couplings and flanged coupling adapter gaskets with soapy
water or manufacturer's standard lubricant before installing on the pipe ends.
H. Install couplings, service saddles, and anchor studs in accordance with the
manufacturer's instruction.
I. Tighten bolts progressively, drawing up bolts on opposite sides a little at a time
until all bolts have a uniform tightness.
J. Use torque -limiting wrenches to tighten bolts to the manufacturer's specified
torque values.
END OF SECTION
03720-048-01 15121-4 MISCELLANEOUS PIPE FITTINGS
August 2019 AND ACCESSORIES
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SECTION 15122
FLEXIBLE PIPE COUPLINGS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. This Section presents requirements for materials and installation of flexible pipe
couplings.
1.02 RELATED WORK
A. Section 01330, Submittals and Acceptance.
B. Section 01650, Delivery, Storage, and Handling.
C. Section 01780, Warranties and Bonds.
D. Section 01830, Operations and Maintenance Manuals.
E. Section 09900, Painting and Coating.
F. Section 15144, Pressure Testing of Piping.
1.03 SUBMITTALS
The Contractor shall submit shop drawings in accordance with Section 01330, Submittals and
Acceptance:
A. The manufacturer's catalog data on flexible pipe couplings. Show the
manufacturer's model or figure number for each type of coupling or joint for each
type of pipe material for which couplings and joints are used. Show coatings.
B. The manufacturer's recommended torques to which the coupling bolts shall be
tightened for the flexible sleeve -type pipe couplings.
C. Materials of construction by ASTM reference and grade. Show dimensions.
D. The number, size, and material of construction of tie rods and lugs for each thrust
harness on the project.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be the latest
revision of any such document in effect at the bid time. The following documents are a part of
03720-048-01 15122-1 FLEXIBLE PIPE COUPLINGS
August 2019
this Section. Where this Section differs from these documents, the requirements of this Section
shall apply.
A. American Society for Testing and Materials (ASTM)
1. ASTM A240/A240M—Standard Specification for Chromium and
Chromium -Nickel Stainless Steel Plate, Sheet, and Strip for Pressure
Vessels and for General Applications.
2. ASTM D2000—Standard Classification System for Rubber Products in
Automotive Applications.
B. American Water Works Association (AWWA)
1. AWWA C219 Bolted Sleeve -Type Couplings for Plain -End Pipe.
C. NSF International (NSF)
1. NSF 61—Drinking Water Systems Components – Health Effects.
1.06 QUALITY ASSURANCE (NOT USED)
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
1.09 QUALIFICATIONS (NOT USED)
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 MAINTENANCE (NOT USED)
1.12 OPERATIONS AND MAINTENANCE (O&M) MANUALS
A. O&M Manuals shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01830, Operations and Maintenance Manuals.
03720-048-01
August 2019
15122-2 FLEXIBLE PIPE COUPLINGS
PART 2 PRODUCTS
2.01 GENERAL
A. Each flexible coupling shall be designed for the type, size, and pressure rating of
the connecting piping.
B. All wetted materials shall be suitable for use with the fluid being conveyed.
C. Wetted materials for flexible coupling used to convey drinking water shall be
resistant to free chlorine and chloramine concentrations up to 10 mg/L.
D. All flexible couplings used in association with drinking water service shall be
certified as suitable for contact with drinking water by an accredited certification
organization in accordance with NSF 61.
2.02 BOLTED -SLEEVE -TYPE COUPLINGS (TYPE C105)
A. Bolted -sleeve -type couplings shall be designed and manufactured conforming to
AWWA C219.
B. Type C105: Flanged Coupling Adapter:
1. Adapters for ductile iron pipe 12 inches and smaller shall be ductile iron:
Dresser Style 127, Smith -Blair Series 912, or equal.
2. Adapters for ductile -iron pipe larger than 12 inches and steel pipe shall be
steel: Dresser Style 128, Smith -Blair Type 913, or equal.
3. Flange ends shall match the flange of the connecting pipe.
2.06 BOLTING FOR FLEXIBLE PIPE COUPLINGS
A. Bolts and nuts for flexible pipe couplings shall be as specified for the adjacent
piping.
PART 3 EXECUTION
3.01 INSTALLING FLEXIBLE PIPE COUPLINGS
A. Clean oil, scale, rust, and dirt from pipe ends. Clean gaskets in flexible pipe
couplings before installation.
B. Lubricate bolt threads with graphite and oil before installation.
03720-048-01 15122-3 FLEXIBLE PIPE COUPLINGS
August 2019
C. Install threaded nut and bolt thread protection caps after completing the bolt, nut,
and gasket installation.
3.02 PAINTING AND COATING
A. Exterior Coating of Buried Flexible Pipe Couplings: Coat buried flexible pipe
couplings (including joint harness assemblies) as specified in Section 09900,
Painting and Coating, System No. 21. Coat buried bolt threads, tie bolt threads,
and nuts according to Section 09900, Painting and Coating, System No. 24.
B. Exterior Coating of Exposed Flexible Pipe Coupling (Non -Submerged): Coat
flexible pipe couplings (including joint harness assemblies) located indoors, in
vaults and structures, and above ground with the same coating system as specified
for the adjacent pipe. If the adjacent pipe is not coated, coat couplings according
to Section 09900, Painting and Coating, System No. 10. Apply prime coat at the
factory.
C. Exterior Coating of Exposed Flexible Pipe Coupling (Submerged): Coat flexible
pipe couplings (including joint harness assemblies) that will be submerged
according to Section 09900, Painting and Coating. Apply prime coat at the
factory.
D. Line carbon steel and iron -flexible pipe couplings according to Section 09900,
Painting and Coating.
3.03 HYDROSTATIC TESTING
A. Hydrostatically test flexible pipe couplings in place with the pipe being tested.
Test in accordance with Section 15144, Pressure Testing of Piping.
END OF SECTION
03720-048-01 15122-4 FLEXIBLE PIPE COUPLINGS
August 2019
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SECTION 15125
PIPING APPURTENANCES
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish all labor, materials, equipment, and incidentals
required and install complete and ready for operation all piping appurtenances as
shown on the Contract Drawings and as specified in this Section.
B. All piping appurtenances shall be of the size shown on the Contract Drawings. All
equipment of the same type shall be from one manufacturer, unless authorized in
writing by the Engineer.
C. All piping appurtenances shall have the name of the manufacturer and the
working pressure for which they are designed cast in raised letters upon the body.
D. The piping appurtenances shall include, but not be limited to, the following:
1. Pressure Gauge Assembly.
2. Annular Diaphragm Seal and Pressure Gauge Assembly.
1.02 RELATED WORK
A. Section 01330, Submittals and Acceptance.
B. Section 01650, Delivery, Storage, and Handling.
C. Section 01780, Warranties and Bonds.
D. Section 01830, Operations and Maintenance Manuals.
E. Section 09900, Painting and Coating.
F. Section 15055, Piping Systems—General.
1.03 SUBMITTALS
The Contractor shall submit shop drawings in accordance with Section 01330, Submittals and
Acceptance:
A. Product technical submittal data shall contain the following information and data:
1. Acknowledgment that products submitted meet requirements of standards
referenced.
2. Manufacturer's installation instructions.
03720-048-01 15125-1 PIPING APPURTENANCES
August 2019
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be the latest
revision of any such document in effect at the bid time. The following documents are a part of
this Section. Where this Section differs from these documents, the requirements of this Section
shall apply.
A. American Iron and Steel Institute (AISI)
1. AISI T
2. AISI T
e 304L—Stainless Steel.
e 316—Stainless Steel, Annealed Sheet.
B. American Society for Testing and Materials (ASTM)
1. ASTM A536—Standard Specification for Ductile Iron Castings.
2. ASTM C285—Standard Test Methods for Sieve Analysis of Wet -Milled
and Dry -Milled Porcelain Enamel.
C. American Society of Mechanical Engineers (ASME)
1. ASME B16.5—Pipe Flanges and Flanged Fittings NPS 1/2 through
NPS 24 Metric/Inch Standard.
D. American Water Works Association (AWWA)
1. AWWA C105/A21.5—Polyethylene Encasement for Ductile -Iron Pipe
Systems.
2. AWWA C207—Steel Pipe Flanges for Waterworks Service, Sizes 4 -Inch
through 144 -Inch (100 mm through 3,600 mm).
3. AWWA C210—Liquid-Epoxy Coatings and Linings for Steel Water Pipe
and Fittings.
4. AWWA C213—Fusion-Bonded Epoxy Coatings and Linings for Steel
Water Pipe and Fittings.
E. National Sanitation Foundation (NSF)
1. NSF 61—Drinking Water System Components – Health Effects.
1.06 QUALITY ASSURANCE (NOT USED)
03720-048-01
August 2019
15125-2 PIPING APPURTENANCES
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1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, HANDLING, AND STORAGE
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
B. All piping appurtenances, unless otherwise directed, shall be loaded and unloaded
by lifting, and under no circumstances shall any piping appurtenances be dropped,
skidded, or rolled.
C. Slings, hooks, or tongs used for lifting shall be padded to prevent damage to
exterior surface or interior linings of piping appurtenances. If any part of the
coating, lining, or components is damaged, the Contractor shall make repairs or
replacement at his expense and in a manner satisfactory to the Engineer before
attempting to install such piping appurtenances.
D. Only new piping appurtenances will be allowed for installation and shall be stored
to prevent damage and be kept free of dirt, mud, or other debris.
1.09 QUALIFICATIONS
A. All the piping appurtenances shall be products of well-established firms that are
fully experienced, reputable, have been selling this product for a minimum of 10
years, and qualified in the manufacture of the particular product furnished. The
piping appurtenances shall be designed, constructed, and installed in accordance
with the requirements and procedures of applicable AWWA standards and shall
comply with these Specifications as applicable.
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 MAINTENANCE (NOT USED)
1.12 OPERATIONS AND MAINTENANCE (O&M) MANUALS
A. O&M Manuals shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01830, Operations and Maintenance Manuals.
03720-048-01 15125-3 PIPING APPURTENANCES
August 2019
1
PART 2 PRODUCTS 1
2.01 PRESSURE -GAUGE ASSEMBLY
A. Pressure -gauge assemblies shall be provided at locations listed below or as shown
on the Contract Drawings. All pressure -gauge assemblies shall include a pressure
gauge, AISI Type 316 stainless steel, NPT threaded ball valves for isolation and
venting, and sensor piping. Sensor piping tubing and fittings shall be Type 316
stainless steel. The pressure gauge shall be constructed of Type 316 stainless-steel
wetted parts and Type 304 stainless-steel case and bayonet ring, adjustable
pointer, laminated safety -glass window, glycerin liquid -filled case, 1.5% span
accuracy, and shall have a 2.5 -inch -diameter dial size, minimum. The pressure
gauge shall be as manufactured by Onyx Valve, WIKA Instrument Corporation,
Type LM 233.54, or approved equal.
B. The Contractor shall furnish and install pressure -gauge assemblies with pressure -
gauge ranges as follows and/or shown on the Contract Drawings.
2.02 ANNULAR DIAPHRAGM SEAL AND PRESSURE GAUGE ASSEMBLY
A. Annular diaphragm seal and pressure gauge assemblies shall be provided at
locations listed in this Section, Section 11356, Progressive Cavity Pumps, or as
shown on the Contract Drawings. All annular diaphragm -seal pressure gauge
assemblies shall include an ethylene -glycol factory liquid -filled pressure -gauge
and an annular seal assembly factory calibrated and ready for field installation.
The annular seal assembly shall consist of a Buna-N diaphragm annual seal
sleeve, carbon steel body, and ASME B16.5 Class 150 full-faced flanges (through
bolted configuration). Pressure gauges shall be constructed with a stainless steel
case with pressure ranges listed below. Annular diaphragm seal and pressure -
gauge assemblies shall be as manufactured by the Red Valve Company,
Incorporated, Series 48, Onyx Valve, or approved equal.
B. The Contractor shall furnish and install annular seal and pressure -gauge
assemblies with pressure gauge ranges as follows and/or shown on the Drawings:
Location
Number of Assemblies Pressure Gauge Range (psi)
Truck -off Loading 4 30
Pumping Station
Digester Feed 4 30
Pumping Station
03720-048-01 15125-4 PIPING APPURTENANCES
August 2019
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Location
Number of Assemblies Pressure Gauge Range (psi)
Dewatering Feed 8 60
Pumping Station
Blended Sludge 2 10
Grinder Station
Combined Thickened
Grinder Station
2.03 TOOLS
2 10
A. If required for normal operation and maintenance, special tools shall be supplied
with the' equipment.
PART 3 EXECUTION
3.01 INSTALLATION
A. The Contractor shall install all piping appurtenances as shown on the Contract
Drawings.
B. All piping appurtenances shall be installed in the location shown, unless approved
otherwise, true to alignment and rigidly supported. Any damage to the above
items shall be repaired to the satisfaction of the Owner and the Engineer.
C. Install concrete inserts for hangers and supports as soon as forms are erected and
before concrete is poured. Before setting these items, the Contractor shall check
all plans and figures which have a direct bearing on their location and shall be
responsible for the proper location of these piping appurtenances during the
construction of the structures.
3.02 SHOP PAINTING
A. Exterior surfaces of ferrous valves and piping appurtenances shall be painted in
accordance with Section 09900, Painting and Coating, unless noted or specified
otherwise.
3.03 INSPECTION AND TESTING
A. Completed valves and piping appurtenances shall be subjected to hydrostatic
pressure test as described in Section 15055, Piping Systems—General, and the
detail pipe sections of these Specifications. All leaks in valves and piping
03720-048-01 15125-5 PIPING APPURTENANCES
August 2019
03720-048-01
August 2019
appurtenances shall be repaired and lines retested as approved by the Engineer.
Before testing, the valves and pipelines shall be supported and thrust restrained
for forces exceeding the test pressure to prevent movement during tests.
END OF SECTION
15125-6 PIPING APPURTENANCES
SECTION 15144
PRESSURE TESTING OF PIPING
PART 1 GENERAL
1.01 SCOPE OF WORK
A. This Section specifies the hydrostatic, pneumatic, and leakage testing of pressure
piping for pumping stations, wastewater treatment plants, force mains and lift
stations.
1.02 RELATED WORK
A. Section 01330, Submittals and Acceptance.
B. Section 01500, Temporary Facilities and Controls.
1.03 SUBMITTALS
The Contractor shall submit shop drawings in accordance with Section 01330, Submittals and
Acceptance:
A. Test bulkhead locations and design calculations, pipe attachment details, and
methods to prevent excessive pipe wall stresses.
B. One electronic PDF and three hard copies of the test records to the Engineer upon
completion of the testing.
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be the latest
revision of any such document in effect at the bid time. The following documents are a part of
this Section. Where this Section differs from these documents, the requirements of this Section
shall apply.
A. American Water Works Association (AWWA)
1. AWWA C600—Installation of Ductile -Iron Mains and Their
Appurtenances.
2. AWWA C605—Underground Installation of Polyvinyl Chloride (PVC)
and Molecularly Oriented Polyvinyl Chloride (PVCO) Pressure Pipe and
Fittings.
03720-048-01 15144-1 PRESSURE TESTING OF PIPING
August 2019
1.06 QUALITY ASSURANCE (NOT USED)
1.07 WARRANTIES (NOT USED)
1.08 DELIVERY, STORAGE, AND HANDLING (NOT USED)
1.09 QUALIFICATIONS (NOT USED)
1.10 TEST PRESSURES
A. Test pressures for the various services and types of piping are shown in the Piping
Schedule in the Drawings. The Engineer shall provide any pressure requirements
that are not included in the Piping Schedule.
1.11 TESTING RECORDS
A. The Contractor shall provide records of each piping installation during the testing.
These records shall include the following information:
1. Date and times of test.
2. Identification of process, pipeline, or pipeline section tested or retested.
3. Identification of pipeline material.
4. Identification of pipe specification.
5. Test fluid.
6. Test duration.
B. Test pressure at low point in process, pipeline, or pipeline section.
C. Remarks: Leaks identified (type and location), types of repairs, or corrections
made.
D. Certification by Contractor that the leakage rate measured conformed to the
Specifications.
1.12 MAINTENANCE (NOT USED)
1.13 OPERATIONS AND MAINTENANCE (O&M) MANUALS (NOT USED)
03720-048-01
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15144-2 PRESSURE TESTING OF PIPING
PART 2 PRODUCTS
2.01 VENTS AND DRAINS FOR ABOVEGROUND PIPING
A. The Contractor shall install vents on the high points of aboveground piping,
whether shown in the Contract Drawings or not. Install drains on low points of
aboveground piping, whether shown in the Contract Drawings or not. Provide a
valve at each vent or drain point. Valves shall be 3/4 inch for piping 3 inches and
larger and 1/2 inch for piping smaller than 3 inches. Valves shall be ball or gate
valves unless otherwise shown on the Contract Drawings. Valves shall be rated
for the pressure of the adjacent piping and shall be suitable for use with the
adjacent pipe material.
2.02 MANUAL AIR -RELEASE VALVES FOR BURIED PIPING
A. The Contractor shall provide temporary manual air -release valves at test
bulkheads for pipeline test. Construct the pipe outlet in the same manner as for a
permanent air valve and, after use, seal with a blind flange, pipe cap, or plug and
coat the same as the adjacent pipe.
2.03 TEST BULKHEADS
A. The Contractor shall design and fabricate test bulkheads in accordance with
Section VIII of the ASME Boiler and Pressure Vessel Code. Materials shall
comply with Part UCS of the code. Design pressure shall be at least 2.0 times the
specified test pressure for the section of pipe containing the bulkhead. Limit
stresses to 70% of yield strength of the bulkhead material at the bulkhead design
pressure. Include air -release and water drainage connections.
2.04 TESTING FLUID
A. The Owner will provide a source of supply from the existing treated water
distribution system for the Contractor's use in filling the lines. An air break shall
be maintained at all times between the Owner's distribution system and the
Contractor's equipment to prevent cross -connection. The line shall be slowly
filled with water and the specified test pressure shall be maintained in the pipe for
the entire test period by means of a pump furnished by the Contractor. Provide
accurate means for measuring the quantity of water required to maintain this
pressure. The amount of water required is a measure of the leakage.
B. Testing fluid shall be potable water unless a pneumatic test is indicated on the
Piping Schedule.
03720-048-01 15144-3 PRESSURE TESTING OF PIPING
August 2019
C. For potable water pipelines, obtain and use only potable water for hydrostatic
testing.
D. Submit request for use of water from waterlines of Owner 48 hours in advance.
E. The Contractor shall provide back flow prevention control for temporary
connections to existing water mains.
2.05 TESTING EQUIPMENT
A. The Contractor shall provide calibrated pressure gauges for the range of pressures
to be tested, pipes, bulkheads, pumps, compressors, chart recorder, and meters to
perform the hydrostatic testing. The Contractor shall provide any necessary
assistance required for testing.
PART 3 EXECUTION
3.01 TESTING PREPARATION
A. Pipes shall be in place, backfilled, and anchored before beginning pressure
testing.
B. The Contractor shall conduct pressure tests on exposed and aboveground piping
after the piping has been installed and attached to the pipe supports, hangers,
anchors, expansion joints, valves, and meters.
C. For buried piping, the pipe may be partially backfilled and the joints left exposed
for inspection during an initial leakage test. However, perform the final pressure
test after completely backfilling and compacting the trench.
D. Provide any temporary piping needed to carry the test fluid to the piping that is to
be tested. After the test has been completed and demonstrated to comply with the
Specifications, disconnect and remove temporary piping. Do not remove exposed
vent and drain valves at the high and low points in the tested piping; remove any
temporary buried valves and cap the associated outlets. Plug taps or connections
to the existing piping from which the test fluid was obtained.
E. Provide temporary drain lines needed to carry testing fluid away from the pipe
being tested. Remove such temporary drain lines after completing the pressure
testing.
03720-048-01 15144-4 PRESSURE TESTING OF PIPING
August 2019
F. Before starting the test, the Contractor shall notify the Engineer and the Owner's
Representative.
3.02 CLEANING
A. Before conducting hydrostatic tests, the Contractor shall flush pipes with water to
remove dirt and debris. For pneumatic tests, blow air through the pipes. Maintain
a flushing velocity of at least 3 fps for water testing and at least 2,000 fpm for
pneumatic testing. Flush pipes for the period given by the formula
T
2L
3
in which:
T = flushing time (seconds).
L = pipe length (feet).
B. For pipelines 24 inches or larger in diameter, acceptable alternatives to flushing
are use of high-pressure water jet, sweeping, or scrubbing. Water, sediment, dirt,
and foreign material accumulated during this cleaning operation shall be
discharged, vacuumed, or otherwise removed from the pipe.
3.03 LENGTH OF TEST SECTION FOR BURIED PIPING
A. The maximum length of test section for buried pipe of 12 inches or smaller in
diameter is 3,500 feet; for buried pipe larger than 12 inches, 1 mile. Provide
intermediate test bulkheads where the pipeline length exceeds these limits.
3.04 INITIAL PIPELINE FILLING FOR HYDROSTATIC TESTING
A. The maximum rate of filling shall not cause the water velocity in the pipeline to
exceed 1 fps. Filling may be facilitated by removing automatic air valves and
releasing air manually.
3.05 TESTING NEW PIPE WHICH CONNECTS TO EXISTING PIPE
A. Before testing new pipelines that are to be connected to existing pipelines, the
Contractor shall isolate the new line from the existing line by test bulkheads,
spectacle flanges, or blind flanges. After the new line has been successfully
tested, remove test bulkheads or flanges and connect to the existing piping.
03720-048-01 15144-5 PRESSURE TESTING OF PIPING
August 2019
3.06 HYDROSTATIC TESTING OF ABOVEGROUND OR EXPOSED PIPING
A. Open vents at high points of the piping system to purge air while the pipe is being
filled with water. Venting during system filling may also be provided by
temporarily loosening flanges.
B. Subject the piping system to the test pressure indicated on the Piping Schedule in
the Contract Drawings. Maintain the test pressure for a minimum of 2 hours.
Examine joints, fittings, valves, and connections for leaks. The piping system
shall show zero leakage or weeping. Correct leaks and retest until zero leakage is
obtained.
3.07 HYDROSTATIC TESTING OF BURIED PIPING
A. Where any section of the piping contains concrete thrust blocks or encasement,
the Contractor shall not make the pressure test until at least 10 days after the
concrete has been placed. When testing mortar -lined or PVC piping, fill the pipe
to be tested with water and allow it to soak for at least 24 hours to absorb water
before conducting the pressure test.
B. Apply and maintain the test pressure by a positive displacement hydraulic force
pump.
C. Maintain the test pressure for the 2 hours by restoring the pressure whenever it
falls 5 psi.
D. After the test pressure is reached, use a meter to measure the additional water
added to maintain the pressure. This amount of water is the loss due to leakage in
the piping system. The allowable leakage volume is defined by the formulas:
PVC Pipe:
L=
in which:
03720-048-01
August 2019
ND(P) v2
C
L = allowable leakage (gallons).
N = number of rubber-gasketed joints in the pipe tested.
D = diameter of the pipe (inches).
P = specified test pressure (psig).
C = 7,400.
15144-6 PRESSURE TESTING OF PIPING
Ductile Iron Pipe:
L
in which:
SD(P)v2
C
L = allowable leakage (gallons).
S = length of pipe tested (feet).
D = diameter of the pipe (inches).
P = specified test pressure (psig).
C = 133,200.
E. The leakage test shall be a separate test following the pressure test and shall not
be less than 2 hours long. All leaks evident at the surface shall be repaired and
leakage eliminated regardless of the total leakage as shown by test. Lines that fail
to meet tests shall be repaired and retested as necessary until test requirements are
complied with. Defective materials, pipes, valves, and accessories shall be
removed and replaced.
F. The allowable leakage for buried piping having threaded, brazed, or welded
(including solvent welded) joints shall be zero.
G. Submit plan for testing to the Engineer for review at least 10 days before starting
the test.
H. Peening shall not be used to repair pinhole leaks in welded pipes. Any leakage in
welded pipes shall be repaired by appropriate welding techniques.
I. Repair and retest any pipes showing leakage rates greater than that allowed in the
criteria above.
3.08 REPETITION OF TEST
A. If the actual leakage exceeds the allowable leakage, locate and correct the faulty
work and repeat the test. Restore the work and all damage resulting from the leak
and its repair. Eliminate visible leakage.
3.09 BULKHEAD AND TEST FACILITY REMOVAL
A. After a satisfactory test, the Contractor shall remove the testing fluid, remove test
bulkheads and other test facilities, and restore the pipe coatings/linings.
END OF SECTION
03720-048-01 15144-7 PRESSURE TESTING OF PIPING
August 2019
SECTION 15155
DUCTILE IRON PIPE AND FITTINGS
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall provide all materials and incidentals, including piping,
fittings, flanged joints, mechanical joints, retainer glands, polyethylene bagging
for buried ductile iron piping, fittings, valves, and appurtenances for the ductile
iron piping systems required for the work shown on the Contract Drawings, in the
Piping Schedule in the Contract Drawings, and described in Section 15060, Pipe
Hangers and Supports.
1.02 RELATED WORK
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
Section 01330,
Section 01650,
Section 01780,
Section 01830,
Section 02240,
Section 02305,
Section 09900,
Section 15055,
Section 15060,
Section 15075,
Section 15144,
1.03 SUBMITTALS
Submittals and Acceptance.
Delivery, Storage, and Handling.
Warranties and Bonds.
Operations and Maintenance Manuals.
Dewatering.
Earthwork for Utilities.
Painting and Coating.
Piping Systems—General.
Pipe Hangers and Supports.
Process Equipment, Piping, and Valve Identification.
Pressure Testing of Piping.
The Contractor shall submit shop drawings in accordance with Section 01330, Submittals and
Acceptance:
A. All ductile iron pipe and fittings to be installed under this Contract shall be
inspected and tested at the foundry where the material for this project is
manufactured. The Contractor shall submit sworn certificates of such tests and
their results.
B. Shop Drawings, including layout drawings, shall be submitted as specified in
Section 15055, Piping Systems—General.
C. The Contractor shall submit the pipe manufacturer's certification of compliance
with the applicable sections of the Specifications.
03720-048-01 15155-1 DUCTILE IRON PIPE AND FITTINGS
January 2021
1.04 WORK SEQUENCE (NOT USED)
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be the latest
revision of any such document in effect at the bid time. The following documents are a part of
this Section. Where this Section differs from these documents, the requirements of this Section
shall apply.
A. American Society for Testing and Materials (ASTM)
1. ASTM A193/A193M—Standard Specification for Alloy -Steel and
Stainless Steel Bolting Materials for High Temperature or High Pressure
Service and Other Special Purpose Applications.
2. ASTM A194/A194M—Standard Specification for Carbon Steel, Alloy
Steel, and Stainless Steel Nuts for Bolts for High Pressure and High
Temperature Service, or Both.
3. ASTM A307—Standard Specification for Carbon Steel Bolts, Studs, and
Threaded Rod 60,000 psi Tensile Strength.
4. ASTM A536—Standard Specification for Ductile Iron Castings.
5. ASTM A563—Standard Specification for Carbon and Alloy Steel Nuts.
6. ASTM B 117—Standard Practice for Operating Salt Spray (Fog)
Apparatus.
7. ASTM C 150/C 150M—Standard Specification for Portland Cement.
8. ASTM C283—Standard Test Methods for Resistance of Porcelain
Enameled Utensils to Boiling Acid.
9. ASTM D714—Standard Test Method for Evaluating Degree of Blistering
of Paints.
10. ASTM D792—Standard Test Methods for Density and Specific Gravity
(Relative Density) of Plastics by Displacement.
11. ASTM D1238—Standard Test Method for Melt Flow Rates of
Thermoplastics by Extrusion Plastometer.
12. ASTM E96/E96M—Standard Test Methods for Water Vapor
Transmission of Materials.
13. ASTM G95—Standard Test Method for Cathodic Disbondment Test of
Pipeline Coatings (Attached Cell Method).
B. American Society of Mechanical Engineers (ASME)
1. ASME B 1.1—Unified Inch Screw Threads (UN and UNR Thread Form).
2. ASME B16.1—Gray Iron Pipe Flanges and Flanged Fittings Classes 25,
125, and 250.
3. ASME B16.21—Nonmetallic Flat Gaskets for Pipe Flanges.
03720-048-01 15155-2 DUCTILE IRON PIPE AND FITTINGS
January 2021
1
C. American Water Works Association (AWWA) 1
1. AWWA C104/A21.4—Cement-Mortar Lining for Ductile -Iron Pipe and
Fittings.
2. AWWA C110/A21.10—Ductile-Iron and Gray -Iron Fittings.
3. AWWA C1111A21.11—Rubber-Gasket Joints for Ductile -Iron Pressure
Pipe and Fittings.
4. AWWA C115/A21.15—Flanged Ductile -Iron Pipe with Ductile -Iron or
Gray -Iron Threaded Flanges.
5. AWWA C150/A21.50—Thickness Design of Ductile -Iron Pipe.
6. AWWA C151/A21.51—Ductile-Iron Pipe, Centrifugally Cast.
7. AWWA C153/A21.53—Ductile-Iron Compact Fittings.
8. AWWA C207—Steel Pipe Flanges for Waterworks Service, Sizes 4 -Inch
through 144 -Inch (1 OOmm through 3,600mm).
1
9. AWWA C600—Installation of Ductile -Iron Mains and their
Appurtenances.
10. AWWA C651—Disinfecting Water Mains.
D. International Organization for Standardization (ISO) 1
1. ISO-9001—Quality Management Systems – Requirements.
E. NSF International (NSF) I
1. NSF 61—Drinking Water System Components – Health Effects. 1
1.06 QUALITY ASSURANCE
A. Source Quality Control:
1. The ductile iron pipe manufacturer shall submit certification that the pipe
and fitting products meet all tests required by AWWA C151/A21.51.
2. All materials shall be new and have a manufacturer's certificate verifying
I
compliance to all tests and inspections as required in this Section. The
weight, class, and casting period shall be shown on each piece of pipe. The
manufacturer's "mark," the year produced, and the word "Ductile" or the
letters "DI" shall be cast or stamped on all pipe.
1.07 WARRANTIES I
A. Warranties shall be in accordance with General Conditions, Supplementary
I
Conditions, and Section 01780, Warranties and Bonds.
1
03720-048-01 15155-3 DUCTILE IRON PIPE AND FITTINGS
I
January 2021
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
1.09 QUALIFICATIONS (NOT USED)
1.10 TESTING REQUIREMENTS
A. See Section 15144, Pressure Testing of Piping, for testing requirements.
1.11 MAINTENANCE (NOT USED)
1.12 OPERATIONS AND MAINTENANCE (O&M) MANUALS
A. O&M Manuals shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01830, Operations and Maintenance Manuals.
PART 2 PRODUCTS
2.01 GENERAL
A. All ductile iron piping shall be designed and manufactured in accordance with
AWWA C150/A21.50 and AWWA C151/A21.51 for the following minimum
operating conditions:
1. The minimum internal design pressure shall be 150 psi with a 100 -psi
surge allowance, and a safety factor of 2, for a total internal design
pressure of 500 psi.
2. The external loads design criteria shall be for the minimum cover
indicated on the Drawings at 120 lb per cubic foot soil weight and live
load based on one AASHTO H-20 truck load. The thickness design of
ductile iron pipe shall be in accordance with AWWA C150/A21.50.
3. The horizontal deflection of cement -mortar -lined ductile iron pipe
resulting from external load conditions shall not exceed 3% of the pipe
diameter based on the trench design shown on the Drawings.
03720-048-01 15155-4 DUCTILE IRON PIPE AND FITTINGS
January 2021
4. Pressure Class: All ductile iron piping shall meet the following minimum
working pressure classes:
a. Pipe 4 inches through 12 inches: 350 psi.
b. Pipe greater than 12 inches: 250 psi.
2.02 JOINTS
A. Ductile iron fittings shall be furnished with push -on joint, mechanical joints, and
flanged joints as shown on the Contract Drawings and specified in this Section:
1. Push -On Joints: Push -on joints shall conform to AWWA C111/A21.11.
Gaskets shall be EPDM or approved equal.
2. Mechanical Joints: All buried ductile iron fittings shall be furnished with
mechanical joint ends unless noted otherwise. Mechanical joints shall
conform to AWWA C111/A21.11. Glands shall be constructed of ductile
iron.
3. Flanged Joints: Pipe for threaded flange fabrication shall be Special
Thickness Class 53 in accordance with AWWA C110/A21.10,
AWWA C111/A21.11, and AWWA Cl15/A21.15. Bolt circle and bolt
holes shall match those of ASME B16.1 Class 125 flanges. The flanges
shall be rated for a maximum working pressure of 250 psi. Threaded
flanges shall be individually fitted and machine tightened on the pipe ends.
Flange facing shall be smooth or with shallow serrations in accordance
with AWWA C115/A21.15.
2.03 FITTINGS
A. General: Ductile iron pipe fittings shall be the compact type meeting the
requirements of AWWA C110/A21.10 and AWWA C153/A21.53 where
applicable. Ductile iron, cement lined and seal coated, glass lined, or ceramic
epoxy lined. Lining of fitting shall conform to in the Piping Schedule as specified
on the Contract Drawings. Fittings shall be manufactured in accordance with
AWWA C 110/A21.10. Where taps are shown on fittings, tapping bosses shall be
provided. At a minimum, fittings shall have the same pressure rating as the
connecting pipe.
1. Flanged Joint: AWWA C110/21.10 and ASME B16.1, faced and drilled
125 -pound ANSI standard.
03720-048-01 15155-5 DUCTILE IRON PIPE AND FITTINGS
January 2021
2. Mechanical Joint: AWWA C 110/A21.10
a. Provide mechanical joint fittings for all buried fittings as shown in
the Drawings, unless noted otherwise.
b. Provide specified gaskets.
2.04 LINING AND COATING
A. The Contractor shall provide lined ductile iron piping and fittings in accordance
with the Piping Schedule in the Contract Drawings. The Contractor shall perform
all field measurements confirming the accuracy of the piping sizes and lengths
shown on the Contract Drawings. The Contractor shall notify the Engineer
immediately before deviating from or altering the lining of ductile iron piping
shown on the approved layout schedule.
B. Ceramic Epoxy Lined Pipe and Fittings: The Contractor shall notify the Engineer
immediately before cutting epoxy -lined ductile iron pipe in the field. The
Contractor shall repair the cut end in accordance with the pipe manufacturer's
written procedures.
1. General: The lining shall be an amine -cured novalac epoxy containing at
least 20% by volume of ceramic quartz pigment. The lining material shall
be Protecto 401 Ceramic Epoxy as manufactured by Induron Protective
Coatings, Inc. The lining shall be applied by a competent pipe lining
specialty firm with a successful history of applying linings to the interior
of ductile iron pipe and fittings.
2. Lining Materials: Lining material shall meet the following requirements
and properties:
a. A permeability rating of 0.00 when tested according to Method A
of ASTM E96/E96M, Procedure A with a test duration of 30 days.
3. Application: The lining applicator shall apply lining according to the
requirements of the Protecto 401 Specification and application methods
and procedures.
C. Cement -Lined Ductile Iron Pipe and Fittings: Interior surfaces of all cement -lined
ductile iron pipe, fittings, and specials shall be cleaned and lined in the shop with
a standard thickness cement -mortar lining applied in conformity with
AWWA C104/A21.4. Every precaution shall be taken to prevent damage to the
lining. If lining is damaged or found faulty at delivery site, the Contractor shall
repair or replace damaged or unsatisfactory portions with lining conforming to
03720-048-01 15155-6 DUCTILE IRON PIPE AND FITTINGS
January 2021
these Specifications at no additional cost to the Owner. Pipe linings for potable
water lines shall be NSF 61 approved.
1. All ductile iron pipe and fittings cement -mortar linings shall be surface
sealed with an asphaltic seal coating, 1 mil, in accordance with
AWWA C104/A21.4.
2.05 MANUFACTURERS
A. Acceptable ductile iron pipe manufacturers include US Pipe, American Ductile
Pipe, Griffin Pipe, or approved equal.
2.06 BOLTS
A. All bolts, studs, and threaded rods used in the finished work for flanges shall be of
carbon steel and shall conform to ASTM A307 Grade B. All bolts and nuts
intended for underground service shall be corrosion -resistant Cor -Ten ASTM
A242. The ends of all bolts shall be finished to the standard radius in an
acceptable manner. All screw threads shall be "American Standard, Coarse
Thread (N.C.)." Stud bolts shall be hexagonal, cold -pressed, semi -finished and
made of medium open-hearth steel. All dimensions shall be in accordance with
"American Standard, Heavy." Nuts used shall be "Grade A Heavy Hex" in
conformance with ASTM A563 and be compatible with the bolts. Bolts and nuts
shall be cadmium- or zinc -plated at the point of manufacture with a plating
thickness of 0.0003 to 0.0005 inch. All bolts and nuts furnished shall be delivered
to the field free from grease, rust, and dirt.
2.07 GASKETS
A. Gaskets for mechanical joints shall be compatible with sewage pipe service. See
Section 15055, Piping System—General, for gasket requirements.
B. Gaskets for flanged joints shall be 1/8 -inch -thick, cloth -inserted rubber
conforming to applicable parts of ASME B16.21 and AWWA C207. Gasket
material shall be free from corrosive alkali or acid ingredients and suitable for use
in sewage and reclaimed water lines. Gaskets shall be full -face type for 125 -
pound flanges.
2.08 RETAINER GLANDS
A. Retainer glands shall be provided for all buried ductile -iron mechanical joints,
fitting, and ductile -iron pipe connections to buried valves. Retainer glands shall
be designed for joint retaining through the use of a follower gland and set screw -
anchoring devices that impart multiple wedging action against the pipe. The
03720-048-01 15155-7 DUCTILE IRON PIPE AND FITTINGS
January 2021
mechanical joint -restraint device shall be UL listed and shall have a working
pressure of at least 250 psi with a minimum safety factor of 2.
1. Gland: Manufactured of ductile iron conforming to ASTM A536. Gland
dimensions shall match AWWA C111/A21.11 and A21.53.
2. Restraining Devices: Manufactured of ductile iron heat treated to a
minimum hardness of 370 BHN. Restraining devices shall incorporate a
set screw/twist-off nut bolt to ensure the proper actuating of the restraining
device. The twist -off nut shall be designed to come off at the torque limit
desired to anchor the restraining device in place on the pipe.
3. Joint Deflection: Retainer gland joint deflection shall be limited to
manufacturer's recommended maximum deflection angle. Joint deflection
shall be applied before the set screws are torqued.
4. Acceptable Manufacturers:
a. EBAA Iron, Inc. — Megalug 1100 Series.
b. Or approved equal.
2.09 EXTERNAL PIPE RESTRAINTS
A. Ductile iron pipe push -on (bell and spigot) joint restraint shall be provided by a
restraining harness consisting of a restraint ring, connecting tie -rods, and split -
ring assembly installed at all push -on joints. The restraint ring shall consist of
wedging components made from 60-42-12 ductile iron conforming to
ASTM A536 and wedges heat treated to minimum 370 BHN. Torque limiting
twist -off nuts shall be provided on each wedge to ensure proper applied
installation torque. The split ring shall be made from 60-42-12 ductile iron
conforming to ASTM A536. The connecting rods shall be made of steel
conforming to AWWA C111/Al2.11. Sizes 4- to 16 -inch -diameter restraining
harnesses shall have 350 -psi maximum working pressure rating and 18- to 36 -
inch -diameter restraining harnesses shall have 250 -psi maximum working
pressure rating. All harnesses shall be designed with a 2 -to -1 safety factor applied
to the maximum working pressure rating.
B. Acceptable Manufacturers:
1. EBAA Iron, Inc. — Series 1700.
2. Or approved equal.
03720-048-01 15155-8 DUCTILE IRON PIPE AND FITTINGS
January 2021
2.10 INTERNAL PIPE RESTRAINT
A. Acceptable Manufacturers:
1. American Ductile Iron Pipe:
a. Fastite Joint with Fast -Grip Gasket.
b. Flex Ring® Joint.
2. US Pipe:
a. Field Lok 360® Gasket.
b. TR Flex® Restrained Joint.
3. Or Engineer -approved equal.
2.11 POLYETHYLENE BAGGING
A. Polyethylene bagging for buried ductile iron pipe, fittings, and valves shall be
8 mils thickness minimum polyethylene, manufactured in accordance with
ASTM D1238, Type I, Class C, Grade El.
2.12 COLOR CODING OR MARKING
A. Color Coding and Marking shall be in accordance with the Pipe Schedule in the
Contract Drawings and Section 15075, Process Equipment, Piping, and Valve
Identification.
PART 3 EXECUTION
3.01 HANDLING PIPE AND FITTINGS
A. Care shall be taken in loading, transporting, and unloading to prevent injury to the
pipe, fitting, lining, and coating. Pipe and fittings shall not be dropped. All pipe
and fittings shall be examined before installation, and no piece that the Engineer
finds defective shall be installed. The Contractor shall repair any damage to the
pipe and fittings coating and/or lining as directed by the Engineer. If the Engineer
determines that the coating and/or lining cannot be repaired, the Contractor shall
replace the damaged pipe and fittings at no additional compensation.
B. All pipe and fittings shall be subjected to a careful inspection immediately before
installation.
03720-048-01
January 2021
15155-9 DUCTILE IRON PIPE AND FITTINGS
1 C. If any defective pipe is discovered after it has been installed, the Contractor shall
remove and replace it with a pipe in satisfactory condition at no additional
1 expense to the Owner.
' D. Ceramic epoxy and glass -lined pipe and fittings shall be handled only from the
outside of the pipe and fittings. No forks, chains, straps, hooks, etc. shall be
placed inside the pipe and fittings for lifting, positioning, or laying.
3.02 PIPE INSTALLATION
A. The Contractor shall provide and use proper implements, tools, and facilities for
the safe and convenient performance of the work. All pipe, fittings, valves, and
appurtenances shall be lowered carefully into the trench and at above -grade
locations to prevent damage to the pipe, protective coating, lining, and
polyethylene bagging. Under no circumstances shall pipeline materials be
dropped off or dumped. A trench shall be dewatered before the pipe is installed.
B. The Contractor shall carefully examine all pipe fittings, valves, and other
' appurtenances for damage and other defects immediately before installation and
before bagging buried ductile -iron pipe. The Contractor shall mark and hold
defective materials for inspection by the Engineer, who may prescribe corrective
1 repairs or reject the materials.
C. The Contractor shall remove all lumps, blisters, and excess coating from the
socket and plain ends of push -on joint pipe for buried service. The outside of the
plain end and the inside of the bell shall be wiped clean and dry and be free from
' dirt, sand, grit, or any foreign material before the pipe is laid in trench.
D. The Contractor shall prevent foreign material from entering the pipe while the
1 pipe is being placed in the trench. During installation, no debris, tools, clothing, or
other materials shall be placed in the pipe.
' E. As each length of buried pipe is placed in the trench, the joint shall be assembled,
and the pipe brought to correct line and grade. The pipe shall be secured in place
with approved backfill material.
F. When pipe is not being laid, the open ends of pipe shall be closed by a watertight
' plug or other means approved by the Engineer. When practical, the plug shall
remain in place until the trench is pumped completely dry. Care shall be taken to
prevent pipe flotation should the trench fill with water.
G. Trench width at the top of pipe, bedding conditions, and backfill placement and
compaction shall be such that design loadings on the pipe will not be exceeded.
' 03720-048-01 15155-10 DUCTILE IRON PIPE AND FITTINGS
January 2021
H. Joint Assembly: Pipe joints shall be assembled in accordance with the
manufacturer's instructions and the requirements of ANSUAWWA C600.
1. Flanged Joint: Before connecting flanged pipe the Contractor shall
thoroughly clean all faces of the flanges of all oil, grease, and foreign
material. The rubber gaskets shall be checked for proper fit and thoroughly
cleaned. Care shall be taken to ensure proper sealing of the flange gasket.
Bolts shall be tightened so that the pressure on the gasket is uniform.
Torque -limiting wrenches shall be used to ensure uniform bearing insofar
as possible. If joints leak when the hydrostatic test is applied, the gaskets
shall be removed and reset and bolts retightened.
2. Push -On, Restrained Joint, or Mechanical Joint: The Contractor shall joint
piping in accordance with the manufacturer's recommendations. Provide
all special tools and devices, such as special jacks, chokers, and similar
items required for proper installation. Lubricant for the pipe gaskets shall
be furnished by the pipe manufacturer, and no substitutes will be permitted
under any circumstance.
Pipe Deflection: When it is necessary to deflect pipe from a straight line in either
the vertical or horizontal plane or where long radius curves are permitted, the
amount of deflection shall not exceed that shown in ANSI/AWWA C600 and that
recommended by the retainer gland manufacturer for mechanical joint pipe and
fittings.
J. Pipe Cutting: For inserting valves, fittings, or closure pieces; pipe shall be cut in a
neat, workmanlike manner without damaging the pipe or lining. Ductile cast iron
may be cut using an abrasive pipe saw, rotary wheel cutter, guillotine pipe saw,
milling wheel saw, or oxyacetylene torch. Cut ends and rough edges shall be
ground smooth, and for push -on joint connections the cut end shall be beveled.
3.03 ABOVE -GROUND PIPE INSTALLATION
A. The Contractor shall install pipe in horizontal or vertical planes, parallel or
perpendicular to building, flooring, and pad surfaces unless otherwise shown.
Support pipe and fittings to prevent strain on joints, valves, and equipment. Install
flanged joints so that contact faces bear uniformly on the gasket. Tighten bolts in
accordance with the pipe manufacturer's recommendations.
3.04 SURFACE PREPARATION AND PAINTING
A. All exposed pipe and fittings shall be painted as specified in Section 09900,
Painting and Coating.
03720-048-01 15155-11 DUCTILE IRON PIPE AND FITTINGS
January 2021
B. All buried steel bolts, nuts, washers, rods, harnesses, clamps, sleeves, and
appurtenances shall be painted with System No. 21 as specified in Section 09900,
Painting and Coating.
3.05 INSPECTION AND TESTING
A. See Section 15055, Piping Systems—General, and Section 15144, Pressure
Testing of Piping.
END OF SECTION
03720-048-01 15155-12 DUCTILE IRON PIPE AND FITTINGS
January 2021
SECTION 15290
PVC PIPE, 3 INCHES AND SMALLER
PART 1 GENERAL
1.01 SCOPE OF WORK
A. This Section includes materials, installation, and testing of PVC pipe and fittings
sized 3 inches and smaller for use in process piping having a maximum design
pressure of 150 psi and having a maximum design temperature of 105°F.
1.02 RELATED WORK
A. Section 01330, Submittals and Acceptance.
B. Section 01650, Delivery, Storage, and Handling.
C. Section 01780, Warranties and Bonds.
D. Section 01830, Operations and Maintenance Manuals.
E. Section 09900, Painting and Coating.
F. Section 15055, Piping Systems—General.
G. Section 15144, Pressure Testing of Piping.
1.03 SUBMITTALS
A. The Contractor shall submit shop drawings in accordance with Section 01330,
Submittals and Acceptance.
B. The Contractor shall do the following:
1. Submit materials list showing materials of pipe and fittings with ASTM
reference and grade. Submit manufacturer's certification of compliance
with referenced standards, e.g., ASTM D1784, D1785, and D2467. Show
wall thickness of pipe and fittings. Show fitting dimensions.
2. Submit data sheets for solvent cement and demonstrating compliance with
ASTM D2564 and F656.
3. Submit data sheets showing that the pipe and fittings are NSF 61 listed for
use in potable water service and that the pipe will bear the NSF logo for
potable water use.
1.04 WORK SEQUENCE (NOT USED)
03720-048-01 15290-1 PVC PIPE, 3 INCHES AND SMALLER
August 2019
1.05 REFERENCE STANDARDS
Reference standards and recommended practices referred to in this Section shall be the latest
revision of any such document in effect at the bid time. The following documents are a part of
this Section. Where this Section differs from these documents, the requirements of this Section
shall apply.
A. American Society for Testing and Materials (ASTM)
1. ASTM D1784—Standard Specification for Rigid Poly(Vinyl Chloride)
(PVC) Compounds and Chlorinated Poly(Vinyl Chloride) (CPVC)
Compounds.
2. ASTM D1785—Standard Specification for Poly(Vinyl Chloride) (PVC)
Plastic Pipe, Schedules 40, 80, and 120.
3. ASTM D2464—Standard Specification for Threaded Poly(Vinyl
Chloride) (PVC) Plastic Pipe Fittings, Schedule 80.
4. ASTM D2467 Standard Specification for Poly(Vinyl Chloride) (PVC)
Plastic Pipe Fittings, Schedule 80.
5. ASTM D2564—Standard Specification for Solvent Cements for
Poly(Vinyl Chloride) (PVC) Plastic Piping Systems.
6. ASTM D2774—Standard Practice for Underground Installation of
Thermoplastic Pressure Piping.
7. ASTM D2855—Standard Practice for the Two -Step (Primer and Solvent
Cement) Method of Joining Poly (Vinyl Chloride) (PVC) or Chlorinated
Poly (Vinyl Chloride) (CPVC) Pipe and Piping Components with Tapered
Sockets.
8. ASTM F656—Standard Specification for Primers for Use in Solvent
Cement Joints of Poly(Vinyl Chloride) (PVC) Plastic Pipe and Fittings.
B. American Society of Mechanical Engineers (ASME)
1. ASME B1.20.1—Pipe Threads, General Purpose (Inch).
2. ASME B16.5—Pipe Flanges and Flanged Fittings NPS 1/2 through
NPS 24 Metric/Inch Standard.
C. NSF International (NSF)
1. NSF 61—Drinking Water System Components – Health Effects.
1.06 QUALITY ASSURANCE (NOT USED)
03720-048-01 15290-2 PVC PIPE, 3 INCHES AND SMALLER
August 2019
1.07 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
1.08 DELIVERY, STORAGE, AND HANDLING
A. The Contractor shall adhere to the requirements specified in Section 01650,
Delivery, Storage, and Handling, for storing and protecting the items specified in
this Section.
1.09 QUALIFICATIONS (NOT USED)
1.10 TESTING REQUIREMENTS (NOT USED)
1.11 MAINTENANCE (NOT USED)
1.12 OPERATIONS AND MAINTENANCE (O&M) MANUALS
A. O&M Manuals shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01830, Operations and Maintenance Manuals.
PART 2 PRODUCTS
2.01 GENERAL
A. All pipe joints and fittings shall have the same schedule, pressure ratings, thermal
resistance, chemical resistance, and other pertinent properties as the pipe being
joined or connected. Plastic fittings shall be manufactured of the same resin as
used in the manufacture of the pipe being joined.
B. Each pipe length shall be clearly marked with the manufacturer's name or
trademark, applicable ASTM standards, size, pressure rating, and/or schedule.
C. Provide line -size reducing tees for connecting lateral or instrumentation to pipe
systems. Seal threaded fittings with TeflonTM tape or TeflonTM paste. Engage
threaded fittings in accordance with ASTM A53.
2.02 PIPE 1
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1
1
1
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A. Pipe shall be Schedule 80, Type I, Grade 1 (Class 12454-B), conforming to
ASTM D1784 and D1785.
03720-048-01
August 2019
15290-3 PVC PIPE, 3 INCHES AND SMALLER
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2.03 FITTINGS
A. Fittings shall be Schedule 80 and shall conform to ASTM D2464 for threaded
fittings and ASTM D2467 for socket -type fittings.
2.04 FLANGES
A. PVC flanges shall be of the one-piece solid socket design and shall be made of the
same material as the pipe. Pressure rating shall be at least 150 psi at a temperature
of 73°F. Minimum burst pressure shall be 500 psi. Flanges shall match the
dimensions of ASME B16.5, Class 150, steel flanges for outside diameter, bolt
circle, and bolt holes. Do not use Van Stone flanges.
2.05 UNIONS
A. Unions shall have socket -type ends, Viton O -rings, and shall be Schedule 80.
Material shall be Type I, Grade 1 PVC, per ASTM D1784.
2.06 JOINTS
A. Pipe and fitting joints shall be socket welded except where threaded and flanged
joints are required to connect to valves and equipment.
2.07 SOLVENT CEMENT IN OTHER THAN CHEMICAL AND CHEMICAL CARRIER
WATER SERVICE (NOT USED)
2.08 SOLVENT CEMENT IN CHEMICAL AND CHEMICAL CARRIER WATER
SERVICE
A. Solvent cement shall be free of silica. Products: IPS "Weld -On 724" or Oatey
"Lo V.O.C. PVC Heavy Duty Gray."
2.09 GASKETS FOR FLANGES
A. See Section 15055, Piping Systems—General.
2.10 BOLTS AND NUTS FOR FLANGES
A. See Section 15055, Piping Systems—General.
2.11 LUBRICANT FOR STAINLESS STEEL BOLTS AND NUTS
A. See Section 15055, Piping Systems—General.
03720-048-01 15290-4 PVC PIPE, 3 INCHES AND SMALLER
August 2019
PART 3 EXECUTION
3.01 GENERAL
The Contractor shall adhere to the following:
A. Do not install PVC pipe when the temperature is below 40°F or above 90°F. Store
loose pipes on racks with a maximum support spacing of 3 feet. Provide shade for
pipe stored outdoors or installed outdoors until the pipe is filled with water.
B. Store fittings indoors in their original cartons.
C. Store solvent cement indoors or, if outdoors, shade from direct sunlight exposure.
Do not use solvent cements that have exceeded the shelf life marked on the
storage container.
D. Before installation, check pipe and fittings for cuts, scratches, gouges, buckling,
kinking, or splitting on pipe ends. Remove any pipe section containing defects by
cutting out the damaged section of pipe.
E. Do not drag PVC pipe over the ground, drop it onto the ground, or drop objects on
it.
3.02 SOLVENT -WELDED JOINTS
A. Before solvent welding, remove fittings and couplings from their cartons and
expose them to the air at the same temperature conditions as the pipe for at least
1 hour.
B. Cut pipe ends square and remove all burrs, chips, and filings before joining pipe
or fittings. Bevel solvent -welded pipe ends as recommended by the pipe
manufacturer.
C. Wipe away loose dirt and moisture from the inside and outside of the pipe end
and the inside of the fitting before applying solvent cement. Clean the surfaces of
both pipes and fittings that are to be solvent welded with a clean cloth moistened
with acetone or methylethyl ketone. Do not apply solvent cement to wet surfaces.
D. The pipe and fitting socket shall have an interference fit. The diametrical
clearance between pipe and entrance of the fitting socket shall not exceed
0.04 inch. Check the fit at every joint before applying solvent cement.
E. Make up solvent -welded joints in accordance with ASTM D2855. Application of
cement to both surfaces to be joined and assembly of these surfaces shall produce
03720-048-01
August 2019
15290-5 PVC PIPE, 3 INCHES AND SMALLER
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a continuous bond between them with visual evidence of cement at least flush
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with the outer end of the fitting bore around the entire circumference.
F. Allow at least 8 hours of drying time before moving solvent -welded joints or
subjecting the joints to any internal or external loads or pressures.
G. Acceptance criteria for solvent -welded joints shall be as follows:
1. Unfilled Areas in Joint: None permitted.
2. Unbonded Areas in Joint: None permitted.
3. Protrusion of Material into Pipe Bore, Percent of Pipe Wall Thickness:
Cement, 50%.
3.03 FLANGED JOINTS
A. Lubricate carbon steel bolt threads with graphite and oil before installation.
B. Tighten bolts on PVC flanges by tightening the nuts diametrically opposite each
other using a torque wrench. Complete tightening shall be accomplished in stages
and the final torque values shall be as shown in the following table:
Pipe Size
(inches)
Final Torque
(foot-pounds)
1/2 to 1-1/2
10 to 15
2to3
20to30
3.04 INSTALLATION OF STAINLESS STEEL BOLTS AND NUTS
A. See Section 15055, Piping Systems—General.
3.05 THREADED JOINTS
A. Cut threaded ends on PVC to the dimensions of ASME B1.20.1. Ends shall be
square cut. Follow the pipe manufacturer's recommendations regarding pipe hold-
down methods, saw cutting blade size, and saw cutting speed.
B. Pipe or tubing cutters shall be specifically designed for use on PVC pipe. Use
cutters manufactured by Reed Manufacturing Company, Ridge Tool Company, or
equal.
C. If a hold-down vise is used when the pipe is cut, insert a rubber sheet between the
vise jaws and the pipe to avoid scratching the pipe.
03720-048-01 15290-6 PVC PIPE, 3 INCHES AND SMALLER
August 2019
D. Thread cutting dies shall be clean and sharp and shall not be used to cut materials
other than plastic.
E. Apply Teflon thread compound or Teflon tape lubricant to threads before
screwing on the fitting.
3.06 INSTALLING UNIONS
A. Provide unions on exposed (above grade and in vaults) piping 3 inches and
smaller as follows:
1. At every change in direction (horizontal and vertical).
2. Six to 12 inches downstream of valves.
3. Every 40 feet in straight pipe runs.
4. Where shown on the Drawings.
3.07 INSTALLING BURIED PIPE
A. Install in accordance with Section 02305, Earthwork for Utilities, and as follows.
B. Trench bottom shall be continuous, smooth, and free of rocks. See the details on
the Drawings for trench dimensions, pipe bedding, and backfill.
C. After the pipe has been solvent -welded and the joints have set, snake the pipe in
the trench according to the pipe manufacturer's recommendations to allow for
thermal expansion and contraction of the pipe.
D. Do not backfill the pipe trench until the solvent -welded joints have set. Support
the pipe unifolluly and continuously over its entire length on firm, stable soil. Do
not use blocking to change pipe grade or to support pipe in the trench.
E. Install buried PVC pipe in accordance with ASTM D2774 and the pipe
manufacturer's recommendations. Backfill materials in the pipe zone shall be
imported sand as specified in Section 02305, Earthwork for Utilities. If water
flooding is used, do not add successive layers unless the previous layer is
compacted to 90% relative compaction.
3.08 INSTALLING ABOVEGROUND OR EXPOSED PIPING
A. See Section 15055, Piping Systems—General.
B. Fill empty piping with water, provide temporary shading, or use other means to
keep the surface temperature of the pipe below 100°F.
03720-048-01 15290-7 PVC PIPE, 3 INCHES AND SMALLER
August 2019
3.09 PAINTING AND COATING
A. Coat piping that is exposed to sunlight as specified Section 09900, Painting and
Coating, System No. 41.
3.10 PIPE LABELS AND COLOR CODING
A. Label and color code exposed piping and piping inside concrete pipe trenches
with flow stream identification labels and banding in accordance with
Section 15075, Process Equipment, Piping, and Valve Identification, and the
Piping Schedule on the Drawings.
3.11 HYDROSTATIC TESTING
A. Perform hydrostatic testing for leakage in accordance with Section 15144,
Pressure Testing of Piping.
03720-048-01
August 2019
END OF SECTION
15290-8 PVC PIPE, 3 INCHES AND SMALLER
SECTION 15860
ODOR CONTROL SYSTEM EQUIPMENT
PART 1 GENERAL
1.01 SCOPE OF WORK
A. The Contractor shall furnish and install all equipment and materials necessary to
provide the Owner with a completely operational Biological Odor Control
System. The system shall be a completely packaged two-stage, biological
absorption/adsorption system. The Contractor shall be responsible for providing a
complete Odor Control System that shall include but not be limited to FRP vessel,
nozzles, two independent stages of inorganic treatment media, moisture controls,
nutrient supply system, air supply fan, interconnecting ducting, and all necessary
accessories.
1.02 SUBMITTALS
The Contractor shall submit shop drawings in accordance with Section 01330, Submittals and
Acceptance:
A. Complete Shop Drawings for the System, together with all piping, ductwork,
valves, and control for review by the Engineer.
B. Shop Drawings: The following information for approval before equipment is
fabricated:
03720-048-01
August 2019
1. Drawings of system showing assemblies, arrangements, piping, electrical,
mounting details, equipment outline dimensions, fitting size and location,
motor data, operating weights of all equipment and sufficient information
to allow the Engineer to check clearances, connections, and conformance
with the Specifications.
2. Materials of construction of all equipment.
3. The manufacturer's catalog data and operating literature plus
specifications, performance data, and calibration curves for exhaust fan
and auxiliary components.
4. Complete instrumentation, control, logic, and power wiring diagrams in
sufficient detail to allow installation of the instrumentation, controls, and
electrical components.
5. Manuals: The manufacturer's installation, operation and maintenance
manuals, bulletins, and spare parts lists.
6. Reference list demonstrating minimum qualifications as required in
Paragraph 1.01.A above.
15860-1
ODOR CONTROL SYSTEM
EQUIPMENT
C. Pre -Approval Submittals: Each supplier submitting an alternate to the equipment
defined in this Section shall provide the following submittals 20 days before the
established bid date. Failure to provide a complete and thorough submittal
package shall render their pre -approval request non-responsive and the request
will not be considered. Approval of manufacturers will be the sole decision of the
Engineer and the Owner. A blanket statement that equipment proposed will meet
all requirements will not be sufficient to establish equivalence to the specified
manufacturer(s). If requested by the Engineer, the supplier must be prepared to
demonstrate a unit similar to the one proposed. The following information is
required:
1. A complete set of drawings as described in Paragraph 1.02B. Provide a
minimum of one drawing per system clearly showing how the proposed
system will fit on the site.
2. A reference list of no fewer than five two-stage installations of the type
and size of system proposed. The installations must have been in service
for a minimum of 5 years. The list shall include the following
information: Owner name and accurate contact information, placed -in-
service date, and design conditions including air flow rate and H2S
loading. Provide graphical performance data from a minimum of five
systems showing the inlet and outlet levels of hydrogen sulfide. Failure to
submit references for non-standard units may deem the proposal "non-
responsive" and the proposal will be rejected without further review.
3. A complete summary of operating cost shall be provided. At a minimum
the following information shall be provided:
a. Annual electrical operating cost. Show calculations and use
$0.06/kW-hr.
b. Media replacement cost.
c. Nutrient cost per year.
4. A copy of the performance guarantee and the warranty.
5. It shall be the supplier's responsibility to carefully examine each item of
the Specifications. Failure to offer a complete proposal or failure to
respond to each section of the technical specifications will cause the
proposal to be rejected without further review as "non-responsive." All
exceptions and/or deviations shall be fully described in the appropriate
section. The supplier must include a separate sheet listing any and all
deviations to the Specifications. The Engineer understands that
manufacturers design systems with different features. This listing is
03720-048-01 15860-2 ODOR CONTROL SYSTEM
August 2019 EQUIPMENT
therefore integral to the Engineer's determination of an equivalent
product. Each deviation must reference the listed Specification, by number
if necessary, and explain in full detail how the proposed system is
different.
6. Provide information on service center and personnel as required by
Article 3.05 below.
7. If, after review of the pre -approval submittal, the Engineer deems the
alternate system acceptable, the Engineer shall notify the bidding
contractors of the approved manufacturer's name and model number via
an addendum. Manufacturers are not approved unless they have been
listed as such by the Engineer in an addendum.
1.03 REFERENCES
Reference standards and recommended practices referred to in this Section shall be the latest
revision of any such document in effect at the bid time. The following documents are a part of
this Section. Where this Section differs from these documents, the requirements of this Section
shall apply.
A. American Society of Testing and Materials (ASTM)
1. ASTM D883—Standard Terminology Relating to Plastics.
2. ASTM D2563 Standard Practice for Classifying Visual Defects in Glass -
Reinforced Plastic Laminate Parts.
3. ASTM D2583—Standard Test Method for Indentation Hardness of Rigid
Plastics by Means of a Barcol Impressor.
4. ASTM D3299—Standard Specification for Filament -Wound Glass -Fiber -
Reinforced Thermoset Resin Corrosion -Resistant Tanks.
5. ASTM D4097—Standard Specification for Contact -Molded Glass -Fiber -
Reinforced Thermoset Resin Corrosion -Resistant Tanks.
B. American Society of Mechanical Engineers (ASME)
1. ASME RTP 1—Reinforced Thermoset Plastic Corrosion -Resistant
Equipment.
C. National Bureau of Standards (NBS)
03720-048-01
August 2019
1. NBS PS 15-69—Voluntary Product Standard – Custom Contact -Molded
Reinforced -Polyester Chemical -Resistant Process Equipment.
15860-3 ODOR CONTROL SYSTEM
EQUIPMENT
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D. National Fire Protection Association (NFPA)
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1. NFPA 820 Standard for Fire Protection in Wastewater Treatment and
Collection Facilities.
1.04 QUALITY ASSURANCE
A. Manufacturer: The products furnished under this Section shall be manufactured
by a manufacturer who has been regularly engaged in the design and manufacture
of the equipment and who has a minimum of 5 years experience in design,
fabrication, and testing of biological odor -control systems. The odor -control
system manufacturer shall show evidence of at least five identical two-stage
design installations in satisfactory operation in wastewater treatment plant
facilities for at least 5 years. The odor -control system manufacturer shall have
used proposed biofiltration media for a minimum of 5 years. Any proposed non-
specified manufacturers shall demonstrate to the satisfaction of the Engineer and
Owner that the quality of their equipment is equal to that made by those
manufacturers specifically named in this Section. Any manufacturer whose main
business is FRP manufacturing shall not be accepted as a supplier of the complete
system.
B. Inspection and Testing Requirements: The Engineer reserves the right to reject
delivery of any or all pieces of equipment found upon inspection to have any or
all of the following: blisters, chips, crazing, exposed glass, cracks, burned areas,
dry spots, foreign matter, surface porosity, sharp discontinuity, or entrapped air at
the surface of the laminate. Any item that does not satisfy the tolerances below
shall be rejected:
03720-048-01
August 2019
Defect
Inside Surface
Outside Surface
Blister
None
Max. dimensions: 1/4 inch
diameter by 1/8 inch high;
Maximum density: 1 per square
foot; Minimum separation:
2 inches apart
Chips
None
Maximum dimension of break:
1/4 inch and thickness no greater
than 10% of wall thickness;
Maximum density: 1 per square
foot
Crazing
None
Maximum length: 1/2 inch;
Maximum density: 5 per square
foot; Minimum separation:
2 inches
Cracks
None
None
Exposed Glass
None
None
Scratches
None
Maximum length: 1 inch;
Maximum depth: 0.010 inch
15860-4
ODOR CONTROL SYSTEM
EQUIPMENT
Defect
Inside Surface
Outside Surface
Burned Areas
None
None
Surface Porosity
None
None
Foreign Matter
None
None
Sharp Discontinuity
None
None
Pits
Maximum 1/8 inch
diameter by 1/32 inch
deep; Maximum: 10 per
square foot
Maximum 1/8 inch diameter by
1/16 inch deep; Maximum
10 per square foot
Dry Spot
None
2 square inches per square foot
Entrapped Air
None at the surface
1/16 inches and 10 per
square inch maximum
1/8 inch and 4 per square inch or
1/16 inch and 10 per square inch
within laminate
C. The Engineer reserves the right to be present at the fabricator's facility for visual
inspection of equipment to be supplied.
D. Upon completion of the installation, each piece of equipment and each system
shall be tested for satisfactory operation without excessive noise, vibration,
overheating, etc. Compliance shall be based on the equipment manufacturer's
specifications and all applicable costs and standards. All equipment must be
adjusted and checked for misalignment, clearances, supports, and adherence to
safety standards.
E. The manufacturer shall be responsible for the successful startup and testing of
each odor -control facility. The manufacturer shall provide all necessary facilities,
manpower, tools, instrumentation, and laboratory testing services required during
this phase of the work.
1.05 WARRANTIES
A. Warranties shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01780, Warranties and Bonds.
B. The manufacturer shall warrantee the whole system, both in material and
workmanship, for 1 year from the day of beneficial occupancy. This period shall
not extend beyond 18 months after delivery of equipment to the job site.
03720-048-01 15860-5 ODOR CONTROL SYSTEM
August 2019 EQUIPMENT
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1.06 MAINTENANCE
A. Manufacturer's Services
1. The system manufacturer's representative shall be present at the job site
for the following period, travel time excluded:
a. Sixteen hours for inspection of the installation and training of
Owner's staff in operation of the system.
b. Provide one trip for 2 days for these tasks.
B. Service Center
1. To be an approved odor -control system supplier, the system supplier shall
have complete ongoing service capability with factory -trained personnel.
The service center shall be located in the southeast US. The service center
shall be able to provide the following services: operational analyses
consisting of field H2S measurements, airflow measurements, sampling
and analysis, and operational trouble shooting.
1.07 OPERATION AND MAINTENANCE (O&M) MANUALS
A. O&M Manuals shall be in accordance with General Conditions, Supplementary
Conditions, and Section 01830, Operations and Maintenance Manuals.
B. Six manuals shall be submitted before final acceptance of the equipment.
1.08 DESCRIPTION
A. Multi -Stage Package System: The manufacturer shall furnish and install a
complete "once -through two-stage," pre -piped, wired, and packaged odor -control
system, including two integral treatment stages, exhaust fan, valves, fittings,
ductwork, and all other equipment and accessories as specified to provide a
complete and functioning system. The biological treatment stage shall use an
inorganic expanded clay media to facilitate absorption and adsorption of odor
compounds. The polishing stage shall use a virgin activated -carbon polishing
media that shall be specifically designed to adsorb odorous compounds with the
ability to support biological degradation of the compounds. The first stage shall
operate with an independently controlled irrigation system to maintain optimum
wetted conditions to support unique microbial growth for biological destruction of
the odorous compounds and removal of toxic metabolites. Systems using any type
of organic media and systems using a single inorganic media shall not be
acceptable.
03720-048-01 15860-6 ODOR CONTROL SYSTEM
August 2019 EQUIPMENT
B. Design Basis: The mechanical, structural, process, and electrical design has been
based on a ZABOCS® Model 8000 odor -control system manufactured by Siemens
Water Technologies, San Diego, CA.
C. Specified Manufacturer: Siemens Water Technologies, or pre -approved equal.
PART 2 PRODUCTS
2.01 GENERAL
A. The manufacturer shall provide an odor -control system as specified, which shall
treat in a single pass the odorous air from the contaminated areas. The system
shall be designed for continuous, automatic operation and also be capable of
manual operation. Access manways shall be provided to allow access to the
internals of the system. The system shall be designed to withstand a temperature
up to 120°F. The multi -stage packaged FRP system shall be as specified in
Article 2.03. The module and all accessories shall be factory mounted, piped, and
wired to the maximum extent possible. If required for NFPA 820 compliance, the
Contractor shall mount the control panel remotely, at least 3 feet from the
airstream. The Contractor shall interconnect the wiring between the remote -
mounted control panel and the junction box on the ZABOCS. The system shall be
provided by Siemens Water Technologies, San Diego, California, or pre -approved
equal.
2.02 DESIGN AND PERFORMANCE CRITERIA
A. Design and Performance Criteria:
03720-048-01
August 2019
1. Criteria: The system shall be capable of removing foul air at a rate no
lower than the rate shown on the following table.
2. Foul air removed from the facility will have an average and peak
concentration of hydrogen sulfide (H2S) and design air flow rate as listed
in the following table. The supplier may consider using a higher capacity
fan and introducing a non -foul air upstream of the odor -treatment system
to dilute the concentration of the stagnant air concentrations listed below.
System I.D.
Air Flow Rate,
cfm
Ave. Inlet H2S
Conc.
Peak H2S Conc.
Stagnant Conditions
Six Mile Creek
0
900 ppm
1,000 ppm
Stagnant Conditions
Grovewood
0
230 ppm
300 ppm
ZB-8000
1,400 cfm
90 ppm
100 ppm
15860-7
ODOR CONTROL SYSTEM
EQUIPMENT
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3. System Performance: The odor -control system shall demonstrate the
following performance when operating under the design flow conditions
listed above.
INLET OUTLET
1-10 ppm H2S 0.1 ppm H2S
Greater than 10 ppm H2S 1.0% of inlet
At no time shall the outlet air concentration from the treatment unit exceed
1.5 ppm of hydrogen sulfide
4. Maximum Pressure Drop: The pressure drop across the odor -control
system shall not exceed 5.0 inches we at the maximum air flow rate
specified above.
2.03 MULTI -STAGE FRP PACKAGED BIOLOGICAL ABSORPTION/ADSORPTION
SYSTEM
A. General: The gas treatment system shall be a Two -Stage, Once -Through
Biologically Active Odor -Removal System designed to remove a minimum of
99% of H2S vapor in a single pass. The system shall consist of one biological gas
conditioning/treatment stage and one vertical gas polishing stage in series. The
first stage shall facilitate biological destruction of odor compounds absorbed by
the liquid in the system and adsorbed on the inorganic media. The biological
section shall include a spray header to distribute liquid evenly over the media. The
complete treatment vessel shall be fabricated of premium -grade FRP.
03720-048-01
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1. The first treatment stage shall contain inorganic expanded clay media,
Siemens' BIOLITE, specifically designed to support biological growth for
degradation of odor compounds. This stage shall absorb odors from the air
stream. The second polishing stage shall contain coal -based virgin media
specifically designed to adsorb odor compounds and to support biological
degradation of those compounds. This stage shall remove odors to the
specified level. Overall media depth shall be a minimum of 48 inches.
2. The first stage of media shall be wetted with fresh potable or re -use make-
up water.
3. The overall system size, including the fan, controls, and appurtenances,
shall not exceed the dimensions shown on the contract drawings. Access
manways shall be provided to allow access to the system internals. At a
minimum, access manways shall be provided between the treatment
stages. A portion of the system top shall be removable for access to the top
of the second stage.
15860-8 ODOR CONTROL SYSTEM
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4. The system shall be included with all piping, valves, and internals. The
material of construction of internals shall be as follows:
Packing Media Support: HDPE and FRP
Liquid Distributor: PVC
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Spray Nozzles: PVC
5. The system shall have all components pre -mounted and piped on the 1
unitary constructed system. The system shall be shipped as a single piece.
B. Material of Construction:
1. The vessel and accessories shall be contact molded manufactured in 1
accordance with NBS PS 15-69, ASTM D4097 for contact molding. Any
material of construction other than FRP with premium grade resin will not I be allowed.
2. Resin used in the system liner shall be a premium vinyl ester type such as I Hetron 922 by Ashland Chemicals, Derakane 411 by Dow Chemical,
Vipel FO10 by AOC, or approved equal. The resin shall be reinforced with
an inner veil of a suitable synthetic organic fiber such as 1
Nexus 111-00010.
3. Reinforcement: Glass -fiber reinforcement used shall be commercial grade
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corrosion -resistance borosilicate glass.
a. All glass -fiber reinforcement shall be Type C, chemical grade, 1
Type E electrical grade.
b. Surfacing veil shall be 10 -mil Nexus 111-00010 or equal.
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c. Mat shall be Type "E" (electrical grade) glass, 1 1/2 ounces per
square foot with a nominal fiber length of 1.25 + 0.25 inches, with
a silane finish and styrene soluble binder. 1
d. Continuous glass roving used in chopper gun spray -up applications
shall be Type "E" grade with chrome or silane coupling agent. I e. Alternate layers of mat and woven roving used for reinforcement.
4. Miscellaneous:
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a. Stainless Steel: Unless otherwise specified, all fasteners and metal
attachments, such as anchors, brackets, etc., shall be ANSI 316SS.
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b. Gaskets: Unless otherwise specified, all gaskets shall be EPDM.
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03720-048-01 15860-9 ODOR CONTROL SYSTEM
August 2019 EQUIPMENT
C. Fabrication:
1. General: Fabrication shall be in accordance with NBS PS 15-69,
ASTM D3299, and ASTM D4097. All non -molded surfaces shall be
coated with resin incorporating paraffin to facilitate a full cure of the
surface. All cut edges, bolt holes, and secondary bonds shall be sealed
with a resin coat before the final paraffinated resin coat. All voids shall be
filled with a resin paste.
2. Corrosion Liner: The inner surface of all laminates shall be resin rich and
reinforced with one NEXUS 111-00010 with a minimum thickness of
10 mils. The interior corrosion layer shall consist of two layers of
1-1/2 ounces per square foot chopped strand mat. If the application is by
chopper gun spray up the glass fiber shall be 1/2 to 2 inches long. The
total corrosion liner thickness shall be a minimum of 100 mils and have a
resin -to -glass ratio of 80/20. All edges of reinforcement to be lapped a
minimum of 1 inch.
3. Structural Laminate: Structural laminates shall consist of alternating layers
of 1-1/2 ounces per square foot mat or chopped glass and 24 ounces per
square yard woven roving applied to reach a designed thickness. Actual
laminate sequences shall be according to the laminate tables shown on
fabrication drawings. The exterior surface shall be relatively smooth and
shall have no glass fibers exposed. The exterior shall be surface coated
with gel coat containing ultra violet light inhibitors.
D. Accessories: Air inlet, air outlet, spray headers, baffles, media support, drain, and
all connections shown on the Drawings shall be provided by the manufacturer.
Tie -down lugs shall be integrally molded into the walls of the vessel. All external
bolts shall be 316SS and designed for the specified loads. Interior fasteners shall
be of corrosion -resistant materials such as PVC or FRP.
E. Neoprene Pad: A 1/4 -inch -thick, 60-durometer neoprene rubber sheet shall be
provided and placed beneath the vessel during installation.
2.04 EXHAUST FAN
A. The exhaust fan shall have a fiberglass -reinforced plastic centrifugal backward -
inclined impeller. The wheel shall be statically and dynamically balanced. Resin
shall be suitable for exposure to the specific service conditions. The shaft shall be
316SS. The shaft seal shall be Teflon or Neoprene.
B. Bearings shall be heavy-duty, self -aligning grease -lubricated ball -type with a
minimum of 100,000 -hour B-10 life. An OSHA -approved weather cover shall be
provided. The motor shall be TEFC, 1,800 RPM with a 1.15 service factor and
suitable for 3/60/230V. The fan shall be provided with a constant V -belt drive.
03720-048-01 15860-10 ODOR CONTROL SYSTEM
August 2019 EQUIPMENT
The motor shall be inverter -duty, suitable for use with an adjustable speed drive
ASD.
C. Fan housing shall be constructed of fiberglass and reinforced with rigid bracing to
increase structural integrity. Bearing support brackets shall be positioned to
directly oppose belt tension forces. Fan housing shall be a curved scroll design.
The fan inlet shall be slip type and the fan outlet shall have a flanged connection.
D. The fan shall be designed for the following specifications:
Exhaust Fan Design Requirements
ZB-8000
Air Flow Rate, cfm
1,400
SP up to System Inlet, in WC
2.0
Total Pressure Drop, in WC
5.0
Motor, HP
3.0
E. The fan shall be New York Blower, Hartzell, or equal. The fan shall have an
AMCA seal.
2.05 INSTRUMENTATION AND SYSTEM CONTROLS
A. The electrical control panel shall provide electrical control for the exhaust fan and
water addition system. A 230V/3Ph/60Hz power supply shall be provided to power
the system.
B. The control panel enclosure shall be of fiberglass construction and rated
NEMA 3R with ventilation fan. The panel shall be mounted to the system
assembly and factory tested to full operation with all other components before
shipment.
C. The panel shall have the following components or capabilities:
1. Fan switch (ON-OFF).
2. Fan ASD.
3. Push -to -test button for water valve.
4. Timer relay for on/off control of water valve.
5. Nutrient pump (HAND -OFF -AUTO).
D. The water control cabinet shall be constructed from a NEMA -12 rated FRP
cabinet with all internal piping SCH 80 PVC. The cabinet shall be mounted to the
system assembly. The cabinet shall contain the following components:
03720-048-01
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1. Pressure -reducing valve.
2. Nutrient pump.
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3. Irrigation solenoid valve.
4. Irrigation system pressure gauge.
E. Water pressure regulator, solenoid valve, and rotameter shall be provided for
control of water application rates. These components shall be mounted in the
water control cabinet.
2.06 ACCESSORIES
A. Water Flow Control: The direct reading rotameter shall be a variable area type
with a Teflon float, EPR "0" rings, and PVC fittings. The rotameter shall have a
direct reading scale.
B. Water Distribution System: The first media stage shall be equipped with an
independent water distribution system. The system shall be designed to irrigate
the top of the first media bed with complete and even coverage via spray nozzles.
C. Nutrient Addition: A nutrient containment and metering system shall be provided
with the system.
2.07 PIPING
A. All make-up water and drain piping shall be SCH 80 PVC. The Contractor shall
insulate and heat trace all external piping.
2.08 NUTRIENT RESERVOIR
A. The Nutrient Reservoir shall be integrated into the system sump. Loose external
tanks shall not be allowed.
2.09 ROUND FRP DAMPERS
A. The Contractor shall furnish and install round FRP single -blade fiberglass
dampers at locations shown on plans. The damper frame shall be of one-piece
construction with a resin -rich interior corrosion barrier minimum of 100 mils. A
structural lay-up shall consist of alternate layers of chopped strand mat and woven
roving to conform to ASME RTP 1 and NBS PS 15-69. The glass -to -resin ratio
shall be a minimum of 35% glass to 65% resin. Wall thickness, flange thickness,
drilling pattern, and width shall conform to NBS PS 15-69. The exterior surface
of the damper shall contain UV inhibitors and a gel -coat color to match the duct
system.
03720-048-01
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15860-12 ODOR CONTROL SYSTEM
EQUIPMENT
B. The damper blade shall be constructed of the same material as the damper frame
and shall have a resin -rich surfacing veil on both sides. Blade stiffeners shall be
FRP or FRP encapsulated as required for stiffness.
C. The axle shall be fiberglass or 316 stainless steel, as required to meet corrosion -
resistance requirements for the stagnant air conditions outlined in
Paragraph 2.02A.2. Leakage shall not exceed 3 cfm per square foot at 12 inches
wc or 5.25 cfm per square foot at 30 inches wc as required in this Section for
isolation. A damper shall be provided with a stainless-steel hand -locking
quadrant, gear operators, chain wheel operators, or other actuation devices as
required in this Section. All interior metal shall be 316 stainless steel. Gaskets
shall be EPDM. Other gasket materials shall be available upon request.
D. All FRP fabrication shall meet or exceed quality requirements of NBS PS 15-69
and ASME RTP 1. The damper shall be Belco Mfg. Model 201.
PART 3 EXECUTION
3.01 SITE AND UTILITIES
A. The system shall be located on a foundation as shown on the Drawing. The
following utilities shall be provided at the site and located as shown on the
Drawing. Site preparation, utility service, and installation are not provided by the
manufacturer under these Specifications.
1. Electrical: 230 -VAC, three-phase, 60 -Hz, 30-A service is required.
2. Water Supply: a 3/4 -inch water supply with backflow preventer are
required. The water supply must provide for a minimum of 30 psi
continuous pressure at 8 GPM and a hardness not to exceed 200 mg/L as
calcium carbonate.
3. Drain: a minimum 2 -inch SCH 80 PVC gravity drain to a sewer with a
barometric trap is required.
3.02 START-UP AND TRAINING
A. The services of a factory representative shall be provided as specified in
Articles 1.04 and 1.06 to ensure proper installation and start-up of the system. The
manufacturer shall make any changes to the system that may be necessary to meet
the specified performance under inlet conditions as specified.
03720-048-01
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END OF SECTION
15860-13 ODOR CONTROL SYSTEM
EQUIPMENT
DIVISION 16
ELECTRICAL
SECTION 16050
ELECTRICAL — GENERAL PROVISIONS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Scope of Work:
1. Furnish all labor, materials, equipment and incidentals required for a complete
electrical system as hereinafter specified and shown on the Drawings, whether or
not specifically shown or called for.
2. The work, apparatus and materials which shall be furnished under these
Specifications and accompanying Drawings shall include all items listed
hereinafter an/or shown on the Drawings. All materials necessary for the
complete installation shall be furnished and installed by the Contractor to provide
complete power, generator, lighting systems, instrumentation, wiring and control
systems as indicated on the Drawings and/or as specified herein whether or not
specifically shown or called for. Certain equipment will be furnished as specified
in other Section of this specification which will require conduit and wire to
complete the installation as required.
3. The Contractor shall furnish and install the necessary cables, transformers, motor
control centers, protective devices (surge protection), conductors, exterior
electrical system, etc., to serve motor loads, lighting loads and miscellaneous
electrical loads as indicated on the Drawings and/or as specified hereinafter.
4. The work shall include complete testing of all equipment and wiring at the
completion of the work and making any minor connection changes or adjustments
necessary for the proper functioning of the system and equipment. All
workmanship shall be of the highest quality; substandard work will be rejected.
5. Provide permitting and acceptance testing.
6. Make all field connections to process instrument panels and other control panels
furnished under other Divisions of these Specifications.
7. For process instrumentation furnish and install all conduit, wire and
interconnections between primary elements, transmitters, local indicators and
receivers. Coordinate wire termination with the instrumentation supplier.
8. It is the intent of these Specifications that the electrical system shall be suitable in
every way for the service required. All material, equipment, appliances and all
03720-048-01
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16050-1 Electrical — General Provisions
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work which may be reasonably implied as being incidental to the work of this
Section shall be furnished at no extra cost.
9. Each bidder or his authorized representatives shall, before preparing a bid, visit all
areas of the existing building and/or proposed site in which work will take place
and be performed to inspect carefully the present installation and conditions. The
submission of the bid by this bidder shall be considered evidence that the bidder
has visited the project and noted the locations and conditions under which the
work will be performed and that the bidder takes full responsibility for a complete
knowledge of all factors governing his work.
10. All necessary temporary power requirements are the responsibility of the
Contractor and shall be furnished at to extra cost to the Owner.
11. All necessary temporary power, control and instrumentation requirements are the
responsibility of the Contractor and shall be furnished at no extra cost to the
Owner. Power and controls shall be furnished to all existing equipment at all
times.
B. Codes, Inspections and Fees:
1. All material and installation shall be in accordance with the latest edition of the
National Electrical Code and all applicable national, local and state codes.
2. Pay all fees required for permits, inspections, and connections.
C. Tests:
1. Test all systems and repair or replace all defective work. Make all necessary
adjustments to the systems and instruct the Owner's personnel in the proper
operation of the systems.
D. Interpretation of Drawings:
1. The Drawings are not intended to show exact location, quantity or size of conduit
runs. All installation of the raceway system shall be as directed by approved shop
drawing. Any installation of a raceway system before shop drawing submittal and
approval will at the sole risk of the Contractor.
2. All three-phase circuits shall be run in separate conduits unless otherwise shown
on the Drawings.
3. Unless otherwise approved by the Engineer, conduit shown exposed shall be
installed exposed; conduit shown concealed shall be installed concealed.
4. Where circuits are shown as "home -runs" all necessary fittings and boxes shall be
provided for a complete raceway installation.
03720-048-01
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16050-2
Electrical — General Provisions
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5. The Contractor shall harmonize the work of the different trades so that
interferences between conduits, piping, equipment, architectural and structural
work will be avoided. All necessary offsets shall be furnished so as to take up a
minimum space and all such offsets, fittings, etc., required to accomplish this
shall be furnished and installed by the Contractor without additional expense to
the Owner. In case interference develops, the Owner's authorized representative is
to decide which equipment, piping, etc., must be relocated, regardless of which
was installed first.
6. Verify with the Engineer exact locations and mounting heights of lighting
fixtures, switches and receptacles prior to installation.
7. The locations of equipment, fixtures, outlets, and similar devices shown on the
Drawings are approximate only. Exact locations shall be as approved by the
Engineer during construction. Obtain in the field all information relevant to the
placing of electrical work and, in case of any interference with other work,
proceed as directed by the Engineer and furnish all labor and materials necessary
to complete the work in an approved manner.
8. Surface mounted panel boxes, junction boxes, conduit, etc., shall be supported by
spacers to provide a clearance between wall and equipment.
9. Circuit layouts shown are not intended to show the number of fittings, or other
installation details. Furnish all labor and materials necessary to install and place
in satisfactory operation all power, lighting, and other electrical systems shown.
Additional circuits shall be installed wherever needed to conform to the specific
requirements of the equipment.
10. The ratings of motors and other electrically operated devices together with the size
shown for their branch circuit conductors and conduits are approximate only and
are indicative of the probable power requirements insofar as they can be
determined in advance of the purchases of the equipment.
11. All connections to equipment shall be made as shown, specified, required, and
directed and in accordance with the approved shop drawings, regardless of the
number of conductors shown on the Electrical Drawings.
F. Size of Equipment:
1. Investigate each space in the building through which equipment must pass to
reach its final location. If necessary, the manufacturer shall be required to ship his
material in sections sized to permit passing through such restricted areas in the
building.
2. The equipment shall be kept upright at all times. When equipment has to be tilted
for each of passage through restricted areas during transportation, the
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16050-3 Electrical — General Provisions
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manufacturer shall be required to brace the equipment suitably, to insure that the
tilting does not impair the functional integrity of the equipment.
G. Component Interconnections:
1. Component equipment furnished under this Specification will not be furnished as
integrated systems.
2. Analyze all systems components and their shop drawings; identify all terminals
and prepare drawings or wiring tables necessary for component interconnection.
I-1. Record Drawings:
1. As the work progresses, legibly record all field changes on a set of project
Contract Drawings. When the project is complete furnish a complete set of
reproducible "as -built" drawings for the Project Record Documents, Section
01720.
1.02 SUBMITTALS
A. Material and Shop Drawings:
1. As specified under Section 01340, shop drawings shall be submitted for approval
of all materials, equipment, apparatus, and other items as required by the
Engineer.
2. Shop drawings shall be submitted for the following equipment:
a. Motor Control Centers
b. Disconnect Switches
c. Wire and Cable
d. Supporting Devices
e. Variable Frequency Drives
f. Test Data
g. Generator
3. The manufacturers' name and product designation or catalog numbers shall be
submitted for the following material:
a. Conduit
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b. Receptacles
c. Boxes and Fittings
d. Switches
e. Lamps
f. Control Relays
4. Prior to submittal by the Contractor, all shop drawings shall be checked for
accuracy and contract requirements. Shop drawings shall bear the date checked
and shall be accompanied by a statement that the shop drawings have been
examined for conformity to Specifications and Drawings. This statement shall
also list all discrepancies with the Specifications and Drawings. Shop drawings
not so checked and noted shall be returned.
5. The Engineer's check shall be only for conformance with the design concept of the
project and compliance with the Specifications and Drawings. The responsibility
of, or the necessity of, furnishing materials and workmanship required by the
Specifications and Drawings which may not be indicated on the shop drawings is
included under the work of this Section.
6. The responsibility for all dimensions to be confirmed and correlated at the job site
and for coordination of this work with the work of all other trades is also included
under the work of this Section.
7. No material shall be ordered or shop work started until the Engineer's approval of
shop drawings has been given.
B. Manufacturer's Services
1. Provide manufacturer's services for testing and start-up of the following
equipment:
a. Motor Control Centers
b. Variable Frequency Drives
b. 480 -volt Switchgear
2. Provide manufacturer's of the above listed equipment shall provide an experienced
Field Service Engineer to accomplish the following tasks:
03720-048-01
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a. The equipment shall be visually inspected upon completion of installation
and prior to energizing to assure that wiring is correct, interconnection
complete and the installation is in compliance with the manufacturer's
criteria. Documentation shall be reviewed to assure that all Drawings,
operation and maintenance manuals, parts list and other data required to
16050-5 Electrical — General Provisions
EMI
check out and sustain equipment operation is available on site.
Documentation shall be red -lined to reflect any changes or modifications
made during the installation so that the "as -built" equipment configuration
will be correctly defined. Spare parts shall be inventoried to assure correct
type and quantity.
b. The Field Service Engineers shall provide engineering support during the
energizing and check out of each major equipment assembly. They shall
perform any calibration or adjustment required for the equipment to meet
the manufacturer's performance specifications.
c. Upon satisfactory completion of equipment test, they shall provide
engineering support of system tests to be performed in accordance with
manufacturer's test specifications.
d. Three (3) 4 -hour training sessions (one for each system) on operation, and
two (2) 4 -hour training sessions (one for each system) on maintenance and
trouble -shooting procedures shall be provided for the Owner's maintenance
personnel. All training shall be conducted at a facility provided by the
Owner. The maintenance and trouble -shooting sessions shall be conducted
with record "as -built" electrical drawings sufficient for a class of eight
personnel.
e. A final report shall be written and submitted to the Contractor within
fourteen days from completion of final system testing. The report shall
document the inspection and test activity, define any open problems and
recommend remedial action.
PART 2 - PRODUCTS
2.01 MATERIALS AND EQUIPMENT
A. The materials used in all systems shall be new, unused and as hereinafter specified. All
materials where not specified shall be of the very best of their respective kinds.
Samples of materials or manufacturer's specifications shall be submitted for approval as
required by the Engineer.
B. Materials and equipment used shall be Underwriters Laboratories, Inc., listed.
C. Electrical equipment shall, at all times during construction, be adequately protected
against mechanical injury or damage by water. Electrical equipment shall not be stored
out-of-doors. Electrical equipment shall be stored in dry permanent shelters. If any
apparatus has been damaged, such damage shall be repaired by the Contractor at his
own cost and expense. If any apparatus has been subject to possible injury by water, it
shall be thoroughly dried out and put through such special tests as directed by the
Engineer, at the cost and expense of the Contractor, or shall be replaced by the
Contractor at his own expense.
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16050-6 Electrical — General Provisions
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D. Surface mounted raceways and boxes mounted on tanks. Tanks walkways shall be
stainless steel as noted on drawings. All fasteners shall be type 316 stainless steel.
PART 3 - EXECUTION
3.01 INSTALLATION
A. Provide and place all sleeves for conduits penetrating floors, walls, partition, etc.
Locate all necessary slots for electrical work and form before concrete is poured.
B. All cutting and patching shall be done in a thoroughly workmanlike manner.
3.02 INSPECTION AND TESTING
A. Test all systems and repair or replace all defective work. Make all necessary
adjustments to the systems and instruct the Owner's personnel in the proper operation of
the systems.
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END OF SECTION
16050-7 Electrical — General Provisions
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SECTION 16110
RACEWAYS AND FITTINGS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Scope of Work:
1. Furnish and install complete raceway systems as shown on the Drawings and as
specified herein.
B. The complete raceway system rigid aluminum above grade and PVC -40 below grade.
1.02 QUALITY ASSURANCE
A. Qualifications:
1. The equipment shall be products of manufacturers who are fully experienced,
reputable and qualified in the manufacture of the equipment to be furnished. The
system components shall be designed, constructed, delivered and installed in
accordance with the best practices and methods.
B. Standards:
1. Underwriters Laboratories, Inc. (U.L.).
2. American Society for Testing and Materials, (ASTM).
3. Federal Specifications.
C. Manufacturers:
1. Non -Metallic Raceways.
a. Carlon.
b. Triangle Pipe and Tube Co.
c. Phillips Petroleum Co.
d. Indian Head Company.
e. Or equal.
2. Metallic Raceways:
a. Youngstown Sheet and Tube Co.
b. Allied Tube and Conduit Corp.
c. Wheeling -Pittsburg Steel Corp.
d. Or equal.
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1.03 SUBMITTALS
A. Material and Shop Drawings:
1. Copies of all materials required to establish compliance with these specifications
shall be submitted in accordance with the provisions of the General Conditions.
Submittals shall include at least the following:
a. Certified shop drawings with performance data and physical characteristics.
b. Descriptive literature, bulletins, and/or catalogs of each item of equipment.
c. All information required by Section 01340.
d. A complete total bill of materials for all equipment.
2. In the event that it is impossible to conform with certain details of the
specifications, describe completely all non -conforming aspects of the Shop
Drawing transmittal.
PART 2 - PRODUCTS
2.01 GENERAL
A. The specifications are intended to give a general description of what is required, but do
not cover all details which may vary in accordance with the exact requirements of the
equipment as offered. They are, however, intended to cover the furnishing, delivery,
installation and field testing of all materials, equipment and apparatus as required. Any
additional auxiliary equipment necessary for the proper operation of the proposed
installation not mentioned in these specifications, or shown on the Drawings shall be
furnished and installed.
B. The material covered by these specifications is intended to be standard equipment of
proven ability and as manufactured by reputable concerns having experience in the
production of such equipment. The equipment furnished shall be designed, constructed,
and installed in accordance with best practice and methods and shall operate
satisfactorily when installed as shown on the Drawings.
2.02 MATERIALS AND EQUIPMENT
A. Metallic Conduit:
1. ALUM conduit shall contain less than 0.1 percent copper and conform to Federal
Specification WW -C -540C.
B. Non -Metallic Conduit and Fittings:
1. PVC conduit shall be schedule 80 composed of High Impact PVC (polyvinyl)
chloride (C-200 Compound), and shall conform to industry standards, and be UL
listed in accordance with Article 347 of National Electrical Code for underground
and exposed use. Materials must have tensile strength of 55 PSI, at 70 degrees F,
03720-048-01 16110-2 Raceways and Fittings
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flexural strength of 11,000 PSI, compression strength of 8600 PSI. Manufacturer
shall have five years' extruding PVC experience.
2. Liquidtight Flexible Conduit and Fittings shall be for use per Article 351 of the
NEC. PVC compounds shall not include fillers. Fittings shall be manufactured
from high impact PVC.
C. Liquidtight, Flexible Non -Metallic Conduit, Couplings and Fittings:
1. Liquidtight, flexible non-metallic conduit shall be all PVC conduit and
manufactured by Thomas and Betts Co., K -Flex, Inc., or equal.
2. Fittings used with Liquidtight flexible conduit shall be of the non-metallic type as
manufactured by the Thomas and Betts Co., Xtraflex System, K -Flex, Inc., or
equal.
D. Flexible Couplings:
1. Flexible Couplings shall be as manufactured by the Thomas and Betts Co., K -
Flex, Inc., or equal.
E. Conduit hubs shall be as manufactured by Myers Electric Products, Inc., Raco„ Div.,
Appleton Electric Co., or equal.
F. Conduit wall seals shall be Type WSK as manufactured by the O.Z. Electrical Mfg. 0.,
or equal.
G. Combination expansion -deflection fittings shall be Type XD as manufactured by the
Crouse -Hinds Co., or equal.
PART 3 - EXECUTION
3.01 INSTALLATION
A. Installation shall be in strict accordance with the manufacturer's instructions and
recommendation, in the location shown on the Drawings.
B. No conduit smaller than 1/2 -inch electrical trade size shall be used, nor any have more
than three 90 degree bends in any one run. Pull boxes shall be provided as required or
directed. Minimum size floor conduit shall be 3/4 -inch.
C. No wire shall be pulled until the conduit system is complete in all details; in the case of
concealed work, until all rough plastering or masonry has been completed; in the case
of exposed work, until the conduit system has been completed in every detail.
D. The ends of all conduit shall be tightly plugged to exclude dust and moisture while the
buildings are under construction.
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E. Conduit supports shall be spaced at intervals of 4 feet or less, as required to obtain rigid
construction. Conduit straps shall be type as manufactured by "CLIC".
F. Single conduits shall be supported by means of one -hole non-metallic pipe clamps in
combination with one -screw back plates, to raise conduits from the surface. Multiple
runs of conduits shall be supported on trapeze type hangers with fiberglass horizontal
members and fiberglass treaded hanger rods. The rods shall be not less than 3/8 -inch
diameter.
G. Conduit hangers shall be attached to structural steel by means of non-metallic beam or
channel clamps. Where attached to concrete surfaces, concrete inserts of the spot type
shall be provided.
H. All conduits on exposed work shall be run at right angles to and parallel with the
surrounding wall and shall conform to the form of the ceiling. No diagonal runs will be
allowed. Bends in parallel conduit runs shall be concentric. All conduit shall be run
perfectly straight and true.
I. No broken run shall exceed 500 feet in length. This length shall be reduced by 75 feet
for each 90 degree elbow.
J. Conduit terminating in boxes shall have sealing double lock -nuts and insulating
bushings.
K. Conduit terminating in gasketed enclosures shall be terminated with sealing conduit
hubs.
L. Conduit wall seals shall be used for all conduits penetrating walls below grade or other
locations shown on the Drawings.
M. Liquidtight flexible metal conduit shall be used for all motor terminations and other
outdoor equipment where vibration is present.
N. Flexible couplings shall be used in hazardous locations for all motor termination and
other equipment where vibration is present.
0. Expansion fittings shall be installed in the following cases: In each conduit run
wherever it crosses an expansion joint in the concrete building structure; in each conduit
run which is mechanically attached to separate structures to relieve strain caused by
shift on one structure in relation to the other; in straight conduit runs above ground
which is more than one hundred feet long and interval between expansion fittings in
such a run shall not be greater than 100 feet.
P. PVC joints shall be solvent welded. Threads will not be permitted on PVC conduit and
fittings. Installation of PVC conduit shall be in accordance with manufacturer's
recommendations. PVC conduit shall not be used to support fixture or equipment.
Field bends shall be made with approved hotbox. Heating with flame and hand-held
dryers are prohibited.
03720-048-01 16110-4 Raceways and Fittings
August 2019 EMI
Q. Conduit installations on roofs shall be kept to a bare minimum. Conduit shall be
supported above roof at least 6 inches using approved conduit supporting devices.
Supports to be fastened to roof using roofing adhesive as approved by roofing
contractor.
R. Cables in vertical raceways shall be supported as per NEC Article 300-19. Provide and
install supporting devices for cables, including any necessary accessible pullbox as
required regardless if shown on drawings or not. Provide and install access panels as
required. Coordinate location of pull box and access panel with the Engineer prior to
installation. This includes empty raceways for future use.
S. Provide and install pullboxes, junction boxes, fire barrier at fire rated walls, etc., as
required by NEC Article 300, whether shown on drawings or not.
T. Paint all field cut threads and coat all aluminum conduits in contact with concrete per
manufacturer's recommendations.
U. Raceways which do not have conductors furnished under this division of specification
shall be left with an approved nylon pullcord in the raceway.
V. Grounding conductor shall be included in total conduit fill determining conduit sizes,
even though not included or shown on drawings. Grounding conductors run with
feeders shall be bonded to portions of conduit that are metal by approved ground
bushings.
W. All aluminum conduits in contact with concrete shall be coated with bitumastic paint.
END OF SECTION
03720-048-01 16110-5 Raceways and Fittings
August 2019 EMI
SECTION 16120
WIRES AND CABLES
PART 1 - GENERAL
1.01 DESCRIPTION
A. Scope of Work:
1. Furnish, install and test all wire, cable and appurtenances as shown on the
Drawings and as hereinafter specified.
B. General Design:
1. Wire for lighting, and receptacle circuits in the administration building shall be
type THHN solid.
2. Wire for all power feeder and motor circuits outside of the administration building
shall be type THHN stranded.
3. Single conductor wire for control, indication and metering shall be type THHN
No. 14 AWG, stranded.
4. Multi -conductor control cable shall be No. 14 AWG, stranded tinned copper.
5. Wire for process instrumentation shall be No. 16 AWG, stranded tinned copper.
6. Except for control and signal leads, no conductor smaller than No. 12 AWG shall
be used.
1.02 QUALITY ASSURANCE
A. Standards:
1. Insulated Cable Engineers Association (ICEA).
2. Underwriters Laboratories, Inc. (U.L.)
3. American Society for Testing and Materials (ASTM)
B. Manufacturers:
1. 600 volt wire and cable.
a. Hi -Tech Cable Corp.
b. Collyer Insulated Wire Co.
c. Okonite Co.
d. Rome Cable Co.
e. American Insulated Wire Corp.
f. Triangle PWC, Inc.. Or equal
03720-048-01 16120-1 Wires and Cables
August 2019 EMI
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2. Instrumentation and Control Cable:
a. American Insulated Wire Corp.
b. Rome Cable Corp.
c. Okonite Co.
d. Eaton Corp. "Polyset".
e. Triangle PWC, Inc.
f. Or Equal.
1.03 PRODUCT DELIVERY, STORAGE AND HANDLING
A. All conductors shall be carefully handled to avoid kinks or damage to the insulation.
B. All conductors stored outdoors shall be covered.
PART 2 - PRODUCTS
2.01 GENERAL
A. Wires and cables shall be of annealed, 98 percent conductivity, soft drawn copper
conductors.
B. All conductors shall be stranded except lighting and receptacle circuits.
2.02 MATERIALS
A. 600 Volt Wire and Cable:
1. Type THHN shall be PVC insulation with nylon jacket.
B. Instrumentation and Control Cable:
1. Process instrumentation wire shall be twisted pair, 600 volt, cross linked
polyethylene insulated, aluminum tape shielded, polyvinyl chloride jacketed, type
"XLP". Multi -conductor cables with individually shielded twisted pairs shall be
installed where indicated.
2. Multi -conductor control cable shall be stranded, 600 volt, cross-linked
polyethylene insulated with PVC jacket, type "XLP".
C. Terminations and Splices:
1. Unless otherwise indicated on the plans, no splices may be made in the cables
without prior approval of the Engineer. Where splicing is approved, the splicing
material shall be as recommended and approved by the cable manufacturer.
03720-048-01
August 2019
16120-2 Wires and Cables
EMI
PART 3 - EXECUTION
3.01 INSTALLATION
A. All conductors shall be carefully handled to avoid kinks or damage to insulation.
B. Lubrications shall be used to facilitate wire pulling. Lubricants shall be U.L. listed for
use with the insulation specified.
C. Shielded instrumentation wire shall be installed from terminal to terminal with no
splicing at any intermediate point.
D. Shielded instrumentation wire shall be installed in rigid steel conduit and pull boxes that
contain only shielded instrumentation wire. Instrumentation cables shall be separated
from control cables in manholes.
E. Shielding on instrumentation wire shall be grounded at one end only as directed by the
supplier of the instrument.
F. Wire and cable connections to terminals, splices, and taps shall be made with
compression connectors. Connections of insulated conductors shall be insulated and
covered. All connections shall be made using materials and installation methods in
accordance with instructions and recommendations of the manufacturer of the particular
item of wire and cable. The conductivity of all completed connections shall not be less
than that of the uncut conductor. The insulation resistance of all completed connections
of insulated conductors shall be not less than that of the uncut conductor.
G. All wire and cable shall be continuous and without splices between points of connection
to equipment terminals, except a splice will be permitted by the Engineer if the length
required between the points of connection exceeds the greatest standard shipping length
available from the manufacturer specified or as approved by the Engineer.
H. Installed, unapproved wire shall be removed and replaced at no additional cost to the
Owner.
I. Steel fish tapes and/or steel pulling cables shall not be used in PVC raceway systems.
J. Remove debris and moisture from the conduits, boxes, and cabinets prior to cable
installation and mandrel with device of one size smaller than conduit and mandrel with
wire brush one size larger than conduit.
3.02 TESTS
A. All 600 -volt wire insulation shall be tested with a megohm meter after installation.
Tests shall be made at not less than 1000-VDC. A cable test data form shall be
provided for Engineer review.
03720-048-01
August 2019
16120-3
Wires and Cables
EMI
B. All service conductors shall be tested as in Paragraph A above. These tests shall be
witnessed by the Engineer.
03720-048-01
August 2019
END OF SECTION
16120-4
Wires and Cables
EMI
SECTION 16130
BOXES
PART 1 - GENERAL
1.01 DESCRIPTION
A. Scope of Work
1. Furnish and install all junction boxes, pull boxes, service entrance boxes and for a
complete raceway system as shown on the Drawings and as specified herein.
B. General Design
1. Unless otherwise hereinafter specified or shown on the Drawings, all boxes and
fasteners shall be type NEMA 4X, 316 -stainless steel.
2. All boxes in air conditioning plenums above ceilings shall be pressed steel.
3. All boxes that do not receive devices are to have blank plates installed matching
wiring device plates.
1.02 QUALITY ASSURANCE
A. Standards
1. Underwriters Laboratories, Inc. (U.L.)
2. Federal Specifications
3. American Society for Testing and Material, (ASTM)
B. Manufacturers
1. Hoffman, Type CHNFSS
2. Or Equal
1.03 SUBMITTALS
A. Materials and Shop Drawings
1. See Section 16050 - General Provisions.
1.04 PRODUCT DELIVERY, STORAGE AND HANDLING
A. Boxes and fittings shall be stored indoors protected from damage.
03720-048-01
August 2019
16130-1
Boxes
EMI
1.05 WARRANTY AND GUARANTEES
A. All boxes and fittings shall be warranted against defects or failure for a period of
1 year from date of acceptance.
PART 2 - PRODUCTS
2.01 MATERIALS
A. Boxes shall be constructed as follows:
1. 14 -gauge 316L stainless steel
2. Continuously welded and ground smooth, no holes or knockouts.
3. Seamless foam in-place gasket, watertight, dust -tight.
4. Stainless steel screws and clamps.
PART 3 - EXECUTION
3.01 INSTALLATION
A. All boxes shall be supported away from surfaces.
B. All boxes shall be sized per the National Electrical Code (NEC)
C. All conduit entries into boxes shall not lower or change the NEMA rating of the box.
03720-048-01
August 2019
END OF SECTION
16130-2
Boxes
EMI
SECTION 16140
WIRING DEVICES
PART 1 - GENERAL
1.01 DESCRIPTION
A. Scope of Work: 1
1
1
1
1
1. Furnish and install wiring devices and all necessary accessories and
I
appurtenances required as hereinafter specified and shown on the Drawings.
2. Wiring devices shall include the following:
a. Wall Switches
b. Device Plates
c. Plugs
d. Receptacles
e. Lighting Control Time Clocks
f. Lighting Contactors
g. Control Stations
h. Ground Fault Interrupter Receptacles
B. Related Work Described Elsewhere:
1. General Provisions: Section 16050.
2. Raceway: Section 16110.
1.02 QUALITY ASSURANCE
A. Standards:
1. Underwriters Laboratories Inc. (UL).
2. National Electric Manufacturers Association (NEMA).
3. National Electrical Code (NEC).
B. Manufacturers:
1. Wall switches, device plates, plugs, and receptacles as follows:
a. Arrow -Hart
b. Bryant
c. Hubbell
d. Leviton
e. or Equal
03720-048-01
August 2019
16140-1
Wiring Devices
EMI
1
1
1
1
1
1
1
1
1
1
1
1
1
2. Clocks:
a. Simplex
b. or Equal
3. Lighting Contactors:
a. Square -D
b. Cutler -Hammer
c. or Equal
4. Dimmer Controls:
a. Leviton
b. Prescolite
c. or Equal
5. Control Stations:
a. Hoffman Engineering Co.
b. Square -D
c. Crouse -Hinds
d. Or equal
1.03 SUBMITTALS
A. Material and Shop Drawings:
1. Submit material list and catalog cut -sheets for all items covered under this
section. Indicate type, ratings, material, color, and manufacturer.
1.04 PRODUCT DELIVERY, STORAGE AND HANDLING
A. All devices covered under this Section shall be stored indoors, protected from damage.
PART 2 - PRODUCTS
2.01 MATERIALS
A. Switches:
1. Wall switches shall be of the indicating, toggle action, flush mounting quiet type.
All switches shall conform to Federal Specification W -S -896-D.
03720-048-01
August 2019
16140-2
Wiring Devices
EMI
2. Wall switches shall be of the following types and manufacturer or equal. Any
reference to a specific figure number of a specific manufacturer is for the purpose
of establishing a type and quality of product and shall not be considered as
proprietary.
a. Single pole - Arrow -Hart, Catalog No. 1991.
b. Double pole - Arrow -Hart, Catalog No. 1992.
c. Three way - Arrow -Hart, Catalog No. 1993.
d. Four way - Arrow -Hart, Catalog No. 1994.
e. Single pole, key operated - Arrow -Hart Catalog No.11991-L.
f. Momentary contact, 2 circuit, center off - Arrow -Hart, Catalog No. 1895.
g. Weatherproof cover for Arrow -Hart 2900 series tap action switches -
Arrow -Hart Catalog No. 2881-G.
B. Receptacles:
1. Wall receptacles shall be of the following types and manufacturer or equal.
a. Single, 20A, 125V, 1P, 3W; Arrow -Hart, Catalog No 5351.
b. Duplex, 20A, 125V, 2P, 3W; Arrow -Hart, Catalog No. 5352.
c. Weatherproof, 20A, 125V, 2P, 3W; Arrow -Hart, Catalog No. 5351 and
WLRD-1 cover.
d. Corrosion -resistant, duplex, 20A, 1 25V, 2P, 3W; Arrow -Hart, Catalog No.
5351 and WLRD-1 cover.
e. 60A, 480V, 3P, 2W; weatherproof receptacle shall be Crouse -Hinds
Catalog No. ARE6324 with Crouse -Hinds Catalog No. APJ 6385 plug.
f. Ground fault interrupter, duplex, 20A, 125V, 3P, 2W; Arrow -Hart Catalog
No. GF5342.
g. Stainless steel indoor mounting plate for G.F.I. receptacle; Arrow -Hart
Catalog No. 97061.
h. Weatherproof cover for G.F.I. receptacle in FS box; Arrow -Hart Catalog
No. 4501 -FS.
i. Clock hanger, 15A, 125V, 2P, 3W; Arrow -Hart Catalog No. 452.
j. Single, 20A, 125V, 2P, 3W; Arrow -Hart Catalog No. 8510BL; cover:
Arrow -Hart Catalog No. 9301C indoor, 7420C weatherproof.
k. Single, 30A, 125V, 2P, 3W; Arrow -Hart Catalog No. 5716N; cover:
Arrow -Hart Catalog No. 9301C indoor, 7420C weatherproof.
1. Clothes dryer, 30A, 125/250V, 3P, 3W; Arrow -Hart Catalog No. 9344N.
Matching cord set shall also be included.
C. Device Plates:
03720-048-01
August 2019
1. Plates for flush mounted devices shall be of the required number of gangs for the
application involved and shall be 302 (18-8) high nickel stainless steel of the
same manufacturer as the device.
16140-3
Wiring Devices
EMI
1
1
1
D. Lighting Contactor:
1. Lighting contactors shall be of the electrically operated, electrically held type in
NEMA 1 enclosures of the number of poles as called for on the Drawings.
2. Contactors shall be rated for 25A-600 volt contacts and be similar and equal to
Automatic Switch Company bulletin 1255-166 RC.
E. Lighting Control Time Switches:
1. Time switches for the control of lighting shall have astronomic dials, reserve
power and be similar and equal to the following types:
a. Where time switch is indicated to be for momentary contact operation it
shall be similar and equal to Intermatic Inc. Catalog No. ET -70115-C.
b. Where time switch is indicated for SPST maintained control it shall be
similar and equal to Intermatic Inc. Catalog No. V -45471 -CR.
c. Where time switch is indicated for DPST maintained control it shall be
similar and equal to Intermatic Inc. Catalog No.V-45471-CR.
d. Where time switch is indicated for roadway or equipment, lighting shall be
similar or equal to Intermatic Inc. Catalog No. ET -7000 Series.
F. Control Stations:
1. Control stations for start/stop pushbutton and hand -off -automatic selector
switches shall be corrosion resistant, dust -tight, watertight and weatherproof,
NEMA 4X, 600 VAC, UL Standard 508 as manufactured by Crouse -Hinds Series
NCS or equal.
PART 3 - EXECUTION
3.01 INSTALLATION
A. Receptacles in process areas and shops shall be mounted 36 inches above the floor
unless otherwise noted on the Drawings.
B. Receptacles in office and other like areas shall be mounted 18 inches above the floor
unless otherwise noted on the Drawings.
C. Use bolt, screws, nuts and other threaded devices having standard threads and heads so
they may be installed and replaced without special tools.
D. Check light switch locations before rough -in to avoid installing a switch behind the
door swing.
E. The Engineer and Owner reserve the right to change any switch or receptacle location
within the same room, without added cost prior to rough -in.
03720-048-01
August 2019
16140-4
Wiring Devices
EMI
F. Locate outlets intended for the supply of specific items such as water coolers, copying
machines, fans, etc., as recommended by the item manufacturer.
03720-048-01
August 2019
END OF SECTION
16140-5
Wiring Devices
EMI
1
1 SECTION 16150
MOTORS
I
PART 1 - GENERAL
1.01 DESCRIPTION
IA. Scope of Work:
1. Furnish and install the motors as hereinafter specified and as called for in
other sections of these Specifications.
IB. Related Work Described Elsewhere:
1 1. Equipment: Division 11.
1.02 QUALIFICATIONS
1 A. Qualifications:
1. Motors shall be sufficient in size for the duty to be performed and shall not
I
exceed their full -rated load when the driven equipment is operating at
specified capacity. Unless otherwise noted, motors driving pumps shall
not be overloaded at any head or discharge condition of the pump.
2. The equipment shall be products of manufacturers who are fully
experienced, reputable and qualified in the manufacture of the equipment
to be furnished. The system components shall be designed, constructed,
I
delivered and installed in accordance with the best practices and methods.
1.03 SUBMITTALS
I
A. The motor manufacturer shall submit to the Engineer: Shop Drawings, Working
Drawings and Samples: certified dimension prints showing nameplate data and
outline dimensions.
B. Guarantee: All equipment furnished and installed under this Section shall be
guaranteed against defects of workmanship, materials and proper installation for a
period of one year from date of acceptance. All such equipment or parts proven
I
defective, due to the above noted causes, shall be replaced in the machines by the
Contractor at no expense to the Owner.
I
PART 2 - PRODUCTS
2.01 GENERAL
IA. The specifications are intended to give a general description of what is required,
but do not cover all details which may vary in accordance with the exact
requirements of the equipment as offered. They are, however, intended to cover
I
the furnishing, delivery, installation and field testing of all materials, equipment
and apparatus as required. Any additional auxiliary equipment necessary for the
proper operation of the proposed installation not mentioned in these
I
specifications, or shown on the Drawings shall be furnished and installed.
I 03720-048-01 16150-1 Motors
August 2019 EMI
B. The material covered by these specifications is intended to be standard equipment
of proven ability and as manufactured by reputable concerns having experience in
the production of such equipment. The equipment furnished shall be designed,
constructed, and installed in accordance with best practice and methods and shall
operate satisfactorily when installed as shown on the Drawings.
2.02 MATERIALS AND EQUIPMENT
A. Rating:
1. Unless otherwise noted, motors 200 horsepower and below shall be
of the low voltage type. Unless otherwise noted, all motors 1/2 through
200 horsepower shall be rated 230/460 volt, 3-phase, 60 Hertz A.C.,
premium efficient, and motors: below 1/2 horsepower shall be rated
115/230 volt, 1 -phase, 60/Hertz A.C.
2. Motor connected to variable frequency drives shall be rated as inverter
duty by the motor manufacturer. The motor manufacturer shall submit in
writing that the motor is suitable for the drive.
B. All dripproof and weather protected Type 1 (WP 1) motors shall have epoxy
encapsulated windings. Small motors not readily available with encapsulated
windings may be standard type, except non -encapsulated motors exposed to the
outside atmosphere shall be totally enclosed.
C. All motors shall include space heaters to prevent condensation on the motor
windings when the motor is not operating. The space heaters shall be sized by the
motor manufacturer; maximum 200 watts; 120 volts.
D. Squirrel -cage rotors shall be made from high-grade steel laminations adequately
fastened together and to the shaft, or shall be cast aluminum or bar -type
construction with brazed end rings.
E. Low Voltage, Three -Phase Motors:
03720-048-01
August 2019
1. Motors shall be of the squirrel -cage or wound rotor induction type as
noted. Horizontal, vertical solid shaft, vertical hollow shaft, normal thrust
and high thrust types shall be furnished as called for on the Drawings and
as specified herein. All motors shall be built in accordance with current
NEMA, IEEE, ANSI and AFMBA standards where applicable. Motors
shall be of the type and quality described by the Specifications, and/or as
shown on the schedule on the Drawings, fully capable of performing in
accordance with manufacturer's nameplate rating, and free from defective
material and workmanship.
2. Motors shall have normal or high starting torque (as required), low starting
current (not to exceed 600 percent full load current), and low slip.
3. Motors shall be of drip proof or weather protected Type 1 or totally
enclosed fan cooled construction as called for on the Drawings or specified
in other sections of these specifications, with 1.15 service factor.
4. Motors shall be suitable for operation in moist air with hydrogen sulfide
gas present
5. The output shaft shall be suitable for direct connection or belt drive as
required.
16150-2
Motors
EMI
03720-048-01
August 2019
6. Motors shall have a Class F non -hygroscopic insulation system. Class F
insulation may be used but shall be limited to Class B temperature rise.
7. All motors shall have a final coating of chemical resistant corrosion and
fungus protective epoxy fortified enamel finish sprayed over red primer
over all interior and exterior surfaces. Stator bore and rotor of all motors
shall be epoxy coated.
8. All fittings, bolts, nuts, screws shall be plated to resist corrosion. Bolts
and nuts shall have hex heads.
9. All machine surfaces shall be coated with rust inhibitor for each
disassembly.
10. Motor terminal boxes shall be cast iron diagonally split, one size larger
than the manufacturer's standard (motors above 200HP only), pipe tapped
for conduit and shall be attached to the motor frame with cadmium plated
hex head cap screws. The box shall be arranged for rotation so that
conduit entry from either sides, or bottom is possible. Gaskets shall be
supplied between the box and the motor frame and between halves of the
box. Cover shall be installed with cadmium plated hex head cap screws.
The box shall come completely assembled to the motor. Motor leads in
the conduit box shall have the same insulation class as the windings, shall
be sized in accordance with EASA suggested minimum ampacity values
using 105 degree C insulated lead wire. The wiring shall be clearly
identified every inch or the lead shall have a metal band in accordance
with ANSI C6.1, latest revision. Nameplates shall be supplied stating the
above data and permanently attached to the motor. Where the leads exit
the motor frame, they shall pass through a tight fitting neoprene rubber
seal to prevent foreign material or air passage and to hold the leads in a
centered position. Motors shall be provided with a compression type
grounding lug, mounted in the conduit box by drilling and tapping into the
motor frame or by a double ended cap screw of silicon bronze.
11. Totally enclosed motors shall be provided with condensate drain hole and
epoxy coated motor windings to protect against moisture.
12. Nameplates shall be stainless steel. Lifting lugs or "0" type bolts shall be
supplied on all frames 254T and larger. Enclosures will have stainless
steel screen and motors shall be protected for corrosion, fungus and
insects.
13. Low voltage, three-phase motors shall be manufactured by, Baldor,
Marathon or Relience Electric.
14. Fractional Horsepower:
a. Fractional horsepower motors shall be rigid, welded -steel designed
to maintain accurate alignment of motor components and provide
adequate protection. End shields shall be reinforced, lightweight
die-cast aluminum. Windings shall be of varnish -insulated wire
with slot insulation of polyester film, baked -on bonding treatment
to make the stator winding strongly resistant to heat, aging,
moisture, electrical stresses and other hazards.
16150-3
Motors
EMI
b. Motor shaft shall be made from high-grade, cold -rolled shaft steel
with drive -shaft extensions carefully machined to standard NEMA
dimensions for the particular drive connection.
c. For light to moderate loading bearings shall be quiet all angle
sleeve type with large oil reservoir that prevents leakage and
permits motor operation in any position.
d. For heavy loading, bearings shall be carefully selected precision
ball bearings with extra quality, long -life grease, and large
reservoir providing 10 years' normal operation without lubrication.
15. Integral Horsepower:
a. Motor frames and end shield shall be cast iron or heavy fabricated
steel of such design and proportions as to hold all motor
components rigidly in proper position and provide adequate
protection for the type of enclosure employed.
b. Windings shall be adequately insulated and securely braced to
resist failure due to electrical stresses and vibrations.
c. The shaft shall be made of high-grade machine steel or steel
forging of size and design adequate to withstand the load stresses
normally encountered in motors of the particular rating. Bearing
journals shall be ground and polished.
d. Rotors shall be made from high-grade steel laminations adequately
fastened together, and to the shaft. Rotor squirrel -cage windings
shall be cast -aluminum or bar -type construction with brazed end
rings.
e. Motors shall be equipped with vacuum -degassed anti -friction
bearings made to AFBMA Standards, and be of ample capacity for
the motor rating. The bearing housing shall be large enough to
hold sufficient lubricant to minimize the need for frequent
lubrication, but facilities shall be provided for adding new
lubricant and draining out old lubricant without motor disassembly.
The bearing housing shall have long, tight, running fits or rotating
seals to protect against the entrance of foreign matter into the
bearings, or leakage of lubricant out of the bearing cavity.
f. Bearings of high thrust motors will be locked for momentary up
thrust or 30 percent down thrust. All bearings shall have a
minimum B10 life rating of 5 years in accordance with AFBMA
life and thrust values.
g. Vertical hollow -shaft motors will have non -reverse ratchets to
prevent backspin.
F. Inverter Duty Motors:
1. In addition to the requirements of 16150-2.02 A., B., C., D., and E.,
motors intended for use with variable frequency drives shall be inverter
duty motors specifically designed for inverter operation, and shall be
applied in accordance with NEMA, ANSI, IEEE, AFBMA AND NEC for
the duty imposed by the driven and drive equipment. Inverter duty motors
shall be specifically certified by the motor manufacturer to be compatible
with the variable frequency drive to be used with the motor. Inverter -duty
motors shall be designed to operate over a frequency range of 0 to
66 Hertz. Motor insulation for all motors operating with variable
frequency drives shall be Class H with Class F temperature rise when
operated with the inverter continuously at all speed and load conditions
throughout the specified operating range. Insulation systems shall be
03720-048-01
August 2019
16150-4
Motors
EMI
capable of withstanding a change in voltage (dV/dT) of 1600 peak volts
and rise time greater than 0.1 microseconds without damage per NEMA
MG -1 Section IV, Part 31.40.4.2. Motors rated less than 200 horsepower
shall be protected with two normally closed thermal protectors in the stator
winding and shall be set to open when the temperature reaches 155°C.
Motors rated 200 horsepower and greater shall have platinum RTD
overtemperature protection The motor frame shall be cast iron. Inverter
Duty motors shall be Baldor Inverter Drive Motors, Reliance Electric.
2. Motors shall be suitable for operation in moist air with hydrogen sulfide
gas present
3. Conduit boxes shall be gasketed. Lead wires between motor frame and
conduit box shall be gasketed.
4. Totally enclosed motors shall be provided with condensate drain hole and
epoxy coated motor windings to protect against moisture.
5. Nameplates shall be stainless steel. Lifting lugs or "0" type bolts shall be
supplied on all frames 254T and larger. Enclosures will have stainless
steel screen and motors shall be protected for corrosion, fungus and
insects.
G. Low Voltage, Single Phase Motors:
1. Single phase motors shall be split -phase and capacitor -start induction
types rated for continuous horsepower at the rpm called for on the
Drawings. Motors shall be rated 115/230 volts, 60 Hertz, single phase,
open, drip proof, or totally enclosed fan cooled as called for on the
Drawings or other sections of these specifications, with temperature rise in
accordance with NEMA Standards for Class B insulation.
2. Totally enclosed fan cooled motors shall be designed for severe duty.
3. Motors shall have corrosion and fungus protective finish on internal and
external surfaces. All fittings shall have a corrosion protecting plating.
4. Mechanical characteristics shall be the same as specified for polyphase
fractional horsepower motors.
PART 3 - EXECUTION
3.01 INSTALLATION
A. Motor connections: All motors shall be connected to the conduit system by a
means of a short section (18 inch maximum) of flexible conduit unless otherwise
indicated. For motor connections of No. 6 AWG and smaller wire size, the
Contractor shall furnish flexible conduit with an approved grounding conductor
inside the flexible section. For motor connections of No. 4 AWG or larger wire
size, the Contractor shall install a grounding conductor in the conduit and
terminate at the motor control center with an approved grounding clamp.
3.02 INSPECTION AND TESTING
A. The following tests shall be performed on all motors after installation but before
putting motors into service.
1. The Contractor shall megger each motor winding before energizing the
motor, and, if insulation resistance is found to be low, shall notify the
Engineer and shall not energize the motor. The following table gives
minimum acceptance insulation resistance in megohms at various
03720-048-01
August 2019
16150-5
Motors
EMI
03720-048-01
August 2019
temperatures and for various voltages with readings being taken after one
minute of megger test run.
Winding Temp (F°) 115V. 230V. 460V.
37
60
108
210
50
32
60
120
68
13
26
50
86
5.6
11
21
104
2.4
4.5
8.8
122
1
2
3.7
140
.50
.85
1.6
2. The Contractor shall check all motors for correct clearances and alignment
and for current lubrication, and shall lubricate if required in accordance
with manufacturer's instructions. The Contractor shall check direction of
rotation of all motors and reverse connections if necessary.
END OF SECTION
16150-6
Motors
EMI
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
SECTION 16160
PANELBOARDS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Scope of Work:
1. Furnish all labor, materials, equipment, and incidentals required and install all
panelboards as hereinafter specified and as shown on the Drawings.
1.02 QUALITY ASSURANCE
A. Standards:
1. Panelboards shall be in accordance with the Underwriter Laboratories, Inc.
"Standard for Panelboards" and "Standard for Cabinets and Boxes" and shall be
so labeled where procedures exist. Panelboards shall also comply with NEMA
Standard for Panelboards and the National Electrical Code.
B. Manufacturer (NEMA 1 and NEMA4X):
1. 120/240V, single phase, 3 wire, and 120/208V three phase, 4 -wire panelboards
shall be as manufactured by the General Electric, Square D Co., or
Cutler/Hammer.
2. 480V, three phase, 3 -wire panelboards shall be as manufactured by the, Square D
Co., I -Line, or Cutler/Hammer or General Electric.
C. Manufacturer (NEMA 3 and 12):
1. NEMA 3 and 12 panelboards shall be type NLP as manufactured by the Crouse -
Hinds Company or equal.
1.03 SUBMITTALS
A. Materials and Shop Drawings:
1. See Section 16050, Electrical — General Provisions.
03720-048-01
August 2019
16160-1
Panelboards
EMI
PART 2 - PRODUCTS
2.01 RATING
A. Panelboard ratings shall be as shown on the Drawings. All panelboards shall be rated
for the intended voltage.
2.02 CONSTRUCTION AREA (NEMA 1)
A. Interiors:
1. All interiors shall be completely factory assembled with circuit breakers, wire
connectors, etc. All wire connectors, except screw terminals, shall be of the anti -
turn solderless type and all shall be suitable for copper or aluminum wire of the
sizes indicated.
2. Interiors shall be so designed that circuit breakers can be replaced without
disturbing adjacent units and without removing the main bus connectors and shall
be so designed that circuits may be changed without machining, drilling or
tapping.
3. Branch circuits shall be arranged using double row construction except when
narrow column panels are indicated. Branch circuits shall be numbered by the
manufacturer.
4. A nameplate shall be provided listing panel type, number of circuit breakers,
ratings and source.
B. Buses:
1. Bus bars for the mains shall be of tin-plated copper. Full size neutral bars shall be
included. Bus bar taps for panels with single pole circuit devices shall be
arranged for sequence phasing of the branch circuit devises. Bussing shall be
braced throughout to conform to industry standard practice governing short circuit
stresses in panelboards. Phase bussing shall be full height without reduction.
Cross connectors shall be copper.
2. Neutral bussing shall have a suitable lug for each outgoing feeder requiring a
neutral connection.
3. Spaces for future circuit breakers shall be bussed for the maximum device that
can be fitted into them.
C. Boxes:
1. Recessed boxes shall be made from galvanized code gauge steel without multiple
knockouts. Surface mounted boxes shall be painted to match the trim. Boxes
shall be of sufficient size to provide a minimum gutter space of 4 inches on all
sides.
2. Surface mounted boxes shall have an internal and external finish as hereinafter
specified in Paragraph D4.
3. At least 4 interior mounting studs shall be provided.
4. All conduit entrances shall be field punched.
03720-048-01
August 2019
16160-2
Panelboards
EMI
D. Trim:
1. Hinged doors covering all circuit breaker handles shall be included in all panel
trims.
2. Doors shall have semi flush type cylinder lock and catch, except that doors over
48 inches in height shall have a vault handle and 3 -point catch, complete with
lock, arranged to fasten door at top, bottom and center. Door hinges shall be
concealed. Two keys shall be supplied for each lock. All locks shall be keyed
alike; directory frame and card having a transparent cover shall be furnished on
each door.
3. The trims shall be fabricated from code gauge sheet steel.
4. All exterior and interior steel surfaces of the panelboard shall be properly cleaned
and finished with ANSI Z55.1, No. 61 light gray paint over a rust -inhibiting
phosphatized coating. The finish paint shall be of a type to which field applied
paint will adhere.
5. Trims for flush panels shall overlap the box by at least 3/4 inch all around.
Surface trims shall have the same width and height as the box. Trims shall be
fastened with quarter turn clamps.
2.03 CONSTRUCTION (NEMA 4X)
A. Interiors and Buses:
1. Interiors and buses shall be as hereinbefore specified for NEMA 1 construction.
2. Interior trim shall be complete. No exposed wiring allowed.
B. Boxes and Covers:
1. Boxes and covers shall be made from 316 stainless steel.
2. Boxes and covers shall be hinged together and gasketed. All metallic parts on
exterior shall be stainless steel.
3. Conduit openings shall be sealed with lock rings or sealing washers.
4. Polycarbonate or plastic enclosures or boxes are unacceptable.
2.04 CIRCUIT BREAKERS
A. Panelboards shall be equipped with circuit breakers with frame size and trip settings as
shown on the Drawings.
B. Circuit breakers shall be molded case, bolt -in type, for NEMA 1 and plug-in for
NEMA 4X.
C. Circuit breakers used in 120/240 and 120/208V panelboards shall have an interrupting
capacity of not less than 10,000 amperes, RMS symmetrical.
D. Three pole breakers used in 480V panelboards shall have an interrupting capacity of not
less than 25,000 amperes, RMS symmetrical.
03720-048-01
August 2019
16160-3
Panelboards
EMI
E. GFCI:
1. GFCI (ground fault circuit interrupter) shall be provided for circuits where
indicated on the Drawings. GFCI units shall be 1 pole, 120 volt, molded case,
bolt -on breakers, incorporating a solid state ground fault interrupter circuit
insulated and isolated from the breaker mechanism. The unit shall be U.L. listed
Class A Group I device (5 milliamp sensitivity, 25 millisecond trip time), and in
interrupting capacity of 10,000 amperes RMS.
PART 3 - EXECUTION
3.01 INSTALLATION
A. Boxes for surface mounted panelboards shall be mounted so there is at least 1/2 -inch air
space between the box and the wall.
B. Unless otherwise noted on the Drawings, top of cabinets shall be mounted 6 -feet 0 -inch
above the floor, properly aligned and adequately supported independently of the
connecting raceways.
C. All wiring in panelboards shall be neatly formed, grouped, laced and identified to
provide a neat and orderly appearance. A typewritten directory card identifying all
circuits shall be placed in the card holder inside the front cover.
03720-048-01
August 2019
END OF SECTION
16160-4
Panelboards
EMI
SECTION 16170
SAFETY SWITCHES
PART I- GENERAL
1.01 DESCRIPTION
A. Scope of Work:
1. Furnish and install all motor and circuit disconnects as hereinafter specified and as
shown on the drawing.
B. General Design:
1. All switches shall be heavy duty and have stainless steel NEMA 4X enclosures
and be horsepower rated.
2. All switches shall have metal nameplates, front cover mounted, that contain a
permanent load, switch -type, catalog number and HP ratings, handle whose
position is easily recognizable and is padlockable in the "off' position, visible
blades, reinforced fuse clips, nonteasible, positive, quick make -quick break
mechanism, switch assembly plus operating handle as an integral part of the
enclosure base.
3. Switches shall have defeatable door interlocks that prevent the door from opening
when the operating handle is in the "on" position. All switches shall have line
terminal shields.
4. All current carrying parts shall be copper.
5. Auxiliary contacts rated 10 ampere at 240 volts shall be provided, for motor space
heater interlock and position indication.
1.02 QUALITY ASSURANCE
A. Standards:
1. National Electrical Manufacturer's Association (NEMA).
2. Underwriter's Laboratories (UL).
3. Federal Specifications.
4. National Electrical Code (NEC).
B. Manufacturer:
1. Switches shall be as manufactured by Square D Co. Class 9422, Cutler -Hammer,
or equal.
03720-048-01
August 2019
16170-1
Safety Switches
EMI
1.03 SUBMITTALS
A. Materials and Shop Drawings:
1. See Section 16050 — Electrical, General Provisions.
1.04 PRODUCT DELIVERY, STORAGE AND HANDLING
A. All switches shall be stored indoors protected from damage.
1.05 WARRANTY AND GUARANTEES
A. All switches shall be warranted against defect, rusting or failure for a period of one year
from date of acceptance.
PART 2 - PRODUCTS
2.01 MATERIALS AND EQUIPMENT
A. Where a six -pole weatherproof disconnect are called for on the Drawings, the
Contractor shall provide two 600 -Volt, 3 -pole non -fusible switches in a single
NEMA 4X stainless steel enclosure with a single operating handle mechanically
interlocked to both disconnects.
B. All parts exposed to the weather or in hose down areas shall be stainless steel.
C. Short circuit rating — 10,000 RMS symmetrical amperes for non-fused switches.
D. Line and load lugs shall be front removable and suitable for copper, 60/75°C wire
through 200A sizes, 75°C wire for 400-800A sizes.
PART 3 - EXECUTION
3.01 INSTALLATION
A. All switches shall be mounted as shown on the Drawings.
B. Location of disconnect switches shall be per the N.E.C. and shall be verified with the
Engineer before installation.
C. All mounting appurtenances shall be 316 stainless steel including fasteners.
03720-048-01
August 2019
END OF SECTION
16170-2
Safety Switches
EMI
SECTION 16370
VARIABLE SPEED DRIVES
PART 1 GENERAL
1.01 DESCRIPTION
A. Scope of Work
1. Furnish and install variable speed drives including all appurtenances
required as shown on the drawing and specified herein.
2. All equipment and accessories shall have approved manufacturer's shop
drawings prior to installation and shall be tested in conformance with these
Performance Specifications prior to acceptance and final payment by the
Owner.
B. Related Work Described Elsewhere
1. Equipment: Division 11.
1.02 QUALITY ASSURANCE
A. Variable speed drives shall be sufficient size for the duty to be performed and
shall not exceed their full -rated capacity when the driven equipment is operating
as specified. Variable speed drives driving pumps shall not be overloaded under
any operating condition of the pump.
B. Standards
1. National Electrical Manufacturers Association (NEMA).
2. Institute of Electrical and Electronics Engineers, Inc. (IEEE).
3. American National Standards Institute (ANSI).
4. National Electric Code (NEC).
C. The variable frequency control shall operate satisfactorily when connected to a
bus supplying other solid state power conversion equipment which may be
causing up to 10% total harmonic voltage distortion and commutation ASDs shall
meet requirements as outlined in the latest edition of IEEE -519 for total harmonic
voltage and current distortion. Individual or simultaneous operation of the ASD's
shall not add more than 5% total harmonic voltage distortion to the normal bus,
nor more than 10% while operating from standby generator. The point of
common coupling shall be the secondary side of the service transformer. Twelve -
pulse (minimum) harmonic rectifier technology are required to meet these
requirements, it is the responsibility of the ASD manufacturer to provide this
harmonic technology within the ASD enclosure.
03720-048-01 16370-1 Variable -Speed Drives
January 2021 EMI
D. The controller shall be subject to, but not limited to, the following quality
assurance controls, procedures and tests:
1. Power transistors, SCR's and diodes shall be tested to ensure correct
function and highest reliability.
2. All printed circuit boards shall be tested at 50 degree C for 50 hours. The
ASD manufacturer shall provide certification that the tests have been
completed.
3. Every controller will be functionally tested with a motor to ensure that if the
drive is started up according to the instruction manual provided, the unit will
run properly.
4. The ASD systems shall be fabricated by the same ASD manufacturer, items
must not be fabricated in whole or in part by parties other than the ASD
manufacturer. Third party distributor or packager modifications to a
standard product will not be allowed.
5. The ASD shall be fully designed and manufactured in the United States of
America.
D. Approved Manufacturers:
1. Yaskawi.
1.03 DRIVE MANUFACTURES'S RESPONSIBILITIES
A. The ASD manufacturer shall be responsible for the installation, testing and start-
up of each drive.
B. The ASD manufacturer shall be responsible for the coordination of the drive with
thier respective motor specfied in other Sections of the Project Specifications.
C. The ASD manufacturer shall be, at no additional cost to the Owner, responsible
for mitigating any harmonic, and/or all RF and/or EMI and/or any electrical type
noise created by the drive which adversly affect the proper operation of any and
all electronic and/or electrical power and/or mechanical devices on this project.
D. The ASD manufacturer shall provide input and/or output filters and/or any other
accessories on each drive to mitigate all electrical and mechanical noise to a limit
which is not detrimental to the motor winding irregardless of the motor lead
length and/or type of conduit or charecteristics to this installation.
E. The ASD manufacturer shall be responsible for all additionnal cost related to the
installation of the drive that is above and beyond the scope of work shown on the
drawings and specification.
F. The ASD manufacturer shall pay for all engineering fees and Owner costs related
to the services required by the Consultant and Owner to assist in the mitigation of
ASD related problems.
03720-048-01 16370-2 Variable -Speed Drives
January 2021 EMI
1.06 PRODUCT DELIVERY, STORAGE AND HANDLING
A. The equipment shall be maintained in an upright position at all times. Lifting shall be
only at the floor sills or the top mounted lifting angles.
B. The equipment shall be protected against damage at all times. Any damage to the paint
shall be carefully repaired using touch-up paint furnished by the ASD Manufacturer.
C. Each box or package shall be properly marked to show its net weight in addition to its
contents.
PART 2 PRODUCTS
2.01 VARIABLE FREQUENCY ADJUSTABLE SPEED DRIVES (VARIABLE TORQUE,
PWM)
A. General:
1. The variable frequency drive (ASD) motor controller shall convert 460 Volt,
three-phase, 60 Hertz utility power to adjustable voltage (0-460V) and
frequency (0-60 Hz.) three-phase, AC power for stepless motor speed
control with a capability of 10:1 speed range. All general options and
modifications shall mount within the standard adjustable frequency
controller enclosure.
2. The adjustable frequency controller shall be a space vector sine -coded
Pulse -Width Modulated (PWM) design. Modulation methods which
incorporate "gear -changing" techniques are not acceptable. Distributor or
packager modifications to a third -party standard product will not be allowed.
All drives shall be manufactured by a single manufacturer, and shall be of
the same technology.
3. The controller(s) shall be suitable for use with any standard configuration
squirrel -cage induction motor(s) having a 1.05 or better service factor, or
with existing standard squirrel -cage induction motor(s) with nameplate data
as shown on the plans. At any time in the future, it shall be possible to
substitute any standard motor (equivalent horsepower, voltage and RPM) in
the field.
4. The Contractor shall be responsible for the erection, installation and start up
on the equipment covered by this Specification.
5. Complete drawings shall be furnished for approval before proceeding with
manufacture and shall consist of master wiring diagrams, elementary or
control schematics including coordination with other electrical control
devices operating in conjunction with the Adjustable Frequency Drive, and
suitable outline drawings with sufficient details for locating conduit stub -
ups and field wiring.
6. The Adjustable Frequency Drive manufacturer shall maintain and staff
engineering service and repair shops throughout the United States,
including the State of Florida, trained to do start up service, emergency
03720-048-01 16370-3 Variable -Speed Drives
January 2021 EMI
service calls, repair work, service contracts and training of customer
personnel.
B. Construction
1. Each Adjustable Frequency Drives shall consist of a 460V, 6 -pulse
minimum rectifier and adjustable frequency inverter with features, functions
and options as specified.
2. The controller shall produce an adjustable AC voltage/frequency output. It
shall have an output voltage regulator to maintain correct output V/Hz.
despite incoming voltage variations.
3. The controller shall have a continuous output current rating of 100% of
motor nameplate current.
4. The ASD shall be of the Pulse -Width Modulated type and shall employ a 6 -
pulse (minimum) dual full -wave diode bridge converters to convert
incoming fixed voltage/frequency to a fixed DC voltage, all components for
12 -pulse converters must be integral to ASD enclosure and require no
additional installation costs. The Pulse Width Modulation strategy shall be
of the space vector type implemented in a microprocessor which generates a
sine -coded output voltage.
5. The inverter output shall be generated by Insulated Gate Bipolar Ttransistors
(IGBT) which shall be controlled by six identical base driver circuits. The
ASD shall not induce excessive power losses in the motor. The worst case
RMS motor line current measured at rated speed, torque and voltage shall
not exceed 1.05 times the rated RMS motor current for pure sine wave
operation.
6. The Adjustable Frequency Drives shall be rated for the HP, full load
amperes and rpm of the motor. They shall be designed to provide
continuous speed adjustment of three-phase motors. The Adjustable
Frequency output voltage shall provide constant volts -per -Hertz excitation
to the motor terminals up to 60 Hertz.
7. Controllers shall be rated for an ambient temperatureof 0°C. to 40°C., an
altitude of up to 3,300 feet above sea level and humidity of 0 to 95% non -
condensing.
8. Controller enclosures shall be NEMA Type I floor -mounted, force
ventilated above 25 HP. The inverters shall have complete front
accessibility with easily removable assemblies.
9. The door of each power unit shall include a "POWER ON light, a ASD fault
light, a ASD run light, stop push-button, start push-button, a fault reset
03720-048-01 16370-4 Variable -Speed Drives
January 2021 EMI
push-button, a "HAND -OFF -AUTOMATIC" selector switch, and a manual
speed control potentiometer.
10. The ASD shall be software programmable to provide automatic restart after
any individual trip condition resulting from either overcurrent, overvoltage,
undervoltage, or overtemperature. For safety, the drive shall shut down and
require manual reset and restart if the automatic reset/restart function is not
successful within a maximum of three attempts within a short time period.
11. A speed droop feature shall be included which reduces the speed of the drive
on transient overloads. The drive is to return to set speed after transient is
removed. If the acceleration or deceleration rates are too rapid for the
moment of inertia of the load, the drive is to automatically compensate to
prevent drive trip.
12. Automatic restart after drive trip or utility failure. Software selectable if not
desired.
13. Process signal inverter. Software selectable to allow speed of drive to vary
inversely with input signal.
14. Proportional and integral setpoint process controller with menu driven
selection and programming via door -mounted keypad.
15. Pick up a spinning load. The ASD shall be able to determine the motor
speed and resume control of a motor which is spinning in either direction
without tripping.
16. A door -mounted membrane keypad with integral 2 -line, 24 -character LCD
display shall be furnished, capable of controlling the ASD and setting drive
parameters, and shall include the following features:
17. The digital display must present all diagnostic message and parameter
values in English engineering units when accessed, without the use of codes.
18. The keypad module shall contain a "self -test" software program which can
be activated to verify proper keypad operations.
19. 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). Drive
parameters shall be factory set in EEPROM and resettable in the field
through the keypad. Six (6) levels of password security shall be available to
protect drive parameters from unauthorized personnel. The EEPROM
03720-048-01 16370-5 Variable -Speed Drives
January 2021 EMI
03720-048-01
January 2021
stored drive variables must be able to be transferred to new boards to
reprogram spare boards.
a. Normally the digital display shall simultaneously display:
1. Speed demand in percent.
2. Output current in amperes.
3. Frequency in hertz.
4. Control Mode: Manual/Automatic.
5. Total three-phase KW or output volts.
20. The controller shall include the following protective features:
a. Single phase fault or 3-phase short circuit on ASD output terminals
without damage to any power component.
b. Static instantaneous overcurrent and overvoltage trip with inverse
overcurrent protection.
c. Static overspeed (overfrequency) protection.
d. Line or fuse loss and undervoltage protection.
e. Power unit overtemperature protection.
f. Electronic motor overload protection.
g. Responsive action to motor winding temperature detectors or
thermostatic switches.
i. LED status indicators on regulator, printed circuit board face plates.
j. Isolated operator controls.
k. Input line fuses.
1. Be insensitive to incoming power phase sequence.
m. Have desaturation circuit to drive inverter section transistor base
current to zero in event of controller fault.
n. Have DC bus discharge circuit for protection of operator and service
personnel with an indicator lamp.
o. Input line noise suppression with line reactor.
21. The following system configuring settings shall be provided, without
exception, field adjustable through the keypad/display unit or via the serial
communication port only.
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 min.
8. Current max.
16370-6 Variable -Speed Drives
EMI
b. ASD Limits
1. Independent accel/decel rates.
2. No load boost.
3. Vmin, Vmax, V/Hz.
4. Full load boost.
5. Overload trip curve select (Inverse or Constant).
6. Min./max. speed (frequency).
7. Auto reset for load or voltage trip select.
8. Slip compensation.
9. Catch -A Spinning -Load select.
10.Overload trip time set.
c. ASD Parameters
1. Voltage loop gain.
2. Voltage loop stability.
3. Current loop stability.
d. Controller Adjustments
1. PID control enable/disable.
2. Setpoint select.
3. Proportional band select.
4. Reset time select.
5. Rate time select.
6. Input signal scaling.
7. Input signal select (4-20mA/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.
22. The ASD 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 ASD.
23. A "FAULT LOG" shall record, store, display and print upon demand, the
following for the 10 most recent events:
a. ASD mode (Auto/Manual).
b. Elapsed time (since previous fault).
c. Type of fault.
25. The fault log record shall be accessible via a RS232 serial link as well as
line by line on the keypad display.
03720-048-01 16370-7 Variable -Speed Drives
January 2021 EMI
26. The following factory installed modifications shall be furnished with the
controller:
a. Input circuit breaker, interlocked with the enclosure door, with
through -the -door handle to provide positive disconnect of incoming
AC power. The circuit breaker shall be rated for 65,000 AIC.
b. Door -mounted meters or keypad display shall be provided on all units
as follows:
1. Analog or digital ammeter (0% - 110%).
2. Analog or digital speed/frequency meter (0 110% speed as well
as Hz).
3. Analog or digital voltmeter (0 - 600 VAC).
4. Analog or digital KW meter(0 - 110%).
5. 5 -digit elapsed time meter.
6. HAND -OFF -REMOTE Selector Switch.
c. The drive is to be provided with isolated 4-20mA DC output signals
proportional to speed and current for remote monitoring of the ASD.
d. Relay output auxiliary contacts to indicate the position of all selector
switches, drive failures and drive status.
e. Ethernet/IP Interface.
f. Provide 120VAC and logic for motor space heater control.
g. Provide control of remote seal water solenoids
h. Provide for motor t -stat shut down.
PART 3 EXECUTION
3.01. SYSTEM OPERATION
03720-048-01
January 2021
1. With the ASD H -O -R switch in the "HAND" position and the remote
H -O -A in the HAND position, the drive shall be controlled by the manual
speed potentiometer or keypad located on the drive door.
2. With the ASD H -O -R switch in the "OFF" position and the remote H -O -A
in the OFF position, the drive shall not start under any condition.
3. With the ASD H -O -R switch in the "REMOTE" position and the remote
H -O -A in the AUTO position, the drive shall be controlled via the
Ethernet/IP interface.
16370-8 Variable -Speed Drives
EMI
1
1
3.02 INSTALLATION
A. Field wiring shall be per manufacturer's recommendation.
B. The manufacturer shall include in his bid one (1) normal work day per drive of a
qualified service engineer's time. This time will be used to ensure proper
connection and functioning of the equipment prior to startup and to train Owner
personnel in the use of the equipment.
C. The manufacturer shall provide one spare for each type of plug-in type PC card.
These spares will be color -coded or otherwise keyed to its original counterpart. In
addition to the cards, the manufacturer shall provide two spares per drive all
expendable items such as fuses, pilot lamps, etc.
3.03 INSPECTION AND TESTING
A. The drive manufacturer shall test the drive controller with a motor load prior to
shipment.
B. The drive manufacturer shall furnish a certified field test report demonstrating
installed compliance for voltage and current distortion at the required point of
common coupling under both utility power and generator power. The test shall
report shall be sealed by a Florida Registered Professional Electrical Engineer.
C. A copy of all tests and checks performed in the field, complete with meter
readings and recordings, where applicable, shall be submitted to the Owner.
03720-048-01
January 2021
END OF SECTION
16370-9 Variable -Speed Drives
EMI
SECTION 16402
UNDERGROUND SYSTEM
PART 1 - GENERAL
1.01 DESCRIPTION
A. Scope of Work
1. Furnish and install a complete underground system of ducts, manholes and
handholes all as hereinafter specified and shown on the Drawings.
B. Related Work Described Elsewhere
1. Excavation and backfilling is included in Division 2.
2. All concrete and reinforcing steel shall be included under Division 3.
3. Conduit for ducts shall be as specified under Section 16110.
4. Ground rods and other grounding materials and methods shall be as specified
under other sections of Division 16.
PART 2 - PRODUCTS
2.01 MATERIALS
A. Ducts shall be encased in concrete as indicated on the plans.
B. Cable racks, supports, pulling -in irons, manhole steps, and hardware shall be galvanized
steel manufactured by Cope or equal.
C. Precast manholes and handholes shall be heavy duty type, designed for a Class H2O
wheel load. Precast manholes and handholes shall be as manufactured by Brooks
Products Co.
D. Handhole covers and frames shall be as shown on the Drawings.
E. Fireproofing tape shall be Irvington No. 7700 or be an approved equal product.
03720-048-01
August 2019
16402-1 Underground System
EMI
1
1
PART 3 - EXECUTION
3.01 INSTALLATION
A. Ducts shall be installed to drain away from buildings; ducts between manholes or
handholes shall drain toward the manholes or handholes. Duct slopes shall not be less
than 3 inches per 100 feet.
B. Duct banks shall be reinforced as shown on the Drawings.
C. Duct lines shall be laid in trenches on a clean backfill bedding not less than 6 inches
thick and well graded.
D. Plastic spacers shall be used to hold ducts in place. Spacers shall provide not less than
2 -inch clearance between ducts.
E. The minimum cover for duct lines shall be 24 inches unless otherwise permitted by the
Engineer.
F. Duct entrances to buildings and structures shall be made with steel conduit not less than
10 feet long.
G. PVC duct termination at manholes shall be with PVC end bells. Steel conduits shall be
terminated with insulated, grounding -type bushings.
H. Where bends in ducts are required, long radius elbows, sweeps and offsets shall be used.
I. All ducts shall be rodded and a mandrel drawn through followed by a swab to clean out
any obstructions which may cause cable abrasions. The mandrel shall be 12 inches in
length and the diameter 1/2 inch less than the inside diameter of the duct.
J. Spare ducts shall be plugged and sealed watertight at all manholes, buildings, and
structures.
K. Ducts in use shall be sealed watertight at all manholes, buildings, and structures.
L. Pulling -in irons shall be installed opposite all duct entrances to manholes, equal to Cope
Catalog No. 311-9.
M. Cable racks shall be similar and equal to Cope Catalog 324-T, cut to length for one,
two, three or four vertical tiers of cables. Racks shall be mounted with 1/2 -inch by
4 -inch expansion bolts on manhole walls. Arms similar and equal to Cope Catalog
No. 325-T4, 325-T75 and/or 325-T10 for one, two and/or three cables, respectively,
shall be furnished and installed with Catalog No. 326-T22 porcelain insulators for
support of cables. Lock clips shall be furnished and installed to secure hooks in
position.
03720-048-01 16402-2 Underground System
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N. Cables shall be trained in manholes and supported on racks and hooks at intervals not
greater than 3 feet - 0 inches and supports shall be installed on each side of all splices.
Furnish inserts on all manhole walls for mounting future racks as well as racks required
for present installation. Branch circuit conductors shall not be run in manholes.
O. Fireproofing shall be furnished for all 5 -KV cables in manholes. Each individual 5 -KV
cable shall be wrapped with an arc -proofing tape. The tape shall be applied in
accordance with the manufacturer's recommendations. The wrapping shall extend into
the end bells.
P. Aluminim rigid conduit shall be used for risers.
Q.
All risers from underground shall be given a heavy coat of bitumastic paint from a point
1 foot - 0 inches below grade to a point not less than 6 inches above grade or surface of
slab.
R. All joints shall be made so as to prevent the passage of concrete inside the conduit to
form obstructions or cause cable abrasions.
S. Manhole covers in streets shall finish flush with finished paving and in other areas shall
finish 3 inches above crown of adjacent roadway. Floor elevations of manholes shall be
so set that the center line of the lowest conduit entering will be not less than 1 foot
above the floor and center line of the highest conduit entering will be not less than
1 foot below the roof slab.
T. Concrete monuments shall be provided at each stubbed conduit location. Monuments
shall be as shown on the Drawings and shall be installed in the same manner outlined
for manhole covers.
U. A #6 bare copper wire (stranded) shall be installed in each 4 -inch PVC conduit.
V. A 5/8 -inch by 10 -foot copper clad ground rod shall be driven in the bottom of each
manhole. All bond wires and galvanized steel conduits shall be bonded to the ground
rod.
END OF SECTION
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SECTION 16450
GROUNDING SYSTEM
PART 1 - GENERAL
1.01 DESCRIPTION
A. Scope of Work
1. Furnish and install a complete grounding system in strict accordance with
Article 250 of the National Electrical Code and as hereinafter specified and shown
on the Drawings.
B. Related Work Described Elsewhere
1. Wire: Section 16120.
2. Conduit: Section 16110.
1.02 QUALITY ASSURANCE
A. Qualifications:
1.
The equipment shall be products of manufacturers who are fully experienced,
reputable and qualified in the manufacture of the equipment to be furnished. The
system components shall be designed, constructed, delivered and installed in
accordance with the best practices and methods.
1.03 SUBMITTALS
A. Material and Shop Drawings:
1. Copies of all materials required to establish compliance with these specifications
shall be submitted in accordance with the provisions of the General Conditions.
Submittals shall include at least the following:
a. Certified shop drawings with performance data and physical characteristics.
b. Descriptive literature, bulletins, and/or catalogs of each item of equipment.
c. All information required by Section 01340.
d. Complete wiring diagrams and schematics of all power and control systems
showing wiring requirements between system and connections to work of
other sections.
1.04 PRODUCT DELIVERY, STORAGE AND HANDLING
A. Deliver a complete system ready to install as job progress requires.
03720-048-01
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16450-1 Grounding System
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PART 2 - PRODUCTS
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A. The specifications are intended to give a general description of what is required, but do
not cover all details which may vary in accordance with the exact requirements of the
equipment as offered. They are, however, intended to cover the furnishings, delivery,
installation and field testing of all materials, equipment and apparatus as required. Any
additional auxiliary equipment necessary for the proper operation of the proposed
installation not mentioned in these specifications, or shown on the Drawings shall be
furnished and installed.
B. The material covered by these specifications is intended to be standard equipment of
proven ability and as manufactured by reputable concerns having experience in the
production of such equipment. The equipment furnished shall be designed, constructed,
and installed in accordance with best practice and methods and shall operate
satisfactorily when installed as shown on the Drawings.
2.02 MATERIALS AND EQUIPMENT
A. Ground rods: Ground rods shall be copper clad steel 3/4 inch x 20 foot, minimum
depth. Ground rods shall be copperweld or equal.
PART 3 - EXECUTION
3.01 INSTALLATION 1
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A. The 480 volt switchgear ground bus shall be grounded to a ground loop system. The
protecting conduits shall be bonded to the grounding conductor at both ends.
B. All steel building columns shall be bonded together and connected to the building
ground grid.
C. Motors shall be grounded as hereinafter specified.
D. Lighting transformer neutrals shall be grounded to the nearest grounding electrode.
E. Grounding electrodes shall be driven as required. Where rock is encountered,
grounding plates may be used in lieu of grounding rods.
F. All equipment enclosures, motor and transformer frames, conduits systems, cable
armor, exposed structural steel and similar items shall be grounded.
G. Exposed connections shall be made by means of approved grounding clamps. Exposed
connections between different metals shall be sealed with No -Oxide Paint Grade A or
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equal. All buried connections shall be made by welding process such as Cadweld or
equal.
H. For reasons of mechanical strength, grounding conductors shall be No. 10 AWG
minimum copper, minimum size.
I. All underground conductors shall be laid slack and where exposed to mechanical injury,
shall be protected by pipes or other substantial guards. If guards are iron pipe or other
magnetic material, conductors shall be electrically connected to both ends of the guard.
J. The Contractor shall exercise care to insure good ground continuity, in particular
between the conduit system and equipment frames and enclosures. Where necessary,
jumper wires shall be installed.
3.02 INSPECTION AND TESTING
A. The Contractor shall obtain the services of an NETA recognized testing firm to measure
the ground resistance of the system. All test equipment shall be provided by the
Contractor and approved by the Engineer. Dry season resistance of the system shall not
exceed 5 ohms. If such resistance cannot be obtained with the system as shown, the
Contractor shall provide additional grounding as directed by the Engineer, without
additional payment.
END OF SECTION
03720-048-01 16450-3 Grounding System
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SECTION 16460
GENERAL PURPOSE TRANSFORMERS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Scope of Work:
1. Furnish and install general purpose transformers and all necessary accessories and
appurtenances required as here -in -after specified and shown on the drawings.
B. Related Work Described Elsewhere:
1. Raceways and Fittings Section 16110.
C. General Design:
1. General purpose transformers shall be dry type, two -winding type, self cooled,
600V class transformers.
2. Transformers shall be designed for continuous operation at rated KVA, with
normal life expectancy as defined in ANSI C57.96.
1.02 QUALITY ASSURANCE
A. Standards
1. National Electrical Manufacturers (NEMA)
2. American National Standards Institute (ANSI)
3. Underwriters Laboratories, Inc. (UL)
B. Equipment Manufacturer
1. General Electric Co.
2. Cutler -Hammer
3. Square D. Co.
4. Or Equal.
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1.03 SUBMITTALS
A. Materials and Shop Drawings:
1. Copies of all materials to establish compliance with these specifications shall be
submitted in accordance with the provisions of the general conditions. Submittals
shall include at least the following:
a. Shop drawings with performance data and physical characteristics.
b. Complete wiring diagrams and schematics of all power connections.
1.04 PRODUCT DELIVERY, STORAGE AND HANDLING:
A. General purpose transformers shall be stored indoors and protected against damage at all
times.
1.05 WARRANTY AND GUARANTEES:
A. The equipment manufacturer shall warrant the units being supplied to the Owner against
defects in workmanship and materials for a period of one (1) year from the date of
equipment startup and acceptance. In the event that the equipment fails to perform as
specified, the equipment manufacturer shall promptly repair or replace the defective
equipment without any cost to the owner
PART 2 - PRODUCTS
2.01 GENERAL:
A. Insulation System:
1. Transformers shall be insulated as follows:
a. 150°C insulation with 80°C rise for 2 KVA and below.
b. 185°C insulation with 15°C rise for 3 KVA to 30 KVA
c. 220°C insulation with 150°C rise for 45 KVA to 112.5 KVA
2. All insulation materials shall be flame retardant and shall not support combustion
as defined in ASTM D635.
B. Coil Assemblies:
1. Transformer cone shall be constructed with high grade, non -aging, grain -oriented
silicon steel with high magnetic permeability and low hysteresis and eddy current
losses. The core volume shall allow efficient transformer operation at 10% above
the highest tap voltage. Coils shall be wound of electrical grade aluminum with
continuous wound construction.
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2. Non -ventilated unit coil assembly shall be completely encapsulated in a mixture
of resin and aggregate.
3. Four full capacity taps shall be furnished, two 2-1/2 percent above and two 2-1/2
percent below rated primary voltage.
C. ENCLOSURES:
1. The enclosures shall be made of heavy gauge steel and shall be degreased,
cleaned, primed, and finished with ANSI 61 color weather -resistant enamel.
2. All ventilation openings shall be protected against falling dirt.
3. The maximum temperature of the enclosure shall not exceed 90°C.
4. The core of the transformer shall be visibly grounded to the enclosure.
5. Enclosure for Lime Building transformer shall be non -ventilating.
PART 3 - EXECUTION
3.01 INSTALLATION:
A. All floor mounted transformers shall be installed on 4 -inch concrete housekeeping pads.
B. All conduit entries to the transformer shall utilize sealtight flexible connectors.
3.01 INSPECTION:
A. The transformer interior shall be cleaned and free of all foreign materials.
03720-048-01
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END OF SECTION
16460-3 General Purpose Transformers
EMI
SECTION 16500
LIGHTING SYSTEM
PART 1 - GENERAL
1.01 DESCRIPTION
A. Scope of Work:
1. Furnish and install complete lighting systems including panelboards,
transformers, lighting fixtures, receptacles, switches, contractors, clocks and all
necessary accessories and appurtenances required as hereinafter specified and
shown on the Drawings.
B. Related Work Described Elsewhere
1. Panelboards: Section 16160.
2. Transformers: Section 16108.
3. Conduit: Section 16110.
4. Wire: Section 16120.
1.02 QUALITY ASSURANCE
A. Qualifications:
1. The equipment shall be a product of manufacturers who are fully experienced,
reputable and qualified in the manufacture of the equipment to be furnished. The
system components shall be designed, constructed, delivered and installed in
accordance with the best practices and methods.
2. The system shall be furnished by a single manufacturer who shall be responsible
for the coordination of the system design and who shall assume complete
responsibility for the proper operation of the system including equipment supplied
but not of his manufacture.
B. Standards:
All lighting fixtures shall be in accordance with the National Electrical Code and shall
be constructed in accordance with the latest edition of the Underwriters Laboratories
"Standards for Safety, Electrical Lighting Fixtures". All lighting fixtures shall be
Underwriters Laboratories labeled.
03720-048-01
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16500-1
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1.03 SUBMITTALS
A. Material and Shop Drawings:
1. Copies of all materials to establish compliance with these specifications shall be
submitted in accordance with the provisions of the General Conditions.
Submittals shall include at least the following:
a. Certified shop drawings with performance data and physical characteristics.
b. Descriptive literature, bulletins, and/or catalogs of each item of equipment.
c. A complete total bill of materials for all equipment.
d. Complete wiring diagrams and schematics of all power and control systems
showing wiring requirements between system and connections to work of
other sections.
2. In the event that it is impossible to conform with certain details of the
specifications, describe completely all non -conforming aspects of the Shop
Drawing transmittal.
PART 2 - PRODUCTS
2.01 GENERAL
A. The specifications are intended to give a general description of what is required, but do
not cover all details which may vary in accordance with the exact requirements of the
equipment as offered. They are, however, intended to cover the furnishing, delivery,
installation and field-testing of all materials, equipment and apparatus as required. Any
additional auxiliary equipment necessary for the proper operation of the proposed
installation not mentioned in these specifications, or shown on the Drawings shall be
furnished and installed.
B. The material covered by these specifications is intended to be standard equipment of
proven ability and as manufactured by reputable concerns having experience in the
production of such equipment. The equipment furnished shall be designed, constructed,
and installed in accordance with best practice and methods and shall operate
satisfactorily when installed as shown on the Drawings.
2.02 MATERIALS AND EQUIPMENT
A. Lighting Fixtures:
1. Lighting fixture types shall be as shown on the "Lighting Fixture Schedule" on
the Drawings. The catalog numbers listed are given as a guide to the design and
quality of fixture desired. Equivalent designs and equal quality fixtures of other
manufacturers will be acceptable.
03720-048-01 16500-2 Lighting System
August 2019 EMI
B. Lamps:
1. Fluorescent lamps shall be medium bi-pin and recessed double contact, rapid
start, standard cool white, all as indicated on the "Fixture Schedule".
2. Fluorescent electronic ballasts shall be Class P, rapid start, high power factor,
energy saving, CBM certified by E.T.L. and listed by Underwriters Laboratories,
Inc., for operation on 120 volts or as indicated in the "Fixture Schedule".
3. High pressure sodium or metal halide ballast shall be of the constant wattage
auto -transformer type of the correct size and voltage for the fixture it is to serve as
called for in the "Lighting Fixture Schedule" on the Drawings. All ballast shall be
as manufactured by Universal Manufacturing Corp., General Electric Company,
Advance Transformer Company or equal.
4. Incandescent lamps shall be inside frosted, extended service, 2500 hour life with
medium base.
5. All lamps shall be of one manufacturer and shall be as manufactured by Sylvania
Electric Products, Inc., General Electric Company, Westinghouse Electric
Corporation or equal.
C. Flexible Fixture Hangers:
1. Flexible fixture hangers used in nonhazardous areas shall be Type ARB and
flexible fixture supports used in hazardous areas shall be Type ECHF as
manufactured by the Crouse -Hinds Company or equal.
2. FRP channel shall be used to span for mounting of fixtures when required by
fixture location or as indicated on the Drawings.
PART 3 - EXECUTION
3.01 INSTALLATION
A. Each fixture shall be a complete finished unit with all components, mounting and/or
hanging devices necessary, for the proper installation of the particular fixture in its
designation location and shall be completely wired ready for connection to the branch
circuit wires at the outlet.
B. When fixtures are noted to be installed flush, they shall be complete with the proper
accessories for installing in the particular ceiling involved. All flush mounted fixtures
shall be supported from the structure and shall not be dependent on the hung ceilings for
their support.
C. Flexible fixture hangers shall be used for all pendant mounted fixtures.
D. Conduit run in areas with hung ceilings shall be installed in the space above the hung
ceiling as close to the structure as possible. Conduit shall be supported from the
structure.
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16500-3
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3.02 REPLACEMENT
A. Lamps used during the building construction, prior to two weeks from completion of the
work, shall be removed and replaced with new lamps.
3.03 CLEANING UP
A. All fixtures shall be left in a clean condition, free of dirt and defects, before acceptance
by the Engineer.
03720-048-01
August 2019
END OF SECTION
16500-4
Lighting System
EMI
SECTION 16601
LIGHTNING PROTECTION SYSTEM
PART 1 - GENERAL
1.01 DESCRIPTION
A. Scope of Work:
1. Furnish all labor, materials, equipment, and incidentals required and install
a complete lightning protection system for all of the proposed above
ground structures. The system shall include grounding of all handrail and
platform structures as follows:
a. Blending Structures
2. Material requirements shall be as listed for Class I buildings.
B. Applicable Publications: The publications listed below form a part of this
specification to the extent referenced. The publications are referred to in the text
by the basic designation only.
1. American National Standards Inst., Inc. (ANSI)
C-135.30 Galvanized Ferrous Ground Rods.
2. National Fire Protection Association (NFPA)
70-1987 National Electrical Code (NEC)
78-1986 Lightning Protection Code
3. Underwriters Laboratories, Inc. (UL)
UL -96 Lightning Protection Components
UL -96A Installation Requirements for Lightning
Protection Systems
UL -467 Grounding and Bonding Equipment
1.02 QUALITY ASSURANCE
A. Equipment Manufacturer: The material furnished under this specification shall
consist of the standard products of a manufacturer regularly engaged in the
production of lightning protection systems.
B. Supervision: The system shall be installed under supervision of, or by, a person
specifically trained for installation of lightning protection systems.
03720-048-01
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16601-1 Lightning Protection System
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1.03 SUBMITTALS
A. Shop Drawings: Shop drawings shall be submitted in accordance with Section
01340 and shall consist of a complete list of materials, including manufacturer's
descriptive and technical literature; catalog cuts; drawings; and installation
instructions. Shop drawings shall contain details to demonstrate that the system
has been coordinated and will function as a unit. Drawings shall show proposed
layout and mounting and relationship to other parts of the work.
B. Proof of Compliance: Where materials or equipment are specified to comply with
requirements of the UL, proof of such compliance shall be submitted. The label
of or listing in the UL Electrical Construction Materials Directory will be
acceptable evidence. In lieu of the label or listing, a written certification may be
submitted from an approved nationally recognized testing organization equipped
to perform such services, stating that the items have been tested and conform to
the requirements and testing methods of Underwriters' Laboratories.
PART 2 - PRODUCTS
2.01 MATERIALS AND EQUIPMENT
A. General Requirements:
1. The system furnished shall be complete with all air terminals, fittings,
clamps, supports, roof conductors, down conductors, and horizontal
grounds required. The system shall be interconnected with the building
ground grid. All conductors, fittings, clamps, and air terminals furnished
shall be of the highest quality.
2. System shall be an exposed conductor system. Care shall be taken that the
materials used will not discolor roofs or walls. Down conductors shall be
protected to 10 feet above grade and shall be located so that visual impact
will be minimal.
3. No combination of materials shall be used that form an electrolytic couple
of such nature that corrosion is accelerated in the presence of moisture
unless moisture is permanently excluded from the junction of such metals.
Where unusual conditions exist which would cause corrosion of
conductors, conductors with protective coatings or oversize conductors
shall be used. Where a mechanical hazard is involved, the conductor size
shall be increased to compensate for the hazard or the conductors shall be
protected by covering them with molding or tubing made of wood or non-
magnetic material.
B. Copper: Copper conductors shall not be less than #6 AWG for main conductor
and #8 for secondary conductor. Below grade conductors shall be #4/0 bare
copper.
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16601-2 Lightning Protection System
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C. Air Terminals: Air terminals shall be 3/8 inch diameter stainless steel and a
minimum 24 inches in length. Air terminals over 24 inches shall be supported.
D. Ground Rods: Ground rods shall be 3/4 inch by 10 feet copper -clad steel, with the
top of the rod, 12 inches below grade minimum and a minimum of 2 feet from
building foundation and footings.
E. Clamp -Type Connectors: Clamp -type connectors shall be of copper, bronze, or
stainless steel. Clamps shall be secured with at least two (2) bolts or cap screws.
F. Metal Bodies: Metal bodies of conductance shall be bonded to the system if not
within the zone of protection on an air terminal. Metal bodies of inductance shall
be bonded to the system at their closest point to the system if within 6 feet of the
system at their closest point to the system if within 6 feet of the system main
conductor or other bonded metal body. The main lightning conductor shall be
bonded to the main potable service water pipe.
PART 3 - EXECUTION
3.01 INSTALLATION
A. General Requirements: The lightning protection system shall consist of air
terminals, roof conductors, down conductors, ground connections, and grounds,
electrically interconnected to form the shortest distance to ground without passing
through any non -conducting parts of the structure. All conductors on the
structures shall be exposed except where conductors are in protective sleeves
exposed on the outside walls. Exposed down conductors shall not be allowed on
the outside face of the High Service Building and Chemical Building. Exposed
conductors shall be installed in a PVC -80 conduit on all other structures.
Secondary conductors shall interconnect with grounded metallic parts within the
building. Interconnections made within side -flash distances shall be at or above
the level of the grounded metallic parts.
B. Air Terminals: Air terminal design and support shall be in accordance with
NFPA 78. Terminals shall be rigidly connected to, and made electrically
continuous with, roof conductors by means of pressure connectors or crimped
joints with of T-shaped malleable metal and connected to the air terminal by a
dowel or threaded fitting. Air terminals at the ends of the structure shall be set not
more than 2 feet from the ends of the ridge or edges and corners of roofs. Spacing
of air terminals 2 feet in height on ridges, parapets and around the perimeter of
buildings with flat roofs shall not exceed 25 feet. In specific instances where it is
necessary to exceed this spacing, the specified height of air terminals shall be
increased not less than 2 inches for each foot of increase over 25 feet. On large,
flat or gently sloping roofs, as defined in NFPA 78, air terminals shall be placed at
points of the intersection of imaginary lines dividing the surface into rectangles
having sides not exceeding 50 feet in length. Air terminals shall be secured
03720-048-01 16601-3 Lightning Protection System
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against overturning either by attachment to the object to be protected or by means
of a substantial tripod or other braces permanently and rigidly attached to the
building or structure. Metal projections and metal parts of buildings,
smokestacks, and other metal objects that do not contain hazardous materials and
that may be struck but not appreciably damaged by lightning, need not be
provided with air terminals. However, these metal objects shall be bonded to the
lightning conductor through a metal conductor of the same unit weight per length
as the main conductor. Where metal ventilators are installed, air terminals shall
be mounted thereon, where practicable. Any air terminal erected by necessity
adjacent to a metal ventilator shall be bonded to the ventilator near the top and
bottom thereof. Where nonmetallic spires, steeples, or ventilators are present, air
terminals shall be mounted thereon or to the side. In addition, where spires or
steeples project more than 10 feet above the building, the conductor between the
air terminal and metal roof shall be continued to the nearest down conductor and
securely connected thereto.
C. Roof Conductors: Roof conductors shall be connected directly to the roof or ridge
roll. Sharp bends or turns in conductors shall be avoided. Necessary turns shall
have a radius of not less than 8 inches. Conductors shall preserve a downward or
horizontal course and shall be rigidly fastened every 4 feet along the roof and
down the building to ground. Metal ventilators shall be rigidly connected to the
roof conductor at three places. All connections shall be electrically continuous.
Roof conductors shall be coursed along the contours of flat roofs, ridges, parapets,
and edges; and where necessary, over flat surfaces, in such a way as to join each
air terminal to all the rest. Roof conductors surrounding tank tops, decks, flat
surfaces, and flat roofs shall be connected to form a closed loop.
D. Down Conductors: Down conductors shall be electrically continuous from air
terminals and roof conductors to grounding electrodes. Down conductors shall be
coursed over extreme outer portions of the building, such as corners, with
consideration given to the location of ground connections and air terminals. Each
building or structure shall have not less than two (2) down conductors located as
widely separated as practicable, at diagonally opposite corners. On irregularly
shaped structures, the total number of down conductors shall be sufficient to make
the average distance between them along the perimeter not greater than 100 feet.
Additional down conductors shall be installed when necessary to avoid "dead
ends" or branch conductors exceeding 16 feet in length, ending at air terminals.
Down conductors shall be equally and symmetrically spaced about the perimeter
of the structure. All down conductors shall be protected and installed in a
raceway, to prevent mechanical injury to the conductor.
E. Interconnection of Metallic Parts: Metal doors, windows, and gutters shall be
connected directly to the grounds or down conductors using not smaller than No.
6 copper conductor, or equivalent. Conductors placed where there is probability
of unusual wear, mechanical injury, or corrosion shall be of greater electrical
capacity than would normally be used, or shall be protected. The ground
03720-048-01
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connection to metal doors and windows shall be by means of mechanical ties
under pressure, or equivalent.
F. Ground Connections: Ground connections Comprising continuations of down
conductors form the structure to the grounding electrode shall securely connect
the down conductor and ground in a manner to ensure electrical continuity
between the two. All connections shall be of the clamp type. There shall be a
ground connection for each down conductor. Metal water pipes and other large
underground metallic objects shall be bonded together with all grounding
mediums. Ground connections shall be protected from mechanical injury. In
making ground connections, advantage shall be taken of all permanently moist
places where practicable, although such places shall be avoided if the area is wet
with waste water that contains chemical substances, especially those corrosive to
metal.
G. Grounding Electrodes: A grounding electrode shall be provided for each down
conductor located as shown. A driven ground shall extend into the earth for a
distance of not less than 10 feet. Ground rods shall be set not less than 2 feet, nor
more than 10 feet, from the structure. The complete installation shall have a total
resistance to ground of not more than 10 ohms (if a counterpoise is not used).
When two of any three ground rods, driven not less than 10 feet into the
perimeter, give a combined value exceeding 50 ohms immediately after driving, a
counterpoise shall be used. A counterpoise, where required, shall be of No. 1/0
copper cable or equivalent material having suitable resistance to corrosion and
shall be laid around the perimeter of the structure in a trench not less than 2 feet
deep at a distance not less than 2 feet nor more than 10 feet from the nearest point
of the structure. All connections between ground connectors and grounds or
counterpoise, and between counterpoise and grounds shall be electrically
continuous. Where so indicated on the drawings, an alternate method for
grounding electrodes in shallow soil shall be provided by digging trenches radially
from the building. The lower ends of the down conductors (or their equivalent in
the form of metal strips or wires) are then buried in the trenches.
H. Interconnection of Metal Bodies: Metal bodies of conductance shall be protected
if not within the zone of protection of an air terminal. All metal bodies of
conductance having an area of 400 square inches or greater or a volume of 1000
cubic inches or greater shall be bonded to the lightning protection system using
main size conductors and a bonding plate having a surface contact area of not less
than 3 square inches. Provisions shall be made to guard against the corrosive
effect of bonding dissimilar metals. Metal bodies of inductance shall be bonded at
their closest point to the lighting protection system using secondary bonding
conductors and fittings. A metal body that exceeds 5 feet in any dimension, that is
situated wholly within a building, and that does not at any point come within
6 feet of a lightning conductor or metal connected thereto shall be independently
grounded.
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3.02 TESTING
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A. System shall be installed so that tests of the grounds may be performed upon I completion of the installation of the system and in the future.
B. As soon as practicable after award of contract, the Contractor shall submit for
approval complete details of the system including a layout drawing so that the
system furnished can be coordinated in the refurbishing of the building.
END OF SECTION
03720-048-01 16601-6 Lightning Protection System
August 2019 EMI
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SECTION 16921
480 -VOLT MOTOR CONTROL CENTERS
PART 1 - GENERAL
1.01 DESCRIPTION
A. Scope of Work:
1. Furnish, install, and test the motor control centers as hereinafter specified and as
shown on the Drawings.
1.02 QUALITY ASSURANCE
A. Standards:
1. The motor control centers shall be the product of a manufacturer who shall also be
the manufacturer of all the circuit breakers, fused switches and motor starters
included in the motor control centers.
2. All units and sections shall be U.L. labeled when possible. Motor control centers
containing service entrance equipment shall be U.L. labeled "Suitable For Use As
Service Equipment".
3. Motor control centers shall be built and tested in accordance with:
a. National Electrical Manufacturers (NEMA).
b. American National Standards Institute (ANSI).
c. Underwriters Laboratories, Inc. (U.L.).
B. Equipment Manufacturer:
1. The motor control centers shall be Model 6 as manufactured by the Square D.
Co., Cutler/Hammer, or General Electric.
1.03 SUBMITTALS
A. Complete master wiring diagrams and elementary or control schematics, including
coordination with other electrical control devices operating in conjunction with the
motor control centers and suitable outline drawings shall be furnished for approval
before proceeding with manufacture. Due to the complexity of the control functions, it
is imperative the above drawings be clear and carefully prepared to facilitate
interconnections with other equipment. Standard preprinted sheets or drawings simply
marked to indicate applicability to this Contract will not be acceptable.
03720-048-01 16921-1 480 -Volt Motor Control Centers
August 2019 EMI
B. Submittals shall include a bill -of -material listing conductor material and insulation type
as well as other hardware and equipment to be furnished.
C. Where it is not explicitly shown and completely obvious from the outline drawings, the
following items shall be verified in a written statement accompanying the shop
drawings:
1. Type of terminal blocks used and that the removal of plug-in compartments can
be performed without disconnecting or removing wires.
2. Tin plating of bus.
3. Insulation and isolation of vertical bus.
4. U.L. approval.
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PART 2 - PRODUCTS
2.01 RATING 1
A. The motor control centers shall be designed for 480 volt, 3 phase, 3 wire, 60 Hz service
and shall have short-circuit rating of not less than 42,000 amperes RMS, symmetrical.
2.02 CONSTRUCTION
A. Structure:
1. The motor control centers shall be a standard metal -enclosed, free-standing,
deadfront structure, not more than 90 -inches in height, and fabricated from
formed sheet steel of not less than No. 14 gauge thickness. The enclosure shall be
NEMA 1. The motor control centers shall consist of vertical sections of equal
height and 20 inches deep containing individual plug-in compartments.
Compartments shall be isolated from each other by separate horizontal steel plates
or by steel plates without openings that are a part of the compartment itself.
2. Plug-in compartments shall totally isolate enclosed equipment. All unused
openings to the adjacent vertical wiring space shall be plugged. All openings
used for wiring shall have insulating grommets.
3. Vertical sections shall be mounted on steel channel sills continuous on four sides,
or with steel channel sills on two sides and end cover plates. Each compartment
shall be provided with a hinged door of pan construction on the front and a door
opening of sufficient size to permit ready removal of any of the equipment in the
compartment. Interlocks shall be provided to prevent opening the compartment
door when the disconnect device in the compartment is in the closed position. An
interlock bypass device shall be furnished. Means of locking the disconnect
device in the "Off' position shall be provided. Disconnect device operating
mechanism shall not be attached to the compartment door.
4. All sections shall have the same structural features with provisions for the
addition of similar sections at either end. Each compartment shall meet NEMA
Standards for the control equipment installed and units of similar size shall be
interchangeable.
03720-048-01 16921-2 480 -Volt Motor Control Centers
August 2019
EMI
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5. Each section shall be provided with a horizontal wiring space which shall line up
with a similar space in the adjacent section or sections, with openings between so
that wires may be pulled the entire length of the control centers. There shall also
be provided in each section a vertical wiring space with separate full height door.
6. The motor control centers shall be designed for against -the -wall mounting. All
wiring, bus joints and other mechanical parts requiring tightening or other
maintenance shall be accessible from the front or top.
7. The motor control centers shall have engraved laminated nameplates screwed to
the doors of each individual compartment and wiring diagrams pasted inside each
door. Compartments containing motor starters shall each have an overload heater
selection table pasted inside the door.
8. The motor control centers shall provide equipment of type, capacity, trip ratings
for the loads shown on the Drawings or otherwise specified.
9. Construction shall be NEMA Class 11, Type B or C. Insofar as possible, all
devices and components used shall be of one manufacturer. The motor control
centers shall be furnished as a completely factory assembled unit where
transportation facilities and installation requirements permit.
10. The motor control centers shall be finished with ANSI Z55.1, No. 61 light gray
enamel over a rust resistant primer.
11. The insulation level of the complete motor control assembly shall be such that it
will meet the field tests required under PART 3.
B. Buses:
1. All buses shall be tin-plated copper. A continuous main horizontal bus shall be
furnished. Main buses shall be rated as shown on the Drawings, but shall be not
less than 600 amperes.
2. Each vertical section shall have a full height vertical bus rated not less than
300 amperes. Vertical buses shall be insulated and isolated with glass polyester
or equivalent continuous insulation. Taped buses will not be acceptable. Unused
stab openings shall be plugged. Lower ends of vertical buses shall be insulated.
3. A 1/4 inch x 2 inch ground bus shall be furnished the entire length of the motor
control centers.
4. Buses shall be braced for 65,000 amperes RMS, symmetrical, short circuit
current.
5. All buses except neutral and ground buses shall be completely isolated by steel
plates or insulating material.
C. Wiring
1. All wiring shall be copper.
2. Compartment wiring shall be to compartment mounted, plug-in terminal blocks
that allow compartment to be withdrawn without having to remove wires from
fixed terminal blocks.
3. Power wiring shall be black. Control wiring shall be red. Wiring energized from
sources other than the starter control power transformer shall be yellow. All
wiring shall be identified at each termination.
03720-048-01 16921-3 480 -Volt Motor Control Centers
August 2019 EMI
D. Signage:
1. Each motor control center shall be furnished with a sign marked "DANGER -
HIGH VOLTAGE". Letters shall be not less than 1 -inch high, 114 inch stroke.
Signs shall be laminated plastic, engraved red letters with a white background.
Signs shall include voltage (i.e., 480v, 120v, etc.) and be fastened to with stainless
steel screws and epoxy cement.
2. All compartments with voltages from sources outside of the compartment, not
disconnected by the motor circuit protector, shall have a sign on the compartment
door marked "CAUTION - THIS UNIT CONTAINS A VOLTAGE FROM A
SOURCE OUTSIDE OF THIS UNIT". Letters shall be black on a high visibility
yellow background. Background shall be laminated plastic approximately
3 inches x 5 inches.
2.03 COMPONENTS
A. Combination Motor Starters:
1. All motor starters shall be a combination motor circuit protector and contactor, 3 -
pole, 60 Hz, 600 -volt, magnetically operated, of the types shown on the
Drawings. NEMA sizes shall be as required for the horsepower shown on the
Drawings, but shall be not less than NEMA Size 1.
2. All motor starters shall have a 120 -volt operating coil, overload relay in each
phase and control power transformer.
3. All motor starters shall have 1-N.O. and 1-N.C. auxiliary contacts. Additional
auxiliary contacts shall be furnished where shown on the Drawings or as required
by the control scheme.
4. Full voltage, non -reversing starters, NEMA Size 4 and smaller shall be of plug-in
type design with stab -on connectors engaging the vertical buses. Larger units
shall be of fixed design.
5. Reduced -voltage starters shall be solid state type with isolation contactor and
surge protection.
03720-048-01
August 2019
a. Construction
1. The power section shall be three phase, 60 hertz, and rated for the HP,
current, and voltage as shown on the drawings. It shall consist of three
sets of back-to-back phase controlled power semi -conductors.
Maximum current -limit shall be 500% for standard units.
2. Resistor/Capacitor snubber networks shall be used to prevent false
firing of SCR's due to dv/dt characteristics of the electrical system.
3. Fan cooled units shall be supplied with thermal sensors on the heat sink
to trip the control protective logic for over temperature condition.
Thermal sensors shall be rated 90 degree C maximum.
16921-4 480 -Volt Motor Control Centers
EMI
4. The one piece logic board shall be mounted for easy testing, service
and replacement.
5. Three-phase current sensing via current transformers for closed loop
control to insure motor stability shall be provided.
6. A contactor shall be placed on the line side of the starter to
automatically isolate the solid state starter from the line when starter
is not energized.
b. The logic circuitry shall include as a minimum:
1. Short circuit electronic trip overcurrent protection. Time not to exceed
1/2 cycle.
2. Inverse time running overcurrent protection.
3. Auxiliary trip circuitry.
4. Gate firing circuit lockout protection on trip.
5. Fault relay lockout protection.
6. 250% - 500% current limit adjustment.
7. Minimum and maximum voltage adjustments.
8. Voltage stability adjustment.
9. Adjustable ramp time (0.5 to 30 seconds).
10. HAND -OFF -REMOTE selector switch.
c. The logic board shall include, as standard, current and voltage sensing
circuitry that continually monitor motor load and regulate motor voltage to
minimize motor kWh energy consumption.
d. External interface circuitry shall include 120 volt relay logic interface
capability.
e. Tripped functions shall be designed to be cleared by removing power from
the solid state logic board.
f. The solid state logic shall provide phase sequence protection.
g.
Two ground lugs shall be furnished, one for incoming and one for outgoing
ground connections.
h. Power terminations shall consist of pressure type terminals for top or bottom
entrance.
i. Testing
1. The manufacturer shall supply certified test results, upon request, to
confirm that the controller has been tested to substantiate designs
according to applicable ANSI and NEMA Standards. The tests shall
verify not only the performance of the unit and integrated assembly, but
also the suitability of the enclosure venting, rigidity and bus bracing. In
addition, the unit shall be factory tested in accordance with ANSI
standards.
03720-048-01 16921-5 480 -Volt Motor Control Centers
August 2019 EMI
2. Manufacturer shall be prepared to show proper evidence of having
tested for noise immunity on both input and output power connections.
Noise testing shall be performed in accordance with NEMA
ICA 2-230.40.
5. Overload relays shall be adjustable and manually reset by push button in
compartment door. Replaceable individual overload relay heaters of the proper
size shall be installed in each phase.
6. Control power transformers shall be sized for additional load where required.
Transformer secondary shall be equipped with time -delay fuses.
7. Motor circuit protectors shall be molded case with adjustable magnetic trip only.
They shall be specifically designed for use with magnetic motor starters. Motor
circuit protectors shall have auxiliary disconnect contacts when used with starters
having external control circuits.
B. Circuit Breakers:
1. Circuit breakers shall be thermal -magnetic, molded case, 480 -volt, with not less
than 65,000 amperes, RMS interrupting capacity. All circuit breakers with
225 amperes frame and larger shall have interchangeable trips. Circuit breakers
shall have auxiliary disconnect contacts when used with starters having external
control circuits.
C. Control Stations:
1. Control stations shall be standard size, heavy-duty, oiltight.
D. Indicating Lights:
1. Indicating lights shall be standard size, heavy duty, low voltage transformer
operated as manufactured by Square -D type SK -Class 9001 or equal.
E. Running Time Meters:
1. Running time meters shall be 3-1/2 inch square case; non -reset, 99,999.9 hour
range; Type 236 as manufactured by the General Electric Co., or equal.
2. Voltmeters, amp meters, and watt meters shall be 4 -1/4 -inch square, 250 -degree
scale, plus or minus 1 -percent accuracy switchboard instruments; General Electric
Co.'s Type AB -40, or equal.
3. A four -position selector switch shall be furnished and installed for selection of
three phases and off
E. Instrument Transformers:
1. Instrument transformers shall be indoor, 600 -volt, butyl -rubber molded, metering
class designed in accordance with ANSI and NEMA standards.
03720-048-01 16921-6 480 -Volt Motor Control Centers
August 2019 EMI
F. Surge Protection:
1. Surge protection equipment shall be a three-phase surge capacitor and three-phase
lightning arrester. The lightning arrestor shall be General Electric Company's
M.O.V. type, Catalog No. 9L15ECC001, or equal. Surge capacitor shall be
General Electric Company Catalog No. 9L18BBB301, or equal.
2. Control Relays:
3. Control relays shall be heavy-duty, machine tool type with suitable rated
convertible contacts. Time delay relays shall be pneumatic, adjustable.
4. Relays shall be CR2810 and CR2920 as manufactured by General Electric Co., or
equal.
G. Nameplates:
1. Unit nameplates shall be black and white laminated plastic having engraved
letters approximately 3/16 -inch high extending through the black face into the
white layer. Nameplates shall identify equipment controlled or circuit designation
as applicable.
2.04 SPARE PARTS
A. The following spare parts shall be furnished:
1. One (1) box of power fuses of each size furnished.
2. One (1) set of starter contacts for each NEMA size installed.
3. One (1) starter coil for each NEMA size installed.
4. One (1) box of pilot lights.
PART 3 - EXECUTION
3.01 INSTALLATION
A. The motor control center housings shall be bolted to angle iron sills imbedded in the
concrete on the two longest sides. The sills shall be the full length of the motor control
center housing and shall be installed level in all directions.
B. Field installed interior wiring shall be neatly grouped by circuit and bound by plastic tie
wraps. Circuit groups shall be supported such that circuit termination are not stresses.
C. The motor control centers shall be maintained in an upright position at all times. Lifting
shall be only at the floor sills or the top mounted lifting angle.
D. The motor control centers shall be protected against damage at all times. Any damage
to the paint shall be carefully repaired using touch-up paint furnished by motor control
centers manufacturer.
03720-048-01 16921-7 480 -Volt Motor Control Centers
August 2019 EMI
3.02 TESTS AND CHECKS
A. The following minimum tests and checks shall be made after the assembly of the motor
control centers, but prior to the termination of any field wiring.
1. Megger terminals and buses after disconnecting devices sensitive to megger
voltage.
2. A 1,000 VDC megger shall be used for these tests.
3. The first test shall be made with main circuit breaker closed and all remaining
breakers open. A second test shall be made with all circuit breakers closed.
4. The test results shall be recorded and forwarded to the Engineer for his review.
Minimum megger readings shall be 100 megohms in both tests.
5. Test failures will be the Contractors responsibility to correct at no charge to the
Owner.
B. The following shall be done before energizing the motor control centers:
1. Remove all current transformer shunts after completing the secondary circuit.
2. Install overload relay heaters based on actual motor nameplate current. If
capacitors are installed between starter and motor, use overload relay heaters
based on measured motor current.
3. Check all mechanical interlocks for proper operation.
4. Vacuum clean all interior equipment.
END OF SECTION
03720-048-01 16921-8 480 -Volt Motor Control Centers
August 2019 EMI
APPENDIX
FORMS AND OTHER PROJECT DOCUMENTATION
Table of Contents
VERIFICATION OF EMPLOYMENT ELIGIBILITY FORM 1
OWNER DIRECT PURCHASE (ODP) DOCUMENTS 2
Owner Direct Purchase (ODP) Instructions 2
REQUEST TO REQUISITION FORM 3
PROJECT PERMITS 4
FDEP Domestic Wastewater Facility Permit Revision 4
SWFWMD ERP Minor ModificationGEOTECHNICAL SOIL REPORT 4
Driggers Engineering Services, Inc. Report of Geotechnical Investigation, dated March 23, 2017ASBESTOS
REPORT 5
APPENDIX i Updated 12/3/2020
APPENDIX— FORMS AND OTHER PROJECT DOCUMENTATION
VERIFICATION OF EMPLOYMENT ELIGIBILITY FORM
PER FLORIDA STATUTE 448.095, CONTRACTORS AND SUBCONTRACTORS MUST REGISTER WITH AND USE THE
E -VERIFY SYSTEM TO VERIFY THE WORK AUTHORIZATION STATUS OF ALL NEWLY HIRED EMPLOYEES.
THIS FORM MUST BE COMPLETED AND SUBMITTED WITH THE BID/PROPOSAL. FAILURE TO SUBMIT THIS
FORM AS REQUIRED MAY DEEM YOUR SUBMITTAL NONRESPONSIVE.
The affiant, by virtue of the signature below, certifies that:
1. The Contractor and its Subcontractors are aware of the requirements of Florida Statute 448.095.
2. The Contractor and its Subcontractors are registered with and using the E -Verify system to verify the
work authorization status of newly hired employees.
3. The Contractor will not enter into a contract with any Subcontractor unless each party to the contract
registers with and uses the E -Verify system.
4. The Subcontractor will provide the Contractor with an affidavit stating that the Subcontractor does
not employ, contract with, or subcontract with unauthorized alien.
5. The Contractor must maintain a copy of such affidavit.
6. The City may terminate this Contract on the good faith belief that the Contractor or its
Subcontractors knowingly violated Florida Statutes 448.09(1) or 448.095(2)(c).
7. If this Contract is terminated pursuant to Florida Statute 448.095(2)(c), the Contractor may not be
awarded a public contract for at least 1 year after the date on which this Contract was terminated.
8. The Contractor is liable for any additional cost incurred by the City as a result of the termination of
this Contract.
STATE OF
COUNTY OF
Authorized Signature
Printed Name
Title
Name of Entity/Corporation
The foregoing instrument was acknowledged before me by means of ❑ physical presence or ❑ online
notarization on, this day of , 20 , by
(name of person whose signature is being notarized) as the (title) of
(name of corporation/entity), personally known , or
produced (type of identification) as identification, and who did/did not take
an oath.
Notary Public
Printed Name
My Commission Expires:
NOTARY SEAL ABOVE
APPENDIX 1 Updated 12/3/2020
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APPENDIX — FORMS AND OTHER PROJECT DOCUMENTATION
OWNER DIRECT PURCHASE (ODP) DOCUMENTS
Owner Direct Purchase (ODP) Instructions
1. Upon award and execution, a contract shall be issued to Contractor for the full amount of award.
2. Contractor shall submit a list (ODP Summary) of potential ODP vendors and estimated dollar amounts
(minimum of $10,000) to the City for consideration prior to initial pay application. Certain bid
proposals will list pre -determined item(s) for ODP and the accompanying tax savings. The ODP
Summary shall list: (a) item cost, (b) corresponding line item number from bid, and (c) sales tax
savings associated with the item. Direct purchase shall be considered for single line items that exceed
$10,000 in value and/or items identified in Section V, Bidders Proposal.
3. Contractor shall prepare Request to Requisition forms (see attached) for each vendor to the City for
review and approval, in electronic, MS Word format. The City will review, code, and process the
requisition form. The City prefers that all Request to Requisitions be included in a single submittal.
4. A Change Order (CO) shall be issued to Contractor reducing their contract by the amount of the ODP
purchase(s) and the sales tax savings (per Request to Requisitions). COs will be drafted by the City
and will be forwarded to the Contractor for execution. Contractor shall submit two (2) originals,
signed, sealed and witnessed, to the City for execution. One fully executed original CO shall be
returned to the Contractor.
5. Concurrently, the City Purchasing Department shall issue ODP Purchase Orders (Pos) directly to each
vendor (via email), along with an executed Certificate of Entitlement and the City's Certificate of Tax
Exemption. The Contractor and City Project Manager will be copied.
6. City's Project Manager shall coordinate delivery with Contractor and Vendor. Material shall be
delivered to the project site. Contractor will verify contents and check for defective materials. Vendor
to send original invoice to the City as the purchaser and a copy to the Contractor. Invoices shall
include the City issued ODP PO number and invoice number.
7. Contractor shall review invoice copy for accuracy and send electronic approval to the City Project
Manager within fourteen (14) calendar days after date of receipt of invoice. This electronic approval
shall consist of the Contractor's signature, date, and indication of approval on the scanned invoice
as well as scanned copies of the delivery documentation or an explanation as to why the invoice
should not be paid. These items shall be emailed to the City Project Manager and City Engineering
Department's Senior Accountant, copy to Construction Inspector.
8. Contractor shall provide delivery documentation (delivery ticket, packing slips, bill of lading, etc.) in
hard copy form to the City Project Manager attached to a copy of the invoice within thirty (30)
calendar days after date of receipt of invoice. If these hard copy items are delivered within fourteen
(14) calendar days after date of receipt of invoice, then electronic approval as noted in paragraph
seven (7) above may be excused.
9. City Project Manager shall have final approval to pay invoices and City Accounting Department shall
issue payment to the Vendor for materials or equipment received.
10. ODP POs must be closed out prior to closing out the Contractor contract. If material costs needed for
the project exceed the ODP PO amount, the ODP PO will not be increased. Amounts in excess of the
ODP PO will be paid for by the Contractor.
APPENDIX 2 Updated 12/3/2020
APPENDIX — FORMS AND OTHER PROJECT DOCUMENTATION
REQUEST TO REQUISITION FORM
For Owner Direct Purchase Materials
City Project Name:
General Item Description:
Vendor:
Street Address:
City/State/Zip:
Receiving Location (Ship to):
Street Address:
City/State/Zip:
General Contractor:
Contact Name:
Date Needed by:
City Contract #:
(Project Location)
Contact Name:
Phone No:
Email:
Attention:
(Company Name)
Phone No:
Phone No:
Email:
Expense Code: (City will complete)
►etailed Description
hipping &, handling charges, if applicab
(refer to Line Item # and details from Bidder's Proposal, Section V)
LS
PO Total
LS
Sales Tax Savings to Owner
(First $5,000 x 7.0%, thereafter Sales Tax Rate is 6.0%)
Equipment shall be in accordance with the applicable technical specifications, and all other applicable provisions
(shop drawings, O&Ms, warranties, etc.,) of contract referenced above. Spare parts provided as per specifications;
freight included'. Start up services and training are included in the above price, if provided for in bid.
Special Delivery Instructions
Send Original Invoices to:
Send Copy of Invoice to:
City of Clearwater
Engineering Department
Phuong Vo
P.O. Box 4748
Clearwater, FL 33758
CONTRACTOR NAME
Attention To:
Mailing Address
Phone Number
Approving Official (City of Clearwater Representative):
Signature:
Print Name:
Title:
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Date: 1
Engineering will provide records retention according to City of Clearwater's Records Management Program
and State Retention Schedules.1
APPENDIX
3
Updated 12/3/2020
APPENDIX— FORMS AND OTHER PROJECT DOCUMENTATION
PROJECT PERMITS
FDEP Domestic Wastewater Facility Permit Revision
SWFWMD ERP Minor Modification
APPENDIX
4
Updated 12/3/2020
FDEP Domestic Wastewater Facility Permit Revision
November 19, 2019
FLORIDA DEPARTMENT OF
Environmental Protection
In the Matter of an
Application for Permit by:
Southwest District
13051 North Telecom Parkway
Temple Terrace, FL 33637-0926
City of Clearwater Public Utilities Dept.
David Porter, P.E., Public Utilities Director
1650 North Arcturas Ave., Building C
Clearwater, Florida 33765-1945
david.porter@myclearwater.com
Ron DeSantis
Governor
Jeanette Nunez
Lt. Governor
Noah Valensteln
Secretary
File Number FL0128937-016-DW1P/RM
Pinellas County
City of Clearwater Northeast WRF
NOTICE OF PERMIT ISSUANCE
Enclosed is Permit Number FL0128937 to operate the City of Clearwater Northeast
WRF, issued under Chapter 403, Florida Statutes.
Monitoring requirements under this permit are effective on the first day of the second
month following the effective date of the permit. Until such time, the permittee shall
continue to monitor and report in accordance with previously effective permit
requirements, if any.
NOTICE OF RIGHTS
This action is final and effective on the date filed with the Clerk of the Department unless
a petition for an administrative hearing is timely filed under Sections 120.569 and 120.57,
F.S., before the deadline for filing a petition. On the filing of a timely and sufficient
petition, this action will not be final and effective until further order of the Department.
Because the administrative hearing process is designed to formulate final agency action,
the subsequent order may modify or take a different position than this action.
Petition for Administrative Hearing
A person whose substantial interests are affected by the Department's action may petition for
an administrative proceeding (hearing) under Sections 120.569 and 120.57, F.S. Pursuant to
Rules 28-106.201 and 28-106.301, F.A.C., a petition for an administrative hearing must
contain the following information:
(a) The name and address of each agency affected and each agency's file or
identification number, if known;
City of Clearwater Northeast WRF
FL0128937-016-D W 1 P/RM
Page 2 of 4
(b) The name, address, any e-mail address, any facsimile number, and telephone
number of the petitioner, if the petitioner is not represented by an attorney or a
qualified representative; the name, address, and telephone number of the
petitioner's representative, if any, which shall be the address for service purposes
during the course of the proceeding; and an explanation of how the petitioner's
substantial interests will be affected by the agency determination;
(c) A statement of when and how the petitioner received notice of the agency
decision;
(d) A statement of all disputed issues of material fact. If there are none, the petition
must so indicate;
(e) A concise statement of the ultimate facts alleged, including the specific facts that
the petitioner contends warrant reversal or modification of the agency's proposed
action;
(f) A statement of the specific rules or statutes that the petitioner contends require
reversal or modification of the agency's proposed action, including an explanation
of how the alleged facts relate to the specific rules or statutes; and
(g) A statement of the relief sought by the petitioner, stating precisely the action that
the petitioner wishes the agency to take with respect to the agency's proposed
action.
The petition must be filed (received by the Clerk) in the Office of General Counsel of the
Department at 3900 Commonwealth Boulevard, Mail Station 35, Tallahassee, Florida
32399-3000, or via electronic correspondence at Agency_Clerk@dep.state.fl.us. Also, a
copy of the petition shall be mailed to the applicant at the address indicated above at the
time of filing.
Time Period for Filing a Petition
In accordance with Rule 62-110.106(3), F.A.C., petitions for an administrative hearing by
the applicant and persons entitled to written notice under Section 120.60(3), F.S., must be
filed within 14 days of receipt of this written notice. Petitions filed by any persons other
than the applicant, and other than those entitled to written notice under Section 120.60(3),
F.S., must be filed within 14 days of publication of the notice or within 14 days of receipt
of the written notice, whichever occurs first. You cannot justifiably rely on the finality of
this decision unless notice of this decision and the right of substantially affected persons
to challenge this decision has been duly published or otherwise provided to all persons
substantially affected by the decision. While you are not required to publish notice of this
action, you may elect to do so pursuant Rule 62-110.106(10)(a), F.A.C.
The failure to file a petition within the appropriate time period shall constitute a waiver of
that person's right to request an administrative determination (hearing) under Sections
120.569 and 120.57, F.S., or to intervene in this proceeding and participate as a party to
it. Any subsequent intervention (in a proceeding initiated by another party) will be only at
the discretion of the presiding officer upon the filing of a motion in compliance with Rule
28-106.205, F.A.C. If you do not publish notice of this action, this waiver may not apply
to persons who have not received a clear point -of -entry.
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City of Clearwater Northeast WRF
FL012 893 7-016-D W 1 P/RM
Page 3 of 4
Extension of Time
Under Rule 62-110.106(4), F.A.C., a person whose substantial interests are affected by
the Department's action may also request an extension of time to file a petition for an
administrative hearing. The Department may, for good cause shown, grant the request for
an extension of time. Requests for extension of time must be filed with the Office of
General Counsel of the Department at 3900 Commonwealth Boulevard, Mail Station 35,
Tallahassee, Florida 32399-3000, or via electronic correspondence at
Agency_Clerk@dep.state.fl.us, before the deadline for filing a petition for an
administrative hearing. A timely request for extension of time shall toll the running of the
time period for filing a petition until the request is acted upon.
Mediation
Mediation is not available in this proceeding.
Judicial Review
Once this decision becomes final, any party to this action has the right to seek judicial
review pursuant to Section 120.68, F.S., by filing a Notice of Appeal pursuant to Florida
Rules of Appellate Procedure 9.110 and 9.190 with the Clerk of the Department in the
Office of General Counsel (Station #35, 3900 Commonwealth Boulevard, Tallahassee,
Florida 32399-3000) and by filing a copy of the Notice of Appeal accompanied by the
applicable filing fees with the appropriate district court of appeal. The notice must be
filed within 30 days from the date this action is filed with the Clerk of the Department.
EXECUTION AND CLERKING
Executed in Temple Terrace, Florida.
STATE OF FLORIDA DEPARTMENT OF ENVIRONMENTAL PROTECTION
Pamala Vazquez
Program Administrator
Permitting & Waste Cleanup Program
Southwest District
Attachment(s):
1. Final Permit No. FL0128937-016-DW1P/RM
2. Final DMRs FLO128937-016-DW1P/RM
3. Final Amended Fact Sheet FL0128937-016-DW 1 P/RM
CERTIFICATE OF SERVICE
The undersigned duly designated deputy clerk hereby certifies that this document and all
attachments were sent on the filing date below to the following listed persons:
City of Clearwater Northeast WRF
FLO128937-016-DW1P/RM
Page 4 of 4
FILING AND ACKNOWLEDGMENT
FILED, on this date, pursuant to Section 120.52, F. S., with the designated Department
Clerk, receipt of which is hereby acknowledged.
Clerk
November 19, 2019
Date
Copies to:
Thomas A. Traina, P.E., Adurra Group, Inc., ttraina(ardurra.com
Jeffrey Elick, Adurra Group, Inc., Jelick(cv,ardurra.com
Randy Barnoski, Chief Operator Clearwater Northeast AWWTP, Randv.Barnoski cr MyClearwater.com
Duy Nguyen, City of Clearwater, Duy.NguyenAMvClearwater.com
Gerald Loesch, FDEP-SWD, Gerald.LoeschAfloridadep.gov
EPA Region IV — Water Management, r4npdespermits(n�epa.gov
Christine Frankford, Pinellas County Dept. of Health, Christine Frankford@doh.state.fl.us
Belinda Oliver, FDEP-SWD, Belinda.Oliver(afloridadep.aov
Astrid Flores Thiebaud, FDEP-SWD, Astrid.FloresThiebaud@floridadep.gov
Lance Kautz, FDEP-SWD, lance.kautz(difloridadep.gov
Ericka Peck, FDEP-SWD, Erica.Peck@,floridadep.gov
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FLORIDA DEPARTMENT OF
Environmental Protection
Southwest District Office
13051 North Telecom Parkway#101
Temple Terrace, Florida 33637-0926
STATE OF FLORIDA
DOMESTIC WASTEWATER FACILITY PERMIT
PERMITTEE:
City of Clearwater Public Utilities Department
RESPONSIBLE OFFICIAL:
David Porter, P.E., Public Utilities Director
1650 North Arcturas Avenue, Building C
Clearwater, Florida 33765-1945
david.porter@myclearwater.com
(727) 562-4960
FACILITY:
City of Clearwater Northeast Water Reclamation Facility (WRF)
3290 S.R. 580
Safety Harbor, FL 34695
Pinellas County
Latitude: 28°1' 41.09" N Longitude: 82°42' 17.72" W
PERMIT NUMBER:
FILE NUMBER:
REVISION NUMBER:
EFFECTIVE DATE:
REVISON DATE:
EXPIRATION DATE:
Ron DeSantls
Governor
Jeanette Nunez
Lt. Governor
Noah Valensteln
Secretary
FL0128937 (Major)
FLO 12893 7-014-D W 1 P/NR
FL0128937-016-DW 1 P/RM
July 2, 2017
November 19, 2019
July 1, 2022
This permit is issued under the provisions of Chapter 403, Florida Statutes (F.S.), and applicable rules of the Florida
Administrative Code (F.A.C.) and constitutes authorization to discharge to waters of the state under the National Pollutant
Discharge Elimination System. This permit does not constitute authorization to discharge wastewater other than as
expressly stated in this permit. The above-named permittee is hereby authorized to operate the facilities in accordance with
the documents attached hereto and specifically described as follows:
WASTEWATER TREATMENT:
An existing 13.5 Million Gallons Per Day (MGD) Annual Average Daily Flow (AADF) Type I domestic advanced
wastewater treatment facility, using the Bardenpho BNR process, consisting of the following components: preliminary
treatment consisting of two mechanically cleaned fine bar screens and one fixed screen; influent flow measurement via a 48 -
inch Parshall flume with an ultrasonic flow meter; primary treatment consisting of sedimentation in two 75 -foot diameter
primary clarifiers (total surface area of 8,835 square feet); a two -unit hydrodynamic vortex grit removal system with
associated grit classifier; four 18 -foot diameter primary sludge gravity thickeners; a biological treatment process consisting
of a convertible four (current operation) or five -stage Bardenpho BNR process that includes two 550,000 gallon
fermentation basins, two 880,000 gallon first -stage anoxic reactors, a five unit Archimedes Screw pump station and a three
submersible pump station, , two 1,700,000 -gallon Carrousel oxidation ditch aeration basins, ten 190,740 -gallon second
anoxic basins, and ten 30,800 -gallon reaeration basins; eight 75 -foot diameter secondary clarifiers (total surface area of
35,325 square feet); polishing filtration consisting of 12 rapid sand, pulsed filtration gravity -type, automatic backwash filters
with a total surface area of 4,320 square feet; an effluent disinfection system using liquid sodium hypochlorite and a
402,000 -gallon, dual channel chlorine contact basin. Also on-site are a 5 -million gallon (MG) reclaimed water storage tank
and a 3.5 MG reject water storage tank.
Chlorinated effluent from the chlorine contact basin is directed to the on-site 5 MG reclaimed water storage tank, the Master
Reuse System (R-001) or piped to Clearwater's East WRF and directed to a mixing basin and combined with chlorinated
effluent from the East WRF. The combined chlorinated effluent streams then flow through a 113,616 -gallon
PERMITTEE: City of Clearwater PERMIT NUMBER: FLO128937-016-DW1P/RM
FACILITY: City of Clearwater Northeast WRF
blending/dechlorination basins that uses flow -paced sodium bisulfite to eliminate the remaining chlorine residual, then
through a 137,840 -gallon dissolved oxygen boost re -aeration basin, to an outfall junction/sampling box and finally through a
1,400 -foot long, 48 -inch diameter outfall pipe that discharges to Old Tampa Bay (D-001).
Waste sludge from the primary clarifiers is pumped to four 18 -foot diameter gravity thickeners. The thickened primary
sludge is then transferred to two anaerobic digesters with a combined capacity of 1,944,800 gallons. Waste sludge from the
secondary clarifiers is pumped to two rotary drum thickeners equipped with polymer injection, then to the anaerobic
digesters. Thickened sludge from the East WRF is also fed to the anaerobic digesters. Additional sludge treatment capacity
is available with four 206,869 -gallon aerobic digesters. Sludge from the digesters is sent to two 160,000 -gallon sludge blend
tanks. The blended sludge is then dewatered using a centrifuge with two belt filter presses available as backup.
FIRST MODIFICATIONS:
Construction of a new intermediate effluent channel from the chlorine contact basin to a new ultrafiltration pretreatment
basin for the new City of Clearwater Advanced Water Purification Plant. The intermediate channel will decrease the current
interior length of the chlorine contact basin (140 feet) by seven feet, decreasing the capacity to 383,933 gallons.
AFTER FIRST MODIFICATIONS:
An existing 13.5 Million Gallons Per Day (MGD) Annual Average Daily Flow (AADF) Type I domestic advanced
wastewater treatment facility, using the Bardenpho BNR process, consisting of the following components: preliminary
treatment consisting of two mechanically cleaned fine bar screens and one fixed screen; influent flow measurement via a 48 -
inch Parshall flume with an ultrasonic flow meter; primary treatment consisting of sedimentation in two 75 -foot diameter
primary clarifiers (total surface area of 8,835 square feet); a two -unit hydrodynamic vortex grit removal system with
associated grit classifier; four 18 -foot diameter primary sludge gravity thickeners; a biological treatment process consisting
of a convertible four (current operation) or five -stage Bardenpho BNR process that includes two 550,000 gallon
fermentation basins, two 880,000 gallon first -stage anoxic reactors, a five unit Archimedes Screw pump station and a three
submersible pump station, , two 1,700,000 -gallon Carrousel oxidation ditch aeration basins, ten 190,740 -gallon second
anoxic basins, and ten 30,800 -gallon reaeration basins; eight 75 -foot diameter secondary clarifiers (total surface area of
35,325 square feet); polishing filtration consisting of 12 rapid sand, pulsed filtration gravity -type, automatic backwash filters
with a total surface area of 4,320 square feet; an effluent disinfection system using liquid sodium hypochlorite and a
383,933 -gallon, dual channel chlorine contact basin. Also on-site are a 5 MG reclaimed water storage tank and a 3.5 MG
reject water storage tank.
Chlorinated effluent from the chlorine contact basin is directed to the on-site 5 MG reclaimed water storage tank, the Master
Reuse System (R-001), the City of Clearwater Advanced Water Purification Plant (R-002) or piped to Clearwater's East
WRF and directed to a mixing basin and combined with chlorinated effluent from the East WRF. The combined chlorinated
effluent streams then flow through a 113,616 -gallon blending/dechlorination basins that uses flow -paced sodium bisulfite to
eliminate the remaining chlorine residual, then through a 137,840 -gallon dissolved oxygen boost re -aeration basin, to an
outfall junction/sampling box and finally through a 1,400 -foot long, 48 -inch diameter outfall pipe that discharges to Old
Tampa Bay (D-001).
Waste sludge from the primary clarifiers is pumped to four 18 -foot diameter gravity thickeners. The thickened primary
sludge is then transferred to two anaerobic digesters with a combined capacity of 1,944,800 gallons. Waste sludge from the
secondary clarifiers is pumped to two rotary drum thickeners equipped with polymer injection, then to the anaerobic
digesters. Thickened sludge from the East WRF is also fed to the anaerobic digesters. Additional sludge treatment capacity
is available with four 206,869 -gallon aerobic digesters. Sludge from the digesters is sent to two 160,000 -gallon sludge blend
tanks. The blended sludge is then dewatered using a centrifuge with two belt filter presses available as backup.
SECOND MODIFICATIONS:
The permittee has proposed to rehabilitate, update, construct, add to, and modify the following primary components:
Temporarily bypassing the pumping and grit removal during construction; demolishing the existing one MGD
Plant/irrigation tank; converting the four Pickett thickeners back to grit removal using stacked tray head cell technology and
re -locating the grit removal unit process to its original configuration immediately following the screening process;
rehabilitate two existing hydro -cyclones and one existing grit classifier; installing one new hydro -cyclone and one new grit
classifier; installing four new grit pumps, and construction and installation of a new two million gallon equalization basin.
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PERMITTEE: City of Clearwater PERMIT NUMBER: FL0128937-016-DW1P/RM
FACILITY: City of Clearwater Northeast WRF
There will also be upgrades to the existing North and South sludge and blend tanks with new tank covers and mixers;
installation of two new pump station and canopies (Truck Off -Loading pump station and anaerobic digester feed pump
station); replacement of the dewatering feed pump station and canopies, rehabilitation of the existing truck off-loading pump
stations and the replacement of the aging yard piping.
AFTER SECOND MODIFICATIONS:
An existing 13.5 Million Gallons Per Day (MGD) Annual Average Daily Flow (AADF) Type I domestic advanced
wastewater treatment facility, using the Bardenpho BNR process, consisting of the following components: preliminary
treatment consisting of two mechanically cleaned fine bar screens and one fixed screen; four cells of stacked tray grit
removal equipment with four 12 -foot diameter trays in each cell, three hydrocyclones, two classifier grit removal units,
influent flow measurement via a 48 -inch Parshall flume with an ultrasonic flow meter; primary treatment consisting of three
moving belt filters (total throughput capacity 5,100 gpm); a 2.0 MG flow equalization basin with pulsed air mixing that can
be taken off line; a biological treatment process consisting of a convertible four (current operation) or five -stage Bardenpho
BNR process that includes two 550,000 gallon fermentation basins, two 880,000 gallon first -stage anoxic reactors, a five
unit Archimedes Screw pump station and a three submersible pump station, , two 1,700,000 -gallon Carrousel oxidation ditch
aeration basins, ten 190,740 -gallon second anoxic basins, and ten 30,800 -gallon reaeration basins; eight 75 -foot diameter
secondary clarifiers (total surface area of 35,325 square feet); polishing filtration consisting of 12 rapid sand, pulsed
filtration gravity -type, automatic backwash filters with a total surface area of 4,320 square feet; an effluent disinfection
system using liquid sodium hypochlorite and a 383,933 -gallon, dual channel chlorine contact basin. Also on-site are a 5 MG
reclaimed water storage tank and a 3.5 MG reject water storage tank.
Chlorinated effluent from the chlorine contact basin is directed to the on-site 5 MG reclaimed water storage tank, the Master
Reuse System (R-001) or piped to Clearwater's East WRF and directed to a mixing basin and combined with chlorinated
effluent from the East WRF. The combined chlorinated effluent streams then flow through a 113,616 -gallon
blending/dechlorination basins that uses flow -paced sodium bisulfite to eliminate the remaining chlorine residual, then
through a 137,840 -gallon dissolved oxygen boost re -aeration basin, to an outfall junction/sampling box and finally through a
1,400 -foot long, 48 -inch diameter outfall pipe that discharges to Old Tampa Bay (D-001).
The thickened primary sludge will be transferred to the North 160,000 -gallon Sludge Blend Tank along with thickened
waste sludge from the secondary clarifiers, thickened with two rotary drum thickeners equipped with polymer injection, and
combined with Thickened Waste Sludge from the East WRF that is truck hauled to the Northeast (NE) WRF for treatment
and dewatering. The three thickened sludges (NE WRF Primary, NE WRF WAS and East WRF WAS) will be blended in
the north tank and transferred over a 24-hour period to two anaerobic digesters with a combined capacity of 1,944,800
gallons. . Following anaerobic digestion of the blended sludge to achieve EPA Part 503 Class B Biosolids stabilization, the
anaerobically digested biosolids are transferred to the South 160,000 -gallon sludge blend tank, mixed for equalization and
temporary storage and then dewatered using a combination of centrifuge and belt filter presses (backup) prior to reuse by
land application or landfill disposal.
DISPOSAL:
Surface Water Discharge D-001: An existing 13.5 MGD AADF permitted discharge to Old Tampa Bay (Class II marine
waters and Outstanding Florida Water, WBID# 1558H) at discharge location D-001, which is approximately 1400 feet in
length and discharges at a depth of approximately 10 feet. The point of discharge is located approximately at latitude 27°57'
19" N, longitude 82°42' 24" W.
Outfall D-001 is shared with the Clearwater East WRF, which contributes up to 5.0 MGD and the Northeast facility
contributes up to 13.5 MGD for a total permitted discharge capacity of 18.5 MGD.
Mixing Zone: The permittee is granted a mixing zone for Dichlorobromomethane consisting of a distance of two meters in
radius from the centerline of the outfall.
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PERMITTEE: City of Clearwater PERMIT NUMBER: FL0I28937-016-DWIP/RM
FACILITY: City of Clearwater Northeast WRF
REUSE:
Land Application R-001: An existing 12 Million Gallons Per Day (MGD) Annual Average Daily Flow (AADF) permitted
capacity slow -rate public access system. The City of Clearwater Northeast WRF serves as a source plant for the City of
Clearwater Master Reuse System, FL0186261.
Reuse System R-002: A new 4.0 MGD daily maximum flow permitted capacity reuse system, which consists of discharge
of reclaimed water for additional treatment at the City of Clearwater Groundwater Replenishment Advanced Water
Purification Plant, FLA009486.
IN ACCORDANCE WITH: The limitations, monitoring requirements, and other conditions set forth in this cover sheet
and Part I through Part IX on pages 5 through 30 of this permit.
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1 I On EN E 1-- I— N M-- I ■■■ N N EN 1
PERMITTEE: City of Clearwater PERMIT NUMBER: FLO128937-016-DWIP/RM
FACILITY: City of Clearwater Northeast WRF
I. RECLAIMED WATER AND EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
A. Surface Water Discharges
1. During the period beginning on the effective date and lasting through the expiration date of this permit, the permittee is authorized to discharge effluent
from Outfall D-001 to Old Tampa Bay. Such discharge shall be limited and monitored by the permittee as specified below and reported in accordance with
Permit Condition I.C.8:
Effluent Limitations
Monitorin Requirements
Parameter
Units
Max/Min
Limit
Statistical Basis
Frequency of
Analysis
Sample Type
Monitoring
Site Number
Notes
Flow (D-001)
MGD
Max
Max
13.5
Report
Annual Average
Monthly Average
Continuous
Recording Flow
Meter with
Totalizer
FLW-02
See I.A.4
BOD, Carbonaceous 5
day, 20C
mg/L
Max
Max
Max
Max
5.0
6.25
7.5
10.0
Annual Average
Monthly Average
Weekly Average
Single Sample
5 Days/Week
24 -hr FPC
EFA -01
Solids, Total Suspended
mg/L
Max
Max
Max
Max
5.0
6.25
7.5
10.0
Annual Average
Monthly Average
Weekly Average
Single Sample
5 Days/Week
24 -hr FPC
EFA -01
Nitrogen, Total (as N)
mg/L
Max
Max
Max
Max
3.0
3.75
4.5
6.0
Annual Average
Monthly Average
Weekly Average
Single Sample
5 Days/Week
24 -hr FPC
EFA -01
Phosphorus, Total (as P)
mg/L
Max
Max
Max
Max
Report
Report
Report
Report
Annual Average
Monthly Average
Weekly Average
Single Sample
5 Days/Week
24 -hr FPC
EFA -01
Solids, Total Suspended
mg/L
Max
5.0
Single Sample
5 Days/Week
Grab
EFB-01
See 1.A.5
pH
s.u.
Min
Max
6.5
8.5
Single Sample
Single Sample
Continuous
Meter
EFA -01
See I.A.3
Coliform, Fecal
percent
Min
75
Monthly Minimum
Monthly
Calculated
EFA -01
See I.A.5
Coliform, Fecal
#/100mL
Max
25
Single Sample
5 Days/Week
Grab
EFA -01
See 1.A.5
Chlorine, Total Residual
(For Disinfection)
mg/L
Min
1.0
Single Sample
Continuous
Meter
EFA -01
See LA.3 and
I.A.6
Chlorine, Total Residual
(For Dechlorination)
mg/L
Max
0.01
Single Sample
Daily; 24 hours
Grab
EFD-01
Enterococci
#/100 mL
Max
35
Monthly Geometric Mean
Monthly
Calculated
EFA -01
See 1.A.7
Enterococci
#/100 mL
Max
276
Single Sample
5/month
Grab
EFA -01
See I.A.7
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PERMITTEE: City of Clearwater
FACILITY: City of Clearwater Northeast WRF
PERMIT NUMBER: FL0128937-016-DW1P/RM
6
OM MO MO MN - - w O - 1111111 - - M N - - - - - I
Effluent Limitations
Monitoring Requirements
Parameter
Units
Max/Min
Limit
Statistical Basis
Frequency of
Analysis
Sample Type
Monitoring
Site Number
Notes
Copper, Total
Recoverable
mg/L
Max
3.7
Single Sample
Monthly
Grab
EFD-01
Dichlorobromomethane
ug/L
Max
43.0
Annual Average
Monthly
Calculated
EFD-01
See LA.8
Dichlorobromomethane
ug/L
Max
Report
Single Sample
Monthly
Grab
EFD-01
See I.A.8
Oxygen, Dissolved (DO)
mg/L
Min
5.0
Single Sample
Daily; 24 hours
Grab
EFD-01
Nitrogen, Total (as N)
Tons/month
Max
Report
Monthly Total
Monthly
Calculated
EFA -01
See I.A.9
Nitrogen, Total (as N)
Tons/year
Max
Report
Annual Total
Monthly
Calculated
EFA -01
See I.A.9
Nitrogen, Total (as N)
Tons/year
Max
Report
5 -Year Average
Monthly
Calculated
EFA -01
See I.A.9
Chronic Whole Effluent
Toxicity, 7 -Day IC25
(Ceriodaphnia dubia)
percent
Min
100
Single Sample
Quarterly
24 -hr FPC
EFD-01
See T.A.10
Chronic Whole Effluent
Toxicity, 7 -Day 1C25
(Pimephales promelas)
Percent
Min
100
Single Sample
Quarterly
24 -hr FPC
EFD-01
See I.A.10
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OM MO MO MN - - w O - 1111111 - - M N - - - - - I
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PERMITTEE: City of Clearwater
FACILITY: City of Clearwater Northeast WRF
PERMIT NUMBER: FL0128937-016-DW 1 P/RM
2. Effluent samples shall be taken at the monitoring site locations listed in Permit Condition I.A.1. and as
described below:
Monitoring Site Number
Description of Monitoring Site
EFA -01
After disinfection
EFB-01
After filtration and prior to disinfection
EFD-01
After dechlorination and prior to final discharge
FLW-02
Sum of three 12 -inch magnetic meters
3. Hourly measurement of pH and total residual chlorine for disinfection during the period of required
operator attendance may be substituted for continuous measurement. [62-600.660(1)1
4. A recording flow meter with totalizer shall be utilized to measure flow and calibrated at least once
every 12 months. [62-600.200(25)1
5. Over a 30 -day period, at least 75 percent of the fecal coliform values shall be below the detection
limits. No sample shall exceed 25 fecal coliforms per 100 mL. No sample shall exceed 5.0 mg/L of
total suspended solids (TSS) at a point before the application of the disinfectant. Note: To report the
"% less than detection," count the number of fecal coliform observations that were less than detection,
divide by the total number of fecal coliform observations in the month, and multiply by 100% (round
to the nearest integer). [62-600.440(6)(a)1
6. A minimum of 1.0 mg/L total residual chlorine must be maintained for a minimum contact time of 15
minutes based on peak hourly flow. [62-600.440(5)(c), (6)(b), and (7)(c)]
7. The enterococci monthly geometric mean value shall be based on all samples of effluent collected
during a period of 30 consecutive days (monthly); a minimum of 5 samples of effluent, each collected
on nonconsecutive days, is required. [62-600.520(5)]
8. The permittee is granted a mixing zone for dichlorobromomethane consisting of a distance of two meters
in radius from the centerline of Outfall D-001.
9. In accordance with the load allocations from the Final 2009 Reasonable Assurance Addendum: Allocation
& Assessment Report, January 22, 2010, the Total Maximum Daily Load for Total Nitrogen shall be
calculated from the monthly average Total Nitrogen concentrations. The Total Nitrogen loading shall be
calculated as a 12 -month rolling total and shall not exceed 40.65 tons/year and the five-year average of
the yearly totals shall not exceed 27.1 tons/year for the combined total load from the City of Clearwater
East WRF (FL0021865), and the City of Clearwater Northeast WRF (FL0128937). The City of
Clearwater Northeast WRF shall report the calculated loading to Outfall D-001 from the Northeast WRF
only. The total combined load from the City of Clearwater Northeast WRF and the City of Clearwater
East WRF shall be reported under the City of Clearwater East WRF permit.
Monthly Total (Mt)
Mt = (Monthly Average Total Nitrogen Concentration, mg/1)(Total Monthly Flow, MG)(8.3454)
2000 lbs
Mt = Tons/Month
Mti = Monthly Total for the ls` Month
Mtn = Monthly Total for the nth Month
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PERMITTEE: City of Clearwater
FACILITY: City of Clearwater Northeast WRF
PERMIT NUMBER: FL0128937-016-DW1P/RM
Annual Rolling Total (At)
Annual Total at the end of the nth Month: At = Mt._i i + Mt. -10 ... Mt.
5 Year Rolling Average (5yr)
5yr. = (Mt._59 + Mt. -58 ... Mt.) / 5
10. Chronic Whole Effluent Toxicity Testing
The permittee shall comply with the following requirements to evaluate chronic whole effluent toxicity
of the discharge from outfall D-001.
a. Effluent Limitation
(1) In any routine or additional follow-up test for chronic whole effluent toxicity, the 25 percent
inhibition concentration (IC25) for reproduction or growth shall not be less than 100% effluent.
[Rules 62-302.530(61) and 62-4.241(1)(b), F.A.C.]
(2) For acute whole effluent toxicity, the 96 -hour LC50 shall not be less than 100% effluent in any
test. [Rule 62-302.500(1)(a)4. and 62-4.241(1)(a), F.A.C.]
b. Monitoring Frequency
(1) Routine toxicity tests shall be conducted once every three months, the first starting within 60
days of the effective date of this permit and lasting for the duration of this permit.
(2) Upon completion of four consecutive valid routine tests that demonstrate compliance with the
effluent limitation in I.A.10.a.(1) above, the permittee may submit a written request to the
Depaaiuent for a reduction in monitoring frequency to once every six months. The request
shall include a summary of the data and the complete bioassay laboratory reports for each test
used to demonstrate compliance. The Department shall act on the request within 45 days of
receipt. Reductions in monitoring shall only become effective upon the Department's written
confirmation that the facility has completed four consecutive valid routine tests that
demonstrate compliance with the effluent limitation in I.A.10.a.(1) above.
(3) If a test within the sequence of the four is deemed invalid based on the acceptance criteria in
EPA -821-R-02-013, but is replaced by a repeat valid test initiated within 21 days after the last
day of the invalid test, the invalid test will not be counted against the requirement for four
consecutive valid tests for the purpose of evaluating the reduction of monitoring frequency.
c. Sampling Requirements
(1) For each routine test or additional follow-up test conducted, a total of three flow proportional
24 -hr composite samples of final effluent shall be collected and used in accordance with the
sampling protocol discussed in EPA -821-R-02-013, Section 8.
(2) The first sample shall be used to initiate the test. The remaining two samples shall be
collected according to the protocol and used as renewal solutions on Day 3 (48 hours) and
Day 5 (96 hours) of the test.
(3) Samples for routine and additional follow-up tests shall not be collected on the same day.
d. Test Requirements
(1) Routine Tests: All routine tests shall be conducted using a control (0% effluent) and a
minimum of five test dilutions: 100%, 50%, 25%, 12.5%, and 6.25% final effluent.
(2) The permittee shall conduct a daplmid, Ceriodaphnia dubia, Survival and Reproduction Test
and a fathead minnow, Pimephales promelas, Larval Survival and Growth Test,
concurrently.
(3) All test species, procedures and quality assurance criteria used shall be in accordance with
Short-term Methods for Estimating the Chronic Toxicity of Effluents and Receiving
Waters to Freshwater Organisms, 4th Edition, EPA -821-R-02-013. Any deviation of the
bioassay procedures outlined herein shall be submitted in writing to the Department for
review and approval prior to use. In the event the above method is revised, the permittee shall
conduct chronic toxicity testing in accordance with the revised method.
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PERMITTEE: City of Clearwater PERMIT NUMBER: FL0128937-016-DW 1 P/RM
FACILITY: City of Clearwater Northeast WRF
(4) The control water and dilution water shall be moderately hard water as described in EPA -821-
R-02-013, Section 7.2.3.
e. Quality Assurance Requirements
(1) A standard reference toxicant (SRT) quality assurance (QA) chronic toxicity test shall be
conducted with each species used in the required toxicity tests either concurrently or initiated
no more than 30 days before the date of each routine or additional follow-up test conducted.
Additionally, the SRT test must be conducted concurrently if the test organisms are obtained
from outside the test laboratory unless the test organism supplier provides control chart data
from at least the last five monthly chronic toxicity tests using the same reference toxicant and
test conditions. If the organism supplier provides the required SRT data, the organism
supplier's SRT data and the test laboratory's monthly SRT -QA data shall be included in the
reports for each companion routine or additional follow-up test required.
(2) If the mortality in the control (0% effluent) exceeds 20% for either species in any test or the
"test acceptability criteria" are not met, the test for that species (including the control) shall be
invalidated and the test repeated. Test acceptability criteria for each species are defined in
EPA -821-R-02-013, Section 13.12 (Ceriodaphnia dubia) and Section 11.11 (Pimephales
promelas). The repeat test shall begin within 21 days after the last day of the invalid test.
(3) If 100% mortality occurs in all effluent concentrations for either test species prior to the end
of any test and the control mortality is less than 20% at that time, the test (including the
control) for that species shall be terminated with the conclusion that the test fails and
constitutes non-compliance.
(4) Routine and additional follow-up tests shall be evaluated for acceptability based on the
observed dose -response relationship as required by EPA -821-R-02-013, Section 10.2.6., and
the evaluation shall be included with the bioassay laboratory reports.
f. Reporting Requirements
(1) Results from all required tests shall be reported on the Discharge Monitoring Report (DMR)
as follows:
(a) Routine and Additional Follow-up Test Results: The calculated IC25 for reproduction or
growth for each test species shall be entered on the DMR.
(2) A bioassay laboratory report for each routine test shall be prepared according to EPA -821-R-
02-013, Section 10, Report Preparation and Test Review, and mailed to the Department at the
address below within 30 days after the last day of the test.
(3) For additional follow-up tests, a single bioassay laboratory report shall be prepared according
to EPA -821-R-02-013, Section 10, and mailed within 30 days after the last day of the second
valid additional follow-up test.
(4) Data for invalid tests shall be included in the bioassay laboratory report for the repeat test.
(5) The same bioassay data shall not be reported as the results of more than one test.
(6) All bioassay laboratory reports shall be sent to:
Florida Department of Environmental Protection
Compliance Assurance Program
Southwest District Office
13051 N Telecom Parkway
Temple Terrace, Florida 33637-0926
SWD DW(dep.state.fl.us
g.
Test Failures
(1) A test fails when the test results do not meet the limits in I.A.10.a.(1).
(2) Additional Follow-up Tests:
(a) If a routine test does not meet the chronic toxicity limitation in I.A.10.a.(1) above, the
permittee shall notify the Department at the address above within 21 days after the last
day of the failed routine test and conduct two additional follow-up tests on each species
that failed the test in accordance with I.A.10.d.
9
PERMITTEE: City of Clearwater PERMIT NUMBER: FL0128937-016-DW1P/RM
FACILITY: City of Clearwater Northeast WRF
(b) The first test shall be initiated within 28 days after the last day of the failed routine test.
The remaining additional follow-up tests shall be conducted weekly thereafter until a
total of two valid additional follow-up tests are completed.
(c) The first additional follow-up test shall be conducted using a control (0% effluent) and a
minimum of five dilutions: 100%, 50%, 25%, 12.5%, and 6.25% effluent. The permittee
may modify the dilution series in the second additional follow-up test to more accurately
bracket the toxicity such that at least two dilutions above and two dilutions below the
target concentration and a control (0% effluent) are run. All test results shall be analyzed
according to the procedures in EPA -821-R-02-013.
(3) In the event of three valid test failures (whether routine or additional follow-up tests) within a
12 -month period, the permittee shall notify the Department within 21 days after the last day of
the third test failure.
(a) The permittee shall submit a plan for correction of the effluent toxicity within 60 days
after the last day of the third test failure.
(b) The Department shall review and approve the plan before initiation.
(c) The plan shall be initiated within 30 days following the Department's written approval of
the plan.
(d) Progress reports shall be submitted quarterly to the Department at the address above.
(e) During the implementation of the plan, the permittee shall conduct quarterly routine
whole effluent toxicity tests in accordance with I.A.10.d. Additional follow-up tests are
not required while the plan is in progress. Following completion or termination of the
plan, the frequency of monitoring for routine and additional follow-up tests shall return to
the schedule established in I.A.10.b.(1). If a routine test is invalid according to the
acceptance criteria in EPA -821-R-02-013, a repeat test shall be initiated within 21 days
after the last day of the invalid routine test.
(f) Upon completion of four consecutive quarterly valid routine tests that demonstrate
compliance with the effluent limitation in I.A.10.a.(1) above, the permittee may submit a
written request to the Department to terminate the plan. The plan shall be terminated
upon written verification by the Department that the facility has passed at least four
consecutive quarterly valid routine whole effluent toxicity tests. If a test within the
sequence of the four is deemed invalid, but is replaced by a repeat valid test initiated
within 21 days after the last day of the invalid test, the invalid test will not be counted
against the requirement for four consecutive quarterly valid routine tests for the purpose
of terminating the plan.
(4) If chronic toxicity test results indicate greater than 50% mortality within 96 hours in an
effluent concentration equal to or less than the effluent concentration specified as the acute
toxicity limit in I.A.10.a.(2), the Department may revise this permit to require acute definitive
whole effluent toxicity testing.
(5) The additional follow-up testing and the plan do not preclude the Department taking
enforcement action for acute or chronic whole effluent toxicity failures.
[62-4.241, 62-620.620(3)1
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i i i i i i i i i i i i i i i i i i i
PERMITTEE: City of Clearwater PERMIT NUMBER: FL0128937-016-DWIP/RM
FACILITY: City of Clearwater Northeast WRF
B. Reuse and Land Application Systems
1. During the period beginning on the effective date and lasting through the expiration date of this permit, the permittee is authorized to direct reclaimed water
to Reuse Systems R-001 and R-002. Such reclaimed water shall be limited and monitored by the permittee as specified below and reported in accordance
with Permit Condition I.C.8:
11
Reclaimed Water Limitations
Monitoring Requirements
Parameter
Units
Max/Min
Limit
Statistical Basis
Frequency of
Analysis
Sample Type
Monitoring
Site Number
Notes
Flow, to R-001
MGD
Max
12.0
Annual Average
Monthly
Calculated
FLW-05
See I.B.4
Flow, to R-001
MGD
Max
Report
Monthly Average
Continuous
Recording Flow
Meter with
Totalizer
FLW-05
Flow, to R-002
MGD
Max
4.0
Daily Maximum
Monthly
Calculated
FLW-06
Flow, to R-002
MGD
Max
Report
Monthly Average
Continuous
Recording Flow
Meter with
Totalizer
FLW-06
BOD, Carbonaceous 5 day,
20C
mg/L
Max
20.0
Annual Average
Monthly
Calculated
BOD, Carbonaceous 5 day,
20C
mg/L
Max
Max
Max
30.0
45.0
60.0
Monthly Average
Weekly Average
Single Sample
5 Days/Week
24 -hr FPC
EFA -01
Solids, Total Suspended
mg/L
Max
5.0
Single Sample
5 Days/Week
Grab
EFB-01
See I.B.5
pHs
u
Min
Max
6.0
8.5
Single Sample
Single Sample
Continuous
Meter
EFA -01
See I.B.3
Coliform, Fecal
percent
Min
75
Monthly Minimum
Monthly
Calculated
EFA -01
See I.B.5
Coliform, Fecal
#/100mL
Max
25
Single Sample
5 Days/Week
Grab
EFA -01
See I.B.5
Chlorine, Total Residual
(For Disinfection)
mg/L
Min
1.0
Single Sample
Continuous
Meter
EFA -01
See I.B.6
Turbidity
NTU
Max
Report
Single Sample
Continuous
Meter
EFB-01
See I.B.7
Giardia
cysts/100L
Max
Report
Single Sample
Bi -annually;
every 2 years
Filtered
EFA -01
See I.B.10
Cryptosporidium
oocysts/100L
Max
Report
Single Sample
Bi -annually;
every 2 years
Filtered
EFA -01
See LB.10
11
PERMITTEE: City of Clearwater PERMIT NUMBER: FL0128937-016-DW1P/RM
FACILITY: City of Clearwater Northeast WRF
2. Reclaimed water samples shall be taken at the monitoring site locations listed in Permit Condition I.B.1. and as
described below:
Monitoring Site Number
Description of Monitoring Site
EFA -01
After disinfection
EFB-01
After filtration and prior to disinfection
FLW-02
Sum of three 12 -inch magnetic meters
FLW-03
Flow meter at East Plant prior to discharge to the MRS
FLW-04
Total Plant flow at 24 -inch magnetic meter
FLW-05
Flow to R-001 = (FLW-04 — FLW-02 — FLW-06)
FLW-06
Flow to R -002 -City of Clearwater Groundwater Replenishment
Advanced Water Purification Plant -Magnetic flow meter in pipeline to
the ultrafiltration pre-treatment basin
3. Hourly measurement of pH during the period of required operator attendance may be substituted for
continuous measurement. [62-600.660(1)]
4. A recording flow meter with totalizer shall be utilized to measure flow and calibrated at least once every 12
months. [62-600.200(25)]
5. Over a 30 -day period, at least 75 percent of the fecal coliform values shall be below the detection limits. No
sample shall exceed 25 fecal coliforms per 100 mL. No sample shall exceed 5.0 mg/L of total suspended
solids (TSS) at a point before the application of the disinfectant. Note: To report the "% less than detection,"
count the number of fecal coliform observations that were less than detection, divide by the total number of
fecal coliform observations in the month, and multiply by 100% (round to the nearest integer). [62-
600.440(6) (a)]
6. The minimum total chlorine residual shall be limited as described in the approved operating protocol, such that
the permit limitation for fecal coliform bacteria will be achieved. In no case shall the total chlorine residual be
less than 1.0 mg/L. [62-600.440(6)(b)][62-610.460(2)][62-610.463(2)]
7. The maximum turbidity shall be limited as described in the approved operating protocol, such that the permit
limitations for total suspended solids and fecal coliforms will be achieved. [62-610.463(2)]
8. The treatment facilities shall be operated in accordance with all approved operating protocols. Only reclaimed
water that meets the criteria established in the approved operating protocol(s) may be released to system storage
or to the reuse system. Reclaimed water that fails to meet the criteria in the approved operating protocol(s) shall
be directed to the following permitted alternate discharge system: D-001 to Old Tampa Bay. [62-610.320(6)
and 62-610.463(2)]
9. Instruments for continuous on-line monitoring of total residual chlorine and turbidity shall be equipped with an
automated data logging or recording device. [62-610.463(2)]
10. Intervals between sampling for Giardia and Cryptosporidium shall not exceed two years. [62-
610.463(4)]
12
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PERMITTEE:
FACILITY:
all I M-- EN S— MO N MI i MI N 1 1 1
City of Clearwater PERMIT NUMBER: FLO128937-016-DWIP/RM
City of Clearwater Northeast WRF
C. Other Limitations and Monitoring and Reporting Requirements
1. During the period beginning on the effective date and lasting through the expiration date of this permit, the treatment facility shall be limited and monitored
by the permittee as specified below and reported in accordance with condition I.C.B.:
13
Limitations
Monitoring Requirements
Parameter
Units
Max/Min
Limit
Statistical Basis
Frequency of
Analysis
Sample Type
Monitoring
Site Number
Notes
Flow, Total Plant
MGD
Max
Max
13.5
Report
Annual Average
Monthly Average
Continuous
Recording Flow
Meter with
Totalizer
FLW-1
See I.C.4
Percent Capacity,
(TMADF/Permitted
Capacity) x 100
Percent
Max
Report
Monthly Maximum
Monthly
Calculation
FLW-1
BOD, Carbonaceous 5
day, 20C (influent)
mg/L
Max
Report
Monthly Average
Weekly
24 -hr FPC
INF -01
See 1.C.3
Solids, Total Suspended
(Influent)
mg/L
Max
Report
Monthly Average
Weekly
24 -hr FPC
INF -01
See 1.C.3
13
PERMITTEE: City of Clearwater PERMIT NUMBER: FL0128937-016-DW1P/RM
FACILITY: City of Clearwater Northeast WRF
2. Samples shall be taken at the monitoring site locations listed in Permit Condition I.C.1. and as described
below:
Monitoring Site Number
Description of Monitoring Site
FLW-01
Flow measured at the Parshall Flume
INF -01
At influent pumping station wet well, before treatment and ahead of any return flows
3. Influent samples shall be collected so that they do not contain digester supernatant or return activated sludge,
or any other plant process recycled waters. [62-600.660(4)(a)]
4. A recording flow meter with totalizer shall be utilized to measure flow and calibrated at least once every 12
months. [62-600.200(25)]
5. Sampling results for giardia and cryptosporidium shall be reported on DEP Form 62-610.300(4)(a)4, Pathogen
Monitoring, which is attached to this permit. This form shall be submitted to the Department's Southwest
District Office and to DEP's Reuse Coordinator in Tallahassee. [62-610.300(4)(a)]
6. The sample collection, analytical test methods, and method detection limits (MDLs) applicable to this permit
shall be conducted using a sufficiently sensitive method to ensure compliance with applicable water quality
standards and effluent limitations and shall be in accordance with Rule 62-4.246, Chapters 62-160 and 62-600,
F.A.C., and 40 CFR 136, as appropriate. The list of Department established analytical methods, and
corresponding MDLs (method detection limits) and PQLs (practical quantitation limits), which is titled "FAC
62-4 MDL/PQL Table (April 26, 2006)" is available at http://www.dep.state.fl.us/labs/library/index.htm. The
MDLs and PQLs as described in this list shall constitute the minimum acceptable MDL/PQL values and the
Department shall not accept results for which the laboratory's MDLs or PQLs are greater than those described
above unless alternate MDLs and/or PQLs have been specifically approved by the Department for this permit.
Any method included in the list may be used for reporting as long as it meets the following requirements:
a. The laboratory's reported MDL and PQL values for the particular method must be equal or less than the
corresponding method values specified in the Department's approved MDL and PQL list;
b. The laboratory reported MDL for the specific parameter is less than or equal to the permit limit or the
applicable water quality criteria, if any, stated in Chapter 62-302, F.A.C. Parameters that are listed as
"report only" in the permit shall use methods that provide an MDL, which is equal to or Less than the
applicable water quality criteria stated in 62-302, F.A.C.; and
c. If the MDLs for all methods available in the approved list are above the stated permit limit or applicable
water quality criteria for that parameter, then the method with the lowest stated MDL shall be used.
When the analytical results are below method detection or practical quantitation limits, the permittee shall
report the actual laboratory MDL and/or PQL values for the analyses that were performed following the
instructions on the applicable discharge monitoring report.
Where necessary, the permittee may request approval of alternate methods or for alternative MDLs or PQLs for
any approved analytical method. Approval of alternate laboratory MDLs or PQLs are not necessary if the
laboratory reported MDLs and PQLs are less than or equal to the permit limit or the applicable water quality
criteria, if any, stated in Chapter 62-302, F.A.C. Approval of an analytical method not included in the above -
referenced list is not necessary if the analytical method is approved in accordance with 40 CFR 136 or deemed
acceptable by the Department. [62-4.246, 62-160]
7. The permittee shall provide safe access points for obtaining representative samples which are required by this
permit. [62-600.650(2)]
8. Monitoring requirements under this permit are effective on the first day of the second month following the
effective date of the permit. Until such time, the permittee shall continue to monitor and report in accordance
with previously effective permit requirements, if any. During the period of operation authorized by this permit,
14
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PERMITTEE: City of Clearwater PERMIT NUMBER: FL0128937-016-DW1P/RM
FACILITY: City of Clearwater Northeast WRF
the permittee shall complete and submit to the Department Discharge Monitoring Reports (DMRs) in
accordance with the frequencies specified by the REPORT type (i.e. monthly, quarterly, semiannual, annual,
etc.) indicated on the DMR forms attached to this permit. Unless specified otherwise in this permit, monitoring
results for each monitoring period shall be submitted in accordance with the associated DMR due dates below.
DMRs shall be submitted for each required monitoring period including periods of no discharge.
REPORT Type on DMR
Monitoring Period
Mail or Electronically Submit by
Monthly
first day of month - last day of month
28th day of following month
Quarterly
January 1 - March 31
April 1 - June 30
July 1 - September 30
October I - December 3 I
April 28
July 28
October 28
January 28
Semiannual
January 1 - June 30
July 1 - December 31
July 28
January 28
Annual
January 1 - December 31
January 28
The permittee shall use the electronic DMR system approved by the Department (EzDMR) and shall
electronically submit the completed DMR forms using the DEP Business Portal at
http://www.fldepportal.com/go/, unless the permittee has a waiver from the Department in accordance with 40
CFR 127.15. Reports shall be submitted to the Department by the twenty-eighth (28th) of the month following
the month of operation.
[62-620.610(18)J[62-600.680(1)1
9. During the period of operation authorized by this permit, reclaimed water or effluent shall be monitored
annually for the primary and secondary drinking water standards contained in Chapter 62-550, F.A.C., (except
for asbestos, total coliform, color, odor, and residual disinfectants). These monitoring results shall be reported
to the Department annually on the DMR. During years when a permit is not renewed, a certification stating
that no new non-domestic wastewater dischargers have been added to the collection system since the last
reclaimed water or effluent analysis was conducted may be submitted with the signed DMR in lieu of
performing the analysis. When such a certification is submitted with the DMR, monitoring not required this
period should be noted on the DMR. The annual reclaimed water or effluent analysis report, and certification if
applicable, shall be completed and submitted in a timely manner so as to be received by the Department at the
address identified on the DMR by January 28 of each year. Approved analytical methods identified in Rule
62-620.100(3)(j), F.A.C., shall be used for the analysis. If no method is included for a parameter, methods
specified in Chapter 62-550, F.A.C., shall be used. [62-600.660(2) and (3)(d)][62-600.680(2)][62-610.300(4)]
10. The permittee shall submit an Annual Reuse Report using DEP Form 62-610.300(4)(a)2. on or before January
1 of each year. [62-610.870(3)]
11. Operating protocol(s) shall be reviewed and updated periodically to ensure continuous compliance with the
minimum treatment and disinfection requirements. Updated operating protocols shall be submitted to the
Department's Southwest District Office for review and approval upon revision of the operating protocol(s) and
with each permit application. [62-610.320(6)][62-610.463(2)]
12. The permittee shall maintain an inventory of storage systems. The inventory shall be submitted to the
Department's Southwest District Office at least 30 days before reclaimed water will be introduced into any new
storage system. The inventory of storage systems shall be attached to the annual submittal of the Annual
Reuse Report. [62-610.464(5)]
13. Unless specified otherwise in this permit, all reports and other information required by this permit, including
24-hour notifications, shall be submitted to or reported to, as appropriate, the Department's Southwest District
Office at the address specified below:
Florida Department of Environmental Protection
Southwest District Office
13051 N Telecom Pkwy
15
PERMITTEE: City of Clearwater PERMIT NUMBER: FL0128937-016-DW1P/RM
FACILITY: City of Clearwater Northeast WRF
Temple Terrace, Florida 33637-926
Phone Number - (813) 470-5700
FAX Number - (813) 470-5996
swd dw((dep.state.fl.us
[62-620.305]
14. All reports and other information shall be signed in accordance with the requirements of Rule 62-620.305,
F.A.C. [62-620.305]
II. BIOSOLIDS MANAGEMENT REQUIREMENTS
A. Basic Requirements
1. Biosolids generated by this facility may be land applied and/or transferred to Biosolids Treatment Facility
(BTF) or disposed of in a Class I solid waste landfill. Transferring biosolids to an alternative biosolids
treatment facility does not require a permit modification. However, use of an alternative biosolids treatment
facility requires submittal of a copy of the agreement pursuant to Rule 62-640.880(1)(c), F.A.C., along with a
written notification to the Department at least 30 days before transport of the biosolids. [62-620.320(6), 62-
640.880(1)]
2. The permittee shall monitor and keep records of the quantities of biosolids generated, received from source
facilities, treated, distributed and marketed, land applied, used as a biofuel or for bioenergy, transferred to
another facility, or landfilled. These records shall be kept for a minimum of five years. [62-640.650(4)(a)]
3. Biosolids quantities shall be monitored by the permittee as specified below. Results shall be reported on the
permittee's Discharge Monitoring Report for Monitoring Group RMP -Q in accordance with Condition I.C.B.
[62-640.650(5)(a)1]
4. Biosolids quantities shall be calculated as listed in Permit Condition II.A.3. and as described below:
Monitoring Site Number
Biosolids Limitations
Monitoring Requirements
Parameter
Units
Max/
Min
Limit
Statistical Basis
Frequency
of Analysis
Sample
Type
Monitoring
Site
Number
Biosolids Quantity
(Landfilled)
dry tons
Max
Report
Monthly Total
MonthlyCalculated
RMP -02
Biosolids Quantity
(Land -Applied)
dry tons
Max
Report
Monthly Total
MonthlyCalculated
RMP -03
Biosolids Quantity
(Transferred)
dry tons
Max
Report
Monthly Total
Monthly Calculated
RMP -01
[62-640.650(5)(a)1]
4. Biosolids quantities shall be calculated as listed in Permit Condition II.A.3. and as described below:
Monitoring Site Number
Description of Monitoring Site Calculations
RMP -01
Biosolids Quantity (Transferred to BTF)
RMP -02
Biosolids Quantity (Landfilled)
RMP -03
Biosolids Quantity (Land -Applied)
5. The treatment, management, transportation, use, land application, or disposal of biosolids shall not cause a
violation of the odor prohibition in subsection 62-296.320(2), F.A.C. [62-640.400(6)]
6. Storage of biosolids or other solids at this facility shall be in accordance with the Facility Biosolids Storage
Plan. [62-640.300(4)]
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PERMITTEE: City of Clearwater PERMIT NUMBER: FL0128937-016-DW 1P/RM
FACILITY: City of Clearwater Northeast WRF
7. Biosolids shall not be spilled from or tracked off the treatment facility site by the hauling vehicle. [62-
640.400(9)]
B. Treatment and Monitoring Requirements
8. The permittee is authorized to produce Class B biosolids.
9. The permittee shall achieve Class B pathogen reduction by meeting the pathogen reduction requirements in
section 503.32(b)(3) (Use of PSRP (Processes to Significantly Reduce Pathogens) -Anaerobic Digestion) of
Title 40 CFR Part 503. [62-640.600(I)(b)]
10. The permittee shall achieve vector attraction reduction for Class B biosolids by meeting the vector attraction
reduction requirements in section 503.33(b)(1) (Reduce the mass of volatile solids by a minimum of 38%) of
Title 40 CFR Part 503. [62-640.600(2)(a)]
11. Time and Temperature shall be routinely monitored to demonstrate compliance with pathogen reduction
requirements specified in Rule 62-640.600, F.A.C. [62-640.650(3)(a)2]
12. Temperature and Time shall be routinely monitored to demonstrate compliance with vector attraction reduction
requirements specified in Rule 62-640.600, F.A.C. [62-640.650(3)(a)2]
13. Treatment of liquid biosolids or septage for the purpose of meeting the pathogen reduction or vector attraction
reduction requirements set forth in Rule 62-640.600, F.A.C., shall not be conducted in the tank of a hauling
vehicle. Treatment of biosolids or septage for the purpose of meeting pathogen reduction or vector attraction
reduction requirements shall take place at the permitted facility. [62-640.400(7)]
14. Class B biosolids shall comply with the limits and be monitored by the permittee as specified below. Results
shall be reported on the permittee's Discharge Monitoring Report in accordance with Permit Condition I.C.8.
Biosolids shall not be land applied if a single sample result for any parameter exceeds the following:
17
Biosolids Limitations
Monitoring Requirements
Parameter
Units
Max/
Min
Limit
Statistical
Basis
Frequency of
Analysis
Sample
Type
Monitoring
Site
Number
Nitrogen, Sludge, Tot,
Dry Wt (as N)
percent
Max
Report
Single Sample
Bi -monthly;
every 2
months
Composite
RMP -B
Phosphorus, Sludge,
Tot, Dry Wt (as P)
percent
Max
Report
Single Sample
Bi -monthly;
every 2
months
Composite
RMP -B
Potassium, Sludge,
Tot, Dry Wt (as K)
percent
Max
Report
Single Sample
Bi -monthly;
every 2
months
Composite
RMP -B
Arsenic Total, Dry
Weight, Sludge
mg/kg
Max
75.0
Single Sample
Bi -monthly;
every 2
months
Composite
RMP -B
Cadmium, Sludge,
Tot, Dry Weight (as
Cd)
mg/kg
Max
85.0
Single Sample
Bi -monthly;
every 2
months
Composite
RMP -B
Copper, Sludge, Tot,
Dry Wt. (as Cu)
mg/kg
Max
4300.0
Single Sample
Bi -monthly;
every 2
months
Composite
RMP -B
Lead, Dry Weight,
Sludge
mg/kg
Max
840.0
Single Sample
Bi -monthly;
every 2
months
Composite
RMP -B
17
PERMITTEE: City of Clearwater
FACILITY: City of Clearwater Northeast WRF
PERMIT NUMBER: FL0128937-016-DW1P/RM
**Reported on Part B of the DMR
[62-640.650(3)(a)(3) and 62-640.700(5)(a)]
15. Sampling and analysis shall be conducted in accordance with 40 CFR Part 503.8 and the U.S. Environmental
Protection Agency publication - POTW Sludge Sampling and Analysis Guidance Document, August 1989. In
cases where conflicts exist between 40 CFR 503.8 and the POTW Sludge Sampling and Analysis Guidance
Document, the requirements in 40 CFR Part 503.8 will apply. [62-640.650(3)(a)1]
16. All samples shall be representative and shall be taken after final treatment of the biosolids but before
land application or distribution and marketing. [62-640.650(3)(a)5]
17. Biosolids samples shall be taken at the monitoring site locations listed in Permit Condition II.B.14 and as
described below:
Monitoring Site Number
Biosolids Limitations
Monitoring Requirements
Parameter
Units
Max/
Min
Limit
Statistical
Basis
Frequency of
Analysis
Sample
Type
Monitoring
Site
Number
Mercury, Dry Weight,
Sludge
mg/kg
Max
57.0
Single Sample
Bi -monthly;
every 2
months
Composite
RMP -B
Molybdenum, Dry
Weight, Sludge
mg/kg
Max
75.0
Single Sample
Bi -monthly;
every 2
months
Composite
RMP -B
Nickel, Dry Weight,
Sludge
mg/kg
Max
420.0
Single Sample
Bi -monthly;
every 2
months
Composite
RMP -B
Selenium Sludge Solid
mg/kg
Max
100.0
Single Sample
Bi -monthly;
every 2
months
Composite
RMP -B
Zinc, Dry Weight,
Sludge
mg/kg
Max
7500.0
Single Sample
Bi -monthly;
every 2
months
Composite
RMP -B
pH
s.u.
Max
Report
Single Sample
Bi -monthly;
every 2
months
Composite
RMP -B
Solids, Total, Sludge,
Percent
percent
Max
Report
Single Sample
Bi -monthly;
every 2
months
Composite
RMP -B
Coliform, Fecal
CFU/g
Max
2 million
Geometric
Mean
Bi -monthly;
every 2
months
Grab
RMP -B
**Temperature
Degrees
C
Min
Report
Single Sample
Weekly
Meter
RMP -B3
**Time
Days
Min
Report
Single Sample
Weekly
Calculated
RMP -B2
**Reported on Part B of the DMR
[62-640.650(3)(a)(3) and 62-640.700(5)(a)]
15. Sampling and analysis shall be conducted in accordance with 40 CFR Part 503.8 and the U.S. Environmental
Protection Agency publication - POTW Sludge Sampling and Analysis Guidance Document, August 1989. In
cases where conflicts exist between 40 CFR 503.8 and the POTW Sludge Sampling and Analysis Guidance
Document, the requirements in 40 CFR Part 503.8 will apply. [62-640.650(3)(a)1]
16. All samples shall be representative and shall be taken after final treatment of the biosolids but before
land application or distribution and marketing. [62-640.650(3)(a)5]
17. Biosolids samples shall be taken at the monitoring site locations listed in Permit Condition II.B.14 and as
described below:
Monitoring Site Number
Description of Monitoring Site
RMP -B
Class B Biosolids
RMP -B2
At the digesters influent
RMP -B3
At the transfer point between the digesters
C. Land Application at Permitted Sites
18. Land application of biosolids at the site shall be in accordance with the site permit, the Nutrient Management
Plan, and the requirements of Chapter 62-640, F.A.C. [62-640]
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PERMITTEE: City of Clearwater PERMIT NUMBER: FL0128937-016-DW1P/RM
FACILITY: City of Clearwater Northeast WRF
19. The biosolids from this facility shall only be land applied at sites identified on the Treatment Facility Biosolids
Plan, Form 62-640.210(2)(a), submitted with the permit application, or revised in accordance with condition
II.C.20 below, which is incorporated as part of this permit. [62-640.300(2)]
20. The permittee shall notify the Department at least 24 hours before beginning biosolids application at a site not
listed in the Treatment Facility Biosolids Plan Form 62-640.210(2)(a). The facility's Treatment Facility
Biosolids Plan shall be revised to include the new site and submitted to the Department within 30 days of using
the site. The revised Treatment Facility Biosolids Plan shall become part of the treatment facility permit.
[62-640.300(2)(c) & 62-640.650(6)(a)]
21. Land application of "other solids" as defined in Chapter 62-640, F.A.C., is only allowed if specifically
addressed in the Nutrient Management Plan(s) approved for the site where the other solids will be applied. [62-
640.860]
22. The permittee shall maintain hauling records to track the transport of biosolids between the treatment facility
and the application site. The hauling records for each party shall contain the following information:
Treatment Facility Permittee
1. Date and time shipped and shipment ID
2. Amount of biosolids shipped
3. Concentration of parameters & date of
analysis
4. Name and ID number of permitted
application site
5. Class of biosolids shipped
6. Signature of certified operator or designee
7. Signature of hauler and name of hauling
firm
Site Permittee
1. Date and time received and shipment ID
2. Name and ID number of treatment facility from which
biosolids are received
3. Signature of hauler
4. Signature of site manager
A copy of the treatment facility hauling records for each shipment shall be provided upon delivery of the
biosolids to the biosolids site manager. The permittee shall report to the Department within 24 hours of
discovery of any discrepancy in the delivery of biosolids leaving the treatment facility and arriving at the
permitted application site. Treatment facility permittees shall notify the Department, site manager, and site
permittee within 24 hours of discovery of sending biosolids that did not meet the requirements of Rule 62-
640.600, F.A.C., or subsection 62-640.700(5), F.A.C., to a land application site.
[62-640.650(4) & (5)]
23. The permittee shall maintain copies of the Biosolids Application Site Annual Summaries, received from site
permittees in accordance with 62-640.650(5)(e), F.A.C., indefinitely. [62-640.650(4)(d)]
24. The permittee shall submit a Treatment Facility Biosolids Annual Summary to the Depai tiuent's Southwest
District Office on Department Form 62-640.210(2)(b). The summary shall include all biosolids shipped during
the period January 1 through December 31 and shall be submitted to the Department by February 19 of the
year following the year of application. [62-640. 650(5)(c)]
D. Disposal
25. Disposal of biosolids, septage, and "other solids" in a solid waste disposal facility, or disposal by placement on
land for purposes other than soil conditioning or fertilization, such as at a monofill, surface impoundment,
waste pile, or dedicated site, shall be in accordance with Chapter 62-701, F.A.C. [62-640.100(6)(b) & (c)]
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PERMITTEE: City of Clearwater PERMIT NUMBER: FL0128937-016-DW1P/RM
FACILITY: City of Clearwater Northeast WRF
E. Transfer
26. The permittee shall not be held responsible for treatment and management violations that occur after its
biosolids have been accepted by a permitted biosolids treatment facility with which the source facility has an
agreement in accordance with subsection 62-640.880(1)(c), F.A.C., for further treatment, management, or
disposal. [62-640.880(1)(b)]
27. The permittee shall keep hauling records to track the transport of biosolids between the facilities. The hauling
records shall contain the following information:
Source Facility
1. Date and time shipped
2. Amount of biosolids shipped
3. Degree of treatment (if applicable)
4. Name and ID Number of treatment facility
5. Signature of responsible party at source
facility
6. Signature of hauler and name of hauling
firm
Biosolids Treatment Facility or Treatment Facility
1. Date and time received
2. Amount of biosolids received
3. Name and ID number of source facility
4. Signature of hauler
5. Signature of responsible party at treatment facility
A copy of the source facility hauling records for each shipment shall be provided upon delivery of the biosolids
to the biosolids treatment facility or treatment facility. The treatment facility permittee shall report to the
Department within 24 hours of discovery any discrepancy in the quantity of biosolids leaving the source
facility and arriving at the biosolids treatment facility or treatment facility.
[62-640.880(4)]
F. Receipt
28. This facility receives biosolids from the Clearwater East WRF, FL0021865.
29. If the permittee intends to accept biosolids from other facilities, a permit revision is required pursuant to
paragraph 62-640.880(2)(d), F.A.C. [62-640.880(2)(d)]
III. GROUND WATER REQUIREMENTS
1. Section III is not applicable to this facility.
IV. ADDITIONAL REUSE AND LAND APPLICATION REQUIREMENTS
A. Part III Public Access System(s)
1. The City of Clearwater Northeast WRF serves as a source plant for reclaimed water which is transferred to the
City of Clearwater Master Reuse System (FL0186261) at a transfer point located immediately downstream of
the distribution flow meter at the source plant. The City of Clearwater Master Reuse System is a Part III slow
rate public access land application system serving the City of Clearwater, Florida under Department permit
number FL0186261.
2. Cross -connections to the potable water system are prohibited. [62-610.469(7)]
3. A cross -connection control program shall be implemented and/or remain in effect within the areas where
reclaimed water will be provided for use and shall be in compliance with the Rule 62-555.360, F.A.C. [62-
610.469(7)]
4. The permittee shall conduct inspections within the reclaimed water service area to verify proper connections,
to minimize illegal cross -connections, and to verify both the proper use of reclaimed water and that the proper
backflow prevention assemblies or devices have been installed and tested. Inspections are required when a
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PERMITTEE: City of Clearwater PERMIT NUMBER: FL0128937-016-DW1P/RM
FACILITY: City of Clearwater Northeast WRF
customer first connects to the reuse distribution system. Subsequent inspections are required as specified in the
cross -connection control and inspection program. [62-610.469(7)(h)]
5. If an actual or potential (e.g. no dual check device on residential connections served by a reuse system) cross -
connection between the potable and reclaimed water systems is discovered, the permittee shall:
a. Immediately discontinue potable water and/or reclaimed water service to the affected area if an actual
cross -connection is discovered.
b.
c.
d.
e.
If the potable water system is contaminated, clear the potable water lines.
Eliminate the cross -connection and install a backflow prevention device as required by the Rule 62-
555.360.F.A.C.
Test the affected area for other possible cross -connections.
Within 24 hours, notify the Department's Southwest District Office's domestic wastewater and drinking
water programs.
f. Within 5 days of discovery of an actual or potential cross -connection, submit a written report to the
Department's Southwest District Office detailing: a description of the cross -connection, how the cross -
connection was discovered, the exact date and time of discovery, approximate time that the cross -
connection existed, the location, the cause, steps taken to eliminate the cross -connection, whether
reclaimed water was consumed, and reports of possible illness, whether the drinking water system was
contaminated and the steps taken to clear the drinking water system, when the cross -connection was
eliminated, plan of action for testing for other possible cross -connections in the area, and an evaluation of
the cross -connection control and inspection program to ensure that future cross -connections do not occur.
[62-555.350(3) and 62-555.360][62-620.610(20)]
6. Maximum obtainable separation of reclaimed water lines and potable water lines shall be provided and the
minimum separation distances specified in Rule 62-610.469(7), F.A.C., shall be provided. Reuse facilities shall
be color coded or marked. Underground piping which is not manufactured of metal or concrete shall be color
coded using Pantone Purple 522C using light stable colorants. Underground metal and concrete pipe shall be
color coded or marked using purple as the predominant color. [62-610.469(7)]
7. In constructing reclaimed water distribution piping, the permittee shall maintain a 75 -foot setback distance
from a reclaimed water transmission facility to public water supply wells. No setback distances are required to
other potable water supply wells or to any nonpotable water supply wells. [62-610.471(3)]
8. A setback distance of 75 feet shall be maintained between the edge of the wetted area and potable water supply
wells, unless the utility adopts and enforces an ordinance prohibiting potable water supply wells within the
reuse service area. No setback distances are required to any nonpotable water supply well, to any surface
water, to any developed areas, or to any private swimming pools, hot tubs, spas, saunas, picnic tables, barbecue
pits, or barbecue grills. [62-610.471(1), (2), (5), and (7)]
9. Reclaimed water shall not be used to fill swimming pools, hot tubs, or wading pools. [62-610.469(4)]
10. Low trajectory nozzles, or other means to minimize aerosol formation shall be used within 100 feet from
outdoor public eating, drinking, or bathing facilities. [62-610.471(6)]
11. A setback distance of 100 feet shall be maintained from indoor aesthetic features using reclaimed water to
adjacent indoor public eating and drinking facilities. [62-610.471(8)]
12. The public shall be notified of the use of reclaimed water. This shall be accomplished by posting of advisory
signs in areas where reuse is practiced, notes on scorecards, or other methods. [62-610.468(2)]
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PERMITTEE: City of Clearwater PERMIT NUMBER: FL0128937-016-DW1P/RM
FACILITY: City of Clearwater Northeast WRF
13. All new advisory signs and labels on vaults, service boxes, or compartments that house hose bibbs along with
all labels on hose bibbs, valves, and outlets shall bear the words "do not drink" and "no beber" along with the
equivalent standard international symbol. In addition to the words "do not drink" and "no beber," advisory
signs posted at storage ponds and decorative water features shall also bear the words "do not swim" and "no
nadar" along with the equivalent standard international symbols. Existing advisory signs and labels shall be
retrofitted, modified, or replaced in order to comply with the revised wording requirements. For existing
advisory signs and labels this retrofit, modification, or replacement shall occur within 365 days after the date of
this permit. For labels on existing vaults, service boxes, or compartments housing hose bibbs this retrofit,
modification, or replacement shall occur within 730 days after the date of this permit. [62-610.468, 62-
610.469]
14. The permittee shall ensure that users of reclaimed water are informed about the origin, nature, and
characteristics of reclaimed water; the manner in which reclaimed water can be safely used; and limitations on
the use of reclaimed water. Notification is required at the time of initial connection to the reclaimed water
distribution system and annually after the reuse system is placed into operation. A description of on-going
public notification activities shall be included in the Annual Reuse Report. [62-610.468(6)]
15. Routine aquatic weed control and regular maintenance of storage pond embankments and access areas are
required. [62-610.414(8)]
16. Overflows from emergency discharge facilities on storage ponds shall be reported as abnormal events in
accordance with Permit Condition IX.20. [62-610.800(9)]
V. OPERATION AND MAINTENANCE REQUIREMENTS
A. Staffing Requirements
1. During the period of operation authorized by this permit, the wastewater facilities shall be operated under the
supervision of one or more operators certified in accordance with Chapter 62-602, F.A.C. In accordance with
Chapter 62-699, F.A.C., this facility is a Category I, Class A facility and, at a minimum, operators with
appropriate certification must be on the site as follows:
A Class C or higher operator 24 hours/day for 7 days/week. The lead/chief operator must be a Class A
operator.
[62-620.630(3)][62-699.310] [62-610.462]
2. The lead/chief operator shall be employed at the plant full time. "Full time" shall mean at least 4 days per
week, working a minimum of 35 hours per week, including leave time. A licensed operator shall be on-site
and in charge of each required shift for periods of required staffing time when the lead/chief operator is not on-
site. An operator meeting the lead/chief operator class for the treatment plant shall be available during all
periods of plant operation. "Available" means able to be contacted as needed to initiate the appropriate action
in a timely manner. [62-699.311(10), (6) and (1)]
B. Capacity Analysis Report and Operation and Maintenance Performance Report Requirements
1. The application to renew this permit shall include an updated capacity analysis report prepared in accordance
with Rule 62-600.405, F.A.C. [62-600.405(5)]
2. The application to renew this permit shall include a detailed operation and maintenance performance report
prepared in accordance with Rule 62-600.735, F.A.C. [62-600.735(1)]
C. Recordkeeping Requirements
1. The permittee shall maintain the following records and make them available for inspection on the site of the
permitted facility.
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PERMITTEE: City of Clearwater PERMIT NUMBER: FL0128937-016-DW1P/RM
FACILITY: City of Clearwater Northeast WRF
a. Records of all compliance monitoring information, including all calibration and maintenance records and
all original strip chart recordings for continuous monitoring instrumentation, including, if applicable, a
copy of the laboratory certification showing the certification number of the laboratory, for at least three
years from the date the sample or measurement was taken;
b. Copies of all reports required by the permit for at least three years from the date the report was prepared;
c. Records of all data, including reports and documents, used to complete the application for the permit for at
least three years from the date the application was filed;
d. Monitoring information, including a copy of the laboratory certification showing the laboratory
certification number, related to the residuals use and disposal activities for the time period set forth in
Chapter 62-640, F.A.C., for at least three years from the date of sampling or measurement;
e. A copy of the current permit;
f. A copy of the current operation and maintenance manual as required by Chapter 62-600, F.A.C.;
g. A copy of any required record drawings;
h. Copies of the licenses of the current certified operators;
i. Copies of the logs and schedules showing plant operations and equipment maintenance for three years
from the date of the logs or schedules. The logs shall, at a minimum, include identification of the plant;
the signature and license number of the operator(s) and the signature of the person(s) making any entries;
date and time in and out; specific operation and maintenance activities, including any preventive
maintenance or repairs made or requested; results of tests performed and samples taken, unless
documented on a laboratory sheet; and notation of any notification or reporting completed in accordance
with Rule 62-602.650(3), F.A.C. The logs shall be maintained on-site in a location accessible to 24-hour
inspection, protected from weather damage, and current to the last operation and maintenance performed;
and
j. Records of biosolids quantities, treatment, monitoring, and hauling for at least five years.
[62-620.350, 62-602.650, 62-640.650(4)]
VI. SCHEDULES
1. The permittee shall conduct and implement according to the following schedule:
Implementation Step
Completion Date
A.
Submit DEP Form 62-620.910(12), Notification of
Completion of Construction for Wastewater Facilities or
Activities prior to activation.
Prior to placing any unit processes into
operation for any purpose other than testing.
B.
Submit DEP Form 62-620.910(13), Notification of
Availability of Record Drawings and Final Operation and
Maintenance Manuals for the construction.
Within six months after any unit is placed
into operation.
[62-620.320(1) and (2), 62-4.070(3)]
2. Prior to placing the modifications to existing facilities into operation or any individual unit processes into
operation, for any purpose other than testing for leaks and equipment operation, the permittee shall complete and
submit to the Department DEP Form 62-620.910(12), Notification of Completion of Construction for
Wastewater Facilities or Activities. [62-620.410(7) and 62-620.630(2)]
3. The permittee is not authorized to discharge to waters of the state after the expiration date of this permit,
unless:
23
PERMITTEE: City of Clearwater PERMIT NUMBER: FL0128937-016-DW1P/RM
FACILITY: City of Clearwater Northeast WRF
a. The permittee has applied for renewal of this permit at least 180 days before the expiration date of this
permit using the appropriate forms listed in Rule 62-620.910, F.A.C., and in the manner established in the
Department of Environmental Protection Guide to Permitting Wastewater Facilities or Activities Under
Chapter 62-620, F.A.C., including submittal of the appropriate processing fee set forth in Rule 62-4.050,
F.A.C.; or
b. The permittee has made complete the application for renewal of this permit before the permit expiration
date.
Please note, effluent testing shall be conducted for each outfall in accordance with the instructions
provided in Sections 3.A.12., 13., and 14. of the application form. A minimum of three samples shall be
taken within four and one-half years prior to the date of the permit application and must be representative
of the seasonal variation in the discharge from each outfall. [62-620.335(1) - (4)]
VII. INDUSTRIAL PRETREATMENT PROGRAM REQUIREMENTS
1. This facility's pretreatment program requirements are included in the City of Clearwater Marshall Street WRF
permit issued by the Department under Permit Number FL0021857.
2. As required by Rules 62-625.600(8) and (12), F.A.C., the permittee shall submit DMRs for Monitoring Site
Numbers PRT -I, PRT -E, and PRT -R to the City of Clearwater Marshall Street WRF (FL0021857) for inclusion
in the annual report.[62-625. 600(8)]
3. Samples for Monitoring Site Numbers PRT -I, PRT -E, and PRT -R shall be taken at the monitoring site
locations described below:
Monitoring Location
Site Number
Description of Monitoring Location
PRT -I
At headworks prior to treatment and ahead of return activated sludge.
PRT -E
After dechlorination and prior to Outfall.
PRT -R
After centrifuge/belt filter press.
VIII. OTHER SPECIFIC CONDITIONS
1. In the event that the treatment facilities or equipment no longer function as intended, are no longer safe in
terms of public health and safety, or odor, noise, aerosol drift, or lighting adversely affects neighboring
developed areas at the levels prohibited by Rule 62-600.400(2)(a), F.A.C., corrective action (which may
include additional maintenance or modifications of the permitted facilities) shall be taken by the permittee.
Other corrective action may be required to ensure compliance with rules of the Department. Additionally, the
treatment, management, use or land application of residuals shall not cause a violation of the odor prohibition
in Rule 62-296.320(2), F.A.C. [62-600.410(5) and 62-640.400(6)]
2. The deliberate introduction of stormwater in any amount into collection/transmission systems designed solely
for the introduction (and conveyance) of domestic/industrial wastewater; or the deliberate introduction of
stormwater into collection/transmission systems designed for the introduction or conveyance of combinations
of storm and domestic/industrial wastewater in amounts which may reduce the efficiency of pollutant removal
by the treatment plant is prohibited, except as provided by Rule 62-610.472, F.A.C. [62-604.130(3)]
3. Collection/transmission system overflows shall be reported to the Department in accordance with Permit
Condition IX. 20. [62-604.550] [62-620.610(20)]
4. The operating authority of a collection/transmission system and the permittee of a treatment plant are
prohibited from accepting connections of wastewater discharges which have not received necessary
pretreatment or which contain materials or pollutants (other than normal domestic wastewater constituents):
a. Which may cause fire or explosion hazards; or
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PERMITTEE: City of Clearwater PERMIT NUMBER: FL0128937-016-DW1P/RM
FACILITY: City of Clearwater Northeast WRF
b. Which may cause excessive corrosion or other deterioration of wastewater facilities due to chemical action
or pH levels; or
c. Which are solid or viscous and obstruct flow or otherwise interfere with wastewater facility operations or
treatment; or
d. Which result in the wastewater temperature at the introduction of the treatment plant exceeding 40°C or
otherwise inhibiting treatment; or
e. Which result in the presence of toxic gases, vapors, or fumes that may cause worker health and safety
problems.
[62-604.130(5)]
5. The treatment facility, storage ponds for Part II systems, rapid infiltration basins, and/or infiltration trenches
shall be enclosed with a fence or otherwise provided with features to discourage the entry of animals and
unauthorized persons. [62-600.400(2)(b)]
6. Screenings and grit removed from the wastewater facilities shall be collected in suitable containers and hauled
to a Department approved Class I landfill or to a landfill approved by the Department for receipt/disposal of
screenings and grit. [62-701.300(1)(a)]
7. Where required by Chapter 471 or Chapter 492, F.S., applicable portions of reports that must be submitted
under this permit shall be signed and sealed by a professional engineer or a professional geologist, as
appropriate. [62-620.310(4)]
8. The permittee shall provide verbal notice to the Department's Southwest District Office as soon as practical
after discovery of a sinkhole or other karst feature within an area for the management or application of
wastewater, wastewater residuals (sludges), or reclaimed water. The permittee shall immediately implement
measures appropriate to control the entry of contaminants, and shall detail these measures to the Department's
Southwest District Office in a written report within 7 days of the sinkhole discovery. [62-620.320(6)]
9. Reopener Clause:
a. The permit shall be revised, or alternatively, revoked and reissued in accordance with the provisions
contained in Rules 62-620.325 and 62-620.345, F.A.C., if applicable, or to comply with any applicable
effluent standard or limitation issued or approved under Sections 301(b)(2)(C) and (D), 304(b)(2) and
307(a)(2) of the Clean Water Act (the Act), as amended, if the effluent standards, limitations, or water quality
standards so issued or approved:
(1) Contains different conditions or is otherwise more stringent than any condition in the permit/or;
(2) Controls any pollutant not addressed in the permit.
(3) The permit as revised or reissued under this paragraph shall also contain any other requirements of the
Act then applicable.
b. The permit may be reopened to adjust effluent limitations or monitoring requirements should future Water
Quality Based Effluent Limitation determinations, water quality studies, DEP approved changes in water
quality standards, or other information show a need for a different limitation or monitoring requirement.
c. The Department may develop a Total Maximum Daily Load (TMDL) during the life of the permit. Once a
TMDL has been established and adopted by rule, the Department shall revise this permit to incorporate the
final findings of the TMDL.
[62-620.325 & 62-620.345]
IX. GENERAL CONDITIONS
1. The terms, conditions, requirements, limitations, and restrictions set forth in this permit are binding and
enforceable pursuant to Chapter 403, Florida Statutes. Any permit noncompliance constitutes a violation of
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PERMITTEE: City of Clearwater PERMIT NUMBER: FL0128937-016-DW1P/RM
FACILITY: City of Clearwater Northeast WRF
Chapter 403, Florida Statutes, and is grounds for enforcement action, permit termination, permit revocation
and reissuance, or permit revision. [62-620.610(1)]
2. This permit is valid only for the specific processes and operations applied for and indicated in the approved
drawings or exhibits. Any unauthorized deviations from the approved drawings, exhibits, specifications, or
conditions of this permit constitutes grounds for revocation and enforcement action by the Department. [62-
620.610(2)]
3. As provided in subsection 403.087(7), F.S., the issuance of this permit does not convey any vested rights or
any exclusive privileges. Neither does it authorize any injury to public or private property or any invasion of
personal rights, nor authorize any infringement of federal, state, or local laws or regulations. This permit is not
a waiver of or approval of any other Department permit or authorization that may be required for other aspects
of the total project which are not addressed in this permit. [62-620.610(3)]
4. This permit conveys no title to land or water, does not constitute state recognition or acknowledgment of title,
and does not constitute authority for the use of submerged lands unless herein provided and the necessary title
or leasehold interests have been obtained from the State. Only the Trustees of the Internal Improvement Trust
Fund may express State opinion as to title. [62-620.610(4)]
5. This permit does not relieve the permittee from liability and penalties for harm or injury to human health or
welfare, animal or plant life, or property caused by the construction or operation of this permitted source; nor
does it allow the permittee to cause pollution in contravention of Florida Statutes and Department rules, unless
specifically authorized by an order from the Department. The permittee shall take all reasonable steps to
minimize or prevent any discharge, reuse of reclaimed water, or residuals use or disposal in violation of this
permit which has a reasonable likelihood of adversely affecting human health or the environment. It shall not
be a defense for a permittee in an enforcement action that it would have been necessary to halt or reduce the
permitted activity in order to maintain compliance with the conditions of this permit. [62-620.610(5)]
6. If the permittee wishes to continue an activity regulated by this permit after its expiration date, the permittee
shall apply for and obtain a new permit. [62-620.610(6)]
7. The permittee shall at all times properly operate and maintain the facility and systems of treatment and control,
and related appurtenances, that are installed and used by the permittee to achieve compliance with the
conditions of this permit. This provision includes the operation of backup or auxiliary facilities or similar
systems when necessary to maintain or achieve compliance with the conditions of the permit. [62-620.610(7)]
8. This permit may be modified, revoked and reissued, or terminated for cause. The filing of a request by the
permittee for a permit revision, revocation and reissuance, or termination, or a notification of planned changes
or anticipated noncompliance does not stay any permit condition. [62-620.610(8)]
9. The permittee, by accepting this permit, specifically agrees to allow authorized Department personnel,
including an authorized representative of the Depai tinent and authorized EPA personnel, when applicable,
upon presentation of credentials or other documents as may be required by law, and at reasonable times,
depending upon the nature of the concern being investigated, to:
a. Enter upon the permittee's premises where a regulated facility, system, or activity is located or conducted,
or where records shall be kept under the conditions of this permit;
b. Have access to and copy any records that shall be kept under the conditions of this permit;
c. Inspect the facilities, equipment, practices, or operations regulated or required under this permit; and
d. Sample or monitor any substances or parameters at any location necessary to assure compliance with this
permit or Department rules.
[62-620.610(9)]
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PERMITTEE: City of Clearwater PERMIT NUMBER: FLO128937-016-DW1P/RM
FACILITY: City of Clearwater Northeast WRF
10. In accepting this permit, the permittee understands and agrees that all records, notes, monitoring data, and
other information relating to the construction or operation of this permitted source which are submitted to the
Department may be used by the Department as evidence in any enforcement case involving the permitted
source arising under the Florida Statutes or Department rules, except as such use is proscribed by Section
403.111, F.S., or Rule 62-620.302, F.A.C. Such evidence shall only be used to the extent that it is consistent
with the Florida Rules of Civil Procedure and applicable evidentiary rules. [62-620.610(10)]
11. When requested by the Department, the permittee shall within a reasonable time provide any information
required by law which is needed to determine whether there is cause for revising, revoking and reissuing, or
terminating this permit, or to determine compliance with the permit. The permittee shall also provide to the
Department upon request copies of records required by this permit to be kept. If the permittee becomes aware
of relevant facts that were not submitted or were incorrect in the permit application or in any report to the
Department, such facts or information shall be promptly submitted or corrections promptly reported to the
Department. [62-620.610(11)]
12. Unless specifically stated otherwise in Department rules, the permittee, in accepting this permit, agrees to
comply with changes in Department rules and Florida Statutes after a reasonable time for compliance;
provided, however, the permittee does not waive any other rights granted by Florida Statutes or Department
rules. A reasonable time for compliance with a new or amended surface water quality standard, other than
those standards addressed in Rule 62-302.500, F.A.C., shall include a reasonable time to obtain or be denied a
mixing zone for the new or amended standard. [62-620.610(12)]
13. The permittee, in accepting this permit, agrees to pay the applicable regulatory program and surveillance fee in
accordance with Rule 62-4.052, F.A.C. [62-620.610(13)]
14. This permit is transferable only upon Department approval in accordance with Rule 62-620.340, F.A.C. The
permittee shall be liable for any noncompliance of the permitted activity until the transfer is approved by the
Department. [62-620.610(14)]
15. The permittee shall give the Department written notice at least 60 days before inactivation or abandonment of a
wastewater facility or activity and shall specify what steps will be taken to safeguard public health and safety
during and following inactivation or abandonment. [62-620.610(15)]
16. The permittee shall apply for a revision to the Department permit in accordance with Rules 62-620.300,
F.A.C., and the Department of Environmental Protection Guide to Permitting Wastewater Facilities or
Activities Under Chapter 62-620, F.A.C., at least 90 days before construction of any planned substantial
modifications to the permitted facility is to commence or with Rule 62-620.325(2), F.A.C., for minor
modifications to the permitted facility. A revised permit shall be obtained before construction begins except as
provided in Rule 62-620.300, F.A.C. [62-620.610(16)]
17. The permittee shall give advance notice to the Department of any planned changes in the permitted facility or
activity which may result in noncompliance with permit requirements. The permittee shall be responsible for
any and all damages which may result from the changes and may be subject to enforcement action by the
Department for penalties or revocation of this permit. The notice shall include the following information:
a. A description of the anticipated noncompliance;
b. The period of the anticipated noncompliance, including dates and times; and
c. Steps being taken to prevent future occurrence of the noncompliance.
[62-620.610(1 7)]
18. Sampling and monitoring data shall be collected and analyzed in accordance with Rule 62-4.246 and Chapters
62-160, 62-600, and 62-610, F.A.C., and 40 CFR 136, as appropriate.
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PERMITTEE: City of Clearwater PERMIT NUMBER: FLO128937-016-DW1P/RM
FACILITY: City of Clearwater Northeast WRF
a. Monitoring results shall be reported at the intervals specified elsewhere in this permit and shall be reported
on a Discharge Monitoring Report (DMR), DEP Form 62-620.910(10), or as specified elsewhere in the
permit.
b. If the permittee monitors any contaminant more frequently than required by the permit, using Depai tment
approved test procedures, the results of this monitoring shall be included in the calculation and reporting
of the data submitted in the DMR.
c. Calculations for all limitations which require averaging of measurements shall use an arithmetic mean
unless otherwise specified in this permit.
d. Except as specifically provided in Rule 62-160.300, F.A.C., any laboratory test required by this permit
shall be performed by a laboratory that has been certified by the Department of Health Environmental
Laboratory Certification Program (DOH ELCP). Such certification shall be for the matrix, test method
and analyte(s) being measured to comply with this permit. For domestic wastewater facilities, testing for
parameters listed in Rule 62-160.300(4), F.A.C., shall be conducted under the direction of a certified
operator.
e. Field activities including on-site tests and sample collection shall follow the applicable standard operating
procedures described in DEP-SOP-001/01 adopted by reference in Chapter 62-160, F.A.C.
f Alternate field procedures and laboratory methods may be used where they have been approved in
accordance with Rules 62-160.220, and 62-160.330, F.A.C.
[62-620.610(18)]
19. Reports of compliance or noncompliance with, or any progress reports on, interim and final requirements
contained in any compliance schedule detailed elsewhere in this permit shall be submitted no later than 14 days
following each schedule date. [62-620.610(19)]
20. The permittee shall report to the Department's Southwest District Office any noncompliance which may
endanger health or the environment. Any information shall be provided orally within 24 hours from the time
the permittee becomes aware of the circumstances. A written submission shall also be provided within five
days of the time the permittee becomes aware of the circumstances. The written submission shall contain: a
description of the noncompliance and its cause; the period of noncompliance including exact dates and time,
and if the noncompliance has not been corrected, the anticipated time it is expected to continue; and steps taken
or planned to reduce, eliminate, and prevent recurrence of the noncompliance.
a. The following shall be included as information which must be reported within 24 hours under this
condition:
(1) Any unanticipated bypass which causes any reclaimed water or effluent to exceed any permit
limitation or results in an unpermitted discharge,
(2) Any upset which causes any reclaimed water or the effluent to exceed any limitation in the permit,
(3) Violation of a maximum daily discharge limitation for any of the pollutants specifically listed in the
permit for such notice, and
(4) Any unauthorized discharge to surface or ground waters.
b. Oral reports as required by this subsection shall be provided as follows:
(1) For unauthorized releases or spills of treated or untreated wastewater reported pursuant to
subparagraph IX.20.(a)4. that are in excess of 1,000 gallons per incident, or where information
indicates that public health or the environment will be endangered, oral reports shall be provided to
the STATE WATCH OFFICE TOLL FREE NUMBER (800) 320-0519, as soon as practical, but no
later than 24 hours from the time the permittee becomes aware of the discharge. The permittee, to the
extent known, shall provide the following information to the State Watch Office:
(a) Name, address, and telephone number of person reporting;
(b) Name, address, and telephone number of permittee or responsible person for the discharge;
(c) Date and time of the discharge and status of discharge (ongoing or ceased);
(d) Characteristics of the wastewater spilled or released (untreated or treated, industrial or domestic
wastewater);
(e) Estimated amount of the discharge;
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PERMITTEE: City of Clearwater PERMIT NUMBER: FL0128937-016-DW1P/RM
FACILITY: City of Clearwater Northeast WRF
(f) Location or address of the discharge;
(g) Source and cause of the discharge;
(h) Whether the discharge was contained on-site, and cleanup actions taken to date;
(i) Description of area affected by the discharge, including name of water body affected, if any; and
(j) Other persons or agencies contacted.
(2) Oral reports, not otherwise required to be provided pursuant to subparagraph IX.20.b.1 above, shall be
provided to the Department's Southwest District Office within 24 hours from the time the permittee
becomes aware of the circumstances.
c. If the oral report has been received within 24 hours, the noncompliance has been corrected, and the
noncompliance did not endanger health or the environment, the Department's Southwest District Office
shall waive the written report.
[62-620.610(20)]
21. The permittee shall report all instances of noncompliance not reported under Permit Conditions IX.17., IX.18.,
or IX.19. of this permit at the time monitoring reports are submitted. This report shall contain the same
information required by Permit Condition IX.20. of this permit. [62-620.610(21)]
22. Bypass Provisions.
a. "Bypass" means the intentional diversion of waste streams from any portion of a treatment works.
b. Bypass is prohibited, and the Department may take enforcement action against a permittee for bypass,
unless the permittee affirmatively demonstrates that:
(1) Bypass was unavoidable to prevent loss of life, personal injury, or severe property damage; and
(2) There were no feasible alternatives to the bypass, such as the use of auxiliary treatment facilities,
retention of untreated wastes, or maintenance during normal periods of equipment downtime. This
condition is not satisfied if adequate back-up equipment should have been installed in the exercise of
reasonable engineering judgment to prevent a bypass which occurred during normal periods of
equipment downtime or preventive maintenance; and
(3) The permittee submitted notices as required under Permit Condition IX.22.c. of this permit.
c. If the permittee knows in advance of the need for a bypass, it shall submit prior notice to the Department,
if possible at least 10 days before the date of the bypass. The permittee shall submit notice of an
unanticipated bypass within 24 hours of learning about the bypass as required in Permit Condition IX.20.
of this permit. A notice shall include a description of the bypass and its cause; the period of the bypass,
including exact dates and times; if the bypass has not been corrected, the anticipated time it is expected to
continue; and the steps taken or planned to reduce, eliminate, and prevent recurrence of the bypass.
d. The Department shall approve an anticipated bypass, after considering its adverse effect, if the permittee
demonstrates that it will meet the three conditions listed in Permit Condition IX.22.b.(1) through (3) of
this permit.
e. A permittee may allow any bypass to occur which does not cause reclaimed water or effluent limitations to
be exceeded if it is for essential maintenance to assure efficient operation. These bypasses are not subject
to the provisions of Permit Condition IX.22.b. through d. of this permit.
[62-620.610(22)]
23. Upset Provisions.
a. "Upset" means an exceptional incident in which there is unintentional and temporary noncompliance with
technology-based effluent limitations because of factors beyond the reasonable control of the permittee.
(1) An upset does not include noncompliance caused by operational error, improperly designed treatment
facilities, inadequate treatment facilities, lack of preventive maintenance, careless or improper
operation.
(2) An upset constitutes an affirmative defense to an action brought for noncompliance with technology
based permit effluent limitations if the requirements of upset provisions of Rule 62-620.610, F.A.C.,
are met.
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PERMITTEE: City of Clearwater PERMIT NUMBER: FL0128937-016-DW1P/RM
FACILITY: City of Clearwater Northeast WRF
b. A permittee who wishes to establish the affirmative defense of upset shall demonstrate, through properly
signed contemporaneous operating logs, or other relevant evidence that:
(1) An upset occurred and that the permittee can identify the cause(s) of the upset;
(2) The permitted facility was at the time being properly operated;
(3) The permittee submitted notice of the upset as required in Permit Condition IX.20. of this permit; and
(4) The permittee complied with any remedial measures required under Permit Condition IX.5. of this
permit.
c. In any enforcement proceeding, the burden of proof for establishing the occurrence of an upset rests with
the permittee.
d. Before an enforcement proceeding is instituted, no representation made during the Department review of a
claim that noncompliance was caused by an upset is final agency action subject to judicial review.
[62-620.610(23)]
Executed in Temple Terrace, Florida.
STATE OF FLORIDA DEPARTMENT OF
ENVIRONMENTAL PROTECTION
Pamala Vazquez
Program Administrator
Permitting & Waste Cleanup Program
Southwest District
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